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Yamaha 25MLHG Owner's Manual PDF

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Page 1

OWNERS MANUAL

6L2-28199-1S

U.S.A.Edition LIT-18626-07-23

6L2-9-1S Hyoshi 07.2.5 10:52 AM 1

Page 2

EMU25061

ZMU01690

Read this owners manual carefully before operating or working on your outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.

6L2-9-1S Hyoshi 07.2.5 10:52 AM 2

Page 3

Important manual information

EMU31281

To the owner

Thank you for choosing a Yamaha outboard motor. This Owners 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 Owners Manual particularly important information is distinguished in the following ways.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

EWM00780

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.

CAUTION:

ECM00700

A CAUTION indicates special precautions that must be taken to avoid damage to the

outboard motor.

NOTE:

A NOTE provides key information to make

procedures easier or clearer.

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current prod- uct information available at the time of print- ing, there may be minor discrepancies between your machine and this manual. If there is any question concerning this manu-

al, please consult your Yamaha dealer.

NOTE:

The 25MH, 25EH, 25ER and the standard accessories are used as a base for the ex- planations and illustrations in this manual. Therefore some items may not apply to ev-

ery model.

EMU25111

25 OWNERS MANUAL

2007 by Yamaha Motor Corporation, USA 1st edition, April 2007

is expressly prohibited. Printed in Japan

P/N LIT-18626-07-23

Page 4

Table of contents

General information .......................... 1

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

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

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

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

Important labels............................... 2

Warning labels .................................. 2

Safety information............................. 4

Safety information ........................... 4

Rotating parts.................................... 4 Hot parts ........................................... 4 Electric shock.................................... 4 Engine shut-off cord.......................... 4 Gasoline............................................ 4 Gasoline exposure and spills ............ 4 Carbon monoxide.............................. 4 Modifications ..................................... 4

Boating safety ................................. 5

Alcohol and drugs ............................. 5 Personal flotation devices ................. 5 People in the water ........................... 5 Passengers ....................................... 5 Overloading....................................... 5 Avoid collisions ................................. 5 Weather ............................................ 6 Accident reporting ............................. 6 Boat education and training .............. 6 Passenger training ............................ 6 Boating safety publications ............... 6 Laws and regulations ........................ 6

Boating organizations...................... 6 Basic boating rules (Rules of the

road) .............................................. 7

Steering and sailing rules and sound signals.................................. 7

Rules when encountering vessels .... 8 Other special situations..................... 9

Basic requirements......................... 11

Fueling instructions ....................... 11

Gasoline.......................................... 11 Engine oil ........................................ 11

Installation requirements ............... 11

Boat horsepower rating................... 11 Mounting motor ............................... 12

Remote control requirements..........12 Battery requirement.........................12 Propeller selection...........................13

Start-in-gear protection ................. 13

Basic components .......................... 14

Main components ......................... 14

Fuel tank .........................................14 Fuel joint..........................................15 Fuel gauge ......................................15 Fuel tank cap...................................15 Air vent screw..................................15 Remote control ................................15 Remote control lever .......................15 Neutral interlock trigger ...................16 Neutral throttle lever ........................16 Choke switch...................................16 Tiller handle.....................................16 Gear shift lever ................................17 Throttle grip .....................................17 Throttle indicator .............................17 Throttle friction adjuster...................17 Engine shut-off switch .....................18 Engine stop button ..........................18 Choke knob for pull type .................19 Manual starter handle .....................19 Starter button ..................................19 Main switch .....................................19 Steering friction adjuster .................20 Trim tab with anode.........................20 Trim rod (tilt pin) ..............................20 Shallow water lever .........................21 Tilt lock mechanism.........................21 Tilt support bar ................................21 Top cowling lock lever(s) (turn

type) ..............................................21 Warning indicator ............................22

Warning system ............................ 22

Overheat warning............................22

Operation ......................................... 23

Installation..................................... 23

Mounting the outboard motor ..........23 Clamping the outboard motor..........24

Breaking in engine ........................ 25

Gasoline and engine oil mixing chart (25:1)....................................25

Page 5

Table of contents

Procedure for pre-mixed models..... 25

Pre-operation checks .................... 26

Fuel ................................................. 26 Oil.................................................... 26 Controls........................................... 26 Stop switches.................................. 26 Engine............................................. 26

Filling fuel and engine oil............... 26

Filling fuel for portable tank............. 26 Ring Free Fuel Additive .................. 27 Gasoline and oil mixing (100:1) ...... 27

Operating engine........................... 28

Feeding fuel (portable tank) ............ 28 Starting engine................................ 29

Warming up engine ....................... 36

Choke start models ......................... 36

Shifting .......................................... 36 Stopping boat ................................ 38 Stopping engine ............................ 38

Procedure ....................................... 38

Trimming outboard motor.............. 39

Adjusting trim angle for manual tilt models .......................................... 40

Adjusting boat trim .......................... 40

Tilting up and down ....................... 41

Procedure for tilting up (manual tilt models) ......................................... 42

Procedure for tilting down (manual tilt models) .................................... 42

Cruising in shallow water .............. 43

Cruising in shallow water (manual tilt models) .................................... 43

Cruising in other conditions........... 44

Maintenance..................................... 46

Specifications ................................ 46 Transporting and storing

outboard motor ............................ 47

Clamp screw mounting models ....... 48 Storing outboard motor ................... 48 Procedure ....................................... 48 Lubrication ...................................... 49 Cleaning and anticorrosion

measures ...................................... 50 Battery care..................................... 50 Cleaning the outboard motor .......... 50

Checking painted surface of motor.............................................51

Periodic maintenance ................... 51

Replacement parts ..........................51 Maintenance chart...........................52 Greasing..........................................54 Cleaning and adjusting spark

plug ...............................................54 Checking fuel system ......................55 Inspecting fuel filter .........................56 Cleaning fuel filter ...........................56 Inspecting idling speed....................57 Checking wiring and connectors .....57 Exhaust leakage..............................57 Water leakage .................................57 Checking propeller ..........................57 Removing propeller .........................58 Installing propeller ...........................59 Changing gear oil ............................59 Cleaning fuel tank ...........................60 Inspecting and replacing

anode(s)........................................60 Checking battery (for electric start

models) .........................................61 Connecting the battery ....................62 Disconnecting the battery................62 Checking top cowling ......................62 Coating the boat bottom..................63

Trouble Recovery............................ 64

Troubleshooting ............................ 64 Temporary action in emergency ... 67

Impact damage ...............................67 Replacing fuse ................................67 Starter will not operate ....................68 Emergency starting engine .............68

Treatment of submerged motor .... 70

Procedure........................................70

Consumer information ................... 71

Important warranty information for U.S.A. and Canada ..................... 71

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ..... 73

IMPORTANT WARRANTY

Page 6

Table of contents

INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ...................... 76

Page 7

General information

EMU25170

Identification numbers record

EMU25183

Outboard motor serial number

The outboard motor serial number is stamped on the label attached to the port side of the clamp 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.

EMU25190

Key number

If a main key switch is equipped with the mo- tor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key.

EMU25221

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 engine for details.

EMU30390

Approval label of emission control certif- icate

This label is attached to the bottom cowling. Existing Technology; N/A

1. Outboard motor serial number location

1. Key number

1. Approval label location

ZMU04828

Page 8

General information

EMU25262

Manufactured date label

This label is attached to the clamp bracket or the swivel bracket.

EMU25382

Important labels

EMU25395

Warning labels

EMU25401

Label

WARNING

EWM01260

Be sure shift control is in neutral before starting engine. (except 2HP)

Do not touch or remove electrical parts when starting or during operation.

Keep hands, hair, and clothes away from flywheel and other rotating parts

while engine is running.

EMU25431

Label

WARNING

EWM01300

This engine is equipped with a neutral starting device.

The engine will not start unless the shift

1. Manufactured date 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. FELs : SPARK PLUG : DISPLACEMENT : ADVERTISED POWER :

IDLE SPEED : SPARK PLUG GAP (mm) : FUEL : GASOLINE VALVE LASH (mm) : IN : N/A EX : N/A

cm kW

g/kW-hr rpm IN NEUTRAL

ZMU05230

1 ZMU04125

ZMU04780

ZMU03684

Page 9

General information

control is in neutral position.

Page 10

Safety information

EMU33620

Safety information

Observe these precautions at all times.

EMU33630

Rotating parts

Hands, feet, hair, jewelry, clothing, PFD straps, etc. can become entangled with inter- nal rotating parts of the engine, resulting in serious injury or death. Keep the top cowling in place whenever pos- sible. Do not remove or replace the cowling with the engine running. Only operate the engine with the cowling re- moved according to the specific instructions in the manual. Keep hands, feet, hair, jewel- ry, clothing, PFD straps, etc. away from any exposed moving parts.

EMU33640

Hot parts

During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the en- gine has cooled.

EMU33650

Electric shock

Do not touch any electrical parts while start- ing or operating the engine. They can cause shock or electrocution.

EMU33670

Engine shut-off cord

Attach the engine shut-off cord so that the engine stops if the operator falls overboard or leaves the helm. This prevents the boat from running away under power and leaving people stranded, or running over people or objects. Always attach the engine shut-off cord to a secure place on your clothing or your arm or leg while operating. Do not remove it to leave the helm while the boat is moving. Do not at- tach the cord to clothing that could tear loose, or route the cord where it could be-

come entangled, preventing it from function- ing. Do not route the cord where it is likely to be accidentally pulled out. If the cord is pulled during operation, the engine will shut off and you will lose most steering control. The boat could slow rapidly, throwing people and ob- jects forward.

EMU33810

Gasoline

Gasoline and its vapors are highly flam- mable and explosive.

Always, refuel ac- cording to the procedure on page 28 to reduce the risk of fire and explosion.

EMU33820

Gasoline exposure and spills

Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Dispose of rags properly. If any gasoline spills onto your skin, immedi- ately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gaso- line vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth.

EMU33900

Carbon monoxide

This product emits exhaust gases which contain carbon monoxide, a colorless, odor- less gas which may cause brain damage or death when inhaled. Symptoms include nau- sea, dizziness, and drowsiness. Keep cock- pit and cabin areas well ventilated. Avoid blocking exhaust outlets.

EMU33780

Modifications

Do not attempt to modify this outboard mo- tor. Modifications to your outboard motor may reduce safety and reliability, and render the outboard unsafe or illegal to use.

Page 11

Safety information

EMU33740

Boating safety

This section includes a few of the many im- portant safety precautions that you should follow when boating.

EMU33710

Alcohol and drugs

Never operate after drinking alcohol or tak- ing drugs. Intoxication is one of the most common factors contributing to boating fatal- ities.

EMU33720

Personal flotation devices

Have an approved personal flotation device (PFD) on board for every occupant. Yamaha recommends that you must 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 boat- ing conditions.

EMU33730

People in the water

Always watch carefully for people in the wa- ter, such as swimmers, skiers, or divers, whenever the engine is running. When someone is in the water near the boat, shift into neutral and shut off the motor. Stay away from swimming areas. Swimmers can be hard to see. The propeller can keep moving even when the motor is in neutral. Shut off the engine when a person is in the water near you.

EMU33750

Passengers

Consult your boat manufacturers instruc- tions for details about appropriate passenger locations in your boat and be sure all pas- sengers are positioned properly before ac- celerating and when operating above an idle speed. Standing or sitting in non-designated locations may result in being thrown either

overboard or within the boat due to waves, wakes, or sudden changes in speed or direc- tion. Even when people are positioned prop- erly, alert your passengers if you must make any unusual maneuver. Always avoid jump- ing waves or wakes.

EMU33760

Overloading

Do not overload the boat. Consult the boat capacity plate or boat manufacturer for max- imum weight and number of passengers. Be sure that weight is properly distributed ac- cording to the boat manufacturers instruc- tions. Overloading or incorrect weight distribution can compromise the boats han- dling and lead to an accident, capsizing or swamping.

EMU33770

Avoid collisions

Scan constantly

for people, objects, and other boats. Be alert for conditions that limit your visibility or block your vision of others.

Operate defensively

at safe speeds and keep a safe distance away from people, ob- jects, and other boats.

Do not follow directly behind other boats or waterskiers.

Avoid sharp turns or other maneuvers that make it hard for others to avoid you or un- derstand where you are going.

Avoid areas with submerged objects or shallow water.

Ride within your limits and avoid aggres- sive maneuvers to reduce the risk of loss of control, ejection, and collision.

Take early action

to avoid collisions. Re- member,

boats do not have brakes

, and stopping the engine or reducing throttle can reduce the ability to steer. If you are not sure that you can stop in time before hitting an obstacle, apply throttle and turn in another direction.

Page 12

Safety information

EMU33790

Weather

Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.

EMU33800

Accident reporting

Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency if their boat is involved in any of the following accidents: 1. There is loss of life or probable loss of

life. 2. There is personal injury that requires

medical attention beyond first aid. 3. There is property damage to boats or

other property over a certain amount. 4. There is complete loss of a boat. Contact local law enforcement personnel if a report is necessary.

EMU33870

Boat education and training

Operators should take a boating safety course. This may be required in your state. Many of the organizations listed in the next section can provide information about cours- es in your area. You may also want to consider an Internet- based program for basic boater education. The Online Boating Safety Course provided by the BoatU.S. Foundation, is approved by the National Association of State Boating Law Administrators (NASBLA) and recog- nized by the United States Coast Guard. Most, but not all, states accept this course to meet their minimum requirements. While it cannot replace an in-depth course such as one offered by the U.S. Coast Guard, U.S. Power Squadron, or other organization, this online course does provide a general over- view of the basics in boating safety, require- ments, navigation, and operation. Upon

successful completion of the course, the user can download a certificate of comple- tion immediately or, for a small charge, re- quest one by mail. To take this free course, go to boatus.org.

EMU33880

Passenger training

Make sure at least one other passenger is trained to operate the boat in the event of an emergency.

EMU33890

Boating safety publications

Be informed about boating safety. Additional publications and information can be obtained from many boating organizations.

EMU33590

Laws and regulations

Know the marine laws and regulations where you will be boating- and obey them. Several sets of rules prevail according to geographic location, but all are basically the same as the International Rules of the Road. The rules presented in the following section are con- densed- and have been provided for your convenience only. Contact the U.S. Coast Guard, the National Association of State Boating Law Adminis- trators, or your local Power Squadron for a complete set of rules governing the waters in which you will be using your boat.

EMU33680

Boating organizations

The following organizations provide boating safety training and information about boating safety and laws.

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

Page 13

Safety information

Boating Safety Hotline: 1-800-368-5647 www.uscgboating.org

United States Power Squadrons

1-888-FOR-USPS (1-888-367-8777) www.usps.org

Boat Owners Association of The United States

1-800-336-BOAT (1-800-336-2628) www.boatus.com

National Association of State Boating Law Administrators (NASBLA)

1500 Leestown Road, Suite 330 Lexington, KY 4051 859-225-9497 859-225-9497 www.nasbla.org

National Marine Manufacturers Associa- tion (NMMA)

200 East Randolph Drive Suite 5100 Chicago, IL 606001 www.nmma.org

Marine Retailers Association of America

155 N. Michigan Ave. Chicago, IL 60601 www.mraa.com

EMU33690

Basic boating rules (Rules of the road)

Just as there are rules that apply when you are driving on streets and highways, there are waterway rules that apply when you are driving your boat. These rules are used inter- nationally. (For USA: and are also enforced by the United States Coast Guard and local agencies.) You should be aware of these

rules, and follow them whenever you en- counter another vessel on the water.

EMU33700

Steering and sailing rules and sound signals

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 that does not have the right-of-way is called the give-way or burdenedvessel. These rules determine which vessel has the right-of-way, and what each vessel should do.

Stand-on vessel

The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision. When you maintain your direction and speed, the other vessel will be able to determine how best to avoid you.

Give-way vessel

The vessel that 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.

The general prudential rule

This rule is called Rule 2 in the International Rules and says, 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.

Page 14

Safety information

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 vessels.

EMU25521

Rules when encountering vessels

There are three main situations that 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 vessels path)

Overtaking:

(you are passing or being passed by another vessel) 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- Way vessels). Both you and the meeting vessel must alter course to avoid each other.

Meeting

If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of- way Both of you should alter course to avoid an accident. You should keep the other ves- sel on your port (left) side. This rule doesnt

apply if both of you will clear one another if you continue on your set course and speed.

Crossing

When two power driven vessels are crossing each others path close enough to run the risk of collision, the vessel which has the oth- er on the starboard (right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; you are the Give-Way vessel. If the other vessel is on your port (left) side, remember that you should maintain course and direc- tion, provided the other vessel gives you the right-of-way as it should.

Overtaking

If you are passing another vessel, you are the Give-Way vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if an- other vessel is passing you, you should

Page 15

Safety information

maintain your speed and direction so that the other vessel can steer itself around you.

EMU25531

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- ter vessels, the operator should sound a pro- longed blast on the whistle (4 to 6 seconds). If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still pro- ceed around the bend with caution. If you navigate such waters with your boat, you will need to carry a portable air horn, available from local marine supply stores.

Fishing vessel right-of-way

All vessels that are fishing with nets, lines or trawls are considered to be fishing vessels under the International Rules. Vessels with trolling lines are not considered fishing ves- sels. Fishing vessels have the right-of-way regardless of position. Fishing vessels can- not, however, impede the passage of other vessels in narrow channels.

Sailing vessel right-of-way

Sailing vessels should normally be given the right-of-way. The exceptions to this are: 1. When the sailing vessel is overtaking

the power-driven vessel, the power-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 that can navigate

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 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. Remember, markings may vary by geo- graphic location. Always consult local boat- ing authorities before driving your boat in unfamiliar waters.

Page 16

Safety information

ZMU01708

Page 17

Basic requirements

EMU25540

Fueling instructions

WARNING

EWM00010

GASOLINE AND ITS VAPORS ARE HIGH- LY FLAMMABLE AND EXPLOSIVE!

Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition.

Stop engine before refueling.

Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat.

Take care not to spill gasoline. If gaso- line spills, wipe it up immediately with dry rags.

Do not overfill the fuel tank.

Tighten the filler cap securely after re- fueling.

If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention.

If any gasoline spills onto your skin, im- mediately wash with soap and water. Change clothing if gasoline spills on it.

Touch the fuel nozzle to the filler open- ing or funnel to help prevent electro-

static sparks.

CAUTION:

ECM00010

Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign mat-

ter.

EMU33960

Gasoline

If knocking or pinging occurs, use a different

brand of gasoline or premium unleaded fuel.

Gasohol

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. E-85 is a fuel blend containing 85% ethanol and therefore must not be used in your outboard motor. All ethanol blends containing more than 10% ethanol can cause fuel system damage or engine performance problems. Yamaha does not recommend gasohol-con- taining methanol because it can cause fuel system damage or engine performance problems.

EMU25650

Engine oil

If the recommended engine oil is not avail- able, another 2-stroke engine oil with an NMMA-certified TC-W3 rating may be used.

EMU33550

Installation requirements

EMU33560

Boat horsepower rating

Before installing the outboard motor(s), con- firm that the total horsepower of your mo- tor(s) does not exceed the boats maximum horsepower rating. See the boats capacity

Recommended gasoline: Regular unleaded gasoline with a min- imum octane rating of 86 (Pump Oc- tane Number) = (R+M)/2

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

Page 18

Basic requirements

plate or contact the manufacturer.

WARNING

EWM01560

Overpowering a boat can cause severe

instability.

EMU33570

Mounting motor

Your dealer or other person experienced in proper rigging should mount the motor using correct equipment and complete rigging in- structions. For further information, see page 23.

WARNING

EWM01570

Improper mounting of the outboard mo- tor could result in hazardous condi- tions such as poor handling, loss of control, or fire hazards.

Because the motor is very heavy, spe- cial equipment and training is required

to mount it safely.

EMU33580

Remote control requirements

The remote control unit must be equipped with a start-in-gear protection device(s). This device prevents the engine from starting un- less it is in neutral.

WARNING

EWM01580

If the engine starts in gear, the boat can move suddenly and unexpectedly, pos- sibly causing a collision or throwing passengers overboard.

If the engine ever starts in gear, the start-in-gear protection device is not working correctly and you should dis- continue using the outboard. Contact

your Yamaha dealer.

EMU25692

Battery requirement

CAUTION:

ECM01061

Do not use a battery that does not meet the specified capacity. If a battery that does not meet specifications is used, the electric system could perform poorly or be overloaded, causing electric system

damage.

For electric start models, choose a battery which meets the following specifications.

EMU25712

Battery specifications

The engine cannot be started if battery volt- age is too low.

EMU25730

Without a rectifier or Rectifier Regulator

CAUTION:

ECM01090

A battery cannot be connected to models that do not have a rectifier or Rectifier

Regulator.

If you wish to use a battery with the models without a rectifier or Rectifier Regulator, in- stall an optional Rectifier Regulator. Using a maintenance-free battery with the above models can shorten the life of the bat- tery significantly.

Minimum cold cranking amps (CCA/ SAE):

25EH 245.0 A 25ER 245.0 A

Minimum marine cranking amps (MCA/ ABYC):

25EH 323.0 A 25ER 323.0 A

Minimum reserve capacity (RC/SAE): 25EH 52 minutes 25ER 52 minutes

Page 19

Basic requirements

Install an optional Rectifier Regulator or use accessories rated to withstand 18 volts or higher with the above models. Consult your Yamaha dealer for details on installing an optional Rectifier Regulator.

EMU34190

Propeller selection

Next to selecting an outboard, choosing the right propeller is one of the most important purchasing decisions a boater can make. The type, size, and design of your propeller have a direct impact on acceleration, top speed, fuel economy, and even engine life. Yamaha designs and manufactures propel- lers for every Yamaha outboard motor and every application. Your outboard motor came with a Yamaha propeller chosen to perform well over a range of applications, but there may be uses where a different propeller would be more appropriate. Your Yamaha dealer can help you select the right propeller for your boating needs. Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat- load. Generally, chose a larger pitch propel- ler for a smaller operating load and a smaller pitch propeller for a heavier load. If you carry loads that vary widely, chose the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle setting to stay within the recommended engine speed range when carrying lighter loads. For instructions on propeller removal and in- stallation, see page 57.

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.

1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark)

ZMU04605

-x 1 2 3

ZMU04604

-x 1 2 3

Page 20

Basic components

EMU2579B

Main components NOTE:

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

els.

EMU25802

Fuel tank

If your model was equipped with a portable

1 2 3 4

2 3

6 7

16 17

ZMU04829

1. Manual starter handle* 2. Choke knob 3. Warning indicator 4. Starter button* 5. Gear shift lever* 6. Tiller handle* 7. Throttle friction adjuster* 8. Engine stop button/Engine shut-off switch* 9. Transom clamp handle 10. Tilt lock lever 11. Trim rod 12. Cooling water inlet 13. Propeller 14. Trim tab (anode)

15. Anti-cavitation plate 16. Clamp bracket 17. Rope attachment 18. Shallow water lever 19. Top cowling 20. Remote control box (side mount type)* 21. Fuel tank*

Page 21

Basic components

fuel tank, its function is as follows.

WARNING

EWM00020

The fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Com- mercial users should conform to relevant licensing or approval authority regula-

tions.

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 tank.

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

Air vent screw

This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise.

EMU26180

Remote control

The remote control lever actuates both the shifter and the throttle. The electrical switch- es are mounted on the remote control box.

EMU26190

Remote control lever

Moving the lever forward from the neutral po- sition engages forward gear. Pulling the le- ver back from neutral engages reverse. The engine will continue to run at idle until the le- ver is moved about 35 (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.

1. Fuel joint 2. Fuel gauge 3. Fuel tank cap 4. Air vent screw

ZMU03157

1 3 4 2

1. Remote control lever 2. Neutral interlock trigger 3. Neutral throttle lever 4. Main switch / choke switch 5. Engine shut-off switch 6. Throttle friction adjuster

1. Neutral

Page 22

Basic components

EMU26201

Neutral interlock trigger

To shift out of neutral, first pull the neutral in- terlock trigger up.

EMU26211

Neutral throttle lever

To open the throttle without shifting into ei- ther forward or reverse, put the remote con- trol lever in the neutral position and lift the neutral throttle lever.

NOTE:

The neutral throttle lever will operate only when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed

position.

EMU26221

Choke switch

To activate the choke system, press in the main switch while the key is turned to the (on) or (start) position. The choke system will then supply the rich fuel mixture required to start the engine. When the key is released, the choke will switch off automatically.

EMU25911

Tiller handle

To change direction, move the tiller handle to the left or right as necessary.

2. Forward

3. Reverse 4. Shift 5. Fully closed 6. Throttle 7. Fully open

1. Neutral interlock trigger

1. Fully open 2. Fully closed

Page 23

Basic components

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.

EMU25941

Throttle grip

The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.

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.

EMU25971

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 adjuster counterclockwise.

WARNING

EWM00031

Do not overtighten the friction adjuster. If

1. Forward

2. Neutral

3. Reverse

ZMU02846

3 R N

ZMU03687

1. Throttle indicator

ZMU02848

ZMU02849

Page 24

Basic components

there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an

accident.

When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting.

EMU25991

Engine shut-off switch

The clip must be attached to the engine shut- off switch for the engine to run. The cord should be attached to a secure place on the operators clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power.

WARNING

EWM00121

Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg while operating.

Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre- venting it from functioning.

Avoid accidentally pulling the cord dur- ing normal operation. Loss of engine 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.

NOTE:

The engine cannot be started with the clip re-

moved.

EMU26001

Engine stop button

To open the ignition circuit and stop the en- gine, push this button.

ZMU03688

1. Cord 2. Clip

2 1

ZMU03689

Page 25

Basic components

EMU26011

Choke knob for pull type

To supply the engine with the rich fuel mix- ture required to start, pull out this knob.

EMU26070

Manual starter handle

To start the engine, first gently pull the han- dle out until resistance is felt. From that posi- tion, then pull the handle straight out quickly to crank the engine.

EMU26080

Starter button

To start the engine with the electric starter, push the starter button.

EMU26090

Main switch

The main switch controls the ignition system; its operation is described below.

(off)

With the main switch in the (off) posi- tion, the electrical circuits are off, and the key can be removed.

(on)

With the main switch in the (on) posi- tion, the electrical circuits are on, and the key cannot be removed.

(start)

With the main switch in the (start) po- sition, the starter motor turns to start the en- gine. When the key is released, it returns automatically to the (on) position.

ZMU03690

ZMU04127

ZMU04856

Page 26

Basic components

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.

To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.

WARNING

EWM00040

Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an

accident.

EMU26243

Trim tab with anode

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.

WARNING

EWM00840

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.

If the boat tends to veer to the left (port side), turn the trim tab rear end to the port side A in the figure. If the boat tends to veer to the right (starboard side), turn the trim tab end to the starboard side B in the figure.

CAUTION:

ECM00840

The trim tab also serves as an anode to protect the engine from electrochemical corrosion. Never paint the trim tab as it

will become ineffective as an anode.

EMU26261

Trim rod (tilt pin)

The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.

ZMU02908

1. Trim tab 2. Bolt

Bolt tightening torque: 18.0 Nm (13 ft-lb) (1.8 kgf-m)

ZMU02822

Page 27

Basic components

EMU26270

Shallow water lever

Lifting this lever will tilt the motor up partially to provide more clearance when operating in shallow water.

EMU30530

Tilt lock mechanism

The tilt lock mechanism is used to prevent the outboard motor from lifting out of the wa- ter when in reverse gear.

To lock it, set the tilt lock lever in the lock po- sition. To release, push the tilt lock lever in the release position.

EMU26331

Tilt support bar

The tilt support bar keeps the outboard motor in the tilted up position.

CAUTION:

ECM00660

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.

EMU26372

Top cowling lock lever(s) (turn type)

To remove the engine top cowling, turn the lock lever(s) and lift off the cowling. When in- stalling the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by returning the lever(s) to the lock position.

1. Tilt lock lever

ZMU02929

ZMU04111

ZMU03695

ZMU03699

Page 28

Basic components

EMU26302

Warning indicator

If the engine develops a condition which is cause for warning, the indicator lights up. For details on how to read the warning indicator, see page 22.

EMU26801

Warning system

CAUTION:

ECM00090

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.

EMU26817

Overheat warning

This engine has an overheat-warning de- vice. If the engine temperature rises too high, the warning device will activate.

Activation of warning device

The engine speed will automatically de- crease to about 2000 r/min.

If equipped with an overheat-warning indi- cator, it will light or blink.

The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel).

If the warning system has activated, stop the engine and check the cooling water inlet for clogging.

1. Top cowling lock lever(s)

ZMU037011

ZMU03703

ZMU03706

Page 29

Operation

EMU26902

Installation

The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat and motor combination. Prop- er mounting depends in part on experience and the specific boat and motor combination.

WARNING

EWM01590

Overpowering 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.

Improper mounting of the outboard mo- tor could result in hazardous condi- tions such as poor handling, loss of control, or fire hazards. For permanent- ly mounted models, your dealer or oth- er person experienced in proper

rigging should mount the motor.

EMU26911

Mounting the outboard motor

WARNING

EWM01720

Your dealer or other person experienced in proper outboard motor mounting should show you how to mount your out-

board motor.

The outboard motor should be mounted so that the boat is well balanced. Otherwise, the boat could be hard to steer. For single-en- gine boats, mount the outboard motor on the centerline (keel line) of the boat.

EMU26921

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 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.

1. Center line (keel line)

ZMU017601

Page 30

Operation

CAUTION:

ECM01630

During water testing, check the buoy- ancy of the boat, at rest, with its maxi- mum load. Check that the static water level on the exhaust housing is low enough to prevent water entry into the power head when water rises due to waves when the outboard is not run- ning.

Incorrect engine height or obstructions to the smooth flow of water (such as the design or condition of the boat, or ac- cessories such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. If the motor is operated con- tinuously in the presence of airborne water spray, enough water could enter the engine through the intake opening on the cowling to cause severe engine damage. Eliminate the cause of the air-

borne water spray.

NOTE:

The 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.

For instructions on setting the trim angle of

the outboard motor, see page 39.

EMU26970

Clamping the outboard motor

1. Place the outboard motor on the tran- som so that it is positioned as close to the center as possible. Tighten the tran- som clamp screws evenly and securely. Occasionally check the clamp screws for tightness during operation of the out- board motor because they could be- come loose due to engine vibration.

WARNING

EWM00640

Loose clamp screws could 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.

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

ZMU02011

025mm (01in.)

ZMU02012

Page 31

Operation

if it accidentally falls off the transom.

3. Secure the clamp bracket to the transom using the bolts provided with the out- board (if packed). For details, consult your Yamaha dealer.

WARNING

EWM00650

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.

EMU30173

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 life.

CAUTION:

ECM00800

Failure to follow the break-in procedure could result in reduced engine life or

even severe engine damage.

EMU27050

Gasoline and engine oil mixing chart (25:1)

CAUTION:

ECM00150

Be sure to mix gasoline and oil complete- ly, otherwise the engine may be dam-

aged.

EMU27074

Procedure for pre-mixed models

Run the engine under load (in gear with a propeller installed) for 10 hours as follows. 1. First 10 minutes:

Run the engine at the lowest possible speed. A fast idle in neutral is best.

2. Next 50 minutes: Do not exceed half throttle (approxi- mately 3000 r/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.

1. Bolts

ZMU02013

ZMU02637

1. : Gasoline

2. : Engine oil

Page 32

Operation

3. Next two hours: 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 cool.

4. Remaining seven hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.

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 26.

EMU27104

Pre-operation checks

WARNING

EWM00081

If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the out- board motor. Otherwise an accident

could occur.

CAUTION:

ECM00120

Do not start the engine out of water. Over- heating and serious engine damage can

occur.

EMU27111

Fuel

Check to be sure you have plenty of fuel for your trip.

Make sure there are no fuel leaks or gaso- line fumes.

Check fuel line connections to be sure they are tight (if equipped Yamaha fuel tank or boat tank).

Be sure the fuel tank is positioned on a se- cure, flat surface, and that the fuel line is not twisted or flattened, or likely to contact sharp objects (if equipped Yamaha fuel tank or boat tank).

EMU27120

Oil

Check to be sure you have plenty of oil for your trip.

EMU27130

Controls

Check throttle, shift, and steering for prop- er operation before starting the engine.

The controls should work smoothly, with- out binding or unusual free play.

Look for loose or damaged connections.

Check operation of the starter and stop switches when the outboard motor is in the water.

EMU31721

Stop switches

Confirm that turning the main switch to the (off) position stops the engine.

Confirm that removing the clip from the en- gine shut-off switch stops the engine.

Confirm that the engine cannot be started with the clip removed from the engine shut-off switch.

EMU27140

Engine

Check the engine and engine mounting.

Look for loose or damaged fasteners.

Check the propeller for damage.

EMU27233

Filling fuel and engine oil

EMU27242

Filling fuel for portable tank

WARNING

EWM00060

Gasoline and its vapors are highly flam- mable and explosive. Keep away from sparks, cigarettes, flames, or other

Page 33

Operation

sources of ignition.

1. Remove the fuel tank cap. 2. Fill the fuel tank carefully. 3. Close the cap securely after refueling.

Wipe up any spilled fuel.

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.

EMU27405

Gasoline and oil mixing (100:1)

If equipped with a portable fuel tank 1. Pour oil into the portable fuel tank, and

then add gasoline.

2. Replace the fuel tank cap and close

Fuel tank capacity (if equipped Yamaha fuel tank):

25 L (6.60 US gal) (5.50 Imp.gal)

ZMU03012

Gasoline to engine oil ratio

Break-in period See page 25 After break-in 100:1

1. Engine oil 2. Gasoline

Page 34

Operation

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. 2. Replace the fuel can cap and close tight-

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

oughly. 4. Make sure that the oil and gasoline are

mixed. 5. Pour the gasoline and oil mixture into the

built-in fuel tank.

CAUTION:

ECM00811

Avoid using any oil other than the spec- ified type.

Use a thoroughly blended fuel-oil mix- ture.

If 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.

High oil ratio: Too much oil could cause fouled spark plugs, smoky exhaust,

and heavy carbon deposits.

NOTE:

If using a permanently installed tank, pour the oil gradually as the gasoline is being add-

ed to the tank.

EMU27450

Operating engine

EMU27463

Feeding fuel (portable tank)

WARNING

EWM00420

Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you.

When the air vent screw is loosened, gasoline vapor will be released. Gaso- line is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosen- ing the air vent screw.

This product emits exhaust gases 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.

1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.

2. If there is a fuel joint on the motor, firmly connect the fuel line to the joint. Then firmly connect the other end of the fuel

ZMU02022

Page 35

Operation

line to the joint on the fuel tank.

3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp.

NOTE:

During engine operation place the tank hori- zontally, otherwise fuel cannot be drawn

from the fuel tank.

4. Squeeze the primer pump, with the ar- row pointing up, until you feel it become firm.

EMU27491

Starting engine

WARNING

EWM01600

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 wa-

ter near you.

EMU27506

Manual start models (tiller control)

1. Place the gear shift lever in neutral.

NOTE:

The start-in-gear protection device prevents the engine from starting except when in neu-

tral.

2. Attach the engine shut-off cord to a se- cure place on your clothing, or your arm

ZMU04113

ZMU02024

1. Arrow

ZMU03714

Page 36

Operation

or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

WARNING

EWM00121

Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg while operating.

Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre- venting it from functioning.

be thrown forward.

3. Place the throttle grip in the (start) position.

4. Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position.

NOTE:

It is not necessary to use the choke when starting a warm engine.

If the choke knob is left in the (start) position while the engine is running,

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.

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.

ZMU03744

ZMU02954

ZMU04114

Page 37

Operation

NOTE:

When the engine is cold, it needs to be warmed up. For further information, see page 36.

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 amount and try to start the engine again. If

the engine still fails to start, see page 64.

EMU27563

Electric start models

1. Place the gear shift lever in neutral.

NOTE:

The start-in-gear protection device prevents the engine from starting except when in neu-

tral.

2. Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

WARNING

EWM00121

Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg while operating.

Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre- venting it from functioning.

be thrown forward.

3. Place the throttle grip in the (start) position. After the engine starts, return the throttle to the fully closed po- sition.

ZMU02030

ZMU03714

ZMU03744

Page 38

Operation

4. Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position.

NOTE:

It is not necessary to use the choke when starting a warm engine.

If the choke knob is left in the (start) position while the engine is running,

the engine will run poorly or stall.

5. Push the starter button to start the mo- tor. (Repeat if necessary.)

6. Immediately after the engine starts, re- lease the starter button to allow it to re- turn to its original position.

7. Slowly return the throttle grip to the fully closed position so that the engine does not stall.

CAUTION:

ECM00160

Never push the starter button while the engine is running.

Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it im- possible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, release the starter button, wait 10 sec-

onds, then crank the engine again.

ZMU02959

ZMU04116

ZMU04856

ZMU02962

Page 39

Operation

NOTE:

When the engine is cold, it needs to be warmed up. For further information, see page 36.

the engine still fails to start, see page 64.

EMU27634

Manual start models (remote control)

1. Place the remote control lever in neutral.

NOTE:

The start-in-gear protection device prevents the engine from starting except when in neu-

tral.

2. Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

WARNING

EWM00121

Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg while operating.

Do not attach the cord to clothing that

could tear loose. Do not route the cord where it could become entangled, pre- venting it from functioning.

be thrown forward.

3. Open the throttle slightly without shifting using the neutral throttle lever. You may need to change the throttle opening slightly depending on engine tempera- ture. After the engine starts, return the throttle to the original position.

NOTE:

As a starting point, lift the lever just until you feel resistance, then lift slightly more.

The neutral throttle lever can only be used

ZMU03087

ZMU03088

ZMU03200

Page 40

Operation

when the remote control lever is in neutral.

4. Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position.

NOTE:

It is not necessary to use the choke when starting a warm engine.

If the choke knob is left in the (start) position while the engine is running,

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.

6. After the engine starts, slowly return the manual starter handle to its original po- sition before releasing it.

NOTE:

When the engine is cold, it needs to be

warmed up. For further information, see page 36.

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 and try again. Also if the en- gine is warm and fails to start, open the throttle a small amount and try to start the engine again. If the engine still fails to

start, see page 64.

EMU27643

Electric start / remote control models

1. Place the remote control lever in neutral.

NOTE:

The start-in-gear protection device prevents the engine from starting except when in neu-

tral.

2. Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

WARNING

EWM00121

Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg while operating.

Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre-

ZMU03717

ZMU03008

Page 41

Operation

venting it from functioning.

be thrown forward.

3. Turn the main switch to (on).

4. Open the throttle slightly without shifting using the neutral throttle lever or free ac- celerator. You may need to change the throttle opening slightly depending on engine temperature. After the engine starts, return the throttle to the original position.

NOTE:

On remote controls equipped with a neu- tral throttle lever, a good starting point is to lift the lever just until you feel resistance, then lift slightly more.

The neutral throttle lever or free accelera- tor can only be used when the remote con-

trol lever is in neutral.

5. Press in and hold the main switch to op- erate the remote choke system. The re- mote choke switch automatically returns to its normal position when you release your hand. Therefore keep the switch pressed in.

NOTE:

It is not necessary to use the choke when starting a warm engine.

Push in the main switch fully, or the remote

choke system will not operate.

OFF

ZMU01880

ZMU02314

STARTOFF ON

ZMU02315

Page 42

Operation

6. Turn the main switch to (start), and hold it for a maximum of 5 seconds.

7. Immediately after the engine starts, re- lease the main switch and allow it to re- turn to (on).

CAUTION:

ECM00191

Never turn the main switch to (start) while the engine is running.

again.

EMU27670

Warming up engine

EMU27681

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.

CAUTION:

ECM00511

A continuous flow of water from the cool- ing water pilot hole shows that the water pump is pumping water through the cool- ing passages. If water is not flowing out of the hole at all times while the engine is running, overheating and serious dam- age 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 corrected.

EMU34560

Shifting

WARNING

EWM00180

Before shifting, make sure there are no swimmers or obstacles in the water near

you.

CAUTION:

ECM01610

Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral. If this occurs, stop the engine, shift to neutral, then restart the

STARTOFF ON

ZMU03753

ZMU02856

Page 43

Operation

engine and allow it to warm up.

To shift out of neutral 1. Pull the neutral interlock trigger up (if

equipped).

2. Move the remote control lever / gear shift lever firmly and crisply forward (for forward gear) or backward (for reverse gear) [about 35 (a detent can felt) for re- mote control models]. Be sure to check that the tilt lock lever is in the lock/down position (if equipped) before operating in reverse.

NOTE:

Tiller handle models: The gear shift lever op- erates only when the throttle grip is in the ful-

ly closed position.

To shift from in gear (forward/reverse) to neutral 1. Close the throttle so that the engine

slows to idle speed.

1. Neutral interlock trigger

ZMU03721

R N

ZMU05678

ZMU02030

Page 44

Operation

2. After the engine is at idle speed in gear move the remote control lever / gear shift lever firmly and crisply into the neu- tral position.

EMU31742

Stopping boat

WARNING

EWM01510

Do not use the reverse function to slow down or stop the boat as it could cause you to lose control, be ejected, or im-

pact the steering wheel or other parts of the boat. This could increase the risk of serious injury. It could also damage the shift mechanism.

Do not shift into reverse while traveling at planing speeds. Loss of control, boat swamping, or damage to the boat could

occur.

The boat is not equipped with a separate braking system. Water resistance stops it af- ter the throttle lever is moved back to idle. The stopping distance varies depending on gross weight, water surface conditions, and wind direction.

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.

EMU27845

Procedure

1. Push and hold the engine stop button or turn the main switch to (off).

ZMU03724 ZMU03690

Page 45

Operation

2. After stopping the engine, disconnect the fuel line if there is a fuel joint on the outboard motor.

3. Tighten the air vent screw on the fuel tank cap (if equipped).

4. Remove the key if the boat will be left unattended.

NOTE:

The engine can also be stopped by pulling the cord and removing the clip from the en-

gine shut-off switch, then turning the main

switch to (off).

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 the boat, sea conditions, and running speed.

WARNING

EWM00740

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. ZMU04121

ZMU02041

Page 46

Operation

EMU27872

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. Tilt the outboard motor up, and then re-

move the trim rod from the clamp brack- et.

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 your boat and operating conditions.

WARNING

EWM00400

Stop the engine before adjusting the trim angle.

Use care to avoid being pinched when removing or installing the rod.

Use caution when trying a trim position for the first time. Increase speed gradu- ally and watch for any signs of instabil- ity or control problems. Improper trim

angle can cause loss of control.

NOTE:

The outboard motor 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

1. Trim operating angle

ZMU02858

1. Trim rod

ZMU02909

Page 47

Operation

the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden- cy to steer to one side or the other. Compen- sate for this as you steer. The trim tab can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.

Bow Up

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.

Bow Down

Too much trim-in causes the boat to plow through the water, decreasing fuel economy

and making it hard to increase speed. Oper- ating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of bow steering and making opera- tion difficult and dangerous.

NOTE:

Depending on the type of boat, the outboard motor trim angle may have little effect on the

trim of the boat when operating.

EMU27934

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 lower casing from damage by collision with obstructions, and also to re- duce salt corrosion.

WARNING

EWM00221

Be sure all people are clear of the out- board motor when tilting up and down, Body parts can be crushed between the motor and the clamp bracket when the

motor is trimmed or tilted.

WARNING

EWM00250

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

Page 48

Operation

the engine will be tilted for more than a

few minutes. Otherwise fuel may leak.

CAUTION:

ECM00241

Before tilting the outboard motor, stop the engine by following the procedure on page 38. Never tilt the outboard mo- tor while the engine is running. Severe damage from overheating can result.

Do not tilt up the engine by pushing the tiller handle (if equipped) because this

could break the handle.

EMU27954

Procedure for tilting up (manual tilt models)

1. Place the remote control lever / gear shift lever in neutral.

2. Place the tilt lock lever in the release po- sition.

3. Hold the rear of the top cowling with one hand, tilt the engine up, and turn the tilt support lever to the lock position and support the engine.

CAUTION:

ECM01640

formation, see page 47.

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

ZMU03726

ZMU03747

Page 49

Operation

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

WARNING

EWM00710

Place the gear shift in neutral before us- ing the shallow water cruising system.

Run 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.

Do not rotate the outboard motor 180 and operate the boat in reverse. Place the gear shift in reverse to operate the boat in reverse.

Use extra care when operating in re- verse. Too much reverse thrust can cause the outboard motor to lift out of the water, increasing the chance of ac-

cident and personal injury.

Return the outboard motor to its normal position as soon as the boat is back in

deeper water.

CAUTION:

ECM00260

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.

EMU28133

Procedure

1. Place the remote control lever / gear shift lever in neutral.

ZMU03731

ZMU02868

ZMU03745

Page 50

Operation

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

3. Pull up the shallow water lever.

4. Slightly tilt the outboard motor up. The tilt support bar will lock automatically, supporting the outboard motor in a par- tially raised position.

NOTE:

This outboard motor has 2 positions for shal-

low water cruising.

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.

6. Slightly tilt the outboard motor up until the tilt support bar automatically returns to the free position.

7. Slowly lower the outboard motor to the normal position.

EMU28193

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh wa- ter and, if possible, rinse the power head un- der the cowling.

Cruising in muddy or turbid water

Yamaha strongly recommends that you use the optional chromium-plated water pump kit (available for V4 and large engines) if you

ZMU03525

ZMU03746

ZMU03728

ZMU03729

ZMU03731

Page 51

Operation

use the outboard motor in water with a lot of sediment in it, such as muddy or other turbid (cloudy) water.

Cruising in acidic water

Water in some areas can be acidic. After op- erating in such water, flush the cooling pas- sages with fresh water to prevent corrosion. Also rinse the outside of the outboard motor with fresh water.

Page 52

Maintenance

EMU31480

Specifications NOTE:

(AL) stated in the specification data below represents the numerical value for the alumi- num propeller installed. Likewise, (SUS) represents the value for stainless steel propeller installed and (PL)

for plastic propeller installed.

EMU28219

Dimension:

Overall length: 25EH 936 mm (36.9 in) 25ER 615 mm (24.2 in) 25MH 936 mm (36.9 in)

Overall width: 25EH 358 mm (14.1 in) 25ER 304 mm (12.0 in) 25MH 358 mm (14.1 in)

Overall height S: 1068 mm (42.0 in)

Overall height L: 1195 mm (47.0 in)

Transom height S: 419 mm (16.5 in)

Transom height L: 546 mm (21.5 in)

Weight (AL) S: 25EH 50.5 kg (111 lb) 25ER 49.5 kg (109 lb) 25MH 48.0 kg (106 lb)

Weight (AL) L: 25EH 52.0 kg (115 lb) 25ER 51.0 kg (112 lb) 25MH 49.5 kg (109 lb)

Performance:

Full throttle operating range: 50006000 r/min

Maximum output: 18.4 kW@5500 r/min (25 HP@5500

r/min) Idling speed (in neutral):

750

50 r/min

Engine:

Type: 2-stroke L

Displacement: 395.0 cm

Bore

stroke: 67.0

56.0 mm (2.64

2.20 in) Ignition system:

CDI Spark plug (NGK):

B7HS-10 Spark plug gap:

0.91.0 mm (0.0350.039 in) Control system:

25EH Tiller 25ER Remote control 25MH Tiller

Starting system: 25EH Manual and electric 25ER Manual and electric 25MH Manual

Starting carburetion system: Choke valve

Min. cold cranking amps (CCA/SAE): 25EH 245.0 A 25ER 245.0 A

Min. marine cranking amps (MCA/ABYC): 25EH 323.0 A 25ER 323.0 A

Min. reserve capacity (RC/SAE): 25EH 52 minutes 25ER 52 minutes

Alternator output: 25MH 80 W

Maximum generator output: 25EH 6.0 A 25ER 6.0 A

Drive unit:

Page 53

Maintenance

Gear positions: Forward-neutral-reverse

Gear ratio: 2.08 (27/13)

Trim and tilt system: Manual tilt

Propeller mark: F

Fuel and oil:

Recommended fuel: Regular unleaded gasoline

Min. pump octane: 86

Fuel tank capacity: 25 L (6.60 US gal) (5.50 Imp.gal)

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

Fuel:oil ratio:

Regular gasoline: 100 :1

Lubrication: 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)

Tightening torque for engine:

Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Propeller nut: 35.0 Nm (25.8 ft-lb) (3.57 kgf-m)

EMU28223

Transporting and storing outboard motor

WARNING

EWM00690

Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel

cock to prevent fuel from leaking.

USE CARE when transporting fuel tank, whether in a boat or car.

DO NOT fill fuel container to maximum capacity. Gasoline will expand consid- erably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire

hazard.

WARNING

EWM00700

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.

CAUTION:

ECM00660

in the tilt position.

The outboard motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the tilt po- sition using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details.

Page 54

Maintenance

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.

NOTE:

Place a towel or something similar under the

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-

lowing procedures.

CAUTION:

ECM01411

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.

Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

EMU28303

Procedure

EMU28373

Flushing in a test tank

1. Wash the outboard motor body using fresh water. For further information, see page 50.

2. Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer to each gallon of fuel.

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.

3. Remove the engine top cowling and si- lencer cover.

4. Install the outboard motor on the test tank.

ZMU02870

ZMU02869

Page 55

Maintenance

5. Fill the tank with fresh water to above the level of the anti-cavitation plate.

CAUTION:

ECM00300

Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the en- gine will be damaged from overheating. Before starting the engine, be sure to supply water to the cooling water passag-

es.

CAUTION:

ECM00290

If the fresh water level is below the level of the anti-cavitation plate, or if the water supply is insufficient, engine seizure may

occur.

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.

WARNING

EWM00090

Do not touch or remove electrical parts

when starting or during operation.

Keep hands, hair, and clothes away from the flywheel and other rotating

parts while the engine is running.

7. Run the engine at a fast idle for 1015 minutes in neutral position.

8. Just prior to turning off the engine, quick- ly spray Yamaha Stor-Rite Engine Fogging Oil alternately into each carbu- retor or the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke excessively and almost stall.

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.

EMU28402

Lubrication

1. Install the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 54.

2. Change the gear oil. For instructions, see page 59. Inspect the oil for the pres- ence of water that indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use.

3. Grease all grease fittings. For further de- tails, see page 54.

NOTE:

For long-term storage, fogging the engine with oil is recommended. Contact your Yamaha dealer for information about fogging

oil and procedures for your engine.

1. Water surface 2. Lowest water level

ZMU02051

Page 56

Maintenance

EMU28422

Cleaning and anticorrosion measures

1. Wash down the exterior of the outboard motor with fresh water and dry off com- pletely.

2. Spray the outboard motor exterior with Yamaha Silicone Protectant.

3. Wax the cowling with a non-abrasive wax such as Yamaha Silicone Wax.

EMU28431

Battery care

WARNING

EWM00330

Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive mea- sures:

Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury.

Wear protective eye gear when han- dling or working near batteries.

Antidote (EXTERNAL):

SKIN - Flush with water.

EYES - Flush with water for 15 minutes and get immediate medical attention.

Antidote (INTERNAL):

Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention.

Batteries also generate explosive hydro- gen gas; therefore, you should always follow these preventive measures:

Charge batteries in a well-ventilated ar- ea.

Keep batteries away from fire, sparks, or open flames (for example: welding equipment, lighted cigarettes, and so

on.)

DO NOT SMOKE when charging or han- dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

Follow the manual of the battery for the han- dling of the battery. Batteries vary among manufacturers. Therefore the following pro- cedures may not always apply. Consult your battery manufacturers instructions. Procedure 1. Disconnect and remove the battery from

the boat. Always disconnect the black negative cable first to prevent the risk of shorting.

2. Clean the battery casing and terminals. Fill each cell to the upper level with dis- tilled water.

3. Store the battery on a level surface in a cool, dry, well-ventilated place out of di- rect sunlight.

4. Once a month, check the specific gravity of the electrolyte and recharge as re- quired to prolong battery life.

EMU28450

Cleaning the outboard motor

After use, wash the exterior of the outboard motor with fresh water. Flush the cooling system with fresh water.

NOTE:

For cooling system flushing instructions, see

ZMU02871

Page 57

Maintenance

page 47.

EMU28460

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.

EMU28488

Periodic maintenance

WARNING

EWM01071

Be sure to turn off the engine when you perform maintenance unless otherwise specified. If you are not familiar with ma- chine 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 owners manual.

EMU28511

Replacement parts

If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and ac- cessories are available from your Yamaha dealer.

Page 58

Maintenance

EMU28522

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.

NOTE:

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

water after each use.

The symbol indicates the check-ups which you may carry out yourself. The symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

10 hours (1 month)

50 hours (3

months)

100 hours (6 months)

200 hours (1

year)

Anode(s) (external) Inspection / replace- ment

Anode(s) (internal) Inspection / replace- ment

Battery Inspection / charging

Cooling water pas- sages

Cleaning

Cowling clamp Inspection

Fuel lter (can be dis- assembled)

Inspection / cleaning

Fuel system Inspection

Fuel tank (Yamaha por- table tank)

Inspection / cleaning

Gear oil Change

Greasing points Greasing

Idling speed (carbure- tor models)

Inspection

Propeller and cotter pin Inspection / replace- ment

Shift link / shift cable Inspection / adjustment

Thermostat Inspection / replace- ment

Throttle link / throttle cable / throttle pick-up timing

Inspection / adjustment

Water pump Inspection / replace- ment

Page 59

Maintenance

Spark plug(s) Cleaning / adjustment / replacement

Item Actions

Initial Every

10 hours (1 month)

50 hours (3

months)

100 hours (6 months)

200 hours (1

year)

Page 60

Maintenance

EMU28932

Greasing

Yamaha marine grease (Water resistant grease)

EMU28953

Cleaning and adjusting spark plug

WARNING

EWM00560

When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external

sparks, which could lead to explosion or

fire.

WARNING

EWM01550

The engine will still be very hot when it has just been turned off. Take extremely

ZMU03734

Page 61

Maintenance

care so that neither you nor anyone else gets burnt. To avoid burns, work on the

engine when it has cooled down.

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- ple, if the center electrode porcelain is very 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.

Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification if necessary.

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 spark plug to the correct torque.

NOTE:

If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past fin- ger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a

torque-wrench.

EMU28962

Checking fuel system

WARNING

EWM00060

Gasoline and its vapors are highly flam- mable and explosive. Keep away from sparks, cigarettes, flames, or other

sources of ignition.

WARNING

EWM00910

Leaking fuel can result in fire or explo- sion.

Check for fuel leakage regularly.

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.

Standard spark plug: B7HS-10

1. Spark plug gap 2. Spark plug I.D. mark (NGK) 3. Spark plug part number

Spark plug gap: 0.91.0 mm (0.0350.039 in)

Spark plug torque: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Page 62

Maintenance

Checkpoints

Fuel system parts leakage

Fuel line joint leakage

Fuel line cracks or other damage

Fuel connector leakage

EMU28980

Inspecting fuel filter

WARNING

EWM00310

Gasoline is highly flammable, and its va- pors are flammable and explosive.

If you have any question about properly doing this procedure, consult your Yamaha dealer.

Do not perform this procedure on a hot or running engine. Allow the engine to cool.

There will be fuel in the fuel filter. Keep away from sparks, cigarettes, flames or other sources of ignition.

This procedure will allow some fuel to spill. Catch fuel in a rag. Wipe up any spilled fuel immediately.

The fuel filter must be reassembled carefully with the O-ring, filter cup, and hoses in place. Improper assembly or replacement could result in a fuel leak, which could result in a fire or explosion

hazard.

EMU29001

Cleaning fuel filter

1. Remove the nut holding the fuel filter as- sembly if equipped.

2. Unscrew the filter cup, catching any spilled fuel in a rag.

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.

ZMU04772

1. Nut

1. Filter cup 2. Filter element 3. Filter housing 4. O-ring

ZMU03812

ZMU02079

2 3

Page 63

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.

6. Run the engine and check the filter and lines for leaks.

EMU29041

Inspecting idling speed

WARNING

EWM00451

Do not touch or remove electrical parts when starting or during operation.

Keep hands, hair, and clothes away from the flywheel and other rotating

parts while the engine is running.

CAUTION:

ECM00490

This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be

used.

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.

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.

2. Verify whether the idle speed is set to specification. For idle speed specifica- tions, see page 46.

EMU29112

Checking wiring and connectors

Check that each grounding wire is properly secured.

Check that each connector is engaged se- curely.

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

Water leakage

Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head, and body cylinder.

EMU32110

Checking propeller

WARNING

EWM01610

You could be seriously injured if the en- gine accidentally starts when you are near the propeller.

Before inspecting, removing, or install- ing the propeller, remove the spark plug caps from the spark plugs. Also, place the shift control in neutral, turn the main switch to (off) and re- move the key, and remove the cord

ZMU03737

Page 64

Maintenance

from the engine shut-off switch. Turn off the battery cut-off switch if your boat has one.

Do 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.

Checkpoints

Check each of the propeller blades for wear, erosion from cavitation or ventila- tion, or other damage.

Check the propeller shaft for damage.

Check the splines for wear or damage.

Check for fish line tangled around the pro- peller shaft.

Check the propeller shaft oil seal for dam- age.

EMU30661

Removing propeller

EMU29195

Spline models

1. Straighten the cotter pin and pull it out using a pair of pliers.

2. Remove the propeller nut, washer, and spacer (if equipped).

3. Remove the propeller and thrust wash- er.

ZMU02876

ZMU01897

1. Cotter pin 2. Propeller nut 3. Washer 4. Spacer 5. Propeller 6. Thrust washer

ZMU02829

6 5

4 3 2

Page 65

Maintenance

EMU30671

Installing propeller

EMU29231

Spline models

CAUTION:

ECM00340

Be sure to install the thrust washer be- fore installing the propeller, otherwise the lower case and propeller boss could be damaged.

Be 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.

2. Install the spacer (if equipped), thrust 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.

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.

EMU29282

Changing gear oil

WARNING

EWM00800

Be 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.

Never 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.

1. Tilt the outboard motor so that the gear oil drain screw is at the lowest point pos- sible.

2. Place a suitable container under the gear case.

3. Remove the gear oil drain screw and gasket.

NOTE:

If a magnetic gear oil drain screw is equipped, remove all metal particles from the screw before installing it.

Always use new gaskets. Do not reuse the

removed gaskets.

4. Remove the oil level plug and gasket to

ZMU02063

1. Gear oil drain screw 2. Oil level plug

ZMU03738

Page 66

Maintenance

allow the oil to drain completely.

CAUTION:

ECM00710

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.

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 the gear oil drain screw hole.

6. Put a new gasket on the oil level plug. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.

7. Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw.

EMU29302

Cleaning fuel tank

WARNING

EWM00920

Gasoline is highly flammable, and its va- pors are flammable and explosive.

If you have any question about properly doing this procedure, consult your Yamaha dealer.

Keep away from sparks, cigarettes, flames, or other sources of ignition when cleaning the fuel tank.

Remove the fuel tank from the boat be- fore cleaning it. Work only outdoors in an area with good ventilation.

Wipe up any spilled fuel immediately.

Reassemble the fuel tank carefully. Im- proper assembly can result in a fuel leak, which could result in a fire or ex- plosion hazard.

Dispose of old gasoline according to lo-

cal regulations.

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.

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

Recommended gear oil: Hypoid gear oil SAE#90

Gear oil quantity: 370.0 cm

(12.51 US oz) (13.05 Imp.oz)

ZMU03739

Page 67

Maintenance

from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.

CAUTION:

ECM00720

Do not paint anodes, as this would render

them ineffective.

NOTE:

Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replace- ment of internal anodes attached to the pow-

er unit.

EMU29320

Checking battery (for electric start models)

WARNING

EWM00330

Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive mea- sures:

Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury.

Wear protective eye gear when han-

dling or working near batteries. Antidote (EXTERNAL):

SKIN - Flush with water.

EYES - Flush with water for 15 minutes and get immediate medical attention.

Antidote (INTERNAL):

Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention.

Batteries also generate explosive hydro- gen gas; therefore, you should always follow these preventive measures:

Charge batteries in a well-ventilated ar- ea.

Keep batteries away from fire, sparks, or open flames (for example: welding equipment, lighted cigarettes, and so on.)

DO NOT SMOKE when charging or han- dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

CAUTION:

ECM00360

A poorly maintained battery will quickly deteriorate.

Ordinary tap water contains minerals harmful to a battery, and should not be

used for topping up.

1. Check the electrolyte level at least once a month. Fill to the manufacturers rec- ommended level when necessary. Top up only with distilled water (or pure de- ionized water suitable to use in batter- ies).

ZMU02924

Page 68

Maintenance

2. Always keep the battery in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month or more, re- move the battery from the boat and store it in a cool, dark place. Completely re- charge the battery before using it.

3. If the battery will be stored for longer than a month, check the specific gravity of the fluid at least once a month and re- charge the battery when it is low.

NOTE:

Consult a Yamaha dealer when charging or

re-charging batteries.

EMU29332

Connecting the battery

WARNING

EWM00570

Mount the battery holder securely in a dry, well-ventilated, vibration-free loca- tion in the boat. Install a fully charged bat-

tery in the holder.

CAUTION:

ECM01122

Make sure the main switch (on applica- ble models) is (off) before work- ing on the battery.

Reversal of the battery cables will dam- age the electrical parts.

Connect the red battery cable first

when installing the battery and discon- nect the black battery cable first when removing it.

The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start

the engine.

Connect the red battery cable to the POSI- TIVE (+) terminal first. Then connect the black battery cable to the NEGATIVE (-) ter- minal.

EMU29370

Disconnecting the battery

Disconnect the BLACK cable from the NEG- ATIVE (-) terminal first. Then disconnect the RED cable from the POSITIVE (+) terminal.

EMU29391

Checking top cowling

CAUTION:

ECM01650

Be sure the cowling is closed securely and that there are no gaps. A loose or im- properly fitting cover could allow water

into the engine.

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.

1. Red cable 2. Black cable 3. Battery

Page 69

Maintenance

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. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.

ZMU04677

ZMU01943

Page 70

Trouble Recovery

EMU29425

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. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble-warning indicator is flashing, consult your Yamaha dealer.

Starter will not operate.

Q. Is battery capacity weak or low? A. Check battery condition. Use battery of recommended capacity.

Q. Are battery connections loose or corrod- ed? A. Tighten battery cables and clean battery terminals.

Q. Is fuse for electric start relay or electric cir- cuit blown? A. Check for cause of electric overload and repair. Replace fuse with one of correct am- perage.

Q. Are starter components faulty? A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear? A. Shift to neutral.

Engine will not start (starter operates).

Q. Is fuel tank empty? A. Fill tank with clean, fresh fuel.

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged? A. Clean or replace filter.

Q. Is starting procedure incorrect? A. See page 29.

Q. Has fuel pump malfunctioned? A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Q. Are spark plug cap(s) fitted incorrectly? A. Check and re-fit cap(s).

Q. Is ignition wiring damaged or poorly con- nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro- ken wires.

Q. Are ignition parts faulty? A. Have serviced by a Yamaha dealer.

Q. Is engine shut-off cord not attached? A. Attach cord.

Q. Are engine inner parts damaged? A. Have serviced by a Yamaha dealer.

Engine idles irregularly or stalls.

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Q. Is fuel system obstructed?

Page 71

Trouble Recovery

A. Check for pinched or kinked fuel line or other obstructions in fuel system.

Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged? A. Clean or replace filter.

Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.

Q. Has warning system activated? A. Find and correct cause of warning.

Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.

Q. Is ignition wiring damaged or poorly con- nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro- ken wires.

Q. Is specified engine oil not being used? A. Check and replace oil as specified.

Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.

Q. Are carburetor adjustments incorrect? A. Have serviced by a Yamaha dealer.

Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.

Q. Is air vent screw on fuel tank closed? A. Open air vent screw.

Q. Is choke knob pulled out? A. Return to home position.

Q. Is motor angle too high? A. Return to normal operating position. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect? A. Connect correctly.

Q. Is throttle valve adjustment incorrect? A. Have serviced by a Yamaha dealer.

Q. Is battery cable disconnected? A. Connect securely.

Warning buzzer sounds or indicator lights.

Q. Is cooling system clogged? A. Check water intake for restriction.

Q. Is engine oil level low? A. Fill oil tank with specified engine oil.

Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec- ommended type.

Q. Is specified engine oil not being used? A. Check and replace oil with specified type.

Q. Is engine oil contaminated or deteriorat- ed? A. Replace oil with fresh, specified type.

Q. Is oil filter clogged? A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunc- tioned? A. Have serviced by a Yamaha dealer.

Page 72

Trouble Recovery

Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane.

Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer.

Q. Is there excess water in fuel filter cup? A. Drain filter cup.

Engine power loss.

Q. Is propeller damaged? A. Have propeller repaired or replaced.

Q. Is propeller pitch or diameter incorrect? A. Install correct propeller to operate out- board at its recommended speed (r/min) range.

Q. Is trim angle incorrect? A. Adjust trim angle to achieve most efficient operation.

Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height.

Q. Has warning system activated? A. Find and correct cause of warning.

Q. Is boat bottom fouled with marine growth? A. Clean boat bottom.

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Q. Are weeds or other foreign matter tangled

on gear housing? A. Remove foreign matter and clean lower unit.

Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.

Q. Is fuel filter clogged? A. Clean or replace filter.

Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.

Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.

Q. Is ignition wiring damaged or poorly con- nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro- ken wires.

Q. Have electrical parts failed? A. Have serviced by a Yamaha dealer.

Q. Is specified fuel not being used? A. Replace fuel with specified type.

Q. Is specified engine oil not being used? A. Check and replace oil with specified type.

Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.

Q. Is air vent screw closed? A. Open the air vent screw.

Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.

Page 73

Trouble Recovery

Q. Is fuel joint connection incorrect? A. Connect correctly.

Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec- ommended type.

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.

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.

Q. Is motor mounting bolt loose? A. Tighten bolt.

Q. Is steering pivot loose or damaged? A. Tighten or have serviced by a Yamaha dealer.

EMU29433

Temporary action in emergency

EMU29440

Impact damage

WARNING

EWM00870

The outboard motor can be seriously damaged by a collision while operating or

trailering. Damage could make the out-

board motor unsafe to operate.

If the outboard motor hits an object in the wa- ter, follow the procedure below.

1. Stop the engine immediately. 2. Inspect the control system and all com-

ponents for damage. Also inspect the boat for damage.

3. Whether damage is found or not, return to the nearest harbor slowly and careful- ly.

4. Have a Yamaha dealer inspect the out- board motor before operating it again.

EMU29462

Replacing fuse

If the fuse has blown on an electric start model, open the fuse holder and replace the fuse with a new one of the proper amperage.

WARNING

EWM00630

Be sure to use the specified fuse. An in- correct fuse or a piece of wire could allow excessive current flow. This could cause

electric system damage and a fire hazard.

Page 74

Trouble Recovery

NOTE:

Consult your Yamaha dealer if the new fuse

immediately blows again.

EMU29532

Starter will not operate

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.

WARNING

EWM01021

Use this procedure only in an emergen- cy to return to the nearest port for re- pairs.

When 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.

Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating the boat.

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.

Avoid 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.

Make sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure someone.

An unguarded, rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the fly- wheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.

Do not touch the ignition coil, spark plug wire, spark plug cap, or other elec- trical components when starting or op- erating the motor. You could get an

electrical shock.

EMU29562

Emergency starting engine

1. Remove the top cowling. 2. Remove the start-in-gear protection ca-

ble from the starter, if equipped.

1. Fuse holder 2. Fuse (10 A)

ZMU04839

1 2

Page 75

Trouble Recovery

3. Remove the starter/flywheel cover after removing the bolt(s).

4. Prepare the engine for starting. For fur- ther information, see page 29. Be sure the engine is in neutral and that the clip is attached to the engine shut-off switch. The main switch must be (on), if equipped.

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.

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

1. Start-in-gear protection cable

ZMU03740

ZMU03741

ZMU03742

ZMU02334

ON STARTOFF

ZMU01906

ZMU04119

Page 76

Trouble Recovery

and start the engine. Repeat if neces- sary.

EMU29760

Treatment of submerged motor

If the outboard motor is submerged, immedi- ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi- ately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the proce- dure below in order to minimize engine dam- age.

EMU29771

Procedure

1. Thoroughly wash away mud, salt, sea- weed, and so on, with fresh water.

2. Remove the spark plugs and face the spark plug holes downward to allow any water, mud, or contaminants to drain.

3. Drain the fuel from the 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.

5. Take the outboard motor to a Yamaha dealer as soon as possible.

CAUTION:

ECM00400

Do not attempt to run the outboard motor

until it has been completely inspected.

ZMU02928

ZMU01909

ZMU01910

ZMU01911

Page 77

Consumer information

EMU29811

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

Page 78

Consumer information

Page 79

Consumer information

EMU29820

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY

Page 80

Consumer information

Page 81

Consumer information

Page 82

Consumer information

EMU29841

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA

Page 83

6L2-9-1S Hyoshi 07.2.5 10:52 AM 3

Page 84

Printed in Japan April 20070.2 1 ! Printed on recycled paper

6L2-9-1S Hyoshi 07.2.5 10:52 AM 4

Page 85

YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON

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 linspection ont t faits dans le respect des directives dinspection et

que la marche suivre pour la garantie et lentretien a t explique lacheteur au dtail.

OUTBOARD MOTOR MODEL AND SERIAL NUMBER (From I.D. label on clamp bracket) MODLE ET NO. DE SRIE DU MOTEUR HORS-BORD (sur ltiquette didentification de la presse de fixation)

(For Dealer Use Only) (A lusage du concessionnaire) YAMAHA DEALER NUMBER NO. DU CONCESSIONNAIRE YAMAHA

DEALER NAME NOM DU CONCESSIONNAIRE

DATE SOLD DATE DE LIVRAISON

OWNERS NAME NOM DU PROPRITAIRE

ADDRESS ADRESSE

PHONE NUMBER ( ) NUMRO DE TLPHONE

USAGE (Check One) UTILISATION (En cocher un.)

PLEASURE LOISIR COMMERCIAL COMMERCIAL

MONTH DAY YEAR MOIS JOUR ANNE

FIRST LAST PRNOM NOM DE FAMILLE

STREET RUE

CITY STATE/PROVINCE ZIP VILLE PROVINCE CODE POSTAL

Warranty card-04 2/17/03 2:41 PM Page 1

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