Yamaha EMU25060 ZMU01690 manual

F4D O WNER’S MANU AL 68D-F8199-14 U .S.A.Edition LIT -18626-05-97 68D-9-14 Hyoshi 1/28/04 10:20 AM Page 1[...]

EMU25060 ZMU01690 Read this owner ’ s manual carefully before operating your outboard motor. 68D-9-14 Hyoshi 1/28/04 10:20 AM 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 Star labels ......................................... 2 Safety information .......................... 3 Import[...]

Table of contents Lubrication (except oil injection models) ......................................... 37 Cleaning and anticorrosion measures ...................................... 37 Cleaning the outboard motor .......... 38 Checking painted surface of motor ............................................. 38 Periodic maintenance .................... [...]

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 EMU25272 Star labels Your outboard motor is labeled with a Cali- fornia Air Resources Board (CARB) star la- bel. See below for a description of your particular label. EMU25280 One Star — Low Emission The one-star label identifies engines that meet the Air Resources Board ’ s 2001 ex- haust emission standards. Engines meeti[...]

General information 3 these standards have 65% lower emissions than One Star-Low-Emission engines. EMU25360 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 ’ [...]

General information 4 watch for obstacles and other traffic. ● Always watch carefully for swimmers dur- ing the engine operation. ● Stay away from swimming areas. ● When a swimmer is in the water near you shift into neutral and shut off the engine. Be informed about boating safety. Additional publications and information can be obtained from [...]

General information 5 EMU25481 Label CAUTION: ECM01200 Store the engine only as shown. Otherwise, engine damage could result from Leaking oil. 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 [...]

General information 6 Overtaking: (you are passing or being passed by another vessel) In the following illustration, your boat is in the center. You should give the right-of-way to any vessels shown in white area (you are the Give-Way vessel). Any vessels in the shad- ed area must yield to you (they are the Give- Way vessels). Both you and the meet[...]

General information 7 If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still pro- ceed around the bend with caution. If you navigate such waters with your boat, you will need to carry a portable air horn, available from local marine supply stores. Fishing vessel right-of-wa[...]

General information 8 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 9 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 10 on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine. Yamaha outboard motors are fitted with pro- pellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would [...]

11 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. F4D 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 1 2 4 8 7 6 9 3 5 10 2 11 14 18 17 16[...]

Basic components 12 its dedicated fuel reservoir and must not be used as a fuel storage container. Com- mercial users should conform to relevant licensing or approval authority regula- tions. EMU25821 Fuel tank If your model included a fuel tank, its parts and functions are as follows. EMU25830 Fuel joint This joint is used to connect the fuel line[...]

Basic components 13 EMU25901 Open The fuel cock has two open positions, one for selecting fuel flow from the built-in fuel tank, and one for an external tank. Fuel flows to the carburetor with the lever or knob in either open position. These are the normal running positions. EMU25911 Tiller handle To change direction, move the tiller handle to the [...]

Basic components 14 EMU25941 Throttle grip The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed. 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[...]

Basic components 15 EMU25990 Engine stop lanyard switch The lock plate must be attached to the en- gine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator ’ s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition t[...]

Basic components 16 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 quickly to crank the engine. EMU26121 Steering friction adjuster A friction device provides adjustable resis- tance to the steering mechanism, and can be set acc[...]

Basic components 17 EMU26382 Top cowling lock lever (pull up type) To remove the engine top cowling, pull up the lock lever(s) and lift off the cowling. When installing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling by moving the lever(s) down- ward. EMU26450 Carrying handle A carrying handle is provided on[...]

18 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 19 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 20 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 21 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 stop switches when the outboard motor is in the water. EMU27140 Engine ● Check the engine and engine mounting. ● Look for loose or [...]

Operation 22 3. Securely close the cap after filling the tank. Wipe up any spilled fuel. NO TE: The upper fuel level mark is indicated on the built-in fuel tank. EMU27450 Operating engine EMU27472 Feeding fuel W ARNING EWM00420 ● Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions[...]

Operation 23 3. If you are using an external fuel tank, connect the fuel joints securely and squeeze the primer pump with the outlet end up until you feel it become firm (if equipped the fuel joint). EMU27490 Starting engine EMU27505 Manual start models (tiller control) 1. Place the gear shift lever in neutral. NO TE: The start-in-gear protection d[...]

Operation 24 lanyard where it could become entan- gled, 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 engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward. 3. [...]

Operation 25 NO TE: ● When the engine is cold, it needs to be warmed up. For further information, see page 25. ● If the engine does not start on the first try, repeat the procedure. If the engine fails to start after 4 or 5 tries, open the throttle a small amount (between 1/8 and 1/4) and try again. Also if the engine is warm and fails to start[...]

Operation 26 EMU27763 Forward (tiller handle and remote control models) Tiller control models 1. Place the throttle grip in the fully closed position. 2. Move the gear shift lever quickly and firmly from neutral to forward. Remote control models 1. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and fir[...]

Operation 27 until the engine comes to a complete stop. 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 lanya[...]

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 W ARNING EWM00220 Be sure all people are clear of the out- board motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket. W ARNING EWM00230 Leaking fuel is a fire hazard. Tighten the air vent screw and place the fuel cock in the closed position if the outboard motor will be [...]

Operation 31 4. Close the fuel cock. 5. Tilt support bar equipped models: Hold the rear of the top cowling or the rear handle (if equipped) with one hand and tilt the outboard motor up fully until the tilt support bar automatically locks. 6. Tilt support knob equipped models: Hold the rear of the top cowling with one hand, fully tilt the outboard m[...]

Operation 32 3. If the tilt support knob equipped: pull out it, then slowly tilt the engine down. 4. Loosen the steering friction adjuster by turning it counterclockwise, and adjust the steering friction according to opera- tor preference. W ARNING EWM00720 If there is too much resistance it could be difficult to steer, which could result in an acc[...]

Operation 33 EMU28101 Procedure 1. Place the gear shift lever in neutral and face the outboard motor forward. 2. Slightly tilt the outboard motor up until the tilt support bar automatically turns to the lock position to support the engine. 3. To lower the outboard motor to the nor- mal running position, first slightly tilt the outboard motor up. Th[...]

34 Maintenance EMU28213 Specifications Dimension: Overall length: 717 mm (28.2 in) Overall width: 361 mm (14.2 in) Overall height S: 1029 mm (40.5 in) Overall height L: 1156 mm (45.5 in) Transom height S: 435 mm (17.1 in) Transom height L: 562 mm (22.1 in) Weight (AL) S: 22.0 kg (49 lb) Weight (AL) L: 23.0 kg (51 lb) Performance: Full throttle oper[...]

Maintenance 35 Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) Engine oil drain bolt: 20.0 Nm (15.0 ft-lb) (2.0 kgf-m) EMU28222 Transporting and storing outboard motor W ARNING EWM00690 ● Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. ● USE CARE[...]

Maintenance 36 NO TE: Place a towel or something similar under the outboard motor to protect it from damage. EMU28241 Storing outboard motor When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard mot[...]

Maintenance 37 5. Fill the tank with fresh water to above the level of the anti-cavitation plate. CAUTION: ECM00300 Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the en- gine will be damaged from overheating. Before starting the engine, be sure to supply water to the cooling water pas[...]

Maintenance 38 2. Spray the outboard motor exterior with “ Yamaha Silicone Protectant ” (Part No. LUB-SILCNE-13-00). CAUTION: ECM01330 If equipped Electronic Fuel Injection: Do not spray when the engine is running. Al- so, do not spray near the silencer and ox- ygen sensor cover or into the engine. Otherwise the oxygen sensor for Elec- tronic F[...]

Maintenance 39 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 40 NO TE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. EMU28931 Greasing Yamaha marine grease (Water resistant grease) F4D EMU28950 Cleaning and adjusting spark plug W ARNING EWM00560 When removing or installing a spark plug, be careful not to damage the insulator. A [...]

Maintenance 41 The spark plug is an important engine com- ponent and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For exam- 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 [...]

Maintenance 42 Checkpoints ● Fuel system parts leakage ● Fuel line joint leakage ● Fuel line cracks or other damage ● Fuel connector leakage EMU28990 Checking fuel filter Check the fuel filter periodically. The fuel fil- ter is a one piece, disposable type. If foreign matter is found in the filter, replace it. For re- placement of the fuel [...]

Maintenance 43 or other qualified mechanic. 2. Verify whether the idle speed is set to specification. For idle speed specifica- tions, see page 34. EMU29103 Changing engine oil W ARNING EWM00760 ● Avoid draining the engine oil immedi- ately after stopping the engine. The oil is hot and should be handled with care to avoid burns. ● Be sure the o[...]

Maintenance 44 en 1/4 - 1/2 turn. Have the drain plug torqued to the correct value with a torque wrench as soon as possible. 4. Add the correct amount of oil through the filler hole. Install the filler cap. 5. Start the engine and make sure that there are no oil leaks. 6. Turn off the engine and wait 3 minutes. Recheck the oil level using the dipst[...]

Maintenance 45 Checkpoints ● Check each of the propeller blades for wear, erosion from cavitation or ventila- tion, or other damage. ● Check the propeller shaft for damage. ● Check the splines / shear pin for wear or damage. ● Check for fish line tangled around the pro- peller shaft. ● Check the propeller shaft oil seal for dam- age. NO T[...]

Maintenance 46 the propeller could come off during op- eration and be lost. 1. Apply Yamaha marine grease or a cor- rosion resistant grease to the propeller shaft. 2. Install the spacer (if equipped), thrust washer, and propeller on the propeller shaft. 3. Install the spacer (if equipped) and the washer. Tighten the propeller nut until there is no [...]

Maintenance 47 ized filling device, inject the gear oil into the gear oil drain screw hole. 6. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. 7. Insert and tighten the gear oil drain screw. EMU29302 Cleaning fuel tank W ARNING EWM00920 Gasoline is highly flammable, and its va- pors are flammable a[...]

Maintenance 48 NO TE: Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replace- ment of internal anodes attached to the pow- er unit. EMU29390 Checking top cowling 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 deal[...]

49 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 50 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 51 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 52 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 53 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 54 6. Prepare the engine for starting. For fur- ther information, see page 23. Be sure the engine is in neutral and that the en- gine stop switch lanyard lock plate is at- tached to the engine stop switch. 7. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns ar[...]

Trouble Recovery 55 filter, and fuel line. Drain the engine oil completely. 4. Fill the sump with the fresh engine oil. 5. Feed engine fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking the engine with the manual starter or emergency starter rope. 6. Take the outboard motor to a Yamaha dealer as soon as possible[...]

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

Consumer information 57[...]

Consumer information 58 EMU29830 YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY[...]

Consumer information 59[...]

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

Printed in Fr ance April 2004–0.5 × 1 ! 68D-9-14 Hyoshi 1/28/04 10:20 AM Page 4[...]

Warranty card 12/6/01 7:40 PM Page 1[...]

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