EMU25110 Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important information is distinguished in the following OWNER’S MANUAL...
Table of contents General information ......1 Main switch ........18 Steering friction adjuster ....18 Identification numbers record..1 Steering friction adjuster ....19 Outboard motor serial number ..1 Power trim and tilt switch on remote Key number........1 control or tiller handle....
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Table of contents Manual start and electric start motor..........54 models .......... 35 Periodic maintenance ....54 Shifting .......... 35 Replacement parts ......54 Forward (tiller handle and remote Maintenance chart......56 control models) ......35 Maintenance chart (additional) ..57 Reverse (automatic reverse lock Greasing..........
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Table of contents YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY ........ 79 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ...... 81...
Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto- len. 1. Key number...
General information particular label. ZMU05159 ZMU04977 EMU25262 Manufactured date label 1. Star labels location This label is attached to the clamp bracket or the swivel bracket. EMU25280 One Star—Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 ex- haust emission standards.
General information the outboard should be equal to or less than the rated horsepower capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer. Do not modify the outboard. Modifications could make the motor unfit or unsafe to use.
If nec- essary, verify the necessary replacement procedure with the dealer. Never illegally discard (dump) the product. Yamaha recommends consulting the deal- er on discarding the product. ZMU05275 Be informed about boating safety. Additional...
General information EMU25401 EMU25473 Label Label EWM01260 ECM01191 WARNING CAUTION: Be sure shift control is in neutral before Transport and store the engine only as starting engine. (except 2HP) shown. Otherwise, engine damage could Do not touch or remove electrical parts result from leaking oil.
General information Stand-on vessel Overtaking: (you are passing or being The vessel with the right-of-way has the duty passed by another vessel) to continue its course and speed, except to In the following illustration, your boat is in the avoid an immediate collision. When you center.
General information risk of collision, the vessel which has the oth- If another vessel is around the bend, it too er on the starboard (right) side must keep out should sound the whistle. Even if no reply is of the way of the other. If the other vessel is heard, however, the vessel should still pro- on your right, you must keep out of its way;...
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General information ter into port, and black buoys are to port (left) side. When navigating out of port, your posi- tion with respect to the buoys should be re- versed; red buoys should be to port and black buoys to starboard. Many bodies of water used by boaters are entirely within the boundaries of a particular state.
General information ZMU01708 EMU25540 away from sparks, flames, or other Fueling instructions sources of ignition. EWM00010 Stop engine before refueling. WARNING Refuel in a well-ventilated area. Refuel GASOLINE AND ITS VAPORS ARE HIGH- portable fuel tanks off the boat. LY FLAMMABLE AND EXPLOSIVE! Take care not to spill gasoline.
10% and CAUTION: the fuel meets minimum octane ratings. All 4-stroke engines are shipped from the Yamaha does not recommended gasohol factory without engine oil. containing methanol because it can cause fuel system damage or engine performance...
Install an optional Rectifier Regulator or use accessories rated to withstand 18 volts or ZMU01710 higher with the above models. Consult your EMU25690 Yamaha dealer for details on installing an Battery requirement optional Rectifier Regulator. ECM01060 EMU25742 CAUTION:...
For instructions on propeller removal and in- stallation, see page 63. EMU25770 Start-in-gear protection Yamaha outboard motors or Yamaha-ap- proved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is in neutral. Always select neutral...
Basic components EMU25799 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. ZMU05026 1. Top cowling 15. Tiller handle* 2. Top cowling lock lever 16. Fuel tank 3.
Basic components its dedicated fuel reservoir and must not es are mounted on the remote control box. be used as a fuel storage container. Com- mercial users should conform to relevant licensing or approval authority regula- tions. 1. Power trim and tilt switch 2.
Basic components 4. Shift 5. Fully closed 6. Throttle 7. Fully open EMU26201 Neutral interlock trigger To shift out of neutral, first pull the neutral in- terlock trigger up. 1. Fully open 2. Fully closed EMU25911 Tiller handle To change direction, move the tiller handle to the left or right as necessary.
Basic components 1. Throttle indicator 1. Forward “ ” 2. Neutral “ ” EMU25971 3. Reverse “ ” Throttle friction adjuster A friction device provides adjustable resis- EMU25941 tance to movement of the throttle grip or the Throttle grip remote control lever, and can be set accord- The throttle grip is on the tiller handle.
Basic components NOTE: The engine cannot be started with the lock plate removed. ZMU03169 When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting. EMU25990 Engine stop lanyard switch 1. Lanyard 2. Lock plate The lock plate must be attached to the en- gine stop switch for the engine to run.
Basic components gine. When the key is released, it returns automatically to the “ ” (on) position. START EMU26070 ZMU03590 Manual starter handle To start the engine, first gently pull the han- dle out until resistance is felt. From that posi- tion, then pull the handle straight out quickly to crank the engine.
Basic components justing screw or bolt is located on the swivel bracket. ZMU02810 If the resistance does not increase even ZMU02908 when the lever is turned to the port side “A”, make sure that the nut is tightened to the To increase resistance, turn the adjuster specified torque.
Basic components cle. ZMU04038 NOTE: For instructions on using the power trim and tilt switch, see page 42. EMU26241 Trim tab with anode The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force.
Basic components ZMU02822 ZMU04040 EMU26372 1. Trim tab Top cowling lock lever(s) (turn type) 2. Bolt To remove the engine top cowling, turn the lock lever(s) and lift off the cowling. When in- EMU26312 Tilt lock mechanism stalling the cowling, check to be sure it fits The tilt lock mechanism is used to prevent properly in the rubber seal.
Basic components ZMU04578 ZMU04042 1. Flushing device 1. Tachometer 2. Warning indicator(s) EMU26302 Warning indicator EMU26491 Digital tachometer If the engine develops a condition which is The tachometer shows the engine speed cause for warning, the indicator lights up. For and has the following functions.
Basic components ous engine damage will occur. NOTE: The low oil pressure warning indicator The water separator and engine trouble does not indicate the engine oil level. warning indicators only operate when the en- Use the oil dipstick to check the re- gine is equipped with the appropriate func- maining oil quantity.
Basic components EMU26581 the trim angle to the desired setting with the Overheat warning indicator (digital power trim and tilt switch. type) EMU26620 If the engine temperature rises too high, the Trim meter (digital type) warning indicator will start to blink. For fur- This meter shows the trim angle of your out- ther information on reading the indicator, see board motor.
Warning system ECM00090 CAUTION: Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem can- not be located and corrected. EMU26816 Overheat warning This engine has an overheat warning device.
If the oil Activation of warning device level is correct and the warning device does The engine speed will automatically de- not switch off, consult your Yamaha dealer. crease to about 2000 r/min. ECM00100 If equipped with a low oil pressure warning CAUTION: indicator, it will light or blink.
Operation EMU26901 specific boat and motor combination. Installation EWM00830 ECM00110 WARNING CAUTION: Improper mounting of the outboard mo- Incorrect engine height or obstructions tor could result in hazardous conditions to smooth water flow (such as the design such as poor handling, loss of control, or or condition of the boat, or accessories fire hazards.
If any item in the preoperation check is mine the optimum mounting height. Con- not working properly, have it inspected sult your Yamaha dealer boat and repaired before operating the out- manufacturer for further information on de- board motor. Otherwise an accident termining the proper mounting height.
Operation line fumes. Check fuel line connections to be sure they are tight (if equipped Yamaha fuel tank or boat tank). Be sure the fuel tank is positioned on a se- cure, flat surface, and that the fuel line is...
While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free Fuel Addi- tive has repeatedly proven its ability to clean ZMU02022 combustion deposits from inside the engine,...
Operation connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank. ZMU02025 EMU27490 Starting engine ZMU04048 EMU27541 Starting engine Place the gear shift lever in neutral. ZMU02024 If a steering friction adjuster is provided on your outboard motor, securely attach...
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Operation lanyard where it could become entan- gled, preventing it from functioning. Avoid accidentally pulling the lanyard during normal operation. Loss of en- gine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
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Operation arm or leg. Then install the lock plate on the other end of the lanyard into the en- gine stop switch. EWM00120 WARNING Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating. Do not attach the lanyard to clothing that could tear loose.
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Operation during normal operation. Loss of en- NOTE: gine power means the loss of most When the engine is cold, it needs to be steering control. Also, without engine warmed up. For further information, see power, the boat could slow rapidly. This page 35.
Check the oil EMU27764 level and add oil if necessary. Consult Forward (tiller handle and remote your Yamaha dealer if the cause for the control models) low oil pressure warning indicator can- Tiller handle models not be found.
Operation ZMU03406 Move the gear shift lever quickly and EMU27785 Reverse (automatic reverse lock and firmly from neutral to forward. power trim and tilt models) EWM00190 WARNING When operating in reverse, go slowly. Do not open the throttle more than half. Oth- erwise the boat could become unstable, which could result in loss of control and an accident.
Operation not open the throttle more than half. Oth- erwise the boat could become unstable, which could result in loss of control and an accident. Tiller handle models Place the throttle grip in the fully closed position. Remote control models Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to...
Operation ZMU03627 Remote control models EMU27820 Stopping engine Check that the tilt lock lever is in the lock Before stopping the engine, first let it cool off position. for a few minutes at idle or low speed. Stop- ping the engine immediately after operating at high speed is not recommended.
Operation the engine stop switch, then turning the main switch to “ ” (off). EMU27861 Trimming outboard motor The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help im- prove performance and fuel economy while reducing strain on the engine.
Operation switch while the boat is moving. Adjust the outboard motor trim angle using the power trim and tilt switch. 1. Power trim and tilt switch ZMU04059 1. Trim operating angle EMU27882 Adjusting trim angle Power trim and tilt models ZMU04060 EWM00751 WARNING...
Operation “ ” (up). To raise the bow (“trim-out”), tilt the engine To lower the bow (trim-in), press the switch “ ” (down). To lower the bow (“trim-in”), tilt the engine Make test runs with the trim set to different down.
Operation salt corrosion. EWM00220 WARNING Be sure all people are clear of the out- board motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket. EWM00250 WARNING Bow Down Leaking fuel is a fire hazard.
Operation ZMU04065 Disconnect the fuel line from the out- EMU28007 Procedure for tilting up (power trim board motor. and tilt models / power tilt models) Place the remote control lever / gear shift lever in neutral. ZMU04063 Place the tilt lock lever in the release po- sition.
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Operation ZMU04066 Push the tilt support knob into the clamp Press the power trim and tilt switch / bracket or pull the tilt support lever to- power tilt switch “ ” (up) until the out- ward you to support the engine. board motor has tilted up completely.
Operation from marine growth and corrosion which could damage the power trim and tilt mechanism. EMU28041 Procedure for tilting down (manual and hydro tilt models) Release the tilt lock lever. ZMU04071 EMU28055 Procedure for tilting down (power trim and tilt models / power tilt models) Push the power trim and tilt switch / pow- er tilt switch “...
Operation ing the shallow water cruising system. Run the boat at the lowest possible speed when using the shallow water cruising system. Use extra care when operating in re- verse. Too much reverse thrust can cause the outboard motor to lift out of the water, increasing the chance of ac- cident and personal injury.
Operation ZMU03087 ZMU04076 EMU28090 Power trim and tilt models / power tilt models The outboard motor can be tilted up partially to allow operation in shallow water. EWM00660 WARNING Place the gear shift in neutral before setting up for shallow water cruising. Return the outboard motor to its normal position as soon as the boat is back in Pull the tilt lock lever up to the release...
For cooling system flushing instructions, see page 50. Cruising in turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (not available for some models) if you use the outboard motor in turbid or muddy water...
Maintenance EMU31480 Displacement: Specifications 747.0 cm (45.58 cu.in) Bore × stroke: NOTE: 65.0 × 75.0 mm (2.56 × 2.95 in) “(AL)” stated in the specification data below Ignition system: represents the numerical value for the alumi- num propeller installed. Spark plug with resistor (NGK): Likewise, “(SUS)”...
18.0 Nm (13.3 ft-lb) (1.84 kgf-m) sition using a motor support device such as Engine oil filter: a transom saver bar. Consult your Yamaha 18.0 Nm (13.3 ft-lb) (1.84 kgf-m) dealer for further details. EMU28222...
12-00) to each gallon of fuel. the engine oil. NOTE: Do not place the outboard motor on its The use of “Yamaha Fuel Conditioner and side before the cooling water has Stabilizer” eliminates the need to drain the drained from it completely, otherwise fuel system.
Seal replacement should be performed occur. by an authorized Yamaha dealer prior to use. Cooling system flushing is essential to Grease all grease fittings. For further de- prevent the cooling system from clog- tails, see page 58.
Maintenance dling or working near batteries. EMU28442 Flushing power unit Antidote (EXTERNAL): Perform this procedure right after operation SKIN - Flush with water. for the most thorough flushing. EYES - Flush with water for 15 minutes ECM01530 and get immediate medical attention. CAUTION: Antidote (INTERNAL): Do not perform this procedure while the...
If you or the owner is not famil- ting after flushing the engine. iar with machine servicing, this work should be done by your Yamaha dealer or NOTE: other qualified mechanic. When flushing the engine with the boat in...
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Maintenance Yamaha genuine parts and accessories are available from your Yamaha dealer.
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer. Initial Every 50 hours Item...
Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) ZMU04081 attempt to diagnose any problems yourself. EMU28952 Cleaning and adjusting spark plug Instead, take the outboard motor to a EWM00560 Yamaha dealer. You should periodically re- WARNING move and inspect the spark plug because...
Check the fuel lines for leaks, crack, or mal- 1. Spark plug gap function. If a problem is found, your Yamaha 2. Spark plug I.D. mark (NGK) dealer or other qualified mechanic should re- pair it immediately.
Yamaha dealer. quires adjustment, consult a Yamaha dealer or other qualified mechanic. Verify whether the idle speed is set to specification. For idle speed specifica- tions, see page 49.
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Con- install the drain screw. tinued operation with a problem could cause severe engine damage. Consult Drain screw tightening torque: your Yamaha dealer if the problem can- 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)
Check for oil leaks on the around the engine. For more information on the disposal of NOTE: used oil, consult your Yamaha dealer. If any leaks are found, consult your Yamaha Change the oil more often when operating dealer. the engine under adverse conditions such as extended trolling.
Tilt the outboard motor down. Check that the trim and tilt rod / the tilt rod oper- ates smoothly. NOTE: Consult your Yamaha dealer if any operation is abnormal. ZMU01897 EMU29171 Checking propeller...
The propeller will then eration and be lost. spin freely on the shaft. If this happens, the shear pin must be replaced. Apply Yamaha marine grease or a cor- rosion resistant grease to the propeller EMU30660 Removing the propeller shaft.
Work only outdoors in Inspecting and replacing anode(s) an area with good ventilation. Yamaha outboard motors are protected from Wipe up any spilled fuel immediately. corrosion by sacrificial anodes. Inspect the Reassemble the fuel tank carefully. Im- external anodes periodically.
Maintenance followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries also generate explosive hydro- gen gas; therefore, you should always follow these preventive measures: Charge batteries in a well-ventilated ar- Keep batteries away from fire, sparks, ZMU02820 or open flames (for example: welding equipment, lighted cigarettes, and so...
NOTE: Consult a Yamaha dealer when charging or 1. Red cable re-charging batteries. 2. Black cable 3.
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Maintenance marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion. ZMU01943...
Q. Has fuel pump malfunctioned? If your outboard motor requires repair, bring A. Have serviced by a Yamaha dealer. it to your Yamaha dealer. If the engine trouble warning indicator is Q. Are spark plug(s) fouled or of incorrect flashing, consult your Yamaha dealer.
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Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Is fuel joint connection incorrect? A.
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Trouble Recovery A. Have serviced by a Yamaha dealer. Q. Are weeds or other foreign matter tangled on gear housing? Q. Is load on boat improperly distributed? A. Remove foreign matter and clean lower A. Distribute load to place boat on an even unit.
(if equipped). Replace it with a spare one of the proper amperage. Q. Is steering pivot loose or damaged? EWM00630 A. Tighten or have serviced by a Yamaha WARNING dealer. Be sure to use the specified fuse. An in-...
Trouble Recovery ZMU04094 ZMU04095 1. Fuse box 1. Manual valve screw 2. Fuse (20 A) Put the engine in the desired position, 3. Spare fuse (20 A) 4. Fuse puller then tighten the manual valve screw by turning it counterclockwise. EMU29532 Starter will not operate If the starter mechanism does not operate...
Trouble Recovery preventing it from functioning. Remove the starter/flywheel cover after Avoid accidentally pulling the lanyard removing the bolt(s). during normal operation. Loss of en- gine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
Trouble Recovery EMU29760 Treatment of submerged motor If the outboard motor is submerged, immedi- ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi- ately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the proce- dure below in order to minimize engine dam- age.
Consumer information EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA...
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Printed in Japan April 2006–0.6 × 1 ! Printed on recycled paper...
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(A l’usage du concessionnaire) MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation) YAMAHA DEALER NUMBER NO. DU CONCESSIONNAIRE YAMAHA DEALER NAME YAMAHA MOTOR CO., LTD. NOM DU MADE IN JAPAN CONCESSIONNAIRE PAYS D'ORIGINE JAPON USAGE...
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PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT...