Yamaha VX200C Owner'S Manual Download

Page: 1 / 122

Printed in Japan
April 2003-0.5

66K-28199-17

(200HETO, 225GETO, 250CETO)

(E)

Printed on recycled paper

VX200C
VX225C
VX250C

OWNER’S MANUAL

U.S.A.Edition

LIT-18626-05-35

66K-9-17-hyoshi 3/3/03 12:16 PM Page 1

Summary of Contents for VX200C

Page 1: ...VX200C VX225C VX250C OWNER S MANUAL U S A Edition LIT 18626 05 35 ...

Page 2: ......

Page 3: ...l 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 advance ments in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your machine and this manual If there...

Page 4: ...1 2 3 4 5 6 E CONTENTS GENERAL INFORMATION BASIC COMPONENTS OPERATION MAINTENANCE TROUBLE RECOVERY INDEX READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR EMA20010 ...

Page 5: ...otor serial number 1 1 Key number 1 1 EMISSION CONTROL INFORMATION 1 2 SAFETY INFORMATION 1 3 IMPORTANT LABELS 1 5 BASIC BOATING RULES 1 6 FUELING INSTRUCTIONS 1 10 Gasoline 1 11 Engine oil 1 11 BATTERY REQUIREMENT 1 12 PROPELLER SELECTION 1 12 START IN GEAR PROTECTION 1 14 1 2 3 4 5 6 ...

Page 6: ... spaces provided to assist you 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 ...

Page 7: ... bracket or the swivel bracket 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 AND IS CERTIFIED TO g kw hr HC NOx ENGINE FAMILY EXHAUST EMISSION STANDARD IN CALIFORNIA REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS...

Page 8: ...fully Make sure there are no gas fumes or leaking fuel before starting the engine 8 This product emits exhaust gases which contain carbon monoxide a colorless 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 8 Check throttle shift and steering for proper opera...

Page 9: ...y organiza tions including the following United 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 10: ...is cover during and after operation To avoid burns do not touch finned resistor with bare hands 65L 83625 40 3 ENGINE OIL ONLY WARNING 6E5 13437 43 Pour the engine oil into this oil tank not gasoline RECOMMENDED OIL YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC W3 certified outborad oil Do not add gasoline to the oil tank Fire or explosion could result OIL TANK CAPACITY 10 5 LITERS 11 1 U S q...

Page 11: ...occur unless both vessels try to avoid each other If that is the case both vessels become Give Way vessels EMB40010 BASIC BOATING RULES Rules of the road Just as there are rules which apply when you are driving on streets and high ways there are waterway rules which apply when you are driving your boat These rules are used internationally and are also enforced by the United States Coast Guard and ...

Page 12: ...he 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 collision the vessel whic...

Page 13: ...nd orange boarders They signify speed zones restricted areas danger areas and general information of its way until you are clear of it Likewise if another vessel is passing you you should maintain your speed and direction so that the other vessel can steer itself around you OTHER SPECIAL SITUATIONS There are three other rules you should be aware of when driving your boat around other vessels Narro...

Page 14: ...w old new old new LIGHTED BUOY Starboard Hand 2 4 6 Even number increasing 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 ...

Page 15: ... 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 funnel to help prevent electrosta tic sparks cC 8 Use only new cl...

Page 16: ...3 oil EMU01804 GASOLINE If knocking or pinging occurs use a differ ent brand of gasoline or premium unlead ed fuel Recommended engine oil YAMALUBE 2 STROKE OUTBOARD OIL Recommended gasoline Regular unleaded gasoline with a minimum octane rating of 86 Pump Octane Number R M 2 EMB50610 Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing e...

Page 17: ...rse effect on the engine EMU01775 BATTERY REQUIREMENT cC Do not use a battery that does not meet the specified capacity If a battery which does not meet specifications is used the electric system could perform poorly or be overloaded causing electric system damage For electric start models choose a battery which meets the following specifications EMU01793 EMU01787 NOTE The engine cannot be started...

Page 18: ...d 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 rpm should be within the upper half of the full throttle operating range as listed in SPECIFICA TIONS on page 4 1 Select a propeller which fulfills this requirement If operating under conditions which allow the engine s rpm to rise above the maxi mum recom...

Page 19: ...Yamaha outboard motors or Yamaha approved remote control units are equipped with start in 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 14 ...

Page 20: ...E MEMO ...

Page 21: ...ote control 2 2 Trim tab 2 6 Power trim tilt switch 2 7 Tilt support lever 2 7 Digital tachometer 2 8 Digital speedometer 2 11 Fuel management meter 2 14 Top cowling release lever 2 18 Flushing device 2 19 WARNING SYSTEM 2 20 Overheat warning 2 20 Oil level warning Oil filter clogging warning 2 21 1 2 3 4 5 6 ...

Page 22: ... support lever 4 Anti cavitation plate 5 Trim tab Anode 6 Propeller 7 Cooling water inlet 8 Anode 9 Clamp bracket 0 Power trim and tilt unit q Cowling release lever w Top cowling e Cooling water pilot hole r Remote control box Side mount type t Digital tachometer y Digital speedometer u Remote oil tank May not be exactly as shown also may not be included as standard equipment on all models ...

Page 23: ...anyard switch 6 Power trim and tilt switch 7 Throttle friction adjusting screw 701011 w q e r t y u R N F q w e r t y u u t r y 701031 EMC50010 Remote control lever Moving the lever forward from the Neutral position engages Forward gear Pulling the lever back from Neutral engages Reverse The engine will contin ue to run at idle until the lever is moved about 35 a detent can be felt Moving the leve...

Page 24: ...al throttle lever NOTE The neutral throttle lever will operate only when the remote control lever is in Neutral The remote control lever will operate only when the neutral throttle lever is in the closed position 1 Fully open 2 Fully closed EMC48110 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 remov...

Page 25: ...y under power 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 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 steer...

Page 26: ...t in an accident E 2 5 701035 Resistance Screw Increase Turn clockwise Decrease Turn counterclockwise UP DN 701034 UP DN EMU01331 Power Trim Tilt Switch The power trim tilt adjusts the motor angle in relation to the transom The power trim tilt switch is located on the remote control lever grip Pushing the switch UP trims the motor up then tilts the motor up Pressing the switch DN tilts the motor d...

Page 27: ...aced to be sure steering is correct Be sure you have tightened the bolt after adjusting the trim tab 1 Trim tab 2 Bolt 3 Cap cC The trim tab also serves as an anode to protect the engine from electroche mical corrosion Never paint the trim tab as it will become ineffective as an anode E 2 6 A B q w e 603014 Boat tends to veer To the left port side To the right starboard side The fin of trim tab Tu...

Page 28: ...Use the power trim 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...

Page 29: ...icator and the overheat warning indicator 1 Tachometer 2 Trim meter 3 Hour meter 4 Oil level 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 after EMU00136 Tachometer This meter shows the engine speed ...

Page 30: ...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 Simulta...

Page 31: ...or cC Do not operate the engine without oil Serious engine damage will occur 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 warning device has activated If neces sary refer to the TROUBLESHOOTING section in this man...

Page 32: ...E After the main switch is first turned on all portions of the meter come on as a check After a few seconds the meters will change to normal operation Watch the meter when turning on the main switch to make sure all segments come on EMD25110 Speedometer The meter will show the boat speed NOTE The speedometer displays km h mph or knots depending upon operator prefer ence Select the desired unit of ...

Page 33: ...data will be lost if the battery is disconnected 802025 TRIP TIME BATT Km h knot mph km mile SPEED YAMAHA set mode EMU01275 Clock This meter shows the current time Repeatedly push and release the mode button until the indicator on the face of the meter points to TIME To set the clock be sure the meter is in the TIME mode Press the set button the hour display will begin blinking Press the mode butt...

Page 34: ...Operation with bow up trim or continu ous turning can give false readings 802032 TRIP TIME BATT Km h knot mph km mile SPEED EMD40410 Warning indicator 8 Fuel warning If the fuel level decreases to one segment the fuel level warning segment 1 begins blinking 8 Low battery voltage warning If battery voltage drops the display 2 will be automatically turned on and it begins blinking cC Do not continue...

Page 35: ...ain switch to make sure all segments come on YAMAHA set mode P S mpg Km L gph I h ECON SYNC TTL FUEL MANAGEMENT q w e P S mpg Km L gph I h ECON SYNC TTL FUEL MANAGEMENT YAMAHA P S gph I h ECON SYNC TTL FUEL MANAGEMENT set mode EMD32010 Fuel flow meter The meter displays fuel flow within one hour at the rate of current engine opera tion If twin engines are installed on your boat the meter will disp...

Page 36: ...e meter was last reset Repeatedly push and release the mode button until the indicator on the face of the meter points to total TTL To reset the total fuel consumption to 0 press the set and mode buttons together P S mpg Km L gph I h ECON SYNC TTL FUEL MANAGEMENT EMU01277 Fuel Economy This meter displays the distance per liter or gallon when cruising for reference use by the operator Repeatedly pu...

Page 37: ...Yamaha digital speedometer and fuel management meter calculates speed miles traveled and fuel econo my by water movement at the stern of the boat This distance can vary greatly from the actual distance traveled because of water currents sea swells and the condition of the water speed sensor partially plugged or damaged 8 Individual engines may slightly vary in their fuel consumption due to manufac...

Page 38: ...ide engine speed is slightly higher 3 Engine speed is synchronized evenly between Port and Starboard side engines 4 Starboard side engine speed is slightly higher 5 Starboard side engine speed is higher NOTE If the two engines speeds are not syn chronized while cruising they can be syn chronized by adjusting trim angle or throttle EMU01207 Water Separator Warning Indicator If the water which has b...

Page 39: ...sure the cowling is locked properly push the cowling from each side If it lifts repeat step 3 cC Make sure the cowling lock connection cable is operating correctly before rein stalling the top cowling 8 When the release lever is operated both front and rear cowling hooks should be released at the same time If not adjust the cable adjuster for the rear clamps 8 Make sure the cable operates smoothly...

Page 40: ... 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 q 000825 ...

Page 41: ...is engine has an overheat warning device 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 Activation of Tiller Remote warning device control control model model The engine speed will automatically 1 decrease to about 2 000 r min The overheat warning 1 indicator wi...

Page 42: ...gine and check for the cause NOTE The warning for oil filter clogging is simi lar to the warnings for low oil level and overheating For easy troubleshooting it is advisable to check for engine overheating first then oil level and finally oil filter clogging 1 Oil filter Warning device Tiller Remote activation control control model model The engine speed will automatically 1 decrease to about 2 000...

Page 43: ...ECKS 3 8 Operation after a long period of storage 3 9 BREAKING IN ENGINE 3 10 STARTING ENGINE 3 12 WARMING UP ENGINE 3 15 SHIFTING 3 16 Forward 3 16 Reverse 3 16 STOPPING ENGINE 3 17 TRIMMING OUTBOARD MOTOR 3 18 Adjusting trim angle 3 19 TILTING UP DOWN 3 21 CRUISING IN OTHER CONDITIONS 3 23 Cruising in salt water 3 23 Cruising in turbid water 3 23 1 2 3 4 5 6 ...

Page 44: ...orne water spray while the boat is cruising Severe engine damage may result if the motor is operated continuously in the presence of airborne 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 outboa...

Page 45: ...ce and 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 ...

Page 46: ...nting height is too high cavitation tends to occur thus reducing the propulsion and causing the engine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engine effi ciency Mount the engine so the anti cavi tation plate is about 130 mm 5 in above the bottom of the boat NOTE 8 The optimum mounting height of the outboard motor is affected by the boat ...

Page 47: ... gasoline has changed the amount of additives 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 add...

Page 48: ...Do not add gasoline into the oil tank Fire or explosion could result E 3 5 001475 ON START OFF 701024 Engine oil tank capacity See Chapter 4 Specifications EMU01825 Using remote oil tank 1 Pour engine oil into the remote oil tank NOTE The oil level lines on the remote oil tank indicate the amount of additional oil that can be added to the tank The top oil level line indicates approximately 1 9 L 0...

Page 49: ...ted for the first time or stored for a period of time a min imum of 5 liters 5 3 US qt 4 4 Imp qt of oil should be kept in the remote oil tank Otherwise the oil feed pump chamber will not be filled with oil and no oil will be supplied ...

Page 50: ... qt 0 26 Imp qt or less More than 300 cm3 0 32 US qt 0 26 Imp qt 300 cm3 0 32 US qt 0 26 Imp qt or less More than 1 500 cm3 1 6 US qt 1 31 Imp qt More than 1 500 cm3 1 6 US qt 1 31 Imp qt 1 500 cm3 1 6 US qt 1 31 Imp qt or less No refilling necessary Add oil refer to FILLING OIL Check oil filter for clogging Check battery cable con nection Buzzer will sound Engine speed is automati cally reduced t...

Page 51: ...Oil 8 Check to be sure you have plenty of oil for your trip Controls 8 Check throttle shift and steering for prop er operation before starting the engine 8 The controls should work smoothly without binding or unusual free play 8 Look for loose or damaged connec tions 8 Check operation of the starter and stop switches when the outboard moter is in the water Engine 8 Check the engine and engine moun...

Page 52: ...nd other rotating parts while the engine is running 3 Watch for oil flowing through the oil feed pipes After any air in the oil lines has been expelled the oil injec tion system should supply oil normal ly If no oil is flowing after 10 minutes of idling consult your Yamaha dealer cC 8 Be sure to take the above steps when operating the engine after a long period of storage Otherwise engine seizure ...

Page 53: ...U01779 BREAKING IN ENGINE Your new engine requires a period of break in to allow mating surfaces of mov ing parts to wear in evenly Correct break in will help ensure proper performance and longer engine life cC 8 Failure to follow the break in procedure could result in reduced engine life or even severe engine damage 8 Premix fuel must be used during break in in addition to oil in the oil injectio...

Page 54: ...then reduce engine speed to three quarter throttle approximately 4 000 r min Vary engine speed occasional ly Run at full throttle for one minute then allow about 10 minutes of opera tion at three quarter throttle or less to let the engine cool 4 Third through tenth hours Avoid operating at full throttle for more than 5 minutes at a time Let the engine cool between full throttle runs Vary engine sp...

Page 55: ... flames and sparks while loosening the air vent screw 8 This 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 I...

Page 56: ...lock plate on the other end of the 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 e...

Page 57: ...witch to START when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds with the main switch in the START position If the starter motor is run continuously 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 sec onds return the main switch to ON wait 10 seconds...

Page 58: ...cC A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling pas sages If water is not flowing out of the pilot hole at all times while the engine is running do not continue to run the engine Overheating and serious damage could occur Stop the engine and check to see if the water inlet on the lower cas ing is blocked If the problem cannot be foun...

Page 59: ...ow speeds EMG22210 FORWARD Pull up the neutral interlock trigger If equipped and move the remote control lever quickly and firmly from Neutral to Forward EMG33310 REVERSE w When operating in Reverse go slowly Do not open the throttle more than half Otherwise the boat may become unsta ble which could result in loss of control and an accident Pull up the neutral interlock trigger If equipped and mov...

Page 60: ... operating at high speed is not recommended EMG41511 1 Turn the main switch to OFF NOTE The engine can also be stopped by pulling the lanyard from the engine stop switch then turning the main switch to OFF 2 Tighten the air vent screw on the fuel tank cap after stopping the engine if it is equipped 3 Remove the key if the boat will be left unattended ...

Page 61: ...at engine 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 read...

Page 62: ...ilt switch 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 ...

Page 63: ... in the water Performance and 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 s...

Page 64: ...e is running Severe damage from overheating can result 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 or close the fuel cock if the engine will be tilted for more than a few minutes Otherwise fuel may leak If the fuel co...

Page 65: ...rt lever toward you and support the engine w After tilting the engine be sure to sup port it with the tilt support lever Otherwise the engine could fall back down suddenly if oil in the power trim tilt unit should lose pressure 4 Once the engine is supported with the tilt support lever push the power trim tilt switch DOWN to retract the trim rods cC Be sure to retract the trim rods complete ly dur...

Page 66: ...TING 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 411021 EMU00303 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 Release the tilt support lever 3 Push the...

Page 67: ...el system 4 13 Cleaning fuel filter 4 14 Checking water trap under engine oil tank 4 15 Inspecting idling speed 4 16 Replacing fuse 4 17 Checking wiring and connectors 4 17 Exhaust leakage 4 17 Water leakage 4 17 Greasing 4 18 Checking power trim and tilt system 4 19 Checking propeller 4 20 Changing gear oil 4 22 Inspecting and replacing anode s 4 23 Checking battery 4 24 Checking bolts and nuts 4...

Page 68: ...ment cm3 cu in Bore stroke mm in Ignition system Spark plug NGK Spark plug gap mm in Control system Starting system 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 2 stroke 76 V6 3 130 191 0 90 0 82 0 3 54 3 23 C D I system Microcomputer BR8HS 10 0 9 ...

Page 69: ...E90 1 150 38 9 40 5 Forward Neutral Reverse 1 81 29 16 Power trim tilt M2 66K 25 2 5 18 55 5 5 40 864 34 0 562 22 1 1 685 66 3 515 20 3 231 5 510 4 500 5 500 183 9 250 at 5 000 r min 700 760 2 stroke 76 V6 3 130 191 0 90 0 82 0 3 54 3 23 C D I system Microcomputer BR9HS 10 0 9 1 0 0 035 0 039 Remote control Electric start 512 675 182 12 35 Electronic Fuel Injection Regular unleaded gasoline Minimu...

Page 70: ...sporting fuel tank whether in a boat or car DO NOT fill fuel container to maximum capacity Gasoline will expand consider ably as it warms up and can build up pres sure 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 no...

Page 71: ... ratios used at idle prior to shutting the engine off for the season It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to stor age However the following procedures can be performed by you the owner with a minimum of tools cC Do not use any chemical goods contain ing Silicon Phosphorus or Lead Otherwise the oxygen sensor for the Electronic Fuel Injection syst...

Page 72: ...from your Yamaha dealer cC Avoid running the outboard at high speed while on the flushing attachment or overheating could occur w 8 Do not touch or remove electrical parts when starting or during operation 8 Keep hands hair and clothes away from flywheel and other rotating parts while engine is running EMK21010 Filling Fuel Tank Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel C...

Page 73: ...t to completely fill the engine main tank Refer to Filling Oil section 4 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 5 Grease all grease fittings Refer to GREASING 3 Run the engine at a fast idle for 10 15 minutes 4 Just prior to turni...

Page 74: ...rior with Yamaha Silicone Protectant Part No LUB SILCNE 13 00 cC Do not spray when the engine is running Also do not spray near the silencer and oxygen sensor cover or into the engine Otherwise the oxygen sensor for Electronic Fuel Injection system could be damaged 3 Wax the cowling with a non abrasive wax such as Yamaha Silicone Wax Part No ACC 11000 15 02 ...

Page 75: ...y Ventilate when charging or using 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 s...

Page 76: ... Yamaha dealer for owners who have the mechanical skills tools and other equipment necessary to perform maintenance not covered by this owner s manual EMK33011 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equiva lents of the same type and of equivalent strength and materials Any part of inferi or quality may malfunction and the resulting loss of control cou...

Page 77: ...oints Greasing Gear oil Change Fuel system Inspection Fuel filter can be disassembled Inspection cleaning Fuel tank Yamaha portable tank Inspection cleaning Idling speed EFI HPDI models Inspection adjustment 1 Anode s external Inspection replacement 1 1 Anode s internal Inspection replacement 1 Cooling water passages Cleaning Propeller and cotter pin Inspection replacement Battery Inspection charg...

Page 78: ...ould indicate an intake 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 y...

Page 79: ...er 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 Spark plug gap Refer to SPECIFICATIONS page 4 1 Spark plug torque Refer to SPECIFICATIONS page 4 1 903022 q w Initial of spark Plug wrench size plug I D mark B 21 mm 13 16 in C BK 16 mm 5 8 in D 18 3 mm 23 32 in EMU16350 CHECKING TOP COWLING Check the fitt...

Page 80: ...m is found 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...

Page 81: ...CLEANING FUEL FILTER w Gasoline petrol is highly flammable and its vapors are flammable and explosive 8 If you have any question about properly doing this procedure consult your Yamaha dealer 8 Do not perform this procedure on a hot or running engine Allow the engine to cool 8 There will be fuel in the fuel filter Keep away from sparks cigarettes flames or other sources of ignition 8 This procedur...

Page 82: ...he ring nut is tight Align one of the four larger ring nut tabs with the spring and release it to lock the ring nut in position 6 Run the engine and check the filter and lines for leaks NOTE If any water is in the fuel the red ring in the fuel filter unit will float If so remove the cup and drain the water 213021 q w EMK56010 CHECKING WATER TRAP UNDER ENGINE OIL TANK There is a trap at the bottom ...

Page 83: ...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 84: ...the engine and check that no water leaks from the joints between the exhaust cover cylinder head and crank case EMU01329 REPLACING FUSE If the fuse has blown on an Electric start model open the fuse holder and replace the fuse with a new one of proper amper age w Be sure to use the specified fuse An incorrect fuse or a piece of wire may allow excessive current flow This could cause electrical syst...

Page 85: ...E 4 18 EML00011 GREASING Yamaha marine grease Water resistant grease ...

Page 86: ...e motor and check that the tilt rod and trim rods are pushed out completely 4 Use the tilt support lever to lock the motor in the UP position Operate the tilt down switch briefly so the motor is supported the tilt support lever 5 Check that the tilt rod and trim rods are free of corrosion or other flaws 6 Activate the tilt down switch until the trim rods have gone completely into the cylinders 7 A...

Page 87: ...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 EMU00976 Removing the Propeller 1 Straighten the cotter pin 1 and pull it out using a pair of pliers 2 Remove the propeller nut 2 washer 3 and spacer 4 3 Remove the propeller 5 and thrust washer 6 ...

Page 88: ... 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 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 ti...

Page 89: ...d motor so that the oil drain plug is at the lowest point possi ble 2 Place a suitable container under the gear case 3 Remove the oil drain plug 1 NOTE The oil drain plug is magnetic Remove all metal particles from the plug before rein stalling it 4 Remove the oil level plug 2 to allow the oil to drain completely cC Inspect the used oil after it has been drained If the oil is milky water is get ti...

Page 90: ...EPLACING ANODE S Yamaha outboard motors are protected from corrosion by sacrificial anodes Inspect the external anodes periodically 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 ...

Page 91: ...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 92: ...alling 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 will be stored for longer than a month check the specific grav ity of the fluid at least once a month and recharge the battery when it is low NOTE Consult a Yamaha d...

Page 93: ...art the engine Connect the RED lead to the POSITIVE terminal first Then connect the BLACK lead to the NEGATIVE terminal 1 Red lead 2 Black lead 3 Battery 8 Using an accessory battery option Use a connecting cable between the terminals of the starting battery and accessory battery See the illustrations of the wiring connections This cable must be made from wire equivalent to the start ing battery c...

Page 94: ...e flywheel are tightened with their specified tightening torques 2 Check the tightening torques of other bolts and nuts EML42012 MOTOR EXTERIOR EML42511 Cleaning the Outboard Motor After use wash the exterior of the out board with fresh water Flush the cooling system with fresh water NOTE Refer to Flushing Cooling System instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR NOTE If a battery se...

Page 95: ...is connect the 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 ...

Page 96: ...fouling paint approved for your area to inhibit marine growth Do not use anti fouling paint which includes copper or graphite These paints can cause more rapid engine corrosion EML42810 Checking Painted Surface of Motor Check the motor for scratches 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...

Page 97: ...EMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Power trim tilt will not operate 5 5 Starter will not operate 5 6 Engine fails to operate 5 8 Low oil level warning activates 5 10 Top cowling does not unlock 5 11 Treatment of submerged motor 5 12 1 2 3 4 5 6 ...

Page 98: ...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 99: ...ttle valve adjustment incorrect 16 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 Ti...

Page 100: ... filter cup 1 Propeller damaged 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...

Page 101: ...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 102: ... 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 607011 411025 q EMG65210 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 103: ...oes not oper ate Make sure the remote control lever is in neutral Otherwise the boat could unexpectedly 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 emergen...

Page 104: ...STARTING ENGINE for procedures Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch 4 Turn the main switch to the ON posi tion 5 Insert the knotted end of the emer gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise 6 Give a strong pull straight out to crank the engine Repeat if necessary ...

Page 105: ...s procedure w When the emergency circuit is used the engine may run faster than normal at idling and low speeds Be prepared slightly increased speeds when operating at low throttle settings cC 8 This emergency circuit should only be used long enough to return to port for repairs Do not continue to operate the engine without getting repairs 8 Do not operate the engine over 3 500 r min while using t...

Page 106: ...f the microcomputer is bypassed 1 CDI unit 2 Yellow White cord 3 Open the throttle slightly without shifting using the neutral throttle lever or the free accelerator After the engine starts return the throttle to the original position 4 Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch The main switch must be on 5 Start the engine N 701014 q w 216016 ON ST...

Page 107: ... too long too much oil will be pumped into the engine tank overflowing it Release the switch when oil reaches the upper level line on the engine oil tank 8 Do not use this emergency procedure unless the oil level warning lamps are installed and working 1 Remove the top cowling 2 Turn the main switch to the ON position 3 Lift the emergency switch to pump reserve oil in remote oil tank into the engi...

Page 108: ...d or misadjusted 1 Pull the cowling release lever 1 to unlock the front lock 2 Pull the emergency cowling release wire 2 coming out of the hole on the side of the pilot hole in the bottom cowling to release the port side rear lock 3 Lift the port side of the top cowling to pull out the emergency cowling release wire 3 from the port side of the bottom cowling 4 Pull the emergency cowling release wi...

Page 109: ...o minimize engine damage 1 Thoroughly wash away mud salt seaweed etc with fresh water 2 Remove the spark plugs and face the spark plug holes downward to allow any water mud or contaminants to drain 3 Drain the fuel from the vapor separa tor 4 Feed fogging oil or engine oil through the intake manifold and spark plug holes while cranking with the emer gency starter rope 5 Take the outboard motor to ...

Page 110: ...E MEMO ...

Page 111: ...E EMP00010 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 ...

Page 112: ... water 3 23 Cruising in turbid water 3 23 D Digital speedometer 2 11 Digital tachometer 2 8 Disconnecting the battery 4 27 E Emergency starting engine 5 7 Emission control information 1 2 Engine fails to operate 5 8 Engine oil 1 11 Engine stop lanyard switch 2 4 Exhaust leakage 4 17 F Filling fuel 3 4 Filling fuel and engine oil 3 4 Filling fuel tank 4 5 Filling oil 3 5 Flushing cooling system and...

Page 113: ...3 16 Ring free fuel additive 3 4 S Safety information 1 3 Shifting 3 16 Specifications 4 1 Speedometer 2 11 Start in gear protection 1 14 Starter will not operate 5 6 Starting engine 3 12 Stopping engine 3 17 Storing outboard motor 4 4 T Tachometer 2 8 Temporary action in emergency 5 5 Throttle friction adjusting screw 2 5 Tilt support lever 2 7 Tilting up down 3 21 Top cowling does not unlock 5 1...

Page 114: ...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 115: ...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 116: ...tor purchased and registered for use in the United States only excluding its territo ries For warranty provisions outside the United States contact the particular country s local Yamaha distributor WARRANTY REGISTRATION To be eligible for warranty coverage the outboard motor must first be registered with Yamaha Motor Corporation U S A A warranty registration form is provided in the Owner s Manual ...

Page 117: ...LSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A Post Office Box 6555 Cypress California 90630 WARRANTY QUESTIONS AND ANSWERS Q What costs are my responsibility during the 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 strai...

Page 118: ...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 119: ...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 120: ...Printed in Japan April 2003 0 5 1 66K 28199 17 200HETO 225GETO 250CETO E Printed on recycled paper ...

Page 121: ...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 122: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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