Yamaha 25C Owner's Manual
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Yamaha 25C Owner's Manual

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25C
OWNER'S MANUAL
U.S.A.Edition
LIT-18626-05-42

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Summary of Contents for Yamaha 25C

  • Page 1 OWNER’S MANUAL U.S.A.Edition LIT-18626-05-42...
  • Page 3 EMU14480 TO THE OWNER Thank you for choosing a Yamaha out- board motor. This Owner’s manual con- A CAUTION indicates special precautions tains information needed for proper oper- that must be taken to avoid damage to ation, maintenance and care. A thorough the outboard motor.

  • Page 4: Table Of Contents

    EMA20010 CONTENTS GENERAL INFORMATION BASIC COMPONENTS OPERATION MAINTENANCE TROUBLE RECOVERY INDEX READ THIS OWNER’S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR.

  • Page 5: General Information

    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...

  • Page 6: Identification Numbers Record

    Record your outboard motor serial num- 401012 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...

  • Page 7: Emission Control Information

    EMU01385 EMISSION CONTROL INFORMATION EMU01386 NORTH AMERICAN MODELS This engine conforms to U.S. Environ- mental Protection Agency (EPA) regula- 108021 tions for marine SI engines. See the label affixed to your engine for details. 25-3/30 Approval label of Emission control certificate This label is attached to the bottom cowl- ing.

  • Page 8: Safety Information

    8 This product emits exhaust gases which EMU00917 SAFETY contain carbon monoxide, a colorless, INFORMATION odorless gas which may cause brain damage or death when inhaled. Symp- toms include nausea, dizziness, and 8 Before mounting or operating the out- drowsiness. Keep cockpit and cabin board motor, read this entire manual.
  • Page 9 8 When 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...

  • Page 10: Important Labels

    LOCATION EMB30010 IMPORTANT LABELS WARNING LABELS WARNING G Be sure shift control is in neutral before starting engine. (except 2HP) G Do not touch or remove electrical parts when starting or during operation. 202023 G Keep hands,hair,and clothes away from flywheel and other rotating parts while engine is running.

  • Page 11: Basic Boating Rules

    EMB40010 Stand-on vessel BASIC BOATING RULES The vessel with the right-of-way has the duty to continue its course and speed, (Rules of the road) except to avoid an immediate collision. When you maintain your direction and Just as there are rules which apply when speed, the other vessel will be able to you are driving on streets and high ways, determine how best to avoid you.
  • Page 12 RULES WHEN ENCOUNTERING side. This rule doesn’t apply if both of you will clear one another if you continue on VESSELS your set course and speed. 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)
  • Page 13 the other vessel is expected to maintain Sailing vessel right-of-way its course and speed. You must stay out Sailing vessels should normally be given of its way until you are clear of it. Like- the right-of-way. The exceptions to this wise, if another vessel is passing you, you are: should maintain your speed and direction...
  • Page 14 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. MAIN CHANNEL BUOYS "...

  • Page 15: Fueling Instructions

    EMU00016 FUELING INSTRUCTIONS 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.

  • Page 16: Gasoline

    EMU01804 GASOLINE Recommended gasoline: Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2 If knocking or pinging occurs, use a differ- ent brand of gasoline or premium unlead- ed fuel. EMU00027 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol.

  • Page 17: Propeller Selection

    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.

  • Page 18: Start-In-Gear Protection

    3 Type of propeller (propeller mark) Refer to the section “CHECKING PRO- PELLER” for instructions on propeller 602016 removal and installation. EMU01209 START-IN-GEAR PROTECTION Yamaha outboard motors or Yamaha approved remote control units equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is Neutral.

  • Page 19: Basic Components

    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...

  • Page 20: Main Components

    EMU01206 MAIN COMPONENTS 101061 1 Recoil starter handle e Trim angle adjusting-rod 2 Choke knob r Rope attachment 3 Warning lamp t Shallow water lever 4 Gear shift lever y Fuel tank 5 Throttle-control grip/Tiller-handle * May not be exactly as shown; also may 6 Engine stop button/ not be included as standard equipment on Engine stop lanyard switch...
  • Page 21 EMU01206 MAIN COMPONENTS 25-3/30 1 Recoil starter handle e Tilt support lever 2 Gear shift lever r Rope attachment 3 Tiller handle t Top cowling 4 Tilt lock lever y Choke knob 5 Shallow water lever u Engine stop button/engine stop lanyard 6 Transom clamp handle switch 7 Trim angle adjusting rod...

  • Page 22: Operations Of Controls And Other Functions

    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.

  • Page 23: Engine Stop Lanyard Switch

    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 operator’s clothing, or arm or leg.

  • Page 24: Engine Stop Button

    EMC27011 25-3/30 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.

  • Page 25: Choke Knob

    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. 502011 Resistance Knob/Screw Increase Turn clockwise...

  • Page 26: Steering Friction Adjusting Screw

    EMD00011 STEERING FRICTION ADJUSTING SCREW(for Tiller control model) A friction device provides resistance to steering movement. This is adjustable for operator preference. adjusting screw/bolt is located on the swivel brack- EMD00310* 408015 Adjustment Resistance Screw/bolt Increased Turn clockwise Decreased Turn counterclockwise overtighten friction screw/bolt.

  • Page 27: Trim Tab

    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. An improperly adjusted trim tab may 603011 cause difficult steering. Always test run after the trim tab has been installed or replaced to be sure steering is correct.

  • Page 28: Shallow Water Lever

    EMD08010 SHALLOW WATER LEVER (If equipped) Lifting this lever will tilt the motor up par- tially to provide more clearance when operating in shallow water. 402075* EMD08110 25-3/30 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.

  • Page 29: Tilt Support Bar

    EMU00156 TILT SUPPORT BAR The tilt support bar 1 keeps the outboard motor in the tilted up position. 403023 EMD60210 25-3/30 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.

  • Page 30: Warning System

    EMD80010 WARNING SYSTEM 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. EMU00170 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate.

  • Page 31: Oil Level Warning / Oil Filter Clogging Warning

    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. ); Included ( ); N/A — Warning device Tiller Remote activation control control...

  • Page 32: Oil Level Warning System

    Oil level warning system The various oil-level warning system functions are as follows: Oil level warning indicator lamp Engine oil tank Remarks (Bottom cowling) more than 200 cm (0.21 US qt, No refilling necessary. 0.181 Imp qt) 200 cm or less (0.21 US qt, 0.181 Buzzer sounds in remote control Imp qt) box and engine speed is limited...

  • Page 33: Operation

    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...

  • Page 34: Installation

    EMF10010 INSTALLATION 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.

  • Page 35: Mounting The Outboard Motor

    EMU00176 MOUNTING THE OUTBOARD MOTOR 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 possible provide complete...
  • Page 36 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.

  • Page 37: Clamping The Outboard Motor

    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 409011 to engine vibration.

  • Page 38: Filling Fuel And Engine Oil

    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. 902055 Wipe up any spilled fuel. Fuel tank capacity: Refer to SPECIFICATIONS on Page 4-1. Ring Free Fuel Additive Gasoline is a precise blend of many differ- ent substances, each chosen to give cer-...

  • Page 39: Filling Oil

    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.
  • Page 40 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. 203012* 1 Engine oil tank 2 Oil tank filler cap...

  • Page 41: Gasoline (Petrol) And Oil Mixing

    EMF35011 GASOLINE (PETROL) AND OIL MIXING Pre-mix model Engine oil : Gasoline (Petrol) Break-in period 1 : 25 After break-in 1 : 100 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.
  • Page 42 Mixing ratio 25 : 1 12 L 14 L 24 L Gasoline (Petrol) (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) 0.04 L 0.48 L 0.56 L 0.96 L Engine oil...

  • Page 43: Pre-Operation Checks

    MU00204 PRE-OPERATION CHECKS 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. Do not start the engine out of water. Overheating and serious engine damage can occur.

  • Page 44: Operation After A Long Period Of Storage

    If no oil is flowing after 10 minutes of idling, consult your Yamaha dealer. Be sure to take the above steps when operating the engine after a long period of storage.

  • Page 45: Breaking In Engine

    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. 8 Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage.
  • Page 46 Make sure to mix gasoline (petrol) and oil completely, otherwise your outboard motor may be damaged. 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.

  • Page 47: Starting Engine

    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. EMU01147 STARTING ENGINE 8 Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions.
  • Page 48 1) If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns. 902053 2) If there is a fuel joint on the motor, 25-3/30 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.
  • Page 49 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. 8 Attach the engine stop switch lanyard to a secure place on your clothing, your 407016 arm or leg while operating.
  • Page 50 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.

  • Page 51: Warming Up Engine

    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. A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling pas-...

  • Page 52: Shifting

    EMU00261 SHIFTING Before shifting, make sure there are no swimmers or obstacles in the water near you. 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). EMU00263 FORWARD 1) Place the throttle control grip in the...

  • Page 53: Reverse

    EMU00268 REVERSE 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. 1) Place the throttle control grip in the fully closed position (for Tiller control model).

  • Page 54: Stopping Engine

    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* EMU00277 25-3/30 1) Push and hold the engine stop button or turn the main switch to “OFF”.

  • Page 55: Trimming Outboard Motor

    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.

  • Page 56: Adjusting Trim Angle

    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 001770 1 from the clamp bracket while tilting the motor up slightly.
  • Page 57 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.

  • Page 58: Cruising In Shallow Water

    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.
  • Page 59 EMG71310 PROCEDURE 1) Place the gear shift lever in the neu- tral position. 2) Push the tilt lock lever down to release. 402061** 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.

  • Page 60: Tilting Up/Down

    3) To return the engine to the normal 25-3/30 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. 412022 EMH10110 TILTING UP/DOWN If the engine will be stopped for some...
  • Page 61 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.) EMG63910 PROCEDURE FOR TILTING UP 1) Place the gear shift lever in Neutral.
  • Page 62 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. EMG63010* PROCEDURE FOR TILTING UP 25-3/30 1) Remove the fuel-line connection from the motor.

  • Page 63: Cruising In Other 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. 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.
  • Page 64 -MEMO-...

  • Page 65: Maintenance

    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...

  • Page 66: Specifications

    EMK10011* SPECIFICATIONS Model Unit 25MHC Item DIMENSIONS 8Overall Length mm (in.) 936 (369) 8Overall Width mm (in.) 358 (14.1) 8Overall Height mm (in.) 1,068 (42.0) 8Transom height mm (in.) 419 (16.5) 8Weight kg (lb.) 48.0 (105.8) PERFORMANCE 8Full throttle operating range r/min 5,000~6,000 8Maximum output...

  • Page 67: Transporting And Storing Outboard Motor

    EMU01369* TRANSPORTING AND STORING OUTBOARD MOTOR Leaking fuel is a fire hazard. When trans- porting and storing the outboard motor, close the air vent screw and fuel cock to 000929 prevent fuel from leaking. TRAILERING OUTBOARD MOTOR The motor should be trailered and stored in the normal running position.

  • Page 68: Storing Outboard Motor

    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.
  • Page 69 “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...
  • Page 70 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...
  • Page 71 EMK26111 Lubrication 1) Remove the spark plugs, and spray a 10 second spray of “Yamaha Stor- Rite Engine Fogging Oil” into each cylinder. Grease spark plug threads and reinstall the spark plugs and torque to proper specification. (Refer to “CLEANING AND ADJUST- ING SPARK PLUG”.)

  • Page 72: Periodic Maintenance

    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.

  • Page 73: Maintenance Chart

    Refer to the sections in this chapter for explanations of each owner-specific action. The mark (G) indicates the check-ups which you may carry out yourself. The mark (1) indicates work to be carried out by your Yamaha dealer. Initial Every...

  • Page 74: Cleaning And Adjusting Spark Plug

    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.

  • Page 75: Checking Top Cowling

    1 Spark plug gap 2 Spark plug I.D. mark (NGK) 903022 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. 4-10...

  • Page 76: Checking Fuel System

    EMK38010 CHECKING FUEL SYSTEM 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- 25-3/30 ha dealer or other qualified mechanic.

  • Page 77: Inspecting Fuel Filter

    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.

  • Page 78: Inspecting Idling Speed

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

  • Page 79: 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- 1 Drain hose 2 Filler neck side...

  • Page 80: Checking Wiring And Connectors

    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.

  • Page 81: Greasing

    MU00366 GREASING Yamaha marine grease (Water resistant grease) 103141b 4-16...
  • Page 82 EMU00366 GREASING Yamaha marine grease (Water resistant grease) 25-3/30 103141a 4-17...

  • Page 83: Checking Propeller

    EMU00388 CHECKING PROPELLER You could be seriously injured if the engine accidentally starts while you are near the propeller. 8 Before inspecting, removing installing the propeller, remove the 210012 spark plug caps from the spark plugs. Also, put the shift control in Neutral, put the main switch in the “OFF”...
  • Page 84 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.

  • Page 85: Changing Gear Oil

    000650 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. 4-20...

  • Page 86: Cleaning Fuel Tank

    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. 601022 Gear oil grade and capacity: See “Specifications”...

  • Page 87: 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. 603023 Do not paint anodes, as this would ren- der them ineffective.

  • Page 88: Checking Bolts And Nuts

    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.

  • Page 89: Trouble Recovery

    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...

  • Page 90: 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.
  • Page 91 3. Fill tank with clean, fresh fuel. 4. Fuel filter clogged. 4. Clean or replace filter. 5. Failed ignition parts. 5. Have serviced by a Yamaha dealer. 6. Warning system activated. 6. Find and correct cause of warning. 7. Spark plug gap incorrect.
  • Page 92 5. Engine oil contaminated or 5. Replace oil with fresh, specified sounds or deteriorated. type. indicator lamp 6. Oil filter clogged. 6. Have serviced by a Yamaha lights. dealer. 7. Oil feed/injection pump 7. Have serviced by a Yamaha malfunctions. dealer.
  • Page 93 13. Check wires for wear or breaks. ignition wiring. Tighten all loose connections. Replace worn or broken wires. 14. Failed ignition parts. 14. Have serviced by a Yamaha dealer. 15. Specified engine oil not used. 15. Check and replace oil with specified type.

  • Page 94: Temporary Action In Emergency

    2) Inspect the control system and all components damage. Also, inspect the boat for damage. 607011 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.

  • Page 95: Starter Will Not Operate

    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. 8 Use this procedure only in an emer- gency and only to return to port for repairs.
  • Page 96 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). 208025 4) Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in Neutral and ON START that the lock plate is attached to the...

  • Page 97: Treatment Of Submerged Motor

    5) Take the outboard motor to a Yamaha dealer as soon as possible. Do not attempt to run the motor until it has been completely inspected.
  • Page 98 -MEMO-...

  • Page 99: Index

    EMP00010 Chapter 6 INDEX INDEX............6-1...
  • Page 100 EMP10010 Flushing cooling system and INDEX fogging engine .........4-5 Forward...........3-19 Fuel hose joint ..........2-3 Adjusting trim angle......3-23 Air vent screw...........2-3 Fuel meter..........2-3 Fuel tank............2-3 Fuel tank cap..........2-3 Basic boating rules ........1-6 Breaking in engine .........3-12 Fueling instructions .......1-10 Gasoline ..........1-11 Changing gear oil........4-20 Checking bolts and nuts......4-23 Gasohol...........1-11...
  • Page 101 Troubleshooting........5-1 Periodic maintenance......4-7 Pre-operation checks ......3-10 Warming up engine.......3-18 Propeller checking point .......4-18 Warning system ........2-11 Propeller selection .........4-11 Warranty information ...see next page Water leakage.........4-15 Recoil starter handle........2-6 Removing the propeller ......4-19 Replacement parts ........4-7 Reverse ...........3-20 Safety information ........1-3 Shallow water lever .........2-9 Shifting............3-19 Specifications ...........4-1...
  • Page 102 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.
  • Page 103 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.
  • Page 104 Owner’s 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 dealer’s place of business.
  • Page 105 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.
  • Page 106 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.
  • Page 107 Yamaha outside the U.S.A. or Canada, please contact an autho- rized Yamaha dealer in your country. 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.
  • Page 108 Printed in Japan March 2003-1.0 × 1 ! 6L2-28199-1K (25NMH) Printed on recycled paper...
  • Page 109 (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...
  • Page 110 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT...

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