Yamaha 25D Owner'S Manual Download

Page: 1 / 68

Printed in Japan
March 2004–0.2

Printed on recycled paper

25D

OWNER’S MANUAL

6L2-28199-1L

U.S.A.Edition

LIT-18626-05-83

6L2-9-1L Hyoshi 3/17/04 2:45 PM Page 1

Summary of Contents for 25D

Page 1: ...25D OWNER S MANUAL 6L2 28199 1L U S A Edition LIT 18626 05 83 ...

Page 2: ...EMU25060 ZMU01690 Read this owner s manual carefully before operating your outboard motor ...

Page 3: ...ut board motor CAUTION ECM00700 A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current prod uct information available at the time of print ing there may be minor ...

Page 4: ...Tilt support bar 15 Top cowling lock lever s turn type 15 Warning system 15 Overheat warning 15 Operation 17 Installation 17 Mounting the outboard motor 17 Clamping the outboard motor 18 Breaking in engine 19 Gasoline and engine oil mixing chart 25 1 19 Procedure for pre mixed models 19 Preoperation checks 20 Fuel 20 Oil 20 Controls 20 Engine 20 Filling fuel and engine oil 20 Filling fuel for port...

Page 5: ...nectors 42 Exhaust leakage 42 Water leakage 42 Checking propeller 43 Removing the propeller 44 Installing the propeller 44 Changing gear oil 44 Cleaning fuel tank 45 Inspecting and replacing anode s 46 Checking top cowling 46 Coating the boat bottom 46 Trouble Recovery 48 Troubleshooting 48 Temporary action in emergency 51 Impact damage 51 Starter will not operate 51 Emergency starting engine 52 T...

Page 6: ...tection Agency EPA regulations for ma rine SI engines See the label affixed to your engine for details EMU30390 Approval label of emission control certif icate This label is attached to the bottom cowling Existing Technology N A EMU25261 Manufactured date label This label is attached to the clamp bracket or the swivel bracket 1 Outboard motor serial number location 1 Approval label location 1 ZMU0...

Page 7: ...en and non swimmers should always wear PFDs and everyone should wear PFDs when there are potentially hazardous boating condi tions Gasoline is highly flammable and its va pors are flammable and explosive Handle and store gasoline carefully Make sure there are no gas fumes or leaking fuel be fore starting the engine This product emits exhaust gases which contain carbon monoxide a colorless odorless...

Page 8: ...be obtained from many organizations including the fol lowing United States Coast Guard Consumer Affairs Staff G BC Office of Boating Public and Consumer Af fairs U S Coast Guard Headquarters Washington D C 20593 0001 Boating Safety Hotline 1 800 368 5647 National Marine Manufacturers Associa tion NMMA 401 N Michigan Ave Chicago Il 60611 Marine Retailers Association of America 155 N Michigan Ave Ch...

Page 9: ...tion and speed the other vessel will be able to determine how best to avoid you Give way vessel The vessel which does not have the right of way has the duty to take positive and timely action to stay out of the way of the Stand On vessel Normally you should not cross in front of the vessel with the right of way You should slow down or change directions brief ly and pass behind the other vessel You...

Page 10: ...f way as it should Overtaking If you are passing another vessel you are the Give Way vessel This means that the other vessel is expected to maintain its course and speed You must stay out of its way until you are clear of it Likewise if an other vessel is passing you you should maintain your speed and direction so that the other vessel can steer itself around you EMU25530 Other special situations ...

Page 11: ...and markers have an arrangement of shapes colors numbers and lights to show which side of the buoy a boater should pass on when navigat ing in a particular direction The markings on these buoys are oriented from the perspec tive of being entered from seaward the boat er is going towards the port This means that red buoys are passed on the starboard right side when proceeding from open wa ter into ...

Page 12: ... FLAMMABLE AND EXPLOSIVE Do not smoke when refueling and keep away from sparks flames or other sources of ignition Stop engine before refueling Refuel in a well ventilated area Refuel portable fuel tanks off the boat Take care not to spill gasoline If gaso line spills wipe it up immediately with ZMU01708 ...

Page 13: ... Engine oil If the recommended engine oil is not avail able another 2 stroke engine oil with an NMMA certified TC W3 rating may be used EMU25741 Propeller selection The performance of your outboard motor will be critically affected by your choice of propel ler as an incorrect choice could adversely affect performance and could also seriously damage the motor Engine speed depends on the propeller s...

Page 14: ...tle setting to maintain the engine in the proper operating range For instructions on propeller removal and in stallation see page 43 EMU25770 Start in gear protection Yamaha outboard motors or Yamaha ap proved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is in neutral Always select neutral before starting the en...

Page 15: ... with this engine is its dedicated fuel reservoir and must not 13 12 11 18 15 14 7 8 1 3 2 4 6 5 9 10 16 17 ZMU04829 1 Top cowling lock lever 2 Choke knob 3 Gear shift lever 4 Tiller handle 5 Throttle friction adjuster 6 Engine stop button Engine stop lanyard switch 7 Transom clamp handle 8 Tilt lock lever 9 Trim rod 10 Cooling water inlet 11 Propeller 12 Trim tab anode 13 Anti cavitation plate 14...

Page 16: ...e EMU25860 Air vent screw This screw is on the fuel tank cap To loosen the screw turn it counterclockwise EMU25911 Tiller handle To change direction move the tiller handle to the left or right as necessary EMU25922 Gear shift lever Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead Pushing the lever away from you puts the engine in reverse gear so...

Page 17: ...s desired tighten the adjuster to maintain the desired throttle set ting EMU25990 Engine stop lanyard switch The lock plate must be attached to the en gine stop switch for the engine to run The lanyard should be attached to a secure place on the operator s clothing or arm or leg Should the operator fall overboard or leave the helm the lanyard will pull out the lock plate stopping ignition to the e...

Page 18: ...l mix ture required to start pull out this knob EMU26070 Manual starter handle To start the engine first gently pull the han dle out until resistance is felt From that posi tion then pull the handle straight out quickly to crank the engine EMU26122 Steering friction adjuster A friction device provides adjustable resis tance to the steering mechanism and can be set according to operator preference ...

Page 19: ...re steering is correct Be sure you have tightened the bolt after ad justing the trim tab If the boat tends to veer the left port side turn the trim tab rear end to the port side A in the figure If the boat tends to veer the right starboard side turn the trim tab end to the starboard side B in the figure CAUTION ECM00840 The trim tab also serves as an anode to protect the engine from electrochemica...

Page 20: ...lock lever s turn type To remove the engine top cowling turn the lock lever s and lift off the cowling When in stalling the cowling check to be sure it fits properly in the rubber seal Then lock the cowling again by returning the lever s to the lock position EMU26801 Warning system CAUTION ECM00090 Do not continue to operate the engine if a warning device has activated Consult your Yamaha dealer i...

Page 21: ...d will automatically de crease to about 2000 r min The overheat warning indicator will light if equipped on the bottom cowling or the ta chometer The buzzer will sound if equipped on the tiller handle remote control box or main switch panel If the warning system has activated stop the engine and check the cooling water inlet for clogging ...

Page 22: ...ec tion is intended as reference only It is not possible to provide complete in structions for every possible boat and motor combination Proper mounting depends in part on experience and the specific boat and motor combination WARNING EWM00830 Improper mounting of the outboard mo tor could result in hazardous conditions such as poor handling loss of control or fire hazards Observe the following Fo...

Page 23: ...otor see page 27 EMU26970 Clamping the outboard motor 1 Place the outboard motor on the tran som so that it is positioned as close to the center as possible Tighten the tran som clamp screws evenly and securely Occasionally check the clamp screws for tightness during operation of the out board motor because they could be come loose due to engine vibration WARNING EWM00640 Loose clamp screws could ...

Page 24: ...ngine oil mixing chart 25 1 CAUTION ECM00150 Be sure to mix gasoline and oil complete ly otherwise the engine may be dam aged EMU27073 Procedure for pre mixed models Run the engine under load in gear with a propeller installed as follows 1 First 10 minutes Run the engine at the lowest possible speed A fast idle in neutral is best 2 Next 50 minutes Do not exceed half throttle approxi mately 3000 r ...

Page 25: ... Be sure the fuel tank is positioned on a se cure flat surface and that the fuel line is not twisted or flattened or likely to contact sharp objects if equipped Yamaha fuel tank or boat tank EMU27120 Oil Check to be sure you have plenty of oil for your trip EMU27130 Controls Check throttle shift and steering for prop er operation before starting the engine The controls should work smoothly with ou...

Page 26: ...ce drops and engine wear in creases dramatically While many additives available may reduce deposits Yamaha recommends the use of Ring Free Fuel Additive available from your Yamaha dealer Ring Free Fuel Addi tive has repeatedly proven its ability to clean combustion deposits from inside the engine notably the critical piston ring land area and fuel system components Follow product la beling for use...

Page 27: ...ng fuel portable tank WARNING EWM00420 Before starting the engine make sure that the boat is tightly moored and that you can steer clear of any obstructions Be sure there are no swimmers in the water near you When the air vent screw is loosened gasoline vapor will be released Gaso line is highly flammable and its vapors are flammable and explosive Refrain from smoking and keep away from open flame...

Page 28: ... Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg Then install the lock plate on the other end of the lanyard into the en gine stop switch WARNING EWM00120 Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg while operating Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it...

Page 29: ... strong pull straight out to crank and start the engine Repeat if necessary 6 After the engine starts slowly return the manual starter handle to its original po sition before releasing it 7 Slowly return the throttle grip to the fully closed position NOTE When the engine is cold it needs to be warmed up For further information see page 25 If the engine does not start on the first try repeat the pr...

Page 30: ... at all times while the engine is run ning overheating and serious damage could occur Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked Consult your Yamaha dealer if the problem cannot be located and cor rected EMU27740 Shifting WARNING EWM00180 Before shifting make sure there are no swimmers or obstacles in the water near you CA...

Page 31: ...equipped with a tilt lock le ver check that it is in the lock down po sition 3 Move the gear shift lever quickly and firmly from neutral to reverse Remote control models 1 Check that the tilt lock lever is in the lock position 2 Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from neutral to reverse EMU27820 Stopping engine Before stopping the...

Page 32: ...helps determine the position of the bow of the boat in the water Correct trim angle will help im prove performance and fuel economy while reducing strain on the engine Correct trim angle depends upon the combination of boat engine and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed WARNING EWM00740 Excessive trim for the operating ...

Page 33: ...t works best for your boat and operating conditions WARNING EWM00400 Stop the engine before adjusting the trim angle Use care to avoid being pinched when removing or installing the rod Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any signs of instabil ity or control problems Improper trim angle can cause loss of control NOTE The outboard motor ...

Page 34: ...reasing fuel economy and making it hard to increase speed Oper ating with excessive trim in at higher speeds also makes the boat unstable Resistance at the bow is greatly increased heightening the danger of bow steering and making opera tion difficult and dangerous NOTE Depending on the type of boat the outboard motor trim angle may have little effect on the trim of the boat when operating EMU2793...

Page 35: ...re for tilting up Manual tilt models 1 Place the gear shift lever in neutral 2 Disconnect the fuel line if a fuel joint is provided on the outboard motor 3 Place the tilt lock lever in the release po sition 4 Hold the rear of the top cowling with one hand tilt the engine up and turn the tilt support lever to the lock position and support the engine EMU28022 Procedure for tilting down manual tilt m...

Page 36: ...in loss of control Do not rotate the outboard motor 180 and operate the boat in reverse Place the gear shift in reverse to operate the boat in reverse Use extra care when operating in re verse Too much reverse thrust can cause the outboard motor to lift out of the water increasing the chance of ac cident and personal injury Return the outboard motor to its normal position as soon as the boat is ba...

Page 37: ...otor up until the tilt support bar automatically returns to the free position 7 Slowly lower the outboard motor to the normal position EMU28190 Cruising in other conditions Cruising in salt water After operating in salt water wash out the cooling water passages with fresh water to prevent them from becoming clogged with salt deposits NOTE For cooling system flushing instructions see page 33 Cruisi...

Page 38: ... 039 in Control system Tiller Starting system Manual Starting carburetion system Choke valve Alternator output 80 W Drive unit Gear positions Forward neutral reverse Gear ratio 2 08 27 13 Trim and tilt system Manual tilt Propeller mark F Fuel and oil Recommended fuel Regular unleaded gasoline Min pump octane 86 Recommended engine oil YAMALUBE 2 stroke outboard motor oil Fuel oil ratio Regular gaso...

Page 39: ... additional support device to secure it in the tilt position The outboard motor should be trailered and stored in the normal running position If there is insufficient road clearance in this position then trailer the outboard motor in the tilt po sition using a motor support device such as a transom saver bar Consult your Yamaha dealer for further details EMU28235 Clamp screw mounting models When t...

Page 40: ... is to be drained instead 3 Remove the engine top cowling and si lencer cover 4 Install the outboard motor on the test tank 5 Fill the tank with fresh water to above the level of the anti cavitation plate CAUTION ECM00300 Do not run the engine without supplying it with cooling water Either the engine water pump will be damaged or the en gine will be damaged from overheating Before starting the eng...

Page 41: ...ation see page 39 2 Change the gear oil For instructions see page 44 Inspect the oil for the pres ence of water that indicates a leaky seal Seal replacement should be performed by an authorized Yamaha dealer prior to use 3 Grease all grease fittings For further de tails see page 39 EMU28421 Cleaning and anticorrosion measures 1 Wash down the exterior of the outboard motor with fresh water and dry ...

Page 42: ...cluding those to the emission control system must be performed by an authorized Yamaha marine dealership A service manual is available for purchase through your Yamaha dealer for owners who have the mechanical skills tools and other equipment necessary to perform mainte nance not covered by this owner s manual EMU28510 Replacement parts If replacement parts are necessary use only genuine Yamaha pa...

Page 43: ... Item Actions Initial Every 10 hours 1 month 50 hours 3 months 100 hours 6 months 200 hours 1 year Anode s external Inspection replace ment Anode s internal Inspection replace ment Cooling water pas sages Cleaning Cowling clamp Inspection Fuel filter can be dis assembled Inspection cleaning Fuel system Inspection Fuel tank Yamaha por table tank Inspection cleaning Gear oil Change Greasing points G...

Page 44: ...hen removing or installing a spark plug be careful not to damage the insulator A damaged insulator could allow external sparks which could lead to explosion or fire The spark plug is an important engine com ponent and is easy to inspect The condition of the spark plug can indicate something about the condition of the engine For exam ZMU03734 ...

Page 45: ...plug to the correct torque NOTE If a torque wrench is not available when you are fitting a spark plug a good estimate of the correct torque is 1 4 to 1 2 a turn past fin ger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench EMU28962 Checking fuel system WARNING EWM00060 Gasoline and its vapors are highly flam mable and explosive Keep away from sparks...

Page 46: ...el in a rag Wipe up any spilled fuel immediately The fuel filter must be reassembled carefully with the O ring filter cup and hoses in place Improper assembly or replacement could result in a fuel leak which could result in a fire or explosion hazard EMU29001 Cleaning fuel filter 1 Remove the nut holding the fuel filter as sembly if equipped 2 Unscrew the filter cup catching any spilled fuel in a ...

Page 47: ...whether testing is conducted with the flushing attachment in a test tank or with the outboard motor in the water 1 Start the engine and allow it to warm up fully in neutral until it is running smooth ly 2 hp model Warm the engine with the throttle in the start position or less If the outboard is mounted on a boat be sure the boat is tightly moored NOTE Correct idling speed inspection is only possi...

Page 48: ...ening or tightening the propeller nut Put a wood block be tween the anti cavitation plate and the propeller to prevent the propeller from turning Checkpoints Check each of the propeller blades for wear erosion from cavitation or ventila tion or other damage Check the propeller shaft for damage Check the splines shear pin for wear or damage Check for fish line tangled around the pro peller shaft Ch...

Page 49: ...he washer Tighten the propeller nut to the specified torque 4 Align the propeller nut with the propeller shaft hole Insert a new cotter pin in the hole and bend the cotter pin ends NOTE If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque tighten the nut further to align it with the hole EMU29280 Changing gear oil WARNING EWM00800 Be sure the o...

Page 50: ...When the oil begins to flow out of the oil level plug hole insert and tighten the oil level plug 7 Insert and tighten the gear oil drain screw EMU29302 Cleaning fuel tank WARNING EWM00920 Gasoline is highly flammable and its va pors are flammable and explosive If you have any question about properly doing this procedure consult your Yamaha dealer Keep away from sparks cigarettes flames or other so...

Page 51: ...ect the external anodes periodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes CAUTION ECM00720 Do not paint anodes as this would render them ineffective NOTE Inspect ground leads attached to external anodes on equipped models Consult a Yamaha dealer for inspection and replace ment of internal anodes attached to the pow er unit EMU2939...

Page 52: ...Maintenance 47 copper or graphite These paints can cause more rapid engine corrosion ZMU01943 ...

Page 53: ...A Have serviced by a Yamaha dealer Q Is shift lever in gear A Shift to neutral Engine will not start starter operates Q Is fuel tank empty A Fill tank with clean fresh fuel Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is fuel filter clogged A Clean or replace filter Q Is starting procedure incorrect A See page 23 Q Has fuel pump malfunctioned A Have serviced by a Yamaha deal...

Page 54: ...p damaged A Have serviced by a Yamaha dealer Q Is air vent screw on fuel tank closed A Open air vent screw Q Is choke knob pulled out A Return to home position Q Is motor angle too high A Return to normal operating position Q Is carburetor clogged A Have serviced by a Yamaha dealer Q Is fuel joint connection incorrect A Connect correctly Q Is throttle valve adjustment incorrect A Have serviced by ...

Page 55: ...g s fouled or of incorrect type A Inspect spark plug s Clean or replace with recommended type Q Are weeds or other foreign matter tangled on gear housing A Remove foreign matter and clean lower unit Q Is fuel system obstructed A Check for pinched or kinked fuel line or other obstructions in fuel system Q Is fuel filter clogged A Clean or replace filter Q Is fuel contaminated or stale A Fill tank w...

Page 56: ...lering Damage could make the out board motor unsafe to operate If the outboard motor hits an object in the wa ter follow the procedure below 1 Stop the engine immediately 2 Inspect the control system and all com ponents for damage Also inspect the boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and careful ly 4 Have a Yamaha dealer inspect the out board motor b...

Page 57: ...ngine Use the emergency starter rope only as instructed Do not touch the fly wheel or other moving parts when the engine is running Do not install the starter mechanism or top cowling after the engine is running Do not touch the ignition coil spark plug wire spark plug cap or other elec trical components when starting or op erating the motor You could get an electrical shock EMU29561 Emergency sta...

Page 58: ... start the engine Repeat if neces sary EMU29760 Treatment of submerged motor If the outboard motor is submerged immedi ately take it to a Yamaha dealer Otherwise some corrosion may begin almost immedi ately If you cannot immediately take the outboard motor to a Yamaha dealer follow the proce dure below in order to minimize engine dam age EMU29771 Procedure 1 Thoroughly wash away mud salt sea weed ...

Page 59: ...or engine oil through the carburetor s and spark plug holes while cranking with the manual starter or emergency starter rope 5 Take the outboard motor to a Yamaha dealer as soon as possible CAUTION ECM00400 Do not attempt to run the outboard motor until it has been completely inspected ZMU01910 ZMU01911 ...

Page 60: ...55 Consumer information EMU29811 Important warranty information for U S A and Canada ...

Page 61: ...Consumer information 56 ...

Page 62: ...Consumer information 57 EMU29820 YAMAHA MOTOR CORPORATION U S A OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ...

Page 63: ...Consumer information 58 ...

Page 64: ...Consumer information 59 ...

Page 65: ...Consumer information 60 EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U S A OR CANADA ...

Page 66: ...Printed in Japan March 2004 0 2 1 Printed on recycled paper ...

Page 67: ...r au détail OUTBOARD MOTOR MODEL AND SERIAL NUMBER From I D label on clamp bracket MODÉLE ET NO DE SÉRIE DU MOTEUR HORS BORD sur l étiquette d identification de la presse de fixation For Dealer Use Only A l usage du concessionnaire YAMAHA DEALER NUMBER NO DU CONCESSIONNAIRE YAMAHA DEALER NAME NOM DU CONCESSIONNAIRE DATE SOLD DATE DE LIVRAISON OWNER S NAME NOM DU PROPRIÉTAIRE ADDRESS ADRESSE PHONE ...

Page 68: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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