Yamaha 115CETOX Owner's Manual PDF
Summary of Content for Yamaha 115CETOX Owner's Manual PDF
115
OWNERS MANUAL
6N6-28199-1H
U.S.A.Edition LIT-18626-07-95
q Read this manual carefully before operating this outboard motor.
6N6-9-1H Hyoshi 08.2.21 9:42 1
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.
6N6-9-1H Hyoshi 08.2.21 9:42 2
Important manual information
EMU31283
To the owner
Thank you for choosing a Yamaha outboard motor. This Owners Manual contains infor- mation needed for proper operation, mainte- nance and care. A thorough understanding of these simple instructions will help you ob- tain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owners Manual particularly important information is distinguished in the following ways.
: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that fol- low this symbol to avoid possible injury or death.
WARNING
EWM00781
A WARNING indicates a hazardous situa- tion which, if not avoided, could result in
death or serious injury.
NOTICE
ECM00701
A NOTICE indicates special precautions that must be taken to avoid damage to the
outboard motor or other property.
TIP:
A TIP provides key information to make pro- cedures easier or clearer.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current prod- uct information available at the time of print- ing, there may be minor discrepancies between your machine and this manual. If
there is any question concerning this manu- al, please consult your Yamaha dealer.
TIP:
The 115TR and the standard accessories are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model.
EMU25111
115 OWNERS MANUAL
2008 by Yamaha Motor Corporation, USA 1st edition, April 2008
All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA
is expressly prohibited. Printed in Japan
P/N LIT-18626-07-95
Table of contents
Safety information............................. 1
Outboard motor safety .................... 1
Propeller............................................ 1 Rotating parts.................................... 1 Hot parts ........................................... 1 Electric shock.................................... 1 Power trim and tilt ............................. 1 Engine shut-off cord (lanyard)........... 1 Gasoline............................................ 1 Gasoline exposure and spills ............ 2 Carbon monoxide.............................. 2 Modifications ..................................... 2
Boating safety ................................. 2
Alcohol and drugs ............................. 2 Personal flotation devices ................. 2 People in the water ........................... 2 Passengers ....................................... 2 Overloading....................................... 2 Avoid collisions ................................. 3 Weather ............................................ 3 Accident reporting ............................. 3 Boat education and training .............. 3 Passenger training ............................ 4 Boating safety publications ............... 4 Laws and regulations ........................ 4
Boating organizations...................... 4 Basic boating rules (Rules of the
road).............................................. 4
Steering and sailing rules and sound signals.................................. 5
Rules when encountering vessels .... 5 Other special situations..................... 6
General information .......................... 9
Identification numbers record.......... 9
Outboard motor serial number .......... 9 Key number....................................... 9
Read manuals and labels.............. 10
Warning labels ................................ 10
Specifications and requirements.................................... 13
Specifications ................................ 13 Installation requirements ............... 14
Boat horsepower rating................... 14 Mounting motor ............................... 14
Remote control requirements........ 14 Battery requirements..................... 14
Specifications of Battery..................14 Mounting battery .............................14 Multiple batteries .............................15
Propeller selection ........................ 15 Start-in-gear protection ................. 15 Engine oil requirements ................ 15 Fuel requirements ......................... 16
Gasoline ..........................................16 Ring Free Fuel Additive...................16
Muddy or acidic water ................... 17 Anti-fouling paint ........................... 17 Motor disposal requirements......... 17 Emission control information......... 17
North American models...................17
Components .................................... 19
Components diagram.................... 19
Remote control box .........................19 Remote control lever .......................20 Neutral interlock trigger ...................20 Neutral throttle lever ........................20 Choke switch...................................21 Throttle friction adjuster...................21 Engine shut-off cord (lanyard) and
clip.................................................21 Choke knob for pull type .................22 Main switch .....................................22 Power trim and tilt switch on
remote control ...............................22 Power trim and tilt switch on
bottom engine cowling ..................23 Trim tab with anode.........................23 Tilt support lever for power trim
and tilt model.................................24 Top cowling release lever ...............24 Flushing device ...............................25
Instruments and indicators............ 26
Digital tachometer ......................... 26
Trim meter .......................................26 Hour meter ......................................26 Oil level indicator (digital type) ........26 Overheat-alert indicator...................27
Digital speedometer ...................... 27
Speedometer...................................27
Table of contents
Fuel gauge ...................................... 28 Trip meter / Clock / Voltmeter ......... 28 Fuel level-alert indicator .................. 29 Low battery voltage-alert
indicator ........................................ 29
Analog tachometer ........................ 29
Oil level indicators (three indicators 2) .................................. 29
Analog trim meter.......................... 30
Engine control system.................... 31
Alert system .................................. 31
Overheat alert ................................. 31 Oil level alert and oil filter clogging
alert............................................... 31
Installation ....................................... 33
Installation ..................................... 33
Mounting the outboard motor .......... 33
Operation ......................................... 35
First-time operation ....................... 35
Breaking in engine .......................... 35 Getting to know your boat ............... 35
Checks before starting engine ...... 35
Fuel level......................................... 36 Remove cowling.............................. 36 Fuel system..................................... 36 Controls........................................... 36 Engine shut-off cord (lanyard)......... 37 Oil.................................................... 37 Engine............................................. 37 Operation after a long period of
storage.......................................... 37 Flushing device ............................... 37 Install cowling.................................. 38 Checking power trim and tilt
system .......................................... 38 Battery............................................. 39
Filling fuel and engine oil............... 40
Filling fuel for models without a fuel joint ........................................ 40
Filling oil .......................................... 40 Oil level indicator operation............. 42
Operating engine........................... 43
Feeding fuel .................................... 43 Starting engine................................ 43
Checks after starting engine ......... 45
Cooling water ..................................45
Warming up engine....................... 45
Choke start models .........................45
Checks after engine warm-up....... 45
Shifting ............................................45 Stop switches ..................................45
Shifting.......................................... 46 Stopping boat................................ 47 Stopping engine............................ 47
Procedure........................................47
Trimming outboard motor.............. 47
Adjusting trim angle (Power trim and tilt) ..........................................48
Adjusting boat trim ..........................48
Tilting up and down....................... 49
Procedure for tilting up (power trim and tilt models)..............................50
Procedure for tilting down (power trim and tilt models).......................51
Shallow water................................ 51
Power trim and tilt models...............51
Cruising in other conditions........... 52
Maintenance .................................... 53
Transporting and storing outboard motor ........................... 53
Storing outboard motor ...................53 Procedure........................................53 Lubrication (oil injection models) .....54 Cleaning and anticorrosion
measures ......................................55 Flushing power unit .........................55 Cleaning the outboard motor...........56 Checking painted surface of
motor.............................................56
Periodic maintenance ................... 56
Replacement parts ..........................57 Maintenance interval guidelines......57 Maintenance chart 1........................58 Maintenance chart 2........................60 Greasing..........................................61 Cleaning and adjusting spark
plug ...............................................61 Checking fuel filter...........................62 Inspecting idling speed....................62
Table of contents
Checking water in engine oil tank ... 63 Checking wiring and connectors ..... 63 Checking propeller .......................... 63 Removing propeller ......................... 64 Installing propeller ........................... 64 Changing gear oil ............................ 65 Inspecting and replacing
anode(s)........................................ 66 Checking battery (for electric start
models) ......................................... 67 Connecting the battery .................... 67 Disconnecting the battery ............... 68
Trouble Recovery............................ 69
Troubleshooting ............................ 69 Temporary action in emergency..... 72
Impact damage ............................... 72 Replacing fuse ................................ 72 Power trim and tilt will not
operate.......................................... 73 Starter will not operate .................... 73 Emergency starting engine ............. 74
Engine fails to operate .................. 75
Low oil level alert activates ............. 75
Top cowling does not unlock......... 76 Treatment of submerged motor...... 76
Consumer information.................... 77
Important warranty information for U.S.A. and Canada ................ 77
YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ...... 79
IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA .............. 82
1
Safety information
EMU33622
Outboard motor safety
Observe these precautions at all times.
EMU36500
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 when stationary.
Shut off the engine when a person is in the water near you.
Keep people out of reach of the propeller, even when the engine is off.
EMU33630
Rotating parts
Hands, feet, hair, jewelry, clothing, PFD straps, etc. can become entangled with inter- nal rotating parts of the engine, resulting in serious injury or death. Keep the top cowling in place whenever pos- sible. Do not remove or replace the cowling with the engine running. Only operate the engine with the cowling re- moved according to the specific instructions in the manual. Keep hands, feet, hair, jewel- ry, clothing, PFD straps, etc. away from any exposed moving parts.
EMU33640
Hot parts
During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the en- gine has cooled.
EMU33650
Electric shock
Do not touch any electrical parts while start- ing or operating the engine. They can cause shock or electrocution.
EMU33660
Power trim and tilt
Body parts can be crushed between the mo-
tor and the clamp bracket when the motor is trimmed or tilted. Keep body parts out of this area at all times. Be sure no one is in this area before operating the power trim and tilt mechanism. The power trim and tilt switches operate even when the main switch is off. Keep peo- ple be away from the switches whenever working around the motor. Never get under the lower unit while it is tilt- ed, even when the tilt support lever is locked. Severe injury could occur if the outboard mo- tor accidentally falls.
EMU33671
Engine shut-off cord (lanyard)
Attach the engine shut-off cord so that the engine stops if the operator falls overboard or leaves the helm. This prevents the boat from running away under power and leaving people stranded, or running over people or objects. Always attach the engine shut-off cord to a secure place on your clothing or your arm or leg while operating. Do not remove it to leave the helm while the boat is moving. Do not at- tach the cord to clothing that could tear loose, or route the cord where it could be- come entangled, preventing it from function- ing. Do not route the cord where it is likely to be accidentally pulled out. If the cord is pulled during operation, the engine will shut off and you will lose most steering control. The boat could slow rapidly, throwing people and ob- jects forward.
EMU33810
Gasoline
Gasoline and its vapors are highly flam- mable and explosive.
Always, refuel ac- cording to the procedure on page 43 to reduce the risk of fire and explosion.
Safety information
2
EMU33820
Gasoline exposure and spills
Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Dispose of rags properly. If any gasoline spills onto your skin, immedi- ately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gaso- line vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth.
EMU33900
Carbon monoxide
This product emits exhaust gases which contain carbon monoxide, a colorless, odor- less gas which may cause brain damage or 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 and reliability, and render the outboard unsafe or illegal to use.
EMU33740
Boating safety
This section includes a few of the many im- portant safety precautions that you should follow when boating.
EMU33710
Alcohol and drugs
Never operate after drinking alcohol or tak- ing drugs. Intoxication is one of the most common factors contributing to boating fatal- ities.
EMU33720
Personal flotation devices
Have an approved personal flotation device (PFD) on board for every occupant. Yamaha
recommends that you must wear a PFD whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boat- ing conditions.
EMU33730
People in the water
Always watch carefully for people in the wa- ter, such as swimmers, skiers, or divers, whenever the engine is running. When someone is in the water near the boat, shift into neutral and shut off the motor. Stay away from swimming areas. Swimmers can be hard to see. The propeller can keep moving even when the motor is in neutral. Shut off the engine when a person is in the water near you.
EMU33750
Passengers
Consult your boat manufacturers instruc- tions for details about appropriate passenger locations in your boat and be sure all pas- sengers are positioned properly before ac- celerating and when operating above an idle speed. Standing or sitting in non-designated locations may result in being thrown either overboard or within the boat due to waves, wakes, or sudden changes in speed or direc- tion. Even when people are positioned prop- erly, alert your passengers if you must make any unusual maneuver. Always avoid jump- ing waves or wakes.
EMU33760
Overloading
Do not overload the boat. Consult the boat capacity plate or boat manufacturer for max- imum weight and number of passengers. Be sure that weight is properly distributed ac- cording to the boat manufacturers instruc- tions. Overloading or incorrect weight distribution can compromise the boats han-
Safety information
3
dling and lead to an accident, capsizing or swamping.
EMU33771
Avoid collisions
Scan constantly
for people, objects, and other boats. Be alert for conditions that limit your visibility or block your vision of others.
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.
Avoid areas with submerged objects or shallow water.
Ride within your limits and avoid aggres- sive maneuvers to reduce the risk of loss of control, ejection, and collision.
Take early action
to avoid collisions. Re- member,
boats do not have brakes
, and stopping the engine or reducing throttle can reduce the ability to steer. If you are not sure that you can stop in time before hitting an obstacle, apply throttle and turn in another direction.
EMU33790
Weather
Stay informed about the weather. Check weather forecasts before boating. Avoid
boating in hazardous weather.
EMU33800
Accident reporting
Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency if their boat is involved in any of the following accidents: 1. There is loss of life or probable loss of
life. 2. There is personal injury that requires
medical attention beyond first aid. 3. There is property damage to boats or
other property over a certain amount. 4. There is complete loss of a boat. Contact local law enforcement personnel if a report is necessary.
EMU33870
Boat education and training
Operators should take a boating safety course. This may be required in your state. Many of the organizations listed in the next section can provide information about cours- es in your area. You may also want to consider an Internet- based program for basic boater education. The Online Boating Safety Course provided by the BoatU.S. Foundation, is approved by the National Association of State Boating Law Administrators (NASBLA) and recog- nized by the United States Coast Guard. Most, but not all, states accept this course to meet their minimum requirements. While it cannot replace an in-depth course such as one offered by the U.S. Coast Guard, U.S. Power Squadron, or other organization, this online course does provide a general over- view of the basics in boating safety, require- ments, navigation, and operation. Upon successful completion of the course, the user can download a certificate of comple- tion immediately or, for a small charge, re- quest one by mail. To take this free course,
ZMU06025
Safety information
4
go to boatus.org.
EMU33880
Passenger training
Make sure at least one other passenger is trained to operate the boat in the event of an emergency.
EMU33890
Boating safety publications
Be informed about boating safety. Additional publications and information can be obtained from many boating organizations.
EMU33590
Laws and regulations
Know the marine laws and regulations where you will be boating- and obey them. Several sets of rules prevail according to geographic 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- trators, or your local Power Squadron for a complete set of rules governing the waters in which you will be using your boat.
EMU33680
Boating organizations
The following organizations provide boating safety training and information about boating safety and laws.
United States Coast Guard
Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Af- fairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647 www.uscgboating.org
United States Power Squadrons
1-888-FOR-USPS (1-888-367-8777) www.usps.org
Boat Owners Association of The United States
1-800-336-BOAT (1-800-336-2628) www.boatus.com
National Association of State Boating Law Administrators (NASBLA)
1500 Leestown Road, Suite 330 Lexington, KY 4051 859-225-9497 859-225-9497 www.nasbla.org
National Marine Manufacturers Associa- tion (NMMA)
200 East Randolph Drive Suite 5100 Chicago, IL 606001 www.nmma.org
Marine Retailers Association of America
155 N. Michigan Ave. Chicago, IL 60601 www.mraa.com
EMU33690
Basic boating rules (Rules of the road)
Just as there are rules that apply when you are driving on streets and highways, there are waterway rules that apply when you are driving your boat. These rules are used inter- nationally. (For USA: and are also enforced by the United States Coast Guard and local agencies.) You should be aware of these rules, and follow them whenever you en- counter another vessel on the water.
Safety information
5
EMU33700
Steering and sailing rules and sound signals
Whenever two vessels on the water meet one another, one vessel has the right-of- way; it is called the stand-on vessel. The vessel that does not have the right-of-way is called the give-way or burdenedvessel. These rules determine which vessel has the right-of-way, and what each vessel should do.
Stand-on vessel
The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision. When you maintain your direction and speed, the other 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 right-of-way. You should slow down or change directions brief- ly and pass behind the other vessel. You should always move in such a way that the operator of the other vessel can see what you are doing.
The general prudential rule
This rule is called Rule 2 in the International Rules and says, In obeying and construing these rules due regard shall be had to all dangers of naviga- tion and collision, and to any special circum- stances, which may render a departure from the above rules necessary in order to avoid immediate danger. In other words, follow the standard rules ex- cept when a collision will occur unless both
vessels try to avoid each other. If that is the case, both vessels become Give-Way vessels.
EMU25521
Rules when encountering vessels
There are three main situations that you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed:
Meeting:
(you are approaching another ves- sel head-on)
Crossing:
(you are traveling across the oth- er vessels path)
Overtaking:
(you are passing or being passed by another vessel) In the following illustration, your boat is in the center. You should give the right-of-way to any vessels shown in white area (you are the Give-Way vessel). Any vessels in the shad- ed area must yield to you (they are the Give- Way vessels). Both you and the meeting vessel must alter course to avoid each other.
Meeting
If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of- way Both of you should alter course to avoid an accident. You should keep the other ves- sel on your port (left) side. This rule doesnt apply if both of you will clear one another if you continue on your set course and speed.
Safety information
6
Crossing
When two power driven vessels are crossing each others path close enough to run the risk of collision, the vessel which has the oth- er on the starboard (right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; 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. 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 an- other vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.
EMU25531
Other special situations
There are three other rules you should be aware of when driving your boat around oth- er vessels.
Narrow channels and bends
When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a power- driven vessel is preparing to go around a bend that may obstruct the view of other wa- ter vessels, the operator should sound a pro- longed blast on the whistle (4 to 6 seconds). If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still pro- ceed around the bend with caution. If you navigate such waters with your boat, you will need to carry a portable air horn, available from local marine supply stores.
Fishing vessel right-of-way
All vessels that are fishing with nets, lines or trawls are considered to be fishing vessels under the International Rules. Vessels with trolling lines are not considered fishing ves- sels. Fishing vessels have the right-of-way regardless of position. Fishing vessels can- not, however, impede the passage of other vessels in narrow channels.
Sailing vessel right-of-way
Sailing vessels should normally be given the right-of-way. The exceptions to this are: 1. When the sailing vessel is overtaking
the power-driven vessel, the power-driv- en vessel has the right-of-way.
2. Sailing vessels should keep clear of any fishing vessel.
3. In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel that can navigate only in such a channel.
Safety information
7
Reading buoys and other markers
The waters of the United States are marked for safe navigation by the lateral system of buoyage. Simply put, buoys and markers have an arrangement of shapes, colors, numbers and lights to show which side of the buoy a boater should pass on when navigat- ing in a particular direction. The markings on these buoys are oriented from the perspec- tive of being entered from seaward (the boat- er is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open wa- ter into port, and black buoys are to port (left) side. When navigating out of port, your posi- tion with respect to the buoys should be re- versed; red buoys should be to port and 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 regulato- ry or advisory information. These markers are white with black letters and orange boarders. They signify speed zones, restrict- ed areas, danger areas, and general infor- mation. Remember, markings may vary by geo- graphic location. Always consult local boat- ing authorities before driving your boat in unfamiliar waters.
Safety information
8
ZMU01708
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 parts from your Yamaha dealer or for reference in case your outboard motor is sto- len.
EMU25190
Key number
If a main key switch is equipped with the mo- tor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key.
1. Outboard motor serial number location
1. Key number
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 labels
If these labels are damaged or missing, contact your Yamaha dealer for replacements.
ZMU06196
3
12
General information
11
1 2
3
ZMU05670
General information
12
EMU33843
Symbols
The following symbols mean as follows.
Notice/Warning
Read Owners 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
ZMU05665
ZMU05666
ZMU05667
ZMU05668
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 installed.
EMU2821C
Dimension:
Overall length: 808 mm (31.8 in)
Overall width: 582 mm (22.9 in)
Overall height L: 1472 mm (58.0 in)
Transom height L: 516 mm (20.3 in)
Weight (without propeller) L: 163.0 kg (359 lb)
Performance:
Full throttle operating range: 45005500 r/min
Maximum output: 84.6 kW@5000 r/min (115 HP@5000 r/min)
Idling speed (in neutral): 750
50 r/min
Engine:
Type: 2-stroke V
Displacement: 1730.0 cm
3
Bore
stroke: 90.0
68.0 mm (3.54
2.68 in) Ignition system:
CDI Spark plug with resistor (NGK):
BR8HS-10
Spark plug gap: 0.91.0 mm (0.0350.039 in)
Control system: Remote control
Starting system: Electric
Starting carburetion system: Choke valve
Min. cold cranking amps (CCA/SAE): 380.0 A
Min. marine cranking amps (MCA/ABYC): 502.0 A
Min. reserve capacity (RC/SAE): 124 minutes
Maximum generator output: 20.0 A
Drive unit:
Gear positions: Forward-neutral-reverse
Gear ratio: 2.00 (26/13)
Trim and tilt system: Power trim and tilt
Propeller mark: K
Fuel and oil:
Recommended fuel: Regular unleaded gasoline
Min. pump octane: 86
Recommended engine oil: YAMALUBE 2-stroke outboard motor oil
Lubrication: Oil injection
Engine oil tank capacity: 0.9 L (0.95 US qt, 0.79 Imp.qt)
Remote oil tank capacity: 10.5 L (11.10 US qt, 9.24 Imp.qt)
Recommended gear oil: Hypoid gear oil SAE#90
Specifications and requirements
14
Gear oil quantity: 0.760 L (0.803 US qt, 0.669 Imp.qt)
Tightening torque for engine:
Spark plug: 25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
Propeller nut: 55.0 Nm (5.61 kgf-m, 40.6 ft-lb)
EMU33553
Installation requirements
EMU33563
Boat horsepower rating
WARNING
EWM01560
Overpowering a boat can cause severe
instability.
Before installing the outboard motor(s), con- firm that the total horsepower of your mo- tor(s) does not exceed the boats maximum horsepower rating. See the boats capacity plate or contact the manufacturer.
EMU33571
Mounting motor
WARNING
EWM01570
Improper mounting of the outboard mo- tor could result in hazardous condi- tions such as poor handling, loss of control, or fire hazards.
Because the motor is very heavy, spe- cial equipment and training is required
to mount it safely.
Your dealer or other person experienced in proper rigging should mount the motor using correct equipment and complete rigging in- structions. For further information, see page 33.
EMU33581
Remote control requirements
WARNING
EWM01580
If the engine starts in gear, the boat can
move suddenly and unexpectedly, pos- sibly causing a collision or throwing passengers overboard.
If the engine ever starts in gear, the start-in-gear protection device is not working correctly and you should dis- continue using the outboard. Contact
your Yamaha dealer.
The remote control unit must be equipped with a start-in-gear protection device(s). This device prevents the engine from starting un- less it is in neutral.
EMU25694
Battery requirements
EMU25713
Specifications of Battery
Use a fully charged battery that meets the 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 be overloaded, causing electric system
damage.
EMU36290
Mounting battery
Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the
Minimum cold cranking amps (CCA/SAE):
380.0 A Minimum marine cranking amps (MCA/ABYC):
502.0 A Minimum reserve capacity (RC/SAE):
124 minutes
Specifications and requirements
15
boat.
WARNING! Do not put flammable items, or loose heavy or metal objects in the same compartment as the battery. Fire, explosion or sparks could result.
[EWM01820]
EMU36300
Multiple batteries
To connect multiple batteries, such as for multiple engine configurations or for an ac- cessory battery, consult your Yamaha dealer about battery selection and correct wiring.
EMU34191
Propeller selection
Next to selecting an outboard, choosing the right propeller is one of the most important purchasing decisions a boater can make. The type, size, and design of your propeller have a direct impact on acceleration, top speed, fuel economy, and even engine life. Yamaha designs and manufactures propel- lers for every Yamaha outboard motor and every application. Your outboard motor came with a Yamaha propeller chosen to perform well over a range of applications, but there may be uses where a different propeller would be more appropriate. Your Yamaha dealer can help you select the right propeller for your boating needs. Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat- load. Generally, chose a larger pitch propel- 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 setting to stay within the recommended engine speed range when carrying lighter loads.
For instructions on propeller removal and in- stallation, see page 63.
EMU25770
Start-in-gear protection
Yamaha outboard motors or Yamaha-ap- proved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is in neutral. Always select neutral before starting the engine.
EMU25661
Engine oil requirements
Use Yamalube 2-M outboard oil. If Ya- malube 2-M is not available, use only anoth- er outboard motor manufacturers factory- brand oil with TC-W3 rating.
NOTICE
ECM01290
Serious engine damage can result from the use of lower quality oil, including some commonly available oil brands with TC-W3 on their label. To avoid the risk, use only Yamalube 2-M or, if necessary,
1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark)
Recommended engine oil: YAMALUBE 2 STROKE OUTBOARD OIL
ZMU04608
-x 1 2 3
Specifications and requirements
16
another outboard motor manufacturers
factory-brand TC-W3 oil.
EMU36360
Fuel requirements
EMU36780
Gasoline
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.
NOTICE
ECM01980
Do not use leaded gasoline. Leaded gasoline can seriously damage the en- gine.
Avoid getting water and contaminants in the fuel tank. Contaminated fuel can cause poor performance or engine damage. Use only fresh gasoline that
has been stored in clean containers.
Gasohol
There are two types of gasohol: gasohol con- taining ethanol (E10) and that containing methanol. Ethanol can be used if the ethanol content does not exceed 10% and the fuel meets the minimum octane ratings. E85 is a fuel containing 85% ethanol and must not be used in your outboard motor. All ethanol blends containing more than 10% ethanol can cause fuel system damage or cause en- gine starting and running problems. Yamaha does not recommend gasohol containing methanol because it can cause fuel system
damage or engine performance problems. It is recommended that you install a water- separating marine fuel filter assembly (10 micron minimum) between your boats 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 running complaints and require addition- al fuel system maintenance.
EMU27270
Ring Free Fuel Additive
Gasoline is a precise blend of many different substances, each chosen to give certain characteristics. Gasoline blends have been changing in recent years in response to con- cerns about pollution and resulting emis- sions regulations. One of the most obvious changes has been the elimination of lead from most fuels. As gasoline has changed, the amount of ad- ditives such as aromatics and oxygenates has increased. These additives are impor- tant for the engines in passenger cars, but they can have detrimental effects in marine engines, because of increased deposits in the combustion chamber. When enough de- posits collect, piston rings begin sticking. Performance drops and engine wear in- creases dramatically. 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, notably the critical piston-ring-land area, and fuel system components. Follow product la- beling for use instructions.
Recommended gasoline: Regular unleaded gasoline with a min- imum Octane rating of 86 (Pump Oc- tane Number) = (R+M)/2
Specifications and requirements
17
EMU36880
Muddy or acidic water
Yamaha strongly recommends that you have your dealer install the optional chromium- plated water pump kit if you use the outboard motor in muddy or acidic water conditions. However, depending on the model it might not be required.
EMU36330
Anti-fouling paint
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. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
EMU36340
Motor disposal requirements
Never illegally discard (dump) the motor Yamaha recommends consulting the dealer about discarding the motor.
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 details.
EMU30390
Approval label of emission control certif- icate
This label is attached to the bottom cowling. Existing Technology; N/A
EMU25262
Manufactured date label
This label is attached to the clamp bracket or the swivel bracket.
1. Approval label location
1
ZMU04619
EMISSION CONTROL INFORMATION ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES. REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. FELs : SPARK PLUG : DISPLACEMENT : ADVERTISED POWER :
IDLE SPEED : SPARK PLUG GAP (mm) : FUEL : GASOLINE VALVE LASH (mm) : IN : N/A EX : N/A
cm kW
g/kW-hr rpm IN NEUTRAL
3
ZMU05230
Specifications and requirements
18
1. Manufactured date label location
1 ZMU04618
19
Components
EMU2579H
Components diagram TIP:
* May not be exactly as shown; also may not be included as standard equipment on all mod- els.
115
EMU26181
Remote control box
The remote control lever actuates both the shifter and the throttle. The electrical switch- es are mounted on the remote control box.
4
7
8
9
10
1
2
3
5
6
12
11
13
14 15 16
17 18 19
ZMU04764
1. Top cowling 2. Power trim and tilt switch 3. Flushing device 4. Tilt support lever 5. Anti-cavitation plate 6. Trim tab (anode) 7. Propeller* 8. Cooling water inlet 9. Anode 10. Clamp bracket 11. Top cowling release lever 12. Choke knob 13. Cooling water pilot hole 14. Remote control box (side mount type)* 15. Digital tachometer*
16. Digital speedometer* 17. Tachometer* 18. Trim meter* 19. Remote oil tank*
Components
20
EMU26190
Remote control lever
Moving the lever forward from the neutral po- sition engages forward gear. Pulling the le- ver back from neutral engages reverse. The engine will continue to run at idle until the le- ver is moved about 35 (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.
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 throttle lever.
TIP:
The neutral throttle lever will operate only when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position.
1. Power trim and tilt switch 2. Remote control lever 3. Neutral interlock trigger 4. Neutral throttle lever 5. Main switch / choke switch 6. Engine stop lanyard switch 7. Throttle friction adjuster
1. Neutral
2. Forward
3. Reverse 4. Shift 5. Fully closed
6. Throttle 7. Fully open
1. Neutral interlock trigger
Components
21
EMU26221
Choke switch
To activate the choke system, press in the main switch while the key is turned to the (on) or (start) position. The choke system will then supply the rich fuel mixture required to start the engine. When the key is released, the choke will switch off automatically.
EMU25973
Throttle friction adjuster
A friction device provides adjustable resis- tance to movement of the throttle grip or the remote control lever, and can be set accord- ing to operator preference. To increase resistance, turn the adjuster clockwise.
WARNING! Do not overtighten the friction adjuster. If there is too much
resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident.
[EWM00032]
To decrease resistance, turn the adjuster counterclockwise.
When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting.
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 operators clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power.
WARNING! At- tach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become en- tangled, preventing it from functioning. Avoid accidentally pulling the cord dur- ing 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
1. Fully open 2. Fully closed
ZMU03160
Components
22
thrown forward.
[EWM00122]
EMU26011
Choke knob for pull type
To supply the engine with the rich fuel mix- ture required to start, pull out this knob.
EMU26090
Main switch
The main switch controls the ignition system; its operation is described below.
(off)
With the main switch in the (off) posi- tion, the electrical circuits are off, and the key can be removed.
(on)
With the main switch in the (on) posi- tion, the electrical circuits are on, and the key cannot be removed.
(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.
EMU32052
Power trim and tilt switch on remote control
The power trim and tilt system adjusts the outboard motor angle in relation to the tran- som. Pressing the switch (up) trims the outboard motor up, and then tilts it up. Press- ing the switch (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current position. For instructions on using the power trim and tilt switch, see pages 47 and 49.
1. Cord 2. Clip 3. Engine shut-off switch
ZMU03903
Components
23
EMU26153
Power trim and tilt switch on bottom engine cowling
The power trim and tilt switch is located on the side of the bottom engine cowling. Press- ing the switch (up) trims the outboard motor up, and then tilts it up. Pressing the switch (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current position. For instructions on using the power trim and tilt switch, see page 49.
WARNING
EWM01030
Use the power trim and tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the en- gine off. Attempting to use this switch while the boat is moving could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obsta-
cle.
EMU26244
Trim tab with anode
WARNING
EWM00840
An improperly adjusted trim tab could cause difficult steering. Always test run after the trim tab has been installed or re-
placed to be sure steering is correct. Be sure you have tightened the bolt after ad-
justing the trim tab.
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. If the boat tends to veer to the left (port side), turn the trim tab rear end to the port side A in the figure. If the boat tends to veer to the right (starboard side), turn the trim tab end to the starboard side B in the figure.
NOTICE
ECM00840
The trim tab also serves as an anode to protect the engine from electrochemical corrosion. Never paint the trim tab as it
will become ineffective as an anode.
UP
DN
ZMU03517
1. Trim tab 2. Bolt 3. Cap
1
2
3
ZMU02525
A
B
Components
24
EMU26341
Tilt support lever for power trim and tilt model
To keep the outboard motor in the tilted up position, lock the tilt support lever to the clamp bracket.
NOTICE
ECM00660
Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt sup- port and fall. If the motor cannot be trail- ered in the normal running position, use an additional support device to secure it
in the tilt position.
EMU26400
Top cowling release lever
The top cowling can be removed by operat- ing the cowling release lever. Pulling the front lever unlocks the top cowling for remov- al.
When installing the top cowling: 1. Set the top cowling straight down onto
the engine, being careful to avoid catch- ing spark plug wires or other wires.
2. Align the three cowling hooks with the locks on the bottom cowling.
3. Press down on the top of the cowling at the front and both sides of the back until the three locks click.
4. To make sure the cowling is locked properly push the cowling from each side. If it lifts, repeat step 3.
NOTICE
ECM00070
Make sure the cowling lock connection
Bolt tightening torque: 42.0 Nm (4.2 kgf-m, 31 ft-lb)
1. Tilt support lever
A B
ZMU01863
ZMU03979
1
ZMU03518
ZMU03519
Components
25
cable is operating correctly before rein- stalling the top cowling.
When the release lever is operated, both the front and rear cowling hooks should be released at the same time. If not, adjust the rear clamp cable adjust- ers.
Make sure the cable operates smoothly and is free of corrosion.
Check that the cable is properly se- cured in the holder.
When reinstalling the cowling, ensure that both the front and rear locks have operated properly. If the cowling has not been locked properly, some parts may be damaged by the top cowling
shaking during operation.
EMU26460
Flushing device
This device is used to clean the cooling wa- ter passages of the motor using a garden hose and tap water.
TIP:
For details on usage, see page 55.
1. Flushing device
1
ZMU04139
26
Instruments and indicators
EMU26493
Digital tachometer
The tachometer shows the engine speed and has the following functions. All segments of the display will light momen- tarily after the main switch is turned on and will return to normal thereafter.
TIP:
The water separator and engine trouble-alert indicators only operate when the engine is equipped with the appropriate functions.
EMU26621
Trim meter
This meter shows the trim angle of your out- board motor.
Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired using the power trim and tilt switch.
If the trim angle of your motor exceeds the trim operating range, the top segment on the trim meter display will blink.
EMU26651
Hour meter
This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off.
To change the display format, press the (mode) button. The display can show total hours or trip hours, or turn off. To reset the trip hours, simultaneously press the (set) and (mode) buttons for more than 1 second while the trip hours are displayed. This resets the trip counter to 0 (zero). The total number of hours the engine has been run cannot be reset.
EMU26551
Oil level indicator (digital type)
This indicator shows the engine oil level. If the oil level falls below the lower limit, the
1. Tachometer 2. Trim meter 3. Hour meter 4. Oil level indicator 5. Overheat-alert indicator 6. Set button 7. Mode button
1
3
5 6 7
4
2
ZMU01891
ZMU01869
ZMU01870
Instruments and indicators
27
alert indicator will start to blink. For further in- formation, see page 31.
NOTICE
ECM00030
Do not operate the engine without oil. Se-
rious engine damage will occur.
EMU26583
Overheat-alert indicator
If the engine temperature rises too high, the alert indicator will start to blink. For further in- formation on reading the indicator, see page 31.
NOTICE
ECM00052
Do not continue to run the engine if the overheat-alert indicator is on. Serious en-
gine damage will occur.
EMU26602
Digital speedometer
This gauge shows the boat speed and other information.
All segments of the display will light momen- tarily after the main switch is turned on and will return to normal thereafter.
EMU36061
Speedometer
The speedometer displays km/h, mph, or knots, according to operator preference. Se- lect the desired units of measurement by set- ting the selector switch on the back of the gauge. See the illustration for settings.
1. Oil level indicator
1 ZMU01867
1
ZMU01868
1. Speedometer 2. Fuel gauge 3. Trip meter/clock/voltmeter 4. Alert indicator(s)
1. Cap 2. Selector switch (for speed unit) 3. Selector switch (for fuel sensor)
Instruments and indicators
28
EMU26712
Fuel gauge
Eight segments indicate the fuel level. When all segments are showing, the fuel tank is full.
The fuel level reading can be inaccurate due to by the position of the sensor in the fuel tank and the attitude of the boat in the water. Operation with bow-up trim or continuous turning can give false readings. Do not adjust the selector switch for fuel sen- sor. Incorrectly setting the selector switch on the gauge will give false readings. Consult your Yamaha dealer on how to correctly set the selector switch.
NOTICE:
Running out of fuel can damage the engine.
[ECM01770]
EMU36071
Trip meter / Clock / Voltmeter
The display shows either the trip meter, the clock, or the voltmeter. To change the display, press the (mode) button repeatedly until the indicator on the face of the gauge points to (trip meter), (clock), or (voltmeter).
EMU26691
Trip meter
This gauge displays the distance the boat has traveled since the gauge was last reset. The trip distance is shown in kilometers or miles depending upon the unit of measure- ment selected for the speedometer. To reset the trip meter to zero, press the
(set) and (mode) buttons at the same time. The trip distance is kept in memory by bat- tery power. The stored data will be lost if the battery is disconnected.
EMU26701
Clock
To set the clock: 1. Be sure the gauge is in the (time)
mode. 2. Press the (set) button; the hour dis-
play will begin blinking. 3. Press the (mode) button until the
desired hour is displayed. 4. Press the (set) button again, the
minute display will begin blinking. 5. Press the (mode) button until the
desired minute is displayed. 6. Press the (set) button again to start
the clock.
The clock operates on battery power. Dis-
ZMU01745
Instruments and indicators
29
connecting the battery will stop the clock. Reset the clock after connecting the battery.
EMU36080
Voltmeter
The voltmeter displays the charge of the bat- tery in volts(V).
EMU26721
Fuel level-alert indicator
If the fuel level decreases to one segment, the fuel level alert segment will blink. Do not continue to operate the engine with full throttle if an alert device has activated. Get back to the port within trolling engine speed.
NOTICE:
Running out of fuel can damage the engine.
[ECM01770]
EMU26732
Low battery voltage-alert indicator
If battery voltage drops, the display will auto- matically turn on and blink. Get back to the port soon if an alert device has activated. For charging the battery, con- sult your Yamaha dealer.
EMU26471
Analog tachometer
This gauge shows the engine speed and has the following functions.
EMU26541
Oil level indicators (three indicators 2)
The indicators on the gauge show the status of the oil level. For details on how to read the indicators, see page 42.
NOTICE
ECM00030
Do not operate the engine without oil. Se-
rious engine damage will occur.
1. Fuel level-alert segment
1. Low battery indicator
1. Tachometer 2. Oil level indicator
ZMU04577
1
2
Instruments and indicators
30
EMU26611
Analog trim meter
This gauge shows the trim angle of your out- board motor.
Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired setting with the power trim and tilt switch.
1. Oil level indicators
ZMU04580
1
ZMU04581
31
Engine control system
EMU26803
Alert system
NOTICE
ECM00091
Do not continue to operate the engine if a alert device has activated. Consult your Yamaha dealer if the problem cannot be
located and corrected.
EMU2681A
Overheat alert
This engine has an overheat-alert device. If the engine temperature rises too high, the alert device will activate.
The engine speed will automatically de- crease to about 2000 r/min.
The overheat-alert indicator will light or blink.
The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel).
If the alert system has activated, stop the en- gine and check the cooling water inlets:
Check trim angle to be sure that the cool- ing water inlet is submerged.
Check the cooling water inlet for clogging.
EMU26848
Oil level alert and oil filter clogging alert
Oil injection models
This engine has an oil level alert system. If the oil level falls below the lower limit, the alert system will activate.
Activation of alert device
Engine speed will automatically decrease to about 2000 r/min.
The oil level-alert indicator will light or blink.
ZMU01757
ZMU04766
ZMU02630
Engine control system
32
The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel).
If the alert system has been activated, stop the engine and check for the cause.
TIP:
The alert for oil filter clogging is similar to the alerts for low oil level and overheating. To make troubleshooting easier, check for en- gine overheating first, then oil level, and fi-
nally oil filter clogging.
ZMU03942
ZMU04586
ZMU03025
1. Oil lter
1. Oil lter
1
ZMU03906
1 ZMU01952
33
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.
WARNING
EWM01590
Overpowering a boat could cause se- vere instability. Do not install an out- board motor with more horsepower than the maximum rating on the capac- ity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.
Improper mounting of the outboard mo- tor could result in hazardous condi- tions such as poor handling, loss of control, or fire hazards. For permanent- ly mounted models, your dealer or oth- er person experienced in proper
rigging should mount the motor.
EMU33470
Mounting the outboard motor
The outboard motor should be mounted so that the boat is well balanced. Otherwise, the boat could be hard to steer. For single-en- gine boats, mount the outboard motor on the centerline (keel line) of the boat.
EMU26931
Mounting height (boat bottom)
The mounting height of your outboard motor affects its efficiency and reliability. If it is mounted too high, propeller ventilation may occur, which will reduce propulsion due to excessive propeller slip, and the water in- takes for the cooling system may not get ad- equate water supply, which can cause engine overheating. If the engine is mounted too low, water resistance (drag) will in- crease, thereby reducing engine efficiency and performance. Most commonly, outboard motor should be mounted so that the anti-cavitation plate is in alignment with the bottom of the boat. The optimum mounting height of the outboard motor is affected by the boat/motor combina- tion and the desired use. Test runs at differ- ent heights can help determine the optimum mounting height. Consult your Yamaha deal- er or boat manufacturer for further informa- tion on determining the proper mounting height.
1. Center line (keel line)
1 ZMU01873
Installation
34
NOTICE
ECM01630
During water testing, check the buoy- ancy of the boat, at rest, with its maxi- mum load. Check that the static water level on the exhaust housing is low enough to prevent water entry into the power head when water rises due to waves when the outboard is not run- ning.
Incorrect engine height or obstructions to the smooth flow of water (such as the design or condition of the boat, or ac- cessories such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. If the motor is operated con- tinuously in the presence of airborne water spray, enough water could enter the engine through the intake opening on the cowling to cause severe engine damage. Eliminate the cause of the air-
borne water spray.
ZMU01762
35
Operation
EMU36380
First-time operation
EMU27020
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
ECM00140
Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage.
Premix fuel must be used during break- in in addition to oil in the oil injection
system.
EMU27060
Gasoline and engine oil mixing chart (50:1)
NOTICE
ECM00150
Be sure to mix gasoline and oil complete- ly, otherwise the engine may be dam-
aged.
EMU30311
Procedure for oil injection models
Run the engine under load (in gear with a propeller installed) for 10 hours as follows. 1. First 10 minutes:
Run the engine at the lowest possible speed. A fast idle in neutral is best.
2. Next 50 minutes: Do not exceed half throttle (approxi- mately 3000 r/min). Vary engine speed occasionally. If you have an easy-plan- ing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3000 r/min or less.
3. Next two hours: Accelerate at full throttle onto plane, then reduce engine speed to three-quar- ter throttle (approximately 4000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three- quarter throttle or less to let the engine cool.
4. Remaining seven hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.
5. After the first 10 hours: Operate the engine normally. Use only straight gasoline in the fuel tank. The Yamaha oil injection system provides proper lubrication for normal operation.
EMU36400
Getting to know your boat
Different boats handle differently. Operate cautiously while you learn how your boat handles under different conditions and with different trim angles (see page 47).
EMU36412
Checks before starting engine
WARNING
EWM01920
If any item in the checks before starting engine is not working properly, have it in- spected and repaired before operating the outboard motor. Otherwise an acci-
1. : Gasoline
2. : Engine oil
Operation
36
dent could occur.
NOTICE
ECM00120
Do not start the engine out of water. Over- heating and serious engine damage can
occur.
EMU37150
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, turn the key to (on) and check the fuel level. For fuel filling instructions, see page 40.
EMU36570
Remove cowling
For the following checks, remove the top cowling from the engine. To remove the en- gine top cowling, release the lock lever and lift off the cowling.
EMU36440
Fuel system
WARNING
EWM00060
Gasoline and its vapors are highly flam- mable and explosive. Keep away from sparks, cigarettes, flames, or other
sources of ignition.
WARNING
EWM00910
Leaking fuel can result in fire or explo- sion.
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.
EMU36450
Check for fuel leaks
Check under top cowling and in the boat for fuel leaks or gasoline fumes.
Check fuel line connections to be sure they are tight.
Check fuel lines for cracks, swelling, or other damage.
EMU37320
Check the fuel filter
Check that the fuel filter is clean and free of water. If any water is found in the fuel, or if a significant amount of debris is found, the fuel tank should be checked and cleaned by a Yamaha dealer.
EMU36460
Controls
Turn the steering wheel full-right and full- left. Make sure operation is smooth and unrestricted throughout the whole range with no binding or excessive free play.
ZMU06101
ZMU04151
Operation
37
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 damaged connections of the throttle and shift cables under the en- gine cowling.
EMU36481
Engine shut-off cord (lanyard)
Inspect the engine shut-off cord for damage, such as cuts, breaks, and wear.
EMU27120
Oil
Check to be sure you have plenty of oil for your trip.
EMU27151
Engine
Check the engine and engine mounting.
Look for loose or damaged fasteners.
Check the propeller for damage.
Check for oil leaks.
EMU27171
Operation after a long period of storage
When operating the engine after a long peri- od (12 months) of storage, proceed as fol-
lows: 1. Use a 50:1 gasoline-oil mixture to start
the engine. 2. Start the engine. Leave it idling.
WARNING! Do not touch or remove electrical parts when starting or dur- ing operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.
[EWM00091]
3. Watch for oil flowing through the oil feed
pipes. After any air in the oil lines has been expelled, the oil injection system should supply oil normally. If no oil is flowing after 10 minutes of idling, consult your Yamaha dealer.
NOTICE
ECM00130
Be sure to take the above steps when op- erating the engine after a long period of storage. Otherwise engine seizure could
occur.
EMU36490
Flushing device
Check that flushing devices garden hose connector is securely screwed on to the fit- ting on the bottom cowling.
NOTICE:
If the flushing device is not properly connect- ed, cooling water can leak out and the en- gine can overheat during operation.
[ECM01800]
1. Cord 2. Clip 3. Engine shut-off switch ZMU04141
Operation
38
EMU37520
Install cowling
1. Be sure that a cowling lock lever is re- leased.
2. Be sure that the rubber seal is seated all the way around the engine.
3. Set the top cowling straight down onto the engine, being careful to avoid catch- ing spark plug wires or other wires.
4. Align the three cowling hooks with the locks on the bottom cowling.
5. Press down on the top of the cowling at the front and both sides of the back until the three locks click.
6. Check to be sure it fits properly in the rubber seal.
7. Move the lever to lock the cowling as shown.
NOTICE:
If the cowling is not installed correctly, water spray under
the cowling can damage the engine, or the cowling can blow off at high speeds.
[ECM01990]
After installing, check the fitting of the top cowling by pushing it with both hands. If the top cowling is loose, have it repaired by your Yamaha dealer.
EMU29158
Checking power trim and tilt system
WARNING
EWM01930
Never get under the lower unit while it is tilted, even when the tilt support lever is locked. Severe injury could occur if the outboard motor accidentally falls.
Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted.
Be sure no one is near the outboard
motor before performing this check.
1. Flushing device
1
ZMU04139
ZMU03519
ZMU06126
ZMU04679
Operation
39
1. Check the power trim and tilt unit for any sign of oil leaks.
2. Operate each of the power trim and tilt switches on the remote control and en- gine bottom cowling to check that all switches work.
3. Tilt the outboard motor up and check that the tilt rod and trim rods are extend- ed completely.
4. Use the tilt support lever to lock the mo- tor in the up position. Operate the tilt down switch briefly so the motor is sup- ported by the tilt support lever.
5. Check that the tilt rod and trim rods are free of corrosion or other flaws.
6. Activate the tilt-down switch until the trim
rods have retracted completely into the cylinders.
7. Activate the trim-up switch until the tilt rod is fully extended. Unlock the tilt sup- port lever.
8. Tilt the outboard motor down. Check that the tilt rod and trim rods operate smoothly.
EMU36581
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 the engine. Refer to the battery manufacturers instruc- tions for checks for your particular battery.
1. Tilt rod 2. Trim rods
1. Tilt support lever
ZMU03458
1
2
ZMU04155
1
ZMU04156
ZMU02635
Operation
40
EMU27234
Filling fuel and engine oil
EMU30321
Filling fuel for models without a fuel joint
WARNING
EWM01830
Gasoline and its vapors are highly flam- mable and explosive. Always refuel ac- cording to this procedure to reduce the risk of fire and explosion.
Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and wa- ter. If gasoline spills on your clothing,
change your clothes.
1. Stop the engine. 2. Be sure you are in a well-ventilated out-
door area, either securely moored or trailered.
3. Make sure no one is in the boat. 4. Do not smoke and keep away from
sparks, flames, static electric discharge, or other sources of ignition.
5. If you use a portable container to store and dispense fuel, only use a locally ap- proved GASOLINE container.
6. Touch the fuel nozzle to the filler open- ing or funnel to help prevent electrostatic sparks.
7. Fill the fuel tank, but do not overfill. Fuel can expand and overflow if the tempera- ture increases.
8. Tighten the filler cap securely. 9. Wipe up any spilled gasoline immediate-
ly with dry rags. Dispose rags properly.
According to local laws or regulations.
EMU27282
Filling oil
This engine uses the Yamaha oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operat- ing conditions. No fuel premixing is needed. Simply pour gasoline into the fuel tank and oil into the oil tank. Convenient indicator seg- ments indicate the status of the oil supply. For details on reading the indicator seg- ments, see page 42.
WARNING
EWM00530
Do not add gasoline into the oil tank. Fire
or explosion could result.
To fill the engine oil tank, proceed as follows: 1. Pour engine oil into the remote oil tank.
TIP:
The oil level lines on the remote oil tank indi- cate the amount of additional oil that can be added to the tank. The top oil level line indi- cates approximately 1.9 L (0.5 US gal, 0.4 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. 2. Turn on the main switch. The Yamaha
Engine oil tank capacity: 0.9 L (0.95 US qt, 0.79 Imp.qt)
ZMU04142
Operation
41
oil injection system will automatically feed oil from the remote oil tank to the engine oil tank.
3. After the engine oil tank has filled, turn off the main switch to cancel the oil level alert.
4. Operate the engine normally.
NOTICE
ECM00570
When the engine is operated for the first time or stored for a period of time, a min- imum of 5 liters (5.3 US qt, 4.4 Imp qt) of oil should be kept in the remote oil tank. Otherwise the oil-feed pump chamber will not be filled with oil, and no oil will be
supplied.
ON STARTOFF
ZMU04143
ON STARTOFF
ZMU04144
Operation
42
EMU27321
Oil level indicator operation
The various functions of the oil level system are as follows:
EMU27383
Oil level indicator
Electric start models
Oil level-alert indicator (digital
tachometer)
Oil level-alert indicator (analog
tachometer)
Engine oil tank
Remote oil tank
Remarks
Green
more than 300
cm
3
(0.32 US qt, 0.26
Imp qt)
more than
1500 cm
3
(1.6 US qt, 1.31
Imp qt)
No relling necessary.
Yellow
more than 300
cm
3
(0.32 US qt, 0.26
Imp qt)
1500 cm
3
(1.6 US qt, 1.31 Imp qt) or less
Add oil; see page 40.
RedYellow Green
300 cm
3
(0.32 US qt, 0.26
Imp qt) or less
more than
1500 cm
3
(1.6 US qt, 1.31 Imp qt)
Check oil lter for clog- ging.
Check battery cable connection. Buzzer will sound.
Engine speed is auto- matically reduced to about 2000 r/min.
Red
300 cm
3
(0.32 US qt, 0.26
Imp qt) or less
1500 cm
3
(1.6 US qt, 1.31 Imp qt) or less
Oil has not been added.
Buzzer will sound.
Engine speed is auto- matically reduced to about 2000 r/min.
Buzzer sounds in remote control box and engine speed is limited to about 2000 r/min to help conserve oil.
Operation
43
EMU27451
Operating engine
EMU27482
Feeding fuel
WARNING
EWM00420
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. Gaso- line is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosen- ing the air vent screw.
This product emits exhaust gases which contain carbon monoxide, a col- orless, odorless gas which could cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cab- in areas well ventilated. Avoid blocking
exhaust outlets.
1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.
2. If there is a fuel joint or a fuel cock on the boat, firmly connect the fuel line to the joint or open the fuel cock.
3. Squeeze the primer pump, with the ar- row pointing up, until you feel it become firm.
EMU27492
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 are no swimmers in the wa-
ter near you.
EMU27645
Electric start / remote control 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 clothing that could tear loose. Do not route the cord where it could become entangled, pre- venting it from functioning.
Avoid accidentally pulling the cord dur- ing 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.
1. Place the remote control lever in neutral.
ZMU02025
Operation
44
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 other end of the cord into the engine shut-off switch.
3. Turn the main switch to (on).
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 equipped with a neu- tral throttle lever, a good starting point is to lift the lever just until you feel resistance, then lift slightly more.
The neutral throttle lever or free accelera- tor can only be used when the remote con- trol lever is in neutral.
5. Press in and hold the main switch to op- erate the remote choke system. The re- mote choke switch automatically returns to its normal position when you release your hand. Therefore keep the switch pressed in.
TIP:
It is not necessary to use the choke when starting a warm engine.
Push in the main switch fully, or the remote choke system will not operate.
6. Turn the main switch to (start), and hold it for a maximum of 5 seconds.
OFF
ON
ZMU01880
N
ZMU02314
Operation
45
7. Immediately after the engine starts, re- lease the main switch and allow it to re- turn to (on).
NOTICE:
Never turn the main switch to (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds 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 that the wa- ter pump is pumping water through the cool- ing passages. If the cooling passages are frozen, it may take a while for water to start flowing out of the pilot hole.
NOTICE
ECM01810
If water is not flowing out of the pilot hole at all times while the engine is running,
overheating and serious damage could occur. Stop the engine and check wheth- er the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and cor-
rected.
Check that no water leaks from the joints be- tween the exhaust cover, cylinder head, and body cylinder.
EMU27670
Warming up engine
EMU27683
Choke start models
After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life. Gradually return the choke knob to its home position as the en- gine warms up.
EMU36530
Checks after engine warm-up
EMU36540
Shifting
While tightly moored, and without applying throttle, confirm that the engine shifts smoothly into forward and reverse, and back to neutral.
EMU31721
Stop switches
Confirm that turning the main switch to the (off) position stops the engine.
ZMU03262
ON STARTOFF
ZMU03908
Operation
46
Confirm that removing the clip from the en- gine shut-off switch stops the engine.
Confirm that the engine cannot be started with the clip removed from the engine shut-off switch.
EMU31730
Shifting
WARNING
EWM00180
Before shifting, make sure there are no swimmers or obstacles in the water near
you.
NOTICE
ECM01610
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. If this occurs, stop the engine, shift to neutral, then restart the
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 firmly and crisply forward (for forward gear) or backward (for reverse gear) about 35 (a detent can felt).
To shift from in gear (forward/reverse) to neutral 1. Close the throttle so that the engine
slows to idle speed.
2. After the engine is at idle speed in gear move the remote control lever firmly and crisply into the neutral position.
1. Neutral interlock trigger
Operation
47
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 ejected, or im- pact the steering wheel or other parts of the boat. This could increase the risk of serious injury. It could also damage the shift mechanism.
Do not shift into reverse while traveling at planing speeds. Loss of control, boat swamping, or damage to the boat could
occur.
The boat is not equipped with a separate braking system. Water resistance stops it af- ter the throttle lever is moved back to idle. The stopping distance varies depending on gross weight, water surface conditions, and wind direction.
EMU27821
Stopping engine
Before stopping the engine, first let it cool off for a few minutes at idle or low speed. Stop- ping the engine immediately after operating at high speed is not recommended.
EMU27853
Procedure
1. Turn the main switch to (off).
2. After stopping the engine, disconnect
the fuel line or close the fuel cock if there is a fuel joint or a fuel cock on the boat.
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 removing the clip from the en- gine shut-off switch, then turning the main switch to (off).
EMU27862
Trimming outboard motor
WARNING
EWM00740
Excessive trim for the operating condi- tions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This in- creases 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.
The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help im- prove performance and fuel economy while reducing strain on the engine. Correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.
Operation
48
EMU27884
Adjusting trim angle (Power trim and tilt)
WARNING
EWM00753
Be sure all people are clear of the out- board motor when adjusting the trim angle. Body parts can be crushed be- tween the motor and the clamp bracket when the motor is trimmed or tilted.
Use caution when trying a trim position for the first time. Increase speed gradu- ally and watch for any signs of instabil- ity or control problems. Improper trim angle can cause loss of control.
If equipped with a power trim and tilt switch located on the bottom cowling, use the switch only when the boat is at a complete stop with the engine off. Do 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.
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.
EMU27911
Adjusting boat trim
When the boat is on plane, a bow-up attitude results in less drag, greater stability and effi- ciency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden-
1. Trim operating angle
1 ZMU04145
1. Power trim and tilt switch
1. Power trim and tilt switch
UP
DN ZMU03522
1
Operation
49
cy to steer to one side or the other. Compen- sate for this as you steer. The trim tab can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.
Bow Up
Too much trim-out puts the bow of the boat too high in the water. Performance and econ- omy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces per- formance further, and the boat may por- poise (hop in the water), which could throw the operator and passengers overboard.
Bow Down
Too much trim-in causes the boat to plow through the water, decreasing fuel economy and making it hard to increase speed. Oper- ating with excessive trim-in at higher speeds
also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of bow steering and making opera- tion difficult and dangerous.
TIP:
Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.
EMU27934
Tilting up and down
If the engine will be stopped for some time or if the boat is moored in shallows, the out- board motor should be tilted up to protect the propeller and lower casing from damage by collision with obstructions, and also to re- duce salt corrosion.
WARNING
EWM00221
Be sure all people are clear of the out- board motor when tilting up and down, Body parts can be crushed between the motor and the clamp bracket when the
motor is trimmed or tilted.
WARNING
EWM00250
Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, discon- nect the fuel line or close the fuel cock if the engine will be tilted for more than a
Operation
50
few minutes. Otherwise fuel may leak.
NOTICE
ECM00241
Before tilting the outboard motor, stop the engine by following the procedure on page 47. 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 tiller handle (if equipped) because this
could break the handle.
EMU32723
Procedure for tilting up (power trim and tilt models)
1. Place the remote control lever in neutral.
2. Press the power trim and tilt switch (up) until the outboard motor has tilted up completely.
3. Pull the tilt support lever toward you to support the engine.
WARNING! After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever. Otherwise the out- board motor could fall back down suddenly if oil in the power trim and tilt unit or in the power tilt unit loses pressure.
[EWM00262]
NOTICE:
Do not use the tilt support lever or knob when trailering the boat. The outboard mo- tor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running po- sition, use an additional support de- vice to secure it in the tilt position. For more detailed information, see page 53.
[ECM01641]
4. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim
N
ZMU03196
UP
ZMU04146
ZMU03432
Operation
51
and tilt switch (down) to retract the trim rods.
NOTICE:
Be sure to retract the trim rods completely during mooring. This protects the rods from marine growth and corrosion which could damage the power trim and tilt mechanism.
[ECM00251]
EMU33120
Procedure for tilting down (power trim and tilt models)
1. Push the power trim and tilt switch (up) until the outboard motor is support- ed by the tilt rod and the tilt support lever becomes free.
2. Release the tilt support lever.
3. Push the power trim and tilt switch (down) to lower the outboard motor to the desired position.
EMU28061
Shallow water
EMU32851
Power trim and tilt models
The outboard motor can be tilted up partially to allow operation in shallow water.
NOTICE
ECM00260
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. Otherwise severe damage from overheat-
ing can result.
EMU32922
Procedure for power trim and tilt models
1. Place the remote control lever in neutral.
ZMU03452
ZMU03453
DN
ZMU01936
UP
DN
DN
ZMU04147
Operation
52
2. Slightly tilt the outboard motor up to the desired position using the power trim and tilt switch.
WARNING! Using the power trim and tilt switch on the bot- tom cowling while the boat is moving or engine is on could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obstacle.
[EWM01850]
3. To return the outboard motor to the nor-
mal running position, press the power trim and tilt switch and slowly tilt the out- board motor down.
EMU28194
Cruising in other conditions
Cruising in salt water
After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh wa- ter and, if possible, rinse the power head un- der the cowling.
Cruising in muddy, turbid, or acidic water
Yamaha strongly recommends that you use the optional chromium-plated water pump kit (see page 17) if you use the outboard motor in acidic water or water with a lot of sediment 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.
UP
ZMU01935
UP
DN
UP
ZMU04146
53
Maintenance
EMU28226
Transporting and storing outboard motor
WARNING
EWM00692
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. This can cause fuel leakage and a potential fire
hazard.
WARNING
EWM01860
Leaking fuel is a fire hazard. When trans- porting and storing the outboard motor, close the fuel cock to prevent fuel from leaking. Never get under the engine while it is tilted. Severe injury could occur if the
outboard motor accidentally falls.
NOTICE
ECM00660
Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt sup- port and fall. If the motor cannot be trail- ered in the normal running position, use an additional support device to secure it
in the tilt position.
The outboard motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the tilt po- sition using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details.
EMU30272
Storing outboard motor
When storing your Yamaha outboard motor
for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the fol- 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 place, not in direct sunlight.
EMU28303
Procedure
EMU28383
Flushing with the flushing attachment
1. Wash the outboard motor body using fresh water.
NOTICE:
Do not spray wa- ter into the air intake.
[ECM01840]
For fur- ther information, see page 56.
2. Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer to each gallon of fuel.
TIP:
The use of Yamaha Fuel Conditioner and
ZMU04154
Maintenance
54
Stabilizer eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead. 3. Remove the top cowling and silencer
cover/cap. Remove the propeller. 4. Install the flushing attachment over the
cooling water inlet.
NOTICE:
Do not run the engine without supplying it with cooling water. Either the engine wa- ter pump will be damaged or the en- gine will be damaged from overheating. Before starting the en- gine, be sure to supply water to the cooling water passages. Avoid run- ning the outboard motor at high speed while on the flushing attach- ment, otherwise overheating could occur.
[ECM02000]
5. Cooling system flushing is essential to prevent the cooling system from clog- ging up with salt, sand, or dirt. In addi- tion, fogging/lubricating of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flush- ing and fogging at the same time.
WARNING! Do not touch or remove electrical parts when starting or dur- ing operation. Keep hands, hair, and
clothes away from the flywheel and other rotating parts while the engine is running.
[EWM00091]
6. Run the engine at a fast idle for 1015
minutes in neutral position while supply- ing fresh water.
7. Just prior to turning off the engine, quick- ly spray Yamaha Stor-Rite Engine Fogging Oil alternately into each carbu- retor/each intake manifold. When prop- erly done, the engine will smoke excessively and almost stall.
8. Remove the flushing attachment and wipe off any excess water.
9. Install the silencer cover/cap and top cowling. Install the propeller.
TIP:
A flushing attachment is available from your Yamaha dealer.
EMU28411
Lubrication (oil injection models)
1. Install the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 61.
2. Fill the oil tanks. This prevents the for- mation of condensation. For models with a remote oil tank, it may be necessary to manually override the control unit to completely fill the engine oil tank.
3. Change the gear oil. For instructions, see page 65. Inspect the oil for the pres- ence of water which indicates a leaky seal. Seal replacement should be per- formed by an authorized Yamaha dealer prior to use.
4. Grease all grease fittings. For further de- tails, see page 61.
TIP:
For long-term storage, fogging the engine with oil is recommended. Contact your Yamaha dealer for information about fogging
1. Flushing attachment
Maintenance
55
oil and procedures for your engine.
EMU28423
Cleaning and anticorrosion measures
1. Wash down the exterior of the outboard motor with fresh water and dry off com- pletely.
NOTICE:
Do not spray water into the air intake.
[ECM01840]
2. Spray the outboard motor exterior with
Yamaha Silicone Protectant. 3. Wax the cowling with a non-abrasive
wax such as Yamaha Silicone Wax.
EMU28443
Flushing power unit
Perform this procedure right after operation for the most thorough flushing.
NOTICE
ECM01530
Do not perform this procedure while the engine is running. The water pump may be damaged and severe damage from
overheating can result.
1. After shutting off the engine, unscrew the garden hose connector from the fit- ting on the bottom cowling.
2. Screw the garden hose adapter onto a garden hose, which is connected to a fresh water supply, and then connect it to the garden hose connector.
3. With the engine off, turn on the water tap and let the water flush through the cool- ing passages for about 15 minutes. Turn off the water and disconnect the garden hose adapter from the garden hose con- nector.
4. Reinstall the garden hose connector onto the fitting on the bottom cowling. Tighten the connector securely.
NO- TICE:
Do not leave the garden hose connector loose on the bottom cowl- ing fitting or let the hose hang free during normal operation. Water will leak out of the connector instead of
1. Fitting 2. Garden hose connector 3. Garden hose
1 2 3
ZMU04148
Maintenance
56
cooling the engine, which can cause serious overheating. Be sure the con- nector is tightened securely on the fitting after flushing the engine.
[ECM00541]
TIP:
When flushing the engine with the boat in the water, tilting up the outboard motor un- til it is completely out of the water will achieve better results.
For cooling system flushing instructions, see page 53.
EMU28450
Cleaning the outboard motor
After use, wash the exterior of the outboard motor with fresh water. Flush the cooling system with fresh water.
TIP:
For cooling system flushing instructions, see page 53.
EMU28460
Checking painted surface of motor
Check the motor for scratches, nicks, or flak- ing paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is avail- able from your Yamaha dealer.
EMU2848A
Periodic maintenance
WARNING
EWM01871
These procedures require mechanical skills, tools, and supplies. If you do not have the proper skills, tools, or supplies to perform a maintenance procedure, have a Yamaha dealer or other qualified mechanic do the work. The procedures involve disassembling the motor and exposing dangerous parts. To reduce the risk of injury from moving, hot, or electrical parts:
Turn off the engine and keep the key(s) and engine shut-off cord (lanyard) with you when you perform maintenance unless otherwise specified.
The power trim and tilt switches oper- ate even when the ignition key is off. Keep people away from the switches whenever working around the motor. When the motor is tilted, keep away from the area under it or between it and the clamp bracket. Be sure no one is in this area before operating the power trim and tilt mechanism.
Allow the engine to cool before han- dling hot parts or fluids.
Always completely reassemble the mo-
tor before operation.
Maintenance, replacement, or repair of the emission control devices and sys- 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 dealer for owners who
ZMU02550
Maintenance
57
have the mechanical skills, tools, and other equipment necessary to perform mainte- nance not covered by this owners manual.
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. Yamaha genuine parts and ac- cessories are available from your Yamaha dealer.
EMU35520
Maintenance interval guidelines
The service intervals provided in the Mainte- nance Chart were developed based upon typical use that includes operating at varied speeds, with sufficient time for engine warm up and cool-down, a medium to light load, and an average cruising speed near the 3000 to 4000 rpm range. As with any engine, however, if your normal operating conditions are different, you should consider service more often than shown, especially how often you change your engine and gear oil. Exam- ples might include extended wide-open- throttle use or long periods of trolling or idling, carrying heavy loads, or frequent starting and stopping or shifting. More fre- quent maintenance will often pay off many times over in increased engine life and great- er owner satisfaction. Consult your Yamaha dealer for additional maintenance recom- mendations.
Maintenance
58
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 adjusted when operating the engine under adverse conditions such as extended trolling.
Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
Expendable or consumable parts and lubricants will lose their effectiveness over time and through normal usage regardless of the warranty period.
When operating in salt water, muddy, other turbid (cloudy), acidic 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.
Item Actions
Initial Every
20 hours (3
months)
100 hours (1
year)
300 hours (3 years)
500 hours (5 years)
Anode(s) (external) Inspection or replace- ment as necessary
Anode(s) (cylinder head, thermostat cover)
Inspection or replace- ment as necessary
Anodes (exhaust cover, cooling water passage cover, Rectier Regula- tor cover)
Replacement
Battery (electrolyte level, terminal)
Inspection
Battery (electrolyte level, terminal)
Fill, charging or replac- ing as necessary
Cooling water leakage Inspection or replace- ment as necessary
Cowling clamp Inspection
Engine starting condi- tion/Noise
Inspection
Engine idling speed/ Noise
Inspection
Fuel lter (can be dis- assembled)
Inspection or replace- ment as necessary
Fuel line(High pres- sure)
Inspection
Maintenance
59
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/oil leakage Inspection
Gear oil Replacement
Greasing points Greasing
Impeller/water pump housing
Inspection or replace- ment as necessary
Impeller/water pump housing
Replacement
Oil tank water drain Inspection or cleaning
Oil injection pump/oil feed pump
Inspection or Adjust- ment
Power trim & tilt unit/ Operation,noise and oil leakage
Inspection
Propeller/Propeller nut/ Cotter pin
Inspection or replace- ment as necessary
Shift link/shift cable Inspection, adjustment or replacement as nec- essary
Spark plug(s) Inspection or replace- ment as necessary
Spark plug caps/high tension cords
Inspection or replace- ment as necessary
Water from the cooling water pilot hole
Inspection
Throttle link/Throttle cable/Throttle pick-up timing
Inspection, adjustment or replacement as nec- essary
Thermostat Inspection or replace- ment as necessary
Water inlet Inspection
Item Actions
Initial Every
20 hours (3
months)
100 hours (1
year)
300 hours (3 years)
500 hours (5 years)
Maintenance
60
EMU34451
Maintenance chart 2
Main switch/stop switch/choke switch
Inspection or replace- ment as necessary
(Yamaha) Meter/gauge Inspection
Item Actions Every
1000 hours
Guide exhaust/exhaust manifold
Inspection or replace- ment as necessary
Item Actions
Initial Every
20 hours (3
months)
100 hours (1
year)
300 hours (3 years)
500 hours (5 years)
Maintenance
61
EMU28932
Greasing
Yamaha marine grease (Water resistant grease)
115
EMU28955
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- ple, if the center electrode porcelain is very
white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically re- move and inspect the spark plug because heat and deposits will cause the spark plug
ZMU04149
Maintenance
62
to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should re- place the spark plug with another of the cor- rect type. 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 removing or installing a spark plug, be careful not to damage the in- sulator. A damaged insulator could allow external sparks, which could lead to explosion or fire.
[EWM00561]
3. Be sure to use the specified spark plug, otherwise the engine may not operate properly. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to spec- ification if necessary.
4. When fitting the plug, wipe off any dirt from the threads, and then screw it in to the correct torque.
TIP:
If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past fin- ger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.
EMU37450
Checking fuel filter
Check the fuel filter periodically. If any water or foreign matter is found in the filter, clean or replace it. For cleaning or replacement of the fuel filter, consult your Yamaha dealer.
EMU29041
Inspecting idling speed
WARNING
EWM00451
Do not touch or remove electrical parts when starting or during operation.
Keep hands, hair, and clothes away from the flywheel and other rotating
Standard spark plug: BR8HS-10
1. Spark plug gap 2. Spark plug I.D. mark (NGK) 3. Spark plug part number
Spark plug gap: 0.91.0 mm (0.0350.039 in)
Spark plug torque: 25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
ZMU04151
Maintenance
63
parts while the engine is running.
NOTICE
ECM00490
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. Results may vary depending on whether testing is conducted with the flushing attachment, in a test tank, or with the outboard motor in the water. 1. Start the engine and allow it to warm up
fully in neutral until it is running smooth- ly.
TIP:
Correct idling speed inspection is only possi- ble if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty ver- ifying the idle speed, or the idle speed re- quires adjustment, consult a Yamaha dealer or other qualified mechanic. 2. Verify whether the idle speed is set to
specification. For idle speed specifica- tions, see page 13.
EMU29050
Checking water in engine oil tank
Oil injection models
There is a water trap at the bottom of the en- gine oil tank. If water or foreign matter is vis- ible in this trap, consult your Yamaha dealer.
EMU29112
Checking wiring and connectors
Check that each grounding wire is properly secured.
Check that each connector is engaged se- curely.
EMU32111
Checking propeller
WARNING
EWM01880
You could be seriously injured if the en- gine accidentally starts when you are near the propeller.
Before inspecting, removing, or install- ing the propeller, place the shift control in neutral, turn the main switch to (off) and remove the key, and remove the clip from the engine shut-off switch.
1. Water trap 2. Engine oil tank
2 1
ZMU01895
ZMU03915
Maintenance
64
Turn off the battery cut-off switch if
your boat has one.
Do not use your hand to hold the propeller when loosening or tightening the propeller nut. Put a wood block between the anti-cavi- tation plate and the propeller to prevent the propeller from turning.
Checkpoints
Check each of the propeller blades for wear, erosion from cavitation or ventila- tion, or other damage.
Check the propeller shaft for damage.
Check the splines for wear or damage.
Check for fish line tangled around the pro- peller shaft.
Check the propeller shaft oil seal for dam- age.
EMU30661
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]
3. Remove the propeller, washer (if equipped), and thrust washer.
EMU30671
Installing propeller
EMU29233
Spline models
NOTICE
ECM00500
Be sure to use a new cotter pin and bend the ends over securely. Otherwise the propeller could come off during opera-
tion and be lost.
1. Apply Yamaha marine grease or a cor- rosion resistant grease to the propeller
ZMU01897
1. Cotter pin 2. Propeller nut 3. Washer 4. Spacer 5. Propeller 6. Thrust washer
Maintenance
65
shaft. 2. Install the spacer (if equipped), thrust
washer, washer (if equipped), and pro- peller on the propeller shaft.
NOTICE:
Be sure to install the thrust washer before installing the propeller, other- wise the lower case and propeller boss could be damaged.
[ECM01880]
3. Install the spacer (if equipped) and the
washer. Tighten the propeller nut to the specified torque.
4. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.
NO- TICE:
Do not reuse the cotter pin in- stalled. Otherwise the propeller can come off during operation.
[ECM01890]
TIP:
If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to align it with the hole.
EMU29287
Changing gear oil
WARNING
EWM00800
Be sure the outboard motor is securely 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. Tilt the outboard motor so that the gear oil drain screw is at the lowest point pos- sible.
2. Place a suitable container under the gear case.
3. Remove the gear oil drain screw and gasket.
NOTICE:
If there is an exces- sive quantity of metal particles on the magnetic gear oil drain screw, this can indicate lower unit problem. Con- sult your Yamaha dealer.
[ECM01900]
TIP:
If a magnetic gear oil drain screw is equipped, remove all metal particles from the screw before installing it.
Always use new gaskets. Do not reuse the removed gaskets.
4. Remove the oil level plug and gasket to allow the oil to drain completely.
NO- TICE:
Inspect the used oil after it has
Propeller nut tightening torque: 55.0 Nm (5.61 kgf-m, 40.6 ft-lb)
ZMU03545
1. Gear oil drain screw 2. Oil level plug
ZMU03273
2
1
Maintenance
66
been drained. If the oil is milky, water is getting into the gear case which can cause gear damage. Consult a Yamaha dealer for repair of the lower unit seals.
[ECM00711]
TIP:
For disposal of used oil, consult your Yamaha dealer. 5. Put the outboard motor in a vertical po-
sition. Using a flexible or pressurized fill- ing device, inject the gear oil into the gear oil drain screw hole.
6. Put a new gasket on the oil level plug. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.
7. Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw.
EMU29312
Inspecting and replacing anode(s)
Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.
NOTICE
ECM00720
Do not paint anodes, as this would render
them ineffective.
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.
Recommended gear oil: Hypoid gear oil SAE#90
Gear oil quantity: 0.760 L (0.803 US qt, 0.669 Imp.qt)
Tightening torque: 9 Nm (0.9 kgf-m, 6.6 ft-lb)
Tightening torque: 9 Nm (0.9 kgf-m, 6.6 ft-lb)
ZMU03274
ZMU01901
ZMU03461
Maintenance
67
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 source of ignition near the battery.
Refer to page 14 for detailed safety infor-
mation about batteries.
The procedure for checking the battery var- ies for different batteries. This procedure contains typical checks that apply to many batteries, but you should always refer to the battery manufacturers instructions.
NOTICE
ECM01920
A poorly maintained battery will quickly
deteriorate.
1. Check the electrolyte level.
2. Check the batterys charge. If your boat is equipped with the digital speedome- ter, the voltmeter and low battery alert functions will help you monitor the bat- terys charge. If the battery needs charg-
ing, consult your Yamaha dealer. 3. Check the battery connections. They
should be clean, secure, and covered by an insulating cover.
WARNING! Bad connections can produce shorting or arcing and cause an explosion.
[EWM01910]
EMU29333
Connecting the battery
WARNING
EWM00570
Mount the battery holder securely in a dry, well-ventilated, vibration-free loca- tion in the boat. Install a fully charged bat-
tery in the holder.
NOTICE
ECM01123
Reversal of the battery cables will dam-
age the electrical parts.
1. Make sure the main switch (on applica- ble models) is (off) before working on the battery.
2. Connect the red battery cable to the POSITIVE (+) terminal first. Then con- nect the black battery cable to the NEG- ATIVE (-) terminal.
3. The electrical contacts of the battery and
1. Red cable 2. Black cable 3. Battery
Maintenance
68
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 on, the electrical system can be damaged.
[ECM01930]
2. Disconnect the negative cable(s) from
the negative (-) terminal.
NOTICE:
Al- ways disconnect all negative (-) ca- bles first to avoid a short circuit and damage to the electrical system.
[ECM01940]
3. Disconnect the positive cable(s) and re-
move the battery from the boat. 4. Clean, maintain, and store the battery
according to the manufacturers instruc- tions.
69
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 your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble-alert indicator is flash- ing, consult your Yamaha dealer.
Starter will not operate.
Q. Is battery capacity weak or low? A. Check battery condition. Use battery of recommended capacity.
Q. Are battery connections loose or corrod- ed? A. Tighten battery cables and clean battery terminals.
Q. Is fuse for electric start relay or electric cir- cuit blown? A. Check for cause of electric overload and repair. Replace fuse with one of correct am- perage.
Q. Are starter components faulty? A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear? A. Shift to neutral.
Engine will not start (starter operates).
Q. Is fuel tank empty? A. Fill tank with clean, fresh fuel.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Is starting procedure incorrect? A. See page 43.
Q. Has fuel pump malfunctioned? A. Have serviced by a Yamaha dealer.
Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
Q. Are spark plug cap(s) fitted incorrectly? A. Check and re-fit cap(s).
Q. Is ignition wiring damaged or poorly con- nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro- ken wires.
Q. Are ignition parts faulty? A. Have serviced by a Yamaha dealer.
Q. Is engine shut-off cord (lanyard) not at- tached? A. Attach cord.
Q. Are engine inner parts damaged? A. Have serviced by a Yamaha dealer.
Engine idles irregularly or stalls.
Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
Trouble Recovery
70
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.
Q. Has alert system activated? A. Find and correct cause of alert.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con- nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro- ken wires.
Q. Is specified engine oil not being used? A. Check and replace oil as specified.
Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.
Q. Are carburetor adjustments incorrect? A. Have serviced by a Yamaha dealer.
Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.
Q. Is air vent screw on fuel tank closed? A. Open air vent screw.
Q. Is choke knob pulled out?
A. Return to home position.
Q. Is motor angle too high? A. Return to normal operating position. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect? A. Connect correctly.
Q. Is throttle valve adjustment incorrect? A. Have serviced by a Yamaha dealer.
Q. Is battery cable disconnected? A. Connect securely.
Alert buzzer sounds or indicator lights.
Q. Is cooling system clogged? A. Check water intake for restriction.
Q. Is engine oil level low? A. Fill oil tank with specified engine oil.
Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec- ommended type.
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Is engine oil contaminated or deteriorat- ed? A. Replace oil with fresh, specified type.
Q. Is oil filter clogged? A. Have serviced by a Yamaha dealer.
Q. Has oil feed/injection pump malfunc- tioned? A. Have serviced by a Yamaha dealer.
Trouble Recovery
71
Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane.
Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer.
Q. Is there excess water in fuel filter cup? A. Drain filter cup.
Engine power loss.
Q. Is propeller damaged? A. Have propeller repaired or replaced.
Q. Is propeller pitch or diameter incorrect? A. Install correct propeller to operate out- board at its recommended speed (r/min) range.
Q. Is trim angle incorrect? A. Adjust trim angle to achieve most efficient operation.
Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height.
Q. Has alert system activated? A. Find and correct cause of alert.
Q. Is boat bottom fouled with marine growth? A. Clean boat bottom.
Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
Q. Are weeds or other foreign matter tangled
on gear housing? A. Remove foreign matter and clean lower unit.
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con- nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro- ken wires.
Q. Have electrical parts failed? A. Have serviced by a Yamaha dealer.
Q. Is specified fuel not being used? A. Replace fuel with specified type.
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.
Q. Is air vent screw closed? A. Open the air vent screw.
Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.
Trouble Recovery
72
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 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.
Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer.
Q. Are weeds or other foreign matter tangled on propeller? A. Remove and clean propeller.
Q. Is motor mounting bolt loose? A. Tighten bolt.
Q. Is steering pivot loose or damaged? A. Tighten or have serviced by a Yamaha dealer.
EMU29433
Temporary action in emergency
EMU29440
Impact damage
WARNING
EWM00870
The outboard motor can be seriously damaged by a collision while operating or
trailering. Damage could make the out-
board motor unsafe to operate.
If the outboard motor hits an object in the wa- ter, follow the procedure below.
1. Stop the engine immediately. 2. Inspect the control system and all com-
ponents for damage. Also inspect the boat for damage.
3. Whether damage is found or not, return to the nearest harbor slowly and careful- ly.
4. Have a Yamaha dealer inspect the out- board motor before operating it again.
EMU29463
Replacing fuse
If the fuse has blown on an electric start model, open the fuse holder and replace the fuse with a new one of the proper amperage.
WARNING
EWM00631
Substituting an incorrect fuse or a piece of wire could allow excessive current flow. This could cause electric system
damage and a fire hazard.
Trouble Recovery
73
Consult your Yamaha dealer if the new fuse immediately blows again.
EMU29524
Power trim and tilt will not operate
If the engine cannot be tilted up or down with the power trim and tilt because of a dis- charged battery or a failure with the power trim and tilt unit, the engine can be tilted manually. 1. Loosen the manual valve screw by turn-
ing it counterclockwise until it stops.
2. Put the engine in the desired position, then tighten the manual valve screw by turning it clockwise.
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 this procedure only in an emergen- cy to return to the nearest port for re- pairs.
When the emergency starter rope is used to start the engine, the start-in- gear protection device does not oper- ate. Make sure the remote control lever is in neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.
Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg while operating the boat.
Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre- venting it from functioning.
Avoid accidentally pulling the cord dur- ing 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.
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. Use the emergency starter rope only as instructed. Do not touch the fly-
1. Fuse holder 2. Fuse (20 A, 30 A)
1. Manual valve screw
1
2
ZMU04152
ZMU03464
1
Trouble Recovery
74
wheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.
Do not touch the ignition coil, spark plug wire, spark plug cap, or other elec- trical components when starting or op- erating the motor. You could get an
electrical shock.
EMU29562
Emergency starting engine
1. Remove the top cowling. 2. Remove the start-in-gear protection ca-
ble from the starter, if equipped. 3. Remove the starter/flywheel cover after
removing the bolt(s).
4. Prepare the engine for starting. For fur- ther information, see page 43. 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.
5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms up.
6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise.
7. Give a strong pull straight out to crank
ZMU03920
ZMU02334
ON STARTOFF
ZMU01906
ZMU03921
Trouble Recovery
75
and start the engine. Repeat if neces- sary.
EMU29671
Engine fails to operate
EMU29742
Low oil level alert 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. If this happens, a reserve amount of oil can be pumped from the remote oil tank to the en- gine oil tank using the emergency switch.
WARNING
EWM01050
Be sure to stop the engine before per-
forming this procedure.
NOTICE
ECM00901
If the emergency switch is held up too long, too much oil will be pumped into the engine oil tank, overflowing it. Re- lease the switch when oil reaches the upper level line on the engine oil tank.
Do not use this emergency procedure unless the oil level-alert indicators are
working.
1. Remove the top cowling. 2. Turn on the main switch.
3. Lift the emergency switch to pump re- serve oil into the engine oil tank from the remote oil tank.
4. After using the emergency switch, turn off the main switch, then turn it back on. This resets the alert system to normal
ZMU03466
1. Emergency switch
1. Engine oil tank 2. Remote oil tank
ON STARTOFF
ZMU01906
1
ZMU04153
1 2 ZMU01908
Trouble Recovery
76
operation. The yellow segment will con- tinue to be displayed on the oil level indi- cator.
5. Start the engine and return to the near- est port for more oil.
TIP:
The maximum reserve oil capacity is 1500 cm
3
(1.6 US qt, 1.31 Imp qt).
The oil-feed pump will not operate if the engine is tilted up more than 35. Put the engine in the upright position (not tilted) before using the emergency switch.
EMU29751
Top cowling does not unlock
If the top cowling stays locked when the re- lease lever is operated, the cable may be damaged or incorrectly adjusted. 1. Pull the cowling release lever to unlock
the front lock.
2. Pull the emergency cowling release wire coming out of the hole on the side of the pilot hole in the bottom cowling to re- lease the port side rear lock.
3. Lift the port side of the top cowling to pull out the emergency cowling release wire from the port side of the bottom cowling.
4. Pull the emergency cowling release wire
to release the starboard side rear lock.
NOTICE:
Be sure the problem with the cowling lock is repaired before re- installing the cowling.
[ECM00391]
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 been com- pletely inspected.
[ECM00401]
1. Cowling release lever 2. Starboard-side cowling release wire 3. Port-side cowling release wire
1
2
3
ZMU03544
77
Consumer information
EMU29811
Important warranty information for U.S.A. and Canada
Consumer information
78
Consumer information
79
EMU29820
YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY
Consumer information
80
Consumer information
81
Consumer information
82
EMU29841
IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA
6N6-9-1H Hyoshi 08.2.21 9:42 3
Printed in Japan April 2008-0.3 1 ! Printed on recycled paper
6N6-9-1H Hyoshi 08.2.21 9:42 4
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