Yamaha F2.5B Owner`s manual

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F25B

T25B

OWNER’S MANUAL

U.S.A.Edition

LIT-18626-05-06

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EMU01449

TO THE OWNER

Thank you for choosing a Yamaha outboard motor. This Owner’s manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new

Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.

c C

A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

NOTE:

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

In this Owner’s Manual particularly important information is distinguished in the following ways.

Q

The Safety Alert Symbol means

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

* Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If there is any question concerning this manual, please consult your

Yamaha dealer.

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Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.

NOTE:

The F25MH, T25TR and their standard accessories are used as a base for the explanations and illustrations in this manual.

Therefore, some items may not apply to every model.

EMU01446

F25B, T25B

OWNER’S MANUAL

©2002 by Yamaha Motor Corporation, USA

1st Edition, April 2002

All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, USA is expressly prohibited.

Printed in Japan

P/N LIT-18626-05-06

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EMU00003

CONTENTS

GENERAL INFORMATION

E

BASIC COMPONENTS

OPERATION

MAINTENANCE

TROUBLE RECOVERY

INDEX

READ THIS OWNER’S MANUAL CAREFULLY

BEFORE OPERATING YOUR OUTBOARD MOTOR.

6

4

5

1

2

3

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EMU00004

Chapter 1

GENERAL

INFORMATION

1

IDENTIFICATION NUMBERS RECORD ..1-1

Outboard motor serial number...........1-1

Key number...........................................1-1

EMISSION CONTROL INFORMATION...1-2

2

SAFETY INFORMATION..........................1-4

IMPORTANT LABELS ..............................1-6

3

BASIC BOATING RULES .........................1-7

FUELING INSTRUCTIONS.....................1-11

Gasoline (Petrol) .................................1-12

ENGINE OIL ............................................1-13 4

BATTERY REQUIREMENT ....................1-14

PROPELLER SELECTION .......................1-15

START-IN-GEAR PROTECTION ............1-16 5

6

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EMU00005

IDENTIFICATION NUMBERS

RECORD

EMU00007

OUTBOARD MOTOR SERIAL

NUMBER

q q

YAMAHA

123

401013

YAMAHA MOTOR CO., LTD.

MADE IN JAPAN

PAYS D'ORIGINE JAPON

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

Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen.

1 Outboard motor serial number

EMU00008

KEY NUMBER

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

1 Key number

904011*

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EMU01385

EMISSION CONTROL

INFORMATION

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EMU01387

NORTH AMERICAN MODELS

This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details.

Approval label of Emission control certificate

This label is attached to the bottom cowling.

1 Emission control information label

EMISSION CONTROL INFORMATION EM

ENGINE FAMILY :

THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.

THIS ENGINE CONFORMS TO 2001 CALIFORNIA EMISSION REGULATIONS FOR SI MARINE ENGINES.

REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.

FELs :

SPARK PLUG : g/kw-hr

DISPLACEMENT :

ADVERTISED POWER : cm 3 kw

IDLE SPEED :

SPARK PLUG GAP (mm) :

FUEL : GASOLINE

VALVE LASH (mm) : IN rpm IN NEUTRAL

EX

New Technology ; (4-stroke) EM

Manufactured date label

This label is attached to the clamp bracket.

2 Manufactured date label

Manufactured:

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000853

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EMU01389

STAR LABELS

Your outboard motor is labeled with a

California Air Resources Board (CARB) star label. See below for a description of your particular label.

1 Star label

One Star - Low Emission

The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine engines.

Two Stars - Very Low Emission

The two-star label identifies engines that meet the Air Resources Board’s 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low-Emission engines.

Three Stars - Ultra Low Emission

The three-star label identifies engines that meet the Air Resources Board’s 2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low-Emission engines.

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EMU00917

Q SAFETY

INFORMATION

8 This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symp-

8 Before mounting or operating the outboard motor, read this entire manual.

Reading it should give you an understanding of the motor and its operation.

8 Before operating the boat, read any owner’s or operator’s manuals supplied with it and all labels. Be sure you understand each item before operating.

8 Do not overpower the boat with this outboard motor. Overpowering the equal to or less than the rated horsepower capacity of the boat. If the rated toms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.

8 Check throttle, shift, and steering for proper operation before starting the engine.

8 Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating. If you accidentally leave the helm, the lanyard boat could result in loss of control. The rated power of the outboard should be will pull from the switch, stopping the engine.

8 Know the marine laws and regulations where you will be boating - and obey them. Refer to the “RULES OF THE horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer.

8 Do not modify the outboard. Modifications could make the motor unfit or unsafe to use.

8 Never operate after drinking alcohol or taking drugs. About 50% of all boating

ROAD” section for basic boating rules.

8 Stay informed about the weather.

Check weather forecasts before boating.

Avoid boating in hazardous weather.

8 Tell someone where you are going: leave a Float Plan with a responsible person. Be sure to cancel the Float Plan fatalities involve intoxication.

8 Have an approved personal flotation device (PFD) on board for every occuwhen you return.

8 Use common sense and good judgment when boating. Know your abilities, and pant. It is a good idea to wear a PFD whenever boating. At a minimum, chilbe sure you understand how your boat handles under the different boating dren and non-swimmers should always wear PFDs, and everyone should wear

PFDs when there are potentially hazardous boating conditions.

8 Gasoline is highly flammable, and its vapors are flammable and explosive.

Handle and store gasoline carefully.

Make sure there are no gas fumes or leaking fuel before starting the engine.

conditions you may encounter. Operate within your limits, and the limits of your boat. Always operate at safe speeds, and keep a careful watch for obstacles

1-4 and other traffic.

8 Always watch carefully for swimmers during the engine operation.

8 Stay away from swimming areas.

8 When a swimmer is in the water near you shift into neutral and shut off the engine.

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8 Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the following:

United States Coast Guard

Consumer Affairs Staff (G-BC)

Office of Boating, Public, and Consumer

Affairs

U.S. Coast Guard Headquarters

Washington, D.C. 20593-0001

Boating Safety Hotline: 1-800-368-5647

National Marine Manufacturers

Association (NMMA)

401 N. Michigan Ave.

Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave.

Chicago, Il 60601

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EMU00014

IMPORTANT LABELS q

202054*

WARNING LABELS

1

WARNING

This engine is equipped with a neutral starting device.

The engine will not start unless the shift control is in neutral position.

6E0-83627-41

2

WARNING

7Be sure shift control is in neutral

before starting engine. (except 2HP)

7Do not touch or remove electrical parts

when starting or during operation.

7Keep hands,hair,and clothes away from flywheel

and other rotating parts while engine is running.

6A1-83625-41

CAUTION LABELS

3

CAUTION

T r a n s p o r t a n d s t o r e t h e e n g i n e o n l y a s s h o w n .

O t h e r w i s e , e n g i n e d a m a g e c o u l d r e s u l t f r o m

leaking oil.

6G8-13444-41

1-6

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EMU00015

BASIC BOATING RULES

(Rules of the road)

Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast

Guard and local agencies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water.

Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the

Road. The rules presented here in your

Owner’s Manual are condensed, and have been provided for your convenience only.

Consult your local U.S. Coast Guard Auxiliary or Department of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat.

STEERING AND SAILING RULES AND

SOUND SIGNALS

Whenever two vessels on the water meet one another, one vessel has the right-ofway; it is called the “stand-on” vessel.

The vessel which does not have the rightof-way is called the “give-way” or “burdened” vessel. These rules determine which vessel has the right-of-way, and what each vessel should do.

Stand-on vessel

The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision.

When you maintain your direction and speed, the other vessel will be able to determine how best to avoid you.

Give-way vessel

The vessel which does not have the rightof-way has the duty to take positive and timely action to stay out of the way of the

Stand-On vessel. Normally, you should not cross in front of the vessel with the right-of-way. You should slow down or change directions briefly and pass behind the other vessel. You should always move in such a way that the operator of the other vessel can see what you are doing.

“The general prudential rule”

This rule is called Rule 2 in the International Rules and says,

‘In obeying and construing these rules due regard shall be had to all dangers of navigation and collision, and to any special circumstances, which may render a departure from the above rules necessary in order to avoid immediate danger.’

In other words, follow the standard rules except when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become

“Give-Way” vessels.

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RULES WHEN ENCOUNTERING

VESSELS

There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed: will clear one another if you continue on your set course and speed.

Meeting (you are approaching another vessel head-on)

Crossing (you are traveling across the other vessel’s path)

Overtaking (you are passing or being passed by another vessel)

102044

In the following illustration, your boat is in the center. You should give the right-ofway to any vessels shown in white area

(you are the Give-Way vessel). Any vessels in the shaded area must yield to you

(they are the Give-Way vessels). Both you and the meeting vessel must alter course to avoid each other.

Crossing

When two power driven vessels are crossing each other’s path close enough to run the risk of collision, the vessel which has the other on the starboard

(right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; you are the Give-Way vessel. If the other vessel is on your port (left) side, remember that you should maintain course and direction, provided the other vessel gives you the right-of-way as it should.

102045

Meeting

If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of-way! Both of you should alter course to avoid an accident. You should keep the other vessel on your port (left) side. This rule doesn’t apply if both of you

102046

Overtaking

If you are passing another vessel, you are the “Give-Way” vessel. This means that the other vessel is expected to maintain

1-8

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E its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.

OTHER SPECIAL SITUATIONS

There are three other rules you should be aware of when driving your boat around other vessels.

Narrow channels and bends

When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a power-driven vessel is preparing to go around a bend that may obstruct the view of other water vessels, the operator should sound a prolonged blast on the whistle (4 to 6 seconds). If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still proceed around the bend with caution. If you navigate such waters with your boat, you will need to carry a portable air horn, available from local marine supply stores.

Fishing vessel right-of-way

All vessels which are fishing with nets, lines or trawls are considered to be “fishing vessels” under the International

Rules. Vessels with trolling lines are not considered fishing vessels. Fishing vessels have the right-of-way regardless of position. Fishing vessels cannot, however, impede the passage of other vessels in narrow channels.

Sailing vessel right-of-way

Sailing vessels should normally be given the right-of-way. The exceptions to this are:

1.

When the sailing vessel is overtaking the power-driven vessel, the powerdriven vessel has the right-of-way.

2.

Sailing vessels should keep clear of any fishing vessel.

3.

In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel which can navigate only in such a channel.

Reading buoys and other markers

The waters of the United states are marked for safe navigation by the lateral system of buoyage. Simply put, buoys and markers have an arrangement of shapes, colors, numbers and lights to show which side of the buoy a boater should pass on when navigating in a particular direction. The markings on these buoys are oriented from the perspective of being entered from seaward (the boater is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open water into port, and black buoys are to port (left) side. When navigating out of port, your position with respect to the buoys should be reversed; red buoys should be to port and black buoys to starboard.

Many bodies of water used by boaters are entirely within the boundaries of a particular state. The Uniform State Waterway

Marking System has been devised for these waters. This system uses buoys and signs with distinctive shapes and colors to show regulatory or advisory informa-

1-9

65W-9-16-1 3/15/02 5:11 PM Page 15 tion. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information.

Remember, markings may vary by geographic location. Always consult local boating authorities before driving your boat in unfamiliar waters.

" 7"

MA

IN

CH

A

N

N

E

L

" 6"

R B " L " or

R G " L "

L

C " 1"

A

R

Y

C

HANNE

SECOND

MAIN CHANNEL BUOYS

" 1" " 3" " 5" " 7"

LIGHTED BUOY (Port Hand)`

Odd number. increasing toward head of navigation.Leave to port (left) proceeding upstream.

1

White Light

OR

1

Green Light

" 5" old new

" 3"

" A"

" 4"

BUOY

COLOR CODE

BLACK

RED

GREEN

" 2" " 4" " 6"

LIGHTED BUOY (Starboard Hand)`

Even number,increasing toward head of navigation. Leave to starboard (right) proceeding upstream.

2

White Light

OR

2

Red Light

" 2" old new

" 1"

C " 1"

Proceeding toward head of navigation from seaward

SECONDARY CHANNEL BUOYS

STARTS NEW NUMBERING SYSTEM

CAN BUOY

Odd number. Leave to port.

1

OR

1

" A"

LIGHTED SAFE WATER BUOY

No number. Marks midchannel, pass on either side. Letter has no lateral significance, used for identification and location purposes.

Top Mark

White Light

White Light

A A

OR old new old

N " 2"

NUN BUOY

Even number. Leave to starboard new

2

R B " L " R G " L "

LIGHTED PREFERRED CHANNEL TO

PORT BUOY

N o n u m b e r . T o p m o s t b a n d r e d - p r e f e r r e d channel is to left of buoy. Letter has no lateral significance, used for identification and location purposes.

Red or

White Light

Red Light

L L new old

No change

102052

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EMU00016

FUELING INSTRUCTIONS w

GASOLINE AND ITS VAPORS ARE HIGH-

LY FLAMMABLE AND EXPLOSIVE!

8 Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition.

8 Stop engine before refueling.

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

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

8 Do not overfill the fuel tank.

8 Tighten the filler cap securely after refueling.

8 If you should swallow some gasoline inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention.

8 If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it.

8 Touch the fuel nozzle to the filler open- ing or funnel to help prevent electrostatic sparks.

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Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign matter.

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EMU01804

GASOLINE

Recommended gasoline:

Regular unleaded gasoline with a minimum octane rating of 86

(Pump Octane Number) = (R+M)/2

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If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.

EMU00027

Gasohol

There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or engine performance problems.

1-12

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001162

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EMU01769

ENGINE OIL

Recommended engine oil:

4-stroke motor oil with a combination of corresponding SAE and API as shown in the chart.

SAE

10W-30

10W-40

API

SE

SF

SG

SH

SJ

Engine oil quantity:

See Chapter 4, “Specifications.” c C

All 4-stroke engines are shipped from the factory without engine oil.

1-13

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EMU01775

BATTERY REQUIREMENT c C

Do not use a battery that does not meet the specified capacity. If a battery which does not meet specifications is used, the electric system could perform poorly or be overloaded, causing electric system damage.

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

EMU01859

Minimum cold cranking amps

(CCA/SAE):

245 amps at -18°C (-0.4°F)

Minimum marine cranking amps

(MCA/ABYC):

323 amps at 0°C (32°F)

Minimum reserve capacity (RC/SAE):

52 minutes

EMU01783¯ c C

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

Regulator.

Models without a rectifier or Rectifier

Regulator: F25MH

8 If you wish to use a battery with the above models, install an optional Rectifier Regulator.

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10-3/4x17-F

1 2 3

12-1/4 x 9 - G q w e

EMU01395

PROPELLER SELECTION

E

The performance of your outboard motor will be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine.

Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable for a smaller operating load.

000601

602016

Yamaha dealers stock a range of propellers, and can advise you and install a propeller on your outboard that is best suited to your application.

NOTE:

At full throttle and under a maximum boat load, the engine’s rpm should be within the upper half of the full throttle operating range, as listed in “SPECIFICA-

TIONS” on page 4-1. Select a propeller which fulfills this requirement.

If operating under conditions which allow the engine’s rpm to rise above the maximum recommended range (such as light boat loads), reduce the throttle setting to maintain the rpm in the proper operating range.

1-15

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1 Propeller diameter (in inches)

2 Propeller pitch (in inches)

3 Type of propeller (propeller mark)

Refer to the section “CHECKING PRO-

PELLER” for instructions on propeller removal and installation.

EMU01209

START-IN-GEAR PROTECTION

Yamaha outboard motors or Yamaha approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is Neutral.

Always select Neutral before starting the engine.

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-MEMO-

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EMU00037

Chapter 2

BASIC COMPONENTS

1

MAIN COMPONENTS..............................2-1

OPERATIONS OF CONTROLS AND

OTHER FUNCTIONS ................................2-2

Fuel tank.................................................2-2

Gear shift lever ......................................2-3

Recoil starter handle.............................2-3

Starter button ........................................2-3

Tiller handle...........................................2-3

Remote control......................................2-6

Steering friction adjusting lever ........2-10

Trim tab................................................2-11

Trim angle adjusting rod....................2-13

Power trim/tilt switch..........................2-13

Warning indicator(s) ...........................2-14

Digital tachomoter ..............................2-14

Tilt lock mechanism............................2-17

Tilt support knob.................................2-17

Tilt support bar....................................2-17

Top cowling lock lever .......................2-17

Flushing device ...................................2-18

WARNING SYSTEM ..............................2-19

Overheat warning ...............................2-19

Low oil pressure warning ..................2-20

2

3

4

5

6

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EMU01206

!0

o i u y

MAIN COMPONENTS

!1

q

@0

!9

!8

!7

w e r t

@2 @3

@1

!6

@4

!2

!3

!4

!5

E

1 Top cowling

2 Top cowling lock lever

3 Oil drain bolt

4 Anti-cavitation plate

5 Trim tab

6 Propeller

7 Cooling water inlet

8 Trim angle adjusting rod

9 Clamp bracket

* 0 Power trim and tilt switch

* q Starter button

* w Recoil starter handle

* e Warning indicator

* r Gear shift lever

* t Tiller handle

* y Steering friction adjusting lever

* u Clamp screw

* i Rope attachment

* o Tilt lock lever p Flushing device

* a Tilt support knob

* s Remote control box

* d Digital tachometer

* f Fuel tank

2-1

* May not be exactly as shown; also may not be included as standard equipment on all models.

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EMU00039

OPERATIONS OF CONTROLS

AND

OTHER FUNCTIONS q e r w

902051

EMU00040

FUEL TANK

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

1 Fuel hose joint

2 Fuel meter (If equipped)

3 Fuel tank cap

4 Air vent screw (If equipped)

EMU00042

Fuel Hose Joint

This connector is provided for connecting or disconnecting fuel hose.

EMU00044

Fuel Meter

This meter is on the fuel tank cap. It shows current fuel quantity in the fuel tank approximately.

EMU00045

Fuel Tank Cap

This cap is for filling fuel. To remove it, turn it counterclockwise.

EMU00046

Air Vent Screw

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

2-2

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EMU00051

GEAR SHIFT LEVER

(for Tiller control model)

Turning the gear-shift lever towards you engages the clutch with the forward gear so that the boat moves ahead. Turning the lever away from you engages the reverse gear so that the boat moves astern.

1 Neutral

2 Forward

3 Reverse

EMU00059

RECOIL STARTER HANDLE

(If equipped)

Pull the handle gently until resistance is felt. Then vigorously pull the handle straight out to crank the engine to start it.

EMU00060

STARTER BUTTON


When you push the starter button, the electric starter motor cranks the engine to start it.

r w e q

101043**

EMU00064

TILLER HANDLE


Moving the tiller handle sideways to adjust the steering direction. In addition, this handle contains the functions as follows.

2-3

1 Throttle control grip

2 Throttle indicator

3 Throttle friction adjusting knob/screw

4 Engine stop button / Engine stop lanyard switch

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EMU00065

Throttle Control Grip

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

502016

EMU00067

Throttle Indicator

The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position.

Choose the setting that offers the best performance and fuel economy for the desired operation.

1 Throttle indicator

EMU01294

Throttle Friction Adjusting Knob

A friction device in the tiller handle provides resistance to movement of the throttle grip. This is adjustable for operator preference.

Resistance

Increase

Decrease

Knob

Turn clockwise

Turn counterclockwise

When constant speed is desired, tighten the adjusting knob to maintain the desired throttle setting.

w

Do not overtighten the friction adjusting knob. If there is too much resistance, it may be difficult to move the throttle grip, which could result in an accident.

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65W-9-16-2 3/15/02 5:12 PM Page 6 q w

000647

E

EMU00932

Engine Stop Lanyard Switch

The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away under power.

w

8 Attach the lanyard to a secure place on your clothing, your arm or leg while operating.

8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard in such a way that it could become entangled, preventing it from functioning.

8 Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly.

This could cause people and objects in the boat to be thrown forward.

NOTE:

The engine cannot be started with the lock-plate removed.

EMU00072

Engine Stop Button

Pushing this button opens the ignition circuit and stops the engine.

506021

2-5

65W-9-16-2 3/15/02 5:12 PM Page 7 y q u w e r t

000200

E

EMU00096*

REMOTE CONTROL

Both the shifter and the throttle are actuated by the remote control lever.

Additionally, the remote control also has the electrical switches.

1 Remote control lever

2 Neutral interlock trigger

3 Neutral throttle lever

4 Main switch

5 Engine stop lanyard switch

6 Power trim and tilt switch (if equipped)

7 Throttle friction adjusting screw y w

F

r

N

q r t t

R

e u y u

701031

EMU00098*

Remote Control Lever

Moving the lever forward from the

Neutral position engages Forward gear.

Pulling the lever back from Neutral engages Reverse. The engine will continue to run at idle until the lever is moved about 35° (a detent can be felt). Moving the lever further opens the throttle, and the engine will begin to accelerate.

1 Neutral

2 Forward

3 Reverse

4 Shift

5 Fully closed

6 Throttle

7 Fully open

EMU00099

Neutral Interlock Trigger

To shift out of Neutral, the neutral interlock trigger of the remote control lever must first be pulled up.

701036

2-6

65W-9-16-2 3/15/02 5:12 PM Page 8

N

q w

701033*

E

EMU00100

Neutral Throttle Lever

To open the throttle without shifting into either Forward or Reverse, place the remote control lever in the Neutral position and lift the neutral throttle lever.

NOTE:

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

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

1 Fully open

2 Fully closed

OFF

ON

START

701021

EMU00101

Main switch

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

8 OFF

Electrical circuits switched off.

(The key can be removed.)

8 ON

Electrical circuits switched on.

(The key cannot be removed.)

8 START

Starter-motor will turn and start engine.

(When the key is released, it returns automatically to “ON”.)

2-7

65W-9-16-2 3/15/02 5:12 PM Page 9 w

000569 q

E

EMU00934

Engine Stop Lanyard Switch

The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away under power.

w

8 Attach the lanyard to a secure place on your clothing, your arm or leg while operating.

8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard in such a way that it could become entangled, preventing it from functioning.



NOTE:

The engine cannot be started with the lock-plate removed.

2-8

65W-9-16-2 3/15/02 5:12 PM Page 10

UP

DN

UP

DN

701034*

E

EMU01331

Power Trim/Tilt Switch

The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the remote control lever grip. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.

NOTE:

Refer to the sections “ADJUSTING TRIM

ANGLE” and “TILTING UP/DOWN” in

Chapter 3 for instructions on usage.

701035

EMU01155

Throttle Friction Adjusting Screw

A friction device in the remote control box provides adjustable resistance to movement of the remote control lever, and can be set according to operator preference.

An adjusting screw is located on the front of the remote control box.

Resistance

Increase

Decrease

Screw

Turn clockwise

Turn counterclockwise w

Do not overtighten the friction adjusting screw. If there is too much resistance, it may be difficult to move the lever, which could result in an accident.

2-9

65W-9-16-2 3/15/02 5:12 PM Page 11

408026

E

EMU00110*

STEERING FRICTION ADJUSTING

LEVER

A friction device provides resesistance steering movement. This is adjustable for operator preference.

Resistance

Increase

Decrease

Lever

Turn clockwise

Turn counterclockwise w

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

2-10

65W-9-16-2 3/15/02 5:12 PM Page 12 q w

A

B

603013*

E

EMU00114

TRIM TAB

The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force.

w

An improperly adjusted trim tab may cause difficult steering. Always test run after the trim tab has been installed or replaced to be sure steering is correct. Be sure you have tightened the bolt after adjusting the trim tab.

1 Trim tab

2 Bolt

Boat tends to veer

To the left

(port side)

To the right

(starboard side)

The fin of trim tab

“Turn to the left(port side), “A” in the figure”

“Turn to the right(starboard side), “B” in the figure”

2-11

65W-9-16-2 3/15/02 5:12 PM Page 13

FT25 q

A w

B

E

EMU00113*

TRIM TAB

FT25

The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force.

w

An improperly adjusted trim tab may cause difficult steering. Always test run after the trim tab has been installed or replaced to be sure steering is correct. Be sure you have tightened the bolt after adjusting the trim tab.

603021

1 Trim tab

2 Bolt

Boat tends to veer

To the left

(port side)

To the right

(starboard side)

The fin of trim tab

Turn to the left

(A in the figure)

Turn to the right

(B in the figure) c C

The trim tab also serves as an anode to protect the engine from electrochemical corrosion. Never paint the trim tab as it will become ineffective as an anode.

2-12

65W-9-16-2 3/15/02 5:12 PM Page 14

E

EMU01297

TRIM ANGLE ADJUSTING ROD

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

404012

UP

DN

302014*

EMU01125

POWER TRIM/TILT SWITCH

The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the side of the bottom engine cowling.

Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.

w

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

NOTE:

Refer to the section “Adjusting Trim

Angle” and “Tilting Up/Down” for instructions on usage.

2-13

65W-9-16-2 3/15/02 5:12 PM Page 15 q e t y q

223012

E

EMU01128

WARNING INDICATOR(S)

If the engine develops a condition monitored by the warning system, an indicator will come on.

Refer to the “WARNING SYSTEM” section for details.

1 Warning indicator(s) w u r

001081

EMU01617

DIGITAL TACHOMETER

This gauge contains the tachometer, trim meter, hour meter, low oil pressure warning indicator, and the overheat warning indicator.

1 Tachometer

2 Trim meter

3 Hour meter

4 Low oil pressure warning indicator

5 Overheat warning indicator

6 Set button

7 Mode button

NOTE:

All segments of the display will light momentarily after the main switch is turned on and will return to normal thereafter.

001085

EMU00136

Tachometer

This meter shows the engine speed.

001058

2-14

65W-9-16-2 3/15/02 5:12 PM Page 16

001059

E

EMU01109

Trim Meter

This meter shows the trim angle of your outboard motor.

NOTE:

8 Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired setting by operating the power trim and tilt switch.

8 If the trim angle of your motor exceeds the trim operating range, the top segment on the trim meter display will start to blink.

001088

EMU01620

Hour Meter

This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off.

8 Changing the display format

Pressing the MODE button changes the display format in the following circular pattern:

Total hours - Trip hours - Display off

8 Resetting the trip hours

Simultaneously pressing the SET and

MODE buttons for more than 1 second while the trip hours are displayed resets the trip counter to 0 (zero).

NOTE:

The total number of hours the engine has been run cannot be reset.

2-15

65W-9-16-2 3/15/02 5:12 PM Page 17 q q

001060

E

EMU01110

Low Oil Pressure Warning Indicator

If oil pressure drops too low, the warning indicator will start to blink. Refer to the section “LOW OIL PRESSURE WARNING” for details.

1 Low oil pressure warning indicator c C

8 Do not operate the engine without oil.

Serious engine damage will occur.

8 The low oil pressure warning indicator does not indicate the oil level in the engine. Use the Oil Level Gauge to check the remaining oil quantity. (Refer to the section “CHECKING THE ENGINE

OIL LEVEL” for details.)

001061

EMU01553

Overheat Warning Indicator

If the engine temperature rises too high, the warning indicator will start to blink.

Refer to “OVERHEAT WARNING” for details.

1 Overheat warning indicator c C

Do not continue to operate the engine if a warning device has activated. If necessary, refer to the “TROUBLESHOOTING” section in this manual. Consult your dealer if the problem cannot be located and corrected.

2-16

65W-9-16-2 3/15/02 5:12 PM Page 18 q

402073

E

EMU00153

TILT LOCK MECHANISM

(for Manual tilt model)

The tilt-lock mechanism is used to prevent reverse thrust from the propeller lifting the outboard motor when reversing.

To lock it, set the tilt-lock lever in the Lock position.

To release it, place the tilt-lock lever in the

Tilt position.

1 Tilt-lock lever

EMU00155

TILT SUPPORT KNOB

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

403054

EMU00156

TILT SUPPORT BAR

The tilt support bar 1 keeps the outboard motor in the tilted up position.

q

403052 q

301044

EMU00162

TOP COWLING LOCK LEVER

To remove the engine top cowling, turn the lock lever. Then lift off the cowling.

When replacing the cowling, check to be sure it fits properly in the rubber seal.

Then lock the cowling again by moving the lever upward.

1 Top cowling lock lever

2-17

65W-9-16-2 3/15/02 5:12 PM Page 19 q

101043*

E

EMU01146

FLUSHING DEVICE

This device 1 is used to clean the cooling water passages of the motor using a garden hose and tap water.

NOTE:

Refer to “Cleaning Cooling-water

Passages” in Chapter 4 for instructions on usage.

2-18

65W-9-16-2 3/15/02 5:12 PM Page 20

E

EMU00169

WARNING SYSTEM c C

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

001053

701054

605021

EMU01476

OVERHEAT WARNING

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

( 1 ) ; Included (–); N/A

Activation of warning device

Tiller Remote control control model model

The engine speed will automatically decrease to about

2,000 r/min.

The overheat warning indicator will come on.

The buzzer will sound.

1

—

—

1

1*

1

If the warning system has been activated, stop the engine and check the water inlet for clogging.

* Not equipped on all models.

2-19

65W-9-16-2 3/15/02 5:12 PM Page 21

F25MH/F25EH

E

EMU00173

LOW OIL PRESSURE WARNING

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

223012**

001063

( 1 ):Included (–):N/A

Activation of warning device

Tiller Remote control control model model

Engine speed will automatically decrease to about 2,000 r/min.

The low oil pressure warning indicator will come on.

The buzzer will sound.

1

1

1

1

— 1

If the warning system has been activated, stop the engine as soon as it is safe to do so. Check oil level and add oil as needed.

If the oil level is correct, consult your

Yamaha dealer.

c C

Do not continue to run the engine if the low oil pressure lamp is “ON”. Serious engine damage may occur.

701054

2-20

65W-9-16-2 3/15/02 5:12 PM Page 22

-MEMO-

E

65W-9-16-3 3/15/02 5:13 PM Page 1

E

EMU00174

Chapter 3

OPERATION

1

INSTALLATION ........................................3-1

Mounting the outboard motor ............3-2

Clamping the outboard motor.............3-4

BREAKING IN (RUNNING IN) ENGINE ..3-5

2

PRE-OPERATION CHECKS ......................3-6

Checking the engine oil level...............3-7

FILLING FUEL ...........................................3-8

3

STARTING ENGINE .................................3-9

WARMING UP ENGINE .........................3-14

SHIFTING ................................................3-15

Forward................................................3-15

Reverse ................................................3-16

STOPPING ENGINE ...............................3-17

4

TRIMMING OUTBOARD MOTOR.........3-18

Adjuting trim angle.............................3-19

TILTING UP/DOWN ...............................3-22

5

CRUISING IN SHALLOW WATER.........3-25

CRUISING IN OTHER CONDITIONS.....3-27

Cruising in salt water..........................3-27

Cruising in turbid water .....................3-27

6

65W-9-16-3 3/15/02 5:13 PM Page 2

E

EMU00175

INSTALLATION c C

Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat or accessories such as transom ladders/depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operated continuously in the presence of airborne water spray.

NOTE:

During water testing check the buoyancy of the boat, at rest, with its maximum load. Check that the static water level on the exhaust housing is low enough to prevent water entry into the powerhead, when water rises due to waves when the outboard is not running.

3-1

65W-9-16-3 3/15/02 5:13 PM Page 3 q

104011

3-2

E

EMU00176

MOUNTING THE OUTBOARD

MOTOR

w

Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Observe the following:

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

8 Your dealer or other person experi- enced in proper rigging should mount the motor. If you are mounting the motor yourself, you should be trained by an experienced person. [permanent mounted type]

8 Your dealer or other person experi- enced in proper outboard motor mounting should show you how to mount your motor. [portable type]

Mount the outboard motor on the center line (keel line) of the boat, and ensure that the boat itself is well balanced. Otherwise, the boat will be hard to steer. For boats without a keel or which are asymmetrical, consult your dealer.

1 Center line (keel line)

65W-9-16-3 3/15/02 5:13 PM Page 4

0~25mm

(0~1in.)

E w

Overpowering a boat may cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.

104013*

EMU01298

Mounting Height

To run your boat at optimum efficiency, the water-resistance (drag) of the boat and outboard motor must be made as little as possible. The mounting-height of the outboard motor greatly affects the water-resistance. If the mounting-height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting-height is too low, the water-resistance will increase and thereby reduce engine efficiency.

Mount the engine so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in.) below it.

NOTE:

8 The optimum mounting height of the outboard motor is affected by the boat/motor combination and the desired use. Test runs at different heights can help determine the optimum mounting height.

8 Refer to the section “TRIMMING OUT-

BOARD MOTOR” for instructions on setting the trim angle of the outboard.

3-3

65W-9-16-3 3/15/02 5:13 PM Page 5 q

409011

E

EMU01318

CLAMPING THE OUTBOARD MOTOR

Manual tilt model

1) Place the outboard on the transom so that it is positioned as close to the center as possible. Tighten the transom clamp screws evenly and securely. Check the clamp-screws for tightness occasionally during operation of the motor as they can work loose due to engine vibration.

w

Loose clamp screws could allow the motor to move on the transom or fall off the transom. This could cause loss of control and serious injury. Make sure the transom screws are tightened securely.

Occasionally check the screws for tightness during operation.

410012

409014

2) An engine restraint cable or chain should be used. Attach one end to the engine restraint cable attachment point and the other to a secure mounting point on the boat.

Otherwise, the engine could be completely lost if it accidentally falls off the transom.

Secure the clamp bracket to the transom with the bolts provided with the outboard. For details, consult your dealer.

w

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

3-4

1 Motor mounting parts

65W-9-16-3 3/15/02 5:13 PM Page 6

3-5

E

EMU00224

BREAKING IN (RUNNING IN)

ENGINE

Your new engine requires a period of break-in (running-in) to allow mating surfaces of moving parts to wear-in evenly.

Correct break-in (running-in) will help ensure proper performance and longer engine life.

c C

Failure to follow the break-in (running-in) procedure may result in reduced engine life or even severe engine damage.

Break-in (running-in) time: 10 hours

EMU00233

Run the engine under load (in gear with a propeller installed) as follows.

1) For the first hour of operation:

Run the engine at 2,000 r/min or at approximately half throttle.

2) For the second hour of operation:

Run the engine at 3,000 r/min or at approximately three-quarter throttle, and during this period run it at full throttle for approximately one minute every ten minutes.

3) For the next eight hours of operation:

Avoid continuous operation at full throttle for more than five minutes at a time.

4) After these first 10 hours:

Operate the engine normally.

65W-9-16-3 3/15/02 5:13 PM Page 7

3-6

E

EMU00204

PRE-OPERATION CHECKS w

If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur.

c C

Do not start the engine out of water.

Overheating and serious engine damage can occur.

EMU00206

Fuel

8 Check to be sure you have plenty of fuel for your trip.

8 Make sure there are no fuel leaks or gasoline fumes.

8 Check fuel line connections to be sure they are tight.

8 Be sure the fuel tank is positioned on a secure, flat surface, and that the fuel hose is not twisted or flattened, or likely to contact sharp objects.

EMU00208

Oil

8 Check the level of the oil in the sump with the dipstick. If necessary, add oil to bring the level up to the upper mark.

65W-9-16-3 3/15/02 5:13 PM Page 8 w e q

E

EMU00209

Controls

8 Check throttle, shift, and steering for proper operation before starting the engine.

8 The controls should work smoothly, without binding or unusual free play.

8 Look for loose or damaged connections.

8 Check operation of the starter and stop switches when the outboard motor is in the water.

EMU00210

Engine

8 Check the engine and engine mounting.

8 Look for loose or damaged fasteners.

8 Check the propeller for damage.

q

201015

EMU01436

CHECKING THE ENGINE OIL LEVEL

1) Put the outboard motor in an upright position (not tilted).

2) Pull out the oil dipstick and wipe it clean.

3) Completely re-insert the dipstick and pull out it again.

4) Check the oil level using the dipstick to be sure the level falls between the upper and lower marks. Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark.

1 Oil dipstick

2 Lower level mark

3 Upper level mark

201012*

3-7

65W-9-16-3 3/15/02 5:13 PM Page 9

E

EMU00202

FILLING FUEL

902055

1) Remove the fuel tank cap.

2) Fill the fuel tank carefully.

3) Close the cap securely after refueling.

Wipe up any spilled fuel.

Fuel tank capacity:

Refer to SPECIFICATIONS, page 4-1.

EMU00203

Ring Free Fuel Additive

Gasoline is a precise blend of many different substances, each chosen to give certain characteristics. Gasoline blends have been changing in recent years in response to concerns about pollution and resulting emissions regulations. One of the most obvious changes has been the elimination of lead from most fuels.

As gasoline has changed, the amount of additives such as aromatics and oxygenates has increased. These additives are important for the engines in passenger cars, but they can have detrimental effects in marine engines, because of increased deposits in the combustion chamber. When enough deposits collect, piston rings begin sticking. Performance drops and engine wear increases dramatically.

While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free has repeatedly proven its ability to clean combustion deposits from inside the engine, notably the critical piston-ringland area, and fuel system components.

Follow product labeling for use instruc-

3-8 tions.

65W-9-16-3 3/15/02 5:13 PM Page 10

E

EMU01147

STARTING ENGINE

902053

304042 w

8 Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions.

Be sure there are no swimmers in the water near you.

8 When the air vent screw is loosened, gasoline (petrol) vapor will be released.

Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw.

8 This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled.

Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.

902061

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

2) If there is a fuel joint on the motor, firmly connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank.

NOTE:

During engine operation place the tank horizontally, or fuel cannot be drawn into the engine.

902025

3-9

3) Squeeze the primer bulb with the outlet end up until you feel it become firm.

65W-9-16-3 3/15/02 5:13 PM Page 11

START

START

N

000648

E

EMU01497

PROCEDURE FOR TILLER CONTROL

MODEL

4) Place the gear-shift lever in the neutral position.

NOTE:

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

5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock plate on the other end of the lanyard in the engine stop switch.

w

8 Attach the engine stop switch lanyard to a secure place on your clothing, your arm or leg while operating.

8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard where it could become entangled, preventing it from functioning.



6) Place the throttle control grip in the

“START” position.

3-10

65W-9-16-3 3/15/02 5:13 PM Page 12

E

EMU01005

Manual Start Model

7) Pull the starter handle slowly until you feel resistance. Then, give a strong pull straight out to crank and start the engine. Repeat it, if necessary.

NOTE:

If the warm engine fails to start, open the throttle slightly and try to start the engine.

8) After the engine starts, return the starter handle slowly to the original position before releasing it.

101043**

EMU00245

Electric Start Model

7) Push the starter button to start the starting motor.

8) Immediately the engine starts, release the starter-switch to return it to its home position.

c C

8 Do not push the starter-switch when the engine is running.

8 Do not keep the starter-motor turning for more than 5 seconds. If the startermotor is run continuously for more than 5 seconds, the battery will rapidly become exhausted and it will be impossible for it to start the engine. If the engine does not start within 5 seconds, release your hand from starterswitch, wait 10 seconds, and then crank the engine again.

3-11

65W-9-16-3 3/15/02 5:13 PM Page 13

N

E

EMU00247

PROCEDURE FOR REMOTE

CONTROL MODEL

4) Place the remote control lever in the

Neutral position.

NOTE:

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

701015

000293

5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock plate on the other end of the lanyard in the engine stop switch.

w

8 Attach the engine stop switch lanyard to a secure place on your clothing, your arm or leg while operating.

8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard where it could become entangled, preventing from functioning.



6) Turn the main switch to “ON”.

3-12

65W-9-16-3 3/15/02 5:13 PM Page 14

OFF

ON

START

701022

E

EMU00949

Electric Start Model

7) Turn the main switch to “START”, and hold it for a maximum of 5 seconds.

8) Immediately after the engine starts, release the main switch to return it to

“ON”.

c C

8 Do not turn the main switch to

“START” when the engine is running.

8 Do not keep the starter-motor turning for more than 5 seconds. The battery will rapidly become exhausted and it will be impossible for it to start the engine. If the engine does not start within 5 seconds, return the main switch to “ON”, wait 10 seconds, and then crank the engine again.

3-13

65W-9-16-3 3/15/02 5:13 PM Page 15

EMU00258

WARMING UP ENGINE

E

309016

1) Before beginning operation, allow the engine to warm up at idling speed for

3 minutes. (Failure to do this will shorten engine life.)

2) Be sure the low oil pressure warning indicator goes off after starting the engine.

3) Check for a steady flow of water from the cooling-water pilot hole.

c C

8 If the low oil pressure indicator does not go off after the engine starts, stop the engine. Otherwise, serious engine damage could occur. Check the oil level and add oil if necessary. If the cause for the low oil pressure warning indicator cannot be found, consult your Yamaha dealer.

8 A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages. If water is not flowing out of the pilot hole at all times while the engine is running, do not continue to run the engine. Overheating and serious damage could occur. Stop the engine and check to see if the water inlet on the lower casing is blocked. If the problem cannot be found and corrected, consult your Yamaha dealer.

3-14

65W-9-16-3 3/15/02 5:13 PM Page 16

START

N

F

E

EMU00261

SHIFTING w

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

c C

To change the shifting position from forward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speeds).

EMU00265

FORWARD

Tiller control model

1) Place the throttle control grip in the fully closed position.

2) Turn the gear-shift lever quickly and firmly from Neutral to Forward.

F N

701043

3-15

Remote control model

Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from Neutral to

Forward.

65W-9-16-3 3/15/02 5:13 PM Page 17

START

E

EMU01326

REVERSE

w

When operating in Reverse, go slowly. Do not open the throttle more than half.

Otherwise, the boat may become unstable, which could result in loss of control and an accident.

1) Place the throttle control grip in the fully closed position (for Tiller control model).

2) Check that the tilt-lock lever (for

Manual tilt/Hydro-tilt model) is in the locked position.

R

N

402073*

Tiller control model

3) Turn the gear-shift lever quickly and firmly from Neutral to Reverse.

N

R

701044

3-16

Remote control model

3) Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from

Neutral to Reverse.

65W-9-16-3 3/15/02 5:13 PM Page 18

OFF

ON

START

506021

E

EMU00273

STOPPING ENGINE

Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended.

EMU00277

1) Push and hold the engine stop button or turn the main switch to “OFF”.

701023

2) If the fuel joints are provided, disconnect the fuel line from the motor after stopping the engine.

304043

902052

3) Tighten the air vent screw on the fuel tank cap after stopping the engine, if it is equipped.

4) Remove the key if the boat will be left unattended.

NOTE:

The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop lanyard switch

(then turning the main switch to “OFF”).

3-17

65W-9-16-3 3/15/02 5:13 PM Page 19 q

EMU01412

TRIMMING OUTBOARD

MOTOR

E

The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.

w

Excessive trim for the operating conditions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.

000910

NOTE:

Refer to the section “ADJUSTING TRIM

ANGLE” for instructions on usage.

1 Trim operating angle

3-18

65W-9-16-3 3/15/02 5:13 PM Page 20 q

404012*

E

ADJUSTING TRIM ANGLE

EMU00951*


There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim angle.

1) Stop the engine.

2) Remove the trim angle adjusting rod

1 from the clamp bracket while tilting the motor up slightly.

3) Reposition the rod in the desired hole.

To raise the bow (“trim-out”), move the rod away from the transom.

To lower the bow (“trim-in”), move the rod toward the transom.

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

w

8 Stop the engine before adjusting the trim angle.

8 Use care to avoid being pinched when removing or installing the rod.

8 Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim angle can cause loss of control.

NOTE:

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

3-19

65W-9-16-3 3/15/02 5:13 PM Page 21

UP

DN

UP

DN q

701034**

E

EMU01401

Power Trim/Tilt Model w

8 Be sure all people are clear of the out- board motor when adjusting the trim/tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket.

8 Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems.

8 Use the power trim/tilt switch located on the bottom engine cowling (if equipped) only when the boat is at a complete stop with the engine off.

The outboard motor trim angle can be adjusted operating the power trim/tilt switch 1.

To raise the bow (“trim-out”), push the switch UP.

To lower the bow (“trim-in”), push the switch DN.

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

NOTE:

To adjust the trim angle while the boat is moving, use the power trim and tilt switch located on the remote control device or tiller handle, if so equipped.

3-20

65W-9-16-3 3/15/02 5:13 PM Page 22 q w e

E

EMU00282

Bow Up

When the boat is on plane, a bow-up attitude result in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. When trimmed out, the boat may have more tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adjusted to help offset this effect.

105011

Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag.

Excessive trim-up can cause the propeller to ventilate, which reduces performance further. When trimmed-out too much, a boat may “porpoise” (hop in the water), which could throw the operator and passengers overboard.

EMU00283

Bow Down

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

105013

Too much trim-in causes the boat to

“plow” through the water, decreasing fuel economy and making in hard to increase speed.

Operating with excessive trim-in at higher speeds also makes the boat unstable.

Resistance at the bow is greatly increased, heightening the danger of

“bow steering” and making operation difficult and dangerous.

105015

1 Bow up

2 Bow down

3 Optimum angle

3-21

65W-9-16-3 3/15/02 5:13 PM Page 23

105031

E

EMU00285

TILTING UP/DOWN

If the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion.

c C

8 Before tilting the motor, follow the pro- cedures under “STOPPING ENGINE”.

Never tilt the motor while the engine is running. Severe damage from overheating can result.

8 Do not tilt up the engine by pushing the steering handle as this could break the handle.

w

Be sure all people are clear of the outboard motor when adjusting the tilt angle, also be careful not to pinch any body parts between the drive unit and engine bracket.

w

Leaking fuel is a fire hazard. Disconnect the fuel line if the engine will be tilted for more than a few minutes. Otherwise, fuel may leak. (If the fuel connector is provided on the motor.)

3-22

65W-9-16-3 3/15/02 5:13 PM Page 24

E

EMU00290

PROCEDURE FOR TILTING UP


1) Place the gear shift lever in Neutral.

2) Remove the fuel line connection from the motor.

304043

3) Place the tilt lock lever in the release position.

402071

4) Hold the rear of the top cowling with one hand and fully tilt the engine up.

5) The tilt support bar turns to the locked position automatically.

403052

402074

EMU00300

PROCEDURE FOR TILTING DOWN


1) Place the tilt lock lever in the lock position.

2) Slightly tilt up the engine until the tilt support bar is released automatically.

3) Tilt down the engine.

3-23

65W-9-16-3 3/15/02 5:13 PM Page 25

UP

DN

UP

DN

E

EMU00296

PROCEDURE FOR TILTING UP

Power trim/tilt model

1) Remove the fuel-line connection from the motor.

304043

2) Push the power trim/tilt switch “UP” until the outboard has tilted up completely.

701034*

403054

3) Push the tilt support knob into the clamp bracket to support the engine.

w

After tilting the engine, be sure to support it with the tilt support knob.

Otherwise, the engine could fall back down suddenly if oil in the power trim/tilt unit should lose pressure.

3-24

EMU00305

PROCEDURE FOR TILTING DOWN

Power trim/tilt model

1) Push the power trim/tilt switch “UP” until the engine is supported by the tilt rod.

2) Pull out the tilt support knob.

3) Push the power trim/tilt switch “DN”

(Down) to lower the engine to the desired position.

65W-9-16-3 3/15/02 5:13 PM Page 26

000911

EMU00306

CRUISING IN SHALLOW

WATER

E


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

w

8 Place the gear shift in the Neutral posi- tion before using the shallow water cruising system.

8 Run the boat at the lowest possible speed when using the shallow water cruising system. The tilt-lock mechanism does not work while the shallow water cruising system is being used.

Hitting an underwater obstacle could cause the engine to lift out of the water, resulting in loss of control.

8 Use extra care when operating in reverse. Too much reverse thrust can cause the engine to lift out of the water, increasing the chance of accident and personal injury.

8 Return the engine to its normal posi- tion as soon as the boat is back in deeper water.

c C

Place the gear-shift in the Neutral position before using the shallow water cruising system.

3-25

65W-9-16-3 3/15/02 5:13 PM Page 27

N

E

EMU00310

PROCEDURE

1) Place the gear shift lever in the neutral position.

2) Place the tilt lock lever in the release position.

402071

3) Slightly tilt up the engine. The tiltsupport bar will lock automatically, supporting the engine in a partially raised position.

NOTE:

This motor has 2 positions for shallow water cruising.

403051

402074

RETURNING TO ORIGINAL POSITION

1) Place the tilt lock lever in the lock position.

2) Slightly tilt up the engine until the tiltsupport bar automatically returns to the free position.

3) Then, slowly lower the engine to the normal position.

3-26

65W-9-16-3 3/15/02 5:13 PM Page 28

EMU00316

CRUISING IN OTHER

CONDITIONS

E

CRUISING IN SALT WATER

After operating in salt water, wash out the cooling-water passages with fresh water to prevent them from becoming cloggedup with salt deposits.

NOTE:

Refer to cooling system flushing instructions in “TRANSPORTING AND STORING

OUTBOARD MOTOR”.

CRUISING IN TURBID WATER

It is strongly recommended that the optional chromium-plated water-pump kit be installed if the outboard is to be used in turbid (muddy) water conditions.

3-27

65W-9-16-4 3/15/02 5:16 PM Page 1

E

EMU00317

Chapter 4

MAINTENANCE

1

SPECIFICATIONS .....................................4-1

TRANSPORTING AND STORING

OUTBOARD MOTOR ...............................4-4

Trailering outboard motor ...................4-4

Storing outboard motor .......................4-5

PERIODIC MAINTENANCE....................4-10

Replacement parts ..............................4-10

Maintenance chart ..............................4-11

Greasing...............................................4-12

Cleaning and adjusting spark plug ...4-14

Checking fuel system .........................4-16

Inspecting fuel filter ............................4-17

Adjusting idling speed .......................4-18

Changing engine oil............................4-19

Checking timing belt...........................4-21

Replacing fuse .....................................4-22

Checking wiring and connectors.......4-22

Exhaust leakage ..................................4-22

Water leakage......................................4-22

Checking power trim and tilt system ..................................................4-23

Checking propeller..............................4-24

Changing gear oil................................4-26

Cleaning fuel tank ...............................4-28

Inspecting and replacing anode(s)....4-29

Checking battery .................................4-30

Checking bolts and nuts.....................4-32

Cleaning cooling-water passages .....4-33

Motor exterior .....................................4-34

Coating the boat bottom ....................4-34

2

3

4

5

6

65W-9-16-4 3/15/02 5:16 PM Page 2

EMU00322*

SPECIFICATIONS

Item

DIMENSIONS

Overall Length

Overall Width

Overall Height

Transom height

Weight

PERFORMANCE

S/L/X

S/L/X

S/L/X

Full throttle operating range

Maximum output

Idling speed (Neutral)

ENGINE

Model

Unit mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.) r/min kW (HP) @ r/min r/min

Type

Displacement

Bore

× stroke

Ignition system

Spark plug

Spark plug gap

Control system

Starting system cm 3 (cu.in.) mm (in.)

NGK mm (in.)

Valve clearance (cold engine) IN

EX mm (in.) mm (in.)

Battery

Min. cold cranking amps (CCA/SAE) amps at -18°C (-0.4°F)

Min. marine cranking amps (MCA/ABYC)

Min. reserve capacity (RC/SAE)

Alternator output

Starting carburetion system amps at 0°C (32°F) minutes

V-A (W)

DRIVE UNIT

Gear positions

Gear ratio

Trim and tilt system

Propeller mark

FUEL AND OIL

Recommended fuel

Fuel tank capacity

Recommended engine oil

P.O.N.

I (US gal, lmp qt)

API

SAE

I (US qt, Imp qt)

I (US qt, Imp qt)

Engine oil capacity (without oil filter)

(with oil filter)

Recommended gear oil

Gear oil capacity

TIGHTENING TORQUE

Spark plug

Propeller nut

Engine oil drain bolt

Engine oil filter cm 3 (US oz, Imp oz)

N·m (kgf·m, lb·ft)




4-1

1,151 (45.3)

430 (16.9)

1,148 (45.2)/1,275 (50.2)/1,354(53.5)

423 (16.7)/550 (21.7)/636(25.0)

62 (137)/64 (141)/66(146)

5,000–6,000

18.4 (25.0) @ 5,500

925–1,025

4-stroke, OHC, L2

498 (30.39)

65.0

× 75.0 (2.56 × 2.95)

CDI system

DPR6EA-9

0.8–0.9 (0.031–0.035)

Tiller control

Manual recoil starter

0.15–0.25 (0.006–0.010)

0.25–0.35 (0.010–0.014)

—

—

—

12-(80)

Prime start

18 (1.8, 13)

35 (3.5, 25)

28 (2.8, 20)

18 (1.8, 13)

F25MHB

Forward-Neutral-Reverse

2.08 (27/13)

Manual

F

Regular unleaded gasoline

(Minimum 86)

25 (6.60, 5.50)

4-stroke motor oil

SE, SF, SG, SH, SJ

10W-30, 10W-40

1.7 (1.80, 1.50)

1.9 (2.00, 1.67)

Hypoid gear oil (SAE90)

320 (10.81, 11.27)

E

65W-9-16-4 3/15/02 5:16 PM Page 3

F25EHB F25ERB

1,151 (45.3)

430 (16.9)

1,148 (45.2)/1,275 (50.2)/1,354 (53.3)

423 (16.7)/550 (21.7)/636 (25.0)

66 (146)/68 (150)/70 (154)

703 (27.7)

376 (14.8)

1,148 (45.2)/1,275 (50.2)/—

423 (16.7)/550 (21.7)/—

65 (143)/67 (148)/—

5,000–6,000

18.4 (25.0) @ 5,500

875–975

4-stroke, OHC, L2

498 (30.39)

65.0

× 75.0 (2.56 × 2.95)

CDI system

DPR6EA-9

0.8–0.9 (0.031–0.035)

Tiller control

Electric start

0.15–0.25 (0.006–0.010)

0.25–0.35 (0.010–0.014)

245

323

52

12-15

Prime start

5,000–6,000

18.4 (25.0) @ 5,500

875–975

4-stroke, OHC, L2

498 (30.39)

65.0

× 75.0 (2.56 × 2.95)

CDI system

DPR6EA-9

0.8–0.9 (0.031–0.035)

Remote control

Electric start

0.15–0.25 (0.006–0.010)

0.25–0.35 (0.010–0.014)

245

323

52

12-15

Prime start


2.08 (27/13)

Manual tilt

F


2.08 (27/13)

Manual tilt

F


(Minimum 86)

25 (6.60, 5.50)

4-stroke motor oil

SE, SF, SG, SH, SJ

10W-30, 10W-40

1.7 (1.80, 1.50)

1.9 (2.00, 1.67)


320 (10.81, 11.27)

18 (1.8, 13)

35 (3.5, 25)

28 (2.8, 20)

18 (1.8, 13)


(Minimum 86)

25 (6.60, 5.50)

4-stroke motor oil

SE, SF, SG, SH, SJ

10W-30, 10W-40

1.7 (1.80, 1.50)

1.9 (2.00, 1.67)


320 (10.81, 11.27)

18 (1.8, 13)

35 (3.5, 25)

28 (2.8, 20)

18 (1.8, 13)

4-2

F25TRB

703 (27.7)

376 (14.8)

—/1,275 (50.2)/—

—/550 (21.7)/—

—/71 (157)/—

5,000–6,000

18.4 (25.0) @ 5,500

875–975

4-stroke, OHC, L2

498 (30.39)

65.0 × 75.0 (2.56 × 2.95)

CDI system

DPR6EA-9

0.8–0.9 (0.031–0.035)

Remote control

Electric start

0.15–0.25 (0.006–0.010)

0.25–0.35 (0.010–0.014)

245

323

52

12-15

Prime start


2.08 (27/13)

Power trim and tilt

F


(Minimum 86)

25 (6.60, 5.50)

4-stroke motor oil

SE, SF, SG, SH, SJ

10W-30, 10W-40

1.7 (1.80, 1.50)

1.9 (2.00, 1.67)


320 (10.81, 11.27)

18 (1.8, 13)

35 (3.5, 25)

28 (2.8, 20)

18 (1.8, 13)

E

65W-9-16-4 3/15/02 5:16 PM Page 4

EMU00322*

SPECIFICATIONS

Item

DIMENSIONS

Overall Length

Overall Width

Overall Height

Transom height

Weight

PERFORMANCE

S/L/X

S/L/X

S/L/X

Full throttle operating range

Maximum output

Idling speed (Neutral)

ENGINE

Model

Unit mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.) r/min kW (HP) @ r/min r/min

Type

Displacement

Bore

× stroke

Ignition system

Spark plug

Spark plug gap

Control system

Starting system cm 3 (cu.in.) mm (in.)

NGK mm (in.)

Valve clearance (cold engine) IN

EX mm (in.) mm (in.)

Battery

Min. cold cranking amps (CCA/SAE) amps at -18°C (-0.4°F)

Min. marine cranking amps (MCA/ABYC)

Min. reserve capacity (RC/SAE)

Alternator output

Starting carburetion system amps at 0°C (32°F) minutes

V-A (W)

DRIVE UNIT

Gear positions

Gear ratio

Trim and tilt system

Propeller mark

FUEL AND OIL

Recommended fuel

Fuel tank capacity

Recommended engine oil

P.O.N.

I (US gal, lmp qt)

API

SAE

I (US qt, Imp qt)

I (US qt, Imp qt)

Engine oil capacity (without oil filter)

(with oil filter)

Recommended gear oil

Gear oil capacity

TIGHTENING TORQUE

Spark plug

Propeller nut

Engine oil drain bolt

Engine oil filter cm 3 (US oz, Imp oz)





4-3

713 (28.1)

373 (14.7)

—/1,311 (51.6)/1,425 (56.1)

—/528 (20.8)/642 (25.3)

—/87 (192)/90 (198)

5,000–6,000

18.4 (25.0) @ 5,500

925–1,025

4-stroke, OHC, L2

498 (30.39)

65.0

× 75.0 (2.56 × 2.95)

CDI system

DPR6EA-9

0.8–0.9 (0.031–0.035)

Remote control

Electric start

0.15–0.25 (0.006–0.010)

0.25–0.35 (0.010–0.014)

245

323

52

12-15

Prime start

18 (1.8, 13)

35 (3.5, 25)

28 (2.8, 20)

18 (1.8, 13)

T25TRB


2.42 (29/12)

Power trim and tilt

G


(Minimum 86)

25 (6.60, 5.50)

4-stroke motor oil

SE, SF, SG, SH, SJ

10W-30, 10W-40

1.9 (2.00, 1.67)

2.1 (2.22, 1.85)


430 (14.54, 15.14)

E

65W-9-16-4 3/15/02 5:16 PM Page 5

001213

E

EMU01369

TRANSPORTING AND

STORING OUTBOARD MOTOR w

Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking.

EMU00326

TRAILERING OUTBOARD MOTOR

The motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the motor in the tilt position using a motor support device such as a transom saver bar.

For further details, consult your Yamaha dealer.

w

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

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

8 DO NOT fill fuel container to maximum capacity. Gasoline will expand considerably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.

4-4 c C

Do not use the tilt support lever/knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor can not be trailered in the down position, use an additional support device to secure it in the up position.

65W-9-16-4 3/15/02 5:16 PM Page 6 q w

000912

102**2

E

EMU00330

STORING OUTBOARD MOTOR

When storing your Yamaha outboard for prolonged periods of time, (2 months or longer), several important procedures must be performed to prevent expensive damage.

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

c C

8 To prevent problems which can be caused by oil entering the cylinder from the sump, keep the engine in the attitude shown when transporting and storing it.

8 Do not place the engine on its side before the cooling water has drained from it completely, or water may enter the cylinder through the exhaust port and cause problems.

8 Store the engine in a dry, well-ventilat- ed place, not in direct sunlight.

1 Vertical position

2 Horizontal position

EMU00335

Filling Fuel Tank

Fill the fuel tank with fresh fuel and add one ounce of “Yamaha Fuel Conditioner and Stabilizer” (Part No. LUB-FUELC-12-

00) to each gallon of fuel.

NOTE:

The use of “Yamaha Fuel Conditioner and

Stabilizer” eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead.

4-5

65W-9-16-4 3/15/02 5:16 PM Page 7

E

EMU00338

Flushing Cooling System and Fogging

Engine

Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging of the engine is mandatory to prevent expensive engine damage due to rust. Perform the flushing and fogging at the same time.

w

8 Do not touch or remove electrical parts when starting or during operation.

8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running.

4-6

EMU00339

8 Flushing in a Water Tank c C

If the fresh water level is below the level of the anti-cavitation plate, or if the water supply is insufficient, engine seizure may occur.

1) Remove the engine top cowling and silencer cover.

2) Install the outboard motor on the water tank.

3) Fill the tank with fresh water to above the level of the anti-cavitation plate.

4) Run the engine at a fast idle for 10~15 minutes.

5) Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite

Engine Fogging Oil” (Part No. LUB-

STRRT-12-00) alternately into each carburetor. When properly done, the engine will smoke excessively and almost stall.

65W-9-16-4 3/15/02 5:16 PM Page 8 q q w

E

6) Remove the motor from the water tank.

7) Install the silencer cover and top cowling.

1 Water surface

2 Lowest water level

605024

605014*

EMU00342

8 Flushing with the Flushing Attachment c C

Avoid running the outboard at high speed while on the flushing attachment, or overheating could occur.

1) Remove the top cowling and the propeller.

2) Install a flushing attachment 1 to the cooling water inlet.

3) Run the engine at a fast idle for 10~15 minutes supplying fresh water.

4) Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite

Engine Fogging Oil” (Part No. LUB-

STRRT-12-00) alternately into the silencer cover. When properly done, the engine will smoke excessively and almost stall.

5) Remove the flushing attachment and wipe off any excess water.

6) Install the top cowling and the propeller.

NOTE:

A flushing attachment is available from a

Yamaha dealer.

4-7

65W-9-16-4 3/15/02 5:16 PM Page 9

E

EMU00349

Lubrication

1) Remove the spark plug(s). Spray a

Yamaha “Stor-Rite Engine Fogging

Oil” into each cylinder for 10 seconds.

Grease the spark plug threads and reinstall the spark plug(s) and torque to proper specification. (Refer to the

“CLEANING AND ADJUSTING

SPARK PLUG”).

2) Turn the engine over with the stop lanyard disconnected to work the fogging oil into the piston rings.

3) Change the gear-case oil. (Refer to

“CHANGING GEAR OIL”). Inspect the oil for the presence of water which indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealership prior to use.

4) Grease all grease fittings. (Refer to the “GREASING”)

4-8

EMU00351

Cleaning and Anti-corrosion Measure

1) Wash down the exterior of the outboard with fresh water and dry off completely.

2) Spray the engine’s exterior with

“Yamaha Silicone Protectant” (Part

No. LUB-SILCNE-13-00).

3) Wax the cowling with a non-abrasive wax such as “Yamaha Silicone Wax”

(Part No. ACC-11000-15-02).

65W-9-16-4 3/15/02 5:16 PM Page 10

UPPER LEVEL

LOWER LEVEL

901015

E

EMU00353

Battery Care w

Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing.

Antidote:

EXTERNAL; Flush with water.

INTERNAL; Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

EYES; Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases: Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in a closed space. Always wear eye protection when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

Batteries vary among manufacturers.

Therefore the following procedures may not always apply. Consult your battery manufacturer’s instructions.

1) Disconnect and remove the battery from the boat. Always disconnect the black negative lead first to prevent the risk of shorting.

2) Clean the battery casing and terminals. Fill each cell to the upper level with distilled water.

3) Store the battery on a level surface in a cool, dry, well-ventilated place out of direct sunlight.

4) Once a month, check the specific gravity of the electrolyte and recharge as required to prolong battery life.

4-9

65W-9-16-4 3/15/02 5:16 PM Page 11

4-10

E

EMU01569

PERIODIC MAINTENANCE w

Be sure to turn off the engine when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual. All warranty repairs, however, including those to the emission control system, must be performed by an authorized

Yamaha marine dealership.

A service manual is available for purchase through a Yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform maintenance not covered by this owner’s manual.

EMU00356

REPLACEMENT PARTS

If replacement parts are necessary, use only genuine Yamaha parts or equivalents of the same type and of equivalent strength and materials. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers.

Yamaha genuine parts and accessories are available from a Yamaha dealer.

65W-9-16-4 3/22/02 4:27 PM Page 12

E

EMU00361*

MAINTENANCE CHART

Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines.

The mark ( ●) indicates the check-ups which you may carry out yourself.

The mark ( 1) indicates work to be carried out by your Yamaha dealer.

Item

Spark plug

Greasing points

Gear oil

Fuel system

Fuel filter

Fuel tank

Idling speed

Cleaning/Adjustment/

Replacement

Greasing

Change

Inspection

Inspection/Replacement

Cleaning

Adjustment

Anode Inspection/Replacement

Outboard motor exterior Inspection

Cooling water passages Cleaning

Propeller

Timing belt

Inspection

Inspection

Battery

Power trim and tilt

Ignition timing

Bolts and nuts

Engine oil

Oil filter

Valve clearance

Thermostat

Inspection

Interval

Inspection

Inspection/Adjustment

Retightening

Change

Change

Inspection/Adjustment

Inspection

Initial

10 hours

(1 month)

50 hours

(3 months)

Every

100 hours

(6 months)

200 hours

(1 year)

●

●

●

●

● (every month)

●

1

1

●

1

●

●

1

●

●

●

●

●

●

●

●

●

●

1

●

●

●

1

●

1

●

1

●

1

1

1

Refer page

4-14

4-12

4-26

4-16

4-17

4-28

4-18

4-29

4-34

4-6, 4-33

4-24

4-21

4-30

4-23

—

4-32

4-19

—

—

—

1. When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

NOTE:

If leaded gasoline is usually used, engine valves and related parts should be inspected after every 300 hours of operation in addition to the items on the maintenance chart above.

4-11

65W-9-16-4 3/15/02 5:16 PM Page 13

EMU00366

GREASING

Yamaha marine grease

(Water resistant grease)

E

4-12

65W-9-16-4 3/15/02 5:16 PM Page 14

EMU00366

GREASING

Yamaha marine grease

(Water resistant grease)

E

4-13

103182

65W-9-16-4 3/15/02 5:16 PM Page 15

4-14

E

EMU01202

CLEANING AND ADJUSTING SPARK

PLUG

w

When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire.

The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself.

Instead, take the outboard motor to a

Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type.

Standard spark plug:

Refer to “SPECIFICATIONS”, page 4-1.

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

Spark plug gap:


65W-9-16-4 3/15/02 5:16 PM Page 16 w

E

When fitting the plug, always clean the gasket surface and use a new gasket.

Wipe off any dirt from the threads and screw in the spark plug to the correct torque.

Spark plug torque:


NOTE:

If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.

q

903033

Initial of spark plug

I.D. mark

B

C/BK

D

Plug wrench size

21 mm (13/16 in.)

16 mm (5/8 in.)

18.3 mm (23/32 in.)

1 Spark plug gap

2 Spark plug I.D. mark (NGK)

4-15

65W-9-16-4 3/15/02 5:16 PM Page 17

106055

E

EMU00369

CHECKING FUEL SYSTEM

w

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

Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by

Yamaha dealer or other qualified mechanic.

Checking points

8 Fuel system parts leakage.

8 Fuel hose joint leakage.

8 Fuel hose cracks or other damage.

8 Fuel connector leakage.

w

Leaking fuel can result in fire or explosion.

8 Check for fuel leakage regularly.

8 If any fuel leakage is found, the fuel system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate.

4-16

65W-9-16-4 3/15/02 5:16 PM Page 18

207053

E

EMU00370

INSPECTING FUEL FILTER

w

Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive.

8 If you have any question about properly doing this procedure, consult your

Yamaha dealer.

8 Do not perform this procedure on a hot or running engine. Allow the engine to cool.

8 There will be fuel in the fuel filter. Keep away from sparks, cigarettes, flames or other sources of ignition.

8 This procedure will allow some fuel to spill. Catch fuel in a rag. Wipe up any spilled fuel immediately.

8 The fuel filter must be reassembled carefully with O-ring, filter cup, and hoses in place. Improper assembly or replacement can result in a fuel leak, which could result in a fire or explosion hazard.

EMU00374

Check the fuel filter periodically.

The fuel filter is a one-piece, disposable type. If foreign matter is found in the filter, replace it. For replacement of the fuel filter, consult a Yamaha dealer.

4-17

65W-9-16-4 3/15/02 5:16 PM Page 19 q

204051

E

EMU00991

ADJUSTING IDLING SPEED

w

8 Do not touch or remove electrical parts when starting or during operation.

8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running.

c C

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

A diagnostic tachometer should be used for this procedure.

1) Start the engine and allow it to warm up fully in Neutral until it is running smoothly. If the outboard is mounted on a boat, be sure the boat is tightly moored.

2) Adjust the throttle stop-screw 1 to set the idling speed to specification

(see “SPECIFICATIONS” on page 4-1) by turning the stop-screw clockwise to increase the idling speed, and turning it counterclockwise to decrease the idling speed.

NOTE:

Correct idling-speed adjustment is only possible if the engine is fully warmed-up.

If not warmed up fully, the speed setting will tend to be too high. If you have difficulty obtaining the specified idle, consult a Yamaha dealer or other qualified mechanic.

4-18

65W-9-16-4 3/15/02 5:16 PM Page 20 q

000912

601025

E

EMU01415

CHANGING ENGINE OIL

w

8 Avoid draining the engine oil immedi- ately after stopping the engine. The oil is hot and should be handled with care to avoid burns.

8 Be sure the outboard is securely fas- tened to the transom or a stable stand.

c C

8 Change the engine oil after the first 10 hours of operation, and every 100 hours or at 6-month intervals thereafter.

Otherwise, the engine will wear quickly.

8 Do not overfill the oil, and be sure the engine is in an upright position (not tilted) when checking and changing the engine oil.

8 If the oil level is above the upper level mark, drain until the level meets the specified capacity. Overfilling the oil may cause leakage or damage.

1) Put the outboard motor in an upright position (not tilted).

2) Prepare a suitable container which can hold a larger amount than the engine oil capacity. Loosen and remove the drain bolt 1 while holding the container under the drain hole. Let the oil drain completely.

Wipe up any spilled oil immediately.

3) Put a new gasket on the drain bolt.

Apply a light coat of oil to the gasket and reinstall the drain bolt.

Tightening torque:


4-19

65W-9-16-4 3/15/02 5:16 PM Page 21 w

203025

201012

E

NOTE:

If a torque wrench is not available when you are installing the drain plug, finger tighten the bolt just until the gasket comes into contact with the surface of the drain hole. Then tighten 1/4 - 1/2 turn.

Have the drain plug torqued to the correct value with a torque wrench as soon as possible.

4) Remove the oil filler cap 2. Add the correct amount of oil through the filler hole.

Reinstall the filler cap.

Engine oil grade/capacity:


5) Start the engine and watch to make sure the low oil pressure warning lamp turns off. Make sure that there are no oil leaks.

c C

If the oil lamp does not turn off, or if there are oil leaks, stop the engine and find the cause. Continued operation with a problem could cause severe engine damage. If the problem cannot be found and corrected, consult your Yamaha dealer.

6) Turn off the engine and wait 3 minutes. Recheck the oil level using the dipstick to be sure the level falls between the upper and lower marks.

Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark.

7) Dispose of used oil according to local regulations.

4-20

65W-9-16-4 3/15/02 5:16 PM Page 22

E

NOTE:

8 For disposal of used oil consult your

Yamaha dealer.

8 The oil should be changed more often when the engine is operated under adverse conditions such as extended trolling.

206013

EMU00380*

CHECKING TIMING BELT

Inspect the timing-belt and replace it if any of the following signs is observed:

8 Cracks in the back of the belt or in the base of belt teeth.

8 Excessive wear at the roots of cogs.

8 Rubber portion swollen by oil.

8 Belt surfaces roughened.

8 Signs of wear on edges or outer surface of belt.

8 Stretching by 10 mm (0.39 in) or more when the belt is pushed with a finger.

c C

Consult your Yamaha dealer when replacing the timing-belt.

4-21

65W-9-16-4 3/15/02 5:16 PM Page 23 w q

205044

E

EMU01329

REPLACING FUSE

If the fuse has blown on an Electric start model, open the fuse holder and replace the fuse with a new one of proper amperage.

w

Be sure to use the specified fuse. An incorrect fuse or a piece of wire may allow excessive current flow. This could cause electrical system damage and a fire hazard.

NOTE:

If the new fuse blows again immediately, consult a Yamaha dealer.

1 Fuse holder

2 Fuse (20A)

EMU00383

CHECKING WIRING AND

CONNECTORS

1) Check that each grounding wire is properly secured.

2) Check that each connector is engaged securely.

413014

EMU00384

EXHAUST LEAKAGE

Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head and crank case.

EMU00385

WATER LEAKAGE

Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head and crank case.

4-22

65W-9-16-4 3/15/02 5:16 PM Page 24 q

E

EMU00992

CHECKING POWER TRIM AND TILT

SYSTEM

w

8 Never get under the lower unit while it is tilted, even when the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls.

8 Make sure no one is under the out- board before performing this test.

411034

1) Check the power trim and tilt unit for any sign of oil leaks.

2) Operate each of the power trim and tilt switches on remote control and engine bottom cowling (If equipped) to check that all switches work.

3) Tilt up the motor and check that the trim and tilt rod 1 is pushed out completely.

4) Check that the trim and tilt rod is free of corrosion or other flaws.

5) Operate the motor to trim and tilt down. Check that the trim and tilt rod operates smoothly.

NOTE:

If any operation is abnormal, consult a

Yamaha dealer.

Recommended fluid;

Yamaha power trim & tilt fluid or ATF

(DEXRON-II)

4-23

65W-9-16-4 3/15/02 5:16 PM Page 25

210011

602051

E

EMU00388

CHECKING PROPELLER

w

You could be seriously injured if the engine accidentally starts while you are near the propeller.

8 Before inspecting, removing or installing the propeller, remove the spark plug caps from the spark plugs.

Also, put the shift control in Neutral, put the main switch in the “OFF” position and remove the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one.

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

602054

EMU00390

Propeller Checking Point

8 Check each of the propeller blades for wear, erosion from cavitation or ventilation, or other damage.

8 Check the splines for wear and damage.

8 Check for fish line winding around the propeller shaft.

8 Check the propeller shaft oil seal for damage.

4-24

65W-9-16-4 3/15/02 5:16 PM Page 26

FT25

1

6

5

4

3

2

602045*

E

EMU00976

Removing the Propeller

1) Straighten the cotter-pin 1 and pull it out using a pair of pliers.

2) Remove the propeller nut 2, washer

3 and spacer 4.

3) Remove the propeller 5 and thrust washer 6 y q e r w t

602073

4-25

EMU00397

Installing the Propeller c C

8 Be sure to install the thrust washer before installing propeller, otherwise, lower case and propeller boss may be damaged.

8 Be sure to use a new cotter pin and bend the ends over securely.

Otherwise, the propeller could come off during operation and be lost.

1) Apply Yamaha Marine grease or

Corrosion resistant grease to the propeller-shaft.

2) Install the thrust washer and propeller on the propeller-shaft.

3) Install the spacer and washer. Tighten the propeller nut to the specified torque.

65W-9-16-4 3/15/02 5:16 PM Page 27

602053

E

Tightening torque:

Refer to “SPECIFICATIONS” page 4-1.

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

NOTE:

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

4-26

EMU01460

CHANGING GEAR OIL

w

8 Be sure the outboard is securely fas- tened to the transom or a stable stand.

You could be severely injured if the outboard falls on you.

8 Never get under the lower unit while it is tilted, even when the tilt-support lever/knob is locked. Severe injury could occur if the outboard accidentally falls.

1) Tilt the outboard motor so that the oil drain plug is at the lowest point possible.

2) Place a suitable container under the gear-case.

65W-9-16-4 3/15/02 5:16 PM Page 28 q w

000650

601022

E

3) Remove the oil drain plug 1.

NOTE:

The oil drain plug is magnetic. Remove all metal particles from the plug before reinstalling it.

4) Remove the oil level plug 2 to allow the oil to drain completely.

c C

Inspect the used oil after it has been drained. If the oil is milky, water is getting into the gear-case which can cause gear damage. Consult a Yamaha dealer for repair of the lower unit seals.

NOTE:

For disposal of used oil consult your

Yamaha dealer.

5) With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the oil drain plug hole.

Gear oil grade/capacity:

Refer to “SPECIFICATIONS,” page 4-1.

6) When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.

7) Insert and tighten the oil drain plug.

4-27

65W-9-16-4 3/22/02 4:27 PM Page 29

E

EMU00401

CLEANING FUEL TANK

w

Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive.

8 If you have any question about properly doing this procedure, consult your

Yamaha dealer.

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

8 Remove the fuel tank from the boat before cleaning it. Work only outdoors in an area with good ventilation.

8 Wipe up any spilled fuel immediately.

8 Reassemble the fuel tank carefully.

Improper assembly can result in a fuel leak, which could result in a fire or explosion hazard.

8 Dispose of old gasoline (petrol)accord- ing to local regulations.

1) Empty the fuel tank into an approved gasoline (petrol) container.

2) Pour a small amount of suitable solvent in the tank. Reinstall the cap and shake the tank. Drain the solvent completely.

902054

EMU00402

Cleaning the Fuel Filter

1) Remove the screws holding the fuel hose joint assembly . Pull the assembly out of the tank.

2) Clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allow the filter to dry.

3) Replace the gasket with a new one.

Reinstall the fuel hose joint assembly and tighten the screws firmly.

4-28

65W-9-16-4 3/15/02 5:16 PM Page 30

604024

405014

E

EMU00831

INSPECTING AND REPLACING

ANODE(S)

Yamaha outboard motor is protected from corrosion by a sacrificial anode(s).

Check the anode(s) periodically. Remove the scales from surfaces of the anode(s).

For the inspection and replacement of the anode(s), consult a Yamaha dealer.

c C

Do not paint the anode(s), for this would render it ineffective

T25

604016

405015

4-29

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4-30

E

EMU00404

CHECKING BATTERY

(for Electric start model)

w

Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic.

Always follow these preventive measures:

8 Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury.

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

Antidote (EXTERNAL):

8 SKIN - Flush with water.

8 EYES - Flush with water for 15 minutes and get immediate medical attention.

Antidote (INTERNAL):

8 Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention.

Batteries also generate explosive hydrogen gas; therefore, you should always follow these preventive measures:

8 Charge batteries in a well-ventilated area.

8 Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.).

8 DO NOT SMOKE when charging or han- dling batteries.

8 KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

65W-9-16-4 3/15/02 5:16 PM Page 32

UPPER LEVEL

LOWER LEVEL

901015

E c C

8 A poorly maintained battery will quick- ly deteriorate.

8 Ordinary tap-water contains minerals harmful to a battery, and should not be used for topping-up.

1) Check the electrolyte level at least once a month. Fill to the manufacturer’s recommended level when necessary. Top up only with distilled water

(or pure de-ionized water suitable to use in batteries).

2) Keep the battery always in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month or more, remove the battery from the boat and store it in a cool, dark place.

Completely recharge the battery before using it.

3) If the battery will be stored for longer than a month, check the specific gravity of the fluid at least once a month and recharge the battery when it is low.

4-31

EMU01279

Connecting the Battery w

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

65W-9-16-4 3/15/02 5:16 PM Page 33 e

UPPER LEVEL

LOWER LEVEL w q

901012

E c C

8 Make sure the main switch (on applica- ble models) is “OFF” before working on the battery.

8 Reversal of the battery leads will dam- age the rectifier.

8 Connect the RED lead first when installing the battery and disconnect the RED lead last when removing it.

Otherwise, the electrical system can be damaged.

8 The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine.

Connect the RED lead to the POSITIVE (+) terminal first.

Then connect the BLACK lead to the NEG-

ATIVE (-) terminal.

1 Red lead

2 Black lead

3 Battery

EMU01280

Disconnecting the Battery

Disconnect the BLACK lead from the NEG-

ATIVE (-) terminal first. Then disconnect the RED lead from the POSITIVE (+) terminal.

EMU00408

CHECKING BOLTS AND NUTS

1) Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torque.

2) Check the tightening torque of other bolts and nuts.

4-32

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000913

E

EMU01172

CLEANING COOLING-WATER

PASSAGES

Flushing device equipped model

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

1) After shutting off the engine, unscrew the garden-hose connector 2 from the fitting 1 on the bottom cowling.

2) Screw the garden-hose connector 2 onto a garden hose 3 which is connected to a fresh-water supply.

3) With the engine off, turn on the water tap and let the water flush through the cooling passages for about 15 minutes. Turn off the water and disconnect the garden hose 3.

4) When flushing is complete, reinstall the garden-hose connector 2 on the fitting 1 on the bottom cowling.

Tighten the connector securely.

c C

Do not leave the garden-hose connector loose on the bottom cowling fitting or let the hose hang free during normal operation. Water will leak out of the connector instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fitting after flushing the engine.

NOTE:

8 When flushing the engine with the boat in the water, tilting up the engine until it is completely out of the water will achieve better results.

8 Refer to cooling system flushing instructions in “TRANSPORTING AND

STORING OUTBOARD MOTOR”.

4-33

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102025

001187

E

EMU00409

MOTOR EXTERIOR

EMU00410

Cleaning the Outboard Motor

After use, wash the exterior of the outboard with fresh water.

Flush the cooling system with fresh water.

NOTE:

Refer to Flushing Cooling System instructions in “TRANSPORTING AND STORING

OUTBOARD MOTOR”.

EMU00412

Checking Painted Surface of Motor

Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from a Yamaha dealer.

EMU00413

COATING THE BOAT BOTTOM

A clean hull improves boat performance.

The boat bottom should be kept as clean of marine growths as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth.

Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.

4-34

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-MEMO-

E

65W-9-16-5 3/22/02 4:28 PM Page 1

E

EMU00414

Chapter 5

TROUBLE RECOVERY

1

TROUBLESHOOTING ..............................5-1

TEMPORARY ACTION IN

EMERGENCY ............................................5-5

Impact damage.....................................5-5

Power trim/tilt will not operate ...........5-5

Starter will not operate ........................5-6

Treatment of submerged motor .........5-9

2

3

4

5

6

65W-9-16-5 3/15/02 5:42 PM Page 2

E

EMU01204¯

TROUBLESHOOTING

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.)

If your outboard motor requires repair, bring it to a Yamaha dealer.

Trouble

A. Starter will not operate.

B. Engine will not start (Starter operates).

Possible Cause

1. Battery capacity weak or low.

2. Battery connections loose or corroded.

3. Fuse for electric start circuit blown.

4. Starter components faulty.

5. Shift lever in gear.

1. Fuel tank empty.

2. Fuel contaminated or stale.

3. Fuel filter clogged.

4. Starting procedure incorrect.

5. Fuel pump malfunctions.

6. Spark plug(s) fouled or incorrect type.

7. Spark plug cap(s) fitted incorrectly.

8. Poor connections or damaged ignition wiring.

9. Ignition parts faulty.

10. Engine stop switch lanyard not attached.

11. Engine inner parts damaged.

Remedy

1. Check battery condition. Use battery of recommended capacity.

2. Tighten battery cables and clean battery terminals.

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

4. Have serviced by a Yamaha dealer.

5. Shift to neutral.

1. Fill tank with clean, fresh fuel.


3. Clean or replace filter.

4. Read "STARTING ENGINE" section.


6. Inspect spark plug(s). Clean or replace with recommended type.

7. Check and re-fit cap(s).

8. Check wires for wear or breaks.

Tighten all loose connections.

Replace worn or broken wires.


10. Attach lanyard.


5-1

65W-9-16-5 3/15/02 5:18 PM Page 3

E

Trouble

C. Engine idles irregularly or stalls.

Possible Cause


2. Fuel system obstructed.



5. Failed ignition parts.

6. Warning system activated.

7. Spark plug gap incorrect.


9. Specified engine oil not used.

10. Thermostat faulty or clogged.

11. Carburetor adjustments incorrect.

12. Fuel pump damaged.

Remedy


2. Check for pinched or kinked fuel line or other obstructions in fuel system.




6. Find and correct cause of warning.

7. Inspect and adjust as specified.




9. Check and replace oil as specified.




13. Open the air vent screw.

13. Air vent screw on the fuel tank closed.

14. Motor angle too high.

15. Carburetor clogged.

16. Fuel joint connection incorrect.

17. Throttle valve adjustment incorrect.

18. Battery lead disconnected.

14. Return to normal operating position.


15. Connect correctly.


18. Connect securely.

5-2

65W-9-16-5 3/15/02 5:18 PM Page 4

E

Trouble

D. Warning buzzer sounds or indicator lamp lights.

E. Engine power loss.

Possible Cause

1. Cooling system clogged.

2. Engine oil level low.

3. Heat range of spark plug incorrect.


5. Engine oil contaminated or deteriorated.

6. Oil filter clogged.

7. Oil feed/injection pump malfunctions.

8. Load on boat improperly distributed.

9. Water pump/thermostat faulty.

1. Propeller damaged.

2. Propeller pitch or diameter incorrect.

3. Trim angle incorrect.

4. Motor mounted at incorrect height on transom.

5. Warning system activated.

6. Boat bottom fouled with marine growth.


8. Weeds or other foreign matter tangled on gear housing.

9. Fuel system obstructed.



12. Spark plug gap incorrect.

Remedy

1. Check water intake for restriction.

2. Fill oil tank with specified engine oil.

3. Inspect spark plug and replace it with recommended type.

4. Check and replace oil with specified type.

5. Replace oil with fresh, specified type.



8. Distribute load to place boat on an even plane.


1. Have propeller repaired or replaced.

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

3. Adjust trim angle to achieve most efficient operation.

4. Have motor adjusted to proper transom height.

5. Find and correct cause of warning.

6. Clean boat bottom.


8. Remove foreign matter and clean lower unit.

9. Check for pinched or kinked fuel line or other obstructions in fuel system.



12. Inspect and adjust as specified.

5-3

65W-9-16-5 3/15/02 5:18 PM Page 5

E

Trouble Possible Cause


14. Failed ignition parts.


E. Engine power loss.

16. Thermostat faulty or clogged.

17. Air vent screw closed.

18. Fuel pump damaged.

19. Fuel joint connection incorrect.

20. Heat range of spark plug incorrect.

F. Engine vibrates excessively.

1. Propeller damaged.

2. Propeller shaft damaged.

3. Weeds or other foreign matter tangled on propeller.

4. Motor mounting bolt loose.

5. Steering pivot loose or damaged.

Remedy





15. Check and replace oil with specified type.


17. Open the air vent screw.


19. Connect correctly.

20. Inspect spark plug and replace it with recommended type.

1. Have propeller repaired or replaced.


3. Remove and clean propeller.

4. Tighten bolt.

5. Tighten or have serviced by a

Yamaha dealer.

5-4

65W-9-16-5 3/15/02 5:18 PM Page 6

EMU00416

TEMPORARY ACTION IN

EMERGENCY

E

EMU01492

IMPACT DAMAGE

w

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

607011

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

1) Stop the engine immediately.

2) Inspect the control system and all components for damage. Also, inspect the boat for damage.

3) Whether damage is found or not, return to the nearest harbor slowly and carefully.

4) Have a Yamaha dealer inspect the outboard motor before operating it again.

EMU00419

POWER TRIM/TILT WILL NOT

OPERATE

If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit, the engine can be tilted manually.

1 Manual valve screw q

411033

5-5

EMU00420

1) Loosen the manual valve screw clockwise until it stops.

2) Put the engine in the desired position, then tighten the manual valve screw counterclockwise.

65W-9-16-5 3/15/02 5:18 PM Page 7

5-6

E

EMU00423

STARTER WILL NOT OPERATE

If the starter mechanism does not operate

(engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.

w

8 Use this procedure only in an emer- gency and only to return to port for repairs.

8 When the emergency starter rope is used to start the engine, the start-ingear protection device does not operate. Make sure the gear shift lever/ remote control lever is in neutral.

Otherwise, the boat could unexpectedly start to move, which could result in an accident.

8 Be sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure someone.

8 An unguarded rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the flywheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.

8 Do not touch the ignition coil, high voltage wire, spark plug cap or other electrical components when starting of operating the motor. You could be shocked.

65W-9-16-5 3/22/02 4:28 PM Page 8 w e

E

EMU00961¯

Emergency Starting Engine

1) Remove the top cowling.

q

2) Remove the start-in-gear protection cable 1 from the starter after removing the clip 2 and the screw 3 if the cable is equipped.

3) Remove the starter/flywheel cover after removing 4 bolts.

Disconnect the leads for the warning indicator.

208061

OFF

ON

START

208062

506021***

4) Prepare the engine for starting. See

“STARTING ENGINE” for procedures.

Be sure the engine is in Neutral and that the lock-plate on the end of lanyard is attached to the engine stop lanyard switch. Set the main switch to

“ON” if equipped.

5-7

65W-9-16-5 3/22/02 4:28 PM Page 9

208063

E

5) Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise.

6) Pull the rope slowly until resistance is felt.

7) Give a strong pull straight out to crank and start the engine. Repeat if necessary.

5-8

65W-9-16-5 3/15/02 5:18 PM Page 10

5-9

E

EMU00446

TREATMENT OF SUBMERGED

MOTOR

If the outboard motor is submerged, immediately take it a Yamaha dealer.

Otherwise, some corrosion may begin almost immediately.

If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure bellow for taking care to minimize engine damage.

EMU00448

1) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.

2) Remove the spark plug(s), then face the spark plug holes downward to allow any water, mud or contaminants to drain.

3) Drain the fuel from the carburetor, fuel filter and fuel line. Drain the engine oil completely.

4) Fill the sump with the fresh engine oil as the same quantity as the engine oil capacity.

Engine oil capacity: Refer to SPECIFI-

CATIONS, Page 4-1.

5) Feed engine fogging oil or engine oil through the carburetor(s) and spark plug hole(s) while cranking the engine with the manual starter or emergency starter rope.

6) Take the outboard motor to a Yamaha dealer as soon as possible.

c C

Do not attempt to run the motor until it has been completely inspected.

65W-9-16-6 3/15/02 5:19 PM Page 1

E

EMU00450

Chapter 6

INDEX

1

INDEX ........................................................6-1 2

3

4

5

6

65W-9-16-6 3/22/02 4:28 PM Page 2

E

EMU00451

INDEX

A

Adjusting idling speed ..........................4-18

Adjusting trim angle ..............................3-19

Air vent screw...........................................2-2

B

Basic boating rules ..................................1-7

Battery care...............................................4-9

Battery requirement ..............................1-14

Bow down...............................................3-21

Bow up ....................................................3-21

Breaking in (running in) engine..............3-5

C

Changing engine oil ..............................4-19

Changing gear oil...................................4-26

Checking battery ....................................4-30

Checking bolts and nuts........................4-32

Checking fuel system ............................4-16

Checking painted surface of motor......4-34

Checking power trim and tilt system...4-23

Checking propeller.................................4-24

Checking the engine oil level..................3-7

Checking timing belt..............................4-21

Checking wiring and connectors..........4-22

Clamping the outboard motor................3-4

Cleaning and adjusting spark plug ......4-14

Cleaning and anti-corrosion measure ...4-8

Cleaning cooling-water passages ........4-33

Cleaning fuel tank ..................................4-28

Cleaning the fuel filter ...........................4-28

Cleaning the outboard motor ...............4-34

Coating the boat bottom .......................4-34

Connecting the battery..........................4-31

Cruising in other conditions .................3-27

Cruising in salt water.............................3-27

Cruising in shallow water .....................3-25

Crusing in turbid water .........................3-27

D

Digital tachometer .................................2-14

Disconnecting the battery .....................4-32

E

Emission control information.................1-2

Emergency starting engine.....................5-7

Engine oil ................................................1-13

Engine stop button ..................................2-5

Engine stop lanyard switch ..............2-5,2-8

Exhaust leakage .....................................4-22

F

Filling fuel .................................................3-8

Filling fuel tank .........................................4-5

Flushing cooling system and fogging engine........................................................4-6

Flushing device ......................................2-18

Forward...................................................3-15

Fuel hose joint ..........................................2-2

Fuel meter.................................................2-2

Fuel tank....................................................2-2

Fuel tank cap.............................................2-2

Fueling instructions ...............................1-11

G

Gasoline ..................................................1-12

Gasohol...................................................1-12

Gear shift lever .........................................2-3

Greasing..................................................4-12

H

Hour meter..............................................2-15

I

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

Impact damage ........................................5-5

Important labels .......................................1-6

Inspecting and replacing anode ...........4-29

Inspecting fuel filter ...............................4-17

Installation ................................................3-1

Installing the propeller ..........................4-25

K

Key number ..............................................1-1

L

Low oil pressure warning .....................2-20

Low oil pressure warning indicator .....2-16

Lubrication................................................4-8

6-1

65W-9-16-6 3/22/02 4:28 PM Page 3

E

M

Main components ....................................2-1

Main switch ..............................................2-7

Maintenance chart .................................4-11

Motor exterior ........................................4-34

Mounting height ......................................3-3

Mounting the outboard motor ...............3-2

N

Neutral interlock trigger ..........................2-6

Neutral throttle lever ...............................2-7

O

Operations of controls and other functions ...................................................2-2

Outboard motor serial number ..............1-1

Overheat warning ..................................2-19

Overheat warning indicator..................2-16

P

Periodic maintenance............................4-10

Power trim/tilt switch ......................2-9,2-13

Power trim/tilt will not operate...............5-5

Pre-operation checks ...............................3-6

Propeller selection .................................1-15

R

Recoil starter handle................................2-3

Remote control.........................................2-6

Remote control lever ...............................2-6

Removing the propeller ........................4-25

Replacement parts .................................4-10

Replacing fuse........................................4-22

Reverse ...................................................3-16

Ring free fuel additive .............................3-8

S

Safety information ...................................1-4

Shifting....................................................3-15

Specifications ...........................................4-1

Star labels .................................................1-3

Start-in-gear protection.........................1-16

Starter button ...........................................2-3

Starter will not operate............................5-6

Starting engine.........................................3-9

Steering friction adjusting lever...........2-10

Stopping engine.....................................3-17

Storing outboard motor ..........................4-5

T

Tachometer ............................................2-14

Temporary action in emergency ............5-5

Throttle control grip.................................2-4

Throttle friction adjusting knob ..............2-4

Throttle friction adjusting screw ...........2-9

Throttle indicator .....................................2-4

Tiller handle..............................................2-3

Tilt lock mechanism...............................2-17

Tilt support bar.......................................2-17

Tilt support knob....................................2-17

Tilting up/down ......................................3-22

Top cowling lock lever ..........................2-17

Trailering outboard motor ......................4-4

Transporting and storing outboard motor.........................................................4-4

Treatment of submerged motor ............5-9

Trim angle adjusting rod.......................2-13

Trim meter ..............................................2-15

Trim tab...................................................2-11

Trimming outboard motor....................3-18

Troubleshooting.......................................5-1

W

Warming up engine...............................3-14

Warning indicator(s) ..............................2-14

Warning system .....................................2-19

Water leakage.........................................4-22

Warranty Information .................Next page

6-2

65W-9-16-6 3/15/02 5:19 PM Page 4

EMU01599

IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND

CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha.

Yamaha is ready to stand behind your purchase with strong warranty coverage. To be sure you receive all the benefits of warranty, please take the following steps:

1. Be sure your new Yamaha is registered for warranty. Your boat dealer should do this at the time of sale. Make sure your dealer gives you a copy of the completed Yamaha registration card for your records. If you are unsure whether or not your Yamaha is registered, complete the Warranty Registration card found inside the cover of the Owner's Manual.

Mail it to the distributor for the country in which you live (see step 6 for the correct address). If your Yamaha is not properly registered, a warranty repair could be unnecessarily delayed while registration records are checked.

2. Read the Limited Warranty statement which follows these instructions. This warranty applies to Yamaha outboard motors sold in the United States, whether purchased separately or when supplied as original equipment by a boat builder. The terms also apply to original equipment packages sold in Canada, with coverage provided by Yamaha Motor

Canada (see ``Warranty Guide'' for Canadian models). This warranty explains the conditions of the warranty, including the obligations that your dealer and you as the owner have under the warranty. For example, your Yamaha outboard must receive a proper pre-delivery inspection (PDI) by the selling dealer. Failure to take this important step could jeopardize warranty coverage!

3. If you need warranty repairs, you must take your Yamaha outboard to an authorized

Yamaha outboard dealer. Be aware that not all selling boat dealers are authorized

Yamaha dealers. Only authorized dealers have the factory training, special tools, and

Yamaha support needed to perform warranty repairs.

4. If you are away from home, or your selling dealer is not an authorized Yamaha dealer, use the following toll-free numbers to find the nearest Yamaha dealer.

United States Dealer Locations: 1-800-692-6242

Canada Dealer Locations: 1-800-267-8577

65W-9-16-6 3/15/02 5:19 PM Page 5

5. Your warranty applies specifically to repairs made in the country of purchase. If your

U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian purchased Yamaha needs service while in the United States, Yamaha will assist the local dealer whenever possible. However, some products available in one country may not be sold or serviced in the other.

6. If you need any additional information about your Yamaha or warranty coverage which your dealer cannot provide, please contact us directly.

Yamaha Motor Corporation, U.S.A.

P.O. Box 6555

Cypress, CA 90630

Attention: Customer Relations Department

Telephone No.

(714) 761-7439

Fax No.

(714) 761-7559

Yamaha Motor Canada Ltd.

480 Gordon Baker Road

Toronto, Ontario

M2H 3B4

Attention: Customer Relations Department

Telephone No.

(416) 498-1911

Fax No.

(416) 491-3122

65W-9-16-6 3/15/02 5:19 PM Page 6

EMU01404

YAMAHA MOTOR CORPORATION, U.S.A.

FOUR-STROKE OUTBOARD MOTOR

THREE-YEAR LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha 1999-or-later model four-stroke outboard motors originally distributed by Yamaha Motor Corporation, U.S.A. will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. Warranty coverage for outboards distributed by non-US Yamaha affiliated companies may be different.

PERIOD OF WARRANTY. Any new Yamaha 1999-or-later model four-stroke outboard motor purchased and registered with Yamaha

Motor Corporation, U.S.A. for pleasure use in the United States, will be warranted against defects in material or workmanship for a period of three (3) years from the date of purchase, subject to exclusions noted herein. Any Yamaha outboard motor purchased and utilized for commercial applications will be warranted for a period of one (1) year from the date of purchase, subject to exclusions noted herein.

Yamaha peripheral equipment included with the motor, such as gauges, fuel tanks, and hoses, remote control boxes, and wiring external from the motor unit, will be warranted for one (1) year from the date of purchase of either pleasure or commercial use. Replacement parts used in warranty repairs will be warranted for the balance of the applicable warranty period.

The second and third year of warranty (if applicable) shall be limited to covering the cost of parts and labor for major components only.

The major components covered are:

Power Unit Section

8 Power Head

8 Intake Manifold

8 Carburetor Assembly and its Related Components

8 Fuel Injection System and its Related Components

8 Fuel and Oil Pump Assemblies

8 Ignition System (Standard and Microcomputer)

Lower Unit Section

8 Exhaust System

8 Upper Casing

8 Lower Unit Assembly

Bracket Section

8 Bracket System

8 Power Trim and Tilt Assembly

WARRANTY REGISTRATION. To be eligible for warranty coverage, the outboard motor must be registered with Yamaha Motor

Corporation, U.S.A. Warranty registration can be accomplished by any authorized Yamaha Outboard Motor Dealer. Upon receipt of the registration, an Owner’s Warranty Card will be sent by Yamaha to the registered purchaser.

OBTAINING REPAIRS UNDER WARRANTY. To receive repairs under this warranty, a valid Owner’s Warranty Card must be presented to an authorized Yamaha Outboard Motor Dealer.

During the period of warranty, any authorized Yamaha outboard dealer will, free of charge, repair or replace, at Yamaha’s option, any parts adjudged defective by Yamaha due to faulty workmanship or material from the factory. All replaced parts will become the property of Yamaha Motor Corporation, U.S.A.

CUSTOMER’S RESPONSIBILITY. Under the terms of this warranty, the customer will be responsible for ensuring that the outboard motor is properly operated, maintained, and stored as specified in the applicable Owner’s Manual.

The owner of the outboard motor shall give notice to an authorized Yamaha Outboard Motor Dealer of any and all apparent defects within ten (10) days of discovery and make the motor available at that time for inspection and repairs at the dealer’s place of business.

3.

4.

5.

6.

GENERAL EXCLUSIONS FROM WARRANTY. This warranty will not cover the repair of damage if the damage is a result of abuse or neglect of the product. Examples of abuse and neglect include, but are not limited to:

1.

Racing or competition use, modification of original parts, abnormal strain.

2.

Lack of proper maintenance and off season storage as described in the Owner’s Manual, installation of parts or accessories that are not equivalent in design and quality genuine Yamaha parts.

Operation of the motor at an rpm other than specified, use of lubricants or oils that are not suitable for outboard motor use.

Damage as a result of accidents, collisions, contact with foreign materials, or submersion.

Growth of marine organism on motor surfaces.

Normal deterioration.

65W-9-16-6 3/15/02 5:19 PM Page 7

SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs, shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes, are not covered by warranty.

Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yamaha Outboard Motor Dealer are excluded from warranty coverage.

Specific parts excluded from the second and third year of warranty (if applicable) are:

8 Top and Bottom Cowling

8 Electric Components (other than ignition system)

8 Rubber Components (such as hoses, tubes, rubber seals, fittings, and clamps)

TRANSFER OF WARRANTY. Transfer of the warranty from the original purchaser to any subsequent purchaser is possible by having the motor inspected by an authorized Yamaha Outboard Motor Dealer and requesting the dealer to submit a change of registration to

Yamaha Motor Corporation, U.S.A. within ten (10) days of the transfer.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND

TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND

EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS

MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUEN-

TIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE

TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A.

Post Office Box 6555

Cypress, California 90630

WARRANTY QUESTIONS AND ANSWERS

Q.

What costs are my responsibility during the warranty period?

A.

The customer`s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages.

Q.

What are some examples of ``abnormal’’ strain, neglect, or abuse?

A.

These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation, and/or tie down. If you have any specific questions on operation or maintenance, please contact your Yamaha outboard dealer for advice.

Q.

Does the warranty cover incidental costs such as towing or transportation due to a failure?

A.

No. The warranty is limited to repair of the machine itself.

Q.

May I perform any or all of the recommended maintenance shown in the Owner’s Manual instead of having the dealer do them?

A.

Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s and Service Manuals. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha outboard dealer.

Q.

Will the warranty be void or canceled if I do not operate or maintain my new outboard exactly as specified in the Owner’s Manual?

A.

No. The warranty on a new outboard cannot be ’’voided`` or ’’canceled``. However, if a particular failure is caused by operation or maintenance other than as shown in the Owner’s Manual, that failure may not be covered under warranty.

Q.

What responsibility does a Yamaha outboard dealer have under this warranty?

A.

Each Yamaha outboard dealer is expected to:

1. Completely set up each outboard he sells prior to delivery.

2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date.

In addition, each Yamaha outboard dealer is held responsible for his setup, service and warranty repair work.

Q.

Is the warranty transferable to second owners?

A.

Yes. The remainder of any existing warranty can be transferred upon request. The unit has to be inspected and re-registered by an authorized Yamaha outboard dealer for the policy to remain effective.

65W-9-16-6 3/15/02 5:19 PM Page 8

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United

States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A.

CUSTOMER RELATIONS DEPARTMENT

P.O.Box 6555

Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include any important information such as names, addresses, model, engine serial number, dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is complied from the purchase registrations sent to Yamaha Motor

Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new outboard, please advise us of your new address by sending a postcard listing your outboard model name, engine serial number, dealer number (or dealer’s name) as it is shown on your warranty identification, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A.

WARRANTY DEPARTMENT

P.O.Box 6555

Cypress, California 90630

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

65W-9-16-6 3/15/02 5:19 PM Page 9

EMU01178

IMPORTANT WARRANTY INFORMATION

IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha.

This model was manufactured as a U.S.A. specification model, and the warranty statement shown in this manual is for market. To receive the benefits of the warranty that applies to the country in which you use your Yamaha, please note the following information.

1.

The warranty on this model is the same as equivalent models sold in the country where you will receive service. If you need more information about your warranty coverage or your Yamaha outside the U.S.A. or Canada, please contact an authorized Yamaha dealer in your country.

2.

Keep a copy of your sales contract or invoice for the purchase of your Yamaha and present it if you need warranty repairs. This document should show the date of purchase, which is important evidence the repairing dealer will need to be sure your Yamaha is covered by warranty.

3.

If your Yamaha needs warranty repairs, contact an authorized Yamaha dealer in the country where you are. He will explain how to get warranty service in that country.

4.

This Yamaha model may not be sold in some countries. Therefore, in some cases your local dealer may not have all the parts or service information he may need, which may unavoidably delay repairs. If this happens, we thank you for your understanding and assure you we will attempt to resolve the situation as quickly as possible.

65W-9-16-6 3/15/02 5:19 PM Page 10

65W-9-16 hyoshi 4/18/02 3:15 PM Page 2 (2,1)

65W-9-16 hyoshi 4/18/02 3:15 PM Page 1 (1,1)

Printed in Japan

April 2002-0.5 × 0.1 !

65W-28199-16

(F25AMH, F25AEH, F25AE, F25AET, FT25BET)

(E)

Printed on recycled paper

OWN

Warranty card 2/27/02 11:47 AM Page 1

OUTBOARD MOTOR WARRANTY REGISTRATION

ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD

Please complete and mail this card. This information is necessary to accurately register your unit for warranty.

Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.

OUTBOARD MOTOR MODEL AND SERIAL NUMBER (From I.D. label on clamp bracket)

MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation)

(For Dealer Use Only)

(A l’usage du concessionnaire)

YAMAHA DEALER NUMBER

NO. DU CONCESSIONNAIRE

YAMAHA

YAMAHA MOTOR CO., LTD.

MADE IN JAPAN

PAYS D'ORIGINE JAPON

DEALER NAME

NOM DU

CONCESSIONNAIRE

DATE SOLD

DATE DE

LIVRAISON

OWNER’S NAME

NOM DU

PROPRIÉTAIRE

ADDRESS

ADRESSE

PHONE NUMBER ( )

NUMÉRO DE TÉLÉPHONE

MONTH

MOIS

CITY

VILLE

DAY

JOUR

USAGE

(Check One)

UTILISATION

(En cocher un.)

PLEASURE

LOISIR

COMMERCIAL

COMMERCIAL

YEAR

ANNÉE

FIRST

PRÉNOM

STREET

RUE

STATE/PROVINCE

PROVINCE

LAST

NOM DE FAMILLE

ZIP

CODE POSTAL

Warranty card 2/27/02 11:47 AM Page 2

ATTN: WARRANTY DEPARTMENT

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POSTAGE

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