Yamaha FT25 (2022) User guide

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Page 1

OWNER’S MANUAL

Read this manual carefully before operating this

outboard motor.

F25G

6FM-28199-77-E0

Page 2

EMU25053

Read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.

Page 3

Important manual information

TIP:

EMU25108

To the owner

Thank you for selecting a Yamaha outboard motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions 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 Owner’s Manual particularly important information is distinguished in the following ways.

: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

EWM00782

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

ECM00702

A NOTICE indicates special precautions that must be taken to avoid damage to the outboard motor or other property.

there is any question concerning this manual, please consult your Yamaha dealer. To ensure long product life, Yamaha recommends that you use the product and perform the specified periodic inspections and maintenance by correctly following the instructions in the owner’s manual. Any damage resulting from neglect of these instructions is not covered by warranty. Some countries have laws or regulations restricting users from taking the product out of the country where it was purchased, and it may be impossible to register the product in the destination country. Additionally, the warranty may not apply in certain regions. When planning to take the product to another country, consult the dealer where the product was purchased for further information. If the product was purchased used, please consult your closest dealer for customer reregistration, and to be eligible for the specified services.

The F25GMH, F25GWH, F25GE, F25GET and the standard accessories are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model.

EMU25123

A TIP provides key information to make procedures easier or clearer.

Yamaha continually seeks advancements 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

F25G

OWNER’S MANUAL

1st Edition, November 2021

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan

Page 4

Table of contents

Safety information............................. 1

Outboard motor safety .....................1

Propeller .............................................. 1

Rotating parts ...................................... 1

Hot parts.............................................. 1

Electric shock ...................................... 1

Power trim and tilt................................ 1

Engine shut-off cord (lanyard) ............. 1

Gasoline .............................................. 2

Gasoline exposure and spills .............. 2

Carbon monoxide ................................ 2

Modifications ....................................... 2

Boating safety ..................................2

Alcohol and drugs................................ 2

Personal flotation devices (PFDs) ....... 2

People in the water.............................. 2

Passengers ......................................... 2

Overloading ......................................... 3

Avoid collisions.................................... 3

Collisions with floating or submerged

objects.............................................. 3

Weather............................................... 4

Passenger training .............................. 4

Boating safety publications.................. 4

Laws and regulations .......................... 4

General information .......................... 5

Identification numbers record...........5

Outboard motor serial number ............ 5

Key number ......................................... 5

EC Declaration of Conformity

(DoC)............................................. 5

CE Marking / UKCA Marking............ 6

Read manuals and labels................. 7

Warning labels .................................... 7

Engine data recording .................... 10

Specifications and requirements... 12

Specifications ................................. 12

Installation requirements ................ 13

Boat horsepower rating ..................... 13

Mounting outboard motor .................. 13

Remote control requirements.........14

Battery requirements...................... 14

Battery specifications ........................ 14

To install the battery .......................... 14

Propeller selection ......................... 14

Start-in-gear protection .................. 15

Engine oil requirements ................. 15

Fuel requirements.......................... 16

Gasoline ............................................16

Muddy or acidic water.................... 17

Anti-fouling paint ............................ 17

Outboard motor disposal

requirements............................... 17

Emergency equipment................... 17

Components .................................... 18

Components diagram..................... 18

Fuel tank............................................ 20

Fuel joint............................................ 21

Fuel gauge ........................................ 21

Fuel tank cap..................................... 21

Air vent screw.................................... 21

Yamaha Security System

(Y-COP/Optional)........................... 21

Remote control box ...........................21

Remote control lever .........................22

Neutral interlock trigger .....................22

Neutral throttle lever .......................... 22

Tiller handle ...................................... 23

Gear shift lever ................................. 23

Throttle grip ......................................23

Throttle indicator ............................... 24

Throttle friction adjuster..................... 24

Engine shut-off cord (lanyard) and

clip.................................................. 25

Engine stop button ........................... 26

Manual starter handle........................ 26

Starter button..................................... 26

Main switch........................................ 26

Steering friction adjuster.................... 27

Power trim and tilt switch on remote

control ............................................28

Power trim and tilt switch on bottom

cowling ........................................... 28

Variable trolling RPM switches ......... 28

Page 5

Table of contents

Trim tab with anode........................... 29

Trim rod (tilt pin) ................................ 29

Tilt lock mechanism........................... 30

Tilt support knob................................ 30

Tilt support bar .................................. 30

Cowling lock lever ............................. 30

Flushing device ................................. 31

Alert indicator ................................... 31

Instruments and indicators ............ 32

Indicators ....................................... 32

Low oil pressure-alert indicator ......... 32

Overheat-alert indicator..................... 32

Engine control system.................... 33

Alert system ...................................33

Overheat alert.................................... 33

Low oil pressure alert ........................ 33

Installation .......................................35

Installation ...................................... 35

Mounting the outboard motor ............ 35

Clamping the outboard motor............ 37

Operation .........................................39

First-time operation ........................ 39

Fill engine oil ..................................... 39

Breaking in engine............................. 39

Getting to know your boat ................. 39

Checks before starting engine .......39

Fuel level ........................................... 40

Remove the top cowling .................... 40

Fuel system ....................................... 40

Controls ............................................. 41

Engine shut-off cord (lanyard) ........... 41

Engine oil........................................... 41

Engine ............................................... 42

Flushing device ................................. 42

Install top cowling .............................. 42

Checking power trim and tilt

system............................................ 43

Battery ............................................... 43

Filling fuel ...................................... 44

Operating engine ........................... 45

Sending fuel (portable tank) ..............45

Starting engine ..................................46

Checks after starting engine .......... 51

Cooling water .................................... 51

Warming up engine........................ 51

Manual start and electric start

models ........................................... 51

Checks after engine warm up ........ 52

Shifting .............................................. 52

Stop switches ....................................52

Shifting........................................... 52

Stopping boat................................. 54

Trolling ........................................... 54

Adjusting trolling speed .....................54

Stopping engine............................. 54

Procedure.......................................... 55

Trimming outboard motor............... 56

Adjusting trim angle for manual tilt

models ........................................... 56

Adjusting trim angle (Power trim and

tilt) ..................................................57

Adjusting boat trim............................. 58

Tilting up and down........................ 58

Procedure for tilting up (manual tilt

models) ..........................................59

Procedure for tilting up (power trim

and tilt models)............................... 60

Procedure for tilting down (manual

tilt models)...................................... 61

Procedure for tilting down (power

trim and tilt models)........................ 62

Shallow water ................................ 62

Cruising in shallow water (manual

tilt models)...................................... 62

Power trim and tilt models ................. 64

Cruising in other conditions............ 65

Maintenance .................................... 66

Transporting and storing outboard

motor........................................... 66

Dismounting the outboard motor ....... 66

Storing outboard motor...................... 68

Page 6

Table of contents

Procedure.......................................... 68

Lubrication......................................... 69

Flushing power unit ........................... 70

Cleaning the outboard motor............. 71

Checking painted surface of

outboard motor............................... 71

Periodic maintenance..................... 71

Replacement parts ............................ 71

Severe operating conditions.............. 72

Maintenance chart 1.......................... 73

Maintenance chart 2.......................... 75

Greasing............................................ 76

Cleaning and adjusting spark plug .... 77

Checking fuel filter............................. 79

Inspecting idle speed......................... 79

Changing engine oil........................... 79

Replacing the engine oil filter ............ 82

Why Yamalube .................................. 83

Inspecting wiring and connectors ...... 83

Checking propeller ............................ 84

Removing propeller ........................... 84

Installing propeller ............................. 85

Changing gear oil .............................. 85

Inspecting and replacing anode(s) .... 87

Checking battery (for electric start

models) .......................................... 87

Connecting the battery ...................... 88

Disconnecting the battery.................. 88

Trouble Recovery............................ 89

Troubleshooting .............................89

Temporary action in emergency..... 92

Impact damage.................................. 92

Replacing fuse................................... 92

Power trim and tilt will not operate .... 93

Starter will not operate ...................... 93

Emergency starting engine (manual

start model) .................................... 94

Emergency starting engine (electric

start model) .................................... 95

Treatment of submerged motor...... 97

INDEX ...............................................98

Page 7

Safety information

EMU33623

Outboard motor safety

Observe these precautions at all times.

EMU36502

Propeller

People can be injured or killed if they come in contact with the propeller. The propeller can keep moving even when the motor is in neutral, and sharp edges of the propeller can cut even when stationary.

 Stop the engine when a person is in the

water near you.

 Keep people out of reach of the propeller,

even when the engine is off.

EMU40272

Rotating parts

Hands, feet, hair, jewelry, clothing, personal flotation device (PFD) straps, etc., can become entangled with internal rotating parts of the engine, resulting in serious injury or death. Keep the top cowling in place whenever possible. Do not remove or replace the top cowling with the engine running. Only operate the engine with the top cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, PFD straps, etc., away from any exposed moving parts.

EMU33641

Hot parts

During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the engine has cooled.

EMU33651

Electric shock

Do not touch any electrical parts while starting or operating the engine. They can cause

shock or electrocution.

EMU33662

Power trim and tilt

Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted. Keep body parts out of this area at all times. Be sure no one is in this area before operating the power trim and tilt mechanism. The power trim and tilt switches operate even when the main switch is off. Keep people away from the switches whenever working around the motor. Never get under the lower unit while it is tilted, even when the tilt support lever is locked. Severe injury could occur if the outboard motor accidentally falls.

EMU33672

Engine shut-off cord (lanyard)

Attach the engine shut-off cord so that the engine stops if the operator falls overboard or leaves the helm. This prevents the boat from running away under power and leaving people stranded, or running over people or objects. Always attach the engine shut-off cord to a secure place on your clothing or your arm or leg while operating. Do not remove it to leave the helm while the boat is moving. Do not attach the cord to clothing that could tear loose, or route the cord where it could become entangled, preventing it from functioning. Do not route the cord where it is likely to be accidentally pulled out. If the cord is pulled during operation, the engine will shut off and you will lose most steering control. The boat could slow rapidly, throwing people and objects forward.

Page 8

Safety information

EMU33811

Gasoline

Gasoline and its vapors are highly flammable and explosive. Always, refuel ac-

cording to the procedure on page 45 to reduce the risk of fire and explosion.

EMU33821

Gasoline exposure and spills

Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Dispose of rags properly. If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth.

EMU33901

Carbon monoxide

This product emits exhaust gases which contain carbon monoxide, a colorless, 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.

EMU33781

Modifications

Do not attempt to modify this outboard motor. Modifications to your outboard motor may reduce safety and reliability, and render the outboard unsafe or illegal to use.

EMU33742

Boating safety

This section includes a few of the many important safety precautions that you should follow when boating.

EMU33711

Alcohol and drugs

Never operate after drinking alcohol or taking drugs. Intoxication is one of the most common factors contributing to boating fatalities.

EMU40281

Personal flotation devices (PFDs)

Have an approved PFD on board for every occupant. Yamaha recommends that you must wear a PFD whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating conditions.

EMU33732

People in the water

Always watch carefully for people in the water, such as swimmers, skiers, or divers, whenever the engine is running. When someone is in the water near the boat, shift into neutral and stop the engine. Stay away from swimming areas. Swimmers can be hard to see. The propeller can keep moving even when the motor is in neutral. Stop the engine when a person is in the water near you.

EMU33752

Passengers

Consult your boat manufacturer’s instructions for details about appropriate passenger locations in your boat and be sure all passengers are positioned properly before accelerating and when operating above an idle speed. Standing or sitting in non-designated locations may result in being thrown either overboard or within the boat due to waves, wakes, or sudden changes in speed or direction. Even when people are positioned properly, alert your passengers if you must make

Page 9

Safety information

ZMU06025

any unusual maneuver. Always avoid jumping waves or wakes.

EMU33763

Overloading

Do not overload the boat. Consult the boat capacity plate or boat manufacturer for maximum weight and number of passengers. Be sure that weight is properly distributed according to the boat manufacturer’s instructions. Overloading or incorrect weight distribution can compromise the boat’s handling and lead to an accident, capsizing or swamping.

EMU33773

Avoid collisions

Scan constantly for people, objects, and other boats. Be alert for conditions that limit your visibility or block your vision of others.

Operate defensively at safe speeds and keep a safe distance away from people, objects, and other boats.

 Do not follow directly behind other boats or

waterskiers.

 Avoid sharp turns or other maneuvers that

make it hard for others to avoid you or understand where you are going.

 Avoid areas with submerged objects or

shallow water.

 Ride within your limits and avoid aggres-

sive maneuvers to reduce the risk of loss

of control, ejection, and collision.

 Take early action to avoid collisions. Re-

member, boats do not have brakes, and stopping the engine or reducing throttle can reduce the ability to steer. If you are not sure that you can stop in time before hitting an obstacle, apply throttle and turn in another direction.

EMU48100

Collisions with floating or submerged objects

If the outboard motor hits a floating object or an obstacle in the water while cruising, the following could occur:

 The passengers and any loose equipment

or luggage could be thrown forward due to the sudden deceleration.

 Parts of the outboard motor could come

loose as a result of the impact and could be thrown into the boat.

 The boat or outboard motor could be dam-

aged as a result of the impact. When you operate the boat in an area where there might be floating objects or obstacles in the water, be sure to adjust the trim angle of the outboard motor, slow down, and operate carefully. For further information, see page 62. If the outboard motor hits a floating object or an obstacle in the water, make sure that there are no abnormalities with the boat and the outboard motor. If anything abnormal is found, return to the nearest harbor at low speed and have a Yamaha dealer inspect the outboard motor.

Page 10

Safety information

EMU33791

Weather

Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.

EMU33881

Passenger training

Make sure at least one other passenger is trained to operate the boat in the event of an emergency.

EMU33891

Boating safety publications

Be informed about boating safety. Additional publications and information can be obtained from many boating organizations.

EMU33602

Laws and regulations

Know the marine laws and regulations where you will be boating—and obey them. Several sets of rules prevail according to geographic location, but all are basically the same as the International Rules of the Road.

Page 11

General information

ZMU08713

3412

ZMU01692

ZMU01694

EMU25172

Identification numbers record

EMU25186

Outboard motor serial number

The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. 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 stolen.

1. Outboard motor serial number location

1. Serial number

2. Model name

3. Motor transom height

4. Engine code

EMU25192

Key number

If a main key switch is equipped with the motor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key.

1. Key number

EMU38984

EC Declaration of Conformity

(DoC)

This declaration is included with outboard motors that conform to European regulations. This outboard motor conforms to certain portions of the European Parliament directive relating to machinery. Each conformed outboard motor accompanied with EC DoC. EC DoC contains the following information;

 Manufacturer  Model name  Engine code  Applied directives

Page 12

General information

ZMU08714

ZMU08715

6EE-G3394-80

15210499

EMU48442

CE Marking / UKCA Marking

This label is affixed to outboard motors that conform to European regulations.

1. CE marking location

CE marking

Outboard motors affixed with this “CE” marking conform with the directives of; 2006/42/EC, 2014/30/EU, and 2013/53/EU.

UKCA marking

This product is in compliance with the Recreational Craft Regulations 2017, Electromagnetic Compatibility Regulations 2016 and Supply of Machinery (Safety) Regulations

2008.

1. CE marking location

Page 13

General information

ZMU08815

EMU33524

Read manuals and labels

Before operating or working on this outboard motor:

 Read this manual.  Read any manuals supplied with the boat.  Read all labels on the outboard motor and the boat.

If you need any additional information, contact your Yamaha dealer.

EMU33836

Warning labels

If these labels are damaged or missing, contact your Yamaha dealer for replacements.

F25GE, F25GET

Page 14

General information

ZMU08717

F25GMH, F25GWH

Page 15

General information

ZMU05746

6EE-G2794-40

6EE-G2794-50

6EE-H1994-40

6EE-H1994-50

6EE-H1995-40

6EE-H1995-50

EMU33913

Contents of labels

The above warning labels mean as follows.

EWM01692

Emergency starting does not have startin-gear protection. Ensure shift control is in neutral before starting engine.

EWM01682

 Keep hands, hair, and clothing away

from rotating parts while the engine is running.

 Do not touch or remove electrical parts

when starting or during operation.

EWM01672

 Read Owner’s Manuals and labels.  Wear an approved personal flotation

device (PFD).

 Attach engine shut-off cord (lanyard) to

your PFD, arm, or leg so the engine

stops if you accidentally leave the

helm, which could prevent a runaway

boat.

Page 16

General information

ZMU05664

ZMU05666

ZMU05667

ZMU05668

EMU33844

Symbols

The following symbols mean as follows.

Notice/Warning

ZMU05696

Read Owner’s Manual

Electrical hazard

Remote control lever/gear shift lever operating direction, dual direction

Engine start/ Engine cranking

Hazard caused by continuous rotation

ZMU05665

EMU48000

Engine data recording

This model’s ECM stores certain engine data to assist in the diagnosis of malfunctions and for research, statistical analysis and development purposes.

Page 17

Although the sensors and recorded data will

https://www.yamaha-motor.eu/eu/ privacy/privacy-policy.aspx

vary by model, the main data points are:

 Engine status and engine performance

data This data will be uploaded only when a special Yamaha diagnostic tool is attached to the engine, such as when maintenance checks or service procedures are performed. Engine data uploaded will be handled appropriately according to the following Privacy Policy.

Yamaha will not disclose this data to a third party except in the following cases. In addition, Yamaha may provide engine data to a contractor in order to outsource services related to the handling of the engine data. Even in this case, Yamaha will require the contractor to properly handle the engine data we provided and Yamaha will appropriately manage the data.

 With the consent of the boat owner  Where obligated by law  For use by Yamaha in litigation  For general Yamaha-conducted research

purposes when the data is not related to

an individual engine or owner

General information

Page 18

Specifications and requirements

TIP:

EMU38092

Specifications

“(AL)” stated in the specification data below represents the numerical value for the aluminum propeller installed.

EMU48360

Dimension and weight:

Overall length:

1130 mm (44.5 in) (F25GMH, F25GWH) 633 mm (24.9 in) (F25GE, F25GET)

Overall width:

378 mm (14.9 in)

Overall height S:

1106 mm (43.5 in) (F25GE, F25GET, F25GMH, F25GWH)

Overall height L:

1233 mm (48.5 in) (F25GE, F25GET, F25GMH, F25GWH)

Motor transom height S:

424 mm (16.7 in) (F25GE, F25GMH, F25GWH) 426 mm (16.8 in) (F25GET)

Motor transom height L:

551 mm (21.7 in) (F25GE, F25GMH, F25GWH) 553 mm (21.8 in) (F25GET)

Dry weight (AL) S:

56 kg (123 lb) (F25GE) 57 kg (126 lb) (F25GMH) 60 kg (132 lb) (F25GWH) 63 kg (139 lb) (F25GET)

Dry weight (AL) L:

58 kg (128 lb) (F25GE) 59 kg (130 lb) (F25GMH) 62 kg (137 lb) (F25GWH) 64 kg (141 lb) (F25GET)

Performance:

Full throttle operating range:

5000–6000 r/min

Rated power:

18.4 kW (25 HP)

Idle speed (in neutral):

850–950 r/min

Power unit:

Type:

4-stroke SOHC L2 4 valves

Total displacement:

Bore × stroke:

Ignition system:

Spark plug (NGK):

Spark plug gap:

Steering system:

Starting system:

Starting carburetion system:

Valve clearance IN (cold engine):

Valve clearance EX (cold engine):

Battery rating (CCA/EN):

Battery rating (20HR/IEC):

Maximum generator output:

432 cm

65.0 × 65.1 mm (2.56 × 2.56 in)

TCI

DPR6EB-9

0.8–0.9 mm (0.031–0.035 in)

Remote steering (F25GE, F25GET) Tiller handle (F25GMH, F25GWH)

Electric starter (F25GE, F25GET) Manual starter (F25GMH) Manual starter and Electric starter (F25GWH)

Fuel injection

0.15–0.25 mm (0.0059–0.0098 in)

0.25–0.35 mm (0.0098–0.0138 in)

347–411 A

40 Ah

16 A

(26.4 c.i.)

Page 19

Specifications and requirements

Lower unit:

Gear shift positions:

Forward-neutral-reverse

Gear ratio:

2.08 (27/13)

Trim and tilt system:

Manual tilt (F25GE, F25GMH, F25GWH) Power trim and tilt (F25GET)

Propeller mark:

Fuel and oil:

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

Fuel tank capacity:

24 L (6.34 US gal, 5.28 Imp.gal)

Recommended engine oil:

YAMALUBE 4 or 4-stroke outboard motor oil

Recommended engine oil grade 1:

SAE 10W-30/10W-40/5W-30

API SG/SH/SJ/SL Engine oil quantity (without oil filter replacement):

1.0 L (1.0 US qt, 0.85 Imp.qt) Engine oil quantity (with oil filter replacement):

1.1 L (1.2 US qt, 1.0 Imp.qt) Lubrication system:

Wet sump

Recommended gear oil:

YAMALUBE outboard gear oil or Hypoid gear oil

Recommended gear oil grade:

SAE 90 API GL-4

Gear oil quantity:

0.370 L (0.391 US qt, 0.326 Imp.qt)

Noise and vibration level:

Operator sound pressure level (ICOMIA 39/94):

83.0 dB(A)

Vibration on tiller handle (ICOMIA 38/94):

4.7 m/s

EMU33556

(F25GMH, F25GWH)

Installation requirements

EMU33566

Boat horsepower rating

EWM01561

Overpowering a boat can cause severe instability.

Before installing the outboard motor(s), confirm that the total horsepower of your outboard motor(s) does not exceed the boat’s maximum horsepower rating. See the boat’s capacity plate or contact the manufacturer.

EMU40491

Mounting outboard motor

EWM02501

 Improper mounting of the outboard mo-

tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards.

 Because the outboard motor is very

heavy, special equipment and training is required to mount it safely.

Your dealer or other person experienced in proper rigging should mount the outboard motor using correct equipment and complete rigging instructions. For further information, see page 35.

Page 20

Specifications and requirements

EMU33582

Remote control requirements

EWM01581

 If the engine starts in gear, the boat can

move suddenly and unexpectedly, possibly causing a collision or throwing passengers overboard.

 If the engine ever starts in gear, the

start-in-gear protection device is not working correctly and you should discontinue using the outboard. Contact your Yamaha dealer.

The remote control unit must be equipped with a start-in-gear protection device(s). This device prevents the engine from starting unless it is in neutral.

EMU25695

Battery requirements

EMU25723

Battery specifications

Battery rating (CCA/EN):

347–411 A

Battery rating (20HR/IEC):

40 Ah

The engine cannot be started if battery voltage is too low.

EMU36293

Mounting battery

Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. WARNING! Do not put flammable

items, or loose heavy or metal objects in the same compartment as the battery. Fire, explosion or sparks could result.

[EWM01821]

Battery cable

The battery cable size and length are critical. Consult your Yamaha dealer about the battery cable size and length.

EMU44771

To install the battery

ECM01091

A battery cannot be connected to models that do not have a rectifier or Rectifier Regulator.

If you wish to use a battery, your outboard motor must be equipped with the following parts.

 Rectifier or Rectifier Regulator  Lighting coil

If you do not know if your outboard motor is equipped with these parts, consult your Yamaha dealer. Install an optional Rectifier Regulator or use accessories rated to withstand 18 volts or higher with the above models. Consult your Yamaha dealer for details on installing an optional Rectifier Regulator.

EMU34196

Propeller selection

Next to selecting an outboard motor, selecting the right propeller is one of the most important purchasing decisions a boater can make. The type, size, and design of your propeller have a direct impact on acceleration, top speed, fuel economy, and even engine life. Yamaha designs and manufactures propellers for every Yamaha outboard motor and every application. Your outboard motor came with a Yamaha propeller selected to perform well over a range of applications, but there may be uses where a different propeller would be more

Page 21

Specifications and requirements

ZMU04605

123

appropriate. Your Yamaha dealer can help you select the right propeller for your boating needs. Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boatload. Generally, select a larger pitch propeller for a smaller operating load and a smaller pitch propeller for a heavier load. If you carry loads that vary widely, select the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle setting to stay within the recommended engine speed range when carrying lighter loads. To check the propeller, see page 84.

123

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

EMU25771

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 in neutral. Always select neutral before starting the engine.

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

ZMU04604

EMU41953

Engine oil requirements

Select an oil grade according to the average temperatures in the area where the outboard motor will be used.

Page 22

Specifications and requirements

TIP:

ZMU08143

122˚F

50˚C

104

SAE API

SG SH

SJ SL

-10

-4

-20

10W–30

10W–40

5W–30

ZMU06855

122˚F

50˚C

104

SAE API

SJ SL

-10

-4

-20

15W–40

20W–40

20W–50

E5 E10

Recommended engine oil:

YAMALUBE 4 or 4-stroke outboard motor oil

Recommended engine oil grade 1:

SAE 10W-30/10W-40/5W-30 API SG/SH/SJ/SL

Recommended engine oil grade 2:

SAE 15W-40/20W-40/20W-50 API SH/SJ/SL

Engine oil quantity (without oil filter replacement):

1.0 L (1.0 US qt, 0.85 Imp.qt)

Engine oil quantity (with oil filter replacement):

1.1 L (1.2 US qt, 1.0 Imp.qt)

If oil grades listed under Recommended engine oil grade 1 are not available, select an alternative oil grade listed under Recommended engine oil grade 2.

Recommended engine oil grade 1

EMU36361

Fuel requirements

EMU40203

Gasoline

Use a good quality gasoline that meets the minimum octane rating. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

ECM01982

 Do not use leaded gasoline. Leaded

gasoline can seriously damage the engine.

 Avoid getting water and contaminants

in the fuel tank. Contaminated fuel can cause poor performance or engine damage. Use only fresh gasoline that has been stored in clean containers.

Recommended engine oil grade 2

 This mark identifies the recommended fuel

for this outboard motor as specified by European regulation (EN228).

 Check that gasoline nozzle has the same

identifier when fueling.

Page 23

Specifications and requirements

Gasohol

There are two types of gasohol: gasohol containing ethanol (E5 and E10) and that containing methanol. Ethanol can be used if the ethanol content does not exceed 10% and the fuel meets the minimum octane ratings. E85 is a fuel containing 85% ethanol and must not be used in your outboard motor. All ethanol blends containing more than 10% ethanol can cause fuel system damage or cause engine starting and running problems. Yamaha does not recommend gasohol containing methanol because it can cause fuel system damage or engine performance problems. It is recommended that you install a waterseparating marine fuel filter assembly (10 micron minimum) between your boat’s fuel tank and outboard motor when using ethanol. Ethanol is known to allow moisture to be absorbed into boat fuel tanks and systems. Moisture in the fuel can cause corrosion of metallic fuel system components, starting and running complaints and require additional fuel system maintenance.

EMU36881

Muddy or acidic water

Yamaha strongly recommends that you have your dealer install the optional chromiumplated water pump kit if you use the outboard motor in muddy or acidic water conditions. However, depending on the model it might not be required.

EMU36331

Anti-fouling paint

A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, 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.

EMU40302

Outboard motor disposal

requirements

Never illegally discard (dump) the outboard motor. Yamaha recommends consulting the dealer about discarding the outboard motor.

EMU36353

Emergency equipment

Keep the following items onboard in case there is trouble with the outboard motor.

 A tool kit with assorted screwdrivers, pli-

ers, wrenches (including metric sizes), and electrical tape.

 Waterproof flashlight with extra batteries.  An extra engine shut-off cord (lanyard)

with clip.

 Spare parts, such as an extra set of spark

plugs.

Consult your Yamaha dealer for details.

Page 24

Components

TIP:

5 6

ZMU08783

EMU46722

Components diagram

* May not be exactly as shown; also may not be included as standard equipment on all models (order from dealer).

F25GMH, F25GWH, F25GE

1. Top cowling

2. Clamp bracket

3. Oil level plug

4. Anti-cavitation plate

5. Cooling water inlet

6. Gear oil drain screw

7. Propeller*

8. Trim tab

9. Drain screw

10. Idle hole

11. Cowling lock lever

Page 25

F25GET

Components

1. Top cowling

2. Clamp bracket

3. Oil level plug

4. Anti-cavitation plate

5. Cooling water inlet

6. Gear oil drain screw

7. Propeller*

8. Trim tab

9. Drain screw

10. Power trim and tilt switch*

11. Idle hole

12. Cowling lock lever

5 6

ZMU08784

Page 26

Components

1. Top cowling

2. Manual starter handle*

3. Starter button*

4. Alert indicator

5. Engine shut-off cord (lanyard)*

6. Engine stop button*

7. Throttle friction adjuster*

8. Gear shift lever*

9. Throttle grip*

10. Variable trolling RPM switch*

11. Clamp screw

12. Tilt lock lever*

13. Restraint cable attachment

14. Steering friction adjuster*

15. Tilt support knob*

16. Flushing device

17. Remote control box (side mount type)*

18. Fuel tank*

19. Yamaha Security System (Y-COP)*

765

EMU25804

Fuel tank

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

EWM00021

The fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Commercial users should conform to relevant licensing or approval authority regulations.

Page 27

1. Fuel joint

ZMU02284

2. Fuel gauge

3. Fuel tank cap

4. Air vent screw

Components

conformity with the relevant laws and regulations regarding radio wave transmission. Therefore, if this product is used outside the country where it was sold, it may violate the laws or regulations regarding radio wave transmission in the country it is used in. For details, consult your Yamaha dealer.

The Yamaha Security System, which protects against theft, consists of the receiver and key fobs. The Yamaha Security System is available from your Yamaha dealer. For details, consult your Yamaha dealer.

EMU25831

Fuel joint

This joint is used to connect the fuel line.

EMU25842

Fuel gauge

This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the approximate amount of fuel remaining in the tank.

EMU25851

Fuel tank cap

This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise.

EMU25861

Air vent screw

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

EMU46753

Yamaha Security System (Y-COP/Optional)

ECM02461

1. Key fob

2. Receiver

The engine cannot be started if the security system is in the lock mode. The engine can be started only in the unlock mode. For more information, see the installation and owner’s manual included with the security system.

EMU26182

Remote control box

The remote control lever actuates both the shifter and the throttle. The electrical switches are mounted on the remote control box.

The Yamaha Security System is sold in

Page 28

Components

TIP:

1 2

ZMU01723

ZMU01725

6. Throttle

7. Fully open

EMU26202

Neutral interlock trigger

To shift out of neutral, first pull the neutral interlock trigger up.

1. Power trim and tilt switch

2. Remote control lever

3. Neutral interlock trigger

4. Neutral throttle lever

5. Main switch

6. Engine shut-off switch

7. Throttle friction adjuster

EMU26191

Remote control lever

Moving the lever forward from the neutral position engages forward gear. Pulling the lever back from neutral engages reverse. The engine will continue to run at idle until the lever is moved about 35° (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.

ZMU01727

1. Neutral interlock trigger

EMU26213

Neutral throttle lever

To open the throttle without shifting into either forward or reverse, put the remote control lever in the neutral position and lift the neutral throttle lever.

ZMU01728

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”

4. Shift

5. Fully closed

1. Fully open

2. Fully closed

The neutral throttle lever will operate only when the remote control lever is in neutral. The remote control lever will operate only

Page 29

when the neutral throttle lever is in the closed

ZMU08722

position.

EMU25914

Tiller handle

To change direction, move the tiller handle to the left or right as necessary.

ZMU08721

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

Components

EMU25925

Gear shift lever

Move the gear shift lever forward to engage the forward gear or rearward to engage the reverse gear.

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

EMU25943

Throttle grip

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

Page 30

Components

111

ZMU03169

ZMU08723

EMU25963

Throttle indicator

The fuel consumption curve on the throttle 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

EMU25978

Throttle friction adjuster

A friction device provides adjustable resistance to movement of the throttle grip or the remote control lever, and can be set according to operator preference. To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. WARNING! Do

not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident.

[EWM00033]

1. Throttle indicator

6FM-00

ZMU08724

Page 31

When constant speed is desired, tighten the

ZMU08725

ZMU08726

adjuster to maintain the desired throttle setting.

Components

Avoid accidentally pulling the cord 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.

1. Engine shut-off cord (lanyard)

2. Clip

3. Engine shut-off switch

[EWM00123]

ZMU01716

EMU25996

Engine shut-off cord (lanyard) and clip

The clip must be attached to the engine shutoff switch for the engine to run. The cord should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power. WARNING! At-

tach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning.

1. Engine shut-off cord (lanyard)

2. Clip

3. Engine shut-off switch

Page 32

Components

111

1. Engine shut-off cord (lanyard)

2. Clip

3. Engine shut-off switch

EMU26004

Engine stop button

The engine stop button stops the engine when the button is pushed.

EMU26075

Manual starter handle

The manual starter handle is used to crank and start the engine.

ZMU08759

EMU26083

Starter button

To start the engine with the electric starter, push the starter button.

ZMU08727

ZMU08729

EMU26092

Main switch

The main switch controls the ignition system; its operation is described below.

 “” (off)

With the main switch in the “ ” (off) position, the electrical circuits are off, and the key can be removed.

 “” (on)

With the main switch in the “ ” (on) position, the electrical circuits are on, and the key cannot be removed.

Page 33

Components

TIP:

STARTOFF

ZMU01718

ZMU08730

ZMU08731

 “” (start)

With the main switch in the “ ” (start) position, the starter motor turns to start the engine. When the key is released, it returns automatically to the “ ” (on) position.

accident.

If the resistance does not increase even when the lever is turned to the starboard side “A”, make sure that the nut is tightened to the specified torque.

EMU47160

Steering friction adjuster

A friction device provides adjustable resistance to the steering mechanism, and can be set according to operator preference. An adjuster lever is located on the bottom of the tiller handle bracket. To increase resistance, turn the lever to the starboard side “A”. To decrease resistance, turn the lever to the port side “B”.

EWM00041

Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an

1. Nut

Nut tightening torque:

7 N·m (0.7 kgf·m, 5.2 lb·ft)

 Steering movement is blocked when the

adjuster lever is set to the “A” position.

 Check the tiller handle for smooth move-

ment when the lever is turned to the port side “B”.

 Do not apply lubricants such as grease to

the friction areas of the steering friction adjuster.

Page 34

Components

EMU32054

Power trim and tilt switch on remote control

The power trim and tilt system adjusts the outboard motor angle in relation to the transom. Pushing the switch “ ” (up) trims the outboard motor up, and then tilts it up. Pushing the switch “ ” (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current position. For instructions on using the power trim and tilt switch, see pages 56 and 58.

UP DN

ZMU01720

trims it down. When the switch is released, the outboard motor will stop in its current position. For instructions on using the power trim and tilt switch, see page 58.

EWM01032

Use the power trim and tilt switch located on the bottom cowling only when the boat is at a complete stop with the engine off. Attempting to use this switch while the boat is moving could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obstacle.

EMU26156

Power trim and tilt switch on bottom cowling

The power trim and tilt switch is located on the side of the bottom cowling. Pushing the switch “ ” (up) trims the outboard motor up, and then tilts it up. Pushing the switch “ ” (down) tilts the outboard motor down and

ZMU08732

1. Power trim and tilt switch

EMU30903

Variable trolling RPM switches

The trolling speed can be adjusted when the outboard motor is trolling. Press the “ ” switch to increase the trolling speed and press the “ ” switch to decrease the trolling speed.

Page 35

Components

TIP:

UPDN

ZMU08786

the starboard side “B” in the figure.

ECM00841

The trim tab also serves as an anode to protect the engine from electrochemical

RPM

corrosion. Never paint the trim tab as it will become ineffective as an anode.

1. Variable trolling RPM switch

 The trolling speed changes approximately

50 r/min each time a switch is pressed.

 If the trolling speed has been adjusted, the

engine returns to the normal trolling speed when the engine is stopped and restarted or when the engine speed exceeds approximately 3000 r/min.

 For instructions on using the variable troll-

ing RPM switches, see page 54.

EMU26246

Trim tab with anode

EWM00841

An improperly adjusted trim tab could 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.

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. If the boat tends to veer to the left (port side), turn the trim tab rear end to the port side “A” in the figure. If the boat tends to veer to the right (starboard side), turn the trim tab end to

ZMU08733

1. Trim tab

2. Bolt

Bolt tightening torque:

18 N·m (1.8 kgf·m, 13 lb·ft)

EMU26263

Trim rod (tilt pin)

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

ZMU08765

1. Trim rod

Page 36

Components

ZMU08735

ZMU08737

EMU47200

Tilt lock mechanism

The tilt lock mechanism is used to prevent the outboard motor from lifting out of the water when in reverse gear.

1. Tilt lock lever

To release the lock, pull up the tilt lock lever in the “ ” (release) position.

EMU26323

Tilt support knob

To keep the outboard motor in the tilted up position, push the tilt support knob under the swivel bracket.

port and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position.

EMU26334

Tilt support bar

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

1. Tilt support bar

ECM01661

Do not use the tilt support bar when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position.

1. Tilt support knob

ECM00661

Do not use the tilt support lever or knob

ZMU08736

when trailering the boat. The outboard motor could shake loose from the tilt sup-

EMU39264

Cowling lock lever

The cowling lock lever(s) is used to secure the top cowling.

Page 37

TIP:

1. Cowling lock lever

ZMU08738

ZMU08739

ZMU08740

EMU26464

Flushing device

This device is used to clean the cooling water passages of the motor using a garden hose and tap water.

Components

EMU26305

Alert indicator

If the engine develops a condition which is cause for alert, the indicator lights up. For details on how to read the alert indicator, see page 33.

1. Alert indicator

1. Flushing device

For details on usage, see page 70.

1. Alert indicator

Page 38

Instruments and indicators

ZMU08741

ZMU08742

EMU36016

Indicators

EMU36026

Low oil pressure-alert indicator

If oil pressure drops too low, this indicator will light up. For further information, see page 33.

ECM00024

 Do not continue to run the engine if the

low oil pressure-alert indicator is on and the engine oil level is lower. Serious engine damage will occur.

 The low oil pressure-alert indicator

does not indicate the engine oil level. Use the oil dipstick to check the oil level. For further information, see page 41.

EMU36034

Overheat-alert indicator

If the engine temperature rises too high, this indicator will light up. For further information on reading the indicator, see page 33.

ECM00053

Do not continue to run the engine if the overheat-alert indicator is on. Serious engine damage will occur.

1. Overheat-alert indicator

1. Low oil pressure-alert indicator

1. Overheat-alert indicator

Page 39

EMU26806

ZMU08743

ZMU01758

ZMU08744

Alert system

ECM00093

Do not continue to operate the engine if an alert device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected.

EMU43754

Overheat alert

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

 The engine speed will automatically de-

crease to 2000–3500 r/min.

 The overheat-alert indicator will light or

blink (if equipped).

Engine control system

If the alert system has activated, stop the engine and check the cooling water inlets:

 Check trim angle to be sure that the cool-

ing water inlet is submerged.

 Check the cooling water inlet for clogging.

 The buzzer will sound (if equipped on the

tiller handle, remote control box, or main switch panel).

EMU26869

Low oil pressure alert

If the oil pressure drops too low, the alert device will activate.

 The engine speed will automatically de-

crease to about 2000–3500 r/min.

Page 40

Engine control system

ZMU08745

ZMU02360

 The low oil pressure-alert indicator will

light or blink (if equipped).

 The buzzer will sound (if equipped).

If the alert system has activated, stop the engine as soon as it is safe to do so. Check the oil level and add oil as needed. If the oil level is correct, consult your Yamaha dealer.

Page 41

Installation

ZMU08787

EMU26903

Installation

The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat and motor combination. Proper mounting depends in part on experience and the specific boat and motor combination.

EWM01591

 Overpowering a boat could cause se-

vere 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 manufacturer.

 Improper mounting of the outboard mo-

tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. For permanently mounted models, your dealer or other person experienced in proper rigging should mount the motor.

tiller handle).

(3) Hold the handgrip as shown in the illus-

tration and lift up the outboard motor using two people.

EMU47170

Mounting the outboard motor

ECM01681

Do not hold the top cowling when mounting or dismounting the outboard motor. The top cowling could come off, causing the outboard motor to fall.

(1) Be sure to mount the outboard motor

while the boat is on land. If the boat is on the water, move it to an area on land.

(2) To prevent steering movement, turn the

adjuster lever to “A” (if equipped with the adjuster lever). To hold the steering bracket easily, raise the tiller handle to the vertical position (if equipped with the

Page 42

Installation

ZMU08788

ZMU08789

ZMU01760

1. Handgrip

1. Center line (keel line)

EMU26926

Mounting height

To run your boat at optimum efficiency, the water resistance (drag) of the boat and outboard motor must be made as little 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 propeller 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 outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in) below it.

(4) 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.

Page 43

Installation

TIP:

ZMU02012

ZMU08746

ECM01635

 Make sure that the idle hole is high

enough to prevent water from entering the engine even if the boat is stationary with the maximum load.

 Incorrect engine height or obstructions

to the smooth flow of water (such as the design or condition of the boat, or accessories, such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. If the outboard motor is operated continuously in the presence of airborne water spray, enough water could enter the engine through the air intake opening in the top cowling to cause severe engine damage. Remove the cause of the airborne water spray.

 The optimum mounting height of the out-

board motor is affected by the boat and motor combination and the desired use. Test runs at different heights can help determine the optimum mounting height. Consult your Yamaha dealer or boat manufacturer for further information on determining the proper mounting height.

 For instructions on setting the trim angle of

the outboard motor, see page 56.

WARNING! Loose clamp screws could allow the outboard motor to fall off or move on the transom. This could cause loss of control and serious injury. Make sure the clamp screws are tightened securely. Occasionally check the screws for tightness during operation.

[EWM00643]

(2) If the restraint cable attachment is

equipped on your engine, a restraint cable or chain should be used. Attach one end to the restraint cable attachment and the other to a secure mounting point on the boat. Otherwise the engine could be completely lost if it accidentally falls off the transom.

EMU26974

Clamping the outboard motor

(1) Place the outboard motor on the tran-

som so that it is positioned as close to the center as possible. Tighten the transom clamp screws evenly and securely. Occasionally check the clamp screws for tightness during operation of the outboard motor because they could become loose due to engine vibration.

(3) Secure the clamp bracket to the transom

using the bolts provided with the outboard (if packed). For details, consult your Yamaha dealer. WARNING! Avoid

using bolts, nuts or washers other

Page 44

Installation

than those contained in the engine packaging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tightening, test run the engine and check their tightness.

[EWM00652]

1. Bolts

ZMU02637

Page 45

Operation

TIP:

ZMU01710

EMU36382

First-time operation

EMU36393

Fill engine oil

The engine is shipped from the factory without engine oil. If your dealer did not fill the oil, you must fill it before starting the engine.

NOTICE: Check that the engine is filled with oil before first-time operation to avoid severe engine damage.

The engine is shipped with the following tag, which should be removed after engine oil is filled for the first time. For more information on checking the engine oil level, see page

41.

[ECM01782]

life. NOTICE: Failure to follow the break-in

procedure could result in reduced engine life or even severe engine damage.

EMU27086

[ECM00802]

Procedure for 4-stroke models

Your new engine requires a period of 10 hours break-in to allow mating surfaces of moving parts to wear in evenly.

Run the engine in the water, under load (in gear with a propeller installed) as follows. For 10 hours for breaking in engine avoid extended idling, rough water and crowded areas. (1) For the first hour of operation:

Run the engine at varying speeds up to 2000 r/min or approximately half throttle.

(2) For the second hour of operation:

Increase engine speed as much as necessary to put the boat on plane (but avoid full-throttle operation), then back off on the throttle while keeping the boat at a planing speed.

(3) Remaining 8 hours:

Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.

(4) After the first 10 hours:

Operate the engine normally.

EMU30175

Breaking in engine

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

EMU36402

Getting to know your boat

All boats have unique handling characteristics. Operate cautiously while you learn how your boat handles under different conditions and various trim angles (see page 56).

EMU36414

Checks before starting engine

EWM01922

If any item in “Checks before starting en-

Page 46

Operation

ZMU08747

gine” is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur.

ECM00121

Do not start the engine out of water. Overheating and serious engine damage can occur.

EMU36561

Fuel level

Be sure you have plenty of fuel for your trip. A good rule is to use 1/3 of your fuel to get to the destination, 1/3 to return, and to keep 1/3 as an emergency reserve. With the boat level on a trailer or in the water, check the fuel level. For fuel filling instructions, see page

44.

EMU36573

Remove the top cowling

For the following checks, remove the top cowling from the bottom cowling. To remove the top cowling, release the cowling lock lever and lift off the top cowling.

EMU36443

Fuel system

EWM00061

Gasoline and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition.

EWM00911

Leaking fuel can result in fire or explosion.

 Check for fuel leakage regularly.  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.

EMU36453

Check for fuel leaks

 Check for fuel leaks or gasoline fumes in

the boat.

 Check for fuel leakage from the fuel sys-

tem.

 Check the fuel tank and fuel lines for

cracks, swellings, or other damage.

EMU37323

Checking the fuel filter

Check that the fuel filter is clean and free of water. If any water is found in the fuel, or if a significant amount of debris is found, the fuel tank should be checked and cleaned by a Yamaha dealer.

Page 47

ZMU08748

ZMU08749

EMU38901

Controls

Tiller handle models:

 Move the tiller handle fully to the left and

right to make sure operation is smooth.

 Turn the throttle grip from the fully closed

to the fully open position. Make sure that it turns smoothly and that it completely returns to the fully closed position.

 Look for loose or damaged connections of

the throttle cable and shift link.

Remote control models:

 Turn the steering wheel full-right and full-

left. Make sure operation is smooth and unrestricted throughout the whole range with no binding or excessive free play.

 Operate the throttle levers several times to

make sure there is no hesitation in their travel. Operation should be smooth over the complete range of motion, and each lever should return completely to the idle position.

 Look for loose or damaged connections of

the throttle and shift cables.

Operation

ZMU08750

EMU36484

Engine shut-off cord (lanyard)

Inspect the engine shut-off cord and clip for damage, such as cuts, breaks, and wear.

ZMU06873

1. Clip

2. Engine shut-off cord (lanyard)

EMU40994

Engine oil

(1) Place the outboard motor in a vertical

position (not tilted). NOTICE: If the out-

Page 48

Operation

ZMU08752

ZMU08753

board motor is not level, the oil level indicated on the oil dipstick may not be accurate.

[ECM01862]

(2) Remove the oil dipstick and wipe it

clean.

ZMU08751

1. Oil dipstick

(3) Insert the oil dipstick completely and re-

move it again.

(4) Check that the oil level on the oil dipstick

is between the upper and lower marks. Consult your Yamaha dealer if the oil level is not at the proper level or if it appears milky or dirty.

 Look for loose or damaged fasteners.  Check the propeller for damage.  Check for engine oil leaks.

EMU36494

Flushing device

Check that the flushing device’s garden hose connector is securely screwed on to the fitting on the bottom cowling. NOTICE: If the

garden hose connector is not properly connected, cooling water can leak out and the engine can overheat during operation.

[ECM01802]

2 1

1. Oil dipstick

2. Lower mark

3. Upper mark

EMU27154

Engine

 Check the engine and engine mounting.

1. Fitting

2. Flushing device

EMU36956

Install top cowling

(1) Be sure that the cowling lock lever is re-

leased.

(2) Be sure that the rubber seal is seated all

the way around the top cowling.

Page 49

Operation

ZMU08754

(3) Place the top cowling on the bottom

cowling.

(4) Check to be sure the rubber seal is seat-

ed correctly between the top cowling and the bottom cowling.

(5) Move the cowling lock lever to lock the

top cowling as shown. NOTICE: If the

top cowling is not installed correctly, water spray under the top cowling can damage the engine, or the top cowling can blow off at high speeds.

[ECM01992]

After installing, check the fitting of the top cowling by pushing it with both hands. If the top cowling is loose, have it repaired by your Yamaha dealer.

is tilted, even when the tilt support knob is locked. Severe injury could occur if the outboard motor accidentally falls.

 Body parts can be crushed between the

motor and the clamp bracket when the motor is trimmed or tilted.

 Be sure no one is near the outboard

motor before performing this check.

(1) Check the power trim and tilt unit for any

sign of oil leaks.

ZMU02828

1. Trim and tilt rod

(2) Operate each of the power trim and tilt

switches to check that all switches work.

(3) Tilt the outboard motor up and check

that the trim and tilt rod is pushed out completely.

(4) Check that the trim and tilt rod is free of

corrosion or other flaws.

(5) Tilt the outboard motor down. Check that

the trim and tilt rod operates smoothly.

EMU38911

Checking power trim and tilt system

EWM01971

 Never get under the lower unit while it

EMU36585

Battery

Check the battery’s charge. If your boat is equipped with a Yamaha digital speedometer, the voltmeter and low battery alert functions will help you monitor the battery’s charge. A battery in good condition will provide a minimum of 12 volts. Check that the

Page 50

Operation

ZMU06598

ZMU02301

ZMU02834

battery connections are clean, secure and covered by insulating covers. The electrical connections of the battery and cables must be clean and properly connected or the battery will not start the engine. If the battery needs charging, consult your Yamaha dealer or the battery manufacturer’s instructions.

EMU2743A

Filling fuel

EWM01831

 Gasoline and its vapors are highly flam-

mable and explosive. Always refuel according to this procedure to reduce the risk of fire and explosion.

 Gasoline is poisonous and can cause

injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

(1) Be sure the engine is stopped. (2) Disconnect the fuel line from the fuel

tank and tighten the air vent screw on the fuel tank cap.

(3) Remove the portable tank from the boat. (4) Be sure you are in a well-ventilated out-

door area, either securely moored or trailered.

(5) Do not smoke and keep away from

sparks, flames, static electric discharge, or other sources of ignition.

(6) If you use a portable container to store

and dispense fuel, use only an approved GASOLINE container.

(7) Touch the fuel nozzle to the filler open-

ing or funnel to help prevent electrostatic sparks.

(8) Fill the fuel tank, but do not overfill.

WARNING! Do not overfill. Otherwise fuel can expand and overflow if the temperature increases.

[EWM02611]

Fuel tank capacity:

24 L (6.34 US gal, 5.28 Imp.gal)

(9) Tighten the filler cap securely.

Page 51

(10)Wipe up any spilled gasoline immediate-

TIP:

ZMU02295

ZMU02024

ly with dry rags. Dispose rags properly according to local laws or regulations.

EMU27453

Operating engine

EWM00421

 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.

 When the air vent screw is loosened,

gasoline vapor will be released. Gasoline 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.

 This product emits exhaust gases

which contain carbon monoxide, a colorless, odorless gas which could cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.

Operation

(2) If there is a fuel joint on the motor, align

the fuel joint on the fuel line with the fuel joint on the motor and firmly connect the fuel line to the joint while pinching the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank.

ZMU08816

EMU2746B

Sending fuel (portable tank)

(1) If there is an air vent screw on the fuel

tank cap, loosen it 2 or 3 turns.

Wipe up any spilled gasoline immediately with dry rags. Dispose of rags properly according to local laws or regulations.

Page 52

Operation

TIP:

ZMU08756

ZMU08757

(3) Squeeze the primer pump, with the ar-

row pointing up, until you feel it become firm. During engine operation, place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank.

1. Arrow

EMU27496

Starting engine

EWM01601

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.

EMU27548

Manual start / prime start models

EWM01842

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.

(1) Place the gear shift lever in neutral.

The start-in-gear protection device prevents the engine from starting except when in neutral. (2) Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

 Failure to attach the engine shut-off

cord could result in a runaway boat if operator is ejected. Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning.

 Avoid accidentally pulling the cord dur-

ing normal operation. Loss of engine

(3) Place the throttle grip in the “ ”

(start) position.

Page 53

Operation

TIP:

ZMU08758

ZMU08759

EMU27597

Electric start / prime start models

EWM01842

6FM-00

START

(4) Pull the manual starter handle slowly un-

til you feel resistance. Then give a strong pull straight out to crank and start the engine. Repeat if necessary.

(5) After the engine starts, slowly return the

manual starter handle to its original position before releasing it.

 Failure to attach the engine shut-off

 Avoid accidentally pulling the cord dur-

ing 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.

(1) Place the gear shift lever in neutral.

 When the engine is cold, it needs to be

warmed up. For further information, see page 51.

 If the engine is warm and fails to start,

open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 89.

(6) Slowly return the throttle grip to the fully

closed position.

The start-in-gear protection device prevents the engine from starting except when in neutral. (2) Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

Page 54

Operation

TIP:

(3) Place the throttle grip in the “ ”

(start) position. After the engine starts, return the throttle to the fully closed position.

keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, return the main switch to “ ” (on), wait 10 seconds, then crank the engine again.

 When the engine is cold, it needs to be

[ECM00193]

warmed up. For further information, see page 51.

 If the engine is warm and fails to start,

open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 89.

EMU27606

Electric start/prime start models

EWM01842

(4) Turn the main switch to “ ” (start),

and hold it for a maximum of 5 seconds.

(5) Immediately after the engine starts, re-

lease the main switch and allow it to return to “ ” (on). NOTICE: Never turn

the main switch to “ ” (start) while the engine is running. Do not

 Failure to attach the engine shut-off

 Avoid accidentally pulling the cord dur-

(1) Place the gear shift lever in neutral.

Page 55

TIP:

The start-in-gear protection device prevents

TIP:

ZMU08756

ZMU08757

ZMU08758

ZMU08729

the engine from starting except when in neutral. (2) Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

(3) Place the throttle grip in the “ ”

(start) position. After the engine starts, return the throttle to the fully closed position.

Operation

6FM-00

START

(4) Push the starter button to start the en-

gine.

(5) Immediately after the engine starts, re-

lease the starter button and allow it to return to its original position. NOTICE:

Never push the starter button while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, release the starter button, wait 10 seconds, then crank the engine again.

[ECM00162]

 When the engine is cold, it needs to be

warmed up. For further information, see

Page 56

Operation

TIP:

ZMU01771

START

ZMU01774

page 51.

 If the engine is warm and fails to start,

open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 89.

(6) Slowly return the throttle grip to the fully

closed position.

EMU27666

Electric start and remote control models

EWM01842

 Failure to attach the engine shut-off

 Avoid accidentally pulling the cord dur-

tral. (2) Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

ZMU01772

(3) Turn the main switch to “ ” (on). (4) Turn the main switch to “ ” (start),

and hold it for a maximum of 5 seconds.

(1) Place the remote control lever in neutral.

The start-in-gear protection device prevents the engine from starting except when in neu-

(5) Immediately after the engine starts, re-

lease the main switch and allow it to return to “ ” (on). NOTICE: Never turn

the main switch to “ ” (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged. If the

Page 57

engine will not start after 5 seconds

TIP:

ZMU08761

of cranking, return the main switch to “ ” (on), wait 10 seconds, then crank the engine again.

 When the engine is cold, it needs to be

[ECM00193]

warmed up. For further information, see page 51.

 If the engine is warm and fails to start,

open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 89.

EMU36511

Checks after starting engine

EMU36524

Cooling water

Check for a steady flow of water from the cooling water pilot hole. A continuous flow of water from the pilot hole indicates that the water pump is pumping water through the cooling water passages. If the cooling water passages are frozen, it may take a while for water to start flowing out of the pilot hole.

ECM01811

If water is not flowing out of the pilot hole at all times while the engine is running, overheating and serious damage could occur. Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and corrected.

Operation

EMU27671

Warming up engine

EMU27718

Manual start and electric start models

(1) After starting the engine, allow it to idle

for 3 minutes to warm up. NOTICE: Fail-

ure to do so will shorten engine life.

[ECM04550]

(2) Be sure the low oil pressure-alert indica-

tor goes off after starting the engine.

NOTICE: If the low oil pressure-alert indicator blinks after the engine starts, stop the engine. Otherwise, serious engine damage could occur. Check the oil level and add engine oil if necessary. Consult your Yamaha dealer if the cause for the low oil pressure alert cannot be found.

[ECM01832]

Page 58

Operation

ZMU01727

ZMU08809

EMU36532

Checks after engine warm up

EMU36542

Shifting

While the boat is tightly moored, and without applying throttle, confirm that the engine shifts smoothly into forward and reverse, and back to neutral.

EMU36981

Stop switches

 Turn the main switch to “ ”, or press the

engine stop button and make sure the engine stops.

 Confirm that removing the clip from the en-

gine shut-off switch stops the engine.

 Confirm that the engine cannot be started

with the clip removed from the engine shut-off switch.

EMU34563

Shifting

EWM00181

1. Neutral interlock trigger

(2) Move the remote control lever / gear

shift lever firmly and crisply forward (for forward gear) or backward (for reverse gear) [about 35° (a detent can felt) for remote control models]. Be sure to check that the tilt lock lever is in the lock/down position (if equipped) before operating in reverse.

Before shifting, make sure there are no swimmers or obstacles in the water near you.

ECM01611

Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral. If this occurs, stop the engine, shift to neutral, then restart the engine and allow it to warm up.

To shift out of neutral (1) Pull the neutral interlock trigger up (if

equipped).

32˚

ZMU05460

Page 59

TIP:

Tiller handle models: The gear shift lever op-

ZMU08763

ZMU05462

ZMU08758

ZMU01771

erates only when the throttle grip is in the fully closed position. To shift from in gear (forward/reverse) to neutral (1) Close the throttle so that the engine

slows to idle speed.

Operation

6FM-00

START

(2) After the engine is at idle speed in gear

move the remote control lever / gear shift lever firmly and crisply into the neutral position.

Page 60

Operation

TIP:

ZMU08756

ZMU08790

wind direction.

EMU30881

Trolling

EMU30891

Adjusting trolling speed

The trolling speed on outboard motors equipped with the variable trolling RPM switches can be adjusted approximately 50 r/min with each press of a switch.

RPM

EMU31743

Stopping boat

EWM01511

 Do not use the reverse function to slow

down or stop the boat as it could cause you to lose control, be ejected, or impact the steering wheel or other parts of the boat. This could increase the risk of serious injury. It could also damage the shift mechanism.

 Do not shift into reverse while traveling

at planing speeds. Loss of control, boat swamping, or damage to the boat could occur.

The boat is not equipped with a separate braking system. Water resistance stops it after the throttle lever is moved back to idle. The stopping distance varies depending on gross weight, water surface conditions, and

1. “ ” switch

2. “ ” switch

To increase the trolling speed, press the “ ” switch. To decrease the trolling speed, press the “ ” switch.

 The trolling speed changes approximately

50 r/min each time a switch is pressed.

 If the trolling speed has been adjusted, the

engine returns to the normal trolling speed when the engine is stopped and restarted or when the engine speed exceeds approximately 3000 r/min.

EMU27823

Stopping engine

Before stopping the engine, first let it cool off for a few minutes at idle or low speed. Stopping the engine immediately after operating

Page 61

at high speed is not recommended.

TIP:

ZMU08727

ZMU08817

ZMU02301

EMU2784A

Procedure

(1) Push and hold the engine stop button or

turn the main switch to “ ” (off).

Operation

(2) After stopping the engine, disconnect

the fuel line if there is a fuel joint on the outboard motor.

OFF

(3) Tighten the air vent screw on the fuel

tank cap (if equipped).

ZMU01779

(4) Remove the key if the boat will be left un-

attended.

The engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch, then turning the main

Page 62

Operation

ZMU08765

switch to “ ” (off).

EMU27865

Trimming outboard motor

EWM00741

Excessive trim for the operating conditions (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.

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 improve performance and fuel economy while reducing strain on the engine. 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.

EMU38881

Adjusting trim angle for manual tilt models

EWM00401

 Stop the engine before adjusting the

trim angle.

 Use care to avoid being pinched when

removing or installing the rod.

 Use caution when trying a trim position

for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim angle can cause loss of control.

There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim angle. (1) Stop the engine. (2) Tilt the outboard motor up and remove

the trim rod by pressing clip.

1. Trim operating angle

1. Trim rod

(3) Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom.

Page 63

To lower the bow (“trim-in”), move the rod to-

TIP:

ZMU08766

ZMU08767

ward the transom.

Operation

for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim angle can cause loss of control.

 If equipped with a power trim and tilt

switch located on the bottom cowling, use the switch only when the boat is at a complete stop with the engine off. Do not adjust the trim angle with this switch while the boat is moving.

Adjust the outboard motor trim angle using the power trim and tilt switch.

UP DN

ZMU01781

Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.

The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim rod one hole.

EMU27889

Adjusting trim angle (Power trim and tilt)

EWM00754

 Be sure all people are clear of the out-

board motor when adjusting the trim angle. Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted.

 Use caution when trying a trim position

1. Power trim and tilt switch

To raise the bow (trim-out), press the switch “” (up). To lower the bow (trim-in), press the switch “ ” (down). Make test runs with the trim set to different

Page 64

Operation

TIP:

angles to find the position that works best for your boat and operating conditions.

EMU27913

Adjusting boat trim

When the boat is on plane, a bow-up attitude 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. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.

Bow Down

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.

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.

Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.

EMU27936

Tilting up and down

If the engine will be stopped for some time or if the boat is moored in shallows, the outboard motor should be tilted up to protect the propeller and lower casing from damage by collision with obstructions, and also to re-

Page 65

duce salt corrosion.

ZMU03087

ZMU08756

EWM00223

Make sure that no one is near the outboard motor when tilting the outboard motor up or down. Otherwise, body parts could be crushed between the outboard motor and the clamp bracket.

EWM00251

Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, disconnect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.

ECM00242

 Before tilting the outboard motor, stop

the engine by following the procedure on page 54. Never tilt the outboard motor while the engine is running. Severe damage from overheating can result.

 Do not tilt up the engine by pushing the

tiller handle (if equipped) because this could break the handle.

Operation

(2) Disconnect the fuel hose from the fuel

joint on the outboard motor.

1 2

EMU47190

Procedure for tilting up (manual tilt models)

(1) Place the remote control lever / gear

shift lever in neutral.

ZMU08764

1. Fuel joint

2. Fuel hose

(3) Place the tilt lock lever (if equipped) in

the release/up position.

Page 66

Operation

ZMU08808

ZMU08769

ZMU03196

(4) Hold the rear of the top cowling with one

hand and tilt the engine up fully.

(5) The tilt support bar will turn to the lock

position automatically. NOTICE: Do not

use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position. For more detailed information, see page 66.

[ECM01642]

(2) Press the power trim and tilt switch “ ”

(up) until the outboard motor has tilted up completely.

EMU44590

Procedure for tilting up (power trim and tilt models)

(1) Place the remote control lever / gear

shift lever in neutral.

ZMU01787

Page 67

(3) Push the tilt support knob into the clamp

ZMU08770

ZMU08771

ZMU08809

bracket to support the engine.

WARNING! After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever. Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit or in the power tilt unit loses pressure.

[EWM00263]

NOTICE: Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position. For more detailed information, see page 66.

[ECM01642]

Operation

EMU30193

Procedure for tilting down (manual tilt models)

(1) Place the tilt lock lever in the lock posi-

tion.

(2) Slightly tilt the engine up until the tilt sup-

port bar is automatically released.

ZMU08772

(3) Slowly tilt the engine down.

Page 68

Operation

ZMU08774

EMU44601

Procedure for tilting down (power trim and tilt models)

(1) Push the power trim and tilt switch “ ”

(up) until the outboard motor is supported by the tilt rod and the tilt support knob becomes free.

(2) Pull out the tilt support knob.

ZMU08773

EMU28063

Shallow water

EMU28074

Cruising in shallow water (manual tilt models)

EWM01782

(3) Push the power trim and tilt switch “ ”

(down) to lower the outboard motor to the desired position.

ZMU01936

 Run the boat at the lowest possible

speed when using the shallow water cruising system. The tilt lock mechanism does not work while the shallow water cruising system is being used. Hitting an underwater obstacle could cause the outboard motor to lift out of the water, resulting in loss of control.

 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 accident and personal injury.

ECM00261

Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when setting up for and cruising in shallow water. Otherwise severe damage from overheating can result.

Page 69

Operation

ZMU03087

ZMU08808

ZMU08769

EMU28126

Procedure

(1) Place the remote control lever / gear

shift lever in neutral.

ZMU08756

(2) Place the tilt lock lever in the release/up

position.

(3) Slightly tilt the outboard motor up. The

tilt support bar will lock automatically, supporting the outboard motor in a partially raised position. This outboard motor has 2 positions for shallow water cruising.

(4) To return the outboard motor to the nor-

mal running position, place the remote control lever / gear shift lever in neutral.

(5) Place the tilt lock lever in the lock/down

position, then slightly tilt the outboard motor up until the tilt support bar automatically returns to the free position.

Page 70

Operation

ZMU08809

ZMU01771

ZMU01935

(6) Slowly lower the outboard motor to the

normal position.

EMU32852

Power trim and tilt models

The outboard motor can be tilted up partially to allow operation in shallow water.

ECM00261

EMU32914

Procedure for power trim and tilt models

(1) Place the remote control lever / gear

shift lever in neutral.

(2) Slightly tilt the outboard motor up to the

desired position using the power trim and tilt switch. WARNING! Using the

power trim and tilt switch on the bottom cowling while the boat is moving or engine is on could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obstacle.

[EWM01851]

(3) To return the outboard motor to the nor-

Page 71

mal running position, press the power trim and tilt switch and slowly tilt the outboard motor down.

EMU28196

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh water.

Cruising in muddy, turbid, or acidic water

Yamaha strongly recommends that you use the optional chromium-plated water pump kit (see page 17) if you use the outboard motor in acidic water or water with a lot of sediment in it, such as muddy or turbid (cloudy) water. After operating in such water, flush the cooling passages with fresh water to prevent corrosion. Also rinse the outside of the outboard motor with fresh water.

Operation

Page 72

Maintenance

EMU2822B

Transporting and storing

outboard motor

EWM02621

 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.

 Leaking fuel is a fire hazard. When

transporting and storing the outboard motor, disconnect the fuel line from the outboard motor to prevent fuel from leaking.

 Never get under the outboard motor

while it is tilted. Severe injury could occur if the outboard motor accidentally falls.

 Do not use the tilt support lever or knob

when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the outboard motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position.

ECM02441

 Disconnect the fuel line from the outboard

motor.

 Tighten the fuel tank cap and its air vent

screw.

 When the outboard motor is tilted pro-

longed time for mooring or trailering the boat, disconnect the fuel line from the outboard motor. Tighten the fuel tank cap and

its air vent screw. The outboard motor should be transported and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the tilt position using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details.

EMU47180

Dismounting the outboard motor

ECM01681

Do not hold the top cowling when mounting or dismounting the outboard motor. The top cowling could come off, causing the outboard motor to fall.

(1) Stop the engine and land the boat. (2) Disconnect the fuel line from the out-

board motor.

When storing the outboard motor for prolonged time, fuel must be drained from the fuel tank. The deteriorated fuel could clog the fuel line causing engine start difficulty or malfunction.

When storing or transporting the outboard motor, make sure to follow the procedure listed below.

ZMU08810

(3) For electric start models, disconnect the

battery cables from the battery terminals.

Page 73

(4) To prevent steering movement, turn the

ZMU08787

ZMU08788

ZMU08789

adjuster lever to “A” (if equipped with the adjuster lever). To hold the steering bracket easily, raise the tiller handle to the vertical position (if equipped with the tiller handle).

Maintenance

1. Handgrip

(5) Loosen the clamp screw(s). (6) Hold the handgrip as shown in the illus-

tration and lift up the outboard motor to dismount it from the boat.

(7) When transporting or storing the out-

board motor while removed from a boat, keep the outboard motor in the attitude shown or use an outboard motor stand.

Page 74

Maintenance

TIP:

ZMU02263

ZMU02487

ZMU08291

ZMU03659

be performed to prevent excessive damage. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the following procedures.

ECM01081

 To prevent problems which can be

caused by oil entering the cylinder from

the sump, keep the outboard motor in

the attitude shown when transporting

and storing it. If storing or transporting

the outboard motor on its side (not up-

right), put it on a cushion after draining

the engine oil.

 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 trou-

ble.

 Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

When transporting the outboard motor in a horizontal position, place a towel or something similar under the outboard motor to protect it from damage.

EMU28242

Storing outboard motor

When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must

EMU28306

Procedure

EMU38871

Flushing in a test tank

ECM02131

Do not run the engine without supplying

Page 75

Maintenance

TIP:

ZMU02051

it with cooling water. Either the engine water pump will be damaged or the engine will be damaged from overheating.

Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging/lubricating of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flushing and fogging at the same time. (1) Wash the outboard motor body using

fresh water. NOTICE: Do not spray wa-

ter into the air intake.

[ECM01841] For fur-

ther information, see page 71.

(2) Disconnect the fuel line from the out-

board motor.

(3) Remove the engine top cowling and pro-

peller. For further details, see page 84.

(4) Install the outboard motor on a water

tank. Fill the tank with fresh water until the anti-cavitation plate is immersed in water. NOTICE: 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.

[ECM00292]

Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.

[EWM00092]

(6) Just prior to turning off the engine, quick-

ly spray “Fogging Oil” on to the silencer cover. When properly done, the engine will almost stall.

ZMU08776

If the “Fogging Oil” is not available, run the engine at idle speed until the fuel system becomes empty and the engine stops. Remove the spark plugs and turn the flywheel magnet several times with starter motor or by pulling the manual starter handle to coat the cylinder wall with oil. (7) Remove the outboard motor from the

test tank.

(8) Drain the cooling water completely out of

the motor. Clean the body thoroughly. (9) Install the top cowling. (10)Store the fuel tank in a dry, well-ventilat-

ed place, not in direct sunlight.

1. Water surface

2. Lowest water level

(5) Run the engine at a fast idle for a few

minutes in neutral position. WARNING!

EMU28403

Lubrication

(1) Install the spark plug(s) and torque to

proper specification. For information on

spark plug installation, see page 77.

Page 76

Maintenance

TIP:

ZMU08777

(2) Change the gear oil. For instructions,

see page 85. Inspect the oil for the presence of water that indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use.

(3) Grease all grease fittings. For further de-

tails, see page 76.

For long-term storage, fogging the engine with oil is recommended. Contact your Yamaha dealer for information about fogging oil and procedures for your engine.

EMU28446

Flushing power unit

Perform this procedure right after operation for the most thorough flushing.

ECM01531

Do not perform this procedure while the engine is running. The water pump may be damaged and severe damage from overheating can result.

(1) After shutting off the engine, unscrew

the garden hose connector from the fitting on the bottom cowling.

1. Fitting

2. Garden hose adapter

3. Garden hose connector

(2) Screw the garden hose adapter onto a

garden hose, which is connected to a

fresh water supply, and then connect it

to the garden hose connector. (3) With the engine off, turn on the water tap

and let the water flush through the cool-

ing passages for about 15 minutes. Turn

off the water and disconnect the garden

hose adapter from the garden hose con-

nector. (4) Reinstall the garden hose connector

onto the fitting on the bottom cowling.

Tighten the connector securely.

NOTICE: Do not leave the garden

hose connector loose on the bottom

cowling fitting or let the hose hang

free during normal operation. Water

Page 77

Maintenance

TIP:

ZMU07873

will leak out of the connector instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fitting after flushing the engine.

[ECM00542]

 When flushing the engine with the boat in

the water, tilting up the outboard motor until it is completely out of the water will achieve better results.

 For cooling system flushing instructions,

see page 66.

EMU44342

Cleaning the outboard motor

When cleaning the outboard motor, the top cowling must be installed. (1) Wash the exterior of the outboard motor

using fresh water. NOTICE: Do not

spray water into the air intake.

1. Air intake

[ECM01841]

(2) Drain the cooling water completely out of

the outboard motor. Clean the body thoroughly.

EMU28463

Checking painted surface of outboard motor

Check the outboard motor for scratches,

nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. Touch-up paint is available from your Yamaha dealer.

EMU2847G

Periodic maintenance

EWM01872

These procedures require mechanical skills, tools, and supplies. If you do not have the proper skills, tools, or supplies to perform a maintenance procedure, have a Yamaha dealer or other qualified mechanic do the work. The procedures involve disassembling the motor and exposing dangerous parts. To reduce the risk of injury from moving, hot, or electrical parts:

 Turn off the engine and keep the key(s)

and engine shut-off cord (lanyard) with you when you perform maintenance unless otherwise specified.

 The power trim and tilt switches oper-

ate even when the ignition key is off. Keep people away from the switches whenever working around the motor. When the motor is tilted, keep away from the area under it or between it and the clamp bracket. Be sure no one is in this area before operating the power trim and tilt mechanism.

 Allow the engine to cool before han-

dling hot parts or fluids.

 Always completely reassemble the mo-

tor before operation.

EMU28512

Replacement parts

If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent

Page 78

Maintenance

design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from your Yamaha dealer.

EMU34152

Severe operating conditions

Severe operating conditions involve one or more of the following types of operation on a regular basis:

 Operating continuously at or near maxi-

mum engine speed (rpm) for many hours

 Operating continuously at a low engine

speed (rpm) for many hours

 Operating without sufficient time for engine

to warm up and cool down

 Frequent quick acceleration and decelera-

tion

 Frequent shifting  Frequently starting and stopping the en-

gine(s)

 Operation that fluctuates often between

light and heavy cargo loads Outboard motors operating under any of these above conditions require more frequent maintenance. Yamaha recommends that you do this service twice as often as specified in the maintenance chart. For example, if a particular service should be done at 50 hours, do it instead at 25 hours. This will help prevent more rapid deterioration of engine components.

Page 79

Maintenance

TIP:

EMU46073

Maintenance chart 1

 Refer to the sections in this chapter for explanations of each owner-specific action.  The maintenance cycle on these charts assume usage of 100 hours per year and regular

flushing of the cooling water passages. Maintenance frequency should be adjusted when

operating the engine under adverse conditions such as extended trolling.

 Disassembly or repairs may be necessary depending on the outcome of maintenance

checks.

 Expendable or consumable parts and lubricants will lose their effectiveness over time and

through normal usage regardless of the warranty period.

 When operating in salt water, muddy, other turbid (cloudy), acidic 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

Item Actions

Inspection or

Anode(s) (external)

Anode(s) (internal) *1

Anode(s) (internal) *2

Battery (electrolyte level, terminal)

Cooling water leakage

Cowling lock lever Inspection 40, 42

Engine starting condition/noise

Engine idle speed/noise

Engine oil Replacement 79

Engine oil filter (cartridge)

replacement as necessary

Inspection or replacement as necessary

Replacement —

Inspection 87

Fill, charging or replacing as necessary

Inspection or replacement as necessary

Inspection 45

Inspection 79

Replacement 82

20 hours

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

Page

—

Page 80

Maintenance

Initial Every

Item Actions

Fuel filter (can be disassembled)

Fuel line (High pressure)

Fuel line (Low pressure)

Fuel pump

Fuel/engine oil leakage

Gear oil Replacement 85

Greasing points Greasing 76

Clamp bracket bolt (through tube)

Impeller/water pump housing

Power trim and tilt unit

Propeller/propeller nut/cotter pin

Shift link/shift cable

Spark plug(s)

Spark plug caps/spark plug wires

Inspection or replacement as necessary

Inspection —

Inspection or replacement as necessary

Inspection —

Inspection or replacement as necessary

Inspection —

Inspection and greasing

Inspection or replacement as necessary

Replacement —

Inspection 43

Inspection or replacement as necessary

Inspection, adjustment or replacement as necessary

Inspection or replacement as necessary

20 hours

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

Page

—

Page 81

Maintenance

Initial Every

Item Actions

Water from the cooling water pilot hole

Throttle link/throttle cable

Thermostat

Timing belt

Valve clearance

Cooling water inlet Inspection 18

Main switch/stop switch

Wire harness connections/wire coupler connections

(Yamaha) Meter/gauge

Fuel tank (Yamaha portable tank)

EMU47210

Inspection 51

Inspection, adjustment or replacement as necessary

Inspection or replacement as necessary

Inspection and adjustment

Inspection or replacement as necessary

Inspection —

Inspection and cleaning as necessary

20 hours

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

Page

—

*1 Thermostat cover *2 Cylinder head, Cylinder block

EMU46082

Maintenance chart 2

Item Actions

Exhaust guide/exhaust manifold

Timing belt Replacement —

Inspection or replacement as necessary

Every

1000 hours

Page

—

Page 82

Maintenance

ZMU08779

EMU46621

Greasing

Yamalube grease A “ ” (water resistant grease) Yamaha grease D “ ” (corrosion resistant grease)

F25GMH, F25GWH

Page 83

F25GE, F25GET

ZMU08826

Maintenance

EMU47111

Cleaning and adjusting spark plug

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 electrode 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 re-

move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. (1) Disconnect the clamps securing the

spark plug caps.

Page 84

Maintenance

ZMU08803

ZMU08802

ZMU08804

1. Clamp

(2) Remove the spark plug caps from the

spark plugs.

1. Spark plug cap

(3) Remove the spark plug. If electrode ero-

sion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type. WARNING!

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.

[EWM00562]

1. Spark plug

Standard spark plug:

DPR6EB-9

(4) Be sure to use the specified spark plug,

otherwise the engine may not operate properly. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; replace it if out of specification.

1. Spark plug gap

2. Spark plug part number

3. Spark plug I.D. mark (NGK)

Spark plug gap:

0.8–0.9 mm (0.031–0.035 in)

(5) When fitting the plug, wipe off any dirt

from the threads, and then screw it in to the correct torque.

Page 85

Maintenance

TIP:

ZMU08748

Spark plug torque:

17 N·m (1.7 kgf·m, 13 lb·ft)

If a torque-wrench is not available when you are reinstalling a spark plug, a good estimate of the correct torque is 1/12 turn past fingertight. When you are installing a new spark plug, a good estimate of the correct torque is 1/2 turn past finger-tight.

EMU47230

Checking fuel filter

Check the fuel filter periodically. If any water or foreign matter is found in the filter, clean or replace it. For cleaning or replacement of the fuel filter, consult your Yamaha dealer.

ECM00491

This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used.

If the boat is not equipped with a tachometer for the outboard motor, use a diagnostic tachometer for this procedure. Results may vary depending on whether testing is conducted 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.

(2) Once the engine has warmed up, verify

whether the idle speed is set to specification. For idle speed specifications, see page 12. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechanic.

EMU38808

Changing engine oil

EWM00761

After cleaning and/or replacing the fuel filter, make sure the area around the harness is clean and free from obstructions.

EMU29045

Inspecting idle speed

EWM00452

 Do not touch or remove electrical parts

when starting or during operation.

 Keep hands, hair, and clothes away

from the flywheel and other rotating

parts while the engine is running.

 Avoid draining the engine oil immedi-

ately after stopping the engine. The oil is hot and should be handled with care to avoid burns.

 Be sure the outboard motor is securely

fastened to the transom or a stable stand.

ECM01711

Change the engine oil after the first 20 hours of operation or 3 months, and every 100 hours or at 1-year intervals thereafter. Otherwise the engine will wear

Page 86

Maintenance

TIP:

ZMU03659

ZMU08799

ZMU08751

ZMU08797

quickly.

To prevent spilling oil where it could cause damage to nature, it is strongly recommended that you use an oil changer to change the engine oil. If an oil changer is not available, drain the engine oil by removing the drain screw. If you are not familiar with the procedure for changing the engine oil, consult your Yamaha dealer. (1) Put the outboard motor in an upright po-

sition (not tilted). NOTICE: If the out-

board motor is not level, the oil level indicated on the oil dipstick may not be accurate.

[ECM01862]

1. Oil filler cap

(2) Start the engine. Warm it up and keep

the idle speed for 5-10 minutes.

(3) Stop the engine and leave it for 5-10

minutes. (4) Remove the top cowling. (5) Remove the oil filler cap. Pull out the dip-

stick and use the oil changer to extract

the oil completely.

1. Oil dipstick

1. Oil changer

When using an oil changer, skip steps 6 and

7. (6) Prepare a suitable container that holds a

larger amount than the engine oil capac-

Page 87

Maintenance

TIP:

ZMU08798

ZMU08799

ity. Remove the drain screw and gasket

while holding the container under the

drain hole. Let the oil drain completely.

Wipe up any spilled oil immediately.

1. Drain screw

2. Gasket

If the oil does not drain easily, change the tilt angle or turn the outboard motor to port and starboard to drain the oil. (7) Put a new gasket on the oil drain screw.

Apply a light coat of oil to the gasket and

install the drain screw.

Drain screw tightening torque:

27 N·m (2.7 kgf·m, 20 lb·ft)

If a torque wrench is not available when you are installing the drain screw, finger tighten the screw just until the gasket comes into contact with the surface of the drain hole. Then tighten 1/4 to 1/2 turn more. Tighten the drain screw to the correct torque with a torque wrench as soon as possible. (8) Add the correct amount of oil through the

filler hole. Put back the filler cap and the

dipstick. NOTICE: Overfilling the oil

could cause leakage or damage. If the

oil level is above the upper level

mark, drain until the level meets the

specified capacity.

1. Oil filler cap

Recommended engine oil:

YAMALUBE 4 or 4-stroke outboard motor oil

Engine oil quantity (without oil filter replacement):

1.0 L (1.0 US qt, 0.85 Imp.qt)

Engine oil quantity (with oil filter replacement):

1.1 L (1.2 US qt, 1.0 Imp.qt)

(9) Leave the outboard motor for 5-10 min-

utes.

(10)Remove the oil dipstick and wipe it

clean.

(11)Insert the dipstick and remove it again.

Be sure to completely insert the dipstick into the dipstick guide, otherwise the oil level measurement will be incorrect.

(12)Recheck the oil level using the dipstick

to be sure the level falls between the upper and lower marks. Consult your Yamaha dealer if the oil level is out of specified level.

[ECM01851]

Page 88

Maintenance

TIP:

ZMU08752

1. Oil dipstick

2. Lower mark

3. Upper mark

(13)Start the engine and make sure that the

low oil pressure-alert indicator remains

off. Also, make sure that there are no oil

leaks. NOTICE: If the low oil pressure-

alert indicator comes on or if there

are oil leaks, stop the engine and find

the cause. Continued operation with

a problem could cause severe engine

damage. Consult your Yamaha dealer

if the problem cannot be located and

corrected.

(14)Install the top cowling. (15)Dispose of used oil according to local

regulations.

 For more information on the disposal of

used oil, consult your Yamaha dealer.

 Change the oil more often when operating

the engine under adverse conditions such as extended trolling.

[ECM01623]

is hot and should be handled with care to avoid burns.

 Be sure the outboard motor is securely

fastened to the transom or a stable stand.

Yamaha recommends you to have a Yamaha dealer replace the engine oil filter. If you perform replacement yourself, follow the procedure below. If you have any questions, please consult a Yamaha dealer. (1) Drain the engine oil. For further informa-

tion, see page 79. (2) Place a cloth under the engine oil filter. (3) Turn the engine oil filter counterclock-

wise and remove it.

 Wipe up any spilled engine oil.  Dispose of the removed engine oil filter in

accordance with local regulations.

(4) Apply engine oil to the O-ring of the en-

gine oil filter.

EMU48110

Replacing the engine oil filter

EWM00761

 Avoid draining the engine oil immedi-

ately after stopping the engine. The oil

Page 89

1. O-ring

ZMU08780

(5) Turn the engine oil filter clockwise and

tighten it to the specified torque.

Maintenance

base oil’s qualities and blend in the ideal balance of additives to make sure the final oil clears our performance standards. Thus, Yamalube mineral, semisynthetic and synthetic oils have their own distinct characters and value. Yamaha’s experience gained over many years of research and development into oil since the 1960’s helps make Yamalube the best choice for your Yamaha engine.

EMU29116

Inspecting wiring and connectors

 Inspect that each connector is engaged

securely.

 Inspect that each ground lead is properly

secured.

Engine oil filter:

18 N·m (1.8 kgf·m, 13 lb·ft)

(6) Fill up the engine with engine oil. For fur-

ther information, see page 79.

EMU48060

Why Yamalube

YAMALUBE oil is a Genuine YAMAHA Part born of the engineers’ passion and belief that engine oil is an important liquid engine component. We form teams of specialists in the fields of mechanical engineering, chemistry, electronics and track testing, and have them develop the engine together with the oil it will use. Yamalube oils take full advantage of the

Page 90

Maintenance

ZMU01897

ZMU08156

EMU32113

Checking propeller

EWM01882

You could be seriously injured if the engine accidentally starts when you are near the propeller. Before inspecting, removing, or installing the propeller, place the shift control in neutral, turn the main switch to “ ” (off) and remove the key, and remove the clip from the engine shutoff switch. Turn off the battery cut-off switch if your boat has one.

Do not use your hand to hold the propeller when loosening or tightening the propeller nut. Put a wood block between the anti-cavitation plate and the propeller to prevent the propeller from turning.

 Check the propeller shaft oil seal for dam-

age.

EMU30663

Removing propeller

EMU29198

Spline models

(1) Straighten the cotter pin and pull it out

using a pair of pliers. (2) Remove the propeller nut, washer, and

spacer (if equipped). WARNING! Do

not use your hand to hold the propel-

ler when loosening the propeller nut.

[EWM01891]

Checkpoints

 Check each of the propeller blades for ero-

sion from cavitation or ventilation, or other damage.

 Check the propeller shaft for damage.  Check the splines for wear or damage.  Check for fish line tangled around the pro-

peller shaft.

1. Cotter pin

2. Propeller nut

3. Washer

4. Spacer

5. Propeller

6. Thrust washer

(3) Remove the propeller, washer (if

Page 91

Maintenance

TIP:

ZMU02063

equipped), and thrust washer.

EMU30673

Installing propeller

EMU46121

Spline models

ECM00502

Make sure to use a new cotter pin and bend the ends over securely. Otherwise, the propeller could come off during operation and be lost.

(1) Apply Yamalube Marine Grease or a

corrosion resistant grease to the propeller shaft.

(2) Install the spacer (if equipped), thrust

washer, washer (if equipped), and propeller on the propeller shaft. NOTICE:

Make sure to install the thrust washer before installing the propeller. Otherwise, the lower case and propeller boss could be damaged.

[ECM01882]

(3) Install the spacer (if equipped) and the

washer. Tighten the propeller nut to the specified torque.

Propeller nut tightening torque:

34 N·m (3.4 kgf·m, 25 lb·ft)

(4) Align the propeller nut slot with the pro-

peller shaft hole. Insert a new cotter pin

in the hole and bend the cotter pin ends.

NOTICE: Do not reuse the cotter pin.

Otherwise, the propeller can come off

during operation.

[ECM01892]

If the propeller nut slot does not align with the propeller shaft hole after tightening the propeller nut to the specified torque, tighten the nut further to align the slot with the hole.

EMU47070

Changing gear oil

EWM00801

1. Cotter pin

2. Propeller nut

3. Washer

4. Spacer

5. Propeller

6. Thrust washer

ZMU06564

 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.

 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 accidentally falls.

(1) Tilt the outboard motor so that the gear

oil drain screw is at the lowest point pos-

sible.

Page 92

Maintenance

TIP:

ZMU03274

(2) Place a suitable container under the

gear case.

(3) Remove the gear oil drain screw and

gasket. NOTICE: If there is an exces-

sive quantity of metal particles on the magnetic gear oil drain screw, this can indicate lower unit problem. Consult your Yamaha dealer.

[ECM01901]

ZMU03273

1. Gear oil drain screw

2. Oil level plug

 If a magnetic gear oil drain screw is

equipped, remove all metal particles from the screw before installing it.

 Always use new gaskets. Do not reuse the

removed gaskets.

(4) Remove the oil level plug and gasket to

allow the oil to drain completely.

NOTICE: Check the used gear oil after it has been drained. If the gear oil is milky or contains water or a large amount of metal particles, the gear case may be damaged. Have a Yamaha dealer check and repair the outboard motor.

For disposal of used oil, consult your Yamaha dealer. (5) Put the outboard motor in a vertical posi-

tion. Using a flexible or pressurized fill-

[ECM00714]

ing device, inject the gear oil into the

gear oil drain screw hole.

Recommended gear oil:

YAMALUBE outboard gear oil or Hypoid gear oil

Recommended gear oil grade:

SAE 90 API GL-4

Gear oil quantity:

0.370 L (0.391 US qt, 0.326 Imp.qt)

(6) Put a new gasket on the oil level plug.

When the oil begins to flow out of the oil

level plug hole, insert and tighten the oil

level plug.

Apply a light coat of gear oil to the oil level plug thread and gasket before installation.

Tightening torque:

7 N·m (0.7 kgf·m, 5.2 lb·ft)

(7) Put a new gasket on the gear oil drain

screw. Insert and tighten the gear oil

drain screw.

Apply a light coat of gear oil to the gear oil drain screw thread and gasket before installation.

Tightening torque:

7 N·m (0.7 kgf·m, 5.2 lb·ft)

Page 93

Maintenance

TIP:

ZMU02924

ZMU05024

EMU29318

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.

ECM00721

Do not paint anodes, as this would render them ineffective.

EMU29324

Checking battery (for electric start models)

EWM01903

Battery electrolyte is poisonous and caustic, and batteries generate explosive hydrogen gas. When working near the battery:

 Wear protective eye gear and rubber

gloves.

 Do not smoke or bring any other source

of ignition near the battery.

The procedure for checking the battery varies for different batteries. This procedure contains typical checks that apply to many batteries, but you should always refer to the battery manufacturer’s instructions.

ECM01921

A poorly maintained battery will quickly deteriorate.

(1) Check the electrolyte level.

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.

(2) Check the battery’s charge. If your boat

is equipped with the digital speedome-

ter, the voltmeter and low battery alert

functions will help you monitor the bat-

tery’s charge. If the battery needs charg-

ing, consult your Yamaha dealer. (3) Check the battery connections. They

Page 94

Maintenance

ZMU01811

should be clean, secure, and covered by an insulating cover. WARNING! Bad

connections can produce shorting or arcing and cause an explosion.

[EWM01913]

EMU29335

Connecting the battery

EWM00573

Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder.

ECM01125

Do not reverse the battery cables. Otherwise, the electrical parts could be damaged.

(1) Make sure the main switch (on applica-

ble models) is “ ” (off) before working on the battery.

(2) Connect the red battery cable to the

POSITIVE (+) terminal first. Then connect the black battery cable to the NEGATIVE (-) terminal.

cables must be clean and properly con-

nected, or the battery will not start the

engine.

EMU29372

Disconnecting the battery

(1) Turn off the battery cut-off switch (if

equipped) and main switch. NOTICE: If

they are left on, the electrical system

can be damaged.

(2) Disconnect the negative cable(s) from

the negative (-) terminal. NOTICE: Al-

ways disconnect all negative (-) ca-

bles first to avoid a short circuit and

damage to the electrical system.

[ECM01941]

(3) Disconnect the positive cable(s) and re-

move the battery from the boat. (4) Clean, maintain, and store the battery

according to the manufacturer’s instruc-

tions.

[ECM01931]

1. Red cable

2. Black cable

3. Battery

(3) The electrical contacts of the battery and

Page 95

Trouble Recovery

EMU47220

Troubleshooting

This section describes the likely causes and remedies for problems, such as those in the fuel, compression, and ignition systems, poor starting, and loss of power. Please note that all of the items in this section may not apply to your model. If your outboard motor requires repair, bring it to a Yamaha dealer. If the engine trouble-alert indicator is blinking, consult your Yamaha dealer.

Trouble Starter will not operate.

Item Question Answer

Gear shift lever Is gear shift lever in gear? Shift to neutral.

Is battery capacity low or weak?

Battery

Fuse

Starter

Trouble Engine will not start (starter operates).

Item Question Answer

Engine shut-off cord (lanyard)

Fuel tank Is fuel tank empty? Fill tank with clean, fresh fuel. Fuel Is fuel contaminated or stale? Fill tank with clean, fresh fuel. Fuel filter Is fuel filter clogged? Clean or replace fuel filter. Fuel pump Is fuel pump malfunctioning? Have serviced by a Yamaha dealer.

Spark plugs

Spark plug cap

Ignition parts Are ignition parts malfunctioning? Have serviced by a Yamaha dealer.

Ignition wiring

Engine inner parts Are engine inner parts damaged? Have serviced by a Yamaha dealer.

Are battery connections corroded or loose?

Is fuse for starter relay or electric circuit blown?

Are starter components malfunctioning?

Is clip on engine shut-off cord (lanyard) installed?

Are spark plugs fouled or of incorrect type?

Are spark plug cap(s) fitted incorrectly?

Is ignition wiring damaged or poorly connected?

Check battery condition. Use battery of recommended capacity.

Tighten battery cables and clean battery terminals.

Check for cause of electric overload and repair. Replace fuse with one of correct amperage.

Have serviced by a Yamaha dealer.

Install clip to engine shut-off switch.

Inspect spark plugs. Clean or replace with recommended type.

Check and re-fit cap(s).

Inspect wires for breaks and wear. Have connections tightened and broken or worn wires replaced by a Yamaha dealer.

Page 96

Trouble Recovery

Trouble Engine idles irregularly or stalls.

Item Question Answer

Are spark plugs fouled or of incorrect

Spark plugs

Fuel system Is fuel system clogged?

Fuel Is fuel contaminated or stale? Fill tank with clean, fresh fuel. Fuel filter Is fuel filter clogged? Clean or replace fuel filter. Ignition parts Are ignition parts malfunctioning? Have serviced by a Yamaha dealer. Alert system Has alert system activated? Find and correct cause of alert.

Ignition wiring

Engine oil

Thermostat

Fuel pump Is fuel pump malfunctioning? Have serviced by a Yamaha dealer.

Fuel tank

Fuel joint Is fuel joint connection incorrect? Connect correctly. Air vent screw Is air vent screw on fuel tank closed? Open air vent screw. Battery Is battery cable disconnected? Connect securely. Outboard motor

mounting Throttle valve Is throttle valve adjustment incorrect? Have serviced by a Yamaha dealer.

type? Is spark plug gap incorrect? Replace spark plug.

Is ignition wiring damaged or poorly connected?

Is specified engine oil not being used?

Is thermostat clogged or malfunctioning?

Is fuel tank air vent restricted or clogged?

Is motor angle too high? Return to normal operating position.

Inspect spark plugs. Clean or replace with recommended type.

Inspect for pinched or kinked fuel line or other obstructions in fuel system.

Inspect wires for breaks and wear. Have connections tightened and broken or worn wires replaced by a Yamaha dealer.

Inspect engine oil and replace with specified type.

Have serviced by a Yamaha dealer.

Remove obstruction.

Trouble Alert buzzer sounds or indicator lights.

Item Question Answer

Cooling system Is cooling system clogged?

Low oil pressurealert

Spark plugs

Engine oil

Oil filter Is oil filter clogged? Have serviced by a Yamaha dealer. Oil pump Is oil pump malfunctioning? Have serviced by a Yamaha dealer. Thermostat Is thermostat malfunctioning? Have serviced by a Yamaha dealer.

Is low oil pressure-alert indicator on or blinking?

Is heat range of spark plugs incorrect?

Is specified engine oil not being used?

Is engine oil contaminated or deteriorated?

Inspect cooling water inlet for obstructions.

Have serviced by a Yamaha dealer.

Inspect spark plugs and replace with recommended type.

Inspect engine oil and replace with specified type.

Replace engine oil with specified type.

Page 97

Trouble Recovery

Trouble Alert buzzer sounds or indicator lights.

Item Question Answer

Water pump Is water pump malfunctioning? Have serviced by a Yamaha dealer. Fuel filter Is there excess water in fuel filter? Drain fuel filter.

Trouble Engine power loss.

Item Question Answer

Is propeller damaged? Have propeller repaired or replaced.

Propeller

Mounting height

Alert system Has alert system activated? Find and correct cause of alert.

Boat bottom

Spark plugs

Lower unit

Fuel system Is fuel system clogged?

Fuel filter Is fuel filter clogged? Clean or replace fuel filter.

Fuel

Ignition wiring

Electrical parts Are electrical parts malfunctioning? Have serviced by a Yamaha dealer.

Engine oil

Thermostat

Fuel tank

Fuel pump Is fuel pump malfunctioning? Have serviced by a Yamaha dealer. Fuel joint Is fuel joint connection incorrect? Connect correctly.

Gear shift lever

Is propeller pitch or diameter incorrect?

Is outboard motor mounted at incorrect height on transom?

Is boat bottom fouled with marine growth?

Are spark plugs fouled or of incorrect type?

Is spark plug gap incorrect? Replace spark plug. Is heat range of spark plugs incor-

rect? Are weeds or other foreign material

tangled on gear housing?

Is fuel contaminated or stale? Fill tank with clean, fresh fuel. Is specified fuel not being used? Replace fuel with specified type

Is ignition wiring damaged or poorly connected?

Is specified engine oil not being used?

Is thermostat clogged or malfunctioning?

Is fuel tank air vent restricted or clogged?

Is engine not responding properly to gear shift lever position?

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

Have outboard motor adjusted to proper transom height.

Clean boat bottom.

Inspect spark plugs. Clean or replace with recommended type.

Inspect spark plugs and replace with recommended type.

Remove foreign material and clean lower unit.

Inspect for pinched or kinked fuel line or other obstructions in fuel system.

Inspect wires for breaks and wear. Have connections tightened and broken or worn wires replaced by a Yamaha dealer.

Replace engine oil with specified type.

Have serviced by a Yamaha dealer.

Remove obstruction.

Have serviced by a Yamaha dealer.

Page 98

Trouble Recovery

Trouble Engine power loss.

Item Question Answer

Have motor adjusted to proper transom height.

Trouble Engine vibrates excessively.

Item Question Answer

Propeller

Propeller shaft Is propeller shaft damaged? Have serviced by a Yamaha dealer. Outboard motor

mounting Steering pivot Is steering pivot loose or damaged? Have serviced by a Yamaha dealer.

Is trim angle incorrect?

Is motor mounted at incorrect height on transom?

Is propeller damaged? Have propeller repaired or replaced. Are weeds or other foreign material

tangled on propeller?

Are outboard motor mounting bolts loose?

Adjust trim angle to achieve most efficient operation.

Have motor adjusted to proper transom height.

Remove and clean propeller.

Tighten bolts or have serviced by a Yamaha dealer.

EMU29435

Temporary action in

emergency

EMU29442

Impact damage

EWM00871

The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate.

If the outboard motor hits an object in the water, follow the procedure below.

(1) Stop the engine immediately. (2) Check the control system and all compo-

nents for damage. Also, check the boat

for damage. (3) Whether damage is found or not, return

to the nearest harbor slowly and careful-

ly. (4) Have a Yamaha dealer check the out-

board motor before operating it again.

EMU30684

Replacing fuse

If a fuse has blown, open the fuse holder and remove the fuse with a fuse puller. Replace it with a spare one of the proper amperage.

EWM00632

Substituting an incorrect fuse or a piece of wire could allow excessive current flow. This could cause electric system damage and a fire hazard.

Consult your Yamaha dealer if the new fuse immediately blows again.

Page 99

1. Fuse puller

ZMU08781

ZMU04337

ZMU08782

2. Cap

3. Fuse (20 A)

4. Spare fuse (20 A)

Trouble Recovery

(2) Loosen the manual valve screw by turn-

ing it clockwise until it stops.

1. Manual valve screw

(3) Adjust the outboard motor to a navigable

angle, tighten the manual valve screw

counterclockwise, and secure the out-

board motor.

EMU29534

Starter will not operate

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

EWM01023

1. Fuse puller

EMU29516

Power trim and tilt will not operate

EWM02331

Never get under the engine while it is tilted. Severe injury could occur if the outboard motor accidentally falls.

If the outboard motor cannot be tilted up/down using the power trim and tilt unit, e.g. because of a discharged battery or a failure with the unit itself, the outboard motor can be tilted manually. (1) Stop the engine.

 Use this procedure only in an emergen-

cy to return to the nearest port for repairs.

 When the emergency starter rope is

used to start the engine, the start-ingear protection device does not operate. Make sure the remote control lever is in neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.

 Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg while operating the boat.

 Do not attach the cord to clothing that

Page 100

Trouble Recovery

ZMU08793

ZMU08796

could tear loose. Do not route the cord where it could become entangled, preventing it from functioning.

 Avoid accidentally pulling the cord dur-

 Make sure no one is standing behind

you when pulling the starter rope. It could whip behind you and injure someone.

 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 flywheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.

 Do not touch the ignition coil, spark

plug wire, spark plug cap, or other electrical components when starting or operating the motor. You could get an electrical shock.

(2) Remove the manual starter after remov-

ing the bolt(s).

ZMU08794

EMU47121

Emergency starting engine (manual start model)

(1) Disconnect the start-in-gear protection

cable from the manual starter.

(3) Pass the start-in-gear protection cable

under the blow by hose and remove the

spring from it.