Contents

Yamaha 25NMHL Owner's Manual PDF

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Summary of Content for Yamaha 25NMHL Owner's Manual PDF

Printed in Japan March 2003-1.0 1 ! 6L2-28199-1K (25NMH) (E)

Printed on recycled paper

25C

OWNERS MANUAL

U.S.A.Edition LIT-18626-05-42

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Thank you for choosing a Yamaha out- board motor. This Owners manual con- tains information needed for proper oper- ation, maintenance and care. A thorough understanding of these simple instruc- tions will help you obtain 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.

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

w 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.

cC 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 advance- ments in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.

NOTE:

The 25MH and its standard accessories are used as a base for the explanations and illustrations in this manual. There- fore, some items may not apply to every model.

EMU14480

TO THE OWNER

E

EMU01446

25C

OWNER'S MANUAL

2003 by Yamaha Motor Corporation, USA

1st Edition, March 2003

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in Japan

P/N LIT-18626-05-42

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GENERAL INFORMATION

BASIC COMPONENTS

OPERATION

MAINTENANCE

TROUBLE RECOVERY

INDEX

EMA20010

CONTENTS

READ THIS OWNERS MANUAL CAREFULLY

BEFORE OPERATING YOUR OUTBOARD MOTOR.

1

2

3

4

5

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EMB00010

Chapter 1

GENERAL

INFORMATION

IDENTIFICATION NUMBERS RECORD ..1-1 Outboard motor serial number...........1-1

EMISSION CONTROL INFORMATION...1-2

SAFETY INFORMATION..........................1-3

IMPORTANT LABELS ..............................1-5

BASIC BOATING RULES .........................1-6

FUELING INSTRUCTIONS.....................1-10 Gasoline ..............................................1-11 Engine oil ............................................1-11

PROPELLER SELECTION .......................1-12

START-IN-GEAR PROTECTION ............1-13

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1-1

EMU00005

IDENTIFICATION NUMBERS

RECORD

EMU00007

OUTBOARD MOTOR SERIAL NUM-

BER

The outboard motor serial number is stamped on the label attached to the port side of the clamp-bracket. Record your outboard motor serial num- ber in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your out- board motor is stolen.

1 Outboard motor serial number

1

401012

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

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1

2

108021

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2

108022

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EMU01385

EMISSION CONTROL

INFORMATION

EMU01386

NORTH AMERICAN MODELS

This engine conforms to U.S. Environ- mental Protection Agency (EPA) regula- tions for marine SI engines. See the label affixed to your engine for details.

Approval label of Emission control

certificate

This label is attached to the bottom cowl- ing.

1 Emission control information label

Existing Technology ; N/A

Manufactured date label

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

2 Manufactured date label

EMISSION CONTROL INFORMATION ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES. 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 EX

cm kw

g/kw-hr rpm IN NEUTRAL

3

Manufactured:

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8 This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symp- toms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets. 8 Check throttle, shift, and steering for

proper operation before starting the engine. 8 Attach the engine stop switch lanyard

to a secure place on your clothing, or your arm or leg while operating. If you accidentally leave the helm, the lanyard will pull from the switch, stopping the engine. 8 Know the marine laws and regulations

where you will be boating - and obey them. Refer to the RULES OF THE ROAD section for basic boating rules. 8 Stay informed about the weather.

Check weather forecasts before boating. Avoid boating in hazardous weather. 8 Tell someone where you are going:

leave a Float Plan with a responsible person. Be sure to cancel the Float Plan when you return. 8 Use common sense and good judgment

when boating. Know your abilities, and be sure you understand how your boat handles under the different boating conditions you may encounter. Operate within your limits, and the limits of your boat. Always operate at safe speeds, and keep a careful watch for obstacles and other traffic. 8 Always watch carefully for swimmers

during the engine operation. 8 Stay away from swimming areas.

EMU00917

SAFETY

INFORMATION

8 Before mounting or operating the out- board motor, read this entire manual. Reading it should give you an under- standing of the motor and its operation. 8 Before operating the boat, read any

owners or operators manuals supplied with it and all labels. Be sure you under- stand each item before operating. 8 Do not overpower the boat with this

outboard motor. Overpowering the boat could result in loss of control. The rated power of the outboard should be equal to or less than the rated horse- power capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer. 8 Do not modify the outboard. Modifica-

tions could make the motor unfit or unsafe to use. 8 Never operate after drinking alcohol or

taking drugs. About 50% of all boating fatalities involve intoxication. 8 Have an approved personal flotation

device (PFD) on board for every occu- pant. It is a good idea to wear a PFD whenever boating. At a minimum, chil- dren and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially haz- ardous boating conditions. 8 Gasoline is highly flammable, and its

vapors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel before starting the engine.

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8When a swimmer is in the water near you shift into neutral and shut off the engine. 8 Be informed about boating safety. Addi-

tional publications and information can be obtained from many organizations, including the following:

United States Coast Guard

Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647

National Marine Manufacturers

Association (NMMA)

401 N. Michigan Ave. Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave. Chicago, Il 60601

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EMB30010

IMPORTANT LABELS

WARNING LABELS

1

2

202023

q

w

WARNING This engine is equipped with a neutral starting device. The engine will not start unless the shift control is in neutral position.

6E0-83627-41

WARNING 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.

6A1-83625-41

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LOCATION

202061

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EMB40010

BASIC BOATING RULES

(Rules of the road)

Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast Guard and local agencies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water.

Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the Road. The rules presented here in your Owners Manual are condensed, and have been provided for your convenience only. Consult your local U.S. Coast Guard Aux- iliary or Department of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat.

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

Stand-on vessel

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

Give-way vessel

The vessel which does not have the right- 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 briefly 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 Interna- tional Rules and says,

In obeying and construing these rules due regard shall be had to all dangers of navigation and collision, and to any special circumstances, which may render a departure from the above rules necessary in order to avoid immediate danger.

In other words, follow the standard rules except when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become Give-Way vessels.

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RULES WHEN ENCOUNTERING

VESSELS

There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steer- ing Rules are followed:

Meeting (you are approaching another vessel head-on) Crossing (you are travelling across the other 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 ves- sels in the shaded 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 vessel 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 other 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 ves- sel is on your port (left) side, remember that you should maintain course and direction, 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

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the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Like- wise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.

OTHER SPECIAL SITUATIONS

There are three other rules you should be aware of when driving your boat around other vessels.

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 water vessels, the operator should sound a prolonged 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 proceed around the bend with caution. If you navi- gate such waters with your boat, you will need to carry a portable air horn, avail- able from local marine supply stores.

Fishing vessel right-of-way

All vessels which are fishing with nets, lines or trawls are considered to be fish- ing vessels under the International Rules. Vessels with trolling lines are not considered fishing vessels. Fishing ves- sels have the right-of-way regardless of position. Fishing vessels cannot, howev- er, 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- driven vessel has the right-of-way.

2. Sailing vessels should keep clear of any fishing vessel.

3. In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel which 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 navigating in a par- ticular direction. The markings on these buoys are oriented from the perspective of being entered from seaward (the boater is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open water into port, and black buoys are to port (left) side. When navi- gating out of port, your position with respect to the buoys should be reversed; 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 partic- ular state. The Uniform State Waterway Marking System has been devised for these waters. This system uses buoys and signs with distinctive shapes and colors to show regulatory or advisory informa-

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tion. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geo- graphic location. Always consult local boating authorities before driving your boat in unfamiliar waters.

E

1 1

A

1 1

Proceeding toward head of navigation from seaward

CAN BUOY

Odd number. Leave to port.

OR

SECONDARY CHANNEL BUOYS STARTS NEW NUMBERING SYSTEM

old new

C " 1"

NUN BUOY

Even number. Leave to starboard

N " 2"

No change

BUOY COLOR CODE

BLACK

RED

GREEN

" A"

" 2"

" 1"

" 3"

" 4"

" 5"

" 7"

N " 2"

" 6" C " 1"

RB " L"

RG " L" or

SECONDARY CHANNEL

M AIN

CHANNEL

old new

2

2 2

A

LL

Odd number. increasing toward head of naviga-

MAIN CHANNEL BUOYS

" 1" " 3" " 5" " 7"

tion.Leave to port (left) proceeding upstream.

LIGHTED BUOY (Port Hand)`

White Light Green Light

old new

old new

old new

LIGHTED BUOY (Starboard Hand)`

" 2" " 4" " 6"

Even number,increasing toward head of naviga- tion. Leave to starboard (right) proceeding up- stream.

White Light Red Light

" A"

LIGHTED SAFE WATER BUOY

No number. Marks midchannel, pass on either side. Letter has no lateral significance, used for

No number . Topmost band red - prefer red

Top Mark

White LightWhite Light

OR

OR

LIGHTED PREFERRED CHANNEL TO

RB " L" RG " L"

PORT BUOY

identification and location purposes.

channel is to left of buoy. Letter has no lateral significance, used for identification and location purposes.

Red Light Red or White Light

OR

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EMU00016

FUELING INSTRUCTIONS

w GASOLINE AND ITS VAPORS ARE HIGH-

LY FLAMMABLE AND EXPLOSIVE!

8 Do not smoke when refueling, and

keep away from sparks, flames, or

other sources of ignition.

8 Stop engine before refueling.

8 Refuel in a well-ventilated area. Refuel

portable fuel tanks off the boat.

8 Take care not to spill gasoline. If gaso-

line spills, wipe it up immediately with

dry rags.

8 Do not overfill the fuel tank.

8 Tighten the filler cap securely after

refueling.

8 If you should swallow some gasoline

inhale a lot of gasoline vapor, or get

gasoline in your eyes, get immediate

medical attention.

8 If any gasoline spills onto your skin,

immediately wash with soap and

water. Change clothing if gasoline spills

on it.

8 Touch the fuel nozzle to the filler open-

ing or funnel to help prevent electrosta-

tic sparks.

cC Use only new clean gasoline which has

been stored in clean containers and is not

contaminated with water or foreign mat-

ter.

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EMU00858

ENGINE OIL

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

EMU00027

Gasohol

There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Gasohol containing methanol is not recommended by Yama- ha because it can cause fuel system dam- age or engine performance problems.

EMU01804

GASOLINE

If knocking or pinging occurs, use a differ- ent brand of gasoline or premium unlead- ed fuel.

Recommended gasoline: Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2

Recommended engine oil: YAMALUBE 2 STROKE OUTBOARD OIL

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EMU01395

PROPELLER SELECTION

The performance of your outboard motor will be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine.

Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct engine speed to be main- tained. Conversely, a larger-pitch pro- peller is more suitable for a smaller oper- ating load.

Yamaha dealers stock a range of pro- pellers, and can advise you and install a propeller on your outboard that is best suited to your application.

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EMU01209

START-IN-GEAR PROTECTION

Yamaha outboard motors or Yamaha approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is Neutral. Always select Neutral before starting the engine.

602016

10-3/4x17-F

1 23

NOTE:

At full throttle and under a maximum boat load, the engines rpm should be within the upper half of the full throttle operating range, as listed in SPECIFICA- TIONS on page 4-1. Select a propeller which fulfills this requirement. If operating under conditions which allow the engines rpm to rise above the maxi- mum recommended range (such as light boat loads), reduce the throttle setting to maintain the rpm in the proper operating range.

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

Refer to the section CHECKING PRO- PELLER for instructions on propeller removal and installation.

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EMC00010

Chapter 2

BASIC COMPONENTS

MAIN COMPONENTS..............................2-1

OPERATIONS OF CONTROLS AND

OTHER FUNCTIONS ................................2-3 Fuel tank ................................................2-3 Gear shift lever .....................................2-3 Engine stop lanyard switch.................2-4 Engine stop button...............................2-5 Tiller handle ..........................................2-5 Choke knob ...........................................2-6 Recoil starter handle ............................2-6 Steering friction adjusting screw........2-7 Trim tab .................................................2-8 Trim angle adjusting rod .....................2-8 Shallow water lever .............................2-9 Tilt lock mechanism .............................2-9 Tilt support bar ...................................2-10 Tilt support lever ................................2-10 Top cowling lock lever.......................2-10

WARNING SYSTEM ..............................2-11 Overheat warning...............................2-11 Oil level warning / oil filter clogging warning ...............................................2-12

1

2

3

4

5

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EMU01206

MAIN COMPONENTS

101061

!1

!0

!6!2

!4 u

i

q

r

w

t

y

e

!3

o

!5

1 Recoil starter handle 2 Choke knob 3 Warning lamp 4 Gear shift lever 5 Throttle-control grip/Tiller-handle 6 Engine stop button/

Engine stop lanyard switch 7 Transom-clamp handle 8 Tilt lock lever 9 Cooling water inlet 0 Propeller q Trim tab (Anode) w Anti-cavitation plate

e Trim angle adjusting-rod r Rope attachment t Shallow water lever y Fuel tank

* May not be exactly as shown; also may not be included as standard equipment on all models.

25

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EMU01206

MAIN COMPONENTS

1

2

34

6

8

9

0

q

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w

u i

e r

t

y

o

p

5

1 Recoil starter handle 2 Gear shift lever 3 Tiller handle 4 Tilt lock lever 5 Shallow water lever 6 Transom clamp handle 7 Trim angle adjusting rod 8 Cooling water inlet

*9 Propeller 0 Anti-cavitation plate q Trim tab w Clamp bracket

e Tilt support lever r Rope attachment t Top cowling y Choke knob u Engine stop button/engine stop lanyard

switch i Warning indicator

*o Remote control box *p Fuel tank

* May not be exactly as shown; also may not be included as standard equipment on all models.

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EMC20010

OPERATIONS OF CONTROLS

AND OTHER FUNCTIONS EMC21012

FUEL TANK

If your model was equipped with a portable fuel tank, its function is as fol- lows.

1 Fuel hose joint 2 Fuel meter(If equipped) 3 Fuel tank cap 4 Air vent screw(If equipped)

Fuel hose joint

This connector is provided for connecting or disconnecting fuel hose.

Fuel meter

This meter is on the fuel tank cap. It shows current fuel quantity in the fuel tank approximately.

Fuel tank cap

This cap is for filling fuel. To remove it, turn it counterclockwise.

Air Vent screw

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

EMC25010

GEAR SHIFT LEVER (for Tiller control

model)

Turning the gear-shift lever towards you engages the clutch with the forward gear so that the boat moves ahead. Turning the lever away from you engages the reverse gear so that the boat moves astern.

1 Neutral 2 Forward 3 Reverse

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EMC28111

ENGINE STOP LANYARD SWITCH

(for Tiller control model)

The lock-plate on the end of the lanyard must be attached to the engine stop switch for the engine to run. The lanyard 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 lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away under power.

1 Lock-plate 2 Lanyard

w 8 Attach the engine stop switch lanyard

to a secure place on your clothing, your

arm or leg while operating.

8 Do not attach the lanyard to clothing

that could tear loose. Do not route the

lanyard in such a way that it could

become entangled, preventing it from

functioning.

8 Avoid accidentally pulling the lanyard

during normal operation. Loss of

engine power means the loss of most

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 lock-plate removed.

1 2

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001126

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EMC27011

ENGINE STOP BUTTON

(for Tiller control model)

Pushing this button opens the ignition cir- cuit and stops the engine.

EMU00062

TILLER HANDLE (for Tiller control

model)

Moving the tiller handle sideways to adjust the steering direction. In addition, this handle contains the functions as fol- lows.

1 Throttle control grip 2 Throttle indicator 3 Throttle friction adjusting knob/screw

E

503022**q

503021* e

qw

503032

EMU00067

Throttle Indicator

The fuel consumption curve on the throt- tle 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.

1 Throttle indicator

3

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EMU00065

Throttle Control Grip

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

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502011

EMU01293

Throttle friction adjusting screw/ knob

A friction device in the tiller handle pro- vide resistance to movement of the throt- tle grip. This is adjustable for operator preference. An adjusting screw/knob is located within the tiller handle.

When constant speed is desired, tighten the adjusting screw/bolt to maintain the desired throttle setting.

w Do not over tighten the friction adjusting

screw/ knob.

If there is too much resistance, it may be

difficult to move the throttle grip, which

could result in an accident.

Resistance Knob/Screw Increase Turn clockwise Decrease Turn counterclockwise

EMC42010

CHOKE KNOB

Pulling out this knob (setting it to ON) supplies a rich mixture required to start the engine.

NOTE:

The choke knob for Remote control model has the same function as the choke switch on the remote control box.

209015

305022* 305023*

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EMC44010

RECOIL STARTER HANDLE

(If equipped)

Pull the handle gently until resistance is felt. Then vigorously pull the handle straight out to crank the engine to start it.

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EMD00011

STEERING FRICTION ADJUSTING

SCREW(for Tiller control model)

A friction device provides resistance to steering movement. This is adjustable for operator preference. An adjusting screw/bolt is located on the swivel brack- et. EMD00310*

Adjustment

w Do not overtighten the friction

screw/bolt.

If there is too much resistance, it may be

difficult to steer, which could result in an

accident.

Resistance Screw/bolt Increased Turn clockwise Decreased Turn counterclockwise

408015

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EMU00113

TRIM TAB

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.

w An improperly adjusted trim tab may

cause difficult steering. Always test run

after the trim tab has been installed or

replaced to be sure steering is correct. Be

sure you have tightened the bolt after

adjusting the trim tab.

1 Trim tab 2 Bolt 3 Cap (If equipped)

cC The trim tab also serves as an anode to

protect the engine from electrochemical

corrosion. Never paint the trim tab as it

will become ineffective as an anode.

603011

w q

A B

001769

25

404015

25-3/30

Boat tends The fin of trim tabto veer

To the left Turn to the left (port side) (A in the figure)

To the right Turn to the right (starboard (B in the figure)side)

EMU01297

TRIM ANGLE ADJUSTING ROD

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

6L2-9-1K-2 2/14/03 18:39 Page 9

2-9

E

EMD08010

SHALLOW WATER LEVER

(If equipped)

25

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

402075*

25

402072*

25-3/30 EMD08110

SHALLOW WATER LEVER

(If equipped)

25-3/30

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

EMD44010

TILT LOCK MECHANISM

(for Manual tilt model)

The tilt-lock mechanism is used to pre- vent reverse thrust from the propeller lift- ing the outboard motor when reversing. To lock it, set the tilt-lock lever in the up position. To release it, push the tilt-lock lever down.

1 Tilt-lock lever

402035*

q

402061*q

25-3/30

25

6L2-9-1K-2 2/14/03 18:39 Page 10

2-10

E

EMD62010

TOP COWLING LOCK LEVER

To remove the engine top cowling, push the lock lever downward. Then lift off the cowling. When replacing the cowling, check to be sure it fits properly in the rub- ber seal. Then lock the cowling again by moving the lever upward.

403023

q

403024

25

25-3/30 EMD60210

TILT SUPPORT LEVER

25-3/30

To keep the outboard motor in the tilted- up position, lock the tilt support lever to the swivel bracket.

EMU00156

TILT SUPPORT BAR

25

The tilt support bar 1 keeps the outboard motor in the tilted up position.

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2-11

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EMD80010

WARNING SYSTEM

cC Do not continue to operate the engine if

the warning device has activated. Consult

your Yamaha dealer if the problem can-

not be located and corrected.

303013

303014

25

25-3/30

EMU00170

OVERHEAT WARNING

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

(2); Included (); N/A

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

Activation of warning device

The engine speed will automatically decrease to about 2,000 r/min.

The overheat warning indicator will come on.

The buzzer will sound.

Tiller Remote control control model model

2

2

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2-12

E

213023

q

303014

30

EMU00172

OIL LEVEL WARNING / OIL FILTER

CLOGGING WARNING

This engine has an oil level warning sys- tem. If oil level falls below lower limit, the warning device will activate.

(2); Included (); N/A

If the warning system has been activated, stop the engine and check for the cause. NOTE:

The warning for oil filter clogging is simi- lar to the warnings for low oil level and overheating. For easy troubleshooting, it is advisable to check for engine overheat- ing first, then oil level and finally oil filter clogging.

1 Oil filter

Warning device activation

The engine speed will automatically decrease to about 2,000 r/min.

The oil level warning indicator will come on.

The buzzer will sound.

Tiller Remote control control model model

2

2

6L2-9-1K-2 2/14/03 18:39 Page 13

2-13

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Oil level warning system

30

The various oil-level warning system functions are as follows:

Oil level warning indicator lamp (Bottom cowling)

RemarksEngine oil tank

OFF No refilling necessary.more than 200 cm3 (0.21 US qt, 0.181 Imp qt)

Red ON Buzzer sounds in remote control box and engine speed is limited to about 2,000 r/min to help conserve oil. Check oil filter for clogging. Add oil.

200 cm3 or less (0.21 US qt, 0.181 Imp qt)

6L2-9-1K-2 2/14/03 18:39 Page 14

EMF00010

Chapter 3

OPERATION

INSTALLATION ........................................3-1 Mounting the outboard motor............3-2 Clamping the outboard motor ............3-4

FILLING FUEL AND ENGINE OIL ............3-5 Filling fuel..............................................3-5 Filling oil ................................................3-6 Gasoline (petrol) and oil mixing .........3-8

PRE-OPERATION CHECKS ....................3-10 Operation after a long period of storage.................................................3-11

BREAKING IN ENGINE ..........................3-12

STARTING ENGINE ...............................3-14

WARMING UP ENGINE .........................3-18

SHIFTING ................................................3-19 Forward ...............................................3-19 Reverse................................................3-20

STOPPING ENGINE ...............................3-21

TRIMMING OUTBOARD MOTOR.........3-22 Adjusting trim angle ..........................3-23

CRUISING IN SHALLOW WATER.........3-25

TILTING UP/DOWN ...............................3-27

CRUISING IN OTHER CONDITIONS.....3-30 Cruising in salt water .........................3-30 Cruising in turbid water.....................3-30

1

2

3

4

5

6

E

6L2-9-1K-3 2/17/03 18:40 Page 1

3-1

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EMF10010

INSTALLATION

cC Incorrect engine height or obstructions to

smooth water flow (such as the design or

condition of the boat or accessories such

as transom ladders/depth finder trans-

ducers) can create airborne water spray

while the boat is cruising. Severe engine

damage may result if the motor is operat-

ed continuously in the presence of air-

borne water spray.

NOTE:

During water testing check the buoyancy of the boat, at rest, with its maximum load. Check that the static water level on the exhaust housing is low enough to pre- vent water entry into the powerhead, when water rises due to waves when the outboard is not running.

6L2-9-1K-3 2/17/03 18:40 Page 2

3-2

EMU00176

MOUNTING THE OUTBOARD

MOTOR

w Improper mounting of the outboard

motor could result in hazardous condi-

tions such as poor handling, loss of con-

trol, or fire hazards. Observe the follow-

ing:

8 The information presented in this sec-

tion is intended as reference only. It is

not possible to provide complete

instructions for every possible

boat/motor combination. Proper

mounting depends in part on experi-

ence and the specific boat/motor com-

bination.

8 Your dealer or other person experi-

enced in proper rigging should mount

the motor. If you are mounting the

motor yourself, you should be trained

by an experienced person. [permanent

mounted type]

8 Your dealer or other person experi-

enced in proper outboard motor

mounting should show you how to

mount your motor. [portable type]

Mount the outboard motor on the center line (keel line) of the boat, and ensure that the boat itself is well balanced. Otherwise, the boat will be hard to steer. For boats without a keel or which are asymmetrical, consult your dealer.

1 Center line (keel line)

E

104011q

6L2-9-1K-3 2/17/03 18:40 Page 3

3-3

w Overpowering a boat may cause severe

instability. Do not install an outboard

motor with more horsepower than the

maximum rating on the capacity plate of

the boat. If the boat does not have a

capacity plate, consult the boat manufac-

turer.

E

104013

0~25mm

EMU01298

Mounting Height

To run your boat at optimum efficiency, the water-resistance (drag) of the boat and outboard motor must be made as lit- tle as possible. 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 pro- peller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting-height is too low, the water-resistance will increase and thereby reduce engine efficiency. Mount the engine so that the anti-cavita- tion plate is between the bottom of the boat and a level 25 mm (1 in.) below it. NOTE:

8 The optimum mounting height of the outboard motor is affected by the boat/motor combination and the desired use. Test runs at different heights can help determine the opti- mum mounting height. 8 Refer to the section TRIMMING OUT-

BOARD MOTOR for instructions on setting the trim angle of the outboard.

6L2-9-1K-3 2/17/03 18:40 Page 4

3-4

EMF14010

CLAMPING THE OUTBOARD MOTOR

1) Place the outboard on the transom so that it is positioned as close to the center as possible. Tighten the tran- som clamp screws evenly and secure- ly. Check the clamp-screws for tight- ness occasionally during operation of the motor as they can work loose due to engine vibration.

w Loose clamp screws could allow the

motor to move on the transom or fall off

the transom. This could cause loss of

control and serious injury. Make sure the

transom screws are tightened securely.

Occasionally check the screws for tight-

ness during operation.

2) An engine restraint cable or chain should be used. Attach one end to the engine restraint cable attachment point and the other to a secure mounting point on the boat. Other- wise, the engine could be completely lost if it accidentally falls off the tran- som.

E

409011

410012

6L2-9-1K-3 2/17/03 18:40 Page 5

3-5

E

EMF30010

FILLING FUEL AND

ENGINE OIL

FILLING FUEL

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

Wipe up any spilled fuel.

Ring Free Fuel Additive

Gasoline is a precise blend of many differ- ent substances, each chosen to give cer- tain characteristics. Gasoline blends have been changing in recent years in response to concerns about pollution and resulting emissions regulations. One of the most obvious changes has been the elimination of lead from most fuels.

As gasoline has changed, the amount of additives such as aromatics and oxy- genates has increased. These additives are important for the engines in passen- ger cars, but they can have detrimental effects in marine engines, particularly 2- cycle outboards because of increased deposits in the combustion chamber. When enough deposits collect, piston rings begin sticking. Performance drops and engine wear increases dramatically.

902055

Fuel tank capacity: Refer to SPECIFICATIONS on Page 4-1.

6L2-9-1K-3 2/17/03 18:40 Page 6

3-6

E

While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, avail- able from your Yamaha dealer. Ring Free 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 labeling for use instruc- tions

Engine oil tank capacity: See Chapter 4, Specifications.

EMU01800

FILLING OIL

This engine uses the oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operat- ing conditions. No fuel premixing is need- ed (except during break-in). Simply pour gasoline into the fuel tank and oil into the oil tank. Convenient indicator segments indicate the status of the oil supply. For details on reading the indicator segments, see Oil level indicator in this chapter. To fill the engine oil tank, proceed as fol- lows:

Do not add gasoline into the oil tank. Fire

or explosion could result.

6L2-9-1K-3 2/17/03 18:40 Page 7

3-7

E

EMU00192

Procedure

1) Remove the top cowling. 2) Open the oil tank filler cap by pulling

the tab. 3) Slowly fill the engine oil into the

engine oil tank. 4) After filling, replace the cap securely. 5) Replace the top cowling securely.

1 Engine oil tank 2 Oil tank filler cap

203012*

q

w 30

6L2-9-1K-3 2/17/03 18:40 Page 8

3-8

E

EMF35011

GASOLINE (PETROL) AND OIL

MIXING

Pre-mix model

1) Pour oil and gasoline into the fuel tank, in that order.

1 Engione oil 2 Gasoline (Petrol)

2) Then mix the fuel thoroughly by shak- ing.

3) Make sure the oil is mixed with gaso- line .

cC 8 Avoid using any oil other than the des-

ignated type.

8 Use a thoroughly blended fuel-oil mix-

ture.

8 If the mixture is not thoroughly blend-

ed, 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.

Engine oil : Gasoline (Petrol)

Break-in period 1 : 25

After break-in 1 : 100

q

902033

w

6L2-9-1K-3 2/17/03 18:40 Page 9

3-9

E

Mixing ratio 25 : 1

Gasoline (Petrol)

Engine oil 0.04 L 0.48 L 0.56 L 0.96 L

(0.04 US qt, (0.51 US qt, (0.59 US qt, (1.01 US qt, 0.04 Imp qt) 0.42 Imp qt) 0.49 Imp qt) 0.84 Imp qt)

1 L 12 L 14 L 24 L (0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal, 0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.3 Imp gal)

Mixing ratio 100 : 1

Gasoline (Petrol)

Engine oil 0.01 L 0.12 L 0.14 L 0.24 L

(0.01 US qt, (0.13 US qt, (0.15 US qt, (0.25 US qt, 0.01 Imp qt) 0.11 Imp qt) 0.12 Imp qt) 0.21 Imp qt)

1 L 12 L 14 L 24 L (0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal, 0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.3 Imp gal)

NOTE:

If using a permanently installed tank, pour the oil gradually as the fuel is being added to the tank.

6L2-9-1K-3 2/17/03 18:40 Page 10

3-10

E

MU00204

PRE-OPERATION CHECKS

w 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.

cC Do not start the engine out of water.

Overheating and serious engine damage

can occur.

EMU00206

Fuel

8 Check to be sure you have plenty of fuel for your trip. 8 Make sure there are no fuel leaks or

gasoline fumes. 8 Check fuel line connections to be sure

they are tight. 8 Be sure the fuel tank is positioned on a

secure, flat surface, and that the fuel hose is not twisted or flattened, or likely to contact sharp objects.

EMU00207

Oil

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

EMU00209

Controls

8 Check throttle, shift, and steering for proper operation before starting the engine. 8 The controls should work smoothly,

without binding or unusual free play. 8 Look for loose or damaged connec-

tions. 8 Check operation of the starter and stop

switches when the outboard motor is in the water.

6L2-9-1K-3 2/17/03 18:40 Page 11

3-11

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203024

OI L

30

30

EMU00210

Engine

8 Check the engine and engine mounting. 8 Look for loose or damaged fasteners. 8 Check the propeller for damage.

EMU01790

OPERATION AFTER A LONG PERIOD

OF STORAGE

When operating the engine after a long period (12 months) of storage, proceed as follows: 1) Use a 50:1 gasoline-oil mixture to

start the engine. 2) Start the engine. Leave it idling.

w 8 Do not touch or remove electrical parts

when starting or during operation.

8 Keep hands, hair, and clothes away

from the flywheel and other rotating

parts while the engine is running.

3) Watch for oil flowing through the oil feed pipes. After any air in the oil lines has been expelled, the oil injec- tion system should supply oil normal- ly. If no oil is flowing after 10 minutes of idling, consult your Yamaha dealer.

cC Be sure to take the above steps when

operating the engine after a long period

of storage. Otherwise engine seizure

could occur.

6L2-9-1K-3 2/17/03 18:40 Page 12

EMU00225

3-12

E

EMU01781

BREAKING IN ENGINE

Your new engine requires a period of break-in to allow mating surfaces of mov- ing parts to wear in evenly. Correct break- in will help ensure proper performance and longer engine life.

cC 8 Failure to follow the break-in procedure

could result in reduced engine life or

even severe engine damage.

8 Premix fuel must be used during break-

in in addition to oil in the oil injection

system.

For oil injection system models Gasoline to engine oil premix ratio during break-in: 50:1

Break-in time: 10 hours

For premix models Gasoline to engine oil premix ratio during break-in: 25:1 For details on mixing fuel and oil, see Gasoline and oil mixing in this chapter.

Mixing ratio 50 : 1

Gasoline (Petrol)

Engine oil 0.02 L 0.24 L 0.28 L 0.48 L

(0.02 US qt, (0.25 US qt, (0.30 US qt, (0.51 US qt, 0.02 Imp qt) 0.21 Imp qt) 0.25 Imp qt) 0.42 Imp qt)

1 L 12 L 14 L 24 L (0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal, 0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.3 Imp gal)

6L2-9-1K-3 2/17/03 18:40 Page 13

3-13

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EMU01786

Break-in procedure

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

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

2) Next 50 minutes: Do not exceed half throttle (approxi- mately 3,000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 r/min or less.

3) Second hour: Accelerate at full throttle onto plane, then reduce engine speed to three- quarter throttle (approximately 4,000 r/min). Vary engine speed occasional- ly. Run at full throttle for one minute, then allow about 10 minutes of opera- tion at three-quarter throttle or less to let the engine cool.

4) Third through tenth hours: Avoid operating at full throttle for more than 5 minutes at a time. Let the engine cool between full-throttle runs. Vary engine speed occasionally.

For premix models

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 Gasoline and oil mixing in this chapter.

cC Make sure to mix gasoline (petrol) and oil

completely, otherwise your outboard

motor may be damaged.

6L2-9-1K-3 2/17/03 18:40 Page 14

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E

EMU01147

STARTING ENGINE

w 8 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.

8When the air vent screw is loosened,

gasoline (petrol) vapor will be released.

Gasoline (petrol) is highly flammable,

and its vapors are flammable and

explosive. Refrain from smoking, and

keep away from open flames and

sparks while loosening the air vent

screw.

8 This product emits exhaust gases

which contain carbon monoxide, a col-

orless, odorless gas which may cause

brain damage or death when inhaled.

Symptoms include nausea, dizziness,

and drowsiness. Keep cockpit and

cabin areas well ventilated. Avoid

blocking exhaust outlets.

Oil injection system models

5) After the first 10 hours: Operate the engine normally. Use only straight gasoline in the fuel tank. The oil injection system provides proper lubrication for normal opera- tion.

6L2-9-1K-3 2/17/03 18:40 Page 15

3-15

E

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

902053

25-3/30

304024*

001671

902061

25

N

406012

3) Squeeze the primer bulb with the out- let end up until you feel it become firm.

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

NOTE:

During engine operation place the tank horizontally, or fuel cannot be drawn into the engine.

EMU01497

PROCEDURE FOR TILLER CONTROL

MODEL

4) Place the gear-shift lever in the neu- tral position.

NOTE:

The start-in-gear protection device pre- vents the engine from starting except when in Neutral.

6L2-9-1K-3 2/17/03 18:40 Page 16

3-16

E

5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock plate on the other end of the lanyard in the engine stop switch.

w 8 Attach the engine stop switch lanyard

to a secure place on your clothing, your

arm or leg while operating.

8 Do not attach the lanyard to clothing

that could tear loose. Do not route the

lanyard where it could become entan-

gled, preventing it from functioning.

8 Avoid accidentally pulling the lanyard

during normal operation. Loss of

engine power means the loss of most

steering control. Also, without engine

power, the boat could slow rapidly.

This could cause people and objects in

the boat to be thrown forward.

6) Place the throttle control grip in the START position.

407016

308013*

25

25-3/30

503022

305022* 305023*

25 25-3/30 EMU00240

Manual Start Model

7) Pull out the choke knob completely. After the engine starts, return the knob to the original position.

NOTE:

8 It is not necessary to use the choke when restarting a warm engine. 8 If the choke knob is left pulled out after

the engine starts, the engine will stall.

6L2-9-1K-3 2/17/03 18:40 Page 17

3-17

E

8) Pull the starter handle slowly until you feel resistance. Then, give a strong pull straight out to crank and start the engine. Repeat it, if neces- sary.

9) After the engine starts, return the starter handle slowly to the original position before releasing it.

209015

503012

10) Return the throttle to the fully closed position.

6L2-9-1K-3 2/17/03 18:40 Page 18

3-18

E

309012

EMG00010

WARMING UP ENGINE

1) Before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (Failure to do this will shorten engine life.)

2) Check for a steady flow of water from the cooling-water pilot hole.

cC A continuous flow of water from the pilot

hole shows that the water pump is

pumping water through the cooling pas-

sages. If water is not flowing out of the

pilot hole at all times while the engine is

running, do not continue to run the

engine. Overheating and serious damage

could occur. Stop the engine and check

to see if the water inlet on the lower cas-

ing is blocked. If the problem cannot be

found and corrected, consult your Yama-

ha dealer.

6L2-9-1K-3 2/17/03 18:40 Page 19

3-19

E

EMU00261

SHIFTING

w Before shifting, make sure there are no

swimmers or obstacles in the water near

you.

cC To change the shifting position from for-

ward to reverse or vice-versa, close the

throttle first so that the engine idles (or

runs at low speeds).

406013

N

F

503012

2) Turn the gear shift lever quickly and firmly from Neutral to Forward.

EMU00263

FORWARD

1) Place the throttle control grip in the fully closed position.

6L2-9-1K-3 2/17/03 18:40 Page 20

3-20

E

EMU00268

REVERSE

w When operating in Reverse, go slowly. Do

not open the throttle more than half. Oth-

erwise, the boat may become unstable,

which could result in loss of control and

an accident.

406014

N

R

503012

402062* 402051*

25 25-3/30 2) Check that the tilt-lock lever (for Man-

ual tilt model) is in the locked posi- tion.

3) Turn the gear-shift lever quickly and firmly from Neutral to Reverse.

1) Place the throttle control grip in the fully closed position (for Tiller control model).

6L2-9-1K-3 2/17/03 18:40 Page 21

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E

EMG38010

STOPPING ENGINE

Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended.

407016*

308013

25

25-3/30

902052

EMU00277

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

2) If the fuel joints are provided, discon- nect the fuel line from the motor after stopping the engine.

3) Tighten the air vent screw on the fuel tank cap after stopping the engine, if it is equipped.

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

NOTE:

The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop lanyard switch (then turning the main switch to OFF).

6L2-9-1K-3 2/17/03 18:40 Page 22

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000910

q

EMU01412

TRIMMING OUTBOARD

MOTOR

The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The 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.

w Excessive trim for the operating condi-

tions (either trim up or trim down) can

cause boat instability and can make

steering the boat more difficult. This

increases the possibility of an accident. If

the boat begins to feel unstable or is hard

to steer, slow down and/or readjust the

trim angle.

NOTE:

Refer to the section ADJUSTING TRIM ANGLE for instructions on usage.

1 Trim operating angle

6L2-9-1K-3 2/17/03 18:40 Page 23

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001770

q

404015*

q

25

25-3/30

ADJUSTING TRIM ANGLE

EMU00951

Manual tilt model

There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim angle. 1) Stop the engine. 2) Remove the trim angle adjusting rod

1 from the clamp bracket while tilting the motor up slightly.

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 toward the transom. Make test runs with the trim set to differ- ent angles to find the position that works best for your boat and operating condi- tions.

w 8 Stop the engine before adjusting the

trim angle.

8 Use care to avoid being pinched when

removing or installing the rod.

8 Use caution when trying a trim position

for the first time. Increase speed gradu-

ally and watch for any signs of instabili-

ty 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 adjusting-rod one hole.

6L2-9-1K-3 2/17/03 18:40 Page 24

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E

001672

q

001673

w

001674

e

EMU19160

Trim angle settings and boat handling

When the boat is on plane, a bow-up atti- tude results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adjust- ed to help offset this effect.

1 Optimum angle (level keel line) 2 Bow up 3 Bow down

Bow Up

Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces performance further, and the boat may porpoise (hop in the water), which could throw the operator and passengers overboard.

Bow Down

When the bow of the boat is down, it is easier to accelerate from a standing start onto plane. Too much trim-in causes the boat to plow through the water, decreasing fuel economy and making it hard to increase speed. Operating 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 operation difficult and dangerous.

6L2-9-1K-3 2/17/03 18:40 Page 25

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E

NOTE:

Depending on the type of boat, the out- board motor trim angle may have little effect on the trim of the boat when oper- ating.

EMG70011

CRUISING IN SHALLOW

WATER

Manual tilt model

The outboard motor can be tilted up par- tially to allow operation in shallow water.

w 8 Place the gear shift in the Neutral posi-

tion before using the shallow water

cruising system.

8 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 engine to lift out of the

water, resulting in loss of control.

8 Use extra care when operating in

reverse. Too much reverse thrust can

cause the engine to lift out of the

water, increasing the chance of acci-

dent and personal injury.

8 Return the engine to its normal posi-

tion as soon as the boat is back in

deeper water.

cC Place the gear-shift in the Neutral posi-

tion before using the shallow water cruis-

ing system.

000832

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402061**

25 EMG71310

PROCEDURE

25

1) Place the gear shift lever in the neu- tral position.

2) Push the tilt lock lever down to release.

402072*

25-3/30

25

403023*

25

402075

EMG80511*

PROCEDURE

25-3/30

1) Push the shallow water lever down to the release position.

2) For setting the outboard motor at the partially tilted position, slightly tilt up the engine until the plate turns com- pletely

3) Pull up the shallow water lever. 4) Slightly tilt up the engine. The tilt-

support bar will lock automatically, supporting the engine in a partially raised position.

NOTE:

If the engine is tilted up completely, the tilt-lock lever automatically locks. The shallow water lever is no longer effective.

5) When lowering the engine, set the tilt- lock lever and shallow water lever to the lock position. Slightly tilt up the engine until the tilt-support bar auto- matically returns to the free position. Then, slowly lower the engine to the normal position.

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EMH10110

TILTING UP/DOWN

If the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion.

cC 8 Before tilting the motor, follow the pro-

cedures under STOPPING ENGINE.

Never tilt the motor while the engine is

running. Severe damage from over-

heating can result.

8 Do not tilt up the engine by pushing

the steering handle as this could break

the handle.

8 Keep the power unit higher than the

propeller at all times. Otherwise, water

can run into the cylinder, causing dam-

age.

w Be sure all people are clear of the out-

board motor when adjusting the tilt

angle, also be careful not to pinch any

body parts between the drive unit and

engine bracket.

105031

412022

25-3/30 3) To return the engine to the normal

position, put the engine in Neutral, then slightly tilt up the engine. Set the tilt-lock lever and shallow water lever to the lock position and slowly tilt the engine down.

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EMG63910

PROCEDURE FOR TILTING UP

25

1) Place the gear shift lever in Neutral. 2) Remove the fuel line connection from

the motor.

N

406012

402061**

402075*

3) Push the tilt lock lever to release.

4) Pull up the shallow water lever.

w Leaking fuel is a fire hazard. Disconnect

the fuel line if the engine will be tilted for

more than a few minutes. Otherwise, fuel

may leak. (If the fuel connector is provid-

ed on the motor.)

6L2-9-1K-3 2/17/03 18:40 Page 29

3-29

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402035

403024

402075*

EMG73410

PROCEDURE FOR TILTING DOWN

25

1) Return the shallow water lever. 2) Slightly tilt up the engine until the tilt

support bar is released automatically. 3) Tilt down the engine.

EMG63010*

PROCEDURE FOR TILTING UP

25-3/30

1) Remove the fuel-line connection from the motor. (If the fuel connector is provided on the motor.)

2) Place the tilt-lock lever in Release.

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

5) Hold the rear of the top cowling with one hand and fully tilt the engine up.

6) The tilt support bar turns to the locked position automatically.

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403036

EMH60010

CRUISING IN OTHER

CONDITIONS

CRUISING IN SALT WATER

After operating in salt water, wash out the cooling-water passages with fresh water to prevent them from becoming clogged- up with salt deposits. NOTE:

Refer to cooling system flushing instruc- tions in TRANSPORTING AND STORING OUTBOARD MOTOR.

CRUISING IN TURBID WATER

It is strongly recommended that the optional chromium-plated water-pump kit be installed if the outboard is to be used in turbid (muddy) water conditions.

EMG73210

PROCEDURE FOR TILTING DOWN

25-3/30

1) Return the tilt support lever tilting up the engine slightly.

2) Tilt down the engine.

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-MEMO-

6L2-9-1K-3 2/17/03 18:40 Page 32

EMK00010

Chapter 4

MAINTENANCE

SPECIFICATIONS .....................................4-1

TRANSPORTING AND STORING

OUTBOARD MOTOR ...............................4-2 Trailering outboard motor...................4-2 Storing outboard motor ......................4-3

PERIODIC MAINTENANCE......................4-7 Replacement parts ...............................4-7 Maintenance chart................................4-8 Cleaning and adjusting spark plug....4-9 Checking top cowling ........................4-10 Checking fuel system.........................4-11 Inspecting fuel filter ...........................4-12 Inspecting idling speed......................4-13 Checking water in engine oil tank ....4-14 Checking wiring and connectors ......4-15 Exhaust leakage..................................4-15 Water leakage .....................................4-15 Greasing ..............................................4-16 Checking propeller .............................4-18 Changing gear oil ...............................4-20 Cleaning fuel tank...............................4-21 Inspecting and replacing anode(s) ...4-22 Checking bolts and nuts ....................4-23 Motor exterior.....................................4-23 Coating the boat bottom ...................4-23

1

2

3

4

5

6

E

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EMK10011*

SPECIFICATIONS

Model Unit 25MHC

Item

25 (2.5, 18) 35 (3.5, 25)

8Spark plug Nm (kgfm, lbft) 8Propeller nut Nm (kgfm, lbft)

DIMENSIONS

PERFORMANCE

8Overall Length mm (in.) 8Overall Width mm (in.) 8Overall Height S mm (in.) 8Transom height S mm (in.) 8Weight S kg (lb.)

936 (369) 358 (14.1) 1,068 (42.0) 419 (16.5) 48.0 (105.8)

8Full throttle operating range r/min 8Maximum output kW (HP) 8Idling speed r/min

5,000~6,000 18.4 (25) at 5,500 r/min 700~800

ENGINE

8Type Number of cylinder Displacement cm3 (cu.in.) Bore stroke mm (in.) 8Ignition system 8Spark plug NGK

Spark plug gap mm (in.) 8Control system 8Starting system 8Alternator output V-A (W) 8Starting carburetion system

2-stroke, L 2 395 (24.1) 67 56 (2.6 2.2) C.D.I system B7HS-10 0.9~1.0 (0.035~0.039) Tiller control Manual start 12V-(80W) Choke start system

DRIVE UNIT

8Gear positions Gear ratio 8Trim/tilt system 8Propeller mark

Forward-Neutral-Reverse 2.08 (27/13) Manual F

FUEL AND OIL

TIGHTENING TORQUE

8Fuel

Fuel tank capacity L (US gal, Imp gal) 8Recommended engine oil

8Lubrication Engine oil capacity (engine oil tank) L (US qt, Imp qt) Fuel:oil ratio Fuel:Oil 8Recommended gearcase oil

Gear oil capacity cm3 (US oz, Imp oz)

Regular-unleaded gasoline (P.O.N.: minimum 86) 25 (6.6, 5.5) YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC-W3 certified outboard oil. Premix 100 : 1 Hypoid gear oil (SAE 90) 370 (12.5, 13.0)

6L2-9-1K-4 2/25/03 15:51 Page 2

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EMU01369*

TRANSPORTING AND

STORING

OUTBOARD MOTOR

w Leaking fuel is a fire hazard. When trans-

porting and storing the outboard motor,

close the air vent screw and fuel cock to

prevent fuel from leaking.

TRAILERING OUTBOARD MOTOR

The motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the motor in the tilt position using a motor support device such as a transom saver bar.

cC Do not use the tilt support lever/knob

when trailering the boat. The outboard

motor could shake loose from the tilt

support and fall. If the motor can not be

trailered in the down position, use an

additional support device to secure it in

the up position.

w 8 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 accidentally falls.

8 USE CARE when transporting fuel tank,

whether in a boat or car.

DO NOT fill fuel container to maximum

capacity.

Gasoline will expand considerably as it

warms up and can build up pressure in

the fuel container. This can cause fuel

leakage and a potential fire hazard.

000929

6L2-9-1K-4 2/25/03 15:51 Page 3

4-3

E

When transporting or storing the out- board motor while removed from a boat, fold the tiller handle and lean the motor on the tiller handle to keep in a horizontal position.

NOTE:

Place a towel or the like under the out- board motor to protect it from damage.

cC Keep the power unit higher than the pro-

peller at all times. Otherwise, cooling

water can run into the cylinder, which

could result in damage.

102013

EMU01785

STORING OUTBOARD MOTOR

25, 25-3

When storing your 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 out- board motor serviced by an authorized Yamaha dealer prior to storage. However, the following procedures can be per- formed by the owner with a minimum of tools.

cC 8 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

trouble.

8 Store the outboard motor in a dry,

well-ventilated place, not in direct sun-

light.

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EMK21010

Filling Fuel Tank

Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer (Part No. LUB-FUELC-12- 00) to each gallon of fuel.

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.

EMU01796

STORING OUTBOARD MOTOR

30

When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important pro- cedures must be performed to prevent excessive damage. This is especially important for your oil injection-equipped outboard motor due to the lean oil ratios used at idle prior to shutting the engine off for the season. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to stor- age. However, the following procedures can be performed by you, the owner, with a minimum of tools.

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EMK22211

Flushing Cooling System and Fogging

Engine

Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fog- ging of the engine is mandatory to pre- vent expensive engine damage due to rust. Perform the flushing and fogging at the same time. 1) Remove the cowling. 2) Install the outboard motor on the

water tank, and fill the tank with fresh water to above the level of the anti- cavitation plate.

1 Water surface 2 Lowest water level

cC If the fresh water level is below the level

of the anti-cavitation plate, or if the water

supply is insufficient, engine seizure may

occur.

w 8 Do not touch or remove electrical parts

when starting or during operation.

8 Keep hands, hair and clothes away

from flywheel and other rotating parts

while engine is running.

3) Run the engine at a fast idle for 10~15 minutes.

4) Just prior to turning off the engine, quickly spray Yamaha Stor-Rite Engine Fogging Oil (Part No. LUB- STRRT-12-00) alternately into carbu- retor. When properly done, the engine will smoke excessively and almost stall.

5) Turn off the engine and water supply.

605024

q

w

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EMK26111

Lubrication

1) Remove the spark plugs, and spray a 10 second spray of Yamaha Stor- Rite Engine Fogging Oil into each cylinder. Grease the spark plug threads and reinstall the spark plugs and torque to proper specification. (Refer to CLEANING AND ADJUST- ING SPARK PLUG.)

2) Turn the engine over with the stop lanyard disconnected to work the fog- ging oil into the piston rings.

3) Fill the oil tanks. This prevents the for- mation of condensation. For models with a remote tank, it may be neces- sary to manually override the control unit to completely fill the engine main tank. (Refer to TEMPORARY ACTION IN EMERGENCY).

4) Change the lower unit oil. (Refer to CHANGING GEAR OIL). Inspect the oil for the presence of water which indicates a leaky seal. Seal replace- ment should be performed by an authorized Yamaha dealership prior to use.

5) Grease all grease fittings. (Refer to GREASING)

EMK27011

Cleaning and Anti-corrosion Measure

1) Wash down the exterior of the out- board with fresh water and dry off completely.

2) Spray the engines exterior with Yamaha Silicone Protectant (Part No. LUB-SILCNE-13-00).

3) Wax the cowling with a non-abrasive wax such as Yamaha Silicone Wax (Part No. ACC-11000-15-02).

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EMK33011

REPLACEMENT PARTS

If replacement parts are necessary, use only genuine Yamaha parts or equiva- lents of the same type and of equivalent strength and materials. Any part of inferi- or quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from a Yamaha dealer.

EMU01569

PERIODIC MAINTENANCE

w Be sure to turn off the engine when you

perform maintenance unless otherwise

specified. If the owner is not familiar with

machine servicing, this work should be

done by a Yamaha dealer or other quali-

fied mechanic.

Maintenance, replacement, or repair of

the emission control devices and systems

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 a Yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform maintenance not covered by this owners manual.

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EMU19460

MAINTENANCE CHART

Frequency of maintenance operations may be adjusted according to the operating con- ditions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. The mark () indicates the check-ups which you may carry out yourself. The mark (1) indicates work to be carried out by your Yamaha dealer.

NOTE:

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

10 hours 50 hours 100 hours 200 hours (1 month) (3 months) (6 months) (1 year)

Spark plug(s) Cleaning / adjustment / replacement

Greasing points Greasing

Gear oil Change

Fuel system Inspection

Fuel filter (can be disassembled) Inspection / cleaning

Fuel tank (Yamaha portable tank) Inspection / cleaning

Idling speed (carburetor models) Inspection / adjustment /1 /1

Anode(s) (external) Inspection / replacement /1 /1 Anode(s) (internal) Inspection / replacement 1

Cooling water passages Cleaning

Propeller and cotter pin Inspection / replacement

Battery Inspection / charging /1 Throttle link / throttle cable / throttle pick-up timing Inspection / adjustment 1

Shift link / shift cable Inspection / adjustment 1

Oil tank water drain Inspection / cleaning /1 /1 /1 Oil pump Inspection / adjustment 1

Thermostat Inspection 1

Power trim and tilt unit Inspection 1

Water pump Inspection 1

Cowling clamp Inspection

ActionsItem Initial Every

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EMU01202

CLEANING AND ADJUSTING SPARK

PLUG

w 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.

The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center elec- trode 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 remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type.

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

Standard spark plug: Refer to SPECIFICATIONS, page 4-1.

Spark plug gap: Refer to SPECIFICATIONS, page 4-1.

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When fitting the plug, always clean the gasket 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 esti- mate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.

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

Spark plug torque: Refer to SPECIFICATIONS, page 4-1.

Initial of spark Plug-wrench size

plug I.D. mark

B 21 mm (13/16 in.)

C/BK 16 mm (5/8 in.)

D 18.3 mm (23/32 in.)

903022

qw

EMU16350

CHECKING TOP COWLING

Check the fitting of the top cowling by pushing it with both hands. If the fitting is loose have it repaired by a Yamaha dealer.

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EMK38010

CHECKING FUEL SYSTEM

w Gasoline (petrol) and its vapors are highly

flammable and explosive. Keep away

from sparks, cigarettes, flames or other

sources of ignition.

Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by Yama- ha dealer or other qualified mechanic.

Checking points

8 Fuel system parts leakage. 8 Fuel hose joint leakage. 8 Fuel hose cracks or other damage. 8 Fuel connector leakage.

w Leaking fuel can result in fire or explo-

sion.

8 Check for fuel leakage regularly.

8 If any fuel leakage is found, the fuel

system must be repaired by a qualified

mechanic. Improper repairs can make

the outboard unsafe to operate.

25

25-3/30

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EMU00370

INSPECTING FUEL FILTER

w Gasoline (petrol) is highly flammable, and

its vapors are flammable and explosive.

8 If you have any question about properly

doing this procedure, consult your

Yamaha dealer.

8 Do not perform this procedure on a hot

or running engine. Allow the engine to

cool.

8 There will be fuel in the fuel filter. Keep

away from sparks, cigarettes, flames or

other sources of ignition.

8 This procedure will allow some fuel to

spill. Catch fuel in a rag. Wipe up any

spilled fuel immediately.

8 The fuel filter must be reassembled

carefully with O-ring, filter cup, and

hoses in place. Improper assembly or

replacement can result in a fuel leak,

which could result in a fire or explosion

hazard.

000983

q

w

e r

EMU09782

1) Remove the nut holding the fuel filter assembly if equipped.

2) Unscrew the filter cup 1, catching any spilled fuel in a rag.

3) Remove the filter element 2, and wash it in solvent. Allow it to dry. Inspect the filter element and O-ring 3 to make sure they are in good con- dition. 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.

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 4.

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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.

EMU09912

INSPECTING IDLING SPEED

w 8 Do not touch or remove electrical parts

when starting or during operation.

8 Keep hands, hair and clothes away

from flywheel and other rotating parts

while engine is running.

cC This procedure must be performed while

the outboard motor is in the water. A

flushing attachment or test tank can also

be used.

A diagnostic tachometer should be used for this procedure. Results may vary depending on whether testing is conduct- ed 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 smoothly. If the outboard motor is mounted on a boat, be sure the boat is tightly moored.

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2) Verify whether the idle speed is set to specification. For idle speed specifica- tions, see Specifications in this chapter.

NOTE:

Correct idling speed inspection is only possible if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechan- ic.

q

w

EMU03782

CHECKING WATER IN ENGINE OIL

TANK

A translucent water drain hose is connect- ed from the bottom of the oil tank to the filler neck. If water or foreign matter col- lects in this hose, consult a Yamaha deal- er.

1 Drain hose 2 Filler neck side

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EMK78010

CHECKING WIRING AND

CONNECTORS

1) Check that each grounding wire is properly secured.

2) Check that each connector is engaged securely.

EXHAUST LEAKAGE

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

WATER LEAKAGE

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

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MU00366

GREASING

Yamaha marine grease (Water resistant grease)

25

103141b

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25-3/30

103141a

EMU00366

GREASING

Yamaha marine grease (Water resistant grease)

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EMU00388

CHECKING PROPELLER

w You could be seriously injured if the

engine accidentally starts while you are

near the propeller.

8 Before inspecting, removing or

installing the propeller, remove the

spark plug caps from the spark plugs.

Also, put the shift control in Neutral,

put the main switch in the OFF posi-

tion and remove the key, and remove

the lanyard from the engine stop

switch. Turn off the battery cut-off

switch if your boat has one.

8 Do not use your hand to hold the pro-

peller when loosening or tightening the

propeller nut. Put a wood block

between the cavitation plate and the

propeller to prevent the propeller from

turning.

210012

602052*

602051

602054

EMU00390

Propeller Checking Point

8 Check each of the propeller blades for wear, erosion from cavitation or ventila- tion, or other damage. 8 Check the splines for wear and damage. 8 Check for fish line winding around the

propeller shaft. 8 Check the propeller shaft oil seal for

damage.

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EMU00397

Installing the Propeller

cC 8 Be sure to install the thrust washer

before installing propeller, otherwise,

lower case and propeller boss may be

damaged.

8 Be sure to use a new cotter pin and

bend the ends over securely. Other-

wise, the propeller could come off dur-

ing operation and be lost.

1) Apply Yamaha Marine grease or Cor- rosion resistant grease to the pro- peller-shaft.

2) Install the thrust washer and propeller on the propeller-shaft.

3) Install the spacer and washer. Tighten the propeller nut to the specified torque.

4) Align the propeller nut with the pro- peller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.

NOTE:

If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, then tighten the nut fur- ther to align it with the hole.

EMU00976

Removing the Propeller

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

2) Remove the propeller nut 2, washer 3 and spacer 4.

3) Remove the propeller 5 and thrust washer 6.

000635

y

r

t

q

e w

Tightening torque: Refer to SPECIFICATIONS page 4-1.

602053

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000650 q

w

EMU01773

CHANGING GEAR OIL

w 8 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.

8 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 acci-

dentally falls.

1) Tilt the outboard motor so that the gear oil drain screw is at the lowest point possible.

2) Place a suitable container under the gear case.

3) Remove the gear oil drain screw 1. 4) Remove the oil level plug 2 to allow

the oil to drain completely.

cC Inspect the used oil after it has been

drained. If the oil is milky, water is get-

ting into the gear case which can cause

gear damage. Consult a Yamaha dealer

for repair of the lower unit seals.

cC Be sure to use a new cotter pin and bend

the ends over securely. Otherwise, the

propeller could come off during operation

and be lost.

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NOTE:

For disposal of used oil consult your Yamaha dealer.

5) With the outboard motor in a vertical position, and using a flexible or pres- surized filling device, inject the gear oil into the gear oil drain screw hole.

6) When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.

7) Insert and tighten the gear oil drain screw.

601022 Gear oil grade and capacity: See Specifications in this chapter.

EML22011

CLEANING FUEL TANK

w Gasoline (petrol) is highly flammable, and

its vapors are flammable and explosive.

8 If you have any question about properly

doing this procedure, consult your

Yamaha dealer.

8 Keep away from sparks, cigarettes,

flames or other sources of ignition

when cleaning the fuel tank.

8 Remove the fuel tank from the boat

before cleaning it. Work only outdoors

in an area with good ventilation.

8Wipe up any spilled fuel immediately.

8 Reassemble the fuel tank carefully.

Improper assembly can result in a fuel

leak, which could result in a fire or

explosion hazard.

8 Dispose of old gasoline (petrol)accord-

ing to local regulations.

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603023

902054

To clean the fuel tank

1) Empty the fuel tank into an approved gasoline (petrol) container.

2) Pour a small amount of suitable sol- vent in the tank. Reinstall the cap and shake the tank. Drain the solvent completely.

To clean the fuel filter

1) Remove the screws holding the fuel hose joint assembly . Pull the assem- bly out of the tank.

2) Clean the filter (located on the end of the suction pipe) in a suitable clean- ing solvent. Allow the filter to dry.

3) Replace the gasket with a new one. Reinstall the fuel hose joint assembly and tighten the screws firmly.

EMU14622

INSPECTING AND REPLACING

ANODE(S)

Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.

cC Do not paint anodes, as this would ren-

der them ineffective.

NOTE:

Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit.

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001183

102025

EMU00409

MOTOR EXTERIOR

EMU00410

Cleaning the Outboard Motor

After use, wash the exterior of the out- board with fresh water. Flush the cooling system with fresh water. NOTE:

Refer to Flushing Cooling System instruc- tions in TRANSPORTING AND STORING OUTBOARD MOTOR.

Checking Painted Surface of Motor

Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. Consult a Yamaha dealer for touch-up paint.

EML44010

COATING THE BOAT BOTTOM

A clean hull improves boat performance. The boat bottom should be kept as clean of marine growths as possible. If neces- sary, the boat bottom can be coated with an anti-fouling paint approved for 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.

CHECKING BOLTS AND NUTS

1) Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torques.

2) Check the tightening torques of other bolts and nuts.

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EMN00010

Chapter 5

TROUBLE RECOVERY

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

TEMPORARY ACTION IN

EMERGENCY ............................................5-5 Impact damage.....................................5-5 Starter will not operate ........................5-6 Treatment of submerged motor.........5-8

1

2

3

4

5

6

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EMU01204

TROUBLESHOOTING

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possi- ble remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.) If your outboard motor requires repair, bring it to a Yamaha dealer.

Trouble Possible Cause Remedy

A. Engine will not start (Starter operates).

1. Fuel tank empty. 2. Fuel contaminated or stale. 3. Fuel filter clogged. 4. Starting procedure incorrect.

5. Fuel pump malfunctions.

6. Spark plug(s) fouled or incorrect type.

7. Spark plug cap(s) fitted incorrectly. 8. Poor connections or damaged

ignition wiring.

9. Ignition parts faulty.

10. Engine stop switch lanyard not attached.

11. Engine inner parts damaged.

1. Fill tank with clean, fresh fuel. 2. Fill tank with clean, fresh fuel. 3. Clean or replace filter. 4. Read "STARTING ENGINE"

section. 5. Have serviced by a Yamaha

dealer. 6. Inspect spark plug(s). Clean or

replace with recommended type. 7. Check and re-fit cap(s). 8. Check wires for wear or breaks.

Tighten all loose connections. Replace worn or broken wires.

9. Have serviced by a Yamaha dealer.

10. Attach lanyard.

11. Have serviced by a Yamaha dealer.

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B. Engine idles irregularly or stalls.

Trouble Possible Cause Remedy

1. Spark plug(s) fouled or incorrect type.

2. Fuel system obstructed.

3. Fuel contaminated or stale. 4. Fuel filter clogged. 5. Failed ignition parts.

6. Warning system activated. 7. Spark plug gap incorrect. 8. Poor connections or damaged

ignition wiring.

9. Specified engine oil not used. 10. Thermostat faulty or clogged.

11. Carburetor adjustments incorrect.

12. Fuel pump damaged.

13. Air vent screw on the fuel tank closed.

14. Choke knob pulled out. 15. Motor angle too high.

16. Carburetor clogged.

17. Fuel joint connection incorrect. 18. Throttle valve adjustment incorrect.

1. Inspect spark plug(s). Clean or replace with recommended type.

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

3. Fill tank with clean, fresh fuel. 4. Clean or replace filter. 5. Have serviced by a Yamaha

dealer. 6. Find and correct cause of warning. 7. Inspect and adjust as specified. 8. Check wires for wear or breaks.

Tighten all loose connections. Replace worn or broken wires.

9. Check and replace oil as specified. 10. Have serviced by a Yamaha

dealer. 11. Have serviced by a Yamaha

dealer. 12. Have serviced by a Yamaha

dealer. 13. Open the air vent screw.

14. Return to home position. 15. Return to normal operating

position. 16. Have serviced by a Yamaha

dealer. 17. Connect correctly. 18. Have serviced by a Yamaha

dealer.

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C. Warning buzzer sounds or indicator lamp lights.

Trouble Possible Cause Remedy

1. Cooling system clogged. 2. Engine oil level low.

3. Heat range of spark plug incorrect.

4. Specified engine oil not used.

5. Engine oil contaminated or deteriorated.

6. Oil filter clogged.

7. Oil feed/injection pump malfunctions.

8. Load on boat improperly distributed.

9. Water pump/thermostat faulty.

1. Check water intake for restriction. 2. Fill oil tank with specified engine

oil. 3. Inspect spark plug and replace it

with recommended type. 4. Check and replace oil with

specified type. 5. Replace oil with fresh, specified

type. 6. Have serviced by a Yamaha

dealer. 7. Have serviced by a Yamaha

dealer. 8. Distribute load to place boat on an

even plane. 9. Have serviced by a Yamaha

dealer.

1. Propeller damaged.

2. Propeller pitch or diameter incorrect.

3. Trim angle incorrect.

4. Motor mounted at incorrect height on transom.

5. Warning system activated. 6. Boat bottom fouled with marine

growth. 7. Spark plug(s) fouled or incorrect

type. 8. Weeds or other foreign matter

tangled on gear housing. 9. Fuel system obstructed.

10. Fuel filter clogged. 11. Fuel contaminated or stale. 12. Spark plug gap incorrect.

1. Have propeller repaired or replaced.

2. Install correct propeller to operate outboard at its recommended speed (r/min) range.

3. Adjust trim angle to achieve most efficient operation.

4. Have motor adjusted to proper transom height.

5. Find and correct cause of warning. 6. Clean boat bottom.

7. Inspect spark plug(s). Clean or replace with recommended type.

8. Remove foreign matter and clean lower unit.

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

10. Clean or replace filter. 11. Fill tank with clean, fresh fuel. 12. Inspect and adjust as specified.

D. Engine power loss.

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Trouble Possible Cause Remedy

13. Poor connections or damaged ignition wiring.

14. Failed ignition parts.

15. Specified engine oil not used.

16. Thermostat faulty or clogged.

17. Air vent screw closed. 18. Fuel pump damaged.

19. Fuel joint connection incorrect. 20. Heat range of spark plug incorrect.

13. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.

14. Have serviced by a Yamaha dealer.

15. Check and replace oil with specified type.

16. Have serviced by a Yamaha dealer.

17. Open the air vent screw. 18. Have serviced by a Yamaha

dealer. 19. Connect correctly. 20. Inspect spark plug and replace it

with recommended type.

D. Engine power loss.

E. Engine vibrates excessively.

1. Propeller damaged.

2. Propeller shaft damaged.

3. Weeds or other foreign matter tangled on propeller.

4. Motor mounting bolt loose. 5. Steering pivot loose or damaged.

1. Have propeller repaired or replaced.

2. Have serviced by a Yamaha dealer.

3. Remove and clean propeller.

4. Tighten bolt. 5. Tighten or have serviced by a

Yamaha dealer.

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607011

EMN20010

TEMPORARY ACTION IN

EMERGENCY

EMU01492

IMPACT DAMAGE

w 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 any object in the water, follow the procedure below. 1) Stop the engine immediately. 2) Inspect the control system and all

components for damage. Also, inspect the boat for damage.

3) Whether damage is found or not, return to the nearest harbor slowly and carefully.

4) Have a Yamaha dealer inspect the outboard motor before operating it again.

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5-6

EMU00423

STARTER WILL NOT OPERATE

If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.

w 8 Use this procedure only in an emer-

gency and only to return to port for

repairs.

8When the emergency starter rope is

used to start the engine, the start-in-

gear protection device does not oper-

ate. Make sure the gear shift lever/

remote control lever is in neutral. Oth-

erwise, the boat could unexpectedly

start to move, which could result in an

accident.

8 Be sure no one is standing behind you

when pulling the starter rope. It could

whip behind you and injure someone.

8 An unguarded rotating flywheel is very

dangerous. Keep loose clothing and

other objects away when starting the

engine. Use the 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.

8 Do not touch the ignition coil, high

voltage wire, spark plug cap or other

electrical components when starting of

operating the motor. You could be

shocked.

E

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5-7

EMU00950

Emergency Starting Engine

1) Remove the top cowling.

2) Remove the start-in-gear protection cable from the starter if equipped it.

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

4) Prepare the engine for starting. See STARTING ENGINE for procedures. Be sure the engine is in Neutral and that the lock plate is attached to the engine stop lanyard switch. The main switch must be ON if equipped it.

5) Pull out the choke knob when a cold engine starts. After the engine start, return the choke knob.

6) Insert the knotted end of the emer- gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise.

7) Give a strong pull straight out to crank and start the engine. Repeat if necessary.

E

208025

ON STARTOFF

701024

6L2-9-1K-5 2/14/03 18:09 Page 8

5-8

EMN50011

TREATMENT OF SUBMERGED

MOTOR

If the outboard motor is submerged, immediately take it a Yamaha dealer. Oth- erwise, some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure bellow for taking care to minimize engine damage.

1) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.

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

3) Drain the fuel from the carburetor. 4) Feed fogging oil or engine oil through

the carburetors 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.

cC Do not attempt to run the motor until it

has been completely inspected.

E

107012

107013

107014

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-MEMO-

6L2-9-1K-5 2/14/03 18:09 Page 10

EMP00010

Chapter 6

INDEX

INDEX ........................................................6-1

1

2

3

4

5

6

E

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6-1

E

EMP10010

INDEX A

Adjusting trim angle..............................3-23 Air vent screw...........................................2-3 B

Basic boating rules ..................................1-6 Breaking in engine.................................3-12 C

Changing gear oil...................................4-20 Checking bolts and nuts........................4-23 Checking fuel system ............................4-11 Checking painted surface of motor......4-23 Checking propeller.................................4-18 Checking top cowling ............................4-11 Checking water in engine oil tank........4-14 Checking wiring and connectors..........4-15 Choke knob...............................................2-6 Clamping the outboard motor................3-4 Cleaning and adjusting spark plug ........4-9 Cleaning and anti-corrosion measure ...4-7 Cleaning fuel tank ..................................4-21 Cleaning the outboard motor ...............4-23 Coating the boat bottom.......................4-23 Cruising in salt water.............................3-30 Cruising in turbid water ........................3-30 Crusing in other conditions ..................3-30 Crusing in shallow water ......................3-25 E

Emergency starting engine.....................5-7 Emission control information.................1-2 Engine oil ................................................1-11 Engine stop button ..................................2-5 Engine stop lanyard switch.....................2-4 Exhaust leakage .....................................4-16 F

Filling fuel .................................................3-5 Filling fuel and engine oil........................3-5 Filling fuel tank.........................................4-4 Filling oil....................................................3-6

Flushing cooling system and fogging engine .........................................4-5 Forward...................................................3-19 Fuel hose joint ..........................................2-3 Fuel meter.................................................2-3 Fuel tank....................................................2-3 Fuel tank cap.............................................2-3 Fueling instructions ...............................1-10 G

Gasoline ..................................................1-11 Gasohol...................................................1-11 Gasoline (petrol) and oil mixing.............3-8 Gear shift lever.........................................2-3 Greasing..................................................4-16 I

Identificatiion numbers record ...............1-1 Impact damage ........................................5-5 Important labels .......................................1-5 Inspecting and replacing anode(s).......4-23 Inspecting fuel filter ...............................4-12 Inspecting idling speed .........................4-13 Installing the propeller ..........................4-19 Installation ................................................3-1 L

Lubrication................................................4-6 M

Main components....................................2-1 Maintenance chart ...................................4-8 Motor exterior ........................................4-23 Mounting height ......................................3-3 Mounting the outboard motor ...............3-2 O

Oil level warning system.......................2-13 Oil level warning/oil filter clogging warning...................................................2-12 Operation after a long period of storage ....................................................3-11 Operations of controls and other functions ...................................................2-3 Outboard motor serial number ..............1-1 Overheat warning ..................................2-11

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P

Periodic maintenance..............................4-7 Pre-operation checks .............................3-10 Propeller checking point .......................4-18 Propeller selection .................................4-11 R

Recoil starter handle................................2-6 Removing the propeller ........................4-19 Replacement parts...................................4-7 Reverse ...................................................3-20 S

Safety information...................................1-3 Shallow water lever.................................2-9 Shifting....................................................3-19 Specifications ...........................................4-1 Start-in-gear protection.........................1-13 Starter will not operate............................5-6 Starting engine.......................................3-14 Steering friction adjusting screw ...........2-7 Stopping engine.....................................3-21 Storing outboard motor ..........................4-3 T

Temporary action in emergency............5-5 Throttle control grip ................................2-5 Throttle friction adjusting screw/knob...2-6 Throttle indicator .....................................2-5 Tiller handle..............................................2-5 Tilt lock mechanism.................................2-9 Tilt support bar.......................................2-10 Tilt support lever....................................2-10 Tilting up/down......................................3-27 Top cowling lock lever ..........................2-10 Trailering outboard motor ......................4-2 Transporting and storing outboard motor.........................................................4-2 Treatment of submerged motor ............5-8 Trim angle adjusting rod.........................2-8 Trim angle settings and boat handling ..................................................3-24 Trim tab.....................................................2-8 Trimming outboard motor....................3-22

Troubleshooting.......................................5-1 W

Warming up engine...............................3-18 Warning system.....................................2-11 Warranty information ...........see next page Water leakage.........................................4-15

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EMU01599

IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND

CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is commit-

ted to exceptional customer satisfaction, and we want your ownership experience to be

a satisfying one. Please read the following warranty information to help ensure satisfac-

tion with your Yamaha.

Yamaha is ready to stand behind your purchase with strong warranty coverage. To be sure you receive all the benefits of warranty, please take the following steps:

1. Be sure your new Yamaha is registered for warranty. Your boat dealer should do this at the time of sale. Make sure your dealer gives you a copy of the completed Yamaha regis- tration card for your records. If you are unsure whether or not your Yamaha is registered, complete the Warranty Registration card found inside the cover of the Owner's Manual. Mail it to the distributor for the country in which you live (see step 6 for the correct address). If your Yamaha is not properly registered, a warranty repair could be unneces- sarily delayed while registration records are checked.

2. Read the Limited Warranty statement which follows these instructions. This warranty applies to Yamaha outboard motors sold in the United States, whether purchased sepa- rately or when supplied as original equipment by a boat builder. The terms also apply to original equipment packages sold in Canada, with coverage provided by Yamaha Motor Canada (see ``Warranty Guide'' for Canadian models). This warranty explains the condi- tions of the warranty, including the obligations that your dealer and you as the owner have under the warranty. For example, your Yamaha outboard must receive a proper pre-delivery inspection (PDI) by the selling dealer. Failure to take this important step could jeopardize warranty coverage!

3. If you need warranty repairs, you must take your Yamaha outboard to an authorized Yamaha outboard dealer. Be aware that not all selling boat dealers are authorized Yama- ha dealers. Only authorized dealers have the factory training, special tools, and Yamaha support needed to perform warranty repairs.

4. If you are away from home, or your selling dealer is not an authorized Yamaha dealer, use the following toll-free numbers to find the nearest Yamaha dealer.

United States Dealer Locations: 1-800-692-6242

Canada Dealer Locations: 1-800-267-8577

6L2-9-1K-6 2/25/03 15:52 Page 4

5. Your warranty applies specifically to repairs made in the country of purchase. If your U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian pur- chased Yamaha needs service while in the United States, Yamaha will assist the local dealer whenever possible. However, some products available in one country may not be sold or serviced in the other.

6. If you need any additional information about your Yamaha or warranty coverage which your dealer cannot provide, please contact us directly.

Yamaha Motor Corporation, U.S.A.

P.O. Box 6555

Cypress, CA 90630

Attention: Customer Relations Department

Telephone No. (714) 761-7439

Fax No. (714) 761-7559

Yamaha Motor Canada Ltd.

480 Gordon Baker Road

Toronto, Ontario

M2H 3B4

Attention: Customer Relations Department

Telephone No. (416) 498-1911

Fax No. (416) 491-3122

6L2-9-1K-6 2/25/03 15:52 Page 5

EMU00912*

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

Yamaha Motor Corporation, U.S.A. is proud of its heritage and reputation for producing products with high standards of quality and workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Outboard Limit- ed Warranty is your assurance of this commitment.

This warranty provides you with protection against the expense of repairs for your outboard motor that are required as a result of defects in materials or workmanship. When maintained and utilized in the prescribed manner, you can count on your Yamaha outboard to provide reliable service.

This warranty provides you with specific coverage and notes your responsibilities in maintaining and operating your outboard. Please take the time to read and become familiar with this warranty.

PERIOD OF WARRANTY. Any new Yamaha outboard motor purchased and registered with Yamaha Motor Corporation, U.S.A. for plea- sure use in the United States, will be warranted against defects in material or workmanship for a period of two (2) years from date of purchase, subject to exclusions noted herein. Any Yamaha outboard motor purchased and utilized for commercial applications will be warranted for a period of one (1) year from the date of purchase, subject to exclusions noted herein. Yamaha peripheral equipment included with the motor, such as gauges, fuel tanks and hoses, remote control boxes, propellers, and wiring external from the motor unit, will be warranted for one (1) year from the date of purchase for either pleasure or commercial use. Replacement parts used in war- ranty repairs will be warranted for the balance of the applicable warranty period.

The second year of warranty (if applicable) shall be limited to covering the cost of parts and labor for major components only. The major components covered are:

Power Unit Section

8 Power Head 8 Intake Manifold and Reed Valve Assembly 8 Carburetor Assembly and its Related Components 8 Fuel and Oil Pump Assemblies 8 Ignition System (Standard and Microcomputer) 8 Precision Blend System Bracket Section

8 Bracket System 8 Power Trim and Tilt Assembly Lower Unit Section

8 Exhaust System 8 Upper Casing 8 Lower Unit Assembly

The warranty described here applies to outboard motor purchased and registered for use in the United States only excluding its territo- ries. For warranty provisions outside the United States, contact the particular countrys local Yamaha distributor.

WARRANTY REGISTRATION. To be eligible for warranty coverage, the outboard motor must first be registered with Yamaha Motor Cor- poration, U.S.A. A warranty registration form is provided in the Owner`s Manual with each outboard. This form must be completed and mailed to Yamaha by either the selling dealer or the purchaser. Warranty registration can also be accomplished by any authorized Yamaha outboard dealer. Upon receipt of the registration, an Owner`s Warranty Card will be sent by Yamaha to the registered purchas- er.

OBTAINING REPAIRS UNDER WARRANTY. To receive repairs under this warranty, a valid Owner`s Warranty Card must be presented to an authorized Yamaha outboard dealer.

During the period of warranty, any authorized Yamaha outboard dealer will, free of charge, repair or replace, at Yamaha`s option, any parts adjudged defective by Yamaha due to faulty workmanship or material from the factory. All replaced parts will become the property of Yamaha Motor Corporation, U.S.A.

CUSTOMER`S RESPONSIBILITY. Under the terms of this warranty, the customer will be responsible for ensuring that the outboard motor is properly operated, maintained and stored as specified in the applicable Owners Manual.

The owner of the outboard motor shall give notice to an authorized Yamaha marine dealer of any and all apparent defects within ten (10) days of discovery and make the motor available at that time for inspection and repairs at the dealers place of business.

GENERAL EXCLUSIONS FROM WARRANTY. This warranty will not cover the repair of damage if the damage is a result of abuse or neglect of the product. Examples of abuse and neglect include, but are not limited to: 1. Racing or competition use, modification of original parts, abnormal strain. 2. Lack of proper maintenance and off-season storage as described in the Owner`s Manual, improper mounting of the motor, installa-

tion of parts or accessories that are not equivalent in design and quality to genuine Yamaha parts. 3. Operation of the motor at an rpm other than specified, improper propeller selection, use of lubricants, oils, and fuel/oil mixtures

that are not suitable for outboard motor use. 4. Damage as a result of accidents, collisions, contact with foreign materials, or submersion. 5. Growth of marine organisms on motor surfaces. 6. Normal deterioration.

6L2-9-1K-6 2/25/03 15:52 Page 6

SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs, shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes are not covered by warranty. Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yama- ha outboard dealer are excluded from warranty coverage.

Specific parts excluded from the second year of warranty (if applicable) are: 8 Top and Bottom Cowling 8 Electric Components (other than ignition system) 8 Rubber Components (such as hoses, tubes, rubber seals, fittings, and clamps)

TRANSFER OF WARRANTY. Transfer of the warranty from the original purchaser to any subsequent purchaser is possible by having the motor inspected by an authorized Yamaha outboard dealer and requesting the dealer to submit a change of registration to Yamaha Motor Corporation, U.S.A. within ten (10) days of the transfer.

EMISSION CONTROL SYSTEM WARRANTY. Yamaha warrants to the ultimate purchaser and each subsequent purchaser, that this engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act and this engine is free from defects in materials and workmanship which cause said engine to fail to conform with applicable regulations for one (1) year from date of purchase.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND

TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND

EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION

MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUEN-

TIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE

TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A.

Post Office Box 6555

Cypress, California 90630

WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty period? A. The customer`s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision dam-

ages.

Q. What are some examples of ``abnormal strain, neglect, or abuse? A. These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation, and/or tie down. If you have any specific questions on operation or mainte- nance, please contact your Yamaha outboard dealer for advice.

Q. Does the warranty cover incidental costs such as towing or transportation due to a failure? A. No. The warranty is limited to repair of the machine itself.

Q. May I perform any or all of the recommended maintenance shown in the Owners Manual instead of having the dealer do them? A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owners and Service Manuals. We do recommend,

however, that items requiring special tools or equipment be done by a Yamaha outboard dealer.

Q. Will the warranty be void or canceled if I do not operate or maintain my new outboard exactly as specified in the Owners Manual? A. No. The warranty on a new outboard cannot be voided`` or canceled``. However, if a particular failure is caused by operation or

maintenance other than as shown in the Owners Manual, that failure may not be covered under warranty.

Q. What responsibility does a Yamaha outboard dealer have under this warranty? A. Each Yamaha outboard dealer is expected to:

1. Completely set up each outboard he sells prior to delivery. 2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request

at any later date. In addition, each Yamaha outboard dealer is held responsible for his setup, service and warranty repair work.

Q. Is the warranty transferable to second owners? A. Yes. The remainder of any existing warranty can be transferred upon request. The unit has to be inspected and re-registered by an

authorized Yamaha outboard dealer for the policy to remain effective.

6L2-9-1K-6 2/25/03 15:52 Page 7

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT

P.O.Box 6555 Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A. dont forget to include any important information such as names, addresses, model, engine serial number, dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is complied from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new outboard, please advise us of your new address by sending a postcard listing your outboard model name, engine serial number, dealer number (or dealers name) as it is shown on your warranty identification, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A. WARRANTY DEPARTMENT

P.O.Box 6555 Cypress, California 90630

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

6L2-9-1K-6 2/25/03 15:52 Page 8

EMU01178

IMPORTANT WARRANTY INFORMATION

IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is com-

mitted to exceptional customer satisfaction, and we want your ownership experience

to be a satisfying one. Please read the following warranty information to help ensure

satisfaction with your Yamaha.

This model was manufactured as a U.S.A. specification model, and the warranty state- ment shown in this manual is for market. To receive the benefits of the warranty that applies to the country in which you use your Yamaha, please note the following infor- mation.

1. The warranty on this model is the same as equivalent models sold in the country where you will receive service. If you need more information about your warranty coverage or your Yamaha outside the U.S.A. or Canada, please contact an autho- rized Yamaha dealer in your country.

2. Keep a copy of your sales contract or invoice for the purchase of your Yamaha and present it if you need warranty repairs. This document should show the date of purchase, which is important evidence the repairing dealer will need to be sure your Yamaha is covered by warranty.

3. If your Yamaha needs warranty repairs, contact an authorized Yamaha dealer in the country where you are. He will explain how to get warranty service in that country.

4. This Yamaha model may not be sold in some countries. Therefore, in some cases your local dealer may not have all the parts or service information he may need, which may unavoidably delay repairs. If this happens, we thank you for your understanding and assure you we will attempt to resolve the situation as quickly as possible.

6L2-9-1K-6 2/25/03 15:52 Page 9

6L2-9-1K-6 2/25/03 15:52 Page 10

6L2-9-1K Hyoshi 2/14/03 17:25 Page 2

Printed in Japan March 2003-1.0 1 ! 6L2-28199-1K (25NMH) (E)

Printed on recycled paper

25C

OWNERS MANUAL

U.S.A.Edition LIT-18626-05-42

6L2-9-1K Hyoshi 2/14/03 17:25 Page 1

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 2/27/02 11:47 AM Page 1

Manualsnet FAQs

If you want to find out how the 25NMHL Yamaha works, you can view and download the Yamaha 25NMHL Owner's Manual on the Manualsnet website.

Yes, we have the Owner's Manual for Yamaha 25NMHL as well as other Yamaha manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Owner's Manual should include all the details that are needed to use a Yamaha 25NMHL. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Yamaha 25NMHL Owner's Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Yamaha 25NMHL Owner's Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Yamaha 25NMHL Owner's Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Yamaha 25NMHL Owner's Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the Yamaha 25NMHL Owner's Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.