F2.5D OWNER’S MANUAL YAMAHA MOTOR CORPORATION, USA Printed in France January 2004–0.3 × 1 CR U.S.A.
ZMU01690 Read this owner’s manual carefully before operating your outboard motor.
U69M12E0.book Page 1 Monday, June 21, 2004 10:31 AM Important manual information EMU25100 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.
U69M12E0.book Page 1 Monday, June 21, 2004 10:31 AM Table of contents General information ...................... 1 Identification numbers record ...... 1 Operation ..................................... 17 Installation................................. 17 Outboard motor serial number ....... 1 Mounting the outboard motor ....... 17 Clamping the outboard motor ....... 18 Emission control information ....... 1 North American models.................. 1 Star labels ......................................
U69M12E0.book Page 2 Monday, June 21, 2004 10:31 AM Table of contents Cleaning and anticorrosion measures .................................. 33 Cleaning the outboard motor........ 33 Checking painted surface of motor ........................ 34 Periodic maintenance................ 34 Replacement parts ....................... Maintenance chart........................ Greasing....................................... Cleaning and adjusting spark plug ................................. Checking fuel system ....
U69M12E0.book Page 1 Monday, June 21, 2004 10:31 AM 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 your Yamaha dealer or for reference in case your outboard motor is stolen.
U69M12E0.book Page 2 Monday, June 21, 2004 10:31 AM General information Manufactured: ZMU01702 ZMU04346 EMU25272 EMU25290 Star labels Two Stars—Very Low Emission The two-star label identifies engines that meet the Air Resources Board’s 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low-Emission engines. Your outboard motor is labeled with a California Air Resources Board (CARB) star label. See below for a description of your particular label.
U69M12E0.book Page 3 Monday, June 21, 2004 10:31 AM General information ● ZMU01704 ● EMU25360 Safety information ● ● ● ● ● ● 3 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 owner’s or operator’s manuals supplied with it and all labels. Be sure you understand each item before operating. Do not overpower the boat with this outboard motor.
U69M12E0.book Page 4 Monday, June 21, 2004 10:31 AM General information Always watch carefully for swimmers during 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 many organizations, including the following: United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S.
U69M12E0.book Page 5 Monday, June 21, 2004 10:31 AM General information EMU25464 Caution labels Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the Road. The rules presented here in your Owner’s Manual are condensed, and have been provided for your convenience only. Consult your local U.S. Coast Guard Auxiliary or Department of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat.
U69M12E0.book Page 6 Monday, June 21, 2004 10:31 AM General information “In obeying and construing these rules due regard shall be had to all dangers of navigation and collision, and to any special circumstances, which may render a departure from the above rules necessary in order to avoid immediate danger.” In other words, follow the standard rules except when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become “Give-Way” vessels.
U69M12E0.book Page 7 Monday, June 21, 2004 10:31 AM General information Overtaking If you are passing another vessel, you are the “Give-Way” vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.
U69M12E0.book Page 8 Monday, June 21, 2004 10:31 AM General information ZMU01708 EMU25540 Fueling instructions ● EWM00010 WARNING GASOLINE AND ITS VAPORS ARE HIGHLY 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.
U69M12E0.book Page 9 Monday, June 21, 2004 10:31 AM General information ● ● ● ● ● ● Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Do not overfill the fuel tank. Tighten the filler cap securely after refueling. 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, immediately wash with soap and water. Change clothing if gasoline spills on it.
U69M12E0.book Page 10 Monday, June 21, 2004 10:31 AM General information speed is too high or too low for good engine performance, this will have an adverse effect on the engine. Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct engine speed to be maintained.
U69M12E0.book Page 11 Monday, June 21, 2004 10:31 AM Basic components EMU25795 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. 1. Top cowling 2. Top cowling lock lever(s) 3. Carrying handle 4. Steering friction screw 5. Anti-cavitation plate 6. Propeller 7. Cooling water inlet 8. Trim rod 9. Clamp bracket 10.Tiller handle 11.Air vent screw 12.Fuel tank cap 13.Manual starter handle 14.Engine stop button/Engine stop lanyard switch 15.
U69M12E0.book Page 12 Monday, June 21, 2004 10:31 AM Basic components 1. Fuel tank cap 2. Air vent screw EMU25850 Fuel tank cap This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise. 1. Close position EMU25891 Open With the lever/knob in this position, fuel flows to the carburetor. Normal running is done with the lever/knob in this position. EMU25860 Air vent screw This screw is on the fuel tank cap.
U69M12E0.book Page 13 Monday, June 21, 2004 10:31 AM Basic components EMU25930 Gear shift lever Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead. 1. Throttle indicator EMU25970 Throttle friction adjuster 1. Forward “ ” 2. Neutral “ ” EMU25941 Throttle grip The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.
U69M12E0.book Page 14 Monday, June 21, 2004 10:31 AM Basic components EMU25990 EMU26001 Engine stop lanyard switch Engine stop button The lock plate must be attached to the engine 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 to the engine. This will prevent the boat from running away under power.
U69M12E0.book Page 15 Monday, June 21, 2004 10:31 AM Basic components EMU26121 EMU30200 Steering friction adjuster Tilt support lever for manual tilt model A friction device provides adjustable resistance to the steering mechanism, and can be set according to operator preference. An adjusting screw or bolt is located on the swivel bracket. To keep the outboard motor in the tilted up position, lock the tilt support lever to the clamp bracket.
U69M12E0.book Page 16 Monday, June 21, 2004 10:31 AM Basic components EMU26450 Carrying handle A carrying handle is provided on the rear of the outboard motor. It enables you to carry the outboard motor easily with one hand.
U69M12E0.book Page 17 Monday, June 21, 2004 10:31 AM Operation EMU26901 EWM00830 Installation ECM00110 CAUTION: 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 continuously in the presence of airborne water spray.
U69M12E0.book Page 18 Monday, June 21, 2004 10:31 AM Operation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in.) below it.
U69M12E0.book Page 19 Monday, June 21, 2004 10:31 AM Operation EWM00650 EMU27101 Preoperation checks 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 quality of material and strength and must be tightened securely. After tightening, test run the engine and check their tightness.
U69M12E0.book Page 20 Monday, June 21, 2004 10:31 AM Operation EMU30212 Checking the engine oil level 1. 2. Put the outboard motor in an upright position (not tilted). Check the oil level using the oil level check window to be sure the level falls between the upper and lower marks. Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark. 1. Oil level check window 1. Lower level mark 2. Upper level mark EMU27433 Filling fuel EWM00060 2. 3.
U69M12E0.book Page 21 Monday, June 21, 2004 10:31 AM Operation EMU27450 Operating engine EMU27472 Feeding fuel EWM00420 WARNING ● ● ● Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you. When the air vent screw is loosened, gasoline vapor will be released. Gasoline is highly flammable, and its vapors are flammable and explosive.
U69M12E0.book Page 22 Monday, June 21, 2004 10:31 AM Operation EWM00120 WARNING ● ● ● 3. Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating. Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard where it could become entangled, preventing it from functioning. Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control.
U69M12E0.book Page 23 Monday, June 21, 2004 10:31 AM Operation ● 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, open the throttle a same amount and try to start the engine again. If the engine still fails to start, see page 44. blocked. Consult your Yamaha dealer if the problem cannot be located and corrected.
U69M12E0.book Page 24 Monday, June 21, 2004 10:31 AM Operation 2. Move the gear shift lever quickly and firmly from neutral to forward. Remote control models Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward. EMU27810 Reverse EWM00190 WARNING When operating in reverse, go slowly. Do not open the throttle more than half. Otherwise the boat could become unstable, which could result in loss of control and an accident. 1.
U69M12E0.book Page 25 Monday, June 21, 2004 10:31 AM Operation the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle. 2. 3. 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. Disconnect the fuel line if you are using an external fuel tank.
U69M12E0.book Page 26 Monday, June 21, 2004 10:31 AM Operation bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane. 1. Trim rod 3. Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom.
U69M12E0.book Page 27 Monday, June 21, 2004 10:31 AM Operation also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making operation difficult and dangerous. EWM00220 WARNING Be sure all people are clear of the outboard motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket. EWM00230 WARNING Leaking fuel is a fire hazard.
U69M12E0.book Page 28 Monday, June 21, 2004 10:31 AM Operation 7. 2. 3. 4. On full-pivot system models, tighten the steering friction adjuster by turning it clockwise to prevent the motor from turning freely. Tighten the air vent screw. On models equipped with a fuel joint, disconnect the fuel line from the outboard motor. Close the fuel cock. Tilt support lever equipped models: Hold the rear handle and tilt the engine up fully until the tilt support lever automatically locks.
U69M12E0.book Page 29 Monday, June 21, 2004 10:31 AM Operation 4. Loosen the steering friction adjuster by turning it counterclockwise, and adjust the steering friction according to operator preference. EWM00720 WARNING If there is too much resistance it could be difficult to steer, which could result in an accident.
U69M12E0.book Page 30 Monday, June 21, 2004 10:31 AM Maintenance Trim and tilt system: Manual tilt Propeller mark: BS EMU28213 Specifications Dimension: Overall length: 623 mm (24.5 in) Overall width: 345 mm (13.6 in) Overall height S: 1021 mm (40.2 in) Transom height S: 432 mm (17.0 in) Weight (AL) S: 17.0 kg (37 lb) Fuel and oil: Recommended fuel: Unleaded regular gasoline Min. pump octane: 86 Fuel tank capacity: 0.90 L (0.238 US gal) (0.1980 Imp.
U69M12E0.book Page 31 Monday, June 21, 2004 10:31 AM Maintenance pressure in the fuel container. This can cause fuel leakage and a potential fire hazard. EWM00700 WARNING Never get under the lower unit while it is tilted, even if a motor support bar is used. Severe injury could occur if the outboard motor accidentally falls. ECM00660 CAUTION: Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall.
U69M12E0.book Page 32 Monday, June 21, 2004 10:31 AM Maintenance It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the following procedures. 4. Install the outboard motor on the test tank. ECM01080 CAUTION: ● ● ● To prevent problems which can be caused by oil entering the cylinder from the sump, keep the outboard motor in the attitude shown when transporting and storing it.
U69M12E0.book Page 33 Monday, June 21, 2004 10:31 AM Maintenance EWM00090 WARNING ● ● Do not touch or remove electrical parts 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, quickly spray “Yamaha Stor-Rite Engine Fogging Oil” (Part No.
U69M12E0.book Page 34 Monday, June 21, 2004 10:31 AM Maintenance EMU28460 Checking painted surface of motor Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer. EMU28483 Periodic maintenance EWM01070 WARNING Be sure to turn off the engine when you perform maintenance unless otherwise specified.
U69M12E0.book Page 35 Monday, June 21, 2004 10:31 AM Maintenance EMU28521 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating conditions, 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 “ ” symbol indicates work to be carried out by your Yamaha dealer.
U69M12E0.book Page 36 Monday, June 21, 2004 10:31 AM Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) EMU28950 Cleaning and adjusting spark plug EWM00560 WARNING When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire. The spark plug is an important engine component and is easy to inspect.
U69M12E0.book Page 37 Monday, June 21, 2004 10:31 AM Maintenance Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification if necessary. EWM00910 WARNING Leaking fuel can result in fire or explosion. ● Check for fuel leakage regularly. ● If any fuel leakage is found, the fuel system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate. Check the fuel lines for leaks, crack, or malfunction.
U69M12E0.book Page 38 Monday, June 21, 2004 10:31 AM Maintenance start position during warm-up. The boat could unexpectedly start to move, which could result in an accident. ECM00490 CAUTION: This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used. A diagnostic tachometer should be used for this procedure.
U69M12E0.book Page 39 Monday, June 21, 2004 10:31 AM Maintenance ECM00680 CAUTION: If the low oil pressure warning indicator does not turn off or if there are oil leaks, stop the engine and find the cause. Continued operation with a problem could cause severe engine damage. Consult your Yamaha dealer if the problem cannot be located and corrected. 1. Drain screw 3. 6. Turn off the engine and wait 3 minutes.
U69M12E0.book Page 40 Monday, June 21, 2004 10:31 AM Maintenance EMU29120 Exhaust leakage Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head, and body cylinder. EMU29130 Water leakage Start the engine and check that no water leaks from the joints between the exhaust cover, 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.
U69M12E0.book Page 41 Monday, June 21, 2004 10:31 AM Maintenance EMU29193 Removing the propeller 1. Straighten the cotter pin and pull it out using a pair of pliers. Remove the propeller nut, washer, and spacer (if equipped). 2. 1. 2. 3. 4. 5. 3. Cotter pin Propeller nut Washer Propeller Thrust washer Remove the propeller and thrust washer.
U69M12E0.book Page 42 Monday, June 21, 2004 10:31 AM Maintenance 1. Gear oil drain screw 2. Oil level plug NOTE: 6. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. Insert and tighten the gear oil drain screw. If the magnetic gear oil drain screw equipped: remove all metal particles from the screw before installing it. 7. 4. Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically.
U69M12E0.book Page 43 Monday, June 21, 2004 10:31 AM Maintenance EMU29390 Checking top cowling Check the fitting of the top cowling by pushing it with both hands. If it is loose have it repaired by your Yamaha dealer. EMU29400 Coating the boat bottom A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth.
U69M12E0.book Page 44 Monday, June 21, 2004 10:31 AM Trouble Recovery EMU29422 Troubleshooting A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. This section describes 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, bring it to your Yamaha dealer. If the engine trouble warning indicator is flashing, consult your Yamaha dealer.
U69M12E0.book Page 45 Monday, June 21, 2004 10:31 AM Trouble Recovery 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 activated? A. Find and correct cause of warning. Q. Is spark plug gap incorrect? A. Inspect and adjust as specified. Q.
U69M12E0.book Page 46 Monday, June 21, 2004 10:31 AM Trouble Recovery Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. A. Remove foreign matter and clean lower unit. Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer. Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is there excess water in fuel filter cup? A. Drain filter cup. Q. Is fuel filter clogged? A.
U69M12E0.book Page 47 Monday, June 21, 2004 10:31 AM Trouble Recovery A. Inspect spark plug and replace it with recommended type. Q. Is high pressure fuel pump drive belt broken? 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 propeller damaged? A. Have propeller repaired or replaced. 1. 2. 3. Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer. 4. Q.
U69M12E0.book Page 48 Monday, June 21, 2004 10:31 AM Trouble Recovery ● ● ● ● ● 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 engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
U69M12E0.book Page 49 Monday, June 21, 2004 10:31 AM Trouble Recovery 7. Remove the starter case by pulling it towards you. 8. Install the fuel tank bracket by installing the bolts. 10. Prepare the engine for starting; see page 21. Be sure the engine is in neutral and that the engine stop switch lanyard lock plate is attached to the engine stop switch. 11. Turn the lever on the carburetor to operate the choke system when the engine is cold.
U69M12E0.book Page 50 Monday, June 21, 2004 10:31 AM Trouble Recovery 15. Install the top cowling. 4. Fill the sump with the fresh engine oil. EMU29760 Treatment of submerged motor If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure below in order to minimize engine damage. Engine oil capacity: 0.4 L (0.42 US qt) (0.35 Imp.qt) 5.
U69M12E0.book Page 51 Monday, June 21, 2004 10:31 AM Consumer information EMU29811 Important warranty information for U.S.A.
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U69M12E0.book Page 53 Monday, June 21, 2004 10:31 AM Consumer information EMU29830 YAMAHA MOTOR CORPORATION, U.S.A.
U69M12E0.
U69M12E0.book Page 55 Monday, June 21, 2004 10:31 AM Consumer information EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A.
F2.5D OWNER’S MANUAL YAMAHA MOTOR CORPORATION, USA Printed in France January 2004–0.3 × 1 CR U.S.A.
Warranty card 12/6/01 7:40 PM Page 1
Warranty card 12/6/01 7:40 PM Page 2
