EMU25110 Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important...
Table of contents General information ......1 Water separator ......20 Tachometer ........20 Identification numbers record..1 Digital tachometer ......20 Outboard motor serial number ..1 Oil level indicators Key number........1 (three indicators) ......21 Emission control information ... 1 Oil level indicator (digital type) ..
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Table of contents Filling fuel and engine oil....40 Checking painted surface of Filling fuel for models without a motor..........59 fuel joint ........40 Periodic maintenance ....59 Ring Free Fuel Additive ....40 Replacement parts ......59 Filling oil for oil injection models..40 Maintenance chart......
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Table of contents Consumer information....83 Important warranty information for U.S.A. and Canada ..... 83 YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ..85 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ....88...
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 sto- len. 1. Key number...
General information particular label. ZMU05380 ZMU04745 EMU25262 Manufactured date label 1. Star labels location This label is attached to the clamp bracket or the swivel bracket. EMU25280 One Star—Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 ex- haust emission standards.
General information the outboard should be equal to or less than the rated horsepower capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer. Do not modify the outboard. Modifications could make the motor unfit or unsafe to use.
If nec- essary, verify the necessary replacement procedure with the dealer. Never illegally discard (dump) the product. Yamaha recommends consulting the deal- er on discarding the product. ZMU01948 Be informed about boating safety. Additional...
General information EMU25401 EMU25465 Label Caution labels EWM01260 WARNING Be sure shift control is in neutral before starting engine. (except 2HP) Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from flywheel and other rotating parts while engine is running.
General information The rules presented here in your Owner’s stances, which may render a departure from Manual are condensed, and have been pro- the above rules necessary in order to avoid vided for your convenience only. Consult immediate danger.” your local U.S. Coast Guard Auxiliary or De- In other words, follow the standard rules ex- partment of Motor Vehicles for a complete cept when a collision will occur unless both...
General information way! Both of you should alter course to avoid course and speed. You must stay out of its an accident. You should keep the other ves- way until you are clear of it. Likewise, if an- sel on your port (left) side. This rule doesn’t other vessel is passing you, you should apply if both of you will clear one another if maintain your speed and direction so that the...
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General information In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel which can navi- gate only in such a channel. Reading buoys and other markers The waters of the United states are marked for safe navigation by the lateral system of buoyage.
General information ZMU01708 EMU25540 away from sparks, flames, or other Fueling instructions sources of ignition. EWM00010 Stop engine before refueling. WARNING Refuel in a well-ventilated area. Refuel GASOLINE AND ITS VAPORS ARE HIGH- portable fuel tanks off the boat. LY FLAMMABLE AND EXPLOSIVE! Take care not to spill gasoline.
Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Yamaha does not recommended gasohol containing methanol because it can cause fuel system damage or engine performance problems.
66. on the engine. EMU25770 Yamaha outboard motors are fitted with pro- Start-in-gear protection pellers chosen to perform well over a range Yamaha outboard motors or Yamaha-ap- of applications, but there may be uses where...
EMU25799 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. Z200, LZ200 ZMU04850 1. Top cowling 15. Digital tachometer* 2. Top cowling lock lever(s) 16. Digital speedometer* 3.
Basic components ZMU05429 1. Tachometer unit (Square type)* 2. Tachometer unit (Round type)* 3. Speedometer unit (Square type)* 4. Speed & fuel meter unit (Square type)* 5. Speed & fuel meter unit (Round type)* 6. Fuel management meter (Square type)* EMU26180 Remote control The remote control lever actuates both the...
Basic components used when the remote control lever is in NOTE: the neutral position. The neutral throttle lever will operate only After the button is pushed, the throttle be- when the remote control lever is in neutral. gins to open after the remote control lever The remote control lever will operate only is moved at least 35°.
Basic components NOTE: The engine cannot be started with the lock plate removed. ZMU04646 When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting. EMU25990 Engine stop lanyard switch 1. Lanyard 2. Lock plate The lock plate must be attached to the en- gine stop switch for the engine to run.
Basic components “ ” (start) With the main switch in the “ ” (start) po- sition, the starter motor turns to start the en- gine. When the key is released, it returns automatically to the “ ” (on) position. EMU26151 Power trim and tilt switch on bottom engine cowling The power trim and tilt switch is located on...
Basic components For instructions on using the power trim and tilt switches, see pages 47 and 49. EMU26241 Trim tab with anode The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force.
Basic components ZMU03979 1. Tilt support lever EMU26391 Top cowling lock levers To remove the outboard motor top cowling, pull up the front and rear lock levers. Then lift off the cowling. When the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by moving the levers downward.
This device is used to clean the cooling wa- If the warning system has activated, stop ter passages of the motor using a garden the engine and consult a Yamaha dealer hose and tap water. immediately. NOTE:...
Basic components tarily after the main switch is turned on and will return to normal thereafter. ZMU04580 1. Oil level indicators ZMU01958 EMU26550 Oil level indicator (digital type) 1. Tachometer 2. Trim meter This indicator shows the engine oil level. If 3.
Basic components page 33. turning on the main switch to make sure all segments come on. ECM00050 CAUTION: NOTE: Do not continue to run the engine if the The speedometer displays km/h, mph, or overheat warning indicator is on. Serious knots, according to operator preference.
Basic components power trim and tilt switch. Changing the display format Pressing the “ ” (mode) button chang- EMU26620 es the display format in the following pat- Trim meter (digital type) tern: This meter shows the trim angle of your out- Total hours→Trip hours→Display off board motor.
When all segments are showing, the fuel tank is full. ECM00860 CAUTION: The Yamaha fuel tank sensor differs from conventional sensors. Incorrectly setting the selector switch on the gauge will give false readings. Consult your Yamaha dealer on how to correctly set the selec-...
Get back to the port soon if a warning de- to normal operation. Watch the gauge when vice has activated. For charging the bat- turning on the main switch to make sure all tery, consult your Yamaha dealer. segments come on. EMU26750 Fuel flow meter...
Basic components port and starboard engines. NOTE: The fuel flow meter displays gallons/hour or liters/hour according to operator prefer- ence. Select the desired unit of measure- ment by setting the selector switch on the back of the gauge during installation. ZMU01751 EMU26770 Fuel economy...
(winter or summer fuel and amount of additives). The Yamaha digital speedometer and fuel management meter calculates speed, miles traveled, and fuel economy by water movement at the stern of the boat. This...
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If optional sensors are connected to the unit, cooling water pressure display will be available. For the optional sensor, consult your Yamaha dealer. The ta- chometer unit is available in round or square types. Check your tachometer unit type.
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If the buzzer sounds and the wa- level warning device has activated. Seri- ter separator warning indicator blinks, con- ous engine damage will occur. sult your Yamaha dealer immediately. Overheat warning NOTE: If the engine temperature rises too high while To stop the buzzer, press the “...
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Basic components ous engine damage will occur. soon and consult a Yamaha dealer immedi- Do not continue to operate the engine if ately. a warning device has activated. Con- sult your Yamaha dealer if the problem cannot be located and corrected.
NOTE: available. For the optional sensor, consult The speedometer unit shows various kinds your Yamaha dealer. of information according to the setting made using the “ ” (set) and “ ” (mode) but- tons.
CAUTION: Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem can- not be located and corrected. EMU26824 Overheat warning (twin engines) This engine has an overheat warning device.
Basic components on the engine not affected by overheating, turn off the main switch of the engine over- heating. EMU26846 Oil level warning and oil filter clogging warning Oil injection models This engine has an oil level warning system. If the oil level falls below the lower limit, the warning system will activate.
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Basic components ZMU03025 ZMU01952 1. Oil filter START START ZMU04584 If the warning system has been activated, stop the engine and check for the cause. NOTE: The warning for oil filter clogging is similar to the warnings for low oil level and overheat- ing.
Operation EMU26901 specific boat and motor combination. Installation EWM00830 ECM00110 WARNING CAUTION: Improper mounting of the outboard mo- Incorrect engine height or obstructions tor could result in hazardous conditions to smooth water flow (such as the design such as poor handling, loss of control, or or condition of the boat, or accessories fire hazards.
Test runs at different heights can help deter- mine the optimum mounting height. Con- sult your Yamaha dealer boat manufacturer for further information on de- termining the proper mounting height. For instructions on setting the trim angle of the outboard motor, see page 47.
Next 50 minutes: Check fuel line connections to be sure they Do not exceed half throttle (approxi- are tight (if equipped Yamaha fuel tank or mately 3000 r/min). Vary engine speed boat tank). occasionally. If you have an easy-plan-...
Operation blinks, consult your Yamaha dealer imme- your Yamaha dealer. diately. ECM00560 CAUTION: EMU27120 Be sure to take the above steps when Check to be sure you have plenty of oil for operating the engine after a long period your trip.
While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free Fuel Addi- tive has repeatedly proven its ability to clean combustion deposits from inside the engine, ZMU03989...
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Imp gal) can be added, and the bottom oil level line indicates approximately 3.8 L (1 US gal, 0.8 Imp gal) can be added. Turn on the main switch. The Yamaha oil injection system will automatically feed oil from the remote oil tank to the engine oil tank.
Operation EMU27321 Oil level indicator operation The various functions of the oil level system are as follows: EMU27381 Oil level indicator Electric start models Oil level warning Oil level warning Engine oil Remote oil indicator indicator (analog Remarks tank tank (digital tachometer) tachometer)
Operation EMU27450 Operating engine EMU27482 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. 1.
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Operation START START ZMU04588 ZMU04589 Attach the engine stop switch lanyard to Turn the main switch to “ ” (on). a secure place on your clothing, or your NOTE: arm or leg. Then install the lock plate on Dual engine users: When the main switch is the other end of the lanyard into the en- turned on, the buzzer operates for a few sec- gine stop switch.
ZMU04590 hole is blocked. Consult your Yamaha Immediately after the engine starts, re- dealer if the problem cannot be located lease the main switch to return it to “...
Operation you. EMU27785 Reverse (automatic reverse lock and ECM00220 power trim and tilt models) CAUTION: EWM00190 To change the boat direction or shifting WARNING position from forward to reverse or vice- When operating in reverse, go slowly. Do versa, first close the throttle so that the not open the throttle more than half.
Operation EMU27820 switch to “ ” (off). Stopping engine EMU27861 Before stopping the engine, first let it cool off Trimming outboard motor for a few minutes at idle or low speed. Stop- The trim angle of the outboard motor helps ping the engine immediately after operating determine the position of the bow of the boat at high speed is not recommended.
Operation not adjust the trim angle with this switch while the boat is moving. Adjust the outboard motor trim angle using the power trim and tilt switch. 1. Power trim and tilt switch ZMU04718 1. Trim operating angle EMU27882 Adjusting trim angle Power trim and tilt models ZMU04601 EWM00751...
Operation To raise the bow (trim-out), press the switch “ ” (up). To lower the bow (trim-in), press the switch “ ” (down). Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.
Operation salt corrosion. EWM00220 WARNING 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. EWM00250 ZMU04588 WARNING Disconnect the fuel line from the out- Leaking fuel is a fire hazard.
Operation from marine growth and corrosion which could damage the power trim and tilt mechanism. ZMU03995 Push the tilt support knob into the clamp bracket or pull the tilt support lever to- ZMU03997 ward you to support the engine. EMU28055 Procedure for tilting down (power trim and tilt models / power tilt models)
Operation to allow operation in shallow water. EWM00660 WARNING Place the gear shift in neutral before setting up for shallow water cruising. Return the outboard motor to its normal position as soon as the boat is back in deeper water. ECM00260 ZMU01936 CAUTION:...
For cooling system flushing instructions, see page 55. Cruising in turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (not available for some models) if you use the outboard motor in turbid or muddy water conditions.
Maintenance EMU31480 Spark plug gap: Specifications 1.5–1.6 mm (0.059–0.063 in) NOTE: Control system: Remote control “(AL)” stated in the specification data below Starting system: represents the numerical value for the alumi- Electric num propeller installed. Starting carburetion system: Likewise, “(SUS)” represents the value for Electronic fuel injection stainless steel propeller installed and “(PL)”...
Spark plug: sition using a motor support device such as 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) a transom saver bar. Consult your Yamaha Propeller nut: dealer for further details. 55.0 Nm (40.6 ft-lb) (5.61 kgf-m)
12-00) to each gallon of fuel. NOTE: Cooling system flushing is essential to The use of “Yamaha Fuel Conditioner and prevent the cooling system from clog- Stabilizer” eliminates the need to drain the ging up with salt, sand, or dirt. In addi- fuel system.
Install the top cowling and propeller. 10. Drain the cooling water completely out Wax the cowling with a non-abrasive of the motor. Clean the body thoroughly. wax such as “Yamaha Silicone Wax” NOTE: (Part No. ACC-11000-15-02). A flushing attachment is available from your...
Maintenance on.) DO NOT SMOKE when charging or han- dling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN. Batteries vary among manufacturers. There- fore the following procedures may not al- ways apply. Consult your battery manufacturer’s instructions. Procedure Disconnect and remove the battery from the boat.
When flushing the engine with the boat in iar with machine servicing, this work the water, tilting up the outboard motor un- should be done by your Yamaha dealer or til it is completely out of the water will other qualified mechanic.
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer. Initial Every 50 hours Item...
Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) Z200, LZ200 ZMU04724 sparks, which could lead to explosion or EMU28952 Cleaning and adjusting spark plug fire. EWM00560 The spark plug is an important engine com- WARNING ponent and is easy to inspect. The condition...
ZMU01892 Check the fuel lines for leaks, crack, or mal- 1. Spark plug gap function. If a problem is found, your Yamaha 2. Spark plug I.D. mark (NGK) dealer or other qualified mechanic should re- pair it immediately.
There is a water trap at the bottom of the en- Fuel line joint leakage gine oil tank. If water or foreign matter is vis- Fuel line cracks or other damage ible in this trap, consult your Yamaha dealer. Fuel connector leakage EMU29041 Inspecting idling speed...
Maintenance Check that each connector is engaged se- curely. ZMU03458 1. Tilt rod ZMU04007 2. Trim rods EMU29120 Exhaust leakage Use the tilt support lever to lock the mo- Start the engine and check that no exhaust tor in the up position. Operate the tilt leaks from the joints between the exhaust down switch briefly so the motor is sup- cover, cylinder head, and body cylinder.
Unlock the tilt sup- port lever. ZMU01896 ZMU03460 Tilt the outboard motor down. Check that the tilt rod and trim rods operate smoothly. NOTE: Consult your Yamaha dealer if any operation is abnormal. EMU29171 Checking propeller ZMU01897 EWM00321 Checkpoints WARNING...
Remove the propeller nut, washer, and the propeller could come off during op- spacer (if equipped). eration and be lost. Apply Yamaha marine grease or a cor- rosion resistant grease to the propeller shaft. Install the thrust washer and propeller on the propeller shaft.
Severe injury could into the gear case which can cause gear occur if the outboard motor accidental- damage. Consult a Yamaha dealer for re- ly falls. pair of the lower unit seals. Tilt the outboard motor so that the gear...
Maintenance the gear oil drain screw hole. anodes on equipped models. Consult a Yamaha dealer for inspection and replace- Recommended gear oil: ment of internal anodes attached to the pow- Hypoid gear oil SAE#90 er unit. Gear oil quantity: LZ200TR 870.0 cm (29.41 US oz)
KEEP BATTERIES AND ELECTROLYTIC NOTE: FLUID OUT OF REACH OF CHILDREN. Consult a Yamaha dealer when charging or re-charging batteries. ECM00360 CAUTION: EMU29351 A poorly maintained battery will quickly Connecting the Battery deteriorate.
6. Power for accessories 7. Small red lead for accessory battery charg- ing (optional part) NOTE: If a battery selector switch is desired, consult your YAMAHA dealer about correct wiring. 1. Red cable EMU29370 2. Black cable Disconnecting the battery 3.
Maintenance ZMU04679 EMU29400 Coating the boat bottom A clean hull improves boat performance. The boat bottom should be kept as clean of ma- rine growth as possible. If necessary, the boat bottom can be coated with an anti-foul- ing paint approved for your area to inhibit marine growth.
Q. Has fuel pump malfunctioned? If your outboard motor requires repair, bring A. Have serviced by a Yamaha dealer. it to your Yamaha dealer. If the engine trouble warning indicator is Q. Are spark plug(s) fouled or of incorrect flashing, consult your Yamaha dealer.
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Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Is fuel joint connection incorrect? A.
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Trouble Recovery A. Have serviced by a Yamaha dealer. Q. Are weeds or other foreign matter tangled on gear housing? Q. Is load on boat improperly distributed? A. Remove foreign matter and clean lower A. Distribute load to place boat on an even unit.
ECM00370 Q. Is steering pivot loose or damaged? CAUTION: A. Tighten or have serviced by a Yamaha If the boat is operated with one engine in dealer. the water but not running, water may run...
1. Fuse puller main fuse has blown charging capabili- NOTE: ty will be insufficient, and the engine will not start. Consult your Yamaha dealer if the new fuse immediately blows again. EMU29522 Power trim and tilt / power tilt will not operate...
Trouble Recovery ZMU05018 1. Water separator warning indicator 1. Manual valve screw Stop the engine. Put the engine in the desired position, Remove the top cowling. then tighten the manual valve screw by Disconnect the water detection switch turning it clockwise. coupler.
Trouble Recovery mains off. NOTE: Have a Yamaha dealer inspect the outboard motor after returning to port. EMU29541 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 manually with ZMU05501 an emergency starter rope.
Trouble Recovery boat to be thrown forward. Make sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure someone. An unguarded, rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the engine.
Trouble Recovery gine is running. ON START ZMU01906 ZMU04444 Lift the emergency switch to pump re- serve oil into the engine oil tank from the EMU29670 remote oil tank. Engine fails to operate EMU29741 Low oil level warning activates If the oil level is allowed to drop too low, the red segment will appear on the oil level indi- cator, the buzzer will sound, and engine speed will be limited to about 2000 r/min.
Treatment of submerged motor while cranking with the emergency start- If the outboard motor is submerged, immedi- er rope. ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi- ately. If you cannot immediately take the outboard...
Consumer information EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA...
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Printed in Japan May 2006–0.2 × 1 ! Printed on recycled paper...
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(A l’usage du concessionnaire) MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation) YAMAHA DEALER NUMBER NO. DU CONCESSIONNAIRE YAMAHA DEALER NAME YAMAHA MOTOR CO., LTD. NOM DU MADE IN JAPAN CONCESSIONNAIRE PAYS D'ORIGINE JAPON USAGE...
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PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT...