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  5. Owner's Manual

Yamaha 25 Owner's Manual

Summary of 25

  • Page 1

    Printed in japan april 2009–0.1 × 1 ! Printed on recycled paper 25 owner’s manual 6l2-28199-1v u.S.A.Edition lit-18626-08-35 q read this manual carefully before operating this outboard motor. 6l2-9-1v hyoshi 09.2.5 9:54 ページ 1.

  • Page 2

    ※グレースケールで出力してください。 emu25062 zmu01690 read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold. 6l2-9-1v hyoshi 09.2.5 9:54 ページ 2.

  • Page 3

    Important manual information emu31283 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 ...

  • Page 4

    Table of contents safety information............................. 1 outboard motor safety .................... 1 propeller............................................ 1 rotating parts.................................... 1 hot parts ........................................... 1 electric shock ..........

  • Page 5

    Table of contents tilt support bar ................................ 26 cowling lock lever(s) (turn type)...... 26 installation ....................................... 27 installation ..................................... 27 mounting the outboard motor .......... 27 clamping the outboard motor .........

  • Page 6

    Table of contents emergency starting engine ............. 72 treatment of submerged motor..... 74 consumer information.................... 75 yamaha motor corporation, u.S.A. Outboard motor two year limited warranty ...... 75 important warranty information if you use your yamaha outside the usa or c...

  • Page 7

    1 safety information emu33622 outboard motor safety observe these precautions at all times. Emu36501 propeller people can be injured or killed if they come in contact with the propeller. The propeller can keep moving even when the motor is in neutral, and sharp edges of the propeller can cut even wh...

  • Page 8

    Safety information 2 death when inhaled. Symptoms include nau- sea, dizziness, and drowsiness. Keep cock- pit and cabin areas well ventilated. Avoid blocking exhaust outlets. Emu33780 modifications do not attempt to modify this outboard mo- tor. Modifications to your outboard motor may reduce safety...

  • Page 9

    Safety information 3 operate defensively at safe speeds and keep a safe distance away from people, ob- jects, and other boats. ● do not follow directly behind other boats or waterskiers. ● avoid sharp turns or other maneuvers that make it hard for others to avoid you or un- derstand where you are go...

  • Page 10

    Safety information 4 location, but all are basically the same as the international rules of the road. The rules presented in the following section are con- densed- and have been provided for your convenience only. Contact the u.S. Coast guard, the national association of state boating law adminis- t...

  • Page 11

    Safety information 5 vessel will be able to determine how best to avoid you. Give-way vessel the vessel that does not have the right-of- way has the duty to take positive and timely action to stay out of the way of the stand-on vessel. Normally, you should not cross in front of the vessel with the r...

  • Page 12

    Safety information 6 you are the give-way vessel. If the other vessel is on your port (left) side, remember that you should maintain course and direc- tion, provided the other vessel gives you the right-of-way as it should. Overtaking if you are passing another vessel, you are the “give-way” vessel....

  • Page 13

    Safety information 7 black buoys to starboard. Many bodies of water used by boaters are entirely within the boundaries of a particular state. The uniform state waterway marking system has been devised for these waters. This system uses buoys and signs with dis- tinctive shapes and colors to show reg...

  • Page 14

    Safety information 8 zmu01708.

  • Page 15

    9 general information emu25171 identification numbers record emu25183 outboard motor serial number the outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare ...

  • Page 16

    General information 10 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. Emu33831 warning...

  • Page 17

    General information 11 1 2 3 zmu05670

  • Page 18

    General information 12 emu33843 symbols the following symbols mean as follows. Notice/warning read owner’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 zmu0566...

  • Page 19

    13 specifications and requirements emu31480 specifications tip: “(al)” stated in the specification data below represents the numerical value for the alumi- num propeller installed. Likewise, “(sus)” represents the value for stainless steel propeller installed and “(pl)” for plastic propeller install...

  • Page 20

    Specifications and requirements 14 forward-neutral-reverse gear ratio: 2.08 (27/13) trim and tilt system: manual tilt propeller mark: f fuel and oil: recommended fuel: regular unleaded gasoline min. Pump octane: 86 fuel tank capacity: 25 l (6.60 us gal, 5.50 imp.Gal) recommended engine oil: yamalube...

  • Page 21

    Specifications and requirements 15 following specifications. The engine cannot be started if battery voltage is too low. Notice ecm01061 do not use a battery that does not meet the specified capacity. If a battery that does not meet specifications is used, the electric system could perform poorly or...

  • Page 22

    Specifications and requirements 16 ler for a smaller operating load and a smaller pitch propeller for a heavier load. If you carry loads that vary widely, chose the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle set...

  • Page 23

    Specifications and requirements 17 micron minimum) between your boat’s fuel tank and outboard motor when using etha- nol. Ethanol is known to allow moisture to be absorbed into boat fuel tanks and systems. Moisture in the fuel can cause corrosion of metallic fuel system components, starting and runn...

  • Page 24

    Specifications and requirements 18 plugs. Consult your yamaha dealer for details. Emu25221 emission control information emu25230 north american models this engine conforms to u.S. Environmental protection agency (epa) regulations for ma- rine si engines. See the label affixed to your engine for deta...

  • Page 25

    19 components emu2579m components diagram tip: * may not be exactly as shown; also may not be included as standard equipment on all mod- els. 25 emu25802 fuel tank if your model was equipped with a portable fuel tank, its function is as follows. Warning ewm00020 the fuel tank supplied with this engi...

  • Page 26

    Components 20 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 ...

  • Page 27

    Components 21 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 the neutral...

  • Page 28

    Components 22 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 throt...

  • Page 29

    Components 23 emu25993 engine shut-off cord (lanyard) and clip the clip must be attached to the engine shut- off switch for the engine to run. The cord 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 cord will ...

  • Page 30

    Components 24 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. Emu26080 starter button to start the engine with the electric starter, push the starter ...

  • Page 31

    Components 25 to increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. Warning 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. Emu26244 trim ...

  • Page 32

    Components 26 to provide more clearance when operating in shallow water. 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 t...

  • Page 33

    27 installation emu26902 installation the information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat and motor combination. Prop- er mounting depends in part on experience and the specific boat and motor combinatio...

  • Page 34

    Installation 28 notice ecm01631 ● check that the idle hole stays high enough to keep out water getting inside engine even if the boat is in stationary with maximum load. ● incorrect engine height or obstructions to the smooth flow of water (such as the design or condition of the boat, or ac- cessori...

  • Page 35

    Installation 29 3. Secure the clamp bracket to the transom using the bolts provided with the out- board (if packed). For details, consult your yamaha dealer. Warning! Avoid using bolts, nuts or washers other than those contained in the engine packaging. If used, they must be of at least the same qua...

  • Page 36

    30 operation emu36381 first-time operation emu30174 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 engine life. Notice: failure to follow the break-in proc...

  • Page 37

    Operation 31 emu37141 fuel level be sure you have plenty of fuel for your trip. A good rule is to use 1/3 of your fuel to get to the destination, 1/3 to return, and to keep 1/ 3 as an emergency reserve. With the boat level on a trailer or in the water, check the fuel level. For fuel filling instruct...

  • Page 38

    Operation 32 with no binding or excessive free play. ● operate the throttle levers several times to make sure there is no hesitation in their travel. Operation should be smooth over the complete range of motion, and each le- ver should return completely to the idle po- sition. ● look for loose or da...

  • Page 39

    Operation 33 emu36582 battery check that the battery is in good condition, and fully charged. Check that the battery connections are clean, secure and covered by insulating covers. The electrical contacts of the battery and cables must be clean and properly connected or the battery will not start th...

  • Page 40

    Operation 34 ture increases. 9. Tighten the filler cap securely. 10. Wipe up any spilled gasoline immediate- ly with dry rags. Dispose rags properly according to local laws or regulations. Emu27406 gasoline and oil mixing (100:1) notice ecm00811 ● avoid using any oil other than the spec- ified type....

  • Page 41

    Operation 35 tip: if using a permanently installed tank, pour the oil gradually as the gasoline is being add- ed to the tank. Emu27451 operating engine emu27466 sending fuel (portable tank) warning ewm00420 ● before starting the engine, make sure that the boat is tightly moored and that you can stee...

  • Page 42

    Operation 36 firm. During engine operation place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank. Emu27493 starting engine warning ewm01600 before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there a...

  • Page 43

    Operation 37 4. Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position. Tip: ● 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 running, the engine will...

  • Page 44

    Operation 38 emu27565 electric start models warning ewm01840 ● failure to attached engine shut-off cord could result in a runaway boat if opera- tor is ejected. Attach the engine shut- off cord to a secure place on your cloth- ing, or your arm or leg while operating. Do not attach the cord to clothi...

  • Page 45

    Operation 39 ● if the choke knob is left in the “ ” (start) position while the engine is running, the engine will run poorly or stall. 5. Push the starter button to start the mo- tor. (repeat if necessary.) 6. Immediately after the engine starts, re- lease the starter button to allow it to re- turn ...

  • Page 46

    Operation 40 be thrown forward. 1. Place the remote control lever in neutral. Tip: the start-in-gear protection device prevents 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 arm or leg. Then install the clip on the...

  • Page 47

    Operation 41 6. After the engine starts, slowly return the manual starter handle to its original po- sition before releasing it. Tip: ● when the engine is cold, it needs to be warmed up. For further information, see page 43. ● if the engine does not start on the first try, repeat the procedure. If t...

  • Page 48

    Operation 42 4. Open the throttle slightly without shifting using the neutral throttle lever or free ac- celerator. You may need to change the throttle opening slightly depending on engine temperature. After the engine starts, return the throttle to the original position. Tip: ● on remote controls e...

  • Page 49

    Operation 43 of cranking, return the main switch to “ ” (on), wait 10 seconds, then crank the engine again. [ecm00192] emu36510 checks after starting engine emu36520 cooling water check for a steady flow of water from the cooling water pilot hole. A continuous flow of water from the pilot hole shows...

  • Page 50

    Operation 44 engine and allow it to warm up. To shift out of neutral 1. Pull the neutral interlock trigger up (if equipped). 2. Move the remote control lever / gear shift lever firmly and crisply forward (for forward gear) or backward (for reverse gear) [about 35° (a detent can felt) for re- mote co...

  • Page 51

    Operation 45 2. After the engine is at idle speed in gear move the remote control lever / gear shift lever firmly and crisply into the neu- tral position. Emu31742 stopping boat warning ewm01510 ● do not use the reverse function to slow down or stop the boat as it could cause you to lose control, be...

  • Page 52

    Operation 46 2. After stopping the engine, disconnect the fuel line if there is a fuel joint on the outboard motor. 3. Tighten the air vent screw on the fuel tank cap (if equipped). 4. Remove the key if the boat will be left unattended. Tip: the engine can also be stopped by pulling the cord and rem...

  • Page 53

    Operation 47 emu27872 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. Tilt the outboard motor up, and then re- move the trim rod from the clamp brack- et. 3. Reposition the rod in the d...

  • Page 54

    Operation 48 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 m...

  • Page 55

    Operation 49 few minutes. Otherwise fuel may leak. Notice ecm00241 ● before tilting the outboard motor, stop the engine by following the procedure on page 45. Never tilt the outboard mo- tor while the engine is running. Severe damage from overheating can result. ● do not tilt up the engine by pushin...

  • Page 56

    Operation 50 lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position. For more detailed information, see page 53. [...

  • Page 57

    Operation 51 shift lever in neutral. 2. Push the tilt lock lever down to release it. 3. Pull up the shallow water lever. 4. Slightly tilt the outboard motor up. The tilt support bar will lock automatically, supporting the outboard motor in a par- tially raised position. This outboard mo- tor has 2 p...

  • Page 58

    Operation 52 6. Slightly tilt the outboard motor up until the tilt support bar automatically returns to the free position. 7. Slowly lower the outboard motor to the normal position. Emu28195 cruising in other conditions cruising in salt water after operating in salt water, flush the cooling water pa...

  • Page 59

    53 maintenance emu28227 transporting and storing outboard motor warning ewm00693 ● 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. Thi...

  • Page 60

    Maintenance 54 lowing procedures. Notice 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 p...

  • Page 61

    Maintenance 55 almost stall. 9. Remove the outboard motor from the test tank. 10. Drain the cooling water completely out of the motor. Clean the body thoroughly. 11. Install the silencer cover/cap and top cowling. Emu28402 lubrication 1. Install the spark plug(s) and torque to proper specification. ...

  • Page 62

    Maintenance 56 tems may be performed by any marine engine repair establishment or individual. All warranty repairs, however, including those to the emission control system, must be performed by an authorized yamaha marine dealership. A service manual is available for purchase through your yamaha dea...

  • Page 63

    Maintenance 57 emu34445 maintenance chart 1 tip: ● 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 regular flushing of the cooling water passages. Maintenance frequency should be adju...

  • Page 64

    Maintenance 58 fuel line(high pres- sure) inspection or replace- ment as necessary fuel line(low pres- sure) inspection fuel line(low pres- sure) inspection or replace- ment as necessary fuel pump inspection or replace- ment as necessary fuel/engine oil leakage inspection gear oil replacement greasi...

  • Page 65

    Maintenance 59 emu34451 maintenance chart 2 item actions every 1000 hours exhaust guide/exhaust manifold inspection or replace- ment as necessary.

  • Page 66

    Maintenance 60 emu28932 greasing yamaha marine grease (water resistant grease) 25 emu28956 cleaning and adjusting spark plug 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- p...

  • Page 67

    Maintenance 61 to slowly break down and erode. 1. Remove the spark plug caps from the spark plugs. 2. Remove the spark plug. If electrode ero- sion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with an- other of the correct type. Warning! When re...

  • Page 68

    Maintenance 62 flushing attachment or test tank can be used. If the boat is not equipped with a tachometer for the outboard motor, use a diagnostic ta- chometer for this procedure. Results may vary depending on whether testing is con- ducted with the flushing attachment, in a test tank, or with the ...

  • Page 69

    Maintenance 63 age. Emu30662 removing propeller emu29197 spline models 1. Straighten the cotter pin and pull it out using a pair of pliers. 2. Remove the propeller nut, washer, and spacer (if equipped). Warning! Do not use your hand to hold the propel- ler when loosening the propeller nut. [ewm01890...

  • Page 70

    Maintenance 64 fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you. ● never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor accidental- ly falls. 1...

  • Page 71

    Maintenance 65 drain 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 properly doing this procedure, consult your yamaha dealer. ● keep away from sparks, cigarettes, flames, or other sourc...

  • Page 72

    Maintenance 66 emu29322 checking battery (for electric start models) warning ewm01900 battery electrolytic fluid is poisonous and caustic, and batteries generate ex- plosive hydrogen gas. When working near the battery: ● wear protective eye gear and rubber gloves. ● do not smoke or bring any other s...

  • Page 73

    Maintenance 67 ative (-) terminal. 3. The electrical contacts of the battery and cables must be clean and properly con- nected, or the battery will not start the engine. Emu29371 disconnecting the battery 1. Turn off the battery cut-off switch (if equipped) and main switch. Notice: if they are left ...

  • Page 74

    68 trouble recovery emu29427 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 ...

  • Page 75

    Trouble recovery 69 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 servic...

  • Page 76

    Trouble recovery 70 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? ...

  • Page 77

    Trouble recovery 71 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...

  • Page 78

    Trouble recovery 72 consult your yamaha dealer if the new fuse immediately blows again. Emu29533 starter will not operate if the starter mechanism does not operate (the engine cannot be cranked with the start- er), the engine can be started with an emer- gency starter rope. Warning ewm01022 ● use th...

  • Page 79

    Trouble recovery 73 3. Remove the starter/flywheel cover after removing the bolt(s). 4. Prepare the engine for starting. For fur- ther information, see page 36. Be sure the engine is in neutral and that the clip is attached to the engine shut-off switch. The main switch must be “ ” (on), if equipped...

  • Page 80

    Trouble recovery 74 and start the engine. Repeat if neces- sary. Emu33501 treatment of submerged motor if the outboard motor is submerged, immedi- ately take it to a yamaha dealer. Otherwise some corrosion may begin almost immedi- ately. Notice: do not attempt to run the outboard motor until it has ...

  • Page 81

    75 consumer information emu29820 yamaha motor corporation, u.S.A. Outboard motor two year limited warranty.

  • Page 82

    Consumer information 76.

  • Page 83

    Consumer information 77.

  • Page 84

    Consumer information 78 emu29841 important warranty information if you use your yamaha outside the usa or canada.

  • Page 85

    ※グレースケールで出力してください。 emu25062 zmu01690 read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold. 6l2-9-1v hyoshi 09.2.5 9:54 ページ 2.

  • Page 86: Owner’S Manual

    Printed in japan april 2009–0.1 × 1 ! Printed on recycled paper 25 owner’s manual 6l2-28199-1v u.S.A.Edition lit-18626-08-35 q read this manual carefully before operating this outboard motor. 6l2-9-1v hyoshi 09.2.5 9:54 ページ 1.