E25B 25B 25X Motor/yamaha/manual/Yamaha...25X 30H 69R-28199-27-E0 EMU25051 Read this owner’s...

OWNER’S MANUAL

E25B25B25X30H

69R-28199-27-E0

EMU25051

Read this owner’s manual carefully before operating or working on your outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.

Important manual information

EMU25103

To the owner

Thank you for choosing a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understandingof these simple instructions will help you ob-tain maximum enjoyment from your newYamaha. If you have any question about theoperation or maintenance of your outboardmotor, please consult a Yamaha dealer.In this Owner’s Manual particularly importantinformation is distinguished in the followingways.

The Safety Alert Symbol meansATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

WARNING

EWM00780

Failure to follow WARNING instructionscould result in severe injury or death tothe machine operator, a bystander, or aperson inspecting or repairing the out-

board motor.

CAUTION:

ECM00700

A CAUTION indicates special precautionsthat must be taken to avoid damage to the

outboard motor.

NOTE:

A NOTE provides key information to make

procedures easier or clearer.

Yamaha continually seeks advancements inproduct design and quality. Therefore, whilethis manual contains the most current prod-uct information available at the time of print-ing, there may be minor discrepanciesbetween your machine and this manual. Ifthere is any question concerning this manu-

al, please consult your Yamaha dealer.To ensure long product life, Yamaha recom-mends that you use the product and performthe specified periodic inspections and main-tenance by correctly following the instruc-tions in the owner’s manual. Any damageresulting from neglect of these instructions isnot covered by warranty.Some countries have laws or regulations re-stricting users from taking the product out ofthe country where it was purchased, and itmay be impossible to register the product inthe destination country. Additionally, thewarranty may not apply in certain regions.When planning to take the product to anothercountry, consult the dealer where the prod-uct was purchased for further information.If the product was purchased used, pleaseconsult your closest dealer for customer re-registration, and to be eligible for the speci-fied services.

NOTE:

The E25BMH, 25BMH, 25XMH, 30HMH,30HW and the standard accessories areused as a base for the explanations and illus-trations in this manual. Therefore some

items may not apply to every model.

EMU25121

E25B, 25B, 25X, 30HOWNER’S MANUAL

©2007 by Yamaha Motor Co., Ltd.1st Edition, April 2007

All rights reserved.Any reprinting or unauthorized usewithout the written permission of

Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan

Table of contents

General information .......................... 1

Identification numbers record.......... 1

Outboard motor serial number .......... 1Key number....................................... 1

EC label........................................... 1C-Tick label ..................................... 2Important labels............................... 2

Warning labels .................................. 2Caution labels ................................... 3

Safety information............................. 4

Safety information ........................... 4

Rotating parts.................................... 4Hot parts ........................................... 4Electric shock.................................... 4Engine shut-off cord.......................... 4Gasoline............................................ 4Gasoline exposure and spills ............ 4Carbon monoxide.............................. 4Modifications ..................................... 4

Boating safety ................................. 5

Alcohol and drugs ............................. 5Personal flotation devices ................. 5People in the water ........................... 5Passengers ....................................... 5Overloading....................................... 5Avoid collisions ................................. 5Weather ............................................ 6Passenger training ............................ 6Boating safety publications ............... 6Laws and regulations ........................ 6

Basic requirements........................... 7

Fueling instructions ......................... 7

Gasoline............................................ 7Engine oil .......................................... 7

Installation requirements ................. 7

Boat horsepower rating..................... 7Mounting motor ................................. 7Remote control requirements............ 8Battery requirement .......................... 8Propeller selection ............................ 8

Start-in-gear protection ................... 9

Basic components .......................... 10

Main components.......................... 10

Fuel tank ......................................... 10

Fuel joint..........................................11Fuel gauge ......................................11Fuel tank cap...................................11Air vent screw..................................11Remote control ................................11Remote control lever .......................11Neutral interlock trigger ...................12Neutral throttle lever ........................12Choke switch...................................12Tiller handle.....................................12Gear shift lever ................................13Throttle grip .....................................13Throttle indicator .............................13Throttle friction adjuster...................13Engine shut-off switch .....................14Engine stop button ..........................15Choke knob for pull type .................15Manual starter handle .....................15Main switch .....................................15Steering friction adjuster .................15Trim tab ...........................................16Trim rod (tilt pin) ..............................16Shallow water lever .........................16Tilt lock mechanism.........................17Tilt support knob..............................17Top cowling lock lever(s)

(turn type)......................................172-pin connector ...............................18

Warning system ............................ 18

Overheat warning............................18

Operation ......................................... 19

Installation..................................... 19

Mounting the outboard motor ..........19Clamping the outboard motor..........20

Breaking in engine ........................ 21

Gasoline and engine oil mixing chart (25:1)....................................21

Procedure for pre-mixed models.....21

Pre-operation checks.................... 22

Fuel .................................................22Oil ....................................................22Controls...........................................22Stop switches ..................................22Engine .............................................22

Filling fuel and engine oil .............. 22

Table of contents

Filling fuel for portable tank............. 22Gasoline and oil mixing (100:1) ...... 23

Operating engine........................... 24

Feeding fuel (portable tank) ............ 24Starting engine................................ 25

Warming up engine ....................... 30

Choke start models ......................... 30

Shifting .......................................... 30Stopping boat ................................ 32Stopping engine ............................ 32

Procedure ....................................... 32

Trimming outboard motor.............. 33

Adjusting trim angle for manual tilt models .......................................... 34

Adjusting boat trim .......................... 34

Tilting up and down ....................... 35

Procedure for tilting up (manual tilt models) ......................................... 36

Procedure for tilting down (manual tilt models) .................................... 37

Cruising in shallow water .............. 37

Cruising in shallow water (manual tilt models) .................................... 37

Cruising in other conditions........... 38

Maintenance..................................... 39

Specifications ................................ 39Transporting and storing outboard

motor ........................................... 40

Clamp screw mounting models ....... 41Storing outboard motor ................... 41Procedure ....................................... 42Lubrication ...................................... 43Battery care..................................... 43Cleaning the outboard motor .......... 44Checking painted surface of

motor............................................. 44

Periodic maintenance.................... 44

Replacement parts .......................... 44Maintenance chart .......................... 45Maintenance chart (additional)........ 46Greasing ......................................... 47Cleaning and adjusting spark

plug ............................................... 47Checking fuel system...................... 48Inspecting fuel filter ......................... 49

Cleaning fuel filter ...........................49Inspecting idling speed....................50Checking wiring and connectors .....50Exhaust leakage..............................51Water leakage .................................51Checking propeller ..........................51Removing propeller .........................52Installing propeller ...........................52Changing gear oil ............................52Cleaning fuel tank ...........................53Inspecting and replacing

anode(s)........................................54Checking battery (for electric start

models) .........................................54Connecting the battery ....................55Disconnecting the battery................56Checking top cowling ......................56Coating the boat bottom..................56

Trouble Recovery............................ 57

Troubleshooting ............................ 57Temporary action in emergency ... 60

Impact damage ...............................60Replacing fuse ................................60Starter will not operate ....................61Emergency starting engine .............61

Treatment of submerged motor .... 62

Procedure........................................62

1

General information

EMU25170

Identification numbers record

EMU25183

Outboard motor serial number

The outboard motor serial number isstamped on the label attached to the portside of the clamp bracket.Record your outboard motor serial number inthe spaces provided to assist you in orderingspare parts from your Yamaha dealer or forreference in case your outboard motor is sto-len.

EMU25190

Key number

If a main key switch is equipped with the mo-tor, the key identification number is stampedon your key as shown in the illustration.Record this number in the space provided forreference in case you need a new key.

EMU25202

EC label

Engines affixed with this label conform tocertain portions of the European Parliamentdirective relating to machinery. Refer to thelabel and the EC Declaration of Conformityfor more details.

1. Outboard motor serial number location

1

ZMU02931

1. Key number

1. EC label location

1

ZMU04730

General information

2

EMU25213

C-Tick label

Engines affixed with this label conform tocertain portion(s) of the Australian RadioCommunications Act.

EMU25382

Important labels

EMU25395

Warning labels

EMU25401

Label

WARNING

EWM01260

�

Be sure shift control is in neutral beforestarting engine. (except 2HP)

�

Do not touch or remove electrical partswhen starting or during operation.

�

Keep hands, hair, and clothes awayfrom flywheel and other rotating parts

while engine is running.

EMU25431

Label

WARNING

EWM01300

�

This engine is equipped with a neutral

1. C-Tick label location

ZMU01696

1

ZMU05721

ZMU01697

ZMU04735

ZMU02898

General information

3

starting device.

�

The engine will not start unless the shift

control is in neutral position.

EMU25465

Caution labels

EMU30480

Label

CAUTION:

ECM01450

Use premix fuel only.

ZMU04736

4

Safety information

EMU33620

Safety information

Observe these precautions at all times.

EMU33630

Rotating parts

Hands, feet, hair, jewelry, clothing, PFDstraps, etc. can become entangled with inter-nal rotating parts of the engine, resulting inserious injury or death.Keep the top cowling in place whenever pos-sible. Do not remove or replace the cowlingwith the engine running.Only operate the engine with the cowling re-moved according to the specific instructionsin the manual. Keep hands, feet, hair, jewel-ry, clothing, PFD straps, etc. away from anyexposed moving parts.

EMU33640

Hot parts

During and after operation, engine parts arehot enough to cause burns. Avoid touchingany parts under the top cowling until the en-gine has cooled.

EMU33650

Electric shock

Do not touch any electrical parts while start-ing or operating the engine. They can causeshock or electrocution.

EMU33670

Engine shut-off cord

Attach the engine shut-off cord so that theengine stops if the operator falls overboardor leaves the helm. This prevents the boatfrom running away under power and leavingpeople stranded, or running over people orobjects.Always attach the engine shut-off cord to asecure place on your clothing or your arm orleg while operating. Do not remove it to leavethe helm while the boat is moving. Do not at-tach the cord to clothing that could tearloose, or route the cord where it could be-

come entangled, preventing it from function-ing.Do not route the cord where it is likely to beaccidentally pulled out. If the cord is pulledduring operation, the engine will shut off andyou will lose most steering control. The boatcould slow rapidly, throwing people and ob-jects forward.

EMU33810

Gasoline

Gasoline and its vapors are highly flam-mable and explosive.

Always, refuel ac-cording to the procedure on page 24 toreduce the risk of fire and explosion.

EMU33820

Gasoline exposure and spills

Take care not to spill gasoline. If gasolinespills, wipe it up immediately with dry rags.Dispose of rags properly.If any gasoline spills onto your skin, immedi-ately wash with soap and water. Changeclothing if gasoline spills on it.If you swallow gasoline, inhale a lot of gaso-line vapor, or get gasoline in your eyes, getimmediate medical attention. Never siphonfuel by mouth.

EMU33900

Carbon monoxide

This product emits exhaust gases whichcontain carbon monoxide, a colorless, odor-less gas which may cause brain damage ordeath when inhaled. Symptoms include nau-sea, dizziness, and drowsiness. Keep cock-pit and cabin areas well ventilated. Avoidblocking exhaust outlets.

EMU33780

Modifications

Do not attempt to modify this outboard mo-tor. Modifications to your outboard motormay reduce safety and reliability, and renderthe outboard unsafe or illegal to use.

Safety information

5

EMU33740

Boating safety

This section includes a few of the many im-portant safety precautions that you shouldfollow when boating.

EMU33710

Alcohol and drugs

Never operate after drinking alcohol or tak-ing drugs. Intoxication is one of the mostcommon factors contributing to boating fatal-ities.

EMU33720

Personal flotation devices

Have an approved personal flotation device(PFD) on board for every occupant. Yamaharecommends that you must wear a PFDwhenever boating. At a minimum, childrenand non-swimmers should always wearPFDs, and everyone should wear PFDswhen there are potentially hazardous boat-ing conditions.

EMU33730

People in the water

Always watch carefully for people in the wa-ter, such as swimmers, skiers, or divers,whenever the engine is running. Whensomeone is in the water near the boat, shiftinto neutral and shut off the motor.Stay away from swimming areas. Swimmerscan be hard to see.The propeller can keep moving even whenthe motor is in neutral. Shut off the enginewhen a person is in the water near you.

EMU33750

Passengers

Consult your boat manufacturer’s instruc-tions for details about appropriate passengerlocations in your boat and be sure all pas-sengers are positioned properly before ac-celerating and when operating above an idlespeed. Standing or sitting in non-designatedlocations may result in being thrown either

overboard or within the boat due to waves,wakes, or sudden changes in speed or direc-tion. Even when people are positioned prop-erly, alert your passengers if you must makeany unusual maneuver. Always avoid jump-ing waves or wakes.

EMU33760

Overloading

Do not overload the boat. Consult the boatcapacity plate or boat manufacturer for max-imum weight and number of passengers. Besure that weight is properly distributed ac-cording to the boat manufacturers instruc-tions. Overloading or incorrect weightdistribution can compromise the boats han-dling and lead to an accident, capsizing orswamping.

EMU33770

Avoid collisions

Scan constantly

for people, objects, andother boats. Be alert for conditions that limityour visibility or block your vision of others.

Operate defensively

at safe speeds andkeep a safe distance away from people, ob-jects, and other boats.

�

Do not follow directly behind other boats orwaterskiers.

�

Avoid sharp turns or other maneuvers thatmake it hard for others to avoid you or un-derstand where you are going.

�

Avoid areas with submerged objects orshallow water.

�

Ride within your limits and avoid aggres-sive maneuvers to reduce the risk of lossof control, ejection, and collision.

�

Take early action

to avoid collisions. Re-member,

boats do not have brakes

, andstopping the engine or reducing throttlecan reduce the ability to steer. If you arenot sure that you can stop in time beforehitting an obstacle, apply throttle and turnin another direction.

Safety information

6

EMU33790

Weather

Stay informed about the weather. Checkweather forecasts before boating. Avoidboating in hazardous weather.

EMU33880

Passenger training

Make sure at least one other passenger istrained to operate the boat in the event of anemergency.

EMU33890

Boating safety publications

Be informed about boating safety. Additionalpublications and information can be obtainedfrom many boating organizations.

EMU33600

Laws and regulations

Know the marine laws and regulations whereyou will be boating- and obey them. Severalsets of rules prevail according to geographiclocation, but all are basically the same as theInternational Rules of the Road.

7

Basic requirements

EMU25540

Fueling instructions

WARNING

EWM00010

GASOLINE AND ITS VAPORS ARE HIGH-LY FLAMMABLE AND EXPLOSIVE!

�

Do not smoke when refueling, and keepaway from sparks, flames, or othersources of ignition.

�

Stop engine before refueling.

�

Refuel in a well-ventilated area. Refuelportable fuel tanks off the boat.

�

Take care not to spill gasoline. If gaso-line spills, wipe it up immediately withdry rags.

�

Do not overfill the fuel tank.

�

Tighten the filler cap securely after re-fueling.

�

If you should swallow some gasoline,inhale a lot of gasoline vapor, or getgasoline in your eyes, get immediatemedical attention.

�

If any gasoline spills onto your skin, im-mediately wash with soap and water.Change clothing if gasoline spills on it.

�

Touch the fuel nozzle to the filler open-ing or funnel to help prevent electro-

static sparks.

CAUTION:

ECM00010

Use only new clean gasoline which hasbeen stored in clean containers and is notcontaminated with water or foreign mat-

ter.

EMU33980

Gasoline

If knocking or pinging occurs, use a different

brand of gasoline or premium unleaded fuel.If unleaded gasoline is not available, thenpremium gasoline can be used.

Gasohol

There are two types of gasohol: gasohol con-taining ethanol and that containing metha-nol. Gasohol containing ethanol can be usedif ethanol content does not exceed 10% andthe fuel meets minimum octane ratings.Yamaha does not recommended gasoholcontaining methanol because it can causefuel system damage or engine performanceproblems.

EMU25650

Engine oil

If the recommended engine oil is not avail-able, another 2-stroke engine oil with anNMMA-certified TC-W3 rating may be used.

EMU33550

Installation requirements

EMU33560

Boat horsepower rating

Before installing the outboard motor(s), con-firm that the total horsepower of your mo-tor(s) does not exceed the boats maximumhorsepower rating. See the boats capacityplate or contact the manufacturer.

WARNING

EWM01560

Overpowering a boat can cause severe

instability.

EMU33570

Mounting motor

Your dealer or other person experienced inproper rigging should mount the motor usingcorrect equipment and complete rigging in-structions. For further information, see page

Recommended gasoline:Regular unleaded gasoline

Recommended engine oil:YAMALUBE 2-stroke outboard motor oil

Basic requirements

8

19.

WARNING

EWM01570

�

Improper mounting of the outboard mo-tor could result in hazardous condi-tions such as poor handling, loss ofcontrol, or fire hazards.

�

Because the motor is very heavy, spe-cial equipment and training is required

to mount it safely.

EMU33580

Remote control requirements

The remote control unit must be equippedwith a start-in-gear protection device(s). Thisdevice prevents the engine from starting un-less it is in neutral.

WARNING

EWM01580

�

If the engine starts in gear, the boat canmove suddenly and unexpectedly, pos-sibly causing a collision or throwingpassengers overboard.

�

If the engine ever starts in gear, thestart-in-gear protection device is notworking correctly and you should dis-continue using the outboard. Contact

your Yamaha dealer.

EMU25692

Battery requirement

CAUTION:

ECM01061

Do not use a battery that does not meetthe specified capacity. If a battery thatdoes not meet specifications is used, theelectric system could perform poorly orbe overloaded, causing electric system

damage.

For electric start models, choose a batterywhich meets the following specifications.

EMU25721

Battery specifications

The engine cannot be started if battery volt-age is too low.

EMU25730

Without a rectifier or Rectifier Regulator

CAUTION:

ECM01090

A battery cannot be connected to modelsthat do not have a rectifier or Rectifier

Regulator.

If you wish to use a battery with the modelswithout a rectifier or Rectifier Regulator, in-stall an optional Rectifier Regulator.Using a maintenance-free battery with theabove models can shorten the life of the bat-tery significantly.Install an optional Rectifier Regulator or useaccessories rated to withstand 18 volts orhigher with the above models. Consult yourYamaha dealer for details on installing anoptional Rectifier Regulator.

EMU34190

Propeller selection

Next to selecting an outboard, choosing theright propeller is one of the most importantpurchasing decisions a boater can make.The type, size, and design of your propellerhave a direct impact on acceleration, topspeed, fuel economy, and even engine life.Yamaha designs and manufactures propel-lers for every Yamaha outboard motor andevery application.Your outboard motor came with a Yamahapropeller chosen to perform well over arange of applications, but there may be uses

Minimum cold cranking amps (CCA/EN):30HW 347.0 A

Minimum rated capacity (20HR/IEC):30HW 40.0 Ah

Basic requirements

9

where a different propeller would be moreappropriate.Your Yamaha dealer can help you select theright propeller for your boating needs. Selecta propeller that will allow the engine to reachthe middle or upper half of the operatingrange at full throttle with the maximum boat-load. Generally, chose a larger pitch propel-ler for a smaller operating load and a smallerpitch propeller for a heavier load. If you carryloads that vary widely, chose the propellerthat lets the engine run in the proper rangefor your maximum load but remember thatyou may need to reduce your throttle settingto stay within the recommended enginespeed range when carrying lighter loads.For instructions on propeller removal and in-stallation, see page 51.

EMU25760

Start-in-gear protection

Yamaha outboard motors affixed with thepictured label or Yamaha-approved remotecontrol units are equipped with start-in-gearprotection device(s). This feature permits theengine to be started only when it is in neutral.Always select neutral before starting the en-gine.

1. Propeller diameter in inches2. Propeller pitch in inches3. Type of propeller (propeller mark)

ZMU04605

-x1 2 3

1. Start-in-gear protection label

ZMU01713

1

10

Basic components

EMU2579B

Main componentsNOTE:

* May not be exactly as shown; also may not be included as standard equipment on all mod-

els.

E25B, 25B, 25X, 30H

EMU25802

Fuel tank

If your model was equipped with a portable

98

7

6

3

4

5

2

1

1918

17

11

12 13

14

11

19

1817

15

16

141516

20 21

10

ZMU05723

1. Top cowling2. Top cowling lock lever3. Anti-cavitation plate4. Trim tab5. Propeller6. Cooling water inlet7. Shallow water lever8. Tilt rod9. Clamp bracket10. Clip11. Manual starter handle12. Engine stop button/Engine shut-off switch*13. Tiller handle*14. Choke knob

15. Tilt lock lever16. Transom clamp handle17. Rope attachment18. Tilt support knob19. Gear shift lever20. Remote control box (side mount type)*21. Fuel tank*

Basic components

11

fuel tank, its function is as follows.

WARNING

EWM00020

The fuel tank supplied with this engine isits dedicated fuel reservoir and must notbe used as a fuel storage container. Com-mercial users should conform to relevantlicensing or approval authority regula-

tions.

EMU25830

Fuel joint

This joint is used to connect the fuel line.

EMU25841

Fuel gauge

This gauge is located on either the fuel tankcap or on the fuel joint base. It shows the ap-proximate amount of fuel remaining in thetank.

EMU25850

Fuel tank cap

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

EMU25860

Air vent screw

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

EMU26180

Remote control

The remote control lever actuates both theshifter and the throttle. The electrical switch-es are mounted on the remote control box.

EMU26190

Remote control lever

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

1. Fuel joint2. Fuel gauge3. Fuel tank cap4. Air vent screw

ZMU02284

3

1

4

2

1. Remote control lever2. Neutral interlock trigger3. Neutral throttle lever4. Main switch / choke switch5. Engine shut-off switch6. Throttle friction adjuster

1. Neutral “ ”

Basic components

12

EMU26201

Neutral interlock trigger

To shift out of neutral, first pull the neutral in-terlock trigger up.

EMU26211

Neutral throttle lever

To open the throttle without shifting into ei-ther forward or reverse, put the remote con-trol lever in the neutral position and lift theneutral throttle lever.

NOTE:

The neutral throttle lever will operate onlywhen the remote control lever is in neutral.The remote control lever will operate onlywhen the neutral throttle lever is in the closed

position.

EMU26221

Choke switch

To activate the choke system, press in themain switch while the key is turned to the“ ” (on) or “ ” (start) position. Thechoke system will then supply the rich fuelmixture required to start the engine. Whenthe key is released, the choke will switch offautomatically.

EMU25911

Tiller handle

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

2. Forward “ ”

3. Reverse “ ”4. Shift5. Fully closed6. Throttle7. Fully open

1. Neutral interlock trigger

1. Fully open2. Fully closed

Basic components

13

EMU25922

Gear shift lever

Pulling the gear shift lever towards you putsthe engine in forward gear so that the boatmoves ahead. Pushing the lever away fromyou puts the engine in reverse gear so thatthe boat moves astern.

EMU25941

Throttle grip

The throttle grip is on the tiller handle. Turnthe grip counterclockwise to increase speedand clockwise to decrease speed.

EMU25961

Throttle indicator

The fuel consumption curve on the throttleindicator shows the relative amount of fuelconsumed for each throttle position. Choosethe setting that offers the best performanceand fuel economy for the desired operation.

EMU25971

Throttle friction adjuster

A friction device provides adjustable resis-tance to movement of the throttle grip or theremote control lever, and can be set accord-ing to operator preference.To increase resistance, turn the adjusterclockwise. To decrease resistance, turn theadjuster counterclockwise.

WARNING

EWM00031

Do not overtighten the friction adjuster. If

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”

ZMU02937

ZMU02939

N1R

3F2

1. Throttle indicator

ZMU02945

ZMU02938

1

Basic components

14

there is too much resistance, it could bedifficult to move the remote control leveror throttle grip, which could result in an

accident.

When constant speed is desired, tighten theadjuster to maintain the desired throttle set-ting.

EMU25991

Engine shut-off switch

The clip must be attached to the engine shut-off switch for the engine to run. The cordshould be attached to a secure place on theoperator’s clothing, or arm or leg. Should theoperator fall overboard or leave the helm, thecord will pull out the clip, stopping ignition tothe engine. This will prevent the boat fromrunning away under power.

WARNING

EWM00121

�

Attach the engine shut-off cord to a se-

cure place on your clothing, or yourarm or leg while operating.

�

Do not attach the cord to clothing thatcould tear loose. Do not route the cordwhere it could become entangled, pre-venting it from functioning.

�

Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power,the boat could slow rapidly. This couldcause people and objects in the boat to

be thrown forward.

NOTE:

The engine cannot be started with the clip re-

moved.

ZMU02940

ZMU03169

1. Clip2. Cord

1. Clip

ZMU02941

1

2

1

2

ZMU03171

Basic components

15

EMU26001

Engine stop button

To open the ignition circuit and stop the en-gine, push this button.

EMU26011

Choke knob for pull type

To supply the engine with the rich fuel mix-ture required to start, pull out this knob.

EMU26070

Manual starter handle

To start the engine, first gently pull the han-dle out until resistance is felt. From that posi-tion, then pull the handle straight out quicklyto crank the engine.

EMU26090

Main switch

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

�

“ ”

(off)

With the main switch in the “ ” (off) posi-tion, the electrical circuits are off, and the keycan be removed.

�

“ ”

(on)

With the main switch in the “ ” (on) posi-tion, the electrical circuits are on, and the keycannot be removed.

�

“ ”

(start)

With the main switch in the “ ” (start) po-sition, the starter motor turns to start the en-gine. When the key is released, it returnsautomatically to the “ ” (on) position.

EMU26122

Steering friction adjuster

A friction device provides adjustable resis-tance to the steering mechanism, and can be

2. Cord

ZMU02905

ZMU02906

ZMU02942

Basic components

16

set according to operator preference. An ad-justing screw or bolt is located on the swivelbracket.

To increase resistance, turn the adjusterclockwise.To decrease resistance, turn the adjustercounterclockwise.

WARNING

EWM00040

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to steer, which could result in an

accident.

EMU26252

Trim tab

The trim tab should be adjusted so that thesteering control can be turned to either theright or left by applying the same amount offorce.

WARNING

EWM00840

An improperly adjusted trim tab couldcause difficult steering. Always test runafter the trim tab has been installed or re-placed to be sure steering is correct. Besure you have tightened the bolt after ad-

justing the trim tab.

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 (star-board side), turn the trim tab end to the star-board side “B” in the figure.

EMU26261

Trim rod (tilt pin)

The position of the trim rod determines theminimum trim angle of the outboard motor inrelation to the transom.

EMU26270

Shallow water lever

Lifting this lever will tilt the motor up partiallyto provide more clearance when operating inshallow water.

ZMU02908

1. Trim tab2. Bolt

Bolt tightening torque:8.0 Nm (5.8 ft-lb) (0.8 kgf-m)

1

2

ZMU02289

A

B

ZMU02946

Basic components

17

EMU30530

Tilt lock mechanism

The tilt lock mechanism is used to preventthe outboard motor from lifting out of the wa-ter when in reverse gear.

To lock it, set the tilt lock lever in the lock po-sition. To release, push the tilt lock lever inthe release position.

EMU26321

Tilt support knob

To keep the outboard motor in the tilted upposition, push the tilt support knob under theswivel bracket.

CAUTION:

ECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboardmotor could shake loose from the tilt sup-port and fall. If the motor cannot be trail-ered in the normal running position, usean additional support device to secure it

in the tilt position.

EMU26372

Top cowling lock lever(s) (turn type)

To remove the engine top cowling, turn thelock lever(s) and lift off the cowling. When in-stalling the cowling, check to be sure it fitsproperly in the rubber seal. Then lock thecowling again by returning the lever(s) to thelock position.

1. Tilt lock lever

ZMU02917

ZMU02910

1

1. Top cowling lock lever(s)

ZMU02947

ZMU02948

1

Basic components

18

EMU26410

2-pin connector

AC 12 V-40/60/80W power is deliveredthrough this connector. When using it, keepin mind the following points:

�

Use a genuine Yamaha connector.

�

Use lighting equipment only.

�

Connect lighting equipment directly to the2-pin connector.

�

Capacity of the lighting equipment must bemore than 12 V-40/60/80W; otherwise thebulb could burn out.

�

When the connector is not in use, placethe cap on it.

CAUTION:

ECM01000

Do not connect the 2-pin connector di-rectly to the battery terminals. Otherwise

the electric system will be damaged.

EMU26801

Warning system

CAUTION:

ECM00090

Do not continue to operate the engine if awarning device has activated. Consultyour Yamaha dealer if the problem can-

not be located and corrected.

EMU26817

Overheat warning

This engine has an overheat-warning de-vice. If the engine temperature rises too high,

the warning device will activate.

Activation of warning device

�

The engine speed will automatically de-crease to about 2000 r/min.

�

If equipped with an overheat-warning indi-cator, it will light or blink.

�

The buzzer will sound (if equipped on thetiller handle, remote control box, or mainswitch panel).

If the warning system has activated, stop theengine and check the cooling water inlet forclogging.

ZMU04737

ZMU03025

ZMU03026

19

Operation

EMU26902

Installation

The information presented in this section isintended as reference only. It is not possibleto provide complete instructions for everypossible boat and motor combination. Prop-er mounting depends in part on experienceand the specific boat and motor combination.

WARNING

EWM01590

�

Overpowering a boat could cause se-vere instability. Do not install an out-board motor with more horsepowerthan the maximum rating on the capac-ity plate of the boat. If the boat does nothave a capacity plate, consult the boatmanufacturer.

�

Improper mounting of the outboard mo-tor could result in hazardous condi-tions such as poor handling, loss ofcontrol, or fire hazards. For permanent-ly mounted models, your dealer or oth-er person experienced in proper

rigging should mount the motor.

EMU33470

Mounting the outboard motor

The outboard motor should be mounted sothat the boat is well balanced. Otherwise, theboat could be hard to steer. For single-en-gine boats, mount the outboard motor on thecenterline (keel line) of the boat.

EMU26921

Mounting height

To run your boat at optimum efficiency, thewater resistance (drag) of the boat and out-board motor must be made as little as possi-ble. The mounting height of the outboardmotor greatly affects the water resistance. Ifthe mounting height is too high, cavitationtends to occur, thus reducing the propulsion;and if the propeller tips cut the air, the enginespeed will rise abnormally and cause the en-gine to overheat. If the mounting height is toolow, the water resistance will increase andthereby reduce engine efficiency. Mount theoutboard motor so that the anti-cavitationplate is between the bottom of the boat anda level 25 mm (1 in.) below it.

1. Center line (keel line)

ZMU017601

Operation

20

CAUTION:

ECM01630

�

During water testing, check the buoy-ancy of the boat, at rest, with its maxi-mum load. Check that the static waterlevel on the exhaust housing is lowenough to prevent water entry into thepower head when water rises due towaves when the outboard is not run-ning.

�

Incorrect engine height or obstructionsto the smooth flow of water (such as thedesign or condition of the boat, or ac-cessories such as transom ladders ordepth finder transducers) can createairborne water spray while the boat iscruising. If the motor is operated con-tinuously in the presence of airbornewater spray, enough water could enterthe engine through the intake openingon the cowling to cause severe enginedamage. Eliminate the cause of the air-

borne water spray.

NOTE:

�

The optimum mounting height of the out-board motor is affected by the boat andmotor combination and the desired use.Test runs at different heights can help de-termine the optimum mounting height.Consult your Yamaha dealer or boat man-

ufacturer for further information on deter-mining the proper mounting height.

�

For instructions on setting the trim angle of

the outboard motor, see page 33.

EMU26970

Clamping the outboard motor

1. Place the outboard motor on the tran-som so that it is positioned as close tothe center as possible. Tighten the tran-som clamp screws evenly and securely.Occasionally check the clamp screwsfor tightness during operation of the out-board motor because they could be-come loose due to engine vibration.

WARNING

EWM00640

Loose clamp screws could allow the out-board motor to fall off or move on thetransom. This could cause loss of controland serious injury. Make sure the tran-som screws are tightened securely. Oc-casionally check the screws for tightness

during operation.

2. If the engine restraint cable attachmentis equipped on your engine, an enginerestraint cable or chain should be used.Attach one end to the engine restraintcable attachment and the other to a se-cure mounting point on the boat. Other-wise the engine could be completely lost

ZMU02011

0–25mm(0–1in.)

ZMU02012

Operation

21

if it accidentally falls off the transom.

3. Secure the clamp bracket to the transomusing the bolts provided with the out-board (if packed). For details, consultyour Yamaha dealer.

WARNING

EWM00650

Avoid using bolts, nuts or washers otherthan those contained in the engine pack-aging. If used, they must be of at least thesame quality of material and strength andmust be tightened securely. After tighten-ing, test run the engine and check their

tightness.

EMU30173

Breaking in engine

Your new engine requires a period of break-in to allow mating surfaces of moving parts to

wear in evenly. Correct break-in will help en-sure proper performance and longer enginelife.

CAUTION:

ECM00800

Failure to follow the break-in procedurecould result in reduced engine life or

even severe engine damage.

EMU27050

Gasoline and engine oil mixing chart (25:1)

CAUTION:

ECM00150

Be sure to mix gasoline and oil complete-ly, otherwise the engine may be dam-

aged.

EMU27074

Procedure for pre-mixed models

Run the engine under load (in gear with apropeller installed) for 10 hours as follows.1. First 10 minutes:

Run the engine at the lowest possiblespeed. A fast idle in neutral is best.

2. Next 50 minutes:Do not exceed half throttle (approxi-mately 3000 r/min). Vary engine speedoccasionally. If you have an easy-plan-ing boat, accelerate at full throttle ontoplane, then immediately reduce thethrottle to 3000 r/min or less.

1. Bolts

ZMU02013

1

ZMU02014

1. : Gasoline

2. : Engine oil

Operation

22

3. Next two hours:Accelerate at full throttle onto plane,then reduce engine speed to three-quar-ter throttle (approximately 4000 r/min).Vary engine speed occasionally. Run atfull throttle for one minute, then allowabout 10 minutes of operation at three-quarter throttle or less to let the enginecool.

4. Remaining seven hours:Run the engine at any speed. However,avoid operating at full throttle for morethan 5 minutes at a time.

5. After the first 10 hours:Operate the engine normally. Use thestandard premix ratio of gasoline and oil.For details on mixing fuel and oil, seepage 22.

EMU27104

Pre-operation checks

WARNING

EWM00081

If any item in the pre-operation check isnot working properly, have it inspectedand repaired before operating the out-board motor. Otherwise an accident

could occur.

CAUTION:

ECM00120

Do not start the engine out of water. Over-heating and serious engine damage can

occur.

EMU27111

Fuel

�

Check to be sure you have plenty of fuelfor your trip.

�

Make sure there are no fuel leaks or gaso-line fumes.

�

Check fuel line connections to be sure theyare tight (if equipped Yamaha fuel tank orboat tank).

�

Be sure the fuel tank is positioned on a se-cure, flat surface, and that the fuel line isnot twisted or flattened, or likely to contactsharp objects (if equipped Yamaha fueltank or boat tank).

EMU27120

Oil

�

Check to be sure you have plenty of oil foryour trip.

EMU27130

Controls

�

Check throttle, shift, and steering for prop-er operation before starting the engine.

�

The controls should work smoothly, with-out binding or unusual free play.

�

Look for loose or damaged connections.

�

Check operation of the starter and stopswitches when the outboard motor is in thewater.

EMU31721

Stop switches

�

Confirm that turning the main switch to the“ ” (off) position stops the engine.

�

Confirm that removing the clip from the en-gine shut-off switch stops the engine.

�

Confirm that the engine cannot be startedwith the clip removed from the engineshut-off switch.

EMU27140

Engine

�

Check the engine and engine mounting.

�

Look for loose or damaged fasteners.

�

Check the propeller for damage.

EMU27233

Filling fuel and engine oil

EMU27242

Filling fuel for portable tank

WARNING

EWM00060

Gasoline and its vapors are highly flam-mable and explosive. Keep away fromsparks, cigarettes, flames, or other

Operation

23

sources of ignition.

1. Remove the fuel tank cap.2. Fill the fuel tank carefully.3. Close the cap securely after refueling.

Wipe up any spilled fuel.

EMU27405

Gasoline and oil mixing (100:1)

If equipped with a portable fuel tank1. Pour oil into the portable fuel tank, and

then add gasoline.

2. Replace the fuel tank cap and closetightly.

3. Shake the fuel tank to mix the fuel thor-oughly.

4. Make sure that the oil and gasoline aremixed.

If equipped with a built-in fuel tank1. Pour oil into a clean fuel can, and then

add gasoline.2. Replace the fuel can cap and close tight-

ly.3. Shake the fuel can to mix the fuel thor-

oughly.4. Make sure that the oil and gasoline are

mixed.5. Pour the gasoline and oil mixture into the

built-in fuel tank.

CAUTION:

ECM00811

�

Avoid using any oil other than the spec-ified type.

�

Use a thoroughly blended fuel-oil mix-ture.

�

If the mixture is not thoroughly mixed,or if the mixing ratio is incorrect, thefollowing problems could occur.

�

Low oil ratio: Lack of oil could causemajor engine trouble, such as pistonseizure.

�

High oil ratio: Too much oil could causefouled spark plugs, smoky exhaust,

and heavy carbon deposits.

NOTE:

If using a permanently installed tank, pourthe oil gradually as the gasoline is being add-

ed to the tank.

Fuel tank capacity (if equipped Yamaha fuel tank):

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

Gasoline to engine oil ratio

Break-in period See page 21After break-in 100:1

1. Engine oil2. Gasoline

Operation

24

EMU27450

Operating engine

EMU27463

Feeding fuel (portable tank)

WARNING

EWM00420

�

Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in thewater near you.

�

When the air vent screw is loosened,gasoline vapor will be released. Gaso-line is highly flammable, and its vaporsare flammable and explosive. Refrainfrom smoking, and keep away fromopen flames and sparks while loosen-ing the air vent screw.

�

This product emits exhaust gaseswhich contain carbon monoxide, a col-orless, odorless gas which could causebrain damage or death when inhaled.Symptoms include nausea, dizziness,and drowsiness. Keep cockpit and cab-in areas well ventilated. Avoid blocking

exhaust outlets.

1. If there is an air vent screw on the fueltank cap, loosen it 2 or 3 turns.

2. If there is a fuel joint on the motor, firmlyconnect the fuel line to the joint. Thenfirmly connect the other end of the fuel

line to the joint on the fuel tank.

3. If a steering friction adjuster is providedon your outboard motor, securely attachthe fuel line to the fuel line clamp.

NOTE:

During engine operation place the tank hori-zontally, otherwise fuel cannot be drawn

from the fuel tank.

4. Squeeze the primer pump, with the ar-row pointing up, until you feel it becomefirm.

ZMU02295

ZMU02911

ZMU02024

Operation

25

EMU27491

Starting engine

WARNING

EWM01600

Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in the wa-

ter near you.

EMU27506

Manual start models (tiller control)

1. Place the gear shift lever in neutral.

NOTE:

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

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 otherend of the cord into the engine shut-offswitch.

WARNING

EWM00121

�

Attach the engine shut-off cord to a se-cure place on your clothing, or yourarm or leg while operating.

�


�


be thrown forward.

3. Place the throttle grip in the “ ”(start) position.

1. Arrow

N

ZMU02952

ZMU02953

Operation

26

4. Pull out / turn the choke knob fully. Afterthe engine starts, replace / return theknob to the home position.

NOTE:

�

It is not necessary to use the choke whenstarting a warm engine.

�

If the choke knob is left in the “ ”(start) position while the engine is running,

the engine will run poorly or stall.

5. Pull the manual starter handle slowly un-til you feel resistance. Then give astrong pull straight out to crank and startthe engine. Repeat if necessary.

6. After the engine starts, slowly return themanual starter handle to its original po-sition before releasing it.

7. Slowly return the throttle grip to the fullyclosed position.

NOTE:

�

When the engine is cold, it needs to bewarmed up. For further information, seepage 30.

�

If the engine does not start on the first try,repeat the procedure. If the engine fails tostart after 4 or 5 tries, open the throttle asmall amount (between 1/8 and 1/4) andtry again. Also if the engine is warm andfails to start, open the throttle a sameamount and try to start the engine again. If

the engine still fails to start, see page 57.

EMU27634

Manual start models (remote control)

1. Place the remote control lever in neutral.

ZMU02954

ZMU02955

ZMU02956

ZMU02030

Operation

27

NOTE:


tral.

2. Attach the engine shut-off cord to a se-cure place on your clothing, or your armor leg. Then install the clip on the otherend of the cord into the engine shut-offswitch.

WARNING

EWM00121

�


�


�


be thrown forward.

3. Open the throttle slightly without shiftingusing the neutral throttle lever. You mayneed to change the throttle openingslightly depending on engine tempera-ture. After the engine starts, return thethrottle to the original position.

NOTE:

�

As a starting point, lift the lever just untilyou feel resistance, then lift slightly more.

�

The neutral throttle lever can only be used

when the remote control lever is in neutral.

4. Pull out / turn the choke knob fully. Afterthe engine starts, replace / return theknob to the home position.

N

ZMU03087ZMU03088

ZMU03200

N

Operation

28

NOTE:

�


�

If the choke knob is left in the “ ”(start) position while the engine is running,

the engine will run poorly or stall.

5. Pull the manual starter handle slowly un-til you feel resistance. Then give astrong pull straight out to crank and startthe engine. Repeat if necessary.

6. After the engine starts, slowly return themanual starter handle to its original po-sition before releasing it.

NOTE:

�

When the engine is cold, it needs to bewarmed up. For further information, seepage 30.

�

If the engine does not start on the first try,repeat the procedure. If the engine fails tostart after 4 or 5 tries, open the throttle a

small amount and try again. Also if the en-gine is warm and fails to start, open thethrottle a small amount and try to start theengine again. If the engine still fails to

start, see page 57.

EMU27643

Electric start / remote control models

1. Place the remote control lever in neutral.

NOTE:


tral.

2. Attach the engine shut-off cord to a se-cure place on your clothing, or your armor leg. Then install the clip on the otherend of the cord into the engine shut-offswitch.

WARNING

EWM00121

�


�


�

Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power,

ZMU02955

ZMU03008

Operation

29

the boat could slow rapidly. This couldcause people and objects in the boat to

be thrown forward.

3. Turn the main switch to “ ” (on).

4. Open the throttle slightly without shiftingusing the neutral throttle lever or free ac-celerator. You may need to change thethrottle opening slightly depending onengine temperature. After the enginestarts, return the throttle to the originalposition.

NOTE:

�

On remote controls equipped with a neu-tral throttle lever, a good starting point is tolift the lever just until you feel resistance,then lift slightly more.

�

The neutral throttle lever or free accelera-tor can only be used when the remote con-

trol lever is in neutral.

5. Press in and hold the main switch to op-erate the remote choke system. The re-mote choke switch automatically returnsto its normal position when you releaseyour hand. Therefore keep the switchpressed in.

NOTE:

�


�

Push in the main switch fully, or the remote

choke system will not operate.

OFF

ON

ZMU01880

N

ZMU02314

STARTOFFON

ZMU02315

Operation

30

6. Turn the main switch to “ ” (start),and hold it for a maximum of 5 seconds.

7. Immediately after the engine starts, re-lease the main switch and allow it to re-turn to “ ” (on).

CAUTION:

ECM00191

�

Never turn the main switch to “ ”(start) while the engine is running.

�

Do not keep the starter motor turningfor more than 5 seconds. If the startermotor is turned continuously for morethan 5 seconds, the battery will bequickly discharged, thus making it im-possible to start the engine. The startercan also be damaged. If the engine willnot start after 5 seconds of cranking,return the main switch to “ ” (on), wait10 seconds, then crank the engine

again.

EMU27670

Warming up engine

EMU27681

Choke start models

1. After starting the engine, allow it to idlefor 3 minutes to warm up. Failure to doso will shorten engine life. Gradually re-turn the choke knob to its home positionas the engine warms up.

2. Check for a steady flow of water from the

cooling water pilot hole.

CAUTION:

ECM00511

A continuous flow of water from the cool-ing water pilot hole shows that the waterpump is pumping water through the cool-ing passages. If water is not flowing outof the hole at all times while the engine isrunning, overheating and serious dam-age could occur. Stop the engine andcheck whether the cooling water inlet onthe lower case or the cooling water pilothole is blocked. Consult your Yamahadealer if the problem cannot be located

and corrected.

EMU34530

Shifting

WARNING

EWM00180

Before shifting, make sure there are noswimmers or obstacles in the water near

you.

CAUTION:

ECM01610

Warm up the engine before shifting intogear. Until the engine is warm, the idlespeed may be higher than normal. Highidle speed can prevent you from shiftingback to neutral. If this occurs, stop theengine, shift to neutral, then restart the

STARTOFFON

ZMU02316

ZMU02968

Operation

31

engine and allow it to warm up.

To shift out of neutral1. Pull the neutral interlock trigger up (if

equipped).

2. Move the remote control lever / gearshift lever firmly and crisply forward (forforward gear) or backward (for reversegear) [about 35° (a detent can felt) for re-mote control models]. Be sure to checkthat the tilt lock lever is in the lock/downposition (if equipped) before operating inreverse.

To shift from in gear (forward/reverse) toneutral1. Close the throttle so that the engine

slows to idle speed.

1. Neutral interlock trigger

ZMU02971

ZMU05718

NR F

Operation

32

2. After the engine is at idle speed in gearmove the remote control lever / gearshift lever firmly and crisply into the neu-tral position.

EMU31742

Stopping boat

WARNING

EWM01510

�

Do not use the reverse function to slowdown or stop the boat as it could causeyou to lose control, be ejected, or im-

pact the steering wheel or other parts ofthe boat. This could increase the risk ofserious injury. It could also damage theshift mechanism.

�

Do not shift into reverse while travelingat planing speeds. Loss of control, boatswamping, or damage to the boat could

occur.

The boat is not equipped with a separatebraking system. Water resistance stops it af-ter the throttle lever is moved back to idle.The stopping distance varies depending ongross weight, water surface conditions, andwind direction.

EMU27820

Stopping engine

Before stopping the engine, first let it cool offfor a few minutes at idle or low speed. Stop-ping the engine immediately after operatingat high speed is not recommended.

EMU27845

Procedure

1. Push and hold the engine stop button orturn the main switch to “ ” (off).

ZMU02030

N

ZMU02957 ZMU02972

Operation

33

2. After stopping the engine, disconnectthe fuel line if there is a fuel joint on theoutboard motor.

3. Tighten the air vent screw on the fueltank cap (if equipped).

4. Remove the key if the boat will be leftunattended.

NOTE:

The engine can also be stopped by pullingthe cord and removing the clip from the en-

gine shut-off switch, then turning the main

switch to “ ” (off).

EMU27861

Trimming outboard motor

The trim angle of the outboard motor helpsdetermine the position of the bow of the boatin the water. Correct trim angle will help im-prove performance and fuel economy whilereducing strain on the engine. Correct trimangle depends upon the combination ofboat, engine, and propeller. Correct trim isalso affected by variables such as the load inthe boat, sea conditions, and running speed.

WARNING

EWM00740

Excessive trim for the operating condi-tions (either trim up or trim down) cancause boat instability and can makesteering the boat more difficult. This in-creases the possibility of an accident. Ifthe boat begins to feel unstable or is hardto steer, slow down and/or readjust the

trim angle.

ZMU02973

OFFON

START

ZMU02974

ZMU02301

Operation

34

EMU27872

Adjusting trim angle for manual tilt models

There are 4 or 5 holes provided in the clampbracket to adjust the outboard motor trim an-gle.1. Stop the engine.2. Tilt the outboard motor up, and then re-

move the trim rod from the clamp brack-et.

3. Reposition the rod in the desired hole.To raise the bow (“trim-out”), move the rodaway from the transom.To lower the bow (“trim-in”), move the rod to-ward the transom.Make test runs with the trim set to differentangles to find the position that works best foryour boat and operating conditions.

WARNING

EWM00400

�

Stop the engine before adjusting thetrim angle.

�

Use care to avoid being pinched whenremoving or installing the rod.

�

Use caution when trying a trim positionfor the first time. Increase speed gradu-ally and watch for any signs of instabil-ity or control problems. Improper trim

angle can cause loss of control.

NOTE:

The outboard motor trim angle can bechanged approximately 4 degrees by shifting

the trim rod one hole.

EMU27911

Adjusting boat trim

When the boat is on plane, a bow-up attituderesults in less drag, greater stability and effi-ciency. This is generally when the keel line of

1. Trim operating angle

1 ZMU02975

1. Trim rod

ZMU02976

1

Operation

35

the boat is up about 3 to 5 degrees. With thebow up, the boat may have a greater tenden-cy to steer to one side or the other. Compen-sate for this as you steer. The trim tab canalso be adjusted to help offset this effect.When the bow of the boat is down, it is easierto accelerate from a standing start ontoplane.

Bow Up

Too much trim-out puts the bow of the boattoo high in the water. Performance and econ-omy are decreased because the hull of theboat is pushing the water and there is moreair drag. Excessive trim-out can also causethe propeller to ventilate, which reduces per-formance further, and the boat may “por-poise” (hop in the water), which could throwthe operator and passengers overboard.

Bow Down

Too much trim-in causes the boat to “plow”through the water, decreasing fuel economy

and making it hard to increase speed. Oper-ating with excessive trim-in at higher speedsalso makes the boat unstable. Resistance atthe bow is greatly increased, heightening thedanger of “bow steering” and making opera-tion difficult and dangerous.

NOTE:

Depending on the type of boat, the outboardmotor trim angle may have little effect on the

trim of the boat when operating.

EMU27934

Tilting up and down

If the engine will be stopped for some time orif the boat is moored in shallows, the out-board motor should be tilted up to protect thepropeller and lower casing from damage bycollision with obstructions, and also to re-duce salt corrosion.

WARNING

EWM00221

Be sure all people are clear of the out-board motor when tilting up and down,Body parts can be crushed between themotor and the clamp bracket when the

motor is trimmed or tilted.

WARNING

EWM00250

Leaking fuel is a fire hazard. If there is afuel joint on the outboard motor, discon-nect the fuel line or close the fuel cock if

Operation

36

the engine will be tilted for more than a

few minutes. Otherwise fuel may leak.

CAUTION:

ECM00241

�

Before tilting the outboard motor, stopthe engine by following the procedureon page 32. Never tilt the outboard mo-tor while the engine is running. Severedamage from overheating can result.

�

Do not tilt up the engine by pushing thetiller handle (if equipped) because this

could break the handle.

EMU27979

Procedure for tilting up (manual tilt models)

1. Place the remote control lever / gearshift lever in neutral.

2. Place the tilt lock lever (if equipped) inthe release/up position.

3. Pull up the shallow water lever (ifequipped).

4. Hold the rear of the top cowling with onehand and tilt the engine up fully.

5. Push the tilt support knob into the clampbracket. Or the tilt support bar will turn tothe lock position automatically.

CAUTION:

ECM01640

Do not use the tilt support lever or knob

N

ZMU02978

N

ZMU03087

ZMU02979

ZMU02917

ZMU02980

Operation

37

when trailering the boat. The outboardmotor could shake loose from the tilt sup-port and fall. If the motor cannot be trail-ered in the normal running position, usean additional support device to secure itin the tilt position. For more detailed in-

formation, see page 40.

EMU28013

Procedure for tilting down (manual tilt models)

1. Slightly tilt the engine up.2. On models equipped with a tilt support

knob, pull it out.

3. Slowly tilt the engine down.

EMU28060

Cruising in shallow water

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

EMU28071

Cruising in shallow water (manual tilt models)

WARNING

EWM00710

�

Place the gear shift in neutral before us-ing the shallow water cruising system.

�

Run the boat at the lowest possiblespeed when using the shallow watercruising system. The tilt lock mecha-nism does not work while the shallowwater cruising system is being used.Hitting an underwater obstacle could

cause the outboard motor to lift out ofthe water, resulting in loss of control.

�

Do not rotate the outboard motor 180°and operate the boat in reverse. Placethe gear shift in reverse to operate theboat in reverse.

�

Use extra care when operating in re-verse. Too much reverse thrust cancause the outboard motor to lift out ofthe water, increasing the chance of ac-cident and personal injury.

�

Return the outboard motor to its normalposition as soon as the boat is back in

deeper water.

CAUTION:

ECM00260

Do not tilt the outboard motor up so thatthe cooling water inlet on the lower unit isabove the surface of the water when set-ting up for and cruising in shallow water.Otherwise severe damage from overheat-

ing can result.

EMU28153

Procedure

1. Place the remote control lever / gearshift lever in neutral.

ZMU02981

ZMU02982

Operation

38

2. Push the tilt lock lever down to the re-lease position.

3. Slightly tilt the outboard motor up andpull the shallow water lever toward thetransom.

4. To return the outboard motor to the nor-mal position, place the gear shift lever inneutral, then slightly tilt the outboardmotor up. Push the shallow water leverdown. Set the tilt lock lever to the lockposition and slowly tilt the outboard mo-tor down.

EMU28193

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the coolingwater passages with fresh water to preventthem from becoming clogged. Also rinse theoutside of the outboard motor with fresh wa-ter and, if possible, rinse the power head un-der the cowling.

Cruising in muddy or turbid water

Yamaha strongly recommends that you usethe optional chromium-plated water pump kit(available for V4 and large engines) if youuse the outboard motor in water with a lot ofsediment in it, such as muddy or other turbid(cloudy) water.

Cruising in acidic water

Water in some areas can be acidic. After op-erating in such water, flush the cooling pas-sages with fresh water to prevent corrosion.Also rinse the outside of the outboard motorwith fresh water.

N

ZMU02983

N

ZMU03087

ZMU02984

ZMU02917

39

Maintenance

EMU31480

SpecificationsNOTE:

“(AL)” stated in the specification data belowrepresents the numerical value for the alumi-num propeller installed.Likewise, “(SUS)” represents the value forstainless steel propeller installed and “(PL)”

for plastic propeller installed.

EMU28219

Dimension:

Overall length: 25BMH 843 mm (33.2 in)25XMH 843 mm (33.2 in)30HMH 843 mm (33.2 in)30HW 608 mm (23.9 in)E25BMH 843 mm (33.2 in)

Overall width: 25BMH 399 mm (15.7 in)25XMH 399 mm (15.7 in)30HMH 399 mm (15.7 in)30HW 358 mm (14.1 in)E25BMH 399 mm (15.7 in)

Overall height S: 25BMH 1146 mm (45.1 in)25XMH 1146 mm (45.1 in)30HMH 1146 mm (45.1 in)E25BMH 1146 mm (45.1 in)

Overall height L: 25BMH 1273 mm (50.1 in)30HMH 1273 mm (50.1 in)30HW 1273 mm (50.1 in)E25BMH 1273 mm (50.1 in)

Transom height S: 25BMH 423 mm (16.7 in)25XMH 423 mm (16.7 in)30HMH 423 mm (16.7 in)E25BMH 423 mm (16.7 in)

Transom height L: 25BMH 550 mm (21.7 in)

30HMH 550 mm (21.7 in)30HW 550 mm (21.7 in)E25BMH 550 mm (21.7 in)

Weight (AL) S: 25BMH 53.0 kg (117 lb)25XMH 53.0 kg (117 lb)30HMH 53.0 kg (117 lb)E25BMH 53.0 kg (117 lb)

Weight (AL) L: 25BMH 54.5 kg (120 lb)30HMH 54.5 kg (120 lb)30HW 58.0 kg (128 lb)E25BMH 54.5 kg (120 lb)

Performance:

Full throttle operating range: 4500–5500 r/min

Maximum output: 25BMH 18.4 kW@5000 r/min (25 HP@5000 r/min)25XMH 18.4 kW@5000 r/min (25 HP@5000 r/min)30HMH 22.1 kW@5000 r/min (30 HP@5000 r/min)30HW 22.1 kW@5000 r/min (30 HP@5000 r/min)E25BMH 18.4 kW@5000 r/min (25 HP@5000 r/min)

Idling speed (in neutral): 1100

±

50 r/min

Engine:

Type: 2-stroke L

Displacement: 496.0 cm

3

Bore

×

stroke: 72.0

×

61.0 mm (2.83

×

2.40 in)Ignition system:

CDISpark plug with resistor (NGK):

25BMH BR7HS-1025XMH BR8HS-10

Maintenance

40

30HMH BR8HS-1030HW BR8HS-10E25BMH BR7HS-10

Spark plug gap: 0.9–1.0 mm (0.035–0.039 in)

Control system: 25BMH Tiller25XMH Tiller30HMH Tiller30HW Remote controlE25BMH Tiller

Starting system: 25BMH Manual25XMH Manual30HMH Manual30HW Manual and electricE25BMH Manual

Starting carburetion system: Choke valve

Min. cold cranking amps (CCA/EN): 30HW 347.0 A

Min. rated capacity (20HR/IEC): 30HW 40.0 Ah

Alternator output: 25BMH 80 W25XMH 80 W30HMH 80 WE25BMH 80 W

Maximum generator output: 30HW 6.0 A

Drive unit:

Gear positions: Forward-neutral-reverse

Gear ratio: 2.08 (27/13)

Trim and tilt system: Manual tilt

Propeller mark: F

Fuel and oil:

Recommended fuel:

Regular unleaded gasolineFuel tank capacity:

24 L (6.34 US gal) (5.28 Imp.gal)Recommended engine oil:

YAMALUBE 2-stroke outboard motor oil

Fuel:oil ratio:

Regular gasoline: 25BMH 100 :125XMH 100 :130HMH 100 :130HW 100 :1E25BMH 50 :1

Lubrication: Pre-mixed fuel and oil

Recommended gear oil: Hypoid gear oil SAE#90

Gear oil quantity: 320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)

Tightening torque for engine:

Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Propeller nut: 35.0 Nm (25.8 ft-lb) (3.57 kgf-m)

Noise and vibration level:

Operator sound pressure level (ICOMIA 39/94 and 40/94):

30HMH 82.7 dB(A) E25BMH 82.7 dB(A)

Vibration on tiller handle (ICOMIA 38/94): 30HMH Vibration on tiller handle is under 2.5 m/s

2

E25BMH Vibration on tiller handle is under 2.5 m/s

2

EMU28223

Transporting and storing outboard motor

WARNING

EWM00690

�

Leaking fuel is a fire hazard. When

Maintenance

41

transporting and storing the outboardmotor, close the air vent screw and fuelcock to prevent fuel from leaking.

�

USE CARE when transporting fuel tank,whether in a boat or car.

�

DO NOT fill fuel container to maximumcapacity. Gasoline will expand consid-erably as it warms up and can build uppressure in the fuel container. This cancause fuel leakage and a potential fire

hazard.

WARNING

EWM00700

Never get under the lower unit while it istilted, even if a motor support bar is used.Severe injury could occur if the outboard

motor accidentally falls.

CAUTION:

ECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboardmotor could shake loose from the tilt sup-port and fall. If the motor cannot be trail-ered in the normal running position, usean additional support device to secure it

in the tilt position.

The outboard motor should be trailered andstored in the normal running position. If thereis insufficient road clearance in this position,then trailer the outboard motor in the tilt po-sition using a motor support device such asa transom saver bar. Consult your Yamahadealer for further details.

EMU28235

Clamp screw mounting models

When transporting or storing the outboardmotor while removed from a boat, keep theoutboard motor in the attitude shown.

NOTE:

Place a towel or something similar under the

outboard motor to protect it from damage.

EMU30272

Storing outboard motor

When storing your Yamaha outboard motorfor prolonged periods of time (2 months orlonger), several important procedures mustbe performed to prevent excessive damage.It is advisable to have your outboard motorserviced by an authorized Yamaha dealerprior to storage. However, you, the owner,with a minimum of tools, can perform the fol-

ZMU02986

ZMU02987

Maintenance

42

lowing procedures.

CAUTION:

ECM01411

�

Do not place the outboard motor on itsside before the cooling water hasdrained from it completely, otherwisewater may enter the cylinder throughthe exhaust port and cause engine trou-ble.

�

Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

EMU28303

Procedure

EMU28332

Flushing in a test tank

CAUTION:

ECM00300

Do not run the engine without supplyingit with cooling water. Either the enginewater pump will be damaged or the en-gine will be damaged from overheating.Before starting the engine, be sure tosupply water to the cooling water passag-

es.

1. Wash the outboard motor body usingfresh water. For further information, seepage 44.

2. Disconnect the fuel line from the motoror shut off the fuel cock, if equipped.

3. Remove the engine top cowling and si-lencer cover. Remove the propeller.

4. Install the outboard motor on the testtank. Fill the tank with fresh water toabove the level of the anti-cavitationplate.

CAUTION:

ECM00290

If the fresh water level is below the levelof the anti-cavitation plate, or if the watersupply is insufficient, engine seizure may

occur.

5. Cooling system flushing is essential toprevent the cooling system from clog-ging up with salt, sand, or dirt. In addi-tion, fogging/lubricating of the engine ismandatory to prevent excessive enginedamage due to rust. Perform the flush-ing and fogging at the same time.

WARNING

EWM00090

�


�

Keep hands, hair, and clothes awayfrom the flywheel and other rotating

parts while the engine is running.

6. Run the engine at a fast idle for a fewminutes in neutral position.

7. Just prior to turning off the engine, quick-ly spray “Fogging Oil” alternately intoeach carburetor or the fogging hole ofthe silencer cover, if equipped. Whenproperly done, the engine will smoke ex-

1. Water surface2. Lowest water level

ZMU02051

1

2

Maintenance

43

cessively and almost stall.8. Remove the outboard motor from the

test tank.9. Install the silencer cover/cap of fogging

hole and top cowling.10. If the “Fogging Oil” is not available, run

the engine at a fast idle until the fuel sys-tem becomes empty and the enginestops.

11. Drain the cooling water completely outof the motor. Clean the body thoroughly.

12. If the “Fogging Oil” is not available, re-move the spark plug(s). Pour a tea-spoonful of clean engine oil into eachcylinder. Crank several times manually.Replace the spark plug(s).

13. Drain the fuel from the fuel tank.

NOTE:

Store the fuel tank in a dry, well-ventilated

place, not in direct sunlight.

EMU28402

Lubrication

1. Install the spark plug(s) and torque toproper specification. For information onspark plug installation, see page 47.

2. Change the gear oil. For instructions,see page 52. Inspect the oil for the pres-ence of water that indicates a leaky seal.Seal replacement should be performedby an authorized Yamaha dealer prior touse.

3. Grease all grease fittings. For further de-tails, see page 47.

NOTE:

For long-term storage, fogging the enginewith oil is recommended. Contact yourYamaha dealer for information about fogging

oil and procedures for your engine.

EMU28431

Battery care

WARNING

EWM00330

Battery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore ispoisonous and highly caustic.Always follow these preventive mea-sures:

�

Avoid bodily contact with electrolyticfluid as it can cause severe burns orpermanent eye injury.

�

Wear protective eye gear when han-dling or working near batteries.

Antidote (EXTERNAL):

�

SKIN - Flush with water.

�

EYES - Flush with water for 15 minutesand get immediate medical attention.

Antidote (INTERNAL):

�

Drink large quantities of water or milkfollowed by milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.

Batteries also generate explosive hydro-gen gas; therefore, you should alwaysfollow these preventive measures:

�

Charge batteries in a well-ventilated ar-ea.

�

Keep batteries away from fire, sparks,or open flames (for example: weldingequipment, lighted cigarettes, and soon.)

�

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

Follow the manual of the battery for the han-dling of the battery. Batteries vary amongmanufacturers. Therefore the following pro-cedures may not always apply. Consult yourbattery manufacturer’s instructions.

Maintenance

44

Procedure1. Disconnect and remove the battery from

the boat. Always disconnect the blacknegative cable first to prevent the risk ofshorting.

2. Clean the battery casing and terminals.Fill each cell to the upper level with dis-tilled water.

3. Store the battery on a level surface in acool, dry, well-ventilated place out of di-rect sunlight.

4. Once a month, check the specific gravityof the electrolyte and recharge as re-quired to prolong battery life.

EMU28450

Cleaning the outboard motor

After use, wash the exterior of the outboardmotor with fresh water. Flush the coolingsystem with fresh water.

NOTE:

For cooling system flushing instructions, see

page 40.

EMU28460

Checking painted surface of motor

Check the motor for scratches, nicks, or flak-ing paint. Areas with damaged paint aremore likely to corrode. If necessary, cleanand paint the areas. A touch-up paint is avail-able from your Yamaha dealer.

EMU28478

Periodic maintenance

WARNING

EWM01071

Be sure to turn off the engine when youperform maintenance unless otherwisespecified. If you are not familiar with ma-chine servicing, this work should be doneby your Yamaha dealer or other qualified

mechanic.

EMU28511

Replacement parts

If replacement parts are necessary, use onlygenuine Yamaha parts or parts of equivalentdesign and quality. Any part of inferior qualitymay malfunction, and the resulting loss ofcontrol could endanger the operator andpassengers. Yamaha genuine parts and ac-cessories are available from your Yamahadealer.

ZMU02988

Maintenance

45

EMU28522

Maintenance chart

Frequency of maintenance operations may be adjusted according to the operating condi-tions, but the following table gives general guidelines. Refer to the sections in this chapter forexplanations of each owner-specific action.

NOTE:

When operating in salt water, turbid or muddy 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.

Item Actions

Initial Every

10 hours (1 month)

50 hours (3

months)

100 hours (6 months)

200 hours (1

year)

Anode(s) (external)Inspection / replace-ment

Anode(s) (internal)Inspection / replace-ment

Battery Inspection / charging

Cooling water pas-sages

Cleaning

Cowling clamp Inspection

Fuel filter (can be dis-assembled)

Inspection / cleaning

Fuel system Inspection

Fuel tank (Yamaha por-table tank)

Inspection / cleaning

Gear oil Change

Greasing points Greasing

Idling speed (carbure-tor models)

Inspection

Propeller and cotter pinInspection / replace-ment

Shift link / shift cable Inspection / adjustment

ThermostatInspection / replace-ment

Throttle link / throttle cable / throttle pick-up timing

Inspection / adjustment

Water pumpInspection / replace-ment

Maintenance

46

EMU28874

Maintenance chart (additional)

Spark plug(s)Cleaning / adjustment / replacement

Item ActionsEvery

500 hours (2.5 years) 1000 hours (5 years)

Exhaust guide, exhaust manifold

Inspection / replace-ment

Item Actions

Initial Every

10 hours (1 month)

50 hours (3

months)

100 hours (6 months)

200 hours (1

year)

Maintenance

47

EMU28941

Greasing

Yamaha grease A (water resistant grease)Yamaha grease D (corrosion resistant grease; for propeller shaft)

E25B, 25B, 25X, 30H

EMU28953

Cleaning and adjusting spark plug

WARNING

EWM00560

When removing or installing a spark plug,be careful not to damage the insulator. A

damaged insulator could allow externalsparks, which could lead to explosion or

ZMU02918

Maintenance

48

fire.

WARNING

EWM01550

The engine will still be very hot when ithas just been turned off. Take extremelycare so that neither you nor anyone elsegets burnt. To avoid burns, work on the

engine when it has cooled down.

The spark plug is an important engine com-ponent and is easy to inspect. The conditionof the spark plug can indicate somethingabout the condition of the engine. For exam-ple, if the center electrode porcelain is verywhite, this could indicate an intake air leak orcarburetion problem in that cylinder. Do notattempt to diagnose any problems yourself.Instead, take the outboard motor to aYamaha dealer. You should periodically re-move and inspect the spark plug becauseheat and deposits will cause the spark plugto slowly break down and erode. If electrodeerosion becomes excessive, or if carbon andother deposits are excessive, you should re-place the spark plug with another of the cor-rect type.

Before fitting the spark plug, measure theelectrode gap with a wire thickness gauge;adjust the gap to specification if necessary.

When fitting the plug, always clean the gas-ket surface and use a new gasket. Wipe offany dirt from the threads and screw in thespark plug to the correct torque.

NOTE:

If a torque-wrench is not available when youare fitting a spark plug, a good estimate ofthe correct torque is 1/4 to 1/2 a turn past fin-ger-tight. Have the spark plug adjusted to thecorrect torque as soon as possible with a

torque-wrench.

EMU28962

Checking fuel system

WARNING

EWM00060

Gasoline and its vapors are highly flam-mable and explosive. Keep away fromsparks, cigarettes, flames, or other

Standard spark plug:25BMH BR7HS-1025XMH BR8HS-1030HMH BR8HS-1030HW BR8HS-10E25BMH BR7HS-10

1. Spark plug gap2. Spark plug I.D. mark (NGK)3. Spark plug part number

Spark plug gap:0.9–1.0 mm (0.035–0.039 in)

Spark plug torque:25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Maintenance

49

sources of ignition.

WARNING

EWM00910

Leaking fuel can result in fire or explo-sion.

�

Check for fuel leakage regularly.

�

If any fuel leakage is found, the fuelsystem must be repaired by a qualifiedmechanic. Improper repairs can make

the outboard unsafe to operate.

Check the fuel lines for leaks, crack, or mal-function. If a problem is found, your Yamahadealer or other qualified mechanic should re-pair it immediately.

Checkpoints

�

Fuel system parts leakage

�

Fuel line joint leakage

�

Fuel line cracks or other damage

�

Fuel connector leakage

EMU28980

Inspecting fuel filter

WARNING

EWM00310

Gasoline is highly flammable, and its va-pors are flammable and explosive.

�

If you have any question about properlydoing this procedure, consult yourYamaha dealer.

�

Do not perform this procedure on a hotor running engine. Allow the engine tocool.

�

There will be fuel in the fuel filter. Keepaway from sparks, cigarettes, flames orother sources of ignition.

�

This procedure will allow some fuel tospill. Catch fuel in a rag. Wipe up anyspilled fuel immediately.

�

The fuel filter must be reassembledcarefully with the O-ring, filter cup, andhoses in place. Improper assembly orreplacement could result in a fuel leak,which could result in a fire or explosion

hazard.

EMU29001

Cleaning fuel filter

1. Remove the nut holding the fuel filter as-sembly if equipped.

2. Unscrew the filter cup, catching anyspilled fuel in a rag.

3. Remove the filter element, and wash it in

ZMU02990

ZMU03009

Maintenance

50

solvent. Allow it to dry. Inspect the filterelement and O-ring to make sure theyare in good condition. Replace them ifnecessary. If any water is found in thefuel, the Yamaha portable fuel tank orother fuel tanks should be checked andcleaned.

4. Reinstall the filter element in the cup.Make sure the O-ring is in position in thecup. Firmly screw the cup onto the filterhousing.

5. Attach the filter assembly to the bracketso that the fuel hoses are attached to thefilter assembly.

6. Run the engine and check the filter andlines for leaks.

EMU29041

Inspecting idling speed

WARNING

EWM00451

�


�

Keep hands, hair, and clothes awayfrom the flywheel and other rotating

parts while the engine is running.

CAUTION:

ECM00490

This procedure must be performed whilethe outboard motor is in the water. Aflushing attachment or test tank can be

used.

A diagnostic tachometer should be used forthis procedure. Results may vary dependingon whether testing is conducted with theflushing attachment, in a test tank, or with theoutboard motor in the water.1. Start the engine and allow it to warm up

fully in neutral until it is running smooth-ly.

NOTE:

Correct idling speed inspection is only possi-ble if the engine is fully warmed up. If notwarmed up fully, the idle speed will measurehigher than normal. If you have difficulty ver-ifying the idle speed, or the idle speed re-quires adjustment, consult a Yamaha dealer

or other qualified mechanic.

2. Verify whether the idle speed is set tospecification. For idle speed specifica-tions, see page 39.

EMU29112

Checking wiring and connectors

�

Check that each grounding wire is properlysecured.

�

Check that each connector is engaged se-curely.

1. Filter cup2. Filter element3. Filter housing4. O-ring

ZMU02079

1

4

23

Maintenance

51

EMU29120

Exhaust leakage

Start the engine and check that no exhaustleaks from the joints between the exhaustcover, cylinder head, and body cylinder.

EMU29130

Water leakage

Start the engine and check that no waterleaks from the joints between the exhaustcover, cylinder head, and body cylinder.

EMU32110

Checking propeller

WARNING

EWM01610

You could be seriously injured if the en-gine accidentally starts when you arenear the propeller.

�

Before inspecting, removing, or install-ing the propeller, remove the sparkplug caps from the spark plugs. Also,place the shift control in neutral, turnthe main switch to “ ” (off) and re-move the key, and remove the cordfrom the engine shut-off switch. Turnoff the battery cut-off switch if yourboat has one.

�

Do not use your hand to hold the pro-peller when loosening or tightening thepropeller nut. Put a wood block be-tween the anti-cavitation plate and thepropeller to prevent the propeller from

turning.

Checkpoints

�

Check each of the propeller blades forwear, erosion from cavitation or ventila-tion, 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.

�

Check the propeller shaft oil seal for dam-

ZMU02087

ZMU01896

ZMU01897

Maintenance

52

age.

EMU30661

Removing propeller

EMU29195

Spline models

1. Straighten the cotter pin and pull it outusing a pair of pliers.

2. Remove the propeller nut, washer, andspacer (if equipped).

3. Remove the propeller and thrust wash-er.

EMU30671

Installing propeller

EMU29231

Spline models

CAUTION:

ECM00340

�

Be sure to install the thrust washer be-fore installing the propeller, otherwisethe lower case and propeller bosscould be damaged.

�

Be sure to use a new cotter pin andbend the ends over securely. Otherwisethe propeller could come off during op-

eration and be lost.

1. Apply Yamaha marine grease or a cor-rosion resistant grease to the propellershaft.

2. Install the spacer (if equipped), thrustwasher, and propeller on the propellershaft.

3. Install the spacer (if equipped) and thewasher. Tighten the propeller nut to thespecified torque.

4. Align the propeller nut with the propellershaft hole. Insert a new cotter pin in thehole and bend the cotter pin ends.

NOTE:

If the propeller nut does not align with thepropeller shaft hole after tightening to thespecified torque, tighten the nut further to

align it with the hole.

EMU29282

Changing gear oil

WARNING

EWM00800

�

Be sure the outboard motor is securelyfastened to the transom or a stablestand. You could be severely injured ifthe outboard motor falls on you.

�

Never get under the lower unit while itis tilted, even when the tilt support leveror knob is locked. Severe injury couldoccur if the outboard motor accidental-

ly falls.

1. Cotter pin2. Propeller nut3. Washer4. Spacer5. Propeller6. Thrust washer

ZMU02993

1

23

4

56

ZMU02063

Maintenance

53

1. Tilt the outboard motor so that the gearoil drain screw is at the lowest point pos-sible.

2. Place a suitable container under thegear case.

3. Remove the gear oil drain screw andgasket.

NOTE:

�

If a magnetic gear oil drain screw isequipped, remove all metal particles fromthe screw before installing it.

�

Always use new gaskets. Do not reuse the

removed gaskets.

4. Remove the oil level plug and gasket toallow the oil to drain completely.

CAUTION:

ECM00710

Inspect the used oil after it has beendrained. If the oil is milky, water is gettinginto the gear case which can cause geardamage. Consult a Yamaha dealer for re-

pair of the lower unit seals.

NOTE:

For disposal of used oil, consult your

Yamaha dealer.

5. With the outboard motor in a vertical po-

sition, and using a flexible or pressur-ized filling device, inject the gear oil intothe gear oil drain screw hole.

6. Put a new gasket on the oil level plug.When the oil begins to flow out of the oillevel plug hole, insert and tighten the oillevel plug.

7. Put a new gasket on the gear oil drainscrew. Insert and tighten the gear oildrain screw.

EMU29302

Cleaning fuel tank

WARNING

EWM00920

Gasoline is highly flammable, and its va-pors are flammable and explosive.

�

If you have any question about properlydoing this procedure, consult yourYamaha dealer.

�

Keep away from sparks, cigarettes,flames, or other sources of ignitionwhen cleaning the fuel tank.

�

Remove the fuel tank from the boat be-fore cleaning it. Work only outdoors in

1. Gear oil drain screw2. Oil level plug

ZMU02995

2

1

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)

ZMU02994

Maintenance

54

an area with good ventilation.

�

Wipe up any spilled fuel immediately.

�

Reassemble the fuel tank carefully. Im-proper assembly can result in a fuelleak, which could result in a fire or ex-plosion hazard.

�

Dispose of old gasoline according to lo-

cal regulations.

1. Empty the fuel tank into an approvedcontainer.

2. Pour a small amount of suitable solventinto the tank. Install the cap and shakethe tank. Drain the solvent completely.

3. Remove the screws holding the fuel jointassembly. Pull the assembly out of thetank.

4. Clean the filter (located on the end of thesuction pipe) in a suitable cleaning sol-vent. Allow the filter to dry.

5. Replace the gasket with a new one. Re-install the fuel joint assembly and tightenthe screws firmly.

EMU29312

Inspecting and replacing anode(s)

Yamaha outboard motors are protected fromcorrosion by sacrificial anodes. Inspect theexternal anodes periodically. Remove scalesfrom the surfaces of the anodes. Consult aYamaha dealer for replacement of external

anodes.

CAUTION:

ECM00720

Do not paint anodes, as this would render

them ineffective.

NOTE:

Inspect ground leads attached to externalanodes on equipped models. Consult aYamaha dealer for inspection and replace-ment of internal anodes attached to the pow-

er unit.

EMU29320

Checking battery (for electric start models)

WARNING

EWM00330

Battery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore ispoisonous and highly caustic.Always follow these preventive mea-sures:

�

Avoid bodily contact with electrolyticfluid as it can cause severe burns orpermanent eye injury.

�

Wear protective eye gear when han-dling or working near batteries.

Antidote (EXTERNAL):

�

SKIN - Flush with water.

�

EYES - Flush with water for 15 minutes

ZMU02324

ZMU02325

Maintenance

55

and get immediate medical attention.Antidote (INTERNAL):

�

Drink large quantities of water or milkfollowed by milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.

Batteries also generate explosive hydro-gen gas; therefore, you should alwaysfollow these preventive measures:

�

Charge batteries in a well-ventilated ar-ea.

�

Keep batteries away from fire, sparks,or open flames (for example: weldingequipment, lighted cigarettes, and soon.)

�

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

CAUTION:

ECM00360

�

A poorly maintained battery will quicklydeteriorate.

�

Ordinary tap water contains mineralsharmful to a battery, and should not be

used for topping up.

1. Check the electrolyte level at least oncea month. Fill to the manufacturer’s rec-ommended level when necessary. Topup only with distilled water (or pure de-ionized water suitable to use in batter-ies).

2. Always keep the battery in a good stateof charge. Installing a voltmeter will helpyou monitor your battery. If you will notuse the boat for a month or more, re-move the battery from the boat and storeit in a cool, dark place. Completely re-charge the battery before using it.

3. If the battery will be stored for longerthan a month, check the specific gravityof the fluid at least once a month and re-charge the battery when it is low.

NOTE:

Consult a Yamaha dealer when charging or

re-charging batteries.

EMU29332

Connecting the battery

WARNING

EWM00570

Mount the battery holder securely in adry, well-ventilated, vibration-free loca-tion in the boat. Install a fully charged bat-

tery in the holder.

CAUTION:

ECM01122

�

Make sure the main switch (on applica-ble models) is “ ” (off) before work-ing on the battery.

�

Reversal of the battery cables will dam-age the electrical parts.

�

Connect the red battery cable first

Maintenance

56

when installing the battery and discon-nect the black battery cable first whenremoving it.

�

The electrical contacts of the batteryand cables must be clean and properlyconnected, or the battery will not start

the engine.

Connect the red battery cable to the POSI-TIVE (+) terminal first. Then connect theblack battery cable to the NEGATIVE (-) ter-minal.

EMU29370

Disconnecting the battery

Disconnect the BLACK cable from the NEG-ATIVE (-) terminal first. Then disconnect theRED cable from the POSITIVE (+) terminal.

EMU29391

Checking top cowling

CAUTION:

ECM01650

Be sure the cowling is closed securelyand that there are no gaps. A loose or im-properly fitting cover could allow water

into the engine.

Check the fitting of the top cowling by push-ing it with both hands. If it is loose have it re-paired by your Yamaha dealer.

EMU29400

Coating the boat bottom

A clean hull improves boat performance. Theboat bottom should be kept as clean of ma-rine growth as possible. If necessary, theboat bottom can be coated with an anti-foul-ing paint approved for your area to inhibitmarine growth.Do not use anti-fouling paint which includescopper or graphite. These paints can causemore rapid engine corrosion.

1. Red cable2. Black cable3. Battery

ZMU04677

ZMU02997

57

Trouble Recovery

EMU29425

Troubleshooting

A problem in the fuel, compression, or igni-tion systems can cause poor starting, loss ofpower, or other problems. This section de-scribes basic checks and possible remedies,and covers all Yamaha outboard motors.Therefore some items may not apply to yourmodel.If your outboard motor requires repair, bringit to your Yamaha dealer.If the engine trouble-warning indicator isflashing, consult your Yamaha dealer.

Starter will not operate.

Q. Is battery capacity weak or low?A. Check battery condition. Use battery ofrecommended capacity.

Q. Are battery connections loose or corrod-ed?A. Tighten battery cables and clean batteryterminals.

Q. Is fuse for electric start relay or electric cir-cuit blown?A. Check for cause of electric overload andrepair. Replace fuse with one of correct am-perage.

Q. Are starter components faulty?A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear?A. Shift to neutral.

Engine will not start (starter operates).

Q. Is fuel tank empty?A. Fill tank with clean, fresh fuel.

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged?A. Clean or replace filter.

Q. Is starting procedure incorrect?A. See page 25.

Q. Has fuel pump malfunctioned?A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replacewith recommended type.

Q. Are spark plug cap(s) fitted incorrectly?A. Check and re-fit cap(s).

Q. Is ignition wiring damaged or poorly con-nected?A. Check wires for wear or breaks. Tightenall loose connections. Replace worn or bro-ken wires.

Q. Are ignition parts faulty?A. Have serviced by a Yamaha dealer.

Q. Is engine shut-off cord not attached?A. Attach cord.

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

Engine idles irregularly or stalls.


Q. Is fuel system obstructed?

Trouble Recovery

58

A. Check for pinched or kinked fuel line orother obstructions in fuel system.

Q. Is fuel contaminated or stale?A. Fill tank with clean, fresh fuel.


Q. Have ignition parts failed?A. Have serviced by a Yamaha dealer.

Q. Has warning system activated?A. Find and correct cause of warning.

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


Q. Is specified engine oil not being used?A. Check and replace oil as specified.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Are carburetor adjustments incorrect?A. Have serviced by a Yamaha dealer.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw on fuel tank closed?A. Open air vent screw.

Q. Is choke knob pulled out?A. Return to home position.

Q. Is motor angle too high?A. Return to normal operating position. Q. Is carburetor clogged?A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect?A. Connect correctly.

Q. Is throttle valve adjustment incorrect?A. Have serviced by a Yamaha dealer.

Q. Is battery cable disconnected?A. Connect securely.

Warning buzzer sounds or indicatorlights.

Q. Is cooling system clogged?A. Check water intake for restriction.

Q. Is engine oil level low?A. Fill oil tank with specified engine oil.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is engine oil contaminated or deteriorat-ed?A. Replace oil with fresh, specified type.

Q. Is oil filter clogged?A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunc-tioned?A. Have serviced by a Yamaha dealer.

Trouble Recovery

59

Q. Is load on boat improperly distributed?A. Distribute load to place boat on an evenplane.

Q. Is water pump or thermostat faulty?A. Have serviced by a Yamaha dealer.

Q. Is there excess water in fuel filter cup?A. Drain filter cup.

Engine power loss.

Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller pitch or diameter incorrect?A. Install correct propeller to operate out-board at its recommended speed (r/min)range.

Q. Is trim angle incorrect?A. Adjust trim angle to achieve most efficientoperation.

Q. Is motor mounted at incorrect height ontransom?A. Have motor adjusted to proper transomheight.

Q. Has warning system activated?A. Find and correct cause of warning.

Q. Is boat bottom fouled with marine growth?A. Clean boat bottom.


Q. Are weeds or other foreign matter tangled

on gear housing?A. Remove foreign matter and clean lowerunit.

Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line orother obstructions in fuel system.


Q. Is fuel contaminated or stale?A. Fill tank with clean, fresh fuel.

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


Q. Have electrical parts failed?A. Have serviced by a Yamaha dealer.

Q. Is specified fuel not being used?A. Replace fuel with specified type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw closed?A. Open the air vent screw.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Trouble Recovery

60

Q. Is fuel joint connection incorrect?A. Connect correctly.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is high pressure fuel pump drive belt bro-ken?A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shiftlever position?A. Have serviced by a Yamaha dealer.

Engine vibrates excessively.

Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged?A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangledon propeller?A. Remove and clean propeller.

Q. Is motor mounting bolt loose?A. Tighten bolt.

Q. Is steering pivot loose or damaged?A. Tighten or have serviced by a Yamahadealer.

EMU29433

Temporary action in emergency

EMU29440

Impact damage

WARNING

EWM00870

The outboard motor can be seriouslydamaged by a collision while operating or

trailering. Damage could make the out-

board motor unsafe to operate.

If the outboard motor hits an object in the wa-ter, follow the procedure below.

1. Stop the engine immediately.2. Inspect the control system and all com-

ponents for damage. Also inspect theboat for damage.

3. Whether damage is found or not, returnto the nearest harbor slowly and careful-ly.

4. Have a Yamaha dealer inspect the out-board motor before operating it again.

EMU29462

Replacing fuse

If the fuse has blown on an electric startmodel, open the fuse holder and replace thefuse with a new one of the proper amperage.

WARNING

EWM00630

Be sure to use the specified fuse. An in-correct fuse or a piece of wire could allowexcessive current flow. This could cause

electric system damage and a fire hazard.

Trouble Recovery

61

NOTE:

Consult your Yamaha dealer if the new fuse

immediately blows again.

EMU29533

Starter will not operate

If the starter mechanism does not operate(the engine cannot be cranked with the start-er), the engine can be started with an emer-gency starter rope.

WARNING

EWM01022

�

Use this procedure only in an emergen-cy to return to the nearest port for re-pairs.

�

When the emergency starter rope isused to start the engine, the start-in-gear protection device does not oper-ate. Make sure the remote control leveris in neutral. Otherwise the boat couldunexpectedly start to move, whichcould result in an accident.

�

Attach the engine shut-off cord to a se-cure place on your clothing, or yourarm or leg while operating the boat.

�

Do not attach the cord to clothing thatcould tear loose. Do not route the cordwhere it could become entangled, pre-

venting it from functioning.

�

Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power,the boat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

�

Make sure no one is standing behindyou when pulling the starter rope. Itcould whip behind you and injuresomeone.

�

An unguarded, rotating flywheel is verydangerous. Keep loose clothing andother objects away when starting theengine. Use the emergency starter ropeonly as instructed. Do not touch the fly-wheel or other moving parts when theengine is running. Do not install thestarter mechanism or top cowling afterthe engine is running.

�

Do not touch the ignition coil, sparkplug wire, spark plug cap, or other elec-trical components when starting or op-erating the motor. You could get an

electrical shock.

EMU29562

Emergency starting engine

1. Remove the top cowling.2. Remove the start-in-gear protection ca-

ble from the starter, if equipped.

1. Fuse holder2. Fuse (20 A)3. Spare fuse (20 A)

ZMU0299812

3

Trouble Recovery

62

3. Remove the starter/flywheel cover afterremoving the bolt(s).

4. Prepare the engine for starting. For fur-ther information, see page 25. Be surethe engine is in neutral and that the clipis attached to the engine shut-off switch.The main switch must be “ ” (on), ifequipped.

5. If equipped the choke knob, pull out it

when the engine is cold. After the enginestarts, gradually return the choke knobto its home position as the engine warmsup.

6. Insert the knotted end of the emergencystarter rope into the notch in the flywheelrotor and wind the rope several turnsaround the flywheel clockwise.

7. Give a strong pull straight out to crankand start the engine. Repeat if neces-sary.

EMU29760

Treatment of submerged motor

If the outboard motor is submerged, immedi-ately take it to a Yamaha dealer. Otherwisesome corrosion may begin almost immedi-ately.If you cannot immediately take the outboardmotor to a Yamaha dealer, follow the proce-dure below in order to minimize engine dam-age.

EMU29771

Procedure

1. Thoroughly wash away mud, salt, sea-weed, and so on, with fresh water.

1. Start-in-gear protection cable

1

ZMU02999

ZMU03000

ON STARTOFF

ZMU02636

ZMU03002

Trouble Recovery

63

2. Remove the spark plugs and face thespark plug holes downward to allow anywater, mud, or contaminants to drain.

3. Drain the fuel from the carburetor, fuelfilter, and fuel line.

4. Feed fogging oil or engine oil throughthe carburetor(s) and spark plug holeswhile cranking with the manual starter oremergency starter rope.

5. Take the outboard motor to a Yamaha

dealer as soon as possible.

CAUTION:

ECM00400

Do not attempt to run the outboard motor

until it has been completely inspected.

ZMU01909

ZMU01910

ZMU01911

YAMAHA MOTOR CO., LTD.

Printed on recycled paperPrinted in JapanApril 2007–0.5

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E25B 25B 25X Motor/yamaha/manual/Yamaha...25X 30H 69R-28199-27-E0 EMU25051 Read this owner’s...

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Transcript of E25B 25B 25X Motor/yamaha/manual/Yamaha...25X 30H 69R-28199-27-E0 EMU25051 Read this owner’s...