Yamaha 6L2-28199-1L manual

Printed in Japan March 2004–0.2 × 1 ! Printed on recycled paper 25D OWNER’S MANUAL 6L2-28199-1L U.S.A.Edition LIT -18626-05-83 6L2-9-1L Hyoshi 3/17/04 2:45 PM Page 1[...]

EMU25060 ZMU01690 Read this owner ’ s manual carefully before operating your outboard motor. 6L2-9-1L Hyoshi 3/17/04 2:45 PM Page 2[...]

Important manual information EMU25100 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains infor- mation needed for proper operation, mainte- nance and care. A thorough understanding of these simple instructions will help you ob- tain maximum enjoyment from your new Yamaha. If you have any question about the o[...]

Table of contents General information .......................... 1 Identification numbers record ........... 1 Outboard motor serial number .......... 1 Emission control information ............ 1 North American models..................... 1 Safety information ............................ 2 Important labels ................................ 3 Warnin[...]

Table of contents Clamp screw mounting models ....... 34 Storing outboard motor ................... 34 Procedure ....................................... 35 Lubrication (except oil injection models) ......... 36 Cleaning and anticorrosion measures ...................................... 36 Cleaning the outboard motor .......... 36 Checking painted su[...]

1 General information EMU25170 Identification numbers record EMU25182 Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket or the upper part of the swivel bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from[...]

General information 2 EMU25361 Safety information ● Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation. ● Before operating the boat, read any own- er’s or operator’s manuals supplied with it and all labels. Be sure you understand each item befo[...]

General information 3 a Float Plan with a responsible person. Be sure to cancel the Float Plan when you re- turn. ● Use common sense and good judgment when boating. Know your abilities, and be sure you understand how your boat han- dles under the different boating conditions you may encounter. Operate within your limits, and the limits of your bo[...]

General information 4 control is in neutral position. EMU25500 Basic boating rules (Rules of the road) Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast Guard an[...]

General information 5 Way vessels). Both you and the meeting vessel must alter course to avoid each other. Meeting If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of- way! Both of you should alter course to avoid an accident. You should keep the other ves- sel on your [...]

General information 6 Fishing vessel right-of-way All vessels which are fishing with nets, lines or trawls are considered to be “fishing ves- sels” under the International Rules. Vessels with trolling lines are not considered fishing vessels. Fishing vessels have the right-of- way regardless of position. Fishing vessels cannot, however, impede [...]

General information 7 EMU25540 Fueling instructions W ARNING EWM00010 GASOLINE AND ITS VAPORS ARE HIGH- LY FLAMMABLE AND EXPLOSIVE! ● Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. ● Stop engine before refueling. ● Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. ● Tak[...]

General information 8 dry 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 get gasoline in your eyes, get immediate medical attention. ● If any gasoline spills onto your skin, im- mediately wash with soap and water. Change cl[...]

General information 9 NO TE: Select a propeller which will allow the engine to reach the middle or upper half of the oper- ating range at full throttle with the maximum boat load. If operating conditions such as light boat loads then allow the engine r/min to rise above the maximum recommended range, reduce the throttle setting to maintain the engi[...]

10 Basic components EMU25795 Main components NO TE: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. 25D EMU25802 Fuel tank If your model was equipped with a portable fuel tank, its function is as follows. W ARNING EWM00020 The fuel tank supplied with this engine is its dedicated fuel reservoir and must[...]

Basic components 11 be used as a fuel storage container. Com- mercial users should conform to relevant licensing 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 tank cap or on the fuel joint base. It shows the ap- proximate amount of f[...]

Basic components 12 EMU25961 Throttle indicator The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation. EMU25970 Throttle friction adjuster A friction device provides adjustable resis- t[...]

Basic components 13 could cause people and objects in the boat to be thrown forward. NO TE: The engine cannot be started with the lock plate removed. EMU26001 Engine stop button To open the ignition circuit and stop the en- gine, push this button. EMU26011 Choke knob for pull type To supply the engine with the rich fuel mix- ture required to start,[...]

Basic components 14 To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. W ARNING EWM00040 Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident. EMU26240 Trim tab with anode The trim tab should be adjus[...]

Basic components 15 EMU30530 Tilt lock mechanism The tilt lock mechanism is used to prevent the 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 in the release position. EMU26330 Tilt support bar The tilt support bar keeps the outboa[...]

Basic components 16 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. ● The overheat warning indicator will light (if equipped on the bottom cowling or the ta- chometer). ● The buzzer will sound (if equipped on the till[...]

17 Operation EMU26901 Installation CAUTION: ECM00110 Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat, or accessories such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operated conti[...]

Operation 18 motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the en- gine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduc[...]

Operation 19 board (if packed). For details, consult your Yamaha dealer. W ARNING EWM00650 Avoid using bolts, nuts or washers other than those contained in the engine pack- aging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tighten- ing, test run the engine and check their tightn[...]

Operation 20 cool. 4. Third through tenth hours: Avoid operating at full throttle for more than 5 minutes at a time. Let the engine cool between full-throttle runs. Vary en- gine speed occasionally. 5. After the first 10 hours: Operate the engine normally. Use the standard premix ratio of gasoline and oil. For details on mixing fuel and oil, see pa[...]

Operation 21 EMU27270 Ring Free Fuel Additive Gasoline is a precise blend of many different substances, each chosen to give certain characteristics. Gasoline blends have been changing in recent years in response to con- cerns about pollution and resulting emis- sions regulations. One of the most obvious changes has been the elimination of lead from[...]

Operation 22 2. Replace the fuel can cap and close tight- ly. 3. Shake the fuel can to mix the fuel thor- oughly. 4. Make sure that the oil and gasoline are mixed. 5. Pour the gasoline and oil mixture into the built-in fuel tank. CAUTION: ECM00810 ● Avoid using any oil other than the spec- ified type. ● Use a thoroughly blended fuel-oil mix- tu[...]

Operation 23 3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp. NO TE: During engine operation place the tank hori- zontally, otherwise fuel cannot be drawn from the fuel tank. 4. Squeeze the primer pump with the outlet end up until you feel it become firm. EMU27490 Starting [...]

Operation 24 3. Place the throttle grip in the “” (start) position. 4. Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position. NO TE: ● It is not necessary to use the choke when starting a warm engine. ● If the choke knob is left in the “” (start) position while the engine is runnin[...]

Operation 25 amount and try to start the engine again. If the engine still fails to start, see page 48. EMU27670 Warming up engine EMU27680 Choke start models 1. After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life. Gradually re- turn the choke knob to its home position as the engine warms [...]

Operation 26 Remote control models 1. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward. EMU27795 Reverse (manual tilt and hydro tilt models) W ARNING EWM00190 When operating in reverse, go slowly. Do not open the throttle more than half. Oth- erwise the boat could becom[...]

Operation 27 2. After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to the closed position, if equipped. 3. Disconnect the fuel line if you are using an external fuel tank. NO TE: If the outboard motor is equipped with an en- gine stop switch lanyard, the engine can also be stopped by pulli[...]

Operation 28 EMU27871 Adjusting trim angle for manual tilt models There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim an- gle. 1. Stop the engine. 2. Remove the trim rod from the clamp bracket while slightly tilting the outboard motor up. 3. Reposition the rod in the desired hole. To raise the bow ( “ trim-out ?[...]

Operation 29 the boat is up about 3 to 5 degrees. With the bow 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 can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane. Bow Up Too much [...]

Operation 30 the engine will be tilted for more than a few minutes. Otherwise fuel may leak. CAUTION: ECM00241 ● Before tilting the outboard motor, stop the engine by following the procedure on page 26. Never tilt the outboard mo- tor while the engine is running. Severe damage from overheating can result. ● Do not tilt up the engine by pushing [...]

Operation 31 port bar is automatically released. 3. Slowly tilt the engine down. EMU28060 Cruising in shallow water The outboard motor can be tilted up partially to allow operation in shallow water. EMU28071 Cruising in shallow water (manual tilt models) W ARNING EWM00710 ● Place the gear shift in neutral before us- ing the shallow water cruising[...]

Operation 32 4. Slightly tilt the outboard motor up. The tilt support bar will lock automatically, supporting the outboard motor in a par- tially raised position. NO TE: This outboard motor has 2 positions for shal- low water cruising. 5. To return the outboard motor to the nor- mal running position, place the tilt lock lever and shallow water leve[...]

33 Maintenance EMU28216 Specifications Dimension: Overall length: 936 mm (36.9 in) Overall width: 358 mm (14.1 in) Overall height S: 1068 mm (42.0 in) Transom height S: 419 mm (16.5 in) Weight (AL) S: 48.0 kg (106 lb) Performance: Full throttle operating range: 5000 – 6000 r/min Maximum output: 18.4 kW@5500 r/min (25 HP@5500 r/min) Idling speed ([...]

Maintenance 34 transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. ● USE CARE when transporting fuel tank, whether in a boat or car. ● DO NOT fill fuel container to maximum capacity. Gasoline will expand consid- erably as it warms up and can build up pressure in the fuel container. T[...]

Maintenance 35 lowing procedures. CAUTION: ECM01411 ● Do not place the outboard motor on its side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trou- ble. ● Store the outboard motor in a dry, well- ventilated place, not in direct sunlight. EMU28301 Proce[...]

Maintenance 36 when starting or during operation. ● Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. 7. Run the engine at a fast idle for 10 – 15 minutes in neutral position. 8. Just prior to turning off the engine, quick- ly spray “ Yamaha Stor-Rite Engine Fogging Oil ” (Part No. LU[...]

Maintenance 37 EMU28483 Periodic maintenance W ARNING EWM01070 Be sure to turn off the engine when you perform maintenance unless otherwise specified. If you or the owner is not famil- iar with machine servicing, this work should be done by your Yamaha dealer or other qualified mechanic. Maintenance, replacement, or repair of the emission control d[...]

Maintenance 38 EMU28521 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating condi- tions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. The “” symbol indicates the check-ups which you may carry out yourself. The[...]

Maintenance 39 EMU28931 Greasing Yamaha marine grease (Water resistant grease) 25D EMU28951 Cleaning and adjusting spark plug W ARNING EWM00560 When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire. The spark plug is an important engin[...]

Maintenance 40 ple, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically re- move and inspect the spark plug because heat and deposits will cause t[...]

Maintenance 41 Checkpoints ● Fuel system parts leakage ● Fuel line joint leakage ● Fuel line cracks or other damage ● Fuel connector leakage EMU28980 Inspecting fuel filter W ARNING EWM00310 Gasoline is highly flammable, and its va- pors are flammable and explosive. ● If you have any question about properly doing this procedure, consult y[...]

Maintenance 42 4. Reinstall the filter element in the cup. Make sure the O-ring is in position in the cup. Firmly screw the cup onto the filter housing. 5. Attach the filter assembly to the bracket so that the fuel hoses are attached to the filter assembly. 6. Run the engine and check the filter and lines for leaks. EMU29040 Inspecting idling speed[...]

Maintenance 43 EMU29171 Checking propeller W ARNING EWM00321 You could be seriously injured if the en- gine accidentally starts when you are near the propeller. ● Before inspecting, removing, or install- ing the propeller, remove the spark plug caps from the spark plugs. Also, place the shift control in neutral, turn the main switch to “” (of[...]

Maintenance 44 EMU29193 Removing the propeller 1. Straighten the cotter pin and pull it out using a pair of pliers. 2. Remove the propeller nut, washer, and spacer (if equipped). 3. Remove the propeller and thrust wash- er. EMU29230 Installing the propeller CAUTION: ECM00340 ● Be sure to install the thrust washer be- fore installing the propeller[...]

Maintenance 45 gear case. 3. Remove the gear oil drain screw. NO TE: If the magnetic gear oil drain screw equipped: remove all metal particles from the screw before installing it. 4. Remove the oil level plug to allow the oil to drain completely. CAUTION: ECM00710 Inspect the used oil after it has been drained. If the oil is milky, water is getting[...]

Maintenance 46 plosion hazard. ● Dispose of old gasoline according to lo- cal regulations. 1. Empty the fuel tank into an approved container. 2. Pour a small amount of suitable solvent into the tank. Install the cap and shake the tank. Drain the solvent completely. 3. Remove the screws holding the fuel joint assembly. Pull the assembly out of the[...]

Maintenance 47 copper or graphite. These paints can cause more rapid engine corrosion. ZMU01943[...]

48 Trouble Recovery EMU29422 Troubleshooting A problem in the fuel, compression, or igni- tion systems can cause poor starting, loss of power, 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 your model. If your outboard motor requires repair[...]

Trouble Recovery 49 Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other 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 activ[...]

Trouble Recovery 50 A. Have serviced by a Yamaha dealer. Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. 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 prope[...]

Trouble Recovery 51 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 shift lever position? A. Have serviced by a Yamaha dealer. Engine vibrates excessively. Q. Is prop[...]

Trouble Recovery 52 your arm or leg while operating. ● Do not attach the lanyard to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. ● Avoid accidentally pulling the lanyard during normal operation. Loss of en- gine power means the loss of most steering control. Also, without[...]

Trouble Recovery 53 5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms up. 6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise. 7. G[...]

Trouble Recovery 54 3. Drain the fuel from the carburetor, fuel filter, and fuel line. 4. Feed fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking with the manual starter or emergency starter rope. 5. Take the outboard motor to a Yamaha dealer as soon as possible. CAUTION: ECM00400 Do not attempt to run the outbo[...]

55 Consumer information EMU29811 Important warranty information for U.S.A. and Canada[...]

Consumer information 56[...]

Consumer information 57 EMU29820 YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY[...]

Consumer information 58[...]

Consumer information 59[...]

Consumer information 60 EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA[...]

Printed in Japan March 2004–0.2 × 1 ! Printed on recycled paper 25D OWNER’S MANUAL 6L2-28199-1L U.S.A.Edition LIT -18626-05-83 6L2-9-1L Hyoshi 3/17/04 2:45 PM Page 1[...]

YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON OUTBOARD MOTOR W ARRANTY REGISTRA TION ENREGISTREMENT DE LA GARANTIE DU MO TEUR HORS-BORD Please complete and mail this card. This information is necessary to accurately register your unit for warranty . V euillez signer ci-dessous pour attester que le montage et l’inspection ont ét?[...]

PLACE POST AGE HERE A T TN: W ARR ANTY DEP ARTMENT Warranty card 2/27/02 11:47 AM Page 2[...]