Page 3 - Important manual information; To the owner; The Safety Alert Symbol means AT-; WARNING; OWNER’S MANUAL
Important manual information EMU25100 To the owner Thank you for choosing a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understanding ofthese simple instructions will help you obtainmaximum enjoyment from your new Yam...
Page 4 - Table of contents
Table of contents General information ...................... 1 Identification numbers record ...... 1 Outboard motor serial number ....... 1 EC label....................................... 1Safety information ....................... 1Important labels........................... 2 Warning labels.........
Page 5 - Lubrication; Treatment of
Table of contents Lubrication (except oil injection models)...... 29 Cleaning the outboard motor ........ 29Checking painted surface of motor ........................ 29 Periodic maintenance ................ 29 Replacement parts ....................... 29Maintenance chart ........................ 30...
Page 6 - General information; Identification numbers record; Outboard motor serial number; EC label
General information 1 EMU25170 Identification numbers record EMU25182 Outboard motor serial number The outboard motor serial number is stampedon the label attached to the port side of theclamp bracket or the upper part of the swivelbracket.Record your outboard motor serial number inthe spaces provid...
Page 7 - Stay away from swimming areas.; Important labels; Warning labels; Label
General information 2 ● Do not modify the outboard. Modificationscould make the motor unfit or unsafe to use. ● Never operate after drinking alcohol or tak-ing drugs. About 50% of all boating fatalitiesinvolve intoxication. ● Have an approved personal flotation device(PFD) on board for every occupan...
Page 8 - Fueling instructions; Stop engine before refueling.; Gasoline; Propeller selection; Recommended gasoline:
General information 3 EMU25431 Label WARNING EWM01300 ● This engine is equipped with a neutralstarting device. ● The engine will not start unless the shiftcontrol is in neutral position. EMU25540 Fueling instructions WARNING EWM00010 GASOLINE AND ITS VAPORS ARE HIGH-LY FLAMMABLE AND EXPLOSIVE! ● Do ...
Page 10 - Basic components; Main components; Fuel tank
Basic components 5 EMU25795 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. EMU25802 Fuel tank If your model was equipped with a portablefuel tank, its function is as follows. WARNING EWM00020 The fuel tank supplied with this engine ...
Page 11 - This joint is used to connect the fuel line.
Basic components 6 EMU25830 Fuel joint This joint is used to connect the fuel line. EMU25850 Fuel tank cap This cap seals the fuel tank. When removed,the tank can be filled with fuel. To remove thecap, turn it counterclockwise. EMU25860 Air vent screw This screw is on the fuel tank cap. To loosenthe...
Page 12 - Throttle friction adjuster
Basic components 7 EMU25970 Throttle friction adjuster A friction device provides adjustable resis-tance to movement of the throttle grip or theremote control lever, and can be set accord-ing to operator preference.To increase resistance, turn the adjusterclockwise. To decrease resistance, turn thea...
Page 13 - Engine stop button
Basic components 8 EMU26001 Engine stop button To open the ignition circuit and stop the en-gine, push this button. EMU26011 Choke knob for pull type To supply the engine with the rich fuel mixturerequired to start, pull out this knob. EMU26070 Manual starter handle To start the engine, first gently...
Page 14 - Tilt lock mechanism; To lock it, set the tilt lock lever in the “; Tilt support bar
Basic components 9 EMU30460 Tilt lock mechanism The tilt lock mechanism is used to prevent theoutboard motor from lifting out of the waterwhen in reverse gear. To lock it, set the tilt lock lever in the “ ” (lock) position. To release, push the tilt lock le-ver in the “ ” (release) position. EMU2633...
Page 15 - Operation; Installation; Mounting the outboard motor; Mounting height
Operation 10 EMU26901 Installation CAUTION: ECM00110 Incorrect engine height or obstructions tosmooth water flow (such as the design orcondition of the boat, or accessories suchas transom ladders or depth finder trans-ducers) can create airborne water spraywhile the boat is cruising. Severe engineda...
Page 16 - Clamping the outboard motor
Operation 11 tends to occur, thus reducing the propulsion;and if the propeller tips cut the air, the enginespeed will rise abnormally and cause the en-gine to overheat. If the mounting height is toolow, the water resistance will increase andthereby reduce engine efficiency. Mount theoutboard motor s...
Page 17 - Breaking in engine; Procedure for pre-mixed models
Operation 12 3. Secure the clamp bracket to the transomusing the bolts provided with the out-board (if packed). For details, consultyour Yamaha dealer. WARNING EWM00650 Avoid using bolts, nuts or washers otherthan those contained in the engine pack-aging. If used, they must be of at least thesame qu...
Page 18 - Preoperation checks; Filling fuel and engine oil
Operation 13 EMU27101 Preoperation checks WARNING EWM00080 If any item in the preoperation check is notworking properly, have it inspected andrepaired before operating the outboardmotor. Otherwise an accident could occur. CAUTION: ECM00120 Do not start the engine out of water. Over-heating and serio...
Page 19 - Operating engine
Operation 14 2. Replace the fuel tank cap and close tight-ly. 3. Shake the fuel tank to mix the fuel thor-oughly. 4. Make sure that the oil and gasoline aremixed. If equipped with a built-in fuel tank1. Pour oil into a clean fuel can, and thenadd gasoline. 2. Replace the fuel can cap and close tight...
Page 20 - Starting engine; Place the gear shift lever in neutral.
Operation 15 drowsiness. Keep cockpit and cabin ar-eas well ventilated. Avoid blocking ex-haust outlets. 1. If there is an air vent screw on the fueltank cap, loosen it 2 or 3 turns. 2. If there is a fuel joint on the motor, firmlyconnect the fuel line to the joint. Thenfirmly connect the other end ...
Page 21 - Place the throttle grip in the “
Operation 16 2. Attach the engine stop switch lanyard toa secure place on your clothing, or yourarm or leg. Then install the lock plate onthe other end of the lanyard into the en-gine stop switch. WARNING EWM00120 ● Attach the engine stop switch lanyard toa secure place on your clothing, or yourarm ...
Page 22 - Warming up engine; Choke start models
Operation 17 6. After the engine starts, slowly return themanual starter handle to its original posi-tion before releasing it. 7. Slowly return the throttle grip to the fullyclosed position. NOTE: ● When the engine is cold, it needs to bewarmed up. For further information, seepage 17. ● If the engin...
Page 23 - Shifting
Operation 18 EMU27740 Shifting WARNING EWM00180 Before shifting, make sure there are noswimmers or obstacles in the water nearyou. CAUTION: ECM00220 To change the boat direction or shiftingposition from forward to reverse or vice-versa, first close the throttle so that the en-gine idles (or runs at ...
Page 24 - Stopping engine; Procedure; Trimming outboard motor
Operation 19 Remote control models1. Check that the tilt lock lever is in the lockposition. 2. Pull up the neutral interlock trigger (ifequipped) and move the remote controllever quickly and firmly from neutral to re-verse. EMU27820 Stopping engine Before stopping the engine, first let it cool offfo...
Page 25 - Reposition the rod in the desired hole.
Operation 20 WARNING EWM00740 Excessive trim for the operating condi-tions (either trim up or trim down) cancause boat instability and can make steer-ing the boat more difficult. This increasesthe possibility of an accident. If the boatbegins to feel unstable or is hard to steer,slow down and/or rea...
Page 26 - Bow Up; Tilting up and down
Operation 21 bow up, the boat may have a greater tenden-cy to steer to one side or the other. Compen-sate for this as you steer. The trim tab canalso be adjusted to help offset this effect.When the bow of the boat is down, it is easierto accelerate from a standing start onto plane. Bow Up Too much t...
Page 28 - Slightly tilt the outboard motor up.; Cruising in shallow water
Operation 23 EMU28031 Procedure for tilting down (manual tilt models) 1. Slightly tilt the outboard motor up. 2. If the tilt support bar equipped: Slowly tiltthe outboard motor down while pullingthe tilt support bar lever up. 3. If the tilt support knob equipped: pull outit, then slowly tilt the eng...
Page 29 - Cruising in other conditions; Cruising in salt water
Operation 24 2. Place the tilt lock lever in the release po-sition. 3. Slightly tilt the outboard motor up. The tiltsupport bar will lock automatically, sup-porting the outboard motor in a partiallyraised position. NOTE: The outboard motor is equipped with 2 or 3positions for shallow water cruising....
Page 30 - Cruising in turbid water
Operation 25 Cruising in turbid water Yamaha strongly recommends that you usethe optional chromium-plated water pump kitif you use the outboard motor in turbid (mud-dy) water conditions. U67720E0.book Page 25 Friday, March 26, 2004 10:36 AM
Page 31 - Maintenance; Specifications; Tightening torque for engine:; Transporting and storing
Maintenance 26 EMU28215 Specifications Dimension: Overall length: 718 mm (28.3 in) Overall width: 328 mm (12.9 in) Overall height S: 1044 mm (41.1 in) Overall height L: 1184 mm (46.6 in) Transom height S: 442 mm (17.4 in) Transom height L: 582 mm (22.9 in) Weight (AL) S: 28.0 kg (62 lb) Weight (AL) ...
Page 33 - Flushing in a test tank; If the “Fogging Oil” is not available, run
Maintenance 28 EMU28301 Procedure EMU28332 Flushing in a test tank CAUTION: ECM00300 Do not run the engine without supplying itwith cooling water. Either the engine waterpump will be damaged or the engine willbe damaged from overheating. Beforestarting the engine, be sure to supply wa-ter to the coo...
Page 34 - Cleaning the outboard motor; Periodic maintenance
Maintenance 29 NOTE: Store the fuel tank in a dry, well-ventilatedplace, not in direct sunlight. EMU28400 Lubrication (except oil injection models) 1. Grease the spark plug threads and installthe spark plug(s) and torque to properspecification. For information on sparkplug installation, see page 31....
Page 35 - Maintenance chart; ” symbol indicates the check-ups which you may carry out yourself.
Maintenance 30 EMU28521 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating conditions,but the following table gives general guidelines. Refer to the sections in this chapter for expla-nations of each owner-specific action.The “ ” symbol indicates the che...
Page 36 - Greasing
Maintenance 31 EMU28940 Greasing Yamaha grease A (water resistant grease)Yamaha grease D (corrosion resistant grease; for propeller shaft) EMU28951 Cleaning and adjusting spark plug WARNING EWM00560 When removing or installing a spark plug,be careful not to damage the insulator. Adamaged insulator c...
Page 37 - Checking fuel system; Leaking fuel can result in fire or explosion.; Checkpoints
Maintenance 32 should periodically remove and inspect thespark plug because heat and deposits willcause the spark plug to slowly break downand erode. If electrode erosion becomes ex-cessive, or if carbon and other deposits areexcessive, you should replace the spark plugwith another of the correct ty...
Page 38 - Inspecting fuel filter
Maintenance 33 EMU28980 Inspecting fuel filter WARNING EWM00310 Gasoline is highly flammable, and its va-pors are flammable and explosive. ● If you have any question about properlydoing this procedure, consult yourYamaha dealer. ● Do not perform this procedure on a hotor running engine. Allow the en...
Page 39 - Checking wiring and connectors
Maintenance 34 start position during warm-up. The boatcould unexpectedly start to move, whichcould result in an accident. CAUTION: ECM00490 This procedure must be performed whilethe outboard motor is in the water. A flush-ing attachment or test tank can be used. A diagnostic tachometer should be use...
Page 40 - Check the propeller shaft for damage.; Removing the propeller; Remove the shear pin and the propeller.; Installing the Propeller
Maintenance 35 ● Check each of the propeller blades forwear, erosion from cavitation or ventilation,or other damage. ● Check the propeller shaft for damage. ● Check the splines / shear pin for wear ordamage. ● Check for fish line tangled around the pro-peller shaft. ● Check the propeller shaft oil s...
Page 41 - Changing gear oil; Remove the gear oil drain screw.; Recommended gear oil:
Maintenance 36 6. Insert a new cotter pin in the holes, andthen bend the cotter pin ends. NOTE: There is a holder on the bottom cowling forspare shear and cotter pins. Be sure to re-place any used pins. EMU29280 Changing gear oil WARNING EWM00800 ● Be sure the outboard motor is securelyfastened to t...
Page 42 - Cleaning fuel tank; Wipe up any spilled fuel immediately.
Maintenance 37 6. When the oil begins to flow out of the oillevel plug hole, insert and tighten the oillevel plug. 7. Insert and tighten the gear oil drainscrew. EMU29302 Cleaning fuel tank WARNING EWM00920 Gasoline is highly flammable, and its va-pors are flammable and explosive. ● If you have any ...
Page 43 - Checking top cowling
Maintenance 38 EMU29390 Checking top cowling Check the fitting of the top cowling by pushingit with both hands. If it is loose have it repairedby your Yamaha dealer. EMU29400 Coating the boat bottom A clean hull improves boat performance. Theboat bottom should be kept as clean of marinegrowth as pos...
Page 44 - Trouble Recovery; Troubleshooting; Starter will not operate.
Trouble Recovery 39 EMU29422 Troubleshooting A problem in the fuel, compression, or ignitionsystems can cause poor starting, loss of pow-er, or other problems. This section describesbasic checks and possible remedies, and cov-ers all Yamaha outboard motors. Thereforesome items may not apply to your ...
Page 45 - Warning buzzer sounds or indicator lights.
Trouble Recovery 40 A. Check for pinched or kinked fuel line or oth-er obstructions in fuel system. Q. Is fuel contaminated or stale?A. Fill tank with clean, fresh fuel. Q. Is fuel filter clogged?A. Clean or replace filter. Q. Have ignition parts failed?A. Have serviced by a Yamaha dealer. Q. Has wa...
Page 46 - Q. Is heat range of spark plug incorrect?
Trouble Recovery 41 Q. Is load on boat improperly distributed?A. Distribute load to place boat on an evenplane. Q. Is water pump or thermostat faulty?A. Have serviced by a Yamaha dealer. Q. Is there excess water in fuel filter cup?A. Drain filter cup. Engine power loss. Q. Is propeller damaged?A. Ha...
Page 47 - Engine vibrates excessively.; Temporary action in emergency; Impact damage; Stop the engine immediately.; Starter will not operate
Trouble Recovery 42 A. Inspect spark plug and replace it with rec-ommended type. Q. Is high pressure fuel pump drive belt bro-ken?A. Have serviced by a Yamaha dealer. Q. Is engine not responding properly to shiftlever position?A. Have serviced by a Yamaha dealer. Engine vibrates excessively. Q. Is p...
Page 48 - Emergency starting engine; Remove the top cowling.
Trouble Recovery 43 ● Do not attach the lanyard to clothingthat could tear loose. Do not route thecord where it could become entangled,preventing it from functioning. ● Avoid accidentally pulling the lanyardduring normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, wi...
Page 49 - Treatment of submerged motor
Trouble Recovery 44 EMU29760 Treatment of submerged motor If the outboard motor is submerged, immedi-ately take it to a Yamaha dealer. Otherwisesome corrosion may begin almost immediate-ly.If you cannot immediately take the outboardmotor to a Yamaha dealer, follow the proce-dure below in order to mi...
