Yamaha 20D Owner's Manual
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Yamaha 20D Owner's Manual

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OWNER'S MANUAL
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Read this manual carefully before operating this
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outboard motor.
20D
25N
6L2-28199-2H-E0

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Summary of Contents for Yamaha 20D

  • Page 1 OWNER’S MANUAL Read this manual carefully before operating this outboard motor. 6L2-28199-2H-E0...
  • Page 2 EMU25052 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.

  • Page 3: Important Manual Information

    Any damage tain maximum enjoyment from your new resulting from neglect of these instructions is Yamaha. If you have any question about the not covered by warranty. operation or maintenance of your outboard Some countries have laws or regulations re- motor, please consult a Yamaha dealer.

  • Page 4: Table Of Contents

    Table of contents Safety information......1 Fuel requirements ......12 Gasoline .......... 12 Outboard motor safety ....1 Muddy or acidic water ....13 Propeller..........1 Anti-fouling paint ......13 Rotating parts........1 Motor disposal requirements..13 Hot parts ........... 1 Emergency equipment ....
  • Page 5 Table of contents Getting to know your boat ....26 Procedure........49 Checks before starting engine ..26 Lubrication........50 Fuel level......... 27 Cleaning the outboard motor... 50 Remove cowling......27 Checking painted surface of Fuel system........27 motor..........50 Controls...........

  • Page 6: Safety Information

    Safety information EMU33622 engine stops if the operator falls overboard Outboard motor safety or leaves the helm. This prevents the boat Observe these precautions at all times. from running away under power and leaving EMU36500 people stranded, or running over people or Propeller objects.

  • Page 7: Modifications

    Have an approved personal flotation device tions. Overloading or incorrect weight (PFD) on board for every occupant. Yamaha distribution can compromise the boats han- recommends that you must wear a PFD dling and lead to an accident, capsizing or whenever boating.

  • Page 8: Weather

    Safety information 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 going.

  • Page 9: General Information

    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...
  • Page 10 General information ZMU01697...

  • Page 11: Read Manuals And Labels

    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 labels If these labels are damaged or missing, contact your Yamaha dealer for replacements. ZMU06137...
  • Page 12 General information ZMU05697 EMU33912 Contents of labels EWM01671 The above warning labels mean as follows. WARNING Read Owner’s Manuals and labels. EWM01691 Wear an approved personal flotation WARNING device (PFD). Emergency starting does not have start- Attach engine shut-off cord (lanyard) to in-gear protection.
  • Page 13 General information EMU35132 Electrical hazard Symbols The following symbols mean as follows. Notice/Warning ZMU05666 ZMU05696 Read Owner’s Manual ZMU05664 Hazard caused by continuous rotation ZMU05665...

  • Page 14: Specifications And Requirements

    Specifications and requirements EMU31480 25NWC 18.4 kW@5500 r/min Specifications (25 HP@5500 r/min) TIP: Idling speed (in neutral): 750 ±50 r/min “(AL)” stated in the specification data below Engine: represents the numerical value for the alumi- Type: num propeller installed. 2-stroke L Likewise, “(SUS)”...

  • Page 15: Installation Requirements

    EMU33553 working correctly and you should dis- Installation requirements continue using the outboard. Contact EMU33563 your Yamaha dealer. Boat horsepower rating The remote control unit must be equipped EWM01560 WARNING with a start-in-gear protection device(s). This...

  • Page 16: Battery Requirements

    Fire, explosion or sparks could result. where a different propeller would be more appropriate. [EWM01820] Your Yamaha dealer can help you select the EMU36300 Multiple batteries right propeller for your boating needs. Select To connect multiple batteries, such as for...

  • Page 17: Start-In-Gear Protection

    Use a good quality gasoline that meets the minimum octane rating. If knocking or ping- ing occurs, use a different brand of gasoline or premium unleaded fuel. Yamaha re- comends that you use alcohol-free (see Gasohol) gasoline whenever possible. Recommended gasoline:...

  • Page 18: Muddy Or Acidic Water

    Specifications and requirements engine starting and running problems. EMU36351 Emergency equipment Yamaha does not recommend gasohol con- Keep the following items onboard in case taining methanol because it can cause fuel there is trouble with the motor. system damage or engine performance A tool kit with assorted screwdrivers, pli- problems.

  • Page 19: Components

    EMU2579H Components diagram TIP: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. 20D, 25N ZMU04558 1. Manual starter handle 15. Rope attachment 2. Choke knob 16. Shallow water lever 3.

  • Page 20: Fuel Joint

    Components be used as a fuel storage container. Com- mercial users should conform to relevant licensing or approval authority regula- tions. ZMU04108 1. Remote control lever 2. Neutral interlock trigger EMU26190 ZMU02284 Remote control lever 1. Fuel joint Moving the lever forward from the neutral po- 2.

  • Page 21: Neutral Interlock Trigger

    Components EMU26201 EMU26221 Neutral interlock trigger Choke switch To shift out of neutral, first pull the neutral in- To activate the choke system, press in the terlock trigger up. main switch while the key is turned to the “ ” (on) or “ ”...

  • Page 22: Throttle Grip

    Components ZMU02849 ZMU03687 1. Throttle indicator 1. Forward “ ” 2. Neutral “ ” EMU25973 3. Reverse “ ” Throttle friction adjuster A friction device provides adjustable resis- EMU25941 tance to movement of the throttle grip or the Throttle grip remote control lever, and can be set accord- The throttle grip is on the tiller handle.

  • Page 23: Engine Shut-Off Cord (Lanyard) And Clip

    Components 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 pull out the clip, stopping ignition to ZMU03689...

  • Page 24: Manual Starter Handle

    Components gine. When the key is released, it returns automatically to the “ ” (on) position. START ZMU04127 EMU26070 ZMU04567 Manual starter handle To start the engine, first gently pull the han- EMU26122 Steering friction adjuster dle out until resistance is felt. From that posi- tion, then pull the handle straight out quickly A friction device provides adjustable resis- to crank the engine.

  • Page 25: Trim Tab With Anode

    Components EMU26244 EMU26261 Trim tab with anode Trim rod (tilt pin) The position of the trim rod determines the EWM00840 WARNING minimum trim angle of the outboard motor in An improperly adjusted trim tab could relation to the transom. cause difficult steering. Always test run after the trim tab has been installed or re- placed to be sure steering is correct.

  • Page 26: Tilt Support Bar

    ZMU04112 Do not use the tilt support bar when trailering the boat. The outboard motor Use a genuine Yamaha connector. could shake loose from the tilt support Use lighting equipment only. and fall. If the motor cannot be trailered in...
  • Page 27 Components the cap on it. ECM01000 NOTICE Do not connect the 2-pin connector di- rectly to the battery terminals. Otherwise the electric system will be damaged.

  • Page 28: Installation

    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 combination. EWM01590 WARNING ZMU01760...

  • Page 29: Clamping The Outboard Motor

    Other- Test runs at different heights can help de- wise the engine could be completely lost termine the optimum mounting height. if it accidentally falls off the transom. Consult your Yamaha dealer or boat man-...
  • Page 30 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...

  • Page 31: Operation

    Operation EMU36380 plane, then immediately reduce the First-time operation throttle to 3000 r/min or less. EMU30174 Next two hours: Breaking in engine Accelerate at full throttle onto plane, Your new engine requires a period of break- then reduce engine speed to three-quar- in to allow mating surfaces of moving parts to ter throttle (approximately 4000 r/min).

  • Page 32: Fuel Level

    If any water is found in the fuel, or if a gine top cowling, release the lock lever and significant amount of debris is found, the fuel lift off the cowling. tank should be checked and cleaned by a Yamaha dealer. ZMU06092 ZMU06140 EMU36440 Fuel system...

  • Page 33: Engine Shut-Off Cord (Lanyard)

    2. Clip 3. Engine shut-off switch ZMU06117 After installing, check the fitting of the top cowling by pushing it with both hands. If the ZMU03689 top cowling is loose, have it repaired by your Yamaha dealer. 1. Cord 2. Clip...

  • Page 34: Filling Fuel And Engine Oil

    Operation Touch the fuel nozzle to the filler open- ing or funnel to help prevent electrostatic sparks. Fill the fuel tank, but do not overfill. Fuel can expand and overflow if the tempera- ture increases. Fuel tank capacity: 24 L (6.34 US gal, 5.28 Imp.gal) ZMU04677 EMU27234 Filling fuel and engine oil...

  • Page 35: Operating Engine

    Operation Shake the fuel can to mix the fuel thor- Gasoline to engine oughly. oil ratio Make sure that the oil and gasoline are Break-in period See page 26 mixed. After break-in 100:1 Pour the gasoline and oil mixture into the If equipped with a portable fuel tank built-in fuel tank.

  • Page 36: Starting Engine

    Operation ZMU02295 EMU27492 If there is a fuel joint on the motor, firmly Starting engine connect the fuel line to the joint. Then EWM01600 firmly connect the other end of the fuel WARNING line to the joint on the fuel tank. Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions.
  • Page 37 Operation Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position. ZMU03714 TIP: The start-in-gear protection device prevents ZMU04114 the engine from starting except when in neu- TIP: tral. Attach the engine shut-off cord to a se- It is not necessary to use the choke when cure place on your clothing, or your arm...
  • Page 38 Operation be thrown forward. Place the gear shift lever in neutral. TIP: The start-in-gear protection device prevents the engine from starting except when in neu- tral. ZMU02030 TIP: When the engine is cold, it needs to be warmed up. For further information, see page 38.
  • Page 39 Operation Immediately after the engine starts, re- lease the main switch and allow it to re- turn to “ ” (on). Slowly return the throttle grip to the fully closed position so that the engine does not stall. NOTICE: Never turn the main switch to “...
  • Page 40 Operation EMU27636 Manual start models (remote control) EWM01840 WARNING 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 clothing that ZMU03088 could tear loose.
  • Page 41 Operation gine is warm and fails to start, open the throttle a small amount and try to start the engine again. If the engine still fails to start, see page 63. EMU27645 Electric start / remote control models EWM01840 WARNING Failure to attached engine shut-off cord could result in a runaway boat if opera- ZMU04114...
  • Page 42 Operation or leg. Then install the clip on the other TIP: end of the cord into the engine shut-off On remote controls equipped with a neu- switch. tral throttle lever, a good starting point is to lift the lever just until you feel resistance, then lift slightly more.

  • Page 43: Checks After Starting Engine

    Confirm that removing the clip from the en- case or the cooling water pilot hole is gine shut-off switch stops the engine. blocked. Consult your Yamaha dealer if Confirm that the engine cannot be started the problem cannot be located and cor- with the clip removed from the engine rected.

  • Page 44: Shifting

    Operation EMU34530 Shifting EWM00180 WARNING Before shifting, make sure there are no swimmers or obstacles in the water near you. ECM01610 NOTICE ZMU05689 Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral.

  • Page 45: Stopping Boat

    Operation ZMU05690 ZMU03724 EMU31742 Stopping boat EWM01510 WARNING Do not use the reverse function to slow down or stop the boat as it could cause you to lose control, be ejected, or im- pact the steering wheel or other parts of the boat.

  • Page 46: Trimming Outboard Motor

    Operation ZMU02301 ZMU03690 Remove the key if the boat will be left unattended. START TIP: The engine can also be stopped by pulling the cord and removing the clip from the en- gine shut-off switch, then turning the main switch to “ ”...

  • Page 47: Adjusting Trim Angle For Manual Tilt Models

    Operation ZMU02909 1. Trim rod Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom. To lower the bow (“trim-in”), move the rod to- ward the transom. Make test runs with the trim set to different angles to find the position that works best for ZMU02858 your boat and operating conditions.

  • Page 48: Tilting Up And Down

    Operation bow up, the boat may have a greater tenden- ating with excessive trim-in at higher speeds cy to steer to one side or the other. Compen- also makes the boat unstable. Resistance at sate for this as you steer. The trim tab can the bow is greatly increased, heightening the also be adjusted to help offset this effect.

  • Page 49: Procedure For Tilting Up (Manual Tilt Models)

    Operation few minutes. Otherwise fuel may leak. ECM00241 NOTICE Before tilting the outboard motor, stop the engine by following the procedure on page 40. Never tilt the outboard mo- tor while the engine is running. Severe damage from overheating can result. Do not tilt up the engine by pushing the ZMU03747 tiller handle (if equipped) because this...

  • Page 50: Shallow Water

    Operation ter lever to its original position. cause the outboard motor to lift out of the water, increasing the chance of ac- cident and personal injury. ECM00260 NOTICE Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set- ting up for and cruising in shallow water.

  • Page 51: Cruising In Other Conditions

    This outboard mo- Cruising in muddy, turbid, or acidic water tor has 2 positions for shallow water Yamaha strongly recommends that you use cruising. the optional chromium-plated water pump kit To return the outboard motor to the nor-...
  • Page 52 Operation in it, such as muddy or turbid (cloudy) water. After operating in such water, flush the cool- ing passages with fresh water to prevent cor- rosion. Also rinse the outside of the outboard motor with fresh water.

  • Page 53: Maintenance

    Yamaha dealer sition using a motor support device such as prior to storage. However, you, the owner, a transom saver bar. Consult your Yamaha with a minimum of tools, can perform the fol- dealer for further details.

  • Page 54: Procedure

    Maintenance lowing procedures. ECM01411 NOTICE 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. ZMU02051 Store the outboard motor in a dry, well- ventilated place, not in direct sunlight.

  • Page 55: Lubrication

    Yamaha dealer. Seal replacement should be performed EMU37120 Periodic maintenance by an authorized Yamaha dealer prior to use. EWM02010 WARNING Grease all grease fittings. For further de- tails, see page 55.

  • Page 56: Replacement Parts

    EMU28511 Replacement parts If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers.

  • Page 57: Maintenance Chart 1

    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 20 hours Item...
  • Page 58 Water from the cooling Inspection water pilot hole Throttle link/Throttle Inspection, adjustment cable/Throttle pick-up or replacement as nec- timing essary Water inlet Inspection Main switch/stop Inspection or replace- switch/choke switch ment as necessary Inspection and clean- (Yamaha) Fuel tank ing as necessary...

  • Page 59: Maintenance Chart 2

    Maintenance EMU34451 Maintenance chart 2 Every Item Actions 1000 hours Guide exhaust/exhaust Inspection or replace- manifold ment as necessary...

  • Page 60: Greasing

    Maintenance EMU28941 Greasing Yamaha grease A (water resistant grease) Yamaha grease D (corrosion resistant grease; for propeller shaft) 20D, 25N ZMU03734 ple, if the center electrode porcelain is very EMU28955 Cleaning and adjusting spark plug white, this could indicate an intake air leak or The spark plug is an important engine com- carburetion problem in that cylinder.

  • Page 61: Checking Fuel Filter

    For cleaning or replacement of the Be sure to use the specified spark plug, fuel filter, consult your Yamaha dealer. otherwise the engine may not operate properly. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge;...

  • Page 62: Checking Wiring And Connectors

    Turn off the battery cut-off switch if quires adjustment, consult a Yamaha dealer your boat has one. or other qualified mechanic. Do not use your hand to hold the propeller...

  • Page 63: Removing Propeller

    Otherwise the propeller could come off during opera- tion and be lost. Check the propeller shaft oil seal for dam- Apply Yamaha marine grease or a cor- age. rosion resistant grease to the propeller EMU30661 shaft.

  • Page 64: Changing Gear Oil

    Consult a or knob is locked. Severe injury could Yamaha dealer for repair of the lower occur if the outboard motor accidental- unit seals. [ECM00711] ly falls.

  • Page 65: Cleaning Fuel Tank

    EMU29312 If you have any question about properly Inspecting and replacing anode(s) doing this procedure, consult your Yamaha outboard motors are protected from Yamaha dealer. corrosion by sacrificial anodes. Inspect the Keep away from sparks, cigarettes, external anodes periodically. Remove scales flames, or other sources of ignition from the surfaces of the anodes.

  • Page 66: Checking Battery (For Electric Start Models)

    Check the electrolyte level. TIP: 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. Check the battery’s charge. If your boat...

  • Page 67: Disconnecting The Battery

    Maintenance POSITIVE (+) terminal first. Then con- nect the black battery cable to the NEG- ATIVE (-) terminal. 1. Red cable 2. Black cable 3. Battery The electrical contacts of the battery and cables must be clean and properly con- nected, or the battery will not start the engine.

  • Page 68: Trouble Recovery

    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-alert indicator is flash- Q. Are spark plug(s) fouled or of incorrect ing, consult your Yamaha dealer.
  • Page 69 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.
  • Page 70 Q. Is fuel system obstructed? Q. Is water pump or thermostat faulty? A. Check for pinched or kinked fuel line or A. Have serviced by a Yamaha dealer. other obstructions in fuel system. Q. Is there excess water in fuel filter cup? Q.

  • Page 71: Temporary Action In Emergency

    EWM00631 Q. Is steering pivot loose or damaged? WARNING A. Tighten or have serviced by a Yamaha Substituting an incorrect fuse or a piece dealer. of wire could allow excessive current EMU29433 flow.

  • Page 72: Starter Will Not Operate

    2. Fuse (10 A) other objects away when starting the engine. Use the emergency starter rope Consult your Yamaha dealer if the new fuse only as instructed. Do not touch the fly- immediately blows again. wheel or other moving parts when the EMU29533 engine is running.
  • Page 73 Trouble Recovery ZMU04595 ZMU03740 1. Start-in-gear protection cable Remove the starter/flywheel cover after ON START removing the bolt(s). ZMU01906 If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob ZMU03741 to its home position as the engine warms Prepare the engine for starting.

  • Page 74: Treatment Of Submerged Motor

    Repeat if neces- sary. ZMU02928 EMU33500 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. ECM00400 NOTICE Do not attempt to run the outboard motor...
  • Page 76 YAMAHA MOTOR CO., LTD. Printed in Japan April 2008–0.1 × 1 ! Printed on recycled paper...

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