OWNER’S MANUAL

F20AF25AFT25B

65W-28199-7D-E0

EMU25051

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

Important manual information

EMU25103

To the owner

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

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

WARNING

EWM00780

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

board motor.

CAUTION:

ECM00700

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

outboard motor.

NOTE:

A NOTE provides key information to make

procedures easier or clearer.

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

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

NOTE:

The F20AET, F25AMH, F25AE, F25AET,FT25BET and the standard accessories areused as a base for the explanations and illus-trations in this manual. Therefore some

items may not apply to every model.

EMU25121

F20A, F25A, FT25BOWNER’S MANUAL

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

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

Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan

Table of contents

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

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

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

EC label........................................... 1Emission control information ........... 2

SAV models ...................................... 2

Read manuals and labels................ 3

Warning labels .................................. 3

Safety information............................. 6

Safety information ........................... 6

Rotating parts.................................... 6Hot parts ........................................... 6Electric shock.................................... 6Power trim and tilt ............................. 6Engine shut-off cord.......................... 6Gasoline............................................ 6Gasoline exposure and spills ............ 6Carbon monoxide.............................. 7Modifications ..................................... 7

Boating safety ................................. 7

Alcohol and drugs ............................. 7Personal flotation devices ................. 7People in the water ........................... 7Passengers ....................................... 7Overloading....................................... 7Avoid collisions ................................. 7Weather ............................................ 8Passenger training ............................ 8Boating safety publications ............... 8Laws and regulations ........................ 8

Basic requirements........................... 9

Fueling instructions ......................... 9

Gasoline............................................ 9Engine oil .......................................... 9

Installation requirements ............... 10

Boat horsepower rating................... 10Mounting motor ............................... 10Remote control requirements.......... 10Battery requirement ........................ 10Without a rectifier or Rectifier

Regulator ...................................... 11Propeller selection .......................... 11

Start-in-gear protection ................. 12

Basic components .......................... 13

Main components ......................... 13

Fuel tank .........................................13Fuel joint..........................................14Fuel gauge ......................................14Fuel tank cap...................................14Air vent screw..................................14Remote control ................................14Remote control lever .......................15Neutral interlock trigger ...................15Neutral throttle lever ........................15Tiller handle.....................................16Gear shift lever ................................16Throttle grip .....................................16Throttle indicator .............................16Throttle friction adjuster...................17Engine shut-off switch .....................17Engine stop button ..........................18Manual starter handle .....................18Main switch .....................................18Steering friction adjuster .................19Power trim and tilt switch on remote

control ...........................................19Power trim and tilt switch on bottom

engine cowling ..............................19Trim tab with anode.........................20Trim tab ...........................................20Trim rod (tilt pin) ..............................21Tilt lock mechanism.........................21Tilt support knob..............................21Tilt support bar ................................22Top cowling lock lever(s)

(turn type)......................................22Flushing device ...............................22Warning indicator ............................22

Warning system ............................ 23

Overheat warning............................23Low oil pressure warning ................23

Operation ......................................... 25

Installation..................................... 25

Mounting the outboard motor ..........25Clamping the outboard motor..........26

Breaking in engine ........................ 27

Procedure for 4-stroke models........27

Pre-operation checks.................... 28

Table of contents

Fuel ................................................. 28Controls........................................... 28Stop switches.................................. 28Engine............................................. 28Checking the engine oil level .......... 28

Filling fuel ...................................... 29Operating engine........................... 29

Feeding fuel (portable tank) ............ 29Starting engine................................ 30

Warming up engine ....................... 33

Manual start and electric start models .......................................... 33

Shifting .......................................... 33Stopping boat ................................ 35Stopping engine ............................ 35

Procedure ....................................... 35

Trimming outboard motor.............. 36

Adjusting trim angle for manual tilt models .......................................... 36

Adjusting trim angle (Power trim and tilt) .......................................... 37

Adjusting boat trim .......................... 38

Tilting up and down ....................... 39

Procedure for tilting up (manual tilt models) ......................................... 39

Procedure for tilting up (power trim and tilt models) ............................. 40

Procedure for tilting down (manual tilt models) .................................... 41

Procedure for tilting down (power trim and tilt models) ...................... 41

Cruising in shallow water .............. 42

Cruising in shallow water (manual tilt models) .................................... 42

Power trim and tilt models............... 43

Cruising in other conditions........... 44

Maintenance..................................... 45

Specifications ................................ 45Transporting and storing outboard

motor ........................................... 47

Clamp screw mounting models ....... 48Storing outboard motor ................... 48Procedure ....................................... 49Lubrication ...................................... 50Battery care..................................... 50

Flushing power unit .........................51Cleaning the outboard motor...........52Checking painted surface of

motor.............................................52

Periodic maintenance ................... 52

Replacement parts ..........................52Severe operating conditions............52Maintenance chart 1........................54Maintenance chart 2........................56Greasing..........................................57Cleaning and adjusting spark

plug ...............................................58Checking fuel system ......................59Inspecting fuel filter .........................60Cleaning fuel filter ...........................60Inspecting idling speed....................61Changing engine oil ........................61Checking wiring and connectors .....63Exhaust leakage..............................63Water leakage .................................64Engine oil leakage...........................64Checking power trim and tilt

system...........................................64Checking propeller ..........................64Removing propeller .........................65Installing propeller ...........................66Changing gear oil ............................66Cleaning fuel tank ...........................67Inspecting and replacing

anode(s)........................................68Checking battery (for electric start

models) .........................................69Connecting the battery ....................70Disconnecting the battery................70Checking top cowling ......................70Coating the boat bottom..................71

Trouble Recovery............................ 72

Troubleshooting ............................ 72Temporary action in emergency ... 75

Impact damage ...............................75Replacing fuse ................................75Power trim and tilt will not

operate..........................................76Starter will not operate ....................76Emergency starting engine .............77

Table of contents

Treatment of submerged motor..... 78

Procedure ....................................... 78

1

General information

EMU25170

Identification numbers record

EMU25183

Outboard motor serial number

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

EMU25190

Key number

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

EMU25202

EC label

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

1. Outboard motor serial number location

1

ZMU02638

1. Key number

1. EC label location

ZMU04946

1

General information

2

EMU25221

Emission control information

EMU25351

SAV models

Engines affixed with the label pictured belowconform to SAV (the Swiss exhaust emissionregulations for Swiss inshore waters).

Approval label of emission control certif-

icate

Fuel requirement label

1. EC label location

ZMU05495

1

ZMU01696

1. Approval label location

1ZMU04967

YAMAHA MOTOR CO.,LTD.Motorfamilie

Abgastypenpruf-Nummer

ZMU04492

ZMU04494

General information

3

EMU33520

Read manuals and labels

Before operating or working on this motor:

�

Read this manual.

�

Read any manuals supplied with the boat.

�

Read all labels on the outboard motor and the boat.If you need any additional information, contact your Yamaha dealer.

EMU33830

Warning labels

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

1

23

ZMU05798

General information

4

EMU33911

Contents of labels

The above warning labels mean as follows.

1

WARNING

EWM01690

Emergency starting does not have start-in-gear protection. Ensure shift control is

in neutral before starting engine.

2

WARNING

EWM01680

�

Keep hands, hair, and clothing awayfrom rotating parts while the engine isrunning.

�

Do not touch or remove electrical parts

when starting or during operation.

3

WARNING

EWM01670

�

Read Owner’s Manuals and labels.

�

Wear an approved personal flotationdevice (PFD).

�

Attach engine shut-off cord (lanyard) toyour PFD, arm, or leg so the enginestops if you accidentally leave thehelm, which could prevent a runaway

boat.

EMU33841

Symbols

The following symbols mean as follows.

Caution/Warning

ZMU05706

1 2

3

General information

5

Read Operator’s Manual

Hazard caused by continuous rotation

Electrical hazard

Remote control lever/gear shift lever operat-ing direction, dual direction

Engine start/ Engine cranking

ZMU05696

ZMU05664

ZMU05665

ZMU05666

ZMU05667

ZMU05668

6

Safety information

EMU33621

Safety information

Observe these precautions at all times.

EMU33630

Rotating parts

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

EMU33640

Hot parts

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

EMU33650

Electric shock

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

EMU33660

Power trim and tilt

Body parts can be crushed between the mo-tor and the clamp bracket when the motor istrimmed or tilted. Keep body parts out of thisarea at all times. Be sure no one is in thisarea before operating the power trim and tiltmechanism.The power trim and tilt switches operateeven when the main switch is off. Keep peo-ple be away from the switches wheneverworking around the motor.Never get under the lower unit while it is tilt-ed, even when the tilt support lever is locked.

Severe injury could occur if the outboard mo-tor accidentally falls.

EMU33670

Engine shut-off cord

Attach the engine shut-off cord so that theengine stops if the operator falls overboardor leaves the helm. This prevents the boatfrom running away under power and leavingpeople stranded, or running over people orobjects.Always attach the engine shut-off cord to asecure place on your clothing or your arm orleg while operating. Do not remove it to leavethe helm while the boat is moving. Do not at-tach the cord to clothing that could tearloose, or route the cord where it could be-come entangled, preventing it from function-ing.Do not route the cord where it is likely to beaccidentally pulled out. If the cord is pulledduring operation, the engine will shut off andyou will lose most steering control. The boatcould slow rapidly, throwing people and ob-jects forward.

EMU33810

Gasoline

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

Always, refuel ac-cording to the procedure on page 29 toreduce the risk of fire and explosion.

EMU33820

Gasoline exposure and spills

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

Safety information

7

EMU33900

Carbon monoxide

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

EMU33780

Modifications

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

EMU33740

Boating safety

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

EMU33710

Alcohol and drugs

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

EMU33720

Personal flotation devices

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

EMU33730

People in the water

Always watch carefully for people in the wa-ter, such as swimmers, skiers, or divers,whenever the engine is running. Whensomeone is in the water near the boat, shift

into neutral and shut off the motor.Stay away from swimming areas. Swimmerscan be hard to see.The propeller can keep moving even whenthe motor is in neutral. Shut off the enginewhen a person is in the water near you.

EMU33750

Passengers

Consult your boat manufacturer’s instruc-tions for details about appropriate passengerlocations in your boat and be sure all pas-sengers are positioned properly before ac-celerating and when operating above an idlespeed. Standing or sitting in non-designatedlocations may result in being thrown eitheroverboard or within the boat due to waves,wakes, or sudden changes in speed or direc-tion. Even when people are positioned prop-erly, alert your passengers if you must makeany unusual maneuver. Always avoid jump-ing waves or wakes.

EMU33760

Overloading

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

EMU33770

Avoid collisions

Scan constantly

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

Operate defensively

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

�

Do not follow directly behind other boats orwaterskiers.

Safety information

8

�

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

�

Avoid areas with submerged objects orshallow water.

�

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

�

Take early action

to avoid collisions. Re-member,

boats do not have brakes

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

EMU33790

Weather

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

EMU33880

Passenger training

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

EMU33890

Boating safety publications

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

EMU33600

Laws and regulations

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

9

Basic requirements

EMU25540

Fueling instructions

WARNING

EWM00010

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

�

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

�

Stop engine before refueling.

�

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

�

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

�

Do not overfill the fuel tank.

�

Tighten the filler cap securely after re-fueling.

�

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

�

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

�

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

static sparks.

CAUTION:

ECM00010

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

ter.

EMU25580

Gasoline

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

EMU25683

Engine oil

NOTE:

If the recommended engine oil grades arenot available, select an alternative from thefollowing chart according to the average

temperatures in your area.

Recommended gasoline:Regular unleaded gasoline with a min-imum octane rating of 90 (Research Octane Number).

Recommended engine oil:4-stroke motor oil with a combination of the following SAE and API oil classi-fications

Engine oil type SAE:10W-30 or 10W-40

Engine oil grade API:SE, SF, SG, SH, SJ, SL

Engine oil quantity (excluding oil filter):F20AET 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AE 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AET 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AMH 1.7 L (1.80 US qt) (1.50 Imp.qt)FT25BET 1.9 L (2.01 US qt) (1.67 Imp.qt)

Basic requirements

10

CAUTION:

ECM01050

All 4-stroke engines are shipped from the

factory without engine oil.

EMU33551

Installation requirements

EMU33560

Boat horsepower rating

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

WARNING

EWM01560

Overpowering a boat can cause severe

instability.

EMU33570

Mounting motor

Your dealer or other person experienced inproper rigging should mount the motor usingcorrect equipment and complete rigging in-structions. For further information, see page25.

WARNING

EWM01570

�

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

�

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

to mount it safely.

EMU33580

Remote control requirements

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

WARNING

EWM01580

�

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

�

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

your Yamaha dealer.

EMU25693

Battery requirement

CAUTION:

ECM01061

Do not use a battery that does not meetthe specified capacity. If a battery thatdoes not meet specifications is used, the

ZMU01710

Basic requirements

11

electric system could perform poorly orbe overloaded, causing electric system

damage.

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

EMU25721

Battery specifications

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

EMU25730

Without a rectifier or Rectifier Regulator

CAUTION:

ECM01090

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

Regulator.

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

EMU34190

Propeller selection

Next to selecting an outboard, choosing theright propeller is one of the most importantpurchasing decisions a boater can make.The type, size, and design of your propellerhave a direct impact on acceleration, topspeed, fuel economy, and even engine life.Yamaha designs and manufactures propel-lers for every Yamaha outboard motor andevery application.Your outboard motor came with a Yamahapropeller chosen to perform well over arange of applications, but there may be useswhere a different propeller would be moreappropriate.Your Yamaha dealer can help you select theright propeller for your boating needs. Selecta propeller that will allow the engine to reachthe middle or upper half of the operatingrange at full throttle with the maximum boat-load. Generally, chose a larger pitch propel-ler for a smaller operating load and a smallerpitch propeller for a heavier load. If you carryloads that vary widely, chose the propellerthat lets the engine run in the proper rangefor your maximum load but remember thatyou may need to reduce your throttle settingto stay within the recommended enginespeed range when carrying lighter loads.For instructions on propeller removal and in-stallation, see page 64.

Minimum cold cranking amps (CCA/EN):F20AET 347.0 AF25AE 347.0 AF25AET 347.0 AFT25BET 347.0 A

Minimum rated capacity (20HR/IEC):F20AET 40.0 AhF25AE 40.0 AhF25AET 40.0 AhFT25BET 40.0 Ah

Basic requirements

12

EMU25770

Start-in-gear protection

Yamaha outboard motors or Yamaha-ap-proved remote control units are equippedwith start-in-gear protection device(s). Thisfeature permits the engine to be started onlywhen it is in neutral. Always select neutralbefore starting the engine.

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

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

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

ZMU04604

-x1 2 3

ZMU04605

-x1 2 3

ZMU04606

-x1 2 3

13

Basic components

EMU2579B

Main componentsNOTE:

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

els.

F20A, F25A, FT25B

EMU25802

Fuel tank

If your model was equipped with a portable

22

1

3

4

56

10

9

11

8

7

23

1213

14

1720

1819

21

24

2

15

1625

ZMU04968

1. Top cowling2. Cooling water pilot hole3. Top cowling lock lever(s)4. Drain screw5. Anti-cavitation plate6. Trim tab (anode)7. Propeller8. Cooling water inlet9. Trim rod*10. Clamp bracket11. Power trim and tilt switch*12. Manual starter handle*13. Warning indicator14. Gear shift lever*

15. Tiller handle*16. Throttle friction adjuster*17. Engine stop button/Engine shut-off switch*18. Transom clamp handle*19. Rope attachment20. Tilt lock lever*21. Flushing device22. Tilt support knob*23. Fuel tank*24. Remote control box (side mount type)*25. Clip*

Basic components

14

fuel tank, its function is as follows.

WARNING

EWM00020

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

tions.

EMU25830

Fuel joint

This joint is used to connect the fuel line.

EMU25841

Fuel gauge

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

EMU25850

Fuel tank cap

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

EMU25860

Air vent screw

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

EMU26180

Remote control

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

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

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

ZMU03157

1 3 4 2

ZMU02284

3

1

4

2

1. Power trim and tilt switch2. Remote control lever3. Neutral interlock trigger4. Neutral throttle lever5. Main switch / choke switch6. Engine shut-off switch7. Throttle friction adjuster

Basic components

15

EMU26190

Remote control lever

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

EMU26201

Neutral interlock trigger

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

EMU26211

Neutral throttle lever

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

NOTE:

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

position.

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

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”4. Shift5. Fully closed

12

3

4

56

ZMU04862

6. Throttle7. Fully open

1. Neutral interlock trigger

Basic components

16

EMU25911

Tiller handle

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

EMU25922

Gear shift lever

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

EMU25941

Throttle grip

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

EMU25961

Throttle indicator

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

1. Fully open2. Fully closed

ZMU01997

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

ZMU02285

2

1

3R N

F

ZMU01999

Basic components

17

EMU25971

Throttle friction adjuster

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

WARNING

EWM00031

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to move the remote control leveror throttle grip, which could result in an

accident.

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

EMU25991

Engine shut-off switch

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

WARNING

EWM00121

�

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

�

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

�

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

be thrown forward.

NOTE:

The engine cannot be started with the clip re-

1. Throttle indicator

START

1

ZMU02286 ZMU02001

Basic components

18

moved.

EMU26001

Engine stop button

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

EMU26070

Manual starter handle

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

EMU26090

Main switch

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

�

“ ”

(off)

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

�

“ ”

(on)

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

�

“ ”

(start)

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

1. Cord2. Clip

1. Cord2. Clip

2

1ZMU02003

ZMU02083

ZMU02287

Basic components

19

EMU26122

Steering friction adjuster

A friction device provides adjustable resis-tance to the steering mechanism, and can beset according to operator preference. An ad-justing screw or bolt is located on the swivelbracket.

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

WARNING

EWM00040

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

accident.

EMU32051

Power trim and tilt switch on remote control

The power trim and tilt system adjusts the

outboard motor angle in relation to the tran-som. Pressing the switch “ ” (up) trims theoutboard motor up, and then tilts it up. Press-ing the switch “ ” (down) tilts the outboardmotor down and trims it down. When theswitch is released, the outboard motor willstop in its current position.

NOTE:

For instructions on using the power trim and

tilt switch, see pages 36 and 39.

EMU26152

Power trim and tilt switch on bottom engine cowling

The power trim and tilt switch is located onthe side of the bottom engine cowling. Press-ing the switch “ ” (up) trims the outboardmotor up, and then tilts it up. Pressing theswitch “ ” (down) tilts the outboard motordown and trims it down. When the switch isreleased, the outboard motor will stop in itscurrent position.

WARNING

EWM01030

Use the power trim and tilt switch locatedon the bottom engine cowling only whenthe boat is at a complete stop with the en-gine off. Attempting to use this switchwhile the boat is moving could increasethe risk of falling overboard and coulddistract the operator, increasing the riskof collision with another boat or an obsta-

ZMU02288

Basic components

20

cle.

NOTE:

For instructions on using the power trim and

tilt switch, see page 39.

EMU26243

Trim tab with anode

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

WARNING

EWM00840

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

justing the trim tab.

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

CAUTION:

ECM00840

The trim tab also serves as an anode toprotect the engine from electrochemicalcorrosion. Never paint the trim tab as it

will become ineffective as an anode.

EMU26252

Trim tab

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

WARNING

EWM00840

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

justing the trim tab.

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

ZMU02811

UP

DN

1. Trim tab2. Bolt

Bolt tightening torque:18.0 Nm (13 ft-lb) (1.8 kgf-m)

ZMU02822

1

2

A

B

Basic components

21

EMU26261

Trim rod (tilt pin)

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

EMU30530

Tilt lock mechanism

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

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

EMU26321

Tilt support knob

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

CAUTION:

ECM00660

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

in the tilt position.

1. Trim tab2. Bolt

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

1

2

ZMU02289

A

B

ZMU02889

1. Tilt lock lever

ZMU02291

1

ZMU02812

Basic components

22

EMU26332

Tilt support bar

The tilt support bar keeps the outboard motorin the tilted up position.

CAUTION:

ECM01660

Do not use the tilt support bar whentrailering the boat. The outboard motorcould shake loose from the tilt supportand fall. If the motor cannot be trailered inthe normal running position, use an addi-tional support device to secure it in the

tilt position.

EMU26372

Top cowling lock lever(s) (turn type)

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

EMU26460

Flushing device

This device is used to clean the cooling wa-ter passages of the motor using a gardenhose and tap water.

NOTE:

For details on usage, see page 51.

EMU26302

Warning indicator

If the engine develops a condition which iscause for warning, the indicator lights up. Fordetails on how to read the warning indicator,see page 23.

ZMU02292

1. Top cowling lock lever(s)

1. Flushing device

ZMU02009

1

ZMU02813

1

Basic components

23

EMU26801

Warning system

CAUTION:

ECM00090

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

not be located and corrected.

EMU26817

Overheat warning

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

Activation of warning device

�

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

�

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

�

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

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

EMU30168

Low oil pressure warning

If the oil pressure drops too low, the warningdevice will activate.

Activation of warning device

�

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

�

If equipped with a low oil pressure-warningindicator, it will light or blink.

�

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

ZMU02293

ZMU02360

ZMU02294

Basic components

24

If the warning system has activated, stop theengine as soon as it is safe to do so. Checkthe oil level and add oil as needed. If the oillevel is correct and the warning device doesnot switch off, consult your Yamaha dealer.

CAUTION:

ECM00101

Do not continue to run the engine if thelow oil pressure-warning indicator is on.

Serious engine damage could occur.

ZMU02360

25

Operation

EMU26902

Installation

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

WARNING

EWM01590

�

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

�

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

rigging should mount the motor.

EMU33470

Mounting the outboard motor

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

EMU26921

Mounting height

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

1. Center line (keel line)

ZMU017601

Operation

26

CAUTION:

ECM01630

�

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

�

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

borne water spray.

NOTE:

�

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

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

�

For instructions on setting the trim angle of

the outboard motor, see page 36.

EMU26970

Clamping the outboard motor

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

WARNING

EWM00640

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

during operation.

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

ZMU02011

0–25mm(0–1in.)

ZMU02012

Operation

27

if it accidentally falls off the transom.

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

WARNING

EWM00650

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

tightness.

EMU30173

Breaking in engine

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

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

CAUTION:

ECM00800

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

even severe engine damage.

EMU27083

Procedure for 4-stroke models

Your new engine requires a period of ten-hours break-in to allow mating surfaces ofmoving parts to wear in evenly. Correctbreak-in will help ensure proper performanceand longer engine life.

NOTE:

Failure to follow the break-in procedurecould result in reduced engine life or evensevere engine damage. Run the engine inthe water, under load (in gear with a propel-ler installed) as follows. For ten hours forbreaking in engine avoid extended idling,

rough water and crowded areas.

1. For the first hour of operation:Run the engine at varying speeds up to2000 r/min or approximately half throttle.

2. For the second hour of operation:Increase engine speed as much as nec-essary to put the boat on plane (butavoid full-throttle operation), then backoff on the throttle while keeping the boatat a planing speed.

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

4. After the first 10 hours:Operate the engine normally.

1. Bolts

ZMU02013

ZMU02637

1

Operation

28

EMU27104

Pre-operation checks

WARNING

EWM00081

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

could occur.

CAUTION:

ECM00120

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

occur.

EMU27111

Fuel

�

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

�

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

�

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

�

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

EMU27130

Controls

�

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

�

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

�

Look for loose or damaged connections.

�

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

EMU31721

Stop switches

�

Confirm that turning the main switch to the

“ ” (off) position stops the engine.

�

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

�

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

EMU27140

Engine

�

Check the engine and engine mounting.

�

Look for loose or damaged fasteners.

�

Check the propeller for damage.

EMU27163

Checking the engine oil level

1. Put the outboard motor in an upright po-sition (not tilted).

2. Remove oil dipstick and wipe it clean.3. Completely insert the dipstick and re-

move it again.4. Check the oil level using the dipstick to

be sure the level falls between the upperand lower marks. Fill with oil if it is belowthe lower mark, or drain to the specifiedlevel if it is above the upper mark.

1. Oil dipstick

ZMU02833

1

Operation

29

NOTE:

Be sure to completely insert the dipstick into

the dipstick guide.

EMU27441

Filling fuel

WARNING

EWM00060

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

sources of ignition.

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

Wipe up any spilled fuel.

NOTE:

The smaller fuel filling hole on the fuel tankhas been designed to fit unleaded fuel fillersonly for emission control models (for Bod-

ensee).

EMU27450

Operating engine

EMU27463

Feeding fuel (portable tank)

WARNING

EWM00420

�

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

�

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

�

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

exhaust outlets.

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

1. Lower level mark2. Oil dipstick3. Upper level mark

ZMU02082

13

2

ZMU04047

Fuel tank capacity:24 L (6.34 US gal) (5.28 Imp.gal), 25 L (6.60 US gal) (5.50 Imp.gal)

Operation

30

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

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

NOTE:

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

from the fuel tank.

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

EMU27491

Starting engine

WARNING

EWM01600

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

ter near you.

EMU27543

Starting engine

1. Place the gear shift lever in neutral.

NOTE:

The start-in-gear protection device prevents

ZMU02295

ZMU02296

ZMU02024

1. Arrow

ZMU02304

N

Operation

31

the engine from starting except when in neu-

tral.

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

WARNING

EWM00121

�

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

�

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

�

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

be thrown forward.

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

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

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

NOTE:

�

When the engine is cold, it needs to bewarmed up. For further information, seepage 33.

�

If the engine is warm and fails to start,open the throttle slightly and try to start theengine again. If the engine still fails to

start, see page 72.

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

EMU27663

Electric start and remote control models

1. Place the remote control lever in neutral.

ZMU02026

START

START

ZMU02335

ZMU02336

Operation

32

NOTE:

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

tral.

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

WARNING

EWM00121

�

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

�

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

�

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

be thrown forward.

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

and hold it for a maximum of 5 seconds.

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

CAUTION:

ECM00191

�

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

�

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

Operation

33

again.

NOTE:

�

When the engine is cold, it needs to bewarmed up. For further information, seepage 33.

�

If the engine is warm and fails to start,open the throttle slightly and try to start theengine again. If the engine still fails to

start, see page 72.

EMU27670

Warming up engine

EMU27710

Manual start and electric start models

1. After starting the engine, allow it to idlefor 3 minutes to warm up. Failure to doso will shorten engine life.

2. Be sure the low oil pressure warning in-dicator goes off after starting the engine.

3. Check for a steady flow of water from thecooling water pilot hole.

CAUTION:

ECM00210

�

If the low oil pressure warning indicatordoes not go off after the engine starts,stop the engine. Otherwise serious en-gine damage could occur. Check the oillevel and add oil if necessary. Consultyour Yamaha dealer if the cause for thelow oil pressure warning indicator can-not be found.

�

A continuous flow of water from the pi-lot hole shows that the water pump ispumping water through the coolingpassages. If water is not flowing out ofthe pilot hole at all times while the en-gine is running, overheating and seri-ous damage could occur. Stop theengine and check whether the coolingwater inlet on the lower case or the

cooling water pilot hole is blocked.Consult your Yamaha dealer if the prob-

lem cannot be located and corrected.

EMU34530

Shifting

WARNING

EWM00180

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

you.

CAUTION:

ECM01610

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

engine and allow it to warm up.

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

equipped).

ZMU02034

Operation

34

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

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

slows to idle speed.

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

1. Neutral interlock trigger

ZMU02299

ZMU05737

R N

F

ZMU02030

Operation

35

EMU31742

Stopping boat

WARNING

EWM01510

�

Do not use the reverse function to slowdown or stop the boat as it could causeyou to lose control, be ejected, or im-pact the steering wheel or other parts ofthe boat. This could increase the risk ofserious injury. It could also damage theshift mechanism.

�

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

occur.

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

wind direction.

EMU27820

Stopping engine

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

EMU27845

Procedure

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

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

ZMU02304

N

ZMU02083

Operation

36

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

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

NOTE:

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

switch to “ ” (off).

EMU27861

Trimming outboard motor

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

the boat, sea conditions, and running speed.

WARNING

EWM00740

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

trim angle.

EMU27872

Adjusting trim angle for manual tilt models

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

ZMU02302

ZMU02041

1. Trim operating angle

ZMU02641

1

Operation

37

move the trim rod from the clamp brack-et.

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

WARNING

EWM00400

�

Stop the engine before adjusting thetrim angle.

�

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

�

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

angle can cause loss of control.

NOTE:

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

the trim rod one hole.

EMU27883

Adjusting trim angle (Power trim and tilt)

WARNING

EWM00752

�

Be sure all people are clear of the out-board motor when adjusting the tilt an-gle. Body parts can be crushedbetween the motor and the clampbracket when the motor is trimmed ortilted.

�

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

�

If equipped with a power trim and tiltswitch located on the bottom cowling,use the switch only when the boat is ata complete stop with the engine off. Donot adjust the trim angle with this

switch while the boat is moving.

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

1. Trim rod

ZMU02890

1

1. Power trim and tilt switch

Operation

38

To raise the bow (trim-out), press the switch“ ” (up).To lower the bow (trim-in), press the switch“ ” (down).Make test runs with the trim set to differentangles to find the position that works best foryour boat and operating conditions.

EMU27911

Adjusting boat trim

When the boat is on plane, a bow-up attituderesults in less drag, greater stability and effi-ciency. This is generally when the keel line ofthe boat is up about 3 to 5 degrees. With thebow up, the boat may have a greater tenden-cy to steer to one side or the other. Compen-sate for this as you steer. The trim tab canalso be adjusted to help offset this effect.When the bow of the boat is down, it is easierto accelerate from a standing start ontoplane.

Bow Up

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

Bow Down

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

NOTE:

Depending on the type of boat, the outboard

ZMU02811

UP

DN

Operation

39

motor trim angle may have little effect on the

trim of the boat when operating.

EMU27934

Tilting up and down

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

WARNING

EWM00221

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

motor is trimmed or tilted.

WARNING

EWM00250

Leaking fuel is a fire hazard. If there is afuel joint on the outboard motor, discon-nect the fuel line or close the fuel cock ifthe engine will be tilted for more than a

few minutes. Otherwise fuel may leak.

CAUTION:

ECM00241

�

Before tilting the outboard motor, stopthe engine by following the procedureon page 35. Never tilt the outboard mo-tor while the engine is running. Severedamage from overheating can result.

�

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

could break the handle.

EMU32660

Procedure for tilting up (manual tilt models)

1. Place the gear shift lever in neutral.

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

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

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

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

ZMU02304

N

N

ZMU03087

ZMU02305

Operation

40

CAUTION:

ECM01640

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

formation, see page 47.

EMU32722

Procedure for tilting up (power trim and tilt models)

1. Place the remote control lever in neutral.

2. Press the power trim and tilt switch “ ”(up) until the outboard motor has tiltedup completely.

3. Push the tilt support knob into the clampbracket to support the engine.

WARNING

EWM00261

After tilting the outboard motor, be sureto support it with the tilt support knob ortilt support lever. Otherwise the outboardmotor could fall back down suddenly if oilin the power trim and tilt unit or in the

ZMU02292

ZMU02823

UP

ZMU02812

Operation

41

power tilt unit loses pressure.

CAUTION:

ECM01640

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

formation, see page 47.

4. Models equipped with trim rods: Oncethe outboard motor is supported with thetilt support lever, press the power trimand tilt switch “ ” (down) to retract thetrim rods.

CAUTION:

ECM00250

Be sure to retract the trim rods complete-ly during mooring. This protects the rodsfrom marine growth and corrosion whichcould damage the power trim and tilt

mechanism.

EMU30192

Procedure for tilting down (manual tilt models)

1. Place the tilt lock lever in the lock posi-tion.

2. Slightly tilt the engine up until the tilt sup-port bar is automatically released.

3. Slowly tilt the engine down.

EMU33120

Procedure for tilting down (power trim and tilt models)

1. Push the power trim and tilt switch “ ”(up) until the outboard motor is support-ed by the tilt rod and the tilt support knobbecomes free.

2. Pull out the tilt support knob.

3. Push the power trim and tilt switch “ ”(down) to lower the outboard motor tothe desired position.

ZMU02306

ZMU02825

DN

ZMU01936

UP

DN

Operation

42

EMU28060

Cruising in shallow water

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

EMU28071

Cruising in shallow water (manual tilt models)

WARNING

EWM00710

�

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

�

Run the boat at the lowest possiblespeed when using the shallow watercruising system. The tilt lock mecha-nism does not work while the shallowwater cruising system is being used.Hitting an underwater obstacle couldcause the outboard motor to lift out ofthe water, resulting in loss of control.

�

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

�

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

�

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

deeper water.

CAUTION:

ECM00260

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

ing can result.

EMU32740

Procedure

1. Place the gear shift lever in neutral.

ZMU02826

DN

ZMU02830

ZMU02304

N

Operation

43

2. Place the tilt lock lever in the release/upposition.

3. Slightly tilt the outboard motor up. Thetilt support bar will lock automatically,supporting the outboard motor in a par-tially raised position.

NOTE:

This outboard motor has 2 positions for shal-

low water cruising.

4. To return the outboard motor to the nor-mal running position, place the gear shiftlever in neutral, then place the tilt lock le-ver in the lock/down position.

5. Slightly tilt the outboard motor up untilthe tilt support bar automatically returnsto the free position.

6. Slowly lower the outboard motor to thenormal position.

EMU32850

Power trim and tilt models

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

WARNING

EWM00660

�

Place the gear shift in neutral beforesetting up for shallow water cruising.

�

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

deeper water.

CAUTION:

ECM00260

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

ing can result.

EMU32920

Procedure for power trim and tilt

1. Place the remote control lever in neutral.

N

ZMU03087

ZMU02305

ZMU02306

Operation

44

2. Slightly tilt the outboard motor up to thedesired position using the power trimand tilt switch.

3. To return the outboard motor to the nor-mal running position, press the powertrim and tilt switch and slowly tilt the out-board motor down.

EMU28193

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the cooling

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

Cruising in muddy or turbid water

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

Cruising in acidic water

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

UP

ZMU01935

UP

DN

ZMU02823

UP

45

Maintenance

EMU34520

SpecificationsNOTE:

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

for plastic propeller installed.

NOTE:

“*” means, select the engine oil referring tothe chart of engine oil paragraph. For further

information, see page 9.

EMU28219

Dimension:

Overall length: F20AET 703 mm (27.7 in)F25AE 703 mm (27.7 in)F25AET 703 mm (27.7 in)F25AMH 1151 mm (45.3 in)FT25BET 713 mm (28.1 in)

Overall width: F20AET 376 mm (14.8 in)F25AE 376 mm (14.8 in)F25AET 376 mm (14.8 in)F25AMH 430 mm (16.9 in)FT25BET 373 mm (14.7 in)

Overall height S: F25AE 1148 mm (45.2 in)F25AMH 1148 mm (45.2 in)

Overall height L: F20AET 1275 mm (50.2 in)F25AE 1275 mm (50.2 in)F25AET 1275 mm (50.2 in)F25AMH 1275 mm (50.2 in)FT25BET 1311 mm (51.6 in)

Transom height S: F25AE 423 mm (16.7 in)F25AMH 423 mm (16.7 in)

Transom height L: F20AET 550 mm (21.7 in)F25AE 550 mm (21.7 in)F25AET 550 mm (21.7 in)F25AMH 550 mm (21.7 in)FT25BET 528 mm (20.8 in)

Weight (AL) S: F25AE 65.0 kg (143 lb)F25AMH 62.0 kg (137 lb)

Weight (AL) L: F20AET 67.0 kg (148 lb)F25AE 67.0 kg (148 lb)F25AET 71.0 kg (157 lb)F25AMH 64.0 kg (141 lb)FT25BET 86.7 kg (191 lb)

Performance:

Full throttle operating range: 5000–6000 r/min

Maximum output: F20AET 14.7 kW@5500 r/min (20 HP@5500 r/min)F25AE 18.4 kW@5500 r/min (25 HP@5500 r/min)F25AET 18.4 kW@5500 r/min (25 HP@5500 r/min)F25AMH 18.4 kW@5500 r/min (25 HP@5500 r/min)FT25BET 18.4 kW@5500 r/min (25 HP@5500 r/min)

Idling speed (in neutral): F20AET 925

±

50 r/minF25AE 925

±

50 r/minF25AE 950

±

25 r/minF25AET 925

±

50 r/minF25AET 950

±

25 r/minF25AMH 950

±

25 r/minF25AMH 975

±

50 r/minFT25BET 975

±

50 r/min

Engine:

Type: 4-stroke L

Maintenance

46

Displacement: 498.0 cm

3

Bore

×

stroke: 65.0

×

75.0 mm (2.56

×

2.95 in)Ignition system:

CDISpark plug (NGK):

DPR6EA-9Spark plug gap:

0.8–0.9 mm (0.031–0.035 in)Control system:

F20AET Remote controlF25AE Remote controlF25AET Remote controlF25AMH TillerFT25BET Remote control

Starting system: F20AET ElectricF25AE ElectricF25AET ElectricF25AMH ManualFT25BET Electric

Starting carburetion system: Prime start

Valve clearance (cold engine) IN: 0.15–0.25 mm (0.0059–0.0098 in)

Valve clearance (cold engine) EX: 0.25–0.35 mm (0.0098–0.0138 in)

Min. cold cranking amps (CCA/EN): F20AET 347.0 AF25AE 347.0 AF25AET 347.0 AFT25BET 347.0 A

Min. rated capacity (20HR/IEC): F20AET 40.0 AhF25AE 40.0 AhF25AET 40.0 AhFT25BET 40.0 Ah

Alternator output: F25AMH 80 W

Maximum generator output:

F20AET 15.0 AF25AE 15.0 AF25AET 15.0 AFT25BET 15.0 A

Drive unit:

Gear positions: Forward-neutral-reverse

Gear ratio: F20AET 2.08 (27/13)F25AE 2.08 (27/13)F25AET 2.08 (27/13)F25AMH 2.08 (27/13)FT25BET 2.42 (29/12)

Trim and tilt system: F20AET Power trim and tiltF25AE Manual tiltF25AET Power trim and tiltF25AMH Manual tiltFT25BET Power trim and tilt

Propeller mark: F20AET FF25AE FF25AET FF25AMH FFT25BET G

Fuel and oil:

Recommended fuel: Regular unleaded gasoline

Min. research octane: F20AET 90F25AE 90F25AET 90F25AMH 90FT25BET 90

Fuel tank capacity: 24 L (6.34 US gal) (5.28 Imp.gal), 25 L (6.60 US gal) (5.50 Imp.gal)

Recommended engine oil: 4-stroke outboard motor oil

Recommended engine oil group 1*: SAE 10W-30/10W-40/5W-30

Maintenance

47

API SE/SF/SG/SH/SJ/SLRecommended engine oil group 2*:

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

Lubrication: Wet sump

Engine oil quantity (excluding oil filter): F20AET 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AE 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AET 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AMH 1.7 L (1.80 US qt) (1.50 Imp.qt)FT25BET 1.9 L (2.01 US qt) (1.67 Imp.qt)

Recommended gear oil: Hypoid gear oil SAE#90

Gear oil quantity: F20AET 320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)F25AE 320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)F25AET 320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)F25AMH 320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)FT25BET 430.0 cm

3

(14.54 US oz) (15.17 Imp.oz)

Tightening torque for engine:

Spark plug: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

Propeller nut: F20AET 35.0 Nm (25.8 ft-lb) (3.57 kgf-m)F25AE 35.0 Nm (25.8 ft-lb) (3.57 kgf-m)F25AET 35.0 Nm (25.8 ft-lb) (3.57 kgf-m)F25AMH 35.0 Nm (25.8 ft-lb) (3.57

kgf-m)FT25BET 40.0 Nm (29.5 ft-lb) (4.08 kgf-m)

Engine oil drain bolt: F20AET 28.0 Nm (20.7 ft-lb) (2.86 kgf-m)F25AE 28.0 Nm (20.7 ft-lb) (2.86 kgf-m)F25AET 28.0 Nm (20.7 ft-lb) (2.86 kgf-m)F25AMH 28.0 Nm (20.7 ft-lb) (2.86 kgf-m)FT25BET 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

Engine oil filter: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

Noise and vibration level:

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

F20AET 81.9 dB(A)F25AE 81.9 dB(A)F25AET 81.9 dB(A)F25AMH 81.9 dB(A)FT25BET 81.9 dB(A)

Vibration on tiller handle (ICOMIA 38/94): F20AET Vibration on tiller handle is under 2.5 m/s

2

F25AE Vibration on tiller handle is un-der 2.5 m/s

2

F25AET Vibration on tiller handle is under 2.5 m/s

2

F25AMH Vibration on tiller handle is under 2.5 m/s

2

FT25BET Vibration on tiller handle is under 2.5 m/s

2

EMU28223

Transporting and storing outboard motor

WARNING

EWM00690

�

Leaking fuel is a fire hazard. When

Maintenance

48

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

�

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

�

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

hazard.

WARNING

EWM00700

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

motor accidentally falls.

CAUTION:

ECM00660

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

in the tilt position.

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

EMU28235

Clamp screw mounting models

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

NOTE:

Place a towel or something similar under the

outboard motor to protect it from damage.

EMU28241

Storing outboard motor

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

CAUTION:

ECM01080

�

To prevent problems which can becaused by oil entering the cylinder fromthe sump, keep the outboard motor inthe attitude shown when transporting

ZMU02831

ZMU02050

Maintenance

49

and storing it. If storing or transportingthe outboard motor on its side (not up-right), put it on a cushion after drainingthe engine oil.

�

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

�

Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

EMU28303

Procedure

EMU28332

Flushing in a test tank

CAUTION:

ECM00300

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

es.

1. Wash the outboard motor body usingfresh water. For further information, seepage 52.

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

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

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

CAUTION:

ECM00290

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

occur.

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

WARNING

EWM00090

�

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

�

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

parts while the engine is running.

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

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

1. Water surface2. Lowest water level

ZMU02051

1

2

Maintenance

50

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

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

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

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

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

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

13. Drain the fuel from the fuel tank.

NOTE:

Store the fuel tank in a dry, well-ventilated

place, not in direct sunlight.

EMU28402

Lubrication

1. Install the spark plug(s) and torque toproper specification. For information onspark plug installation, see page 58.

2. Change the gear oil. For instructions,see page 66. Inspect the oil for the pres-ence of water that indicates a leaky seal.Seal replacement should be performedby an authorized Yamaha dealer prior touse.

3. Grease all grease fittings. For further de-tails, see page 57.

NOTE:

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

oil and procedures for your engine.

EMU28431

Battery care

WARNING

EWM00330

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

�

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

�

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

Antidote (EXTERNAL):

�

SKIN - Flush with water.

�

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

Antidote (INTERNAL):

�

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

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

�

Charge batteries in a well-ventilated ar-ea.

�

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

�

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

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

Maintenance

51

Procedure1. Disconnect and remove the battery from

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

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

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

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

EMU28442

Flushing power unit

Perform this procedure right after operationfor the most thorough flushing.

CAUTION:

ECM01530

Do not perform this procedure while theengine is running. The water pump maybe damaged and severe damage from

overheating can result.

1. After shutting off the engine, unscrewthe garden hose connector from the fit-ting on the bottom cowling.

2. Screw the garden hose adapter onto agarden hose, which is connected to afresh water supply, and then connect itto the garden hose connector.

3. With the engine off, turn on the water tapand let the water flush through the cool-ing passages for about 15 minutes. Turnoff the water and disconnect the gardenhose adapter from the garden hose con-nector.

4. Reinstall the garden hose connectoronto the fitting on the bottom cowling.Tighten the connector securely.

CAUTION:

ECM00540

Do not leave the garden hose connectorloose on the bottom cowling fitting or letthe hose hang free during normal opera-

1. Fitting2. Garden hose connector3. Garden hose adapter

ZMU02819

1

2 3

Maintenance

52

tion. Water will leak out of the connectorinstead of cooling the engine, which cancause serious overheating. Be sure theconnector is tightened securely on the fit-

ting after flushing the engine.

NOTE:

�

When flushing the engine with the boat inthe water, tilting up the outboard motor un-til it is completely out of the water willachieve better results.

�

For cooling system flushing instructions,

see page 47.

EMU28450

Cleaning the outboard motor

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

NOTE:

For cooling system flushing instructions, see

page 47.

EMU28460

Checking painted surface of motor

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

EMU28478

Periodic maintenance

WARNING

EWM01071

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

mechanic.

EMU28511

Replacement parts

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

EMU34150

Severe operating conditions

Severe operating conditions involve one ormore of the following types of operation on aregular basis:

�

Operating continuously at or near maxi-mum engine speed (rpm) for many hours

�

Operating continuously at a low enginespeed (rpm) for many hours

�

Brief periods of rapid acceleration and de-celeration followed by engine shut off be-fore the engine has reached properoperating temperature

�

Frequent quick acceleration and decelera-tion

�

Frequent shifting

�

Frequently starting and stopping the en-gine(s)

�

Operation that fluctuates often betweenlight and heavy cargo loads

Outboard motors operating under any of

ZMU02832

Maintenance

53

these above conditions require more fre-quent maintenance. Yamaha recommendsthat you do this service twice as often asspecified in the maintenance chart. For ex-ample, if a particular service should be doneat 50 hours, do it instead at 25 hours. Thiswill help prevent more rapid deterioration ofengine components.

Maintenance

54

EMU34442

Maintenance chart 1NOTE:

�

Refer to the sections in this chapter for explanations of each owner-specific action.

�

The maintenance cycle on these charts assume usage of 100 hours per year and regularflushing of the cooling water passages. Maintenance frequency should be adjusted whenoperating the engine under adverse conditions such as extended trolling.

�

Disassembly or repairs may be necessary depending on the outcome of maintenancechecks.

�

Expendable or consumable parts and lubricants will lose their effectiveness over time andthrough normal usage regardless of the warranty period.

�

When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should

be flushed with clean water after each use.

The “ ” symbol indicates the check-ups which you may carry out yourself.The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

20 hours (3

months)

100 hours (1 years)

300 hours (3 years)

500 hours (5 years)

Anode(s) (external)Inspection or replace-ment as necessary

Anode(s) (cylinder head, thermostat cover)

Inspection or replace-ment as necessary

Anodes (exhaust cover, cooling water passage cover, Rectifier Regula-tor cover)

Replacement

Anode(s) (exhaust cover, cover joint)

Replacement

BatteryInspection or charging, replacement as neces-sary

Cooling water leakageInspection or replace-ment as necessary

Cowling clamp Inspection

Engine starting condi-tion/Noise

Inspection

Engine idling speed/Noise

Inspection

Engine oil Replacement

Maintenance

55

Engine Oil filter (car-tridge)

Replacement

Fuel filter (can be dis-assembled)

Inspection or replace-ment as necessary

Fuel pumpInspection or replace-ment as necessary

Fuel/oil leakage Inspection

Fuel pipeInspection or replace-ment as necessary

Fuel pipe Replacement

Gear oil Replacement

Greasing points Greasing

Impeller/water pump housing

Inspection or replace-ment as necessary

Impeller/water pump housing

Replacement

Power trim/tilt unit Inspection

Propeller/Propeller nut/Cotter pin

Inspection or replace-ment as necessary

Shift link/shift cableInspection, adjustment or replacement as nec-essary

Spark plug(s)Inspection, adjustment or replacement as nec-essary

Spark plug caps/high tention cordes

Inspection or replace-ment as necessary

Pilot water Inspection

Throttle link/Throttle cable/Throttle pick-up timing

Inspection, adjustment or replacement as nec-essary

ThermostatInspection or replace-ment as necessary

Timing beltInspection or replace-ment as necessary

Valve clearanceInspection and adjust-ment

Water inlet Inspection

Item Actions

Initial Every

20 hours (3

months)

100 hours (1 years)

300 hours (3 years)

500 hours (5 years)

Maintenance

56

EMU34450

Maintenance chart 2

EMU28910

NOTE:

When using lead or high-sulfur gasoline, inspecting valve clearance may be required more

frequently than every 500 hours.

Main switch/stop switch/choke switch

Inspection or replace-ment as necessary

Wire harness connec-tions/Wire coupler con-nections

Inspection or replace-ment as necessary

(Yamaha) Fuel tankInspection and clean-ing as necessary

Item ActionsEvery

1000 hours

Guide exhaust/exhaust manifold

Inspection or replace-ment as necessary

Timing belt Replacement

Item Actions

Initial Every

20 hours (3

months)

100 hours (1 years)

300 hours (3 years)

500 hours (5 years)

Maintenance

57

EMU28941

Greasing

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

F25AMH

ZMU02307

Maintenance

58

F20AET, F25AE, F25AET, FT25BET

EMU28953

Cleaning and adjusting spark plug

WARNING

EWM00560

When removing or installing a spark plug,be careful not to damage the insulator. Adamaged insulator could allow externalsparks, which could lead to explosion or

fire.

WARNING

EWM01550

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

engine when it has cooled down.

The spark plug is an important engine com-

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

ZMU02827

Maintenance

59

rect type.

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

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

NOTE:

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

torque-wrench.

EMU28962

Checking fuel system

WARNING

EWM00060

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

sources of ignition.

WARNING

EWM00910

Leaking fuel can result in fire or explo-sion.

�

Check for fuel leakage regularly.

�

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

the outboard unsafe to operate.

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

Standard spark plug:DPR6EA-9

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

Spark plug gap:0.8–0.9 mm (0.031–0.035 in)

Spark plug torque:18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

ZMU04969

Maintenance

60

Checkpoints

�

Fuel system parts leakage

�

Fuel line joint leakage

�

Fuel line cracks or other damage

�

Fuel connector leakage

EMU28980

Inspecting fuel filter

WARNING

EWM00310

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

�

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

�

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

�

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

�

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

�

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

hazard.

EMU29001

Cleaning fuel filter

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

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

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

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

1. Nut

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

ZMU02309

1

ZMU02079

1

4

23

Maintenance

61

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

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

EMU29041

Inspecting idling speed

WARNING

EWM00451

�

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

�

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

parts while the engine is running.

CAUTION:

ECM00490

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

used.

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

fully in neutral until it is running smooth-ly.

NOTE:

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

or other qualified mechanic.

2. Verify whether the idle speed is set tospecification. For idle speed specifica-tions, see page 45.

EMU29074

Changing engine oil

WARNING

EWM00760

�

Avoid draining the engine oil immedi-ately after stopping the engine. The oilis hot and should be handled with careto avoid burns.

�

Be sure the outboard motor is securelyfastened to the transom or a stable

stand.

CAUTION:

ECM00970

�

Do not overfill the oil, and be sure theoutboard motor is upright (not tilted)when checking and changing the en-gine oil.

�

If the oil level is above the upper levelmark, drain until the level meets thespecified capacity. Overfilling the oil

could cause leakage or damage.

CAUTION:

ECM01240

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

wise the engine will wear quickly.

NOTE:

Change the engine oil when the oil is still

warm.

1. Put the outboard motor in an upright po-sition (not tilted).

Maintenance

62

2. Prepare a suitable container that holds alarger amount than the engine oil capac-ity. Loosen and remove the drain screwwhile holding the container under thedrain hole. Then remove the oil filler cap.Let the oil drain completely. Wipe up anyspilled oil immediately.

3. Put a new gasket on the oil drain screw.Apply a light coat of oil to the gasket and

install the drain screw.

NOTE:

If a torque wrench is not available when youare installing the drain screw, finger tightenthe screw just until the gasket comes intocontact with the surface of the drain hole.Then tighten 1/4 to 1/2 turn more. Tightenthe drain screw to the correct torque with a

torque wrench as soon as possible.

4. Add the correct amount of oil through thefiller hole. Install the filler cap.

1. Drain screw

ZMU02831

ZMU02310

1

Drain screw tightening torque:F20AET 28.0 Nm (20.7 ft-lb) (2.86 kgf-m)F25AE 28.0 Nm (20.7 ft-lb) (2.86 kgf-m)F25AET 28.0 Nm (20.7 ft-lb) (2.86 kgf-m)F25AMH 28.0 Nm (20.7 ft-lb) (2.86 kgf-m)FT25BET 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

Recommended engine oil:4-stroke outboard motor oil

Engine oil quantity (excluding oil filter):F20AET 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AE 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AET 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AMH 1.7 L (1.80 US qt) (1.50 Imp.qt)FT25BET 1.9 L (2.01 US qt) (1.67 Imp.qt)

Maintenance

63

5. Start the engine and watch to make surethe low oil pressure-warning indicator (ifequipped) turns off. Make sure thatthere are no oil leaks.

CAUTION:

ECM00681

If the low oil pressure-warning indicatordoes not turn off or if there are oil leaks,stop the engine and find the cause. Con-tinued operation with a problem couldcause severe engine damage. Consultyour Yamaha dealer if the problem can-

not be located and corrected.

6. Turn off the engine and wait 3 minutes.Recheck the oil level using the dipstickto be sure the level falls between the up-per and lower marks. Fill with oil if it isbelow the lower mark, or drain to thespecified level if it is above the uppermark.

7. Dispose of used oil according to localregulations.

NOTE:

�

For more information on the disposal ofused oil, consult your Yamaha dealer.

�

Change the oil more often when operatingthe engine under adverse conditions such

as extended trolling.

EMU29112

Checking wiring and connectors

�

Check that each grounding wire is properlysecured.

�

Check that each connector is engaged se-curely.

EMU29120

Exhaust leakage

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

1. Oil filler cap

ZMU02311

1

ZMU02058

ZMU02087

Maintenance

64

EMU29130

Water leakage

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

EMU29140

Engine oil leakage

Check for oil leaks on the around the engine.

NOTE:

If any leaks are found, consult your Yamaha

dealer.

EMU34580

Checking power trim and tilt system

WARNING

EWM00431

�

Never get under the lower unit while itis tilted, even when the tilt support leveris locked. Severe injury could occur ifthe outboard motor accidentally falls.

�

Make sure no one is under the outboardmotor before performing this test. Bodyparts can be crushed between the mo-tor and the clamp bracket when the mo-

tor is trimmed or tilted.

1. Check the power trim and tilt unit for anysign of oil leaks.

2. Operate each of the power trim and tiltswitches to check that all switches work.

3. Tilt the outboard motor up and check

that the trim and tilt rod is pushed outcompletely.

4. Check that the trim and tilt rod is free ofcorrosion or other flaws.

5. Tilt the outboard motor down. Checkthat the trim and tilt rod operatessmoothly.

NOTE:

Consult your Yamaha dealer if any operation

is abnormal.

EMU32110

Checking propeller

WARNING

EWM01610

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

�

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

�

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

turning.

1. Trim and tilt rod

ZMU02828

1

Maintenance

65

Checkpoints

�

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

�

Check the propeller shaft for damage.

�

Check the splines for wear or damage.

�

Check for fish line tangled around the pro-peller shaft.

�

Check the propeller shaft oil seal for dam-age.

EMU30661

Removing propeller

EMU29196

Spline models

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

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

ZMU02814

ZMU01897

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

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

ZMU02829

6 5

4 32

1

Maintenance

66

3. Remove the propeller, washer (ifequipped), and thrust washer.

EMU30671

Installing propeller

EMU29232

Spline models

CAUTION:

ECM00340

�

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

�

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

eration and be lost.

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

2. Install the spacer (if equipped), thrustwasher, washer (if equipped), and pro-peller on the propeller shaft.

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

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

NOTE:

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

align it with the hole.

EMU29282

Changing gear oil

WARNING

EWM00800

�

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

�

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

ly falls.

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

2. Place a suitable container under thegear case.

3. Remove the gear oil drain screw andgasket.

Propeller nut tightening torque:F20AET 35.0 Nm (25.8 ft-lb) (3.57 kgf-m)F25AE 35.0 Nm (25.8 ft-lb) (3.57 kgf-m)F25AET 35.0 Nm (25.8 ft-lb) (3.57 kgf-m)F25AMH 35.0 Nm (25.8 ft-lb) (3.57 kgf-m)FT25BET 40.0 Nm (29.5 ft-lb) (4.08 kgf-m)

ZMU02063

Maintenance

67

NOTE:

�

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

�

Always use new gaskets. Do not reuse the

removed gaskets.

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

CAUTION:

ECM00710

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

pair of the lower unit seals.

NOTE:

For disposal of used oil, consult your

Yamaha dealer.

5. With the outboard motor in a vertical po-sition, and using a flexible or pressur-ized filling device, inject the gear oil into

the gear oil drain screw hole.

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

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

EMU29302

Cleaning fuel tank

WARNING

EWM00920

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

�

If you have any question about properlydoing this procedure, consult your

1. Gear oil drain screw2. Oil level plug

ZMU023231

2

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:F20AET 320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)F25AE 320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)F25AET 320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)F25AMH 320.0 cm

3

(10.82 US oz) (11.29 Imp.oz)FT25BET 430.0 cm

3

(14.54 US oz) (15.17 Imp.oz)

ZMU02065

Maintenance

68

Yamaha dealer.

�

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

�

Remove the fuel tank from the boat be-fore cleaning it. Work only outdoors inan area with good ventilation.

�

Wipe up any spilled fuel immediately.

�

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

�

Dispose of old gasoline according to lo-

cal regulations.

1. Empty the fuel tank into an approvedcontainer.

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

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

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

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

EMU29312

Inspecting and replacing anode(s)

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

CAUTION:

ECM00720

Do not paint anodes, as this would render

them ineffective.

NOTE:

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

er unit.

ZMU02066

ZMU02324

Maintenance

69

EMU29320

Checking battery (for electric start models)

WARNING

EWM00330

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

�

Avoid bodily contact with electrolytic

fluid as it can cause severe burns orpermanent eye injury.

�

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

Antidote (EXTERNAL):

�

SKIN - Flush with water.

�

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

Antidote (INTERNAL):

�

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

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

�

Charge batteries in a well-ventilated ar-ea.

�

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

�

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

CAUTION:

ECM00360

�

A poorly maintained battery will quicklydeteriorate.

�

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

used for topping up.

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

ZMU02325

ZMU02820

ZMU04178

Maintenance

70

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

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

NOTE:

Consult a Yamaha dealer when charging or

re-charging batteries.

EMU29332

Connecting the battery

WARNING

EWM00570

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

tery in the holder.

CAUTION:

ECM01122

�

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

�

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

�

Connect the red battery cable first

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

�

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

the engine.

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

EMU29370

Disconnecting the battery

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

EMU29391

Checking top cowling

CAUTION:

ECM01650

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

into the engine.

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

1. Red cable2. Black cable3. Battery

Maintenance

71

EMU29400

Coating the boat bottom

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

ZMU02068

ZMU01943

72

Trouble Recovery

EMU29425

Troubleshooting

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

Starter will not operate.

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

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

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

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

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

Engine will not start (starter operates).

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

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

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

Q. Is starting procedure incorrect?A. See page 30.

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

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

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

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

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

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

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

Engine idles irregularly or stalls.

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

Q. Is fuel system obstructed?

Trouble Recovery

73

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Warning buzzer sounds or indicatorlights.

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

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

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

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

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

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

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

Trouble Recovery

74

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

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

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

Engine power loss.

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

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

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

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

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

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

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

Q. Are weeds or other foreign matter tangled

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

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

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

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

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

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

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

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

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

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

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

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

Trouble Recovery

75

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

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

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

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

Engine vibrates excessively.

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

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

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

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

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

EMU29433

Temporary action in emergency

EMU29440

Impact damage

WARNING

EWM00870

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

trailering. Damage could make the out-

board motor unsafe to operate.

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

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

ponents for damage. Also inspect theboat for damage.

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

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

EMU29462

Replacing fuse

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

WARNING

EWM00630

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

electric system damage and a fire hazard.

Trouble Recovery

76

NOTE:

Consult your Yamaha dealer if the new fuse

immediately blows again.

EMU29512

Power trim and tilt will not operate

If the engine cannot be tilted up or down withthe power trim and tilt because of a dis-charged battery or a failure with the powertrim and tilt unit , the engine can be tiltedmanually.1. Loosen the manual valve screw by turn-

ing it clockwise until it stops.

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

EMU29533

Starter will not operate

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

WARNING

EWM01022

�

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

�

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

�

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

�

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

�

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

�

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

�

An unguarded, rotating flywheel is verydangerous. Keep loose clothing andother objects away when starting theengine. Use the emergency starter ropeonly as instructed. Do not touch the fly-

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

1. Manual valve screw

ZMU0281513

2

ZMU02816

1

Trouble Recovery

77

wheel or other moving parts when theengine is running. Do not install thestarter mechanism or top cowling afterthe engine is running.

�

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

electrical shock.

EMU30291

Emergency starting engine

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

ble from the starter after removing theclip and the screw, if the cable isequipped.

3. Remove the starter/flywheel cover afterremoving the 4 bolts. Disconnect theleads for the warning indicator.

4. Prepare the engine for starting. For fur-ther information, see page 30. Be surethe engine is in neutral and that the en-gine stop switch lanyard lock plate is at-tached to the engine stop switch. Themain switch must be “ ” (on), ifequipped.

ZMU02337

ZMU02338

ZMU02649

ZMU02026

ZMU02334

Trouble Recovery

78

5. Insert the knotted end of the emergencystarter rope into the notch in the flywheelrotor and wind the rope around the fly-wheel several turns clockwise.

6. Pull the rope slowly until resistance isfelt.

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

EMU29760

Treatment of submerged motor

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

EMU29783

Procedure

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

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

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

4. Fill the sump with the fresh engine oil.

5. Feed engine fogging oil or engine oilthrough the carburetor(s) and spark plugholes while cranking the engine with themanual starter or emergency starterrope.

6. Take the outboard motor to a Yamahadealer as soon as possible.

CAUTION:

ECM00400

Do not attempt to run the outboard motor

until it has been completely inspected.

OFF

ON

ZMU01880

ZMU02339

Engine oil capacity:F20AET 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AE 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AET 1.7 L (1.80 US qt) (1.50 Imp.qt)F25AMH 1.7 L (1.80 US qt) (1.50 Imp.qt)FT25BET 1.9 L (2.01 US qt) (1.67 Imp.qt)

YAMAHA MOTOR CO., LTD.

Printed on recycled paperPrinted in JapanApril 2007–0.5

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