6L2-9-1K Hyoshi 2/14/03 17:25 Page 1 25C OWNER’S MANUAL Printed in Japan March 2003-1.0 × 1 ! 6L2-28199-1K (25NMH) (E) Printed on recycled paper U.S.A.
6L2-9-1K Hyoshi 2/14/03 17:25 Page 2
6L2-9-1K-1 2/14/03 17:33 Page 1 E EMU14480 TO THE OWNER Thank you for choosing 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.
6L2-9-1K-1 2/14/03 17:33 Page 3 EMA20010 CONTENTS E GENERAL INFORMATION 1 BASIC COMPONENTS 2 OPERATION 3 MAINTENANCE 4 TROUBLE RECOVERY 5 INDEX 6 READ THIS OWNER’S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR.
6L2-9-1K-1 2/14/03 17:33 Page 5 E EMB00010 Chapter 1 GENERAL INFORMATION IDENTIFICATION NUMBERS RECORD ..1-1 Outboard motor serial number...........1-1 EMISSION CONTROL INFORMATION...1-2 1 2 SAFETY INFORMATION..........................1-3 IMPORTANT LABELS ..............................1-5 BASIC BOATING RULES .........................1-6 FUELING INSTRUCTIONS.....................1-10 Gasoline ..............................................1-11 Engine oil ............................................
L2-9-1K-1 2/14/03 17:33 Page 6 E EMU00005 IDENTIFICATION NUMBERS RECORD EMU00007 OUTBOARD MOTOR SERIAL NUMBER YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON 1 401012 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.
6L2-9-1K-1 2/14/03 17:33 Page 7 E EMU01385 25 EMISSION CONTROL INFORMATION 1 EMU01386 NORTH AMERICAN MODELS 2 108021 25-3/30 This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details. Approval label of Emission control certificate This label is attached to the bottom cowling. 1 1 Emission control information label 2 EMISSION CONTROL INFORMATION ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S.
6L2-9-1K-1 2/14/03 17:33 Page 8 E EMU00917 Q SAFETY INFORMATION 8 Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation. 8 Before operating the boat, read any owner’s or operator’s manuals supplied with it and all labels. Be sure you understand each item before operating. 8 Do not overpower the boat with this outboard motor. Overpowering the boat could result in loss of control.
6L2-9-1K-1 2/14/03 17:33 Page 9 E 8 When a swimmer is in the water near you shift into neutral and shut off the engine. 8 Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the following: United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast Guard Headquarters Washington, D.C.
6L2-9-1K-1 2/14/03 17:33 Page 10 E EMB30010 LOCATION IMPORTANT LABELS 25 q WARNING LABELS 1 WARNING w ●Be sure shift control is in neutral before starting engine. (except 2HP) ●Do not touch or remove electrical parts when starting or during operation. ●Keep hands,hair,and clothes away from flywheel and other rotating parts while engine is running. 202023 6A1-83625-41 25-3/30 q 2 WARNING This engine is equipped with a neutral starting device.
6L2-9-1K-1 2/14/03 17:33 Page 11 E EMB40010 BASIC BOATING RULES (Rules of the road) Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast Guard and local agencies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water.
6L2-9-1K-1 2/14/03 17:33 Page 12 E RULES WHEN ENCOUNTERING VESSELS There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed: side. This rule doesn’t apply if both of you will clear one another if you continue on your set course and speed.
6L2-9-1K-1 2/14/03 17:33 Page 13 E the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you. OTHER SPECIAL SITUATIONS There are three other rules you should be aware of when driving your boat around other vessels.
6L2-9-1K-1 2/14/03 17:33 Page 14 E tion. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geographic location. Always consult local boating authorities before driving your boat in unfamiliar waters. N EL MAIN CHANNEL BUOYS A N " 6" A C H C " 1" M N N O A N White Light C H D A R Odd number. increasing toward head of navigation.
6L2-9-1K-1 2/14/03 17:33 Page 15 E EMU00016 FUELING INSTRUCTIONS w GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! 8 Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. 8 Stop engine before refueling. 8 Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. 8 Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. 8 Do not overfill the fuel tank. 8 Tighten the filler cap securely after refueling.
6L2-9-1K-1 2/14/03 17:33 Page 16 E EMU01804 GASOLINE Recommended gasoline: Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2 If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. EMU00027 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings.
6L2-9-1K-1 2/14/03 17:33 Page 17 E EMU01395 PROPELLER SELECTION The performance of your outboard motor will be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine.
6L2-9-1K-1 2/14/03 17:33 Page 18 E NOTE: At full throttle and under a maximum boat load, the engine’s rpm should be within the upper half of the full throttle operating range, as listed in “SPECIFICATIONS” on page 4-1. Select a propeller which fulfills this requirement. If operating under conditions which allow the engine’s rpm to rise above the maximum recommended range (such as light boat loads), reduce the throttle setting to maintain the rpm in the proper operating range.
6L2-9-1K-2 2/14/03 18:38 Page 1 E EMC00010 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-3 Fuel tank ................................................2-3 Gear shift lever .....................................2-3 Engine stop lanyard switch .................2-4 Engine stop button...............................2-5 Tiller handle ..........................................2-5 Choke knob ................
6L2-9-1K-2 2/14/03 18:38 Page 2 E EMU01206 MAIN COMPONENTS 25 q w e r t y u !5 !4 !3 !6 !2 !1 i o !0 101061 1 2 3 4 5 6 7 8 9 0 q w e r t y Recoil starter handle Choke knob Warning lamp Gear shift lever Throttle-control grip/Tiller-handle Engine stop button/ Engine stop lanyard switch Transom-clamp handle Tilt lock lever Cooling water inlet Propeller Trim tab (Anode) Anti-cavitation plate Trim angle adjusting-rod Rope attachment Shallow water lever Fuel tank * May not be exactly as shown; a
6L2-9-1K-2 2/14/03 18:38 Page 3 E EMU01206 MAIN COMPONENTS 25-3/30 1 i u y t r e w o 2 3 4 5 6 p 7 q 0 9 8 1 2 3 4 5 6 7 8 *9 0 q w e r t y u Recoil starter handle Gear shift lever Tiller handle Tilt lock lever Shallow water lever Transom clamp handle Trim angle adjusting rod Cooling water inlet Propeller Anti-cavitation plate Trim tab Clamp bracket Tilt support lever Rope attachment Top cowling Choke knob Engine stop button/engine stop lanyard switch i Warning indicator * o Remote control box
6L2-9-1K-2 2/14/03 18:38 Page 4 E EMC20010 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS EMC21012 FUEL TANK If your model was equipped with a portable fuel tank, its function is as follows. q e r w 1 2 3 4 Fuel hose joint Fuel meter(If equipped) Fuel tank cap Air vent screw(If equipped) Fuel hose joint This connector is provided for connecting or disconnecting fuel hose. 902051 Fuel meter This meter is on the fuel tank cap. It shows current fuel quantity in the fuel tank approximately.
6L2-9-1K-2 2/14/03 18:38 Page 5 E EMC28111 25 ENGINE STOP LANYARD SWITCH (for Tiller control model) 1 2 001127 25-3/30 The lock-plate on the end of the lanyard must be attached to the engine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine.
6L2-9-1K-2 2/14/03 18:38 Page 6 E EMC27011 25 25-3/30 ENGINE STOP BUTTON (for Tiller control model) Pushing this button opens the ignition circuit and stops the engine. 3 EMU00062 w TILLER HANDLE (for Tiller control model) q Moving the tiller handle sideways to adjust the steering direction. In addition, this handle contains the functions as follows.
6L2-9-1K-2 2/14/03 18:39 Page 7 E EMU01293 Throttle friction adjusting screw/ knob A friction device in the tiller handle provide resistance to movement of the throttle grip. This is adjustable for operator preference. An adjusting screw/knob is located within the tiller handle. 502011 Resistance Increase Decrease Knob/Screw Turn clockwise Turn counterclockwise When constant speed is desired, tighten the adjusting screw/bolt to maintain the desired throttle setting.
6L2-9-1K-2 2/14/03 18:39 Page 8 E EMD00011 STEERING FRICTION ADJUSTING SCREW(for Tiller control model) A friction device provides resistance to steering movement. This is adjustable for operator preference. An adjusting screw/bolt is located on the swivel bracket. 408015 EMD00310* Adjustment Resistance Increased Decreased Screw/bolt Turn clockwise Turn counterclockwise w Do not overtighten the friction screw/bolt.
6L2-9-1K-2 2/14/03 18:39 Page 9 E EMU00113 A TRIM TAB B w 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. q w 603011 An improperly adjusted trim tab may 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.
6L2-9-1K-2 2/14/03 18:39 Page 10 E EMD08010 25 SHALLOW WATER LEVER (If equipped) 25 Lifting this lever will tilt the motor up partially to provide more clearance when operating in shallow water. 402075* EMD08110 25-3/30 SHALLOW WATER LEVER (If equipped) 25-3/30 Pushing this lever down will tilt the motor up partially to provide more clearance when operating in shallow water.
6L2-9-1K-2 2/14/03 18:39 Page 11 E EMU00156 25 TILT SUPPORT BAR 25 The tilt support bar 1 keeps the outboard motor in the tilted up position. q 403023 EMD60210 25-3/30 TILT SUPPORT LEVER 25-3/30 To keep the outboard motor in the tiltedup position, lock the tilt support lever to the swivel bracket. 403024 EMD62010 TOP COWLING LOCK LEVER To remove the engine top cowling, push the lock lever downward. Then lift off the cowling.
6L2-9-1K-2 2/14/03 18:39 Page 12 E EMD80010 WARNING SYSTEM cC Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU00170 25 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate.
6L2-9-1K-2 2/14/03 18:39 Page 13 E EMU00172 OIL LEVEL WARNING / OIL FILTER CLOGGING WARNING This engine has an oil level warning system. If oil level falls below lower limit, the warning device will activate. (2); Included (—); N/A Warning device activation 30 303014 q Tiller control model The engine speed will automatically decrease to about 2,000 r/min. 2 The oil level warning indicator will come on. 2 The buzzer will sound.
6L2-9-1K-2 2/14/03 18:39 Page 14 E Oil level warning system 30 The various oil-level warning system functions are as follows: Oil level warning indicator lamp (Bottom cowling) Red Engine oil tank Remarks OFF more than 200 cm3 (0.21 US qt, 0.181 Imp qt) No refilling necessary. ON 200 cm3 or less (0.21 US qt, 0.181 Imp qt) Buzzer sounds in remote control box and engine speed is limited to about 2,000 r/min to help conserve oil. Check oil filter for clogging. Add oil.
6L2-9-1K-3 2/17/03 18:40 Page 1 E EMF00010 Chapter 3 OPERATION INSTALLATION ........................................3-1 Mounting the outboard motor............3-2 Clamping the outboard motor ............3-4 FILLING FUEL AND ENGINE OIL ............3-5 Filling fuel..............................................3-5 Filling oil ................................................3-6 Gasoline (petrol) and oil mixing .........3-8 PRE-OPERATION CHECKS....................
6L2-9-1K-3 2/17/03 18:40 Page 2 E EMF10010 INSTALLATION cC Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat or accessories such as transom ladders/depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operated continuously in the presence of airborne water spray. NOTE: During water testing check the buoyancy of the boat, at rest, with its maximum load.
6L2-9-1K-3 2/17/03 18:40 Page 3 E EMU00176 MOUNTING THE OUTBOARD MOTOR w Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Observe the following: 8 The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat/motor combination. Proper mounting depends in part on experience and the specific boat/motor combination.
6L2-9-1K-3 2/17/03 18:40 Page 4 E w Overpowering a boat may cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer. EMU01298 0~25mm 104013 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.
6L2-9-1K-3 2/17/03 18:40 Page 5 E EMF14010 CLAMPING THE OUTBOARD MOTOR 1) 409011 Place the outboard on the transom so that it is positioned as close to the center as possible. Tighten the transom clamp screws evenly and securely. Check the clamp-screws for tightness occasionally during operation of the motor as they can work loose due to engine vibration. w Loose clamp screws could allow the motor to move on the transom or fall off the transom. This could cause loss of control and serious injury.
6L2-9-1K-3 2/17/03 18:40 Page 6 E EMF30010 FILLING FUEL AND ENGINE OIL FILLING FUEL 1) 2) 3) 902055 Remove the fuel tank cap. Fill the fuel tank carefully. Close the cap securely after refueling. Wipe up any spilled fuel. Fuel tank capacity: Refer to SPECIFICATIONS on Page 4-1. Ring Free Fuel Additive Gasoline is a precise blend of many different substances, each chosen to give certain characteristics.
6L2-9-1K-3 2/17/03 18:40 Page 7 E While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free has repeatedly proven its ability to clean combustion deposits from inside the engine, notably the critical piston-ringland area, and fuel system components.
6L2-9-1K-3 2/17/03 18:40 Page 8 E 30 EMU00192 w q 203012* Procedure 1) Remove the top cowling. 2) Open the oil tank filler cap by pulling the tab. 3) Slowly fill the engine oil into the engine oil tank. 4) After filling, replace the cap securely. 5) Replace the top cowling securely.
6L2-9-1K-3 2/17/03 18:40 Page 9 E EMF35011 GASOLINE (PETROL) AND OIL MIXING q Pre-mix model Engine oil : Gasoline (Petrol) w 1) Break-in period 1 : 25 After break-in 1 : 100 Pour oil and gasoline into the fuel tank, in that order. 1 Engione oil 2 Gasoline (Petrol) 2) 3) Then mix the fuel thoroughly by shaking. Make sure the oil is mixed with gasoline . 902033 cC 8 Avoid using any oil other than the designated type. 8 Use a thoroughly blended fuel-oil mixture.
6L2-9-1K-3 2/17/03 18:40 Page 10 E Mixing ratio 25 : 1 Gasoline (Petrol) 1L 12 L 14 L 24 L (0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal, 0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.3 Imp gal) Engine oil 0.04 L 0.48 L 0.56 L 0.96 L (0.04 US qt, (0.51 US qt, (0.59 US qt, (1.01 US qt, 0.04 Imp qt) 0.42 Imp qt) 0.49 Imp qt) 0.84 Imp qt) Mixing ratio 100 : 1 Gasoline (Petrol) 1L 12 L 14 L 24 L (0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal, 0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.
6L2-9-1K-3 2/17/03 18:40 Page 11 E MU00204 PRE-OPERATION CHECKS w If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur. cC Do not start the engine out of water. Overheating and serious engine damage can occur. EMU00206 Fuel 8 Check to be sure you have plenty of fuel for your trip. 8 Make sure there are no fuel leaks or gasoline fumes.
6L2-9-1K-3 2/17/03 18:40 Page 12 E EMU00210 Engine 8 Check the engine and engine mounting. 8 Look for loose or damaged fasteners. 8 Check the propeller for damage. EMU01790 30 OIL OPERATION AFTER A LONG PERIOD OF STORAGE 203024 When operating the engine after a long period (12 months) of storage, proceed as follows: 1) Use a 50:1 gasoline-oil mixture to start the engine. 2) Start the engine. Leave it idling. w 8 Do not touch or remove electrical parts when starting or during operation.
6L2-9-1K-3 2/17/03 18:40 Page 13 E EMU01781 BREAKING IN ENGINE Your new engine requires a period of break-in to allow mating surfaces of moving parts to wear in evenly. Correct breakin will help ensure proper performance and longer engine life. cC 8 Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage. 8 Premix fuel must be used during breakin in addition to oil in the oil injection system.
6L2-9-1K-3 2/17/03 18:40 Page 14 E cC Make sure to mix gasoline (petrol) and oil completely, otherwise your outboard motor may be damaged. EMU01786 Break-in procedure Run the engine under load (in gear with a propeller installed) as follows. 1) First 10 minutes: Run the engine at the lowest possible speed. A fast idle in neutral is best. 2) Next 50 minutes: Do not exceed half throttle (approximately 3,000 r/min). Vary engine speed occasionally.
6L2-9-1K-3 2/17/03 18:40 Page 15 E Oil injection system models 5) After the first 10 hours: Operate the engine normally. Use only straight gasoline in the fuel tank. The oil injection system provides proper lubrication for normal operation. EMU01147 STARTING ENGINE w 8 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.
6L2-9-1K-3 2/17/03 18:40 Page 16 E 1) If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns. 902053 25 2) If there is a fuel joint on the motor, firmly connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank. NOTE: During engine operation place the tank horizontally, or fuel cannot be drawn into the engine. 25-3/30 304024* 3) Squeeze the primer bulb with the outlet end up until you feel it become firm.
6L2-9-1K-3 2/17/03 18:40 Page 17 E 5) 25 Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock plate on the other end of the lanyard in the engine stop switch. w 8 Attach the engine stop switch lanyard to a secure place on your clothing, your arm or leg while operating. 8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard where it could become entangled, preventing it from functioning.
6L2-9-1K-3 2/17/03 18:40 Page 18 E 8) 9) Pull the starter handle slowly until you feel resistance. Then, give a strong pull straight out to crank and start the engine. Repeat it, if necessary. After the engine starts, return the starter handle slowly to the original position before releasing it. 209015 10) Return the throttle to the fully closed position.
6L2-9-1K-3 2/17/03 18:40 Page 19 E EMG00010 WARMING UP ENGINE 1) 2) Before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (Failure to do this will shorten engine life.) Check for a steady flow of water from the cooling-water pilot hole. cC 309012 A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages.
6L2-9-1K-3 2/17/03 18:40 Page 20 E EMU00261 SHIFTING w Before shifting, make sure there are no swimmers or obstacles in the water near you. cC To change the shifting position from forward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speeds). EMU00263 FORWARD 1) Place the throttle control grip in the fully closed position. 2) Turn the gear shift lever quickly and firmly from Neutral to Forward.
6L2-9-1K-3 2/17/03 18:40 Page 21 E EMU00268 REVERSE w When operating in Reverse, go slowly. Do not open the throttle more than half. Otherwise, the boat may become unstable, which could result in loss of control and an accident. 1) Place the throttle control grip in the fully closed position (for Tiller control model). 2) Check that the tilt-lock lever (for Manual tilt model) is in the locked position. 3) Turn the gear-shift lever quickly and firmly from Neutral to Reverse.
6L2-9-1K-3 2/17/03 18:40 Page 22 E EMG38010 25 STOPPING ENGINE Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended. 407016* EMU00277 25-3/30 1) 308013 Push and hold the engine stop button or turn the main switch to “OFF”. 2) If the fuel joints are provided, disconnect the fuel line from the motor after stopping the engine.
6L2-9-1K-3 2/17/03 18:40 Page 23 E EMU01412 TRIMMING OUTBOARD MOTOR The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The 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.
6L2-9-1K-3 2/17/03 18:40 Page 24 E ADJUSTING TRIM ANGLE 25 EMU00951 Manual tilt model q 001770 25-3/30 q 404015* There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim angle. 1) Stop the engine. 2) Remove the trim angle adjusting rod 1 from the clamp bracket while tilting the motor up slightly. 3) Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom. To lower the bow (“trim-in”), move the rod toward the transom.
6L2-9-1K-3 2/17/03 18:40 Page 25 E EMU19160 q 001672 w Trim angle settings and boat handling 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. The trim tab can also be adjusted to help offset this effect.
6L2-9-1K-3 2/17/03 18:40 Page 26 E NOTE: Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating. EMG70011 CRUISING IN SHALLOW WATER Manual tilt model The outboard motor can be tilted up partially to allow operation in shallow water. w 000832 8 Place the gear shift in the Neutral position before using the shallow water cruising system. 8 Run the boat at the lowest possible speed when using the shallow water cruising system.
6L2-9-1K-3 2/17/03 18:40 Page 27 E EMG71310 25 PROCEDURE 25 1) 2) Place the gear shift lever in the neutral position. Push the tilt lock lever down to release. 402061** 3) 4) 25 402075 Pull up the shallow water lever. Slightly tilt up the engine. The tiltsupport bar will lock automatically, supporting the engine in a partially raised position. NOTE: If the engine is tilted up completely, the tilt-lock lever automatically locks. The shallow water lever is no longer effective.
6L2-9-1K-3 2/17/03 18:40 Page 28 E 3) 25-3/30 To return the engine to the normal position, put the engine in Neutral, then slightly tilt up the engine. Set the tilt-lock lever and shallow water lever to the lock position and slowly tilt the engine down.
6L2-9-1K-3 2/17/03 18:40 Page 29 E w Leaking fuel is a fire hazard. Disconnect the fuel line if the engine will be tilted for more than a few minutes. Otherwise, fuel may leak. (If the fuel connector is provided on the motor.) EMG63910 N PROCEDURE FOR TILTING UP 25 1) 2) Place the gear shift lever in Neutral. Remove the fuel line connection from the motor. 3) Push the tilt lock lever to release. 4) Pull up the shallow water lever.
6L2-9-1K-3 2/17/03 18:40 Page 30 E 5) 6) Hold the rear of the top cowling with one hand and fully tilt the engine up. The tilt support bar turns to the locked position automatically. EMG63010* PROCEDURE FOR TILTING UP 25-3/30 1) 2) Remove the fuel-line connection from the motor. (If the fuel connector is provided on the motor.) Place the tilt-lock lever in Release.
6L2-9-1K-3 2/17/03 18:40 Page 31 E EMG73210 PROCEDURE FOR TILTING DOWN 25-3/30 1) 2) Return the tilt support lever tilting up the engine slightly. Tilt down the engine. 403036 EMH60010 CRUISING IN OTHER CONDITIONS CRUISING IN SALT WATER After operating in salt water, wash out the cooling-water passages with fresh water to prevent them from becoming cloggedup with salt deposits. NOTE: Refer to cooling system flushing instructions in “TRANSPORTING AND STORING OUTBOARD MOTOR”.
6L2-9-1K-3 2/17/03 18:40 Page 32 E -MEMO-
6L2-9-1K-4 2/25/03 15:51 Page 1 E EMK00010 Chapter 4 MAINTENANCE SPECIFICATIONS .....................................4-1 TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-2 Trailering outboard motor...................4-2 Storing outboard motor ......................4-3 PERIODIC MAINTENANCE......................4-7 Replacement parts ...............................4-7 Maintenance chart................................4-8 Cleaning and adjusting spark plug....
6L2-9-1K-4 2/25/03 15:51 Page 2 E EMK10011* SPECIFICATIONS Model Item Unit 25MHC DIMENSIONS 8Overall Length 8Overall Width 8Overall Height 8Transom height 8Weight S S S mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.) 936 (369) 358 (14.1) 1,068 (42.0) 419 (16.5) 48.0 (105.8) r/min kW (HP) r/min 5,000~6,000 18.
6L2-9-1K-4 2/25/03 15:51 Page 3 E EMU01369* TRANSPORTING AND STORING OUTBOARD MOTOR w 000929 Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. TRAILERING OUTBOARD MOTOR The motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the motor in the tilt position using a motor support device such as a transom saver bar.
6L2-9-1K-4 2/25/03 15:51 Page 4 E When transporting or storing the outboard motor while removed from a boat, fold the tiller handle and lean the motor on the tiller handle to keep in a horizontal position. 102013 NOTE: Place a towel or the like under the outboard motor to protect it from damage. cC Keep the power unit higher than the propeller at all times. Otherwise, cooling water can run into the cylinder, which could result in damage.
6L2-9-1K-4 2/25/03 15:51 Page 5 E EMU01796 STORING OUTBOARD MOTOR 30 When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. This is especially important for your oil injection-equipped outboard motor due to the lean oil ratios used at idle prior to shutting the engine off for the season. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage.
6L2-9-1K-4 2/25/03 15:51 Page 6 E EMK22211 q w 605024 Flushing Cooling System and Fogging Engine Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging of the engine is mandatory to prevent expensive engine damage due to rust. Perform the flushing and fogging at the same time. 1) Remove the cowling.
6L2-9-1K-4 2/25/03 15:51 Page 7 E EMK26111 Lubrication 1) Remove the spark plugs, and spray a 10 second spray of “Yamaha StorRite Engine Fogging Oil” into each cylinder. Grease the spark plug threads and reinstall the spark plugs and torque to proper specification. (Refer to “CLEANING AND ADJUSTING SPARK PLUG”.) 2) Turn the engine over with the stop lanyard disconnected to work the fogging oil into the piston rings. 3) Fill the oil tanks. This prevents the formation of condensation.
6L2-9-1K-4 2/25/03 15:51 Page 8 E EMU01569 PERIODIC MAINTENANCE w Be sure to turn off the engine when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual.
6L2-9-1K-4 2/25/03 15:51 Page 9 E EMU19460 MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. The mark (●) indicates the check-ups which you may carry out yourself. The mark (1) indicates work to be carried out by your Yamaha dealer.
6L2-9-1K-4 2/25/03 15:51 Page 10 E EMU01202 CLEANING AND ADJUSTING SPARK PLUG w 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. 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.
6L2-9-1K-4 2/25/03 15:51 Page 11 E When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque. Spark plug torque: Refer to “SPECIFICATIONS”, page 4-1. NOTE: If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.
6L2-9-1K-4 2/25/03 15:51 Page 12 E 25 EMK38010 CHECKING FUEL SYSTEM w Gasoline (petrol) and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition. 25-3/30 Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by Yamaha dealer or other qualified mechanic. Checking points 8 Fuel system parts leakage. 8 Fuel hose joint leakage. 8 Fuel hose cracks or other damage.
6L2-9-1K-4 2/25/03 15:51 Page 13 E EMU00370 INSPECTING FUEL FILTER w Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly doing this procedure, consult your Yamaha dealer. 8 Do not perform this procedure on a hot or running engine. Allow the engine to cool. 8 There will be fuel in the fuel filter. Keep away from sparks, cigarettes, flames or other sources of ignition. 8 This procedure will allow some fuel to spill.
6L2-9-1K-4 2/25/03 15:51 Page 14 E 5) 6) Attach the filter assembly to the bracket so that the fuel hoses are attached to the filter assembly. Run the engine and check the filter and lines for leaks. EMU09912 INSPECTING IDLING SPEED w 8 Do not touch or remove electrical parts when starting or during operation. 8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running. cC This procedure must be performed while the outboard motor is in the water.
6L2-9-1K-4 2/25/03 15:51 Page 15 E 2) Verify whether the idle speed is set to specification. For idle speed specifications, see “Specifications” in this chapter. NOTE: Correct idling speed inspection is only possible if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechanic.
6L2-9-1K-4 2/25/03 15:51 Page 16 E EMK78010 CHECKING WIRING AND CONNECTORS 1) 2) Check that each grounding wire is properly secured. Check that each connector is engaged securely. EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head and crank case. WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head and crank case.
6L2-9-1K-4 2/25/03 15:51 Page 17 E MU00366 GREASING Yamaha marine grease (Water resistant grease) 25 103141b 4-16
6L2-9-1K-4 2/25/03 15:51 Page 18 E EMU00366 GREASING Yamaha marine grease (Water resistant grease) 25-3/30 103141a 4-17
6L2-9-1K-4 2/25/03 15:51 Page 19 E EMU00388 CHECKING PROPELLER w 210012 602051 You could be seriously injured if the engine accidentally starts while you are near the propeller. 8 Before inspecting, removing or installing the propeller, remove the spark plug caps from the spark plugs. Also, put the shift control in Neutral, put the main switch in the “OFF” position and remove the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one.
6L2-9-1K-4 2/25/03 15:51 Page 20 E EMU00976 q r y e w t Removing the Propeller 1) Straighten the cotter-pin 1 and pull it out using a pair of pliers. 2) Remove the propeller nut 2, washer 3 and spacer 4. 3) Remove the propeller 5 and thrust washer 6. EMU00397 000635 Installing the Propeller cC 8 Be sure to install the thrust washer before installing propeller, otherwise, lower case and propeller boss may be damaged. 8 Be sure to use a new cotter pin and bend the ends over securely.
6L2-9-1K-4 2/25/03 15:51 Page 21 E cC Be sure to use a new cotter pin and bend the ends over securely. Otherwise, the propeller could come off during operation and be lost. EMU01773 CHANGING GEAR OIL w 8 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. 8 Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked.
6L2-9-1K-4 2/25/03 15:51 Page 22 E NOTE: For disposal of used oil consult your Yamaha dealer. 5) 601022 With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole. Gear oil grade and capacity: See “Specifications” in this chapter. 6) 7) When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. Insert and tighten the gear oil drain screw.
6L2-9-1K-4 2/25/03 15:51 Page 23 E To clean the fuel tank 1) Empty the fuel tank into an approved gasoline (petrol) container. 2) Pour a small amount of suitable solvent in the tank. Reinstall the cap and shake the tank. Drain the solvent completely. To clean the fuel filter 1) Remove the screws holding the fuel hose joint assembly . Pull the assembly out of the tank. 2) Clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allow the filter to dry.
6L2-9-1K-4 2/25/03 15:51 Page 24 E CHECKING BOLTS AND NUTS 1) 2) Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torques. Check the tightening torques of other bolts and nuts. EMU00409 MOTOR EXTERIOR EMU00410 001183 Cleaning the Outboard Motor After use, wash the exterior of the outboard with fresh water. Flush the cooling system with fresh water.
6L2-9-1K-5 2/14/03 18:09 Page 1 E EMN00010 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING ..............................5-1 TEMPORARY ACTION IN EMERGENCY ............................................5-5 Impact damage.....................................5-5 Starter will not operate ........................5-6 Treatment of submerged motor .........
6L2-9-1K-5 2/14/03 18:09 Page 2 E EMU01204¯ TROUBLESHOOTING A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.) If your outboard motor requires repair, bring it to a Yamaha dealer. Trouble Possible Cause 1. 2. 3. 4. A. Engine will not start (Starter operates).
6L2-9-1K-5 2/14/03 18:09 Page 3 E Trouble Possible Cause 1. Spark plug(s) fouled or incorrect type. 2. Fuel system obstructed. 3. Fuel contaminated or stale. 4. Fuel filter clogged. 5. Failed ignition parts. 6. Warning system activated. 7. Spark plug gap incorrect. 8. Poor connections or damaged ignition wiring. B. Engine idles irregularly or stalls. 9. Specified engine oil not used. 10. Thermostat faulty or clogged. 11. Carburetor adjustments incorrect. 12. Fuel pump damaged. 13.
6L2-9-1K-5 2/14/03 18:09 Page 4 E Trouble Possible Cause 1. Cooling system clogged. 2. Engine oil level low. 3. Heat range of spark plug incorrect. 4. Specified engine oil not used. C. Warning buzzer sounds or indicator lamp lights. 5. Engine oil contaminated or deteriorated. 6. Oil filter clogged. 7. Oil feed/injection pump malfunctions. 8. Load on boat improperly distributed. 9. Water pump/thermostat faulty. 1. Propeller damaged. 2. Propeller pitch or diameter incorrect. 3. Trim angle incorrect.
6L2-9-1K-5 2/14/03 18:09 Page 5 E Trouble Possible Cause 13. Poor connections or damaged ignition wiring. 14. Failed ignition parts. 15. Specified engine oil not used. D. Engine power loss. 16. Thermostat faulty or clogged. 17. Air vent screw closed. 18. Fuel pump damaged. 19. Fuel joint connection incorrect. 20. Heat range of spark plug incorrect. 1. Propeller damaged. 2. Propeller shaft damaged. E. Engine vibrates excessively. 3. Weeds or other foreign matter tangled on propeller. 4.
6L2-9-1K-5 2/14/03 18:09 Page 6 E EMN20010 TEMPORARY ACTION IN EMERGENCY EMU01492 IMPACT DAMAGE w The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate. 607011 If the outboard motor hits any object in the water, follow the procedure below. 1) Stop the engine immediately. 2) Inspect the control system and all components for damage. Also, inspect the boat for damage.
6L2-9-1K-5 2/14/03 18:09 Page 7 E EMU00423 STARTER WILL NOT OPERATE If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be started with an emergency starter rope. w 8 Use this procedure only in an emergency and only to return to port for repairs. 8 When the emergency starter rope is used to start the engine, the start-ingear protection device does not operate. Make sure the gear shift lever/ remote control lever is in neutral.
6L2-9-1K-5 2/14/03 18:09 Page 8 E EMU00950 Emergency Starting Engine 1) Remove the top cowling. 2) Remove the start-in-gear protection cable from the starter if equipped it. 3) Remove the starter/flywheel cover after removing the bolt(s). 4) Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in Neutral and that the lock plate is attached to the engine stop lanyard switch. The main switch must be “ON” if equipped it.
6L2-9-1K-5 2/14/03 18:09 Page 9 E EMN50011 TREATMENT OF SUBMERGED MOTOR 107012 If the outboard motor is submerged, immediately take it a Yamaha dealer. Otherwise, some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure bellow for taking care to minimize engine damage. 1) 2) 3) 4) 107013 5) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.
6L2-9-1K-5 2/14/03 18:09 Page 10 E -MEMO-
6L2-9-1K-6 2/25/03 15:52 Page 1 E EMP00010 Chapter 6 INDEX INDEX........................................................
6L2-9-1K-6 2/25/03 15:52 Page 2 E EMP10010 INDEX A Adjusting trim angle..............................3-23 Air vent screw...........................................2-3 B Basic boating rules ..................................1-6 Breaking in engine .................................3-12 C Changing gear oil...................................4-20 Checking bolts and nuts........................4-23 Checking fuel system ............................4-11 Checking painted surface of motor......
6L2-9-1K-6 2/25/03 15:52 Page 3 E P Periodic maintenance..............................4-7 Pre-operation checks .............................3-10 Propeller checking point .......................4-18 Propeller selection .................................4-11 R Recoil starter handle................................2-6 Removing the propeller ........................4-19 Replacement parts ...................................4-7 Reverse ...................................................
6L2-9-1K-6 2/25/03 15:52 Page 4 EMU01599 IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha. Yamaha is ready to stand behind your purchase with strong warranty coverage.
6L2-9-1K-6 2/25/03 15:52 Page 5 5. Your warranty applies specifically to repairs made in the country of purchase. If your U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian purchased Yamaha needs service while in the United States, Yamaha will assist the local dealer whenever possible. However, some products available in one country may not be sold or serviced in the other. 6.
6L2-9-1K-6 2/25/03 15:52 Page 6 EMU00912* YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. is proud of its heritage and reputation for producing products with high standards of quality and workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Outboard Limited Warranty is your assurance of this commitment.
6L2-9-1K-6 2/25/03 15:52 Page 7 SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs, shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes are not covered by warranty. Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yamaha outboard dealer are excluded from warranty coverage.
6L2-9-1K-6 2/25/03 15:52 Page 8 CUSTOMER SERVICE If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you.
6L2-9-1K-6 2/25/03 15:52 Page 9 EMU01178 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha. This model was manufactured as a U.S.A.
6L2-9-1K Hyoshi 2/14/03 17:25 Page 1 25C OWNER’S MANUAL Printed in Japan March 2003-1.0 × 1 ! 6L2-28199-1K (25NMH) (E) Printed on recycled paper U.S.A.
Warranty card 2/27/02 11:47 AM Page 1 OUTBOARD MOTOR WARRANTY REGISTRATION ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD Please complete and mail this card. This information is necessary to accurately register your unit for warranty. Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.
Warranty card 2/27/02 11:47 AM Page 2 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT
