Yamaha F2.5C Owner'S Manual Download

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EMU00414

Chapter 5

TROUBLE RECOVERY

TROUBLESHOOTING

..............................5-1

TEMPORARY ACTION IN
EMERGENCY

............................................5-5

Impact damage.....................................5-5
Power trim/tilt will not operate ...........5-5
Starter will not operate ........................5-6
Treatment of submerged motor .........5-9

65W-9-17-5 3/10/03 14:37 Page 1

Summary of Contents for F2.5C

Page 1: ...F25C T25C OWNER S MANUAL U S A Edition LIT 18626 05 46 ...

Page 2: ......

Page 3: ...al 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 cur rent product information available at the time of printing there may be minor dis crepancies between your machine and this manual If the...

Page 4: ...E GENERAL INFORMATION BASIC COMPONENTS OPERATION MAINTENANCE TROUBLE RECOVERY INDEX READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR 1 2 3 4 5 6 EMU00003 CONTENTS ...

Page 5: ...board motor serial number 1 1 Key number 1 1 EMISSION CONTROL INFORMATION 1 2 SAFETY INFORMATION 1 4 IMPORTANT LABELS 1 6 BASIC BOATING RULES 1 7 FUELING INSTRUCTIONS 1 11 Gasoline Petrol 1 12 ENGINE OIL 1 13 BATTERY REQUIREMENT 1 14 PROPELLER SELECTION 1 15 START IN GEAR PROTECTION 1 16 1 ...

Page 6: ...u in ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor serial number EMU00008 KEY NUMBER If a main key switch is equipped with the motor the key identification number is stamped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key 1 Key number 401013 q 904011 12...

Page 7: ...label New Technology 4 stroke EM Manufactured date label This label is attached to the clamp brack et 2 Manufactured date label EMISSION CONTROL INFORMATION ENGINE FAMILY THIS ENGINE CONFORMS TO 2001 U S EPA REGULATIONS FOR MARINE SI ENGINES THIS ENGINE CONFORMS TO 2001 CALIFORNIA EMISSION REGULATIONS FOR SI MARINE ENGINES REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS F...

Page 8: ...nal carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 stan dards for marine engines Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low Emission The three star label identifi...

Page 9: ... carefully for swimmers during the engine operation 8 Stay away from swimming areas 8 When a swimmer is in the water near you shift into neutral and shut off the engine EMU00917 SAFETY INFORMATION 8 Before mounting or operating the out board motor read this entire manual Reading it should give you an under standing of the motor and its operation 8 Before operating the boat read any owner s or oper...

Page 10: ...ited States Coast Guard Consumer Affairs Staff G BC Office of Boating Public and Consumer Affairs U S Coast Guard Headquarters Washington D C 20593 0001 Boating Safety Hotline 1 800 368 5647 National Marine Manufacturers Association NMMA 401 N Michigan Ave Chicago Il 60611 Marine Retailers Association of America 155 N Michigan Ave Chicago Il 60601 ...

Page 11: ...al position 6E0 83627 41 WARNING 7Be sure shift control is in neutral before starting engine except 2HP 7Do not touch or remove electrical parts when starting or during operation 7Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 6A1 83625 41 6G8 13444 41 CAUTION Transport and store the engine only as shown Otherwise engine damage could result from lea...

Page 12: ... dened vessel These rules determine which vessel has the right of way and what each vessel should do Stand on vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision When you maintain your direction 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 ...

Page 13: ...are close enough to run the risk of collision neither of you has the right of way Both of you should alter course to avoid an accident You should keep the other vessel on your port left side This rule doesn t apply if both of you will clear one another if you continue on your set course and speed Crossing When two power driven vessels are crossing each other s path close enough to run the risk of ...

Page 14: ...de the passage of other vessels in narrow channels Sailing vessel right of way Sailing vessels should normally be given the right of way The exceptions to this are 1 When the sailing vessel is overtaking the power driven vessel the power driven vessel has the right of way 2 Sailing vessels should keep clear of any fishing vessel 3 In a narrow channel a sailing vessel should not hamper the safe pas...

Page 15: ...g toward head of naviga tion Leave to starboard right proceeding up stream White Light Red Light A LIGHTED SAFE WATER BUOY No number Marks midchannel pass on either side Letter has no lateral significance used for No number Topmost band red preferred Top Mark White Light White Light OR OR LIGHTED PREFERRED CHANNEL TO RB L RG L PORT BUOY identification and location purposes channel is to left of bu...

Page 16: ...tely with dry rags 8 Do not overfill the fuel tank 8 Tighten the filler cap securely after refueling 8 If you should swallow some gasoline inhale a lot of gasoline vapor or get gasoline in your eyes get immediate medical attention 8 If any gasoline spills onto your skin immediately wash with soap and water Change clothing if gasoline spills on it 8 Touch the fuel nozzle to the filler open ing or f...

Page 17: ...ting of 86 Pump Octane Number R M 2 EMU00027 Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not recommended by Yama ha because it can cause fuel system dam age or engine performance problems ...

Page 18: ... stroke motor oil with a combination of corresponding SAE and API as shown in the chart cC All 4 stroke engines are shipped from the factory without engine oil Engine oil quantity See Chapter 4 Specifications 001162 SAE API SE SF SG SH SJ 10W 30 10W 40 ...

Page 19: ...ose a battery which meets the following specifications EMU01859 Minimum cold cranking amps CCA SAE 245 amps at 18 C 0 4 F Minimum marine cranking amps MCA ABYC 323 amps at 0 C 32 F Minimum reserve capacity RC SAE 52 minutes EMU01783 cC A battery cannot be connected to models that do not have a rectifier or Rectifier Regulator Models without a rectifier or Rectifier Regulator F25MH 8 If you wish to...

Page 20: ...load a smaller pitch propeller is more suitable as it enables the correct engine speed to be main tained Conversely a larger pitch pro peller is more suitable for a smaller oper ating load Yamaha dealers stock a range of pro pellers and can advise you and install a propeller on your outboard that is best suited to your application NOTE At full throttle and under a maximum boat load the engine s rp...

Page 21: ...gear protection device s This feature permits the engine to be started only when it is Neutral Always select Neutral before starting the engine 1 Propeller diameter in inches 2 Propeller pitch in inches 3 Type of propeller propeller mark Refer to the section CHECKING PRO PELLER for instructions on propeller removal and installation ...

Page 22: ...E MEMO ...

Page 23: ... handle 2 3 Remote control 2 6 Steering friction adjusting lever 2 10 Trim tab 2 11 Trim angle adjusting rod 2 13 Power trim tilt switch 2 13 Warning indicator s 2 14 Digital tachomoter 2 14 Tilt lock mechanism 2 17 Tilt support knob 2 17 Tilt support bar 2 17 Top cowling lock lever 2 17 Flushing device 2 18 WARNING SYSTEM 2 19 Overheat warning 2 19 Low oil pressure warning 2 20 1 2 3 4 5 6 ...

Page 24: ...djusting rod 9 Clamp bracket 0 Power trim and tilt switch q Starter button w Recoil starter handle e Warning indicator r Gear shift lever t Tiller handle y Steering friction adjusting lever u Clamp screw i Rope attachment o Tilt lock lever p Flushing device a Tilt support knob s Remote control box d Digital tachometer f Fuel tank May not be exactly as shown also may not be included as standard equ...

Page 25: ...cap 4 Air vent screw If equipped EMU00042 Fuel Hose Joint This connector is provided for connecting or disconnecting fuel hose EMU00044 Fuel Meter This meter is on the fuel tank cap It shows current fuel quantity in the fuel tank approximately EMU00045 Fuel Tank Cap This cap is for filling fuel To remove it turn it counterclockwise EMU00046 Air Vent Screw This screw is on the fuel tank cap To loos...

Page 26: ...ows 1 Throttle control grip 2 Throttle indicator 3 Throttle friction adjusting knob screw 4 Engine stop button Engine stop lanyard switch EMU00060 STARTER BUTTON for Tiller control model When you push the starter button the electric starter motor cranks the engine to start it q w e EMU00051 GEAR SHIFT LEVER for Tiller control model Turning the gear shift lever towards you engages the clutch with t...

Page 27: ...movement of the throttle grip This is adjustable for opera tor preference When constant speed is desired tighten the adjusting knob to maintain the desired throttle setting w Do not overtighten the friction adjusting knob If there is too much resistance it may be difficult to move the throttle grip which could result in an accident 502016 START q Resistance Knob Increase Turn clockwise Decrease Tu...

Page 28: ... place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly T...

Page 29: ...ed 6 Throttle 7 Fully open EMU00096 REMOTE CONTROL Both the shifter and the throttle are actu ated by the remote control lever Additionally the remote control also has the electrical switches 1 Remote control lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Main switch 5 Engine stop lanyard switch 6 Power trim and tilt switch if equipped 7 Throttle friction adjusting screw 000200 w q e...

Page 30: ... The remote control lever will operate only when the neutral throttle lever is in the closed position 1 Fully open 2 Fully closed N 701033 q w ON START OFF 701021 EMU00101 Main switch The main switch controls the ignition sys tem its operation is described below 8 OFF Electrical circuits switched off The key can be removed 8 ON Electrical circuits switched on The key cannot be removed 8 START Star...

Page 31: ... away under power w 8 Attach the lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control Als...

Page 32: ...ctions ADJUSTING TRIM ANGLE and TILTING UP DOWN in Chapter 3 for instructions on usage EMU01155 Throttle Friction Adjusting Screw A friction device in the remote control box provides adjustable resistance to move ment of the remote control lever and can be set according to operator preference An adjusting screw is located on the front of the remote control box w Do not overtighten the friction adj...

Page 33: ...sesistance steering movement This is adjustable for operator preference w Do not overtighten the friction adjusting lever If there is too much resistance it may be difficult to steer which could result in an accident Resistance Lever Increase Turn clockwise Decrease Turn counterclockwise ...

Page 34: ...ted trim tab may cause difficult steering Always test run after the trim tab has been installed or replaced to be sure steering is correct Be sure you have tightened the bolt after adjusting the trim tab 1 Trim tab 2 Bolt Boat tends to veer To the left port side To the right starboard side The fin of trim tab Turn to the left port side A in the figure Turn to the right star board side B in the fig...

Page 35: ...een installed or replaced to be sure steering is correct Be sure you have tightened the bolt after adjusting the trim tab 1 Trim tab 2 Bolt cC The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode Boat tends to veer To the left port side To the right starboard side The fin of trim tab Turn to the...

Page 36: ...rim tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the engine off Attempting to use the cowl ing mounted power trim tilt switch while the boat is moving could increase the risk of falling overboard and could distract the operator increasing the risk of colli sion with another boat or an obstacle NOTE Refer to the section Adjusting Trim Angle and Tilt...

Page 37: ...ITAL TACHOMETER This gauge contains the tachometer trim meter hour meter low oil pressure warn ing indicator and the overheat warning indicator 1 Tachometer 2 Trim meter 3 Hour meter 4 Low oil pressure warning indicator 5 Overheat warning indicator 6 Set button 7 Mode button NOTE All segments of the display will light momentarily after the main switch is turned on and will return to normal there a...

Page 38: ... EMU01620 Hour Meter This meter shows the number of hours the engine has been run It can be set to show the total number of hours or the number of hours for the current trip The display can also be turned on and off 8 Changing the display format Pressing the MODE button changes the display format in the following circular pattern Total hours Trip hours Display off 8 Resetting the trip hours Simult...

Page 39: ... not indicate the oil level in the engine Use the Oil Level Gauge to check the remaining oil quantity Refer to the section CHECKING THE ENGINE OIL LEVEL for details EMU01553 Overheat Warning Indicator If the engine temperature rises too high the warning indicator will start to blink Refer to OVERHEAT WARNING for details 1 Overheat warning indicator cC Do not continue to operate the engine if a war...

Page 40: ... bar 1 keeps the outboard motor in the tilted up position 403052 q 2 17 EMU00153 TILT LOCK MECHANISM for Manual tilt model The tilt lock mechanism is used to pre vent reverse thrust from the propeller lift ing the outboard motor when reversing To lock it set the tilt lock lever in the Lock position To release it place the tilt lock lever in the Tilt position 1 Tilt lock lever 402073 q 403054 EMU00...

Page 41: ... EMU01146 FLUSHING DEVICE This device 1 is used to clean the cooling water passages of the motor using a gar den hose and tap water NOTE Refer to Cleaning Cooling water Passages in Chapter 4 for instructions on usage ...

Page 42: ...vice If the engine temperature rises too high the warning device will activate 1 Included N A If the warning system has been activated stop the engine and check the water inlet for clogging Not equipped on all models 701054 605021 Activation of warning device The engine speed will automatically decrease to about 2 000 r min The overheat warning indicator will come on The buzzer will sound Tiller R...

Page 43: ... add oil as needed If the oil level is correct consult your Yamaha dealer cC Do not continue to run the engine if the low oil pressure lamp is ON Serious engine damage may occur 223012 701054 Activation of warning device Engine speed will automatically decrease to about 2 000 r min The low oil pressure warning indicator will come on The buzzer will sound Tiller Remote control control model model 1...

Page 44: ...E MEMO ...

Page 45: ...3 6 Checking the engine oil level 3 7 FILLING FUEL 3 8 STARTING ENGINE 3 9 WARMING UP ENGINE 3 14 SHIFTING 3 15 Forward 3 15 Reverse 3 16 STOPPING ENGINE 3 17 TRIMMING OUTBOARD MOTOR 3 18 Adjuting trim angle 3 19 TILTING UP DOWN 3 22 CRUISING IN SHALLOW WATER 3 25 CRUISING IN OTHER CONDITIONS 3 27 Cruising in salt water 3 27 Cruising in turbid water 3 27 1 2 3 4 5 6 ...

Page 46: ...rne water spray while the boat is cruising Severe engine damage may result if the motor is operat ed continuously in the presence of air borne water spray NOTE During water testing check the buoyancy of the boat at rest with its maximum load Check that the static water level on the exhaust housing is low enough to pre vent water entry into the powerhead when water rises due to waves when the outbo...

Page 47: ... the specific boat motor com bination 8 Your dealer or other person experi enced in proper rigging should mount the motor If you are mounting the motor yourself you should be trained by an experienced person permanent mounted type 8 Your dealer or other person experi enced in proper outboard motor mounting should show you how to mount your motor portable type Mount the outboard motor on the center...

Page 48: ... cavitation tends to occur thus reducing the propulsion and if the pro peller tips cut the air the engine speed will rise abnormally and cause the engine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engine efficiency Mount the engine so that the anti cavita tion plate is between the bottom of the boat and a level 25 mm 1 in below it NOTE 8 The...

Page 49: ... Occasionally check the screws for tight ness during operation 2 An engine restraint cable or chain should be used Attach one end to the engine restraint cable attachment point and the other to a secure mounting point on the boat Otherwise the engine could be com pletely lost if it accidentally falls off the transom Secure the clamp bracket to the tran som with the bolts provided with the outboard...

Page 50: ...minutes 3 For the next eight hours of operation Avoid continuous operation at full throttle for more than five minutes at a time 4 After these first 10 hours Operate the engine normally EMU00224 BREAKING IN RUNNING IN ENGINE Your new engine requires a period of break in running in to allow mating sur faces of moving parts to wear in evenly Correct break in running in will help ensure proper perfor...

Page 51: ...mage can occur EMU00206 Fuel 8 Check to be sure you have plenty of fuel for your trip 8 Make sure there are no fuel leaks or gasoline fumes 8 Check fuel line connections to be sure they are tight 8 Be sure the fuel tank is positioned on a secure flat surface and that the fuel hose is not twisted or flattened or likely to contact sharp objects EMU00208 Oil 8 Check the level of the oil in the sump w...

Page 52: ...unting 8 Look for loose or damaged fasteners 8 Check the propeller for damage EMU01436 CHECKING THE ENGINE OIL LEVEL 1 Put the outboard motor in an upright position not tilted 2 Pull out the oil dipstick and wipe it clean 3 Completely re insert the dipstick and pull out it again 4 Check the oil level using the dipstick to be sure the level falls between the upper and lower marks Fill with oil if i...

Page 53: ...ives such as aromatics and oxy genates has increased These additives are important for the engines in passen ger cars but they can have detrimental effects in marine engines because of increased deposits in the combustion chamber When enough deposits collect piston rings begin sticking Performance drops and engine wear increases dramati cally While many additives available may reduce deposits Yama...

Page 54: ...is product emits exhaust gases which contain carbon monoxide a col orless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 1 If there is an air vent screw on the fuel tank cap loosen it 2 or 3 turns 2 If there is a fuel joint on the motor firmly connect the fu...

Page 55: ...e engine stop switch w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering c...

Page 56: ...U00245 Electric Start Model 7 Push the starter button to start the starting motor 8 Immediately the engine starts release the starter switch to return it to its home position cC 8 Do not push the starter switch when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds If the starter motor is run continuously for more than 5 seconds the battery will rapidly become e...

Page 57: ... lanyard in the engine stop switch w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most...

Page 58: ...main switch to return it to ON cC 8 Do not turn the main switch to START when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds The battery will rapidly become exhausted and it will be impossible for it to start the engine If the engine does not start within 5 seconds return the main switch to ON wait 10 seconds and then crank the engine again ...

Page 59: ...rwise serious engine damage could occur Check the oil level and add oil if necessary If the cause for the low oil pressure warning indicator cannot be found consult your Yamaha dealer 8 A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages If water is not flowing out of the pilot hole at all times while the engine is running do not c...

Page 60: ...ottle first so that the engine idles or runs at low speeds START N F 701043 N F EMU00265 FORWARD Tiller control model 1 Place the throttle control grip in the fully closed position 2 Turn the gear shift lever quickly and firmly from Neutral to Forward Remote control model Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from Neutral to Forward ...

Page 61: ...ol grip in the fully closed position for Tiller control model 2 Check that the tilt lock lever for Manual tilt Hydro tilt model is in the locked position START 402073 N R N R 701044 Tiller control model 3 Turn the gear shift lever quickly and firmly from Neutral to Reverse Remote control model 3 Pull up the neutral interlock trigger if equipped and move the remote con trol lever quickly and firmly...

Page 62: ...e stop button or turn the main switch to OFF 2 If the fuel joints are provided discon nect the fuel line from the motor after stopping the engine 3 Tighten the air vent screw on the fuel tank cap after stopping the engine if it is equipped 4 Remove the key if the boat will be left unattended NOTE The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop...

Page 63: ... and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed w Excessive trim for the operating condi tions either trim up or trim down can cause boat instability and can make steering the boat more difficult This increases the possibility of an accident If the boat begins to feel unstable or is hard to steer slow down and or readjust the ...

Page 64: ... in move the rod toward the transom Make test runs with the trim set to differ ent angles to find the position that works best for your boat and operating condi tions w 8 Stop the engine before adjusting the trim angle 8 Use care to avoid being pinched when removing or installing the rod 8 Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any signs ...

Page 65: ... located on the bottom engine cowling if equipped only when the boat is at a complete stop with the engine off The outboard motor trim angle can be adjusted operating the power trim tilt switch 1 To raise the bow trim out push the switch UP To lower the bow trim in push the switch DN Make test runs with the trim set to differ ent angles to find the position that works best for your boat and operat...

Page 66: ...nd economy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces performance further and the boat may porpoise hop in the water which could throw the operator and passengers overboard Bow Down When the bow of the boat is down it is easier to accelerate from a standing start onto plane To...

Page 67: ...er heating can result 8 Do not tilt up the engine by pushing the steering handle as this could break the handle w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinch any body parts between the drive unit and engine bracket w Leaking fuel is a fire hazard Disconnect the fuel line if the engine will be tilted for more than a few minutes Othe...

Page 68: ...e position 4 Hold the rear of the top cowling with one hand and fully tilt the engine up 5 The tilt support bar turns to the locked position automatically 402071 403052 304043 402074 EMU00300 PROCEDURE FOR TILTING DOWN Manual tilt model 1 Place the tilt lock lever in the lock position 2 Slightly tilt up the engine until the tilt support bar is released automatically 3 Tilt down the engine ...

Page 69: ...e the engine could fall back down suddenly if oil in the power trim tilt unit should lose pressure UP DN 701034 UP DN 403054 304043 2 Push the power trim tilt switch UP until the outboard has tilted up com pletely EMU00305 PROCEDURE FOR TILTING DOWN Power trim tilt model 1 Push the power trim tilt switch UP until the engine is supported by the tilt rod 2 Pull out the tilt support knob 3 Push the p...

Page 70: ... lock mecha nism does not work while the shallow water cruising system is being used Hitting an underwater obstacle could cause the engine to lift out of the water resulting in loss of control 8 Use extra care when operating in reverse Too much reverse thrust can cause the engine to lift out of the water increasing the chance of acci dent and personal injury 8 Return the engine to its normal posi ...

Page 71: ...e tilt support bar will lock automatically supporting the engine in a partially raised position NOTE This motor has 2 positions for shallow water cruising RETURNING TO ORIGINAL POSITION 1 Place the tilt lock lever in the lock position 2 Slightly tilt up the engine until the tilt support bar automatically returns to the free position 3 Then slowly lower the engine to the normal position ...

Page 72: ...resh water to prevent them from becoming clogged up with salt deposits NOTE Refer to cooling system flushing instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR CRUISING IN TURBID WATER It is strongly recommended that the optional chromium plated water pump kit be installed if the outboard is to be used in turbid muddy water conditions ...

Page 73: ...5 Checking fuel system 4 16 Inspecting fuel filter 4 17 Inspecting idling speed 4 18 Changing engine oil 4 19 Replacing fuse 4 21 Checking wiring and connectors 4 22 Exhaust leakage 4 22 Water leakage 4 22 Checking power trim and tilt system 4 23 Checking propeller 4 24 Changing gear oil 4 26 Cleaning fuel tank 4 28 Inspecting and replacing anode s 4 29 Checking battery 4 30 Checking bolts and nut...

Page 74: ...X mm in Battery Min cold cranking amps CCA SAE amps at 18 C 0 4 F Min marine cranking amps MCA ABYC amps at 0 C 32 F Min reserve capacity RC SAE minutes Alternator output V A W Starting carburetion system 4 stroke OHC L2 498 30 39 65 0 75 0 2 56 2 95 CDI system DPR6EA 9 0 8 0 9 0 031 0 035 Tiller control Manual recoil starter 0 15 0 25 0 006 0 010 0 25 0 35 0 010 0 014 12 80 Prime start DRIVE UNIT...

Page 75: ...08 27 13 Manual tilt F Forward Neutral Reverse 2 08 27 13 Manual tilt F Regular unleaded gasoline Minimum 86 25 6 60 5 50 4 stroke motor oil SE SF SG SH SJ 10W 30 10W 40 1 7 1 80 1 50 1 9 2 00 1 67 Hypoid gear oil SAE90 320 10 81 11 27 Regular unleaded gasoline Minimum 86 25 6 60 5 50 4 stroke motor oil SE SF SG SH SJ 10W 30 10W 40 1 7 1 80 1 50 1 9 2 00 1 67 Hypoid gear oil SAE90 320 10 81 11 27 ...

Page 76: ...d cranking amps CCA SAE amps at 18 C 0 4 F Min marine cranking amps MCA ABYC amps at 0 C 32 F Min reserve capacity RC SAE minutes Alternator output V A W Starting carburetion system 4 stroke OHC L2 498 30 39 65 0 75 0 2 56 2 95 CDI system DPR6EA 9 0 8 0 9 0 031 0 035 Remote control Electric start 0 15 0 25 0 006 0 010 0 25 0 35 0 010 0 014 245 323 52 12 15 Prime start DRIVE UNIT Gear positions Gea...

Page 77: ... fuel tank whether in a boat or car 8 DO NOT fill fuel container to maximum capacity Gasoline will expand consid erably as it warms up and can build up pressure in the fuel container This can cause fuel leakage and a potential fire hazard cC Do not use the tilt support lever knob when trailering the boat The outboard motor could shake loose from the tilt support and fall If the motor can not be tr...

Page 78: ...own when transporting and storing it 8 Do not place the engine on its side before the cooling water has drained from it completely or water may enter the cylinder through the exhaust port and cause problems 8 Store the engine in a dry well ventilat ed place not in direct sunlight 1 Vertical position 2 Horizontal position 000912 102 2 q w EMU00335 Filling Fuel Tank Fill the fuel tank with fresh fue...

Page 79: ...ing parts while engine is running EMU00339 8 Flushing in a Water Tank cC If the fresh water level is below the level of the anti cavitation plate or if the water supply is insufficient engine seizure may occur 1 Remove the engine top cowling and silencer cover 2 Install the outboard motor on the water tank 3 Fill the tank with fresh water to above the level of the anti cavitation plate 4 Run the e...

Page 80: ...e pro peller 2 Install a flushing attachment 1 to the cooling water inlet 3 Run the engine at a fast idle for 10 15 minutes supplying fresh water 4 Just prior to turning off the engine quickly spray Yamaha Stor Rite Engine Fogging Oil Part No LUB STRRT 12 00 alternately into the silencer cover When properly done the engine will smoke excessively and almost stall 5 Remove the flushing attachment an...

Page 81: ...rings 3 Change the gear case oil Refer to CHANGING GEAR OIL Inspect the oil for the presence of water which indicates a leaky seal Seal replace ment should be performed by an authorized Yamaha dealership prior to use 4 Grease all grease fittings Refer to the GREASING EMU00351 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the out board with fresh water and dry off completely 2 Spr...

Page 82: ...ing in a closed space Always wear eye protection when working near batteries KEEP OUT OF REACH OF CHILDREN Batteries vary among manufacturers Therefore the following procedures may not always apply Consult your battery manufacturer s instructions 1 Disconnect and remove the battery from the boat Always disconnect the black negative lead first to prevent the risk of shorting 2 Clean the battery cas...

Page 83: ...the emission control system must be performed by an authorized Yamaha marine dealership A service manual is available for purchase through a Yamaha dealer for owners who have the mechanical skills tools and other equipment necessary to perform maintenance not covered by this owner s manual EMU00356 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equiva lents o...

Page 84: ...ning adjustment replacement Greasing points Greasing Gear oil Change Fuel system Inspection Fuel filter disposable Inspection replacement 1 1 1 Fuel tank Yamaha portable tank Cleaning Idling speed carburetor models Inspection adjustment 1 1 Anode s Inspection replacement 1 1 1 Cooling water passages Cleaning Propeller and cotter pin Inspection replacement Timing belt Inspection replacement 1 1 Bat...

Page 85: ...E 4 12 EMU00366 GREASING Yamaha marine grease Water resistant grease 500 hours 1000 hours 2 5 years 5 years Timing belt Replacement 1 Item Actions Every ...

Page 86: ...E 4 13 103182 EMU00366 GREASING Yamaha marine grease Water resistant grease ...

Page 87: ...air leak or carburetion problem in that cylinder Do not attempt to diagnose any problems yourself Instead take the outboard motor to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the sp...

Page 88: ... to 1 2 a turn past finger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench 1 Spark plug gap 2 Spark plug I D mark NGK EMU16350 CHECKING TOP COWLING Check the fitting of the top cowling by pushing it with both hands If the fitting is loose have it repaired by a Yamaha dealer 903033 w q Spark plug torque Refer to SPECIFICATIONS page 4 1 Initial of sp...

Page 89: ...und it should be repaired immediately by Yamaha dealer or other qualified mechan ic Checking points 8 Fuel system parts leakage 8 Fuel hose joint leakage 8 Fuel hose cracks or other damage 8 Fuel connector leakage w Leaking fuel can result in fire or explo sion 8 Check for fuel leakage regularly 8 If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper repair...

Page 90: ...cigarettes flames or other sources of ignition 8 This procedure will allow some fuel to spill Catch fuel in a rag Wipe up any spilled fuel immediately 8 The fuel filter must be reassembled carefully with O ring filter cup and hoses in place Improper assembly or replacement can result in a fuel leak which could result in a fire or explosion hazard 207053 EMU00374 Check the fuel filter periodically ...

Page 91: ...th 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 smoothly If the outboard motor is mounted on a boat be sure the boat is tightly moored 2 Verify whether the idle speed is set to specification For idle speed specifica tions see Specifications in this chapter NOTE Correct idling speed ins...

Page 92: ... not tilt ed when checking and changing the engine oil 8 If the oil level is above the upper level mark drain until the level meets the specified capacity Overfilling the oil may cause leakage or damage 1 Put the outboard motor in an upright position not tilted 2 Prepare a suitable container which can hold a larger amount than the engine oil capacity Loosen and remove the drain bolt 1 while hold i...

Page 93: ...warning lamp turns off Make sure that there are no oil leaks cC If the oil lamp does not turn off or if there are oil leaks stop the engine and find the cause Continued operation with a problem could cause severe engine damage If the problem cannot be found and corrected consult your Yamaha deal er 6 Turn off the engine and wait 3 min utes Recheck the oil level using the dipstick to be sure the le...

Page 94: ... incorrect fuse or a piece of wire may allow excessive current flow This could cause electrical system damage and a fire hazard NOTE If the new fuse blows again immediately consult a Yamaha dealer 1 Fuse holder 2 Fuse 20A 4 21 NOTE 8 For disposal of used oil consult your Yamaha dealer 8 The oil should be changed more often when the engine is operated under adverse conditions such as extended troll...

Page 95: ... each connector is engaged securely EMU00384 EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and crank case EMU00385 WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head and crank case ...

Page 96: ...of oil leaks 2 Operate each of the power trim and tilt switches on remote control and engine bottom cowling If equipped to check that all switches work 3 Tilt up the motor and check that the trim and tilt rod 1 is pushed out com pletely 4 Check that the trim and tilt rod is free of corrosion or other flaws 5 Operate the motor to trim and tilt down Check that the trim and tilt rod operates smoothly...

Page 97: ...engine stop switch Turn off the battery cut off switch if your boat has one 8 Do not use your hand to hold the pro peller when loosening or tightening the propeller nut Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning 210011 602051 602054 EMU00390 Propeller Checking Point 8 Check each of the propeller blades for wear erosion from cavitation or v...

Page 98: ...ion and be lost 1 Apply Yamaha Marine grease or Corrosion resistant grease to the pro peller shaft 2 Install the thrust washer and propeller on the propeller shaft 3 Install the spacer and washer Tighten the propeller nut to the specified torque 602073 q w e r t y 602045 6 5 4 3 2 1 EMU00976 Removing the Propeller 1 Straighten the cotter pin 1 and pull it out using a pair of pliers 2 Remove the pr...

Page 99: ...utboard accidentally falls 1 Tilt the outboard motor so that the oil drain plug is at the lowest point possi ble 2 Place a suitable container under the gear case 602053 4 Align the propeller nut with the pro peller 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 torq...

Page 100: ...gear case which can cause gear damage Consult a Yamaha dealer for repair of the lower unit seals NOTE For disposal of used oil consult your Yamaha dealer 5 With the outboard motor in a vertical position and using a flexible or pres surized filling device inject the gear oil into the oil drain plug hole 6 When the oil begins to flow out of the oil level plug hole insert and tighten the oil level pl...

Page 101: ...ion about properly doing this procedure consult your Yamaha dealer 8 Keep away from sparks cigarettes flames or other sources of ignition when cleaning the fuel tank 8 Remove the fuel tank from the boat before cleaning it Work only outdoors in an area with good ventilation 8 Wipe up any spilled fuel immediately 8 Reassemble the fuel tank carefully Improper assembly can result in a fuel leak which ...

Page 102: ...riodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes cC Do not paint anodes as this would ren der them ineffective NOTE Inspect ground leads attached to external anodes on equipped models Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit 604016 405015 T25 ...

Page 103: ...lush with water 8 EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL 8 Drink large quantities of water or milk followed by milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydro gen gas therefore you should always fol low these preventive measures 8 Charge batteries in a well ventilated area 8 Kee...

Page 104: ...el when neces sary Top up only with distilled water or pure de ionized water suitable to use in batteries 2 Always keep the battery in a good state of charge Installing a voltmeter will help you monitor your battery If you will not use the boat for a month or more remove the battery from the boat and store it in a cool dark place Completely recharge the battery before using it 3 If the battery wil...

Page 105: ...que of other bolts and nuts cC 8 Make sure the main switch on applica ble models is OFF before working on the battery 8 Reversal of the battery leads will dam age the rectifier 8 Connect the RED lead first when installing the battery and disconnect the RED lead last when removing it Otherwise the electrical system can be damaged 8 The electrical contacts of the battery and cables must be clean and...

Page 106: ...e garden hose 3 4 When flushing is complete reinstall the garden hose connector 2 on the fitting 1 on the bottom cowling Tighten the connector securely cC Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal opera tion Water will leak out of the connector instead of cooling the engine which can cause serious overheating Be sure the conn...

Page 107: ... nicks or flaking paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas A touch up paint is available from a Yamaha dealer 001187 EMU00413 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clean of marine growths as possible If neces sary the boat bottom can be coated with an anti fouling paint approved for y...

Page 108: ...E MEMO ...

Page 109: ...4 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Power trim tilt will not operate 5 5 Starter will not operate 5 6 Treatment of submerged motor 5 9 1 2 3 4 5 6 ...

Page 110: ...ric overload and repair Replace fuse with one of correct amperage 4 Have serviced by a Yamaha dealer 5 Shift to neutral B Engine will not start Starter operates 1 Fuel tank empty 2 Fuel contaminated or stale 3 Fuel filter clogged 4 Starting procedure incorrect 5 Fuel pump malfunctions 6 Spark plug s fouled or incorrect type 7 Spark plug cap s fitted incorrectly 8 Poor connections or damaged igniti...

Page 111: ...lve adjustment incorrect 18 Battery lead disconnected 1 Inspect spark plug s Clean or replace with recommended type 2 Check for pinched or kinked fuel line or other obstructions in fuel system 3 Fill tank with clean fresh fuel 4 Clean or replace filter 5 Have serviced by a Yamaha dealer 6 Find and correct cause of warning 7 Inspect and adjust as specified 8 Check wires for wear or breaks Tighten a...

Page 112: ...ged 2 Propeller pitch or diameter incorrect 3 Trim angle incorrect 4 Motor mounted at incorrect height on transom 5 Warning system activated 6 Boat bottom fouled with marine growth 7 Spark plug s fouled or incorrect type 8 Weeds or other foreign matter tangled on gear housing 9 Fuel system obstructed 10 Fuel filter clogged 11 Fuel contaminated or stale 12 Spark plug gap incorrect 1 Have propeller ...

Page 113: ...amaha dealer 15 Check and replace oil with specified type 16 Have serviced by a Yamaha dealer 17 Open the air vent screw 18 Have serviced by a Yamaha dealer 19 Connect correctly 20 Inspect spark plug and replace it with recommended type E Engine power loss F Engine vibrates excessively 1 Propeller damaged 2 Propeller shaft damaged 3 Weeds or other foreign matter tangled on propeller 4 Motor mounti...

Page 114: ... boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and carefully 4 Have a Yamaha dealer inspect the outboard motor before operating it again 411033 q 607011 EMU00419 POWER TRIM TILT WILL NOT OPERATE If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit the engine can b...

Page 115: ...at could unexpected ly start to move which could result in an accident 8 Be sure no one is standing behind you when pulling the starter rope It could whip behind you and injure someone 8 An unguarded rotating flywheel is very dangerous Keep loose clothing and other objects away when starting the engine Use the emergency starter rope only as instructed Do not touch the fly wheel or other moving par...

Page 116: ...e clip 2 and the screw 3 if the cable is equipped 3 Remove the starter flywheel cover after removing 4 bolts Disconnect the leads for the warning indicator 4 Prepare the engine for starting See STARTING ENGINE for procedures Be sure the engine is in Neutral and that the lock plate on the end of lan yard is attached to the engine stop lanyard switch Set the main switch to ON if equipped ...

Page 117: ...f the emer gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise 6 Pull the rope slowly until resistance is felt 7 Give a strong pull straight out to crank and start the engine Repeat if necessary ...

Page 118: ...he spark plug holes downward to allow any water mud or contami nants to drain 3 Drain the fuel from the carburetor fuel filter and fuel line Drain the engine oil completely 4 Fill the sump with the fresh engine oil as the same quantity as the engine oil capacity 5 Feed engine fogging oil or engine oil through the carburetor s and spark plug hole s while cranking the engine with the manual starter ...

Page 119: ...E EMU00450 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 ...

Page 120: ...the battery 4 31 Cruising in other conditions 3 27 Cruising in salt water 3 27 Cruising in shallow water 3 25 Crusing in turbid water 3 27 D Digital tachometer 2 14 Disconnecting the battery 4 32 E Emission control information 1 2 Emergency starting engine 5 7 Engine oil 1 13 Engine stop button 2 5 Engine stop lanyard switch 2 5 2 8 Exhaust leakage 4 22 F Filling fuel 3 8 Filling fuel tank 4 5 Flu...

Page 121: ...cifications 4 1 Star labels 1 3 Start in gear protection 1 16 Starter button 2 3 Starter will not operate 5 6 Starting engine 3 9 Steering friction adjusting lever 2 10 Stopping engine 3 17 Storing outboard motor 4 5 T Tachometer 2 14 Temporary action in emergency 5 5 Throttle control grip 2 4 Throttle friction adjusting knob 2 4 Throttle friction adjusting screw 2 9 Throttle indicator 2 4 Tiller ...

Page 122: ...gistration records are checked 2 Read the Limited Warranty statement which follows these instructions This warranty applies to Yamaha outboard motors sold in the United States whether purchased sepa rately or when supplied as original equipment by a boat builder The terms also apply to original equipment packages sold in Canada with coverage provided by Yamaha Motor Canada see Warranty Guide for C...

Page 123: ...ilable in one country may not be sold or serviced in the other 6 If you need any additional information about your Yamaha or warranty coverage which your dealer cannot provide please contact us directly Yamaha Motor Corporation U S A P O Box 6555 Cypress CA 90630 Attention Customer Relations Department Telephone No 714 761 7439 Fax No 714 761 7559 Yamaha Motor Canada Ltd 480 Gordon Baker Road Toro...

Page 124: ...em 8 Power Trim and Tilt Assembly WARRANTY REGISTRATION To be eligible for warranty coverage the outboard motor must be registered with Yamaha Motor Corporation U S A Warranty registration can be accomplished by any authorized Yamaha Outboard Motor Dealer Upon receipt of the registration an Owner s Warranty Card will be sent by Yamaha to the registered purchaser OBTAINING REPAIRS UNDER WARRANTY To...

Page 125: ...he warranty period A The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision dam ages Q What are some examples of abnormal strain neglect or abuse A These terms are general and overlap each other in areas Specific examples include Running the machine out of oil operating the machine with a broken or damaged part which causes anoth...

Page 126: ...ation such as names addresses model engine serial number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is complied from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling deal...

Page 127: ...ll receive service If you need more information about your warranty coverage or your Yamaha outside the U S A or Canada please contact an autho rized Yamaha dealer in your country 2 Keep a copy of your sales contract or invoice for the purchase of your Yamaha and present it if you need warranty repairs This document should show the date of purchase which is important evidence the repairing dealer ...

Page 128: ...Printed in Japan April 2003 0 5 0 1 65W 28199 17 F25AMH F25AEH F25AE F25AET FT25BET E Printed on recycled paper ...

Page 129: ...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 130: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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