This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their
trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the
mechanical and electrical concepts and procedures inherent in the work, for without such
knowledge attempted repairs or service to the equipment could render it unsafe or unfit for
use.
Because Yamaha has a policy of continuously improving its products, models may differ in
detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and
significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
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HOW TO USE THIS MANUAL
MANUAL FORMAT
All of the procedures in this manual are organised in a sequential, step-by-step format. The
information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and
the course of action required will follow the symbol, e.g.,
• Bearings
Pitting/scratches → Replace.
To assist you in finding your way through this manual, the section title and major heading is
given at the top of every page.
MODEL INDICATION
Multiple models are referred to in this manual and their model indications are noted as follows.
Model nameEK25BMH
IndicationEK25BMH
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the
appropriate section or chapter.
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IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following
ways.
The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death
operator, a bystander or a person inspecting or repairing the outboard motor.
CAUTION:
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.
to the machine
HOW TO USE THIS MANUAL
The main points regarding removing/installing and disassembling/assembling proce-
1
dures are shown in the exploded views.
The numbers in the exploded views indicate the required sequence of the procedure and
2
should be observed accordingly.
Symbols are used in the exploded views to indicate important aspects of the procedure.
3
A list of meanings for these symbols is provided on the following page.
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It is important to refer to the job instruction charts at the same time as the exploded views
4
These charts list the sequence that the procedures should be carried out in, as well as
providing explanations on part names, quantities, dimensions and important points relating to each relevant task.
In addition to tightening torques, the dimensions of the bolts and screws are also men-
5
tioned.
Example:
Bolt and screw size10 × 25 mm : bolt and screw diameter (D) × lenght (L)
In addition to the exploded views and job instruction charts, this manual provides indi-
6
vidual illustrations when further explanations are required to explain the relevant procedure.
1
.
2
3
5
4
2
6
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12
GEN
SPEC
INFO
34
CHK
FUEL
ADJ
56
POWRLOWR
78
BRKT
ELEC
910
TRBL
ANLS
1112
–+
SYMBOLS
Symbolstoare designed as thumbtabs to indicate the content of a chapter.
1
General information
2
Specifications
3
Periodic check and adjustments
4
Fuel system
5
Power unit
6
Lower unit
7
Bracket unit
8
Electrical systems
9
Trouble analysis
Symbolstoindicate specific data.
10
Special tool
11
Specified liquid
12
Specified engine speed
13
Specified torque
14
Specified measurement
15
Specified electrical value
[Resistance (Ω), Voltage (V), Electric current
(A)]
19
1015
1314
T
.
R
.
1516
1718
AC
1920
D
2122
GM
2324
LT
271
2526
LT
572
E
M
LT
242
SS
LT
Symboltoin an exploded diagram
1620
indicate the grade of lubricant and the location of the lubrication point.
16
Apply Yamaha 2-stroke motor oil
17
Apply water resistant grease
(Yamaha grease A, Yamaha marine grease)
18
Apply water resistant grease
(Yamaha grease C, Yamaha marine grease)
19
Apply water resistant grease
(Yamaha grease D, Yamaha marine grease)
20
Apply molybdenum disulfide grease
Symbolstoin an exploded dia-
2126
gram indicate the grade of the sealing or
locking agent and the location of the appli-
4
cation point.
21
Apply Gasket Maker
22
Apply Yamabond #4
(Yamaha bond number 4)
23
Apply LOCTITE® No.271 (Red LOCTITE)
24
Apply LOCTITE® No.242 (Blue LOCTITE)
25
Apply LOCTITE® No.572
26
Apply silicon sealant
®
CONTENTS
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GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECK AND
ADJUSTMENT
FUEL SYSTEM
GEN
INFO
SPEC
CHK
ADJ
FUEL
1
2
3
4
RECOIL STARTER
LOWER UNIT
BRACKET UNIT
ELECTRICAL SYSTEM
POWR
LOWR
BRKT
–+
ELEC
5
6
7
8
TROUBLE ANALYSIS
TRBL
ANLS
9
GEN
INFO
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CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION
SERIAL NUMBER ....................................................................................1-1
STARTING SERIAL NUMBERS ............................................................... 1-1
SAFETY WHILE WORKING
FIRE PREVENTION ..................................................................................1-2
The outboard motor’s serial number is
stamped on a label which is attached to the
port clamp bracket.
NOTE:
As an antitheft measure, a special label on
which the outboard motor’s serial number
is stamped is bonded to the port clamp
bracket. The label is specially treated so
that peeling it off causes cracks across the
serial number.
Model name
1
Approval model code
2
Transom height
3
Serial number
4
STARTING SERIAL NUMBERS
The starting serial number blocks are as follows:
Model name
Wor ldw ide
EK25BMH62C
Approval
model code
Starting serial
number
S: 10 0101
L:400101
Y:750101
1-1
GEN
INFO
SAFETY WHILE WORKING
SAFETY WHILE WORKING
The procedures given in this manual are
those recommended by Yamaha to be followed by Yamaha dealers and their
mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Petroleum vapor is explosive if ignited.
Do not smoke while handling gasoline and
keep it away from heat, sparks and open
flames.
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VENTILATION
Petroleum vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe.
When test-running an engine indoors,
maintain good ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety
glasses or safety goggles, when grinding or
when doing any operation which may cause
particles to fly off. Protect hands and feet by
wearing safety gloves or protective shoes if
appropriate to the work you are doing.
OILS, GREASES AND SEALING
FLUIDS
Use only genuine Yamaha oils, greases and
sealing fluids or those recommended by
Ya ma h a.
1-2
GEN
INFO
SAFETY WHILE WORKING
Under normal conditions or use, there
should be no hazards from the use of the
lubricants mentioned in this manual, but
safety is all-important, and by adopting
good safety practices, any risk is minimized.
A summary of the most important precautions is as follows:
1. While working, maintain good stan-
2. Clothing which has become contami-
3. Avoid skin contact with lubricants; do
4. Hands and any other part of the body
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dards of personal and industrial
hygiene.
nated with lubricants should be
changed as soon as practicable, and
laundered before further use.
not, for example, place a soiled wipingrag in your pocket.
which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with
hot water and soap as soon as practicable.
5. To protect the skin, the application of a
suitable barrier cream to the hands
before working, is recommended.
6. A supply of clean lint-free cloths should
be available for wiping purposes.
GOOD WORKING PRACTICES
1. The right tools
Use the recommended special tools to
protect parts from damage. Use the
right tool in the right manner - do not
improvise.
2. Tightening torque
Follow the tightening torque instructions. When tightening bolts, nuts and
screws, tighten the large sizes first, and
tighten inner-positioned fixings before
outer-positioned ones.
1-3
GEN
INFO
SAFETY WHILE WORKING
3. Non-reusable items
DISASSEMBLY AND ASSEMBLY
1. Clean parts with compressed air when
2. Oil the contact surfaces of moving parts
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Always use new gaskets, packings, Orings, split-pins, circlips, etc., on reassembly.
disassembling.
before assembly.
3. After assembly, check that moving parts
operate normally.
4. Install bearings with the manufacturer’s
markings on the side exposed to view,
and liberally oil the bearings.
5. When installing oil seals, apply a light
coating of water-resistant grease to the
outside diameter.
1-4
GEN
INFO
SPECIAL TOOLS
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SPECIAL TOOLS
Using the correct special tools recommended by Yamaha, will aid the work and
enable accurate assembly and tune-up.
Improvising and using improper tools can
damage the equipment.
The EK25B is designed to provide superior fuel economy, serviceability, and durability.
They are based on the previous EK25A with newly designed linkage to control both throttle
opening and ignition timing mechanically and simultaneously.
Special attention was paid on the crankshaft bearings. Collar is now added to the upper main
journal of the crankshaft. Roller bearing is applied for the center bearing.
The collar added on the upper main journal contributes to get and better serviceability.
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Fig. 1
Fig. 2
1-9
GEN
INFO
FEATURES AND BENEFITS
IGNITION SYSTEM
Ignition system on the EK25B consists of flywheel magnet, charge coil, pulser coil, CDI unit,
and ignition coil.
Similar to the previous EK25A, the engine has the mechanical ignition timing advance system
that works by way of the linkage.
Superior fuel economy is attained by the modified ignition timing control arrangement.
Also the system restricts the ignition timing advance to prevent engine kickback when the
shift is in neutral.
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Fig. 3
1-10
GEN
INFO
FEATURES AND BENEFITS
COOLING SYSTEM
New structure applied to the cooling system provides additional cooling capacity in the upper
casing.
With additional cooling water passage (indicated by ), water walls contained in the new
upper casing contribute to the reduction of outer surface temperature.
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Fig. 4
1-11
GEN
INFO
COOLING SYSTEM
FEATURES AND BENEFITS
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Fig. 5
1-12
GEN
INFO
FEATURES AND BENEFITS
TILLER HANDLE
For the throttle grip on the steering handle of the EK25B, 100 degrees of opening angle
covers all ranges from full-closed to wide-open positions.
Also, new steering handle parts were developed to assume the long use. Inner diameter of
the steering handle engagement area, and both inner and outer diameters of steering bracket
are increased.
Please note that if the new steering handle is installed on the previous models, Steering
handle 2, Steering bracket, Collar, and Washer must be replaced.
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Fig. 6
Fig. 7
1-13
GEN
INFO
FEATURES AND BENEFITS
BRACKET AND BOTTOM COWLING
The Bracket 1 is modified on the EK25B, and newly designed rubber seal is added to provide
better sealing ability for the bottom cowling.
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Fig. 8
1-14
SPEC
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CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
POWER UNIT ...........................................................................................2-3
LOWER UNIT ...........................................................................................2-5