Yamaha Outboard Motor 6L2 28199 1L User Manual

25D

OWNER’S MANUAL

U.S.A.Edition

LIT-18626-05-83

6L2-28199-1L

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Important manual information

EMU25100

al, please consult your Yamaha dealer.

To the owner

NOTE:

Thank you for choosing a Yamaha outboard

motor. This Owner’s Manual contains infor-

mation needed for proper operation, mainte-

nance and care. A thorough understanding

of these simple instructions will help you ob-

tain maximum enjoyment from your new

Yamaha. If you have any question about the

operation or maintenance of your outboard

motor, please consult a Yamaha dealer.

In this Owner’s Manual particularly important

information is distinguished in the following

ways.

The 25MH and the standard accessories are

used as a base for the explanations and illus-

trations in this manual. Therefore some

items may not apply to every model.

EMU25110

25D

OWNER’S MANUAL

1st edition, March 2004

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

The Safety Alert Symbol means

ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Printed in Japan

EWM00780

P/N LIT-18626-05-83

WARNING

Failure to follow WARNING instructions

could result in severe injury or death to

the machine operator, a bystander, or a

person inspecting or repairing the out-

board motor.

ECM00700

CAUTION:

A CAUTION indicates special precautions

that must be taken to avoid damage to the

outboard motor.

NOTE:

A NOTE provides key information to make

procedures easier or clearer.

Yamaha continually seeks advancements in

product design and quality. Therefore, while

this manual contains the most current prod-

uct information available at the time of print-

ing, there may be minor discrepancies

between your machine and this manual. If

there is any question concerning this manu-

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Table of contents

General information ..........................1 Operation......................................... 17

Identification numbers record...........1

Outboard motor serial number.......... 1

Emission control information............1

North American models..................... 1

Safety information ............................2

Important labels................................3

Warning labels .................................. 3

Installation...................................... 17

Mounting the outboard motor..........17

Clamping the outboard motor..........18

Breaking in engine......................... 19

Gasoline and engine oil mixing

chart (25:1)....................................19

Procedure for pre-mixed models.....19

Preoperation checks...................... 20

Fuel .................................................20

Oil....................................................20

Controls...........................................20

Engine.............................................20

Filling fuel and engine oil ............... 20

Filling fuel for portable tank.............20

Ring Free Fuel Additive...................21

Gasoline and oil mixing (100:1).......21

Operating engine ........................... 22

Feeding fuel (portable tank) ............22

Starting engine................................23

Warming up engine........................ 25

Choke start models .........................25

Shifting........................................... 25

Forward (tiller handle and remote

Basic boating rules

(Rules of the road) .........................4

Steering and sailing rules and sound

signals............................................. 4

Rules when encountering vessels .... 4

Other special situations..................... 5

Fueling instructions ..........................7

Gasoline............................................ 8

Engine oil .......................................... 8

Propeller selection............................8

Start-in-gear protection ....................9

Basic components ..........................10

Main components...........................10

Fuel tank ......................................... 10

Fuel joint ......................................... 11

Fuel gauge...................................... 11

Fuel tank cap .................................. 11

Air vent screw ................................. 11

Tiller handle .................................... 11

Gear shift lever................................ 11

Throttle grip..................................... 11

Throttle indicator ............................. 12

Throttle friction adjuster................... 12

Engine stop lanyard switch ............. 12

Engine stop button.......................... 13

Choke knob for pull type ................. 13

Manual starter handle ..................... 13

Steering friction adjuster ................. 13

Trim tab with anode ........................ 14

Trim rod (tilt pin).............................. 14

Shallow water lever......................... 14

Tilt lock mechanism......................... 15

Tilt support bar................................ 15

Top cowling lock lever(s)

control models) .............................25

Reverse (manual tilt and hydro tilt

models) .........................................26

Stopping engine............................. 26

Procedure........................................26

Trimming outboard motor............... 27

Adjusting trim angle for manual tilt

models ..........................................28

Adjusting boat trim ..........................28

Tilting up and down........................ 29

Procedure for tilting up....................30

Procedure for tilting down

(manual tilt models).......................30

Cruising in shallow water ............... 31

Cruising in shallow water

(manual tilt models).......................31

Cruising in other conditions............ 32

Maintenance .................................... 33

(turn type) ..................................... 15

Warning system .............................15

Overheat warning............................ 15

Specifications................................. 33

Transporting and storing outboard

motor............................................ 33

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Table of contents

Clamp screw mounting models....... 34

Storing outboard motor ................... 34

Procedure ....................................... 35

Lubrication

IMPORTANT WARRANTY

INFORMATION IF YOU USE

YOUR YAMAHA OUTSIDE

U.S.A. OR CANADA.................... 60

(except oil injection models) ......... 36

Cleaning and anticorrosion

measures...................................... 36

Cleaning the outboard motor .......... 36

Checking painted surface of

motor............................................. 36

Periodic maintenance.....................37

Replacement parts.......................... 37

Maintenance chart .......................... 38

Greasing ......................................... 39

Cleaning and adjusting spark plug.. 39

Checking fuel system...................... 40

Inspecting fuel filter......................... 41

Cleaning fuel filter ........................... 41

Inspecting idling speed ................... 42

Checking wiring and connectors..... 42

Exhaust leakage ............................. 42

Water leakage................................. 42

Checking propeller.......................... 43

Removing the propeller................... 44

Installing the propeller..................... 44

Changing gear oil............................ 44

Cleaning fuel tank ........................... 45

Inspecting and replacing anode(s).. 46

Checking top cowling...................... 46

Coating the boat bottom.................. 46

Trouble Recovery............................48

Troubleshooting .............................48

Temporary action in emergency.....51

Impact damage ............................... 51

Starter will not operate.................... 51

Emergency starting engine ............. 52

Treatment of submerged motor......53

Procedure ....................................... 53

Consumer information....................55

Important warranty information for

U.S.A. and Canada ......................55

YAMAHA MOTOR

CORPORATION, U.S.A.

OUTBOARD MOTOR TWO

YEAR LIMITED WARRANTY.......57

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General information

EMU25170

engine for details.

EMU30390

Identification numbers record

EMU25182

Approval label of emission control certif-

icate

This label is attached to the bottom cowling.

Outboard motor serial number

The outboard motor serial number is

stamped on the label attached to the port

side of the clamp bracket or the upper part of

the swivel bracket.

Record your outboard motor serial number in

the spaces provided to assist you in ordering

spare parts from your Yamaha dealer or for

reference in case your outboard motor is sto-

len.

Existing Technology; N/A

ZMU04828

1. Approval label location

EMISSION CONTROL INFORMATION

ENGINE FAMILY :

THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.

REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.

g/kw-hr

FELs :

IDLE SPEED :

rpm IN NEUTRAL

SPARK PLUG :

SPARK PLUG GAP (mm) :

DISPLACEMENT :

ADVERTISED POWER :

FUEL : GASOLINE

1. Outboard motor serial number location

VALVE LASH (mm) :

ZMU04304

EMU25261

Manufactured date label

This label is attached to the clamp bracket or

the swivel bracket.

EMU25220

Emission control information

EMU25230

North American models

This engine conforms to U.S. Environmental

Protection Agency (EPA) regulations for ma-

rine SI engines. See the label affixed to your

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General information

^GDo not modify the outboard. Modifications

could make the motor unfit or unsafe to

use.

^GNever operate after drinking alcohol or tak-

ing drugs. About 50% of all boating fatali-

ties involve intoxication.

^GHave an approved personal flotation de-

vice (PFD) on board for every occupant. It

is a good idea to wear a PFD whenever

boating. At a minimum, children and non-

swimmers should always wear PFDs, and

everyone should wear PFDs when there

are potentially hazardous boating condi-

tions.

ZMU04125

1. Manufactured date label location

^GGasoline is highly flammable, and its va-

pors are flammable and explosive. Handle

and store gasoline carefully. Make sure

there are no gas fumes or leaking fuel be-

fore starting the engine.

G This product emits exhaust gases which

contain carbon monoxide, a colorless,

odorless gas which may cause brain dam-

age or death when inhaled. Symptoms in-

clude nausea, dizziness, and drowsiness.

Keep cockpit and cabin areas well ventilat-

ed. Avoid blocking exhaust outlets.

^GCheck throttle, shift, and steering for prop-

er operation before starting the engine.

G Attach the engine stop switch lanyard cord

to a secure place on your clothing, or your

arm or leg while operating. If you acciden-

tally leave the helm, the cord will pull from

the switch, stopping the engine.

^GKnow the marine laws and regulations

where you will be boating—and obey

them. For basic boating rules, see “Rules

of the road” on page 4.

G Stay informed about the weather. Check

weather forecasts before boating. Avoid

boating in hazardous weather.

EMU25361

Safety information

^GBefore mounting or operating the outboard

motor, read this entire manual. Reading it

should give you an understanding of the

motor and its operation.

G Before operating the boat, read any own-

er’s or operator’s manuals supplied with it

and all labels. Be sure you understand

each item before operating.

^GDo not overpower the boat with this out-

board motor. Overpowering the boat could

result in loss of control. The rated power of

the outboard should be equal to or less

than the rated horsepower capacity of the

boat. If the rated horsepower capacity of

the boat is unknown, consult the dealer or

boat manufacturer.

G Tell someone where you are going: leave

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General information

EMU25380

EMU25395

a Float Plan with a responsible person. Be

sure to cancel the Float Plan when you re-

turn.

Important labels

Warning labels

^GUse common sense and good judgment

when boating. Know your abilities, and be

sure you understand how your boat han-

dles under the different boating conditions

you may encounter. Operate within your

limits, and the limits of your boat. Always

operate at safe speeds, and keep a careful

watch for obstacles and other traffic.

^GAlways watch carefully for swimmers dur-

ing the engine operation.

ZMU04780

G Stay away from swimming areas.

^GWhen a swimmer is in the water near you

shift into neutral and shut off the engine.

Be informed about boating safety. Additional

publications and information can be obtained

from many organizations, including the fol-

lowing:

United States Coast Guard

Consumer Affairs Staff (G-BC)

Office of Boating, Public, and Consumer Af-

fairs

U.S. Coast Guard Headquarters

Washington, D.C. 20593-0001

ZMU03684

EMU25401

Label

EWM01260

Boating Safety Hotline: 1-800-368-5647

National Marine Manufacturers Associa-

tion (NMMA)

401 N. Michigan Ave.

Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave.

Chicago, Il 60601

WARNING

G Be sure shift control is in neutral before

starting engine. (except 2HP)

^GDo not touch or remove electrical parts

when starting or during operation.

^GKeep hands, hair, and clothes away

from flywheel and other rotating parts

while engine is running.

EMU25431

Label

EWM01300

WARNING

^GThis engine is equipped with a neutral

starting device.

G The engine will not start unless the shift

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General information

control is in neutral position.

Give-way vessel

The vessel which does not have the right-of-

way has the duty to take positive and timely

action to stay out of the way of the Stand-On

vessel. Normally, you should not cross in

front of the vessel with the right-of-way. You

should slow down or change directions brief-

ly and pass behind the other vessel. You

should always move in such a way that the

operator of the other vessel can see what

you are doing.

EMU25500

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 local agen-

cies. You should be aware of these rules,

and follow them whenever you encounter

another vessel on the water.

“The general prudential rule”

This rule is called Rule 2 in the International

Rules and says,

Several sets of rules prevail according to

geographic location, but are all basically the

same as the International Rules of the Road.

The rules presented here in your Owner’s

Manual are condensed, and have been pro-

vided for your convenience only. Consult

your local U.S. Coast Guard Auxiliary or De-

partment of Motor Vehicles for a complete

set of rules governing the waters in which

“In obeying and construing these rules due

regard shall be had to all dangers of naviga-

tion and collision, and to any special circum-

stances, which may render a departure from

the above rules necessary in order to avoid

immediate danger.”

In other words, follow the standard rules ex-

cept when a collision will occur unless both

vessels try to avoid each other. If that is the

case, both vessels become “Give-Way” ves-

you will be using your boat.

EMU25510

sels.

EMU25520

Steering and sailing rules and sound

signals

Rules when encountering vessels

There are three main situations which you

may encounter with other vessels which

could lead to a collision unless the Steering

Rules are followed:

Meeting: (you are approaching another ves-

sel head-on)

Crossing: (you are traveling across the oth-

er vessel’s path)

Whenever two vessels on the water meet

one another, one vessel has the right-of-

way; it is called the “stand-on” vessel. The

vessel which does not have the right-of-way

is called the “give-way” or “burdened” vessel.

These rules determine which vessel has the

right-of-way, and what each vessel should

do.

Stand-on vessel

Overtaking: (you are passing or being

passed by another 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.

In the following illustration, your boat is in the

center. You should give the right-of-way to

any vessels shown in white area (you are the

Give-Way vessel). Any vessels in the shad-

ed area must yield to you (they are the Give-

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General information

Way vessels). Both you and the meeting tion, provided the other vessel gives you the

vessel must alter course to avoid each other. right-of-way as it should.

Meeting

Overtaking

If you are meeting another power vessel If you are passing another vessel, you are

head on, and are close enough to run the risk the “Give-Way” vessel. This means that the

of collision, neither of you has the right-of- other vessel is expected to maintain its

way! Both of you should alter course to avoid course and speed. You must stay out of its

an accident. You should keep the other ves- way until you are clear of it. Likewise, if an-

sel on your port (left) side. This rule doesn’t other vessel is passing you, you should

apply if both of you will clear one another if maintain your speed and direction so that the

you continue on your set course and speed. other vessel can steer itself around you.

EMU25530

Other special situations

There are three other rules you should be

aware of when driving your boat around oth-

er vessels.

Narrow channels and bends

When navigating in narrow channels, you

should keep to the right when it is safe and

practical to do so. If the operator of a power-

driven vessel is preparing to go around a

bend that may obstruct the view of other wa-

Crossing

ter vessels, the operator should sound a pro-

When two power driven vessels are crossing

longed blast on the whistle (4 to 6 seconds).

each other’s path close enough to run the

If another vessel is around the bend, it too

risk of collision, the vessel which has the oth-

should sound the whistle. Even if no reply is

er on the starboard (right) side must keep out

heard, however, the vessel should still pro-

of the way of the other. If the other vessel is

ceed around the bend with caution. If you

on your right, you must keep out of its way;

navigate such waters with your boat, you will

you are the Give-Way vessel. If the other

need to carry a portable air horn, available

vessel is on your port (left) side, remember

that you should maintain course and direc-

from local marine supply stores.

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General information

Fishing vessel right-of-way

state. The Uniform State Waterway Marking

System has been devised for these waters.

This system uses buoys and signs with dis-

tinctive shapes and colors to show regulato-

ry or advisory information. These markers

are white with black letters and orange

boarders. They signify speed zones, restrict-

ed areas, danger areas, and general infor-

mation.

All vessels which are fishing with nets, lines

or trawls are considered to be “fishing ves-

sels” under the International Rules. Vessels

with trolling lines are not considered fishing

vessels. Fishing vessels have the right-of-

way regardless of position. Fishing vessels

cannot, however, impede the passage of

other vessels in narrow channels.

Sailing vessel right-of-way

Remember, markings may vary by geo-

graphic location. Always consult local boat-

ing authorities before driving your boat in

unfamiliar waters.

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-driv-

en 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 passage of

a power-driven vessel which can navi-

gate only in such a channel.

Reading buoys and other markers

The waters of the United states are marked

for safe navigation by the lateral system of

buoyage. Simply put, buoys and markers

have an arrangement of shapes, colors,

numbers and lights to show which side of the

buoy a boater should pass on when navigat-

ing in a particular direction. The markings on

these buoys are oriented from the perspec-

tive of being entered from seaward (the boat-

er is going towards the port). This means that

red buoys are passed on the starboard

(right) side when proceeding from open wa-

ter into port, and black buoys are to port (left)

side. When navigating out of port, your posi-

tion with respect to the buoys should be re-

versed; red buoys should be to port and

black buoys to starboard.

Many bodies of water used by boaters are

entirely within the boundaries of a particular

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General information

ZMU01708

EMU25540

away from sparks, flames, or other

Fueling instructions

sources of ignition.

EWM00010

^GStop engine before refueling.

G Refuel in a well-ventilated area. Refuel

portable fuel tanks off the boat.

^GTake care not to spill gasoline. If gaso-

line spills, wipe it up immediately with

WARNING

GASOLINE AND ITS VAPORS ARE HIGH-

LY FLAMMABLE AND EXPLOSIVE!

^GDo not smoke when refueling, and keep

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General information

EMU25650

dry rags.

Engine oil

G Do not overfill the fuel tank.

^GTighten the filler cap securely after re-

fueling.

G If you should swallow some gasoline,

inhale a lot of gasoline vapor, or get

gasoline in your eyes, get immediate

medical attention.

Recommended engine oil:

YAMALUBE 2-stroke outboard motor

oil

If the recommended engine oil is not avail-

able, another 2-stroke engine oil with an

^GIf any gasoline spills onto your skin, im-

mediately wash with soap and water.

Change clothing if gasoline spills on it.

^GTouch the fuel nozzle to the filler open-

ing or funnel to help prevent electro-

static sparks.

NMMA-certified TC-W3 rating may be used.

EMU25741

Propeller selection

The performance of your outboard motor will

be critically affected by your choice of propel-

ler, as an incorrect choice could adversely

affect performance and could also seriously

damage the motor. Engine speed depends

on the propeller size and boat load. If engine

speed is too high or too low for good engine

performance, this will have an adverse effect

on the engine.

ECM00010

CAUTION:

Use only new clean gasoline which has

been stored in clean containers and is not

contaminated with water or foreign mat-

ter.

Yamaha outboard motors are fitted with pro-

pellers chosen to perform well over a range

of applications, but there may be uses where

a propeller with a different pitch would be

more appropriate. For a greater operating

load, a smaller-pitch propeller is more suit-

able as it enables the correct engine speed

to be maintained. Conversely, a larger-pitch

propeller is more suitable for a smaller oper-

ating load.

EMU25570

Gasoline

If knocking or pinging occurs, use a different

brand of gasoline or premium unleaded fuel.

Recommended gasoline:

Regular unleaded gasoline with a min-

imum octane rating of 86 (Pump Oc-

tane Number) = (R+M)/2

Gasohol

Yamaha dealers stock a range of propellers,

and can advise you and install a propeller on

your outboard that is best suited to your ap-

plication.

There are two types of gasohol: gasohol con-

taining ethanol and that containing metha-

nol. Gasohol containing ethanol can be used

if ethanol content does not exceed 10% and

the fuel meets minimum octane ratings.

Yamaha does not recommended gasohol

containing methanol because it can cause

fuel system damage or engine performance

problems.

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General information

2 3

ZMU04605

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

NOTE:

Select a propeller which will allow the engine

to reach the middle or upper half of the oper-

ating range at full throttle with the maximum

boat load. If operating conditions such as

light boat loads then allow the engine r/min to

rise above the maximum recommended

range, reduce the throttle setting to maintain

the engine in the proper operating range.

For instructions on propeller removal and in-

stallation, see page 43.

EMU25770

Start-in-gear protection

Yamaha outboard motors or Yamaha-ap-

proved remote control units are equipped

with start-in-gear protection device(s). This

feature permits the engine to be started only

when it is in neutral. Always select neutral

before starting the engine.

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Basic components

EMU25795

Main components

NOTE:

* May not be exactly as shown; also may not be included as standard equipment on all mod-

els.

25D

ZMU04829

1. Top cowling lock lever

2. Choke knob

3. Gear shift lever

14. Clamp bracket

15. Rope attachment

16. Shallow water lever

17. Top cowling

4. Tiller handle

5. Throttle friction adjuster

18. Fuel tank*

6. Engine stop button/Engine stop lanyard

switch

EMU25802

Fuel tank

7. Transom clamp handle

8. Tilt lock lever

If your model was equipped with a portable

9. Trim rod

10. Cooling water inlet

11. Propeller

12. Trim tab (anode)

13. Anti-cavitation plate

fuel tank, its function is as follows.

EWM00020

WARNING

The fuel tank supplied with this engine is

its dedicated fuel reservoir and must not

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Basic components

be used as a fuel storage container. Com-

mercial users should conform to relevant

licensing or approval authority regula-

tions.

ZMU02846

EMU25922

Gear shift lever

Pulling the gear shift lever towards you puts

the engine in forward gear so that the boat

moves ahead. Pushing the lever away from

you puts the engine in reverse gear so that

the boat moves astern.

ZMU03157

1. Fuel joint

2. Fuel gauge

3. Fuel tank cap

4. Air vent screw

EMU25830

Fuel joint

This joint is used to connect the fuel line.

EMU25841

Fuel gauge

This gauge is located on either the fuel tank

cap or on the fuel joint base. It shows the ap-

proximate amount of fuel remaining in the

ZMU03687

tank.

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

EMU25850

Fuel tank cap

This cap seals the fuel tank. When removed,

the tank can be filled with fuel. To remove the

cap, turn it counterclockwise.

EMU25860

EMU25941

Throttle grip

The throttle grip is on the tiller handle. Turn

the grip counterclockwise to increase speed

and clockwise to decrease speed.

Air vent screw

This screw is on the fuel tank cap. To loosen

the screw, turn it counterclockwise.

EMU25911

Tiller handle

To change direction, move the tiller handle to

the left or right as necessary.

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Basic components

there is too much resistance, it could be

difficult to move throttle lever or grip,

which could result in an accident.

ZMU02848

EMU25961

Throttle indicator

The fuel consumption curve on the throttle

indicator shows the relative amount of fuel

consumed for each throttle position. Choose

the setting that offers the best performance

and fuel economy for the desired operation.

ZMU03688

When constant speed is desired, tighten the

adjuster to maintain the desired throttle set-

ting.

EMU25990

Engine stop lanyard switch

The lock plate must be attached to the en-

gine stop switch for the engine to run. The

lanyard should be attached to a secure place

on the operator’s clothing, or arm or leg.

Should the operator fall overboard or leave

the helm, the lanyard will pull out the lock

plate, stopping ignition to the engine. This

will prevent the boat from running away un-

ZMU02849

der power.

EWM00120

1. Throttle indicator

WARNING

EMU25970

^GAttach the engine stop switch lanyard

to a secure place on your clothing, or

your arm or leg while operating.

Throttle friction adjuster

A friction device provides adjustable resis-

tance to movement of the throttle grip or the

remote control lever, and can be set accord-

ing to operator preference.

To increase resistance, turn the adjuster

clockwise. To decrease resistance, turn the

^GDo 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.

^GAvoid accidentally pulling the lanyard

during normal operation. Loss of en-

gine power means the loss of most

steering control. Also, without engine

power, the boat could slow rapidly. This

adjuster counterclockwise.

EWM00030

WARNING

Do not overtighten the friction adjuster. If

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Basic components

could cause people and objects in the

boat to be thrown forward.

NOTE:

The engine cannot be started with the lock

plate removed.

ZMU04127

EMU26070

Manual starter handle

To start the engine, first gently pull the han-

dle out until resistance is felt. From that posi-

tion, then pull the handle straight out quickly

to crank the engine.

ZMU03689

1. Lanyard

2. Lock plate

EMU26001

Engine stop button

To open the ignition circuit and stop the en-

gine, push this button.

EMU26122

Steering friction adjuster

A friction device provides adjustable resis-

tance to the steering mechanism, and can be

set according to operator preference. An ad-

justing screw or bolt is located on the swivel

bracket.

ZMU03690

EMU26011

Choke knob for pull type

To supply the engine with the rich fuel mix-

ture required to start, pull out this knob.

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Basic components

starboard side “B” in the figure.

ECM00840

CAUTION:

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.

ZMU02908

To increase resistance, turn the adjuster

clockwise.

To decrease resistance, turn the adjuster

counterclockwise.

EWM00040

WARNING

ZMU02822

Do not overtighten the friction adjuster. If

there is too much resistance, it could be

difficult to steer, which could result in an

accident.

1. Trim tab

2. Bolt

EMU26261

EMU26240

Trim rod (tilt pin)

Trim tab with anode

The position of the trim rod determines the

minimum trim angle of the outboard motor in

relation to the transom.

The trim tab should be adjusted so that the

steering control can be turned to either the

right or left by applying the same amount of

force.

EWM00840

WARNING

An improperly adjusted trim tab could

cause difficult steering. Always test run

after the trim tab has been installed or re-

placed to be sure steering is correct. Be

sure you have tightened the bolt after ad-

justing the trim tab.

ZMU02929

If the boat tends to veer the left (port side),

turn the trim tab rear end to the port side “A”

in the figure. If the boat tends to veer the right

(starboard side), turn the trim tab end to the

EMU26270

Shallow water lever

Lifting this lever will tilt the motor up partially

to provide more clearance when operating in

shallow water.

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Basic components

ZMU04111

ZMU03699

EMU30530

EMU26372

Tilt lock mechanism

Top cowling lock lever(s) (turn type)

The tilt lock mechanism is used to prevent To remove the engine top cowling, turn the

the outboard motor from lifting out of the wa- lock lever(s) and lift off the cowling. When in-

ter when in reverse gear.

stalling the cowling, check to be sure it fits

properly in the rubber seal. Then lock the

cowling again by returning the lever(s) to the

lock position.

ZMU03695

1. Tilt lock lever

ZMU03701

To lock it, set the tilt lock lever in the lock po-

sition. To release, push the tilt lock lever in

1. Top cowling lock lever(s)

the release position.

EMU26330

EMU26801

Tilt support bar

The tilt support bar keeps the outboard motor

Warning system

ECM00090

CAUTION:

in the tilted up position.

Do not continue to operate the engine if a

warning device has activated. Consult

your Yamaha dealer if the problem can-

not be located and corrected.

EMU26813

Overheat warning

This engine has an overheat warning device.

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Basic components

If the engine temperature rises too high, the

warning device will activate.

Activation of warning device

^GThe engine speed will automatically de-

crease to about 2000 r/min.

G The overheat warning indicator will light (if

equipped on the bottom cowling or the ta-

chometer).

^GThe buzzer will sound (if equipped on the

tiller handle, remote control box, or main

switch panel).

If the warning system has activated, stop the

engine and check the cooling water inlet for

clogging.

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Operation

EMU26901

specific boat and motor combination.

Installation

EWM00830

ECM00110

WARNING

CAUTION:

Improper mounting of the outboard mo-

tor could result in hazardous conditions

such as poor handling, loss of control, or

fire hazards. Observe the following:

G For permanently mounted models, your

dealer or other person experienced in

proper rigging should mount the motor.

If you are mounting the motor yourself,

you should be trained by an experi-

enced person.

Incorrect engine height or obstructions

to smooth water flow (such as the design

or condition of the boat, or accessories

such as transom ladders or depth finder

transducers) can create airborne 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.

G For portable models, your dealer or oth-

er person experienced in proper out-

board motor mounting should show

you how to mount your motor.

NOTE:

During water testing check the buoyancy of

the boat, at rest, with its maximum load.

Check that the static water level on the ex-

haust housing is low enough to prevent wa-

ter entry into the powerhead, when water

rises due to waves when the outboard is not

running.

Mount the outboard motor on the center line

(keel line) of the boat, and ensure that the

boat itself is well balanced. Otherwise the

boat will be hard to steer. For boats without

a keel or which are asymmetrical, consult

your dealer.

EMU26910

Mounting the outboard motor

EWM00820

WARNING

^GOverpowering a boat could cause se-

vere instability. Do not install an out-

board motor with more horsepower

than the maximum rating on the capac-

ity plate of the boat. If the boat does not

have a capacity plate, consult the boat

manufacturer.

G The information presented in this sec-

tion is intended as reference only. It is

not possible to provide complete in-

structions for every possible boat and

motor combination. Proper mounting

depends in part on experience and the

ZMU01760

1. Center line (keel line)

EMU26920

Mounting height

To run your boat at optimum efficiency, the

water resistance (drag) of the boat and out-

board motor must be made as little as possi-

ble. The mounting height of the outboard

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Operation

motor greatly affects the water resistance. If

the mounting height is too high, cavitation

tends to occur, thus reducing the propulsion;

and if the propeller tips cut the air, the engine

speed will rise abnormally and cause the en-

gine to overheat. If the mounting height is too

low, the water resistance will increase and

thereby reduce engine efficiency. Mount the

outboard motor so that the anti-cavitation

plate is between the bottom of the boat and

a level 25 mm (1 in.) below it.

come loose due to engine vibration.

EWM00640

WARNING

Loose clamp screws could allow the out-

board motor to fall off or move on the

transom. This could cause loss of control

and serious injury. Make sure the tran-

som screws are tightened securely. Oc-

casionally check the screws for tightness

during operation.

0–25mm

ZMU02012

(0–1in.)

ZMU02011

2. If the engine restraint cable attachment

is equipped on your engine, an engine

restraint cable or chain should be used.

Attach one end to the engine restraint

cable attachment and the other to a se-

cure mounting point on the boat. Other-

wise the engine could be completely lost

if it accidentally falls off the transom.

NOTE:

^GThe optimum mounting height of the out-

board motor is affected by the boat and

motor combination and the desired use.

Test runs at different heights can help de-

termine the optimum mounting height.

Consult your Yamaha dealer or boat man-

ufacturer for further information on deter-

mining the proper mounting height.

G For instructions on setting the trim angle of

the outboard motor, see page 27.

EMU26970

Clamping the outboard motor

1. Place the outboard motor on the tran-

som so that it is positioned as close to

the center as possible. Tighten the tran-

som clamp screws evenly and securely.

Occasionally check the clamp screws

for tightness during operation of the out-

board motor because they could be-

ZMU02013

3. Secure the clamp bracket to the transom

using the bolts provided with the out-

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Operation

EMU27050

board (if packed). For details, consult

Gasoline and engine oil mixing chart

(25:1)

your Yamaha dealer.

EWM00650

WARNING

Avoid using bolts, nuts or washers other

than those contained in the engine pack-

aging. If used, they must be of at least the

same quality of material and strength and

must be tightened securely. After tighten-

ing, test run the engine and check their

tightness.

1. : Gasoline

2. : Engine oil

ECM00150

CAUTION:

Be sure to mix gasoline and oil complete-

ly, otherwise the engine may be dam-

aged.

EMU27073

ZMU02637

Procedure for pre-mixed models

Run the engine under load (in gear with a

propeller installed) as follows.

1. Bolts

1. First 10 minutes:

EMU30172

Run the engine at the lowest possible

speed. A fast idle in neutral is best.

2. Next 50 minutes:

Breaking in engine

Your new engine requires a period of break-

in to allow mating surfaces of moving parts to

wear in evenly. Correct break-in will help en-

sure proper performance and longer engine

Do not exceed half throttle (approxi-

mately 3000 r/min). Vary engine speed

occasionally. If you have an easy-plan-

ing boat, accelerate at full throttle onto

plane, then immediately reduce the

throttle to 3000 r/min or less.

life.

ECM00800

CAUTION:

Failure to follow the break-in procedure

could result in reduced engine life or

even severe engine damage.

3. Second hour:

Accelerate at full throttle onto plane,

then reduce engine speed to three-quar-

ter throttle (approximately 4000 r/min).

Vary engine speed occasionally. Run at

full throttle for one minute, then allow

about 10 minutes of operation at three-

quarter throttle or less to let the engine

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Operation

EMU27120

cool.

Oil

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 en-

gine speed occasionally.

G Check to be sure you have plenty of oil for

your trip.

EMU27130

Controls

G Check throttle, shift, and steering for prop-

er operation before starting the engine.

^GThe controls should work smoothly, with-

out binding or unusual free play.

^GLook for loose or damaged connections.

^GCheck operation of the starter and stop

switches when the outboard motor is in the

5. After the first 10 hours:

Operate the engine normally. Use the

standard premix ratio of gasoline and oil.

For details on mixing fuel and oil, see

page 20.

EMU27101

Preoperation checks

water.

EMU27140

EWM00080

WARNING

Engine

If any item in the preoperation check is

not working properly, have it inspected

and repaired before operating the out-

board motor. Otherwise an accident

could occur.

^GCheck the engine and engine mounting.

^GLook for loose or damaged fasteners.

^GCheck the propeller for damage.

EMU27233

Filling fuel and engine oil

EMU27242

ECM00120

Filling fuel for portable tank

CAUTION:

EWM00060

Do not start the engine out of water. Over-

heating and serious engine damage can

occur.

WARNING

Gasoline and its vapors are highly flam-

mable and explosive. Keep away from

sparks, cigarettes, flames, or other

sources of ignition.

EMU27110

Fuel

^GCheck to be sure you have plenty of fuel

1. Remove the fuel tank cap.

2. Fill the fuel tank carefully.

3. Close the cap securely after refueling.

Wipe up any spilled fuel.

for your trip.

G Make sure there are no fuel leaks or gaso-

line fumes.

^GCheck fuel line connections to be sure they

are tight (if equipped Yamaha fuel tank or

boat tank).

^GBe sure the fuel tank is positioned on a se-

cure, flat surface, and that the fuel line is

not twisted or flattened, or likely to contact

sharp objects (if equipped Yamaha fuel

tank or boat tank).

Fuel tank capacity (if equipped Yamaha

fuel tank):

24L

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Operation

EMU27403

Gasoline and oil mixing (100:1)

Gasoline to engine

oil ratio

Break-in period

After break-in

See page 19

100:1

If equipped with a portable fuel tank

1. Pour oil into the portable fuel tank, and

then add gasoline.

ZMU03012

EMU27270

Ring Free Fuel Additive

Gasoline is a precise blend of many different

substances, each chosen to give certain

characteristics. Gasoline blends have been

changing in recent years in response to con-

cerns about pollution and resulting emis-

sions regulations. One of the most obvious

changes has been the elimination of lead

from most fuels.

As gasoline has changed, the amount of ad-

ditives such as aromatics and oxygenates

has increased. These additives are impor-

tant for the engines in passenger cars, but

they can have detrimental effects in marine

engines, because of increased deposits in

the combustion chamber. When enough de-

posits collect, piston rings begin sticking.

Performance drops and engine wear in-

creases dramatically.

While many additives available may reduce

deposits, Yamaha recommends the use of

Ring Free Fuel Additive, available from

your Yamaha dealer. Ring Free Fuel Addi-

tive has repeatedly proven its ability to clean

combustion deposits from inside the engine,

notably the critical piston-ring-land area, and

fuel system components. Follow product la-

beling for use instructions.

1. Engine oil

2. Gasoline

2. Replace the fuel tank cap and close

tightly.

3. Shake the fuel tank to mix the fuel thor-

oughly.

4. Make sure that the oil and gasoline are

mixed.

If equipped with a built-in fuel tank

1. Pour oil into a clean fuel can, and then

add gasoline.

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Operation

2. Replace the fuel can cap and close tight-

are flammable and explosive. Refrain

from smoking, and keep away from

open flames and sparks while loosen-

ing the air vent screw.

ly.

3. Shake the fuel can to mix the fuel thor-

oughly.

4. Make sure that the oil and gasoline are G This product emits exhaust gases

mixed.

which contain carbon monoxide, a col-

orless, odorless gas which could cause

brain damage or death when inhaled.

Symptoms include nausea, dizziness,

and drowsiness. Keep cockpit and cab-

in areas well ventilated. Avoid blocking

exhaust outlets.

5. Pour the gasoline and oil mixture into the

built-in fuel tank.

ECM00810

CAUTION:

^GAvoid using any oil other than the spec-

ified type.

G Use a thoroughly blended fuel-oil mix-

ture.

1. If there is an air vent screw on the fuel

tank cap, loosen it 2 or 3 turns.

^GIf the mixture is not thoroughly mixed,

or if the mixing ratio is incorrect, the

following problems could occur. Low

oil ratio: Lack of oil could cause major

engine trouble, such as piston seizure.

^GHigh oil ratio: Too much oil could cause

fouled spark plugs, smoky exhaust,

and heavy carbon deposits.

NOTE:

ZMU02022

If using a permanently installed tank, pour

the oil gradually as the gasoline is being add-

ed to the tank.

2. If there is a fuel joint on the motor, firmly

connect the fuel line to the joint. Then

firmly connect the other end of the fuel

line to the joint on the fuel tank.

EMU27450

Operating engine

EMU27461

Feeding fuel (portable tank)

EWM00420

WARNING

G Before starting the engine, make sure

that the boat is tightly moored and that

you can steer clear of any obstructions.

Be sure there are no swimmers in the

water near you.

^GWhen the air vent screw is loosened,

gasoline vapor will be released. Gaso-

line is highly flammable, and its vapors

ZMU04113

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Operation

ZMU03714

ZMU02024

3. If a steering friction adjuster is provided

on your outboard motor, securely attach

the fuel line to the fuel line clamp.

NOTE:

The start-in-gear protection device prevents

the engine from starting except when in neu-

tral.

NOTE:

During engine operation place the tank hori-

zontally, otherwise fuel cannot be drawn

from the fuel tank.

2. Attach the engine stop switch lanyard to

a secure place on your clothing, or your

arm or leg. Then install the lock plate on

the other end of the lanyard into the en-

4. Squeeze the primer pump with the outlet

end up until you feel it become firm.

gine stop switch.

EWM00120

WARNING

G Attach the engine stop switch lanyard

to a secure place on your clothing, or

your arm or leg while operating.

G 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.

^GAvoid accidentally pulling the lanyard

during normal operation. Loss of en-

gine power means the loss of most

steering control. Also, without engine

power, the boat could slow rapidly. This

could cause people and objects in the

boat to be thrown forward.

ZMU02025

EMU27490

Starting engine

EMU27505

Manual start models (tiller control)

1. Place the gear shift lever in neutral.

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Operation

the engine will run poorly or stall.

5. Pull the manual starter handle slowly un-

til you feel resistance. Then give a

strong pull straight out to crank and start

the engine. Repeat if necessary.

ZMU03744

3. Place the throttle grip in the “

(start) position.

”

6. After the engine starts, slowly return the

manual starter handle to its original po-

sition before releasing it.

7. Slowly return the throttle grip to the fully

closed position.

ZMU02954

4. Pull out / turn the choke knob fully. After

the engine starts, replace / return the

knob to the home position.

ZMU02030

NOTE:

G When the engine is cold, it needs to be

warmed up. For further information, see

page 25.

ZMU04114

G If the engine does not start on the first try,

repeat the procedure. If the engine fails to

start after 4 or 5 tries, open the throttle a

small amount (between 1/8 and 1/4) and

try again. Also if the engine is warm and

fails to start, open the throttle a same

NOTE:

^GIt is not necessary to use the choke when

starting a warm engine.

^GIf the choke knob is left in the “

(start) position while the engine is running,

”

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Operation

EMU27740

EWM00180

amount and try to start the engine again. If

the engine still fails to start, see page 48.

Shifting

EMU27670

WARNING

Warming up engine

EMU27680

Before shifting, make sure there are no

swimmers or obstacles in the water near

you.

Choke start models

1. After starting the engine, allow it to idle

for 3 minutes to warm up. Failure to do

so will shorten engine life. Gradually re-

turn the choke knob to its home position

as the engine warms up.

2. Check for a steady flow of water from the

cooling water pilot hole.

ECM00510

ECM00220

CAUTION:

To change the boat direction or shifting

position from forward to reverse or vice-

versa, first close the throttle so that the

engine idles (or runs at low speeds).

EMU27763

CAUTION:

Forward (tiller handle and remote

A flow of water from the hole on the ex-

haust cover shows that the water pump is

pumping water through the cooling pas-

sages. If water is not flowing out of the

hole at all times while the engine is run-

ning, overheating and serious damage

could occur. Stop the engine and check

whether the cooling water inlet on the

lower case or the cooling water pilot hole

is blocked. Consult your Yamaha dealer if

the problem cannot be located and cor-

rected.

control models)

Tiller control models

1. Place the throttle grip in the fully closed

position.

ZMU02030

2. Move the gear shift lever quickly and

firmly from neutral to forward.

ZMU02856

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Operation

sition.

ZMU03718

ZMU03719

Remote control models

1. Pull up the neutral interlock trigger (if 3. Move the gear shift lever quickly and

equipped) and move the remote control

lever quickly and firmly from neutral to

forward.

firmly from neutral to reverse.

EMU27795

Reverse (manual tilt and hydro tilt

models)

EWM00190

WARNING

When operating in reverse, go slowly. Do

not open the throttle more than half. Oth-

erwise the boat could become unstable,

which could result in loss of control and

an accident.

ZMU03720

Remote control models

1. Check that the tilt lock lever is in the lock

position.

Tiller control models

2. Pull up the neutral interlock trigger (if

equipped) and move the remote control

lever quickly and firmly from neutral to

1. Place the throttle grip in the fully closed

position.

reverse.

EMU27820

Stopping engine

Before stopping the engine, first let it cool off

for a few minutes at idle or low speed. Stop-

ping the engine immediately after operating

at high speed is not recommended.

EMU27832

ZMU02030

Procedure

1. Push and hold the engine stop button

until the engine comes to a complete

stop.

2. On models equipped with a tilt lock le-

ver, check that it is in the lock/down po-

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Operation

ing the lock plate from the engine stop

switch.

EMU27861

Trimming outboard motor

The trim angle of the outboard motor helps

determine the position of the bow of the boat

in the water. Correct trim angle will help im-

prove performance and fuel economy while

reducing strain on the engine. Correct trim

angle depends upon the combination of

boat, engine, and propeller. Correct trim is

also affected by variables such as the load in

ZMU03690

2. After stopping the engine, tighten the air

vent screw on the fuel tank cap and set

the fuel cock lever or knob to the closed

position, if equipped.

the boat, sea conditions, and running speed.

EWM00740

WARNING

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 in-

creases the possibility of an accident. If

the boat begins to feel unstable or is hard

to steer, slow down and/or readjust the

trim angle.

ZMU02301

3. Disconnect the fuel line if you are using

an external fuel tank.

ZMU04121

NOTE:

If the outboard motor is equipped with an en-

gine stop switch lanyard, the engine can also

be stopped by pulling the lanyard and remov-

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Operation

ZMU02909

1. Trim rod

3. Reposition the rod in the desired hole.

To raise the bow (“trim-out”), move the rod

away from the transom.

To lower the bow (“trim-in”), move the rod to-

ward the transom.

Make test runs with the trim set to different

angles to find the position that works best for

ZMU02858

your boat and operating conditions.

EWM00400

1. Trim operating angle

WARNING

EMU27871

^GStop the engine before adjusting the

trim angle.

^GUse care to avoid being pinched when

removing or installing the rod.

G Use caution when trying a trim position

for the first time. Increase speed gradu-

ally and watch for any signs of instabil-

ity or control problems. Improper trim

angle can cause loss of control.

Adjusting trim angle for manual tilt

models

There are 4 or 5 holes provided in the clamp

bracket to adjust the outboard motor trim an-

gle.

1. Stop the engine.

2. Remove the trim rod from the clamp

bracket while slightly tilting the outboard

motor up.

NOTE:

The outboard motor trim angle can be

changed approximately 4 degrees by shifting

the trim rod one hole.

EMU27911

Adjusting boat trim

When the boat is on plane, a bow-up attitude

results in less drag, greater stability and effi-

ciency. This is generally when the keel line of

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Operation

the boat is up about 3 to 5 degrees. With the and making it hard to increase speed. Oper-

bow up, the boat may have a greater tenden- ating with excessive trim-in at higher speeds

cy to steer to one side or the other. Compen- also makes the boat unstable. Resistance at

sate for this as you steer. The trim tab can the bow is greatly increased, heightening the

also be adjusted to help offset this effect. danger of “bow steering” and making opera-

When the bow of the boat is down, it is easier tion difficult and dangerous.

to accelerate from a standing start onto

plane.

NOTE:

Depending on the type of boat, the outboard

Bow Up

motor trim angle may have little effect on the

trim of the boat when operating.

Too much trim-out puts the bow of the boat

too high in the water. Performance and econ-

omy 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 per-

formance further, and the boat may “por-

poise” (hop in the water), which could throw

the operator and passengers overboard.

EMU27931

Tilting up and down

If the engine will be stopped for some time or

if the boat is moored in shallows, the out-

board motor should be tilted up to protect the

propeller and casing from damage by colli-

sion with obstructions, and also to reduce

salt corrosion.

EWM00220

WARNING

Be sure all people are clear of the out-

board motor when tilting up and down,

also be careful not to pinch any body

parts between the drive unit and engine

bracket.

EWM00250

WARNING

Leaking fuel is a fire hazard. If there is a

fuel joint on the outboard motor, discon-

nect the fuel line or close the fuel cock if

Bow Down

Too much trim-in causes the boat to “plow”

through the water, decreasing fuel economy

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Operation

the engine will be tilted for more than a

few minutes. Otherwise fuel may leak.

ECM00241

CAUTION:

^GBefore tilting the outboard motor, stop

the engine by following the procedure

on page 26. Never tilt the outboard mo-

tor while the engine is running. Severe

damage from overheating can result.

^GDo not tilt up the engine by pushing the

tiller handle (if equipped) because this

could break the handle.

ZMU03726

4. Hold the rear of the top cowling with one

hand, tilt the engine up, and turn the tilt

support lever to the lock position and

EMU27952

support the engine.

Procedure for tilting up

Manual tilt models

1. Place the gear shift lever in neutral.

EMU28022

Procedure for tilting down (manual

tilt models)

1. Place the tilt lock lever in the release/

down position or return the shallow wa-

ter lever to its original position.

ZMU03724

2. Disconnect the fuel line if a fuel joint is

provided on the outboard motor.

ZMU03747

ZMU03725

ZMU03731

3. Place the tilt lock lever in the release po-

sition.

2. Slightly tilt the engine up until the tilt sup-

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Operation

port bar is automatically released.

3. Slowly tilt the engine down.

EMU28060

Cruising in shallow water

The outboard motor can be tilted up partially

to allow operation in shallow water.

EMU28071

Cruising in shallow water (manual tilt

models)

ZMU02868

EWM00710

WARNING

EMU28132

^GPlace the gear shift in neutral before us-

ing the shallow water cruising system.

^GRun the boat at the lowest possible

speed when using the shallow water

cruising system. The tilt lock mecha-

nism does not work while the shallow

water cruising system is being used.

Hitting an underwater obstacle could

cause the outboard motor to lift out of

the water, resulting in loss of control.

G Do not rotate the outboard motor 180°

and operate the boat in reverse. Place

the gear shift in reverse to operate the

boat in reverse.

Procedure

1. Place the gear shift lever in neutral.

ZMU03745

2. Push the tilt lock lever down to release it.

^GUse extra care when operating in re-

verse. Too much reverse thrust can

cause the outboard motor to lift out of

the water, increasing the chance of ac-

cident and personal injury.

G Return the outboard motor to its normal

position as soon as the boat is back in

deeper water.

ZMU03746

ECM00260

CAUTION:

3. Pull up the shallow water lever.

Do not tilt the outboard motor up so that

the cooling water inlet on the lower unit is

above the surface of the water when set-

ting up for and cruising in shallow water.

Otherwise severe damage from overheat-

ing can result.

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Operation

ZMU03728

ZMU03731

4. Slightly tilt the outboard motor up. The 6. Slightly tilt the outboard motor up until

tilt support bar will lock automatically,

supporting the outboard motor in a par-

tially raised position.

the tilt support bar automatically returns

to the free position.

7. Slowly lower the outboard motor to the

normal position.

NOTE:

EMU28190

This outboard motor has 2 positions for shal-

low water cruising.

Cruising in other conditions

Cruising in salt water

5. To return the outboard motor to the nor-

mal running position, place the tilt lock

lever and shallow water lever to the lock

position.

After operating in salt water, wash out the

cooling water passages with fresh water to

prevent them from becoming clogged with

salt deposits.

NOTE:

For cooling system flushing instructions, see

page 33.

Cruising in turbid water

Yamaha strongly recommends that you use

the optional chromium-plated water pump kit

if you use the outboard motor in turbid (mud-

dy) water conditions.

ZMU03729

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Maintenance

EMU28216

Choke valve

Alternator output:

80 W

Specifications

Dimension:

Overall length:

Drive unit:

Gear positions:

Forward-neutral-reverse

Gear ratio:

2.08 (27/13)

936 mm (36.9 in)

Overall width:

358 mm (14.1 in)

Overall height S:

1068 mm (42.0 in)

Transom height S:

419 mm (16.5 in)

Weight (AL) S:

Trim and tilt system:

Manual tilt

Propeller mark:

48.0 kg (106 lb)

Performance:

Fuel and oil:

Recommended fuel:

Full throttle operating range:

5000–6000 r/min

Maximum output:

18.4 kW@5500 r/min (25 HP@5500

r/min)

Regular unleaded gasoline

Min. pump octane:

Recommended engine oil:

YAMALUBE 2-stroke outboard motor

oil

Idling speed (in neutral):

750 50 r/min

Fuel:oil ratio:

Engine:

Regular gasoline:

Type:

100 :1

2-stroke L

Lubrication:

Displacement:

395.0 cm (24.10 cu.in)

Bore × stroke:

67.0 × 56.0 mm (2.64 × 2.20 in)

Ignition system:

CDI

Pre-mixed fuel and oil

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

370.0 cm (12.51 US oz) (13.05

Imp.oz)

Spark plug (NGK):

B7HS-10

Tightening torque for engine:

Spark plug:

Spark plug with resistor (NGK):

BR7HS-10

25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Propeller nut:

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

Control system:

Tiller

Starting system:

Manual

35.0 Nm (25.8 ft-lb) (3.57 kgf-m)

EMU28222

Transporting and storing

outboard motor

EWM00690

WARNING

Starting carburetion system:

G Leaking fuel is a fire hazard. When

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Maintenance

transporting and storing the outboard

motor, close the air vent screw and fuel

cock to prevent fuel from leaking.

^GUSE CARE when transporting fuel tank,

whether in a boat or car.

^GDO 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.

ZMU02870

EMU28235

Clamp screw mounting models

When transporting or storing the outboard

motor while removed from a boat, keep the

outboard motor in the attitude shown.

EWM00700

WARNING

Never get under the lower unit while it is

tilted, even if a motor support bar is used.

Severe injury could occur if the outboard

motor accidentally falls.

ECM00660

CAUTION:

Do not use the tilt support lever or knob

when trailering the boat. The outboard

motor could shake loose from the tilt sup-

port and fall. If the motor cannot be trail-

ered in the normal running position, use

an additional support device to secure it

in the tilt position.

ZMU02869

NOTE:

Place a towel or something similar under the

The outboard motor should be trailered and

stored in the normal running position. If there

is insufficient road clearance in this position,

then trailer the outboard motor in the tilt po-

sition using a motor support device such as

a transom saver bar. Consult your Yamaha

dealer for further details.

outboard motor to protect it from damage.

EMU30272

Storing outboard motor

When storing your Yamaha outboard motor

for prolonged periods of time (2 months or

longer), several important procedures must

be performed to prevent excessive damage.

It is advisable to have your outboard motor

serviced by an authorized Yamaha dealer

prior to storage. However, you, the owner,

with a minimum of tools, can perform the fol-

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Maintenance

lowing procedures.

ECM01411

CAUTION:

G Do not place the outboard motor on its

side before the cooling water has

drained from it completely, otherwise

water may enter the cylinder through

the exhaust port and cause engine trou-

ble.

ZMU02051

G Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

1. Water surface

EMU28301

2. Lowest water level

Procedure

EMU28372

5. Fill the tank with fresh water to above the

level of the anti-cavitation plate.

ECM00300

Flushing in a test tank

1. Wash the outboard motor body using

fresh water. For further information, see

page 36.

2. Fill the fuel tank with fresh fuel and add

one ounce of “Yamaha Fuel Conditioner

and Stabilizer” (Part No. LUB-FUELC-

12-00) to each gallon of fuel.

CAUTION:

Do not run the engine without supplying

it with cooling water. Either the engine

water pump will be damaged or the en-

gine will be damaged from overheating.

Before starting the engine, be sure to

supply water to the cooling water passag-

es.

NOTE:

The use of “Yamaha Fuel Conditioner and

Stabilizer” eliminates the need to drain the

fuel system. Consult your Yamaha dealer or

other qualified mechanic if the fuel system is

to be drained instead.

ECM00290

CAUTION:

If the fresh water level is below the level

of the anti-cavitation plate, or if the water

3. Remove the engine top cowling and si- supply is insufficient, engine seizure may

lencer cover.

occur.

4. Install the outboard motor on the test

tank.

6. Cooling system flushing is essential to

prevent the cooling system from clog-

ging up with salt, sand, or dirt. In addi-

tion, fogging of the engine is mandatory

to prevent excessive engine damage

due to rust. Perform the flushing and

fogging at the same time.

EWM00090

WARNING

G Do not touch or remove electrical parts

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Maintenance

when starting or during operation.

G Keep hands, hair, and clothes away

from the flywheel and other rotating

parts while the engine is running.

2. Spray the outboard motor exterior with

“Yamaha Silicone Protectant” (Part No.

LUB-SILCNE-13-00).

3. Wax the cowling with a non-abrasive

wax such as “Yamaha Silicone Wax”

7. Run the engine at a fast idle for 10–15

minutes in neutral position.

(Part No. ACC-11000-15-02).

EMU28450

8. Just prior to turning off the engine, quick-

ly spray “Yamaha Stor-Rite Engine

Fogging Oil” (Part No. LUB-STRRT-12-

00) alternately into each carburetor or

the fogging hole of the silencer cover, if

equipped. When properly done, the en-

gine will smoke excessively and almost

stall.

Cleaning the outboard motor

After use, wash the exterior of the outboard

motor with fresh water. Flush the cooling

system with fresh water.

9. Remove the outboard motor from the

test tank.

10. Drain the cooling water completely out

of the motor. Clean the body thoroughly.

11. Install the silencer cover/cap and top

cowling.

EMU28400

Lubrication (except oil injection

models)

1. Grease the spark plug threads and in-

stall the spark plug(s) and torque to

proper specification. For information on

spark plug installation, see page 39.

2. Change the gear oil. For instructions,

see page 44. Inspect the oil for the pres-

ence of water that indicates a leaky seal.

Seal replacement should be performed

by an authorized Yamaha dealer prior to

use.

ZMU02871

NOTE:

For cooling system flushing instructions, see

page 33.

3. Grease all grease fittings. For further de-

EMU28460

tails, see page 39.

Checking painted surface of motor

Check the motor for scratches, nicks, or flak-

ing paint. Areas with damaged paint are

more likely to corrode. If necessary, clean

and paint the areas. A touch-up paint is avail-

able from your Yamaha dealer.

EMU28421

Cleaning and anticorrosion

measures

1. Wash down the exterior of the outboard

motor with fresh water and dry off com-

pletely.

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Maintenance

EMU28483

Periodic maintenance

EWM01070

WARNING

Be sure to turn off the engine when you

perform maintenance unless otherwise

specified. If you or the owner is not famil-

iar with machine servicing, this work

should be done by your Yamaha dealer or

other qualified mechanic.

Maintenance, replacement, or repair of

the emission control devices and sys-

tems may be performed by any marine

engine repair establishment or individual.

All warranty repairs, however, including

those to the emission control system,

must be performed by an authorized

Yamaha marine dealership.

A service manual is available for purchase

through your Yamaha dealer for owners who

have the mechanical skills, tools, and other

equipment necessary to perform mainte-

nance not covered by this owner’s manual.

EMU28510

Replacement parts

If replacement parts are necessary, use only

genuine Yamaha parts or parts of the same

type and of equivalent strength and materi-

als. Any part of inferior quality may malfunc-

tion, and the resulting loss of control could

endanger the operator and passengers.

Yamaha genuine parts and accessories are

available from your Yamaha dealer.

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Maintenance

EMU28521

Maintenance chart

Frequency of maintenance operations may be adjusted according to the operating condi-

tions, but the following table gives general guidelines. Refer to the sections in this chapter for

explanations of each owner-specific action.

The “ ” symbol indicates the check-ups which you may carry out yourself.

The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Initial

Every

50 hours

100

hours (6

months)

200

hours (1

year)

Item

Actions

10 hours

(1 month)

months)

Inspection / replace-

ment

Inspection / replace-

ment

Anode(s) (external)

Anode(s) (internal)

Cooling water pas-

sages

Cleaning

Cowling clamp

Inspection

Fuel ﬁlter (can be dis-

assembled)

Inspection / cleaning

Inspection

Fuel system

Fuel tank (Yamaha por-

table tank)

Inspection / cleaning

Gear oil

Change

Greasing points

Greasing

Idling speed (carbure-

tor models)

Inspection / adjustment

Inspection / replace-

ment

Propeller and cotter pin

Shift link / shift cable

Thermostat

Inspection / adjustment

Inspection

Throttle link / throttle

cable / throttle pick-up

timing

Inspection / adjustment

Water pump

Inspection

Cleaning / adjustment /

replacement

Spark plug(s)

NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushed with clean

water after each use.

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Maintenance

EMU28931

Greasing

Yamaha marine grease (Water resistant grease)

25D

ZMU03734

EMU28951

sparks, which could lead to explosion or

fire.

Cleaning and adjusting spark plug

EWM00560

The spark plug is an important engine com-

ponent and is easy to inspect. The condition

of the spark plug can indicate something

about the condition of the engine. For exam-

WARNING

When removing or installing a spark plug,

be careful not to damage the insulator. A

damaged insulator could allow external

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Maintenance

ple, if the center electrode porcelain is very spark plug to the correct torque.

white, this could 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 re-

move 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 re-

place the spark plug with another of the cor-

rect type.

Spark plug torque:

25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

NOTE:

If a torque-wrench is not available when you

are fitting a spark plug, a good estimate of

the correct torque is 1/4 to 1/2 a turn past fin-

ger-tight. Have the spark plug adjusted to the

correct torque as soon as possible with a

torque-wrench.

EMU28962

Checking fuel system

EWM00060

Standard spark plug:

B7HS-10

WARNING

BR7HS-10

Gasoline and its vapors are highly flam-

mable and explosive. Keep away from

sparks, cigarettes, flames, or other

sources of ignition.

Before fitting the spark plug, measure the

electrode gap with a wire thickness gauge;

adjust the gap to specification if necessary.

EWM00910

WARNING

Leaking fuel can result in fire or explo-

sion.

^GCheck for fuel leakage regularly.

G If any fuel leakage is found, the fuel

system must be repaired by a qualified

mechanic. Improper repairs can make

the outboard unsafe to operate.

Check the fuel lines for leaks, crack, or mal-

function. If a problem is found, your Yamaha

dealer or other qualified mechanic should re-

pair it immediately.

1. Spark plug gap

2. Spark plug I.D. mark (NGK)

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

When fitting the plug, always clean the gas-

ket surface and use a new gasket. Wipe off

any dirt from the threads and screw in the

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Maintenance

EMU29001

Cleaning fuel filter

1. Remove the nut holding the fuel filter as-

sembly if equipped.

ZMU04772

Checkpoints

^GFuel system parts leakage

G Fuel line joint leakage

ZMU03812

^GFuel line cracks or other damage

^GFuel connector leakage

EMU28980

1. Nut

2. Unscrew the filter cup, catching any

spilled fuel in a rag.

Inspecting fuel filter

EWM00310

WARNING

3. Remove the filter element, and wash it in

solvent. Allow it to dry. Inspect the filter

element and O-ring to make sure they

are in good condition. Replace them if

necessary. If any water is found in the

fuel, the Yamaha portable fuel tank or

other fuel tanks should be checked and

cleaned.

Gasoline is highly flammable, and its va-

pors are flammable and explosive.

^GIf you have any question about properly

doing this procedure, consult your

Yamaha dealer.

^GDo not perform this procedure on a hot

or running engine. Allow the engine to

cool.

^GThere will be fuel in the fuel filter. Keep

away from sparks, cigarettes, flames or

other sources of ignition.

^GThis procedure will allow some fuel to

spill. Catch fuel in a rag. Wipe up any

spilled fuel immediately.

^GThe fuel filter must be reassembled

carefully with the O-ring, filter cup, and

hoses in place. Improper assembly or

replacement could result in a fuel leak,

which could result in a fire or explosion

hazard.

ZMU02079

1. Filter cup

2. Filter element

3. Filter housing

4. O-ring

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Maintenance

4. Reinstall the filter element in the cup.

Make sure the O-ring is in position in the

cup. Firmly screw the cup onto the filter

housing.

5. Attach the filter assembly to the bracket

so that the fuel hoses are attached to the

filter assembly.

the boat is tightly moored.

NOTE:

Correct idling speed inspection is only possi-

ble if the engine is fully warmed up. If not

warmed up fully, the idle speed will measure

higher than normal. If you have difficulty ver-

ifying the idle speed, or the idle speed re-

quires adjustment, consult a Yamaha dealer

or other qualified mechanic.

6. Run the engine and check the filter and

lines for leaks.

EMU29040

2. Verify whether the idle speed is set to

specification. For idle speed specifica-

Inspecting idling speed

EWM00450

WARNING

^GDo not touch or remove electrical parts

when starting or during operation.

tions, see page 33.

EMU29111

Checking wiring and connectors

^GCheck that each grounding wire is properly

secured.

G Check that each connector is engaged se-

curely.

G Keep hands, hair, and clothes away

from the flywheel and other rotating

parts while the engine is running.

G 2-hp models: The propeller rotates

whenever the engine is running. Do not

move the throttle control lever from the

start position during warm-up. The boat

could unexpectedly start to move,

which could result in an accident.

ECM00490

CAUTION:

This procedure must be performed while

the outboard motor is in the water. A

flushing attachment or test tank can be

used.

ZMU03737

EMU29120

Exhaust leakage

Start the engine and check that no exhaust

leaks from the joints between the exhaust

cover, cylinder head, and body cylinder.

EMU29130

A diagnostic tachometer should be used for

this procedure. Results may vary depending

on whether testing is conducted with the

flushing attachment, in a test tank, or with the

outboard motor in the water.

1. Start the engine and allow it to warm up

fully in neutral until it is running smooth-

ly.

Water leakage

Start the engine and check that no water

leaks from the joints between the exhaust

cover, cylinder head, and body cylinder.

2-hp model: Warm the engine with the

throttle in the start position or less. If the

outboard is mounted on a boat, be sure

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Maintenance

EMU29171

Checking propeller

EWM00321

WARNING

You could be seriously injured if the en-

gine accidentally starts when you are

near the propeller.

^GBefore inspecting, removing, or install-

ing the propeller, remove the spark

plug caps from the spark plugs. Also,

place the shift control in neutral, turn

ZMU01897

Checkpoints

the main switch to “

” (off) and re-

^GCheck each of the propeller blades for

wear, erosion from cavitation or ventila-

tion, or other damage.

^GCheck the propeller shaft for damage.

G Check the splines / shear pin for wear or

damage.

move the key, and remove the lanyard

from the engine stop switch. Turn off

the battery cut-off switch if your boat

has one.

^GDo not use your hand to hold the pro-

peller when loosening or tightening the

propeller nut. Put a wood block be-

tween the anti-cavitation plate and the

propeller to prevent the propeller from

turning.

^GCheck for fish line tangled around the pro-

peller shaft.

^GCheck the propeller shaft oil seal for dam-

age.

ZMU02876

NOTE:

If the shear pin equipped: it is designed to

break if the propeller hits a hard underwater

obstacle to help protect the propeller and

drive mechanism. The propeller will then

spin freely on the shaft. If this happens, the

shear pin must be replaced.

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Maintenance

EMU29193

washer, and propeller on the propeller

shaft.

3. Install the spacer (if equipped) and the

washer. Tighten the propeller nut to the

specified torque.

4. Align the propeller nut with the propeller

shaft hole. Insert a new cotter pin in the

hole and bend the cotter pin ends.

Removing the propeller

1. Straighten the cotter pin and pull it out

using a pair of pliers.

2. Remove the propeller nut, washer, and

spacer (if equipped).

ZMU02829

1. Cotter pin

2. Propeller nut

3. Washer

4. Spacer

5. Propeller

6. Thrust washer

ZMU02063

NOTE:

If the propeller nut does not align with the

propeller shaft hole after tightening to the

specified torque, tighten the nut further to

align it with the hole.

3. Remove the propeller and thrust wash-

er.

EMU29280

EMU29230

Changing gear oil

Installing the propeller

EWM00800

ECM00340

WARNING

CAUTION:

^GBe sure the outboard motor is securely

fastened to the transom or a stable

stand. You could be severely injured if

the outboard motor falls on you.

^GNever get under the lower unit while it

is tilted, even when the tilt support lever

or knob is locked. Severe injury could

occur if the outboard motor accidental-

ly falls.

G Be sure to install the thrust washer be-

fore installing the propeller, otherwise

the lower case and propeller boss

could be damaged.

^GBe sure to use a new cotter pin and

bend the ends over securely. Otherwise

the propeller could come off during op-

eration and be lost.

1. Apply Yamaha marine grease or a cor-

rosion resistant grease to the propeller

shaft.

1. Tilt the outboard motor so that the gear

oil drain screw is at the lowest point pos-

sible.

2. Install the spacer(if equipped), thrust

2. Place a suitable container under the

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Maintenance

gear case.

the gear oil drain screw hole.

3. Remove the gear oil drain screw.

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

370.0 cm (12.51 US oz) (13.05

Imp.oz)

ZMU03738

1. Gear oil drain screw

2. Oil level plug

NOTE:

ZMU03739

If the magnetic gear oil drain screw

equipped: remove all metal particles from

the screw before installing it.

6. When the oil begins to flow out of the oil

level plug hole, insert and tighten the oil

level plug.

4. Remove the oil level plug to allow the oil

7. Insert and tighten the gear oil drain

screw.

EMU29302

to drain completely.

ECM00710

CAUTION:

Cleaning fuel tank

Inspect the used oil after it has been

drained. If the oil is milky, water is getting

into the gear case which can cause gear

damage. Consult a Yamaha dealer for re-

pair of the lower unit seals.

EWM00920

WARNING

Gasoline is highly flammable, and its va-

pors are flammable and explosive.

G If you have any question about properly

doing this procedure, consult your

Yamaha dealer.

G Keep away from sparks, cigarettes,

flames, or other sources of ignition

when cleaning the fuel tank.

NOTE:

For disposal of used oil consult your Yamaha

dealer.

5. With the outboard motor in a vertical po-

sition, and using a flexible or pressur-

ized filling device, inject the gear oil into

G Remove the fuel tank from the boat be-

fore cleaning it. Work only outdoors in

an area with good ventilation.

G Wipe up any spilled fuel immediately.

^GReassemble the fuel tank carefully. Im-

proper assembly can result in a fuel

leak, which could result in a fire or ex-

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Maintenance

plosion hazard.

G Dispose of old gasoline according to lo-

cal regulations.

NOTE:

Inspect ground leads attached to external

anodes on equipped models. Consult a

Yamaha dealer for inspection and replace-

ment of internal anodes attached to the pow-

er unit.

1. Empty the fuel tank into an approved

container.

2. Pour a small amount of suitable solvent

into the tank. Install the cap and shake

the tank. Drain the solvent completely.

3. Remove the screws holding the fuel joint

assembly. Pull the assembly out of the

tank.

ZMU02924

EMU29390

Checking top cowling

Check the fitting of the top cowling by push-

ing it with both hands. If it is loose have it re-

paired by your Yamaha dealer.

ZMU02066

4. Clean the filter (located on the end of the

suction pipe) in a suitable cleaning sol-

vent. Allow the filter to dry.

5. Replace the gasket with a new one. Re-

install the fuel joint assembly and tighten

the screws firmly.

EMU29312

Inspecting and replacing 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

ZMU04677

EMU29400

Coating the boat bottom

A clean hull improves boat performance. The

boat bottom should be kept as clean of ma-

rine growth as possible. If necessary, the

boat bottom can be coated with an anti-foul-

ing paint approved for your area to inhibit

marine growth.

anodes.

ECM00720

CAUTION:

Do not paint anodes, as this would render

them ineffective.

Do not use anti-fouling paint which includes

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Maintenance

copper or graphite. These paints can cause

more rapid engine corrosion.

ZMU01943

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Trouble Recovery

EMU29422

A. Fill tank with clean, fresh fuel.

Troubleshooting

A problem in the fuel, compression, or igni-

tion systems can cause poor starting, loss of

power, or other problems. This section de-

scribes basic checks and possible remedies,

and covers all Yamaha outboard motors.

Therefore some items may not apply to your

model.

Q. Is fuel filter clogged?

A. Clean or replace filter.

Q. Is starting procedure incorrect?

A. See page 23.

Q. Has fuel pump malfunctioned?

If your outboard motor requires repair, bring

it to your Yamaha dealer.

A. Have serviced by a Yamaha dealer.

If the engine trouble warning indicator is

flashing, consult your Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrect

type?

A. Inspect spark plug(s). Clean or replace

with recommended type.

Starter will not operate.

Q. Is battery capacity weak or low?

A. Check battery condition. Use battery of

recommended capacity.

Q. Are spark plug cap(s) fitted incorrectly?

A. Check and re-fit cap(s).

Q. Are battery connections loose or corrod-

ed?

Q. Is ignition wiring damaged or poorly con-

nected?

A. Tighten battery cables and clean battery

terminals.

A. Check wires for wear or breaks. Tighten

all loose connections. Replace worn or bro-

ken wires.

Q. Is fuse for electric start relay or electric cir-

cuit blown?

Q. Are ignition parts faulty?

A. Check for cause of electric overload and

repair. Replace fuse with one of correct am-

perage.

A. Have serviced by a Yamaha dealer.

Q. Is engine stop switch lanyard not at-

tached?

Q. Are starter components faulty?

A. Attach lanyard.

A. Have serviced by a Yamaha dealer.

Q. Are engine inner parts damaged?

A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear?

A. Shift to neutral.

Engine idles irregularly or stalls.

Q. Are spark plug(s) fouled or of incorrect

type?

Engine will not start (starter operates).

Q. Is fuel tank empty?

A. Fill tank with clean, fresh fuel.

A. Inspect spark plug(s). Clean or replace

with recommended type.

Q. Is fuel contaminated or stale?

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Trouble Recovery

Q. Is fuel system obstructed?

A. Return to home position.

A. Check for pinched or kinked fuel line or

other obstructions in fuel system.

Q. Is motor angle too high?

A. Return to normal operating position.

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

Q. Is carburetor clogged?

A. Have serviced by a Yamaha dealer.

Q. Is fuel filter clogged?

A. Clean or replace filter.

Q. Is fuel joint connection incorrect?

A. Connect correctly.

Q. Have ignition parts failed?

A. Have serviced by a Yamaha dealer.

Q. Is throttle valve adjustment incorrect?

A. Have serviced by a Yamaha dealer.

Q. Has warning system activated?

A. Find and correct cause of warning.

Q. Is battery cable disconnected?

A. Connect securely.

Q. Is spark plug gap incorrect?

A. Inspect and adjust as specified.

Warning buzzer sounds or indicator

lights.

Q. Is ignition wiring damaged or poorly con- Q. Is cooling system clogged?

nected?

A. Check water intake for restriction.

A. Check wires for wear or breaks. Tighten

all loose connections. Replace worn or bro- Q. Is engine oil level low?

ken wires.

A. Fill oil tank with specified engine oil.

Q. Is specified engine oil not being used?

A. Check and replace oil as specified.

Q. Is heat range of spark plug incorrect?

A. Inspect spark plug and replace it with rec-

ommended type.

Q. Is thermostat faulty or clogged?

A. Have serviced by a Yamaha dealer.

Q. Is specified engine oil not being used?

A. Check and replace oil with specified type.

Q. Are carburetor adjustments incorrect?

A. Have serviced by a Yamaha dealer.

Q. Is engine oil contaminated or deteriorat-

ed?

Q. Is fuel pump damaged?

A. Replace oil with fresh, specified type.

A. Have serviced by a Yamaha dealer.

Q. Is oil filter clogged?

Q. Is air vent screw on fuel tank closed?

A. Open air vent screw.

A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunc-

tioned?

Q. Is choke knob pulled out?

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Trouble Recovery

A. Have serviced by a Yamaha dealer.

Q. Is load on boat improperly distributed?

Q. Are weeds or other foreign matter tangled

on gear housing?

A. Remove foreign matter and clean lower

A. Distribute load to place boat on an even unit.

plane.

Q. Is fuel system obstructed?

Q. Is water pump or thermostat faulty?

A. Have serviced by a Yamaha dealer.

A. Check for pinched or kinked fuel line or

other obstructions in fuel system.

Q. Is there excess water in fuel filter cup?

A. Drain filter cup.

Q. Is fuel filter clogged?

A. Clean or replace filter.

Engine power loss.

Q. Is propeller damaged?

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

A. Have propeller repaired or replaced.

Q. Is spark plug gap incorrect?

Q. Is propeller pitch or diameter incorrect?

A. Install correct propeller to operate out-

A. Inspect and adjust as specified.

board at its recommended speed (r/min) Q. Is ignition wiring damaged or poorly con-

range.

nected?

A. Check wires for wear or breaks. Tighten

all loose connections. Replace worn or bro-

Q. Is trim angle incorrect?

A. Adjust trim angle to achieve most efficient ken wires.

operation.

Q. Have ignition parts failed?

Q. Is motor mounted at incorrect height on A. Have serviced by a Yamaha dealer.

transom?

A. Have motor adjusted to proper transom Q. Is specified engine oil not being used?

height.

A. Check and replace oil with specified type.

Q. Has warning system activated?

A. Find and correct cause of warning.

Q. Is thermostat faulty or clogged?

A. Have serviced by a Yamaha dealer.

Q. Is boat bottom fouled with marine growth? Q. Is air vent screw closed?

A. Clean boat bottom. A. Open the air vent screw.

Q. Are spark plug(s) fouled or of incorrect Q. Is fuel pump damaged?

type?

A. Have serviced by a Yamaha dealer.

A. Inspect spark plug(s). Clean or replace

with recommended type.

Q. Is fuel joint connection incorrect?

A. Connect correctly.

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Trouble Recovery

board motor unsafe to operate.

Q. Is heat range of spark plug incorrect?

A. Inspect spark plug and replace it with rec-

ommended type.

If the outboard motor hits an object in the wa-

ter, follow the procedure below.

Q. Is high pressure fuel pump drive belt bro-

ken?

A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shift

lever position?

A. Have serviced by a Yamaha dealer.

Engine vibrates excessively.

Q. Is propeller damaged?

A. Have propeller repaired or replaced.

1. Stop the engine immediately.

2. Inspect the control system and all com-

ponents for damage. Also inspect the

boat for damage.

3. Whether damage is found or not, return

to the nearest harbor slowly and careful-

ly.

Q. Is propeller shaft damaged?

A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangled

on propeller?

A. Remove and clean propeller.

4. Have a Yamaha dealer inspect the out-

board motor before operating it again.

EMU29531

Starter will not operate

Q. Is motor mounting bolt loose?

A. Tighten bolt.

If the starter mechanism does not operate

(the engine cannot be cranked with the start-

er), the engine can be started with an emer-

gency starter rope.

EWM01020

Q. Is steering pivot loose or damaged?

A. Tighten or have serviced by a Yamaha

dealer.

WARNING

G Use this procedure only in an emergen-

cy and only to return to port for repairs.

^GWhen the emergency starter rope is

used to start the engine, the start-in-

gear protection device does 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.

EMU29431

Temporary action in

emergency

EMU29440

Impact damage

EWM00870

WARNING

The outboard motor can be seriously

damaged by a collision while operating or

trailering. Damage could make the out-

^GAttach the engine stop switch lanyard

to a secure place on your clothing, or

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Trouble Recovery

your arm or leg while operating.

G Do not attach the lanyard to clothing

that could tear loose. Do not route the

cord where it could become entangled,

preventing it from functioning.

^GAvoid accidentally pulling the lanyard

during normal operation. Loss of en-

gine power means the loss of most

steering control. Also, without engine

power, the boat could slow rapidly. This

could cause people and objects in the

boat to be thrown forward.

ZMU03740

1. Start-in-gear protection cable

^GBe sure no one is standing behind you

when pulling the starter rope. It could

whip behind you and injure someone.

^GAn 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 parts when the

engine is running. Do not install the

starter mechanism or top cowling after

the engine is running.

3. Remove the starter/flywheel cover after

removing the bolt(s).

ZMU03741

^GDo not touch the ignition coil, spark

plug wire, spark plug cap, or other elec-

trical components when starting or op-

erating the motor. You could get an

electrical shock.

4. Prepare the engine for starting. For fur-

ther information, see page 23. Be sure

the engine is in neutral and that the en-

gine stop switch lanyard lock plate is at-

tached to the engine stop switch. The

main switch must be “ ” (on), if

equipped.

EMU29561

Emergency starting engine

1. Remove the top cowling.

2. Remove the start-in-gear protection ca-

ble from the starter, if equipped.

ZMU03742

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Trouble Recovery

OFF ON START

ZMU02928

ZMU01906

EMU29760

5. If equipped the choke knob, pull out it

when the engine is cold. After the engine

starts, gradually return the choke knob

to its home position as the engine warms

up.

Treatment of submerged motor

If the outboard motor is submerged, immedi-

ately take it to a Yamaha dealer. Otherwise

some corrosion may begin almost immedi-

ately.

If you cannot immediately take the outboard

motor to a Yamaha dealer, follow the proce-

dure below in order to minimize engine dam-

age.

EMU29771

Procedure

1. Thoroughly wash away mud, salt, sea-

weed, and so on, with fresh water.

ZMU04119

6. Insert the knotted end of the emergency

starter rope into the notch in the flywheel

rotor and wind the rope several turns

around the flywheel clockwise.

7. Give a strong pull straight out to crank

and start the engine. Repeat if neces-

sary.

ZMU01909

2. Remove the spark plugs and face the

spark plug holes downward to allow any

water, mud, or contaminants to drain.

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Trouble Recovery

ZMU01910

3. Drain the fuel from the carburetor, fuel

filter, and fuel line.

4. Feed fogging oil or engine oil through

the carburetor(s) and spark plug holes

while cranking with the manual starter or

emergency starter rope.

ZMU01911

5. Take the outboard motor to a Yamaha

dealer as soon as possible.

ECM00400

CAUTION:

Do not attempt to run the outboard motor

until it has been completely inspected.

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Consumer information

EMU29811

Important warranty information for U.S.A. and Canada

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Consumer information

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Consumer information

EMU29820

YAMAHA MOTOR CORPORATION, U.S.A.

OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY

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Consumer information

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Consumer information

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Consumer information

EMU29840

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR

YAMAHA OUTSIDE U.S.A. OR CANADA

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Printed in Japan

March 2004–0.2 × 1 !

Printed on recycled paper

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OUTBOARD MOTOR WARRANTY REGISTRATION

ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD

Please complete and mail this card. This information is necessary to accurately register your unit for warranty.

Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et

que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.

(For Dealer Use Only)

OUTBOARD MOTOR MODEL AND SERIAL NUMBER (From I.D. label on clamp bracket)

(A l’usage du concessionnaire)

MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation)

YAMAHA DEALER NUMBER

NO. DU CONCESSIONNAIRE

YAMAHA

DEALER NAME

NOM DU

CONCESSIONNAIRE

YAMAHA MOTOR CO., LTD.

MADE IN JAPAN

PAYS D'ORIGINE JAPON

USAGE

(Check One)

PLEASURE

LOISIR

DATE SOLD

DATE DE

LIVRAISON

COMMERCIAL

UTILISATION

(En cocher un.)

MONTH

DAY

YEAR

MOIS

JOUR

ANNÉE

OWNER’S NAME

NOM DU

PROPRIÉTAIRE

FIRST

PRÉNOM

LAST

NOM DE FAMILLE

ADDRESS

ADRESSE

STREET

RUE

CITY

VILLE

STATE/PROVINCE

PROVINCE

ZIP

CODE POSTAL

PHONE NUMBER (

)

NUMÉRO DE TÉLÉPHONE

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PLACE

POSTAGE

HERE

ATTN: WARRANTY DEPARTMENT

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