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Yamaha F40BTLR v2 Owner's Manual PDF

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Summary of Content for Yamaha F40BTLR v2 Owner's Manual PDF

F40B

OWNERS MANUAL

67C-28199-1B

U.S.A.Edition LIT-18626-08-06

q Read this manual carefully before operating this outboard motor.

67C-9-1B Hyoshi 08.2.28 13:13 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.

67C-9-1B Hyoshi 08.2.28 13:13 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 F40BMH, F40BER, F40BTR and the standard accessories are used as a base for the explanations and illustrations in this manual. Therefore some items may not ap- ply to every model.

EMU25111

F40B OWNERS MANUAL

2008 by Yamaha Motor Corporation, USA 1st edition, March 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-18626-08-06

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..................... 15

Specifications of Battery..................15 Mounting battery .............................15 Multiple batteries .............................15 Without a rectifier or Rectifier

Regulator ......................................15

Propeller selection ........................ 15 Start-in-gear protection ................. 16 Engine oil requirements ................ 16 Fuel requirements ......................... 16

Gasoline ..........................................16 Ring Free Fuel Additive...................17

Muddy or acidic water ................... 17 Anti-fouling paint ........................... 17 Motor disposal requirements......... 18 Emergency equipment .................. 18 Emission control information......... 18

North American models...................18 Star labels .......................................19

Components .................................... 21

Components diagram.................... 21

Fuel tank .........................................21 Fuel joint..........................................22 Fuel gauge ......................................22 Fuel tank cap...................................22 Air vent screw..................................22 Remote control box .........................22 Remote control lever .......................22 Neutral interlock trigger ...................23 Neutral throttle lever ........................23 Tiller handle.....................................23 Gear shift lever ................................23 Throttle grip .....................................24 Throttle indicator .............................24 Throttle friction adjuster...................24 Engine shut-off cord (lanyard) and

clip.................................................25 Engine stop button ..........................25 Manual starter handle .....................26 Main switch .....................................26 Steering friction adjuster .................26 Steering friction adjuster .................27 Power trim and tilt switch on

remote control or tiller handle .......27 Power trim and tilt switch on

bottom engine cowling ..................28

Table of contents

Trim tab with anode ........................ 28 Tilt lock mechanism......................... 29 Tilt support knob ............................. 29 Top cowling lock lever(s)

(turn type) ..................................... 29 Flushing device ............................... 30 Alert indicator .................................. 30

Instruments and indicators ............ 31

Indicators....................................... 31

Low oil pressure-alert indicator ....... 31 Overheat-alert indicator .................. 31

Digital tachometer ......................... 31

Tachometer ..................................... 32 Trim meter....................................... 32 Hour meter ...................................... 32 Low oil pressure-alert indicator ....... 32 Overheat-alert indicator .................. 33

Analog tachometer ........................ 33

Low oil pressure-alert indicator ....... 33 Overheat-alert indicator .................. 34

Analog trim meter.......................... 34

Engine control system.................... 35

Alert system .................................. 35

Overheat alert ................................. 35 Low oil pressure alert ...................... 35

Installation ....................................... 37

Installation ..................................... 37

Mounting the outboard motor .......... 37

Operation ......................................... 39

First-time operation ....................... 39

Fill engine oil ................................... 39 Breaking in engine .......................... 39 Getting to know your boat ............... 39

Checks before starting engine ...... 39

Fuel level......................................... 40 Remove cowling.............................. 40 Fuel system..................................... 40 Controls........................................... 40 Engine shut-off cord (lanyard)......... 40 Engine oil ........................................ 41 Engine............................................. 41 Flushing device ............................... 41 Install cowling.................................. 42 Power trim and tilt system............... 42

Battery.............................................43

Filling fuel...................................... 43 Operating engine .......................... 43

Feeding fuel (portable tank) ............43 Starting engine ................................45

Checks after starting engine ......... 48

Cooling water ..................................48

Warming up engine....................... 49

Manual start and electric start models ..........................................49

Checks after engine warm-up....... 49

Shifting ............................................49 Stop switches ..................................49

Shifting.......................................... 49 Stopping boat................................ 51 Stopping engine............................ 51

Procedure........................................51

Trimming outboard motor.............. 52

Adjusting trim angle (Power trim and tilt) ..........................................52

Adjusting trim angle for hydro tilt models ..........................................53

Adjusting boat trim ..........................54

Tilting up and down....................... 55

Procedure for tilting up (hydro tilt models) .........................................55

Procedure for tilting up (power trim and tilt models)......................56

Procedure for tilting down (hydro tilt models)....................................57

Procedure for tilting down (power trim and tilt models)......................58

Shallow water................................ 59

Hydro tilt models .............................59 Power trim and tilt models...............60

Cruising in other conditions........... 61

Maintenance .................................... 62

Transporting and storing outboard motor ........................................... 62

Storing outboard motor ...................62 Procedure........................................63 Lubrication.......................................64 Cleaning and anticorrosion

measures ......................................64 Flushing power unit .........................64

Table of contents

Cleaning the outboard motor .......... 65 Checking painted surface of

motor............................................. 65

Periodic maintenance.................... 65

Replacement parts .......................... 66 Maintenance interval guidelines...... 66 Maintenance chart 1 ....................... 67 Maintenance chart 2 ....................... 69 Greasing ......................................... 70 Cleaning and adjusting spark

plug ............................................... 70 Checking fuel filter .......................... 71 Inspecting idling speed ................... 71 Changing engine oil ........................ 72 Checking wiring and connectors ..... 73 Checking propeller .......................... 74 Removing propeller ......................... 74 Installing propeller ........................... 75 Changing gear oil ............................ 75 Cleaning fuel tank ........................... 76 Inspecting and replacing

anode(s)........................................ 77 Checking battery (for electric start

models) ......................................... 77 Connecting the battery .................... 78 Disconnecting the battery ............... 78

Trouble Recovery............................ 80

Troubleshooting ............................ 80 Temporary action in emergency.... 83

Impact damage ............................... 83 Replacing fuse ................................ 83 Power trim and tilt will not

operate.......................................... 84 Starter will not operate .................... 84 Emergency starting engine ............. 85

Treatment of submerged motor..... 86

Consumer information.................... 87

Important warranty information for U.S.A. and Canada ..................... 87

YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY................................ 89

IMPORTANT WARRANTY

INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ...................... 91

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

ZMU04028

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.

F40B

3

12

12

ZMU05783

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

EMU34520

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.

TIP:

* means, select the engine oil referring to the chart of engine oil paragraph. For further information, see page 16.

EMU2821C

Dimension:

Overall length: F40BMH 1332 mm (52.4 in) F40BTR 701 mm (27.6 in)

Overall width: 378 mm (14.9 in)

Overall height S: 1217 mm (47.9 in)

Overall height L: 1340 mm (52.8 in)

Transom height S: 410 mm (16.1 in)

Transom height L: 533 mm (21.0 in)

Weight (without propeller) S: F40BMH 83.8 kg (185 lb) F40BTR 86.1 kg (190 lb)

Weight (without propeller) L: F40BMH 88.1 kg (194 lb) F40BTR 97.0 kg (214 lb)

Performance:

Full throttle operating range: 50006000 r/min

Maximum output: 29.4 kW@5500 r/min (40 HP@5500 r/min)

Idling speed (in neutral): 850

50 r/min

Engine:

Type: 4-stroke L

Displacement: 747.0 cm

3

Bore

stroke: 65.0

75.0 mm (2.56

2.95 in) Ignition system:

CDI Spark plug (NGK):

DPR6EA-9 Spark plug gap:

0.80.9 mm (0.0310.035 in) Control system:

F40BMH Tiller F40BTR Remote control

Starting system: F40BMH Manual F40BTR Electric

Starting carburetion system: Prime start

Valve clearance (cold engine) IN: 0.150.25 mm (0.00590.0098 in)

Valve clearance (cold engine) EX: 0.250.35 mm (0.00980.0138 in)

Min. cold cranking amps (CCA/SAE): F40BTR 380.0 A

Min. marine cranking amps (MCA/ABYC): F40BTR 502.0 A

Min. reserve capacity (RC/SAE): F40BTR 124 minutes

Maximum generator output: 15.0 A

Drive unit:

Gear positions: Forward-neutral-reverse

Gear ratio: 2.00 (26/13)

Trim and tilt system:

Specifications and requirements

14

F40BMH Hydro tilt F40BTR Power trim and tilt

Propeller mark: G

Fuel and oil:

Recommended fuel: Regular unleaded gasoline

Min. pump octane: 86

Fuel tank capacity: 25 L (6.60 US gal, 5.50 Imp.gal)

Recommended engine oil: 4-stroke outboard motor oil

Recommended engine oil group 1*: SAE 10W-30/10W-40/5W-30 API SE/SF/SG/SH/SJ/SL

Recommended engine oil group 2*: SAE 15W-40/20W-40/20W-50 API SH/SJ/SL

Lubrication: Wet sump

Engine oil quantity without replacement of oil filter (Oil pan capacity):

2.0 L (2.11 US qt, 1.76 Imp.qt) Recommended gear oil:

Hypoid gear oil SAE#90 Gear oil quantity:

0.430 L (0.455 US qt, 0.378 Imp.qt)

Tightening torque for engine:

Spark plug: 18.0 Nm (1.84 kgf-m, 13.3 ft-lb)

Propeller nut: 40.0 Nm (4.08 kgf-m, 29.5 ft-lb)

Engine oil drain bolt: 18.0 Nm (1.84 kgf-m, 13.3 ft-lb)

Engine oil filter: 18.0 Nm (1.84 kgf-m, 13.3 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 37.

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

Specifications and requirements

15

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 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.

EMU25730

Without a rectifier or Rectifier Regulator

NOTICE

ECM01090

A battery cannot be connected to models that do not have a rectifier or Rectifier

Regulator.

If you wish to use a battery with the models without a rectifier or Rectifier Regulator, in- stall an optional Rectifier Regulator. Using a maintenance-free battery with the above models can shorten the life of the bat- tery significantly. Install an optional Rectifier Regulator or use accessories rated to withstand 18 volts or higher with the above models. Consult your Yamaha dealer for details on installing an optional Rectifier Regulator.

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

Minimum cold cranking amps (CCA/SAE):

F40BTR 380.0 A Minimum marine cranking amps (MCA/ABYC):

F40BTR 502.0 A Minimum reserve capacity (RC/SAE):

F40BTR 124 minutes

Specifications and requirements

16

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 74.

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.

EMU31443

Engine oil requirements

If the recommended engine oil grades are not available, select an alternative from the following chart according to the average temperatures in your area.

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-

1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark)

ZMU04604

-x 1 2 3

Recommended engine oil: YAMALUBE 4-M FC-W oil or 4-stroke motor oil with a combination of the fol- lowing SAE and API oil classifications

Engine oil type SAE: 10W-30 or 10W-40

Engine oil grade API: SE, SF, SG, SH, SJ, SL

Engine oil quantity without replacement of oil filter (Oil pan capacity):

2.0 L (2.11 US qt, 1.76 Imp.qt)

Specifications and requirements

17

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.

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-

Recommended gasoline: Regular unleaded gasoline with a min- imum Octane rating of 86 (Pump Octane Number) = (R+M)/2

Specifications and requirements

18

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.

EMU36341

Motor disposal requirements

Never illegally discard (dump) the motor. Yamaha recommends consulting the dealer about discarding the motor.

EMU36351

Emergency equipment

Keep the following items onboard in case there is trouble with the motor.

A tool kit with assorted screwdrivers, pli- ers, wrenches (including metric sizes), and electrical tape.

Waterproof flashlight with extra batteries.

An extra engine shut-off cord (lanyard) with clip.

Spare parts, such as an extra set of spark plugs.

Consult your Yamaha dealer for details.

EMU25221

Emission control information

EMU25230

North American models

This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for ma-

rine SI engines. See the label affixed to your engine for details.

EMU25242

Approval label of emission control certif- icate

This label is attached to the bottom cowling. New Technology; (4-stroke/HPDI) EM

EMU25262

Manufactured date label

This label is attached to the clamp bracket or the swivel bracket.

ZMU01943

1. Approval label location

ZMU05759

1

ZMU05159

Specifications and requirements

19

EMU25273

Star labels

Your outboard motor is labeled with a Cali- fornia Air Resources Board (CARB) star la- bel. See below for a description of your particular label.

EMU25280

One StarLow Emission

The one-star label identifies engines that meet the Air Resources Boards 2001 ex- haust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke en- gines. These engines are equivalent to the U.S. EPAs 2006 standards for marine en- gines.

EMU25290

Two StarsVery Low Emission

The two-star label identifies engines that meet the Air Resources Boards 2004 ex- haust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low-Emission engines.

EMU25300

Three StarsUltra Low Emission

The three-star label identifies engines that meet the Air Resources Boards 2008 ex- haust emission standards. Engines meeting

1. Manufactured date label location

1. Star labels location

1

ZMU06275

1

ZMU04977

ZMU01702

ZMU01703

Specifications and requirements

20

these standards have 65% lower emissions than One Star-Low-Emission engines.

EMU33861

Four StarsSuper Ultra Low Emission

The four-star label identifies engines that meet the Air Resources Boards Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meet- ing these standards have 90% lower emis- sions than One Star-Low-Emission engines.

ZMU01704

ZMU05663

21

Components

EMU2579J

Components diagram TIP:

* May not be exactly as shown; also may not be included as standard equipment on all mod- els.

F40B

EMU25802

Fuel tank

If your model was equipped with a portable fuel tank, its function is as follows.

WARNING

EWM00020

The fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Com-

13

1

2

3

4 5

9

8

7

6

16 17 18

13 15

14

10 11

12

19 20

ZMU05026

1. Top cowling 2. Top cowling lock lever 3. Drain screw 4. Anti-cavitation plate 5. Trim tab (anode)* 6. Propeller* 7. Cooling water inlet 8. Clamp bracket 9. Power trim and tilt switch* 10. Manual starter handle* 11. Alert indicator(s)* 12. Steering friction adjuster* 13. Tilt support knob 14. Flushing device 15. Tiller handle*

16. Fuel tank* 17. Tachometer* 18. Trim meter* 19. Digital tachometer* 20. Remote control box (side mount type)*

Components

22

mercial users should conform to relevant licensing or approval authority regula-

tions.

EMU25830

Fuel joint

This joint is used to connect the fuel line.

EMU25841

Fuel gauge

This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the ap- proximate amount of fuel remaining in the tank.

EMU25850

Fuel tank cap

This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise.

EMU25860

Air vent screw

This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise.

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.

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.

1. Fuel joint 2. Fuel gauge 3. Fuel tank cap 4. Air vent screw

1. Power trim and tilt switch 2. Remote control lever 3. Neutral interlock trigger 4. Neutral throttle lever 5. Main switch 6. Engine shut-off switch 7. Throttle friction adjuster

1. Neutral

2. Forward

3. Reverse 4. Shift 5. Fully closed

Components

23

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.

EMU25911

Tiller handle

To change direction, move the tiller handle to the left or right as necessary.

EMU25922

Gear shift lever

Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead. Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern.

6. Throttle 7. Fully open

1. Neutral interlock trigger

1. Fully open 2. Fully closed

Components

24

EMU25941

Throttle grip

The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.

EMU25961

Throttle indicator

The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation.

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.

1. Forward

2. Neutral

3. Reverse

1. Throttle indicator

Components

25

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 thrown forward.

[EWM00122]

EMU26001

Engine stop button

To open the ignition circuit and stop the en- gine, push this button.

ZMU03169

1. Cord 2. Clip 3. Engine shut-off switch

1. Cord 2. Clip 3. Engine shut-off switch

Components

26

EMU26070

Manual starter handle

To start the engine, first gently pull the han- dle out until resistance is felt. From that posi- tion, then pull the handle straight out quickly to crank the engine.

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.

EMU31432

Steering friction adjuster

A friction device provides adjustable resis- tance to the steering mechanism, and can be set according to operator preference. An ad- juster lever is located on the bottom of the tiller handle bracket. To increase resistance, turn the lever to the port side A. To decrease resistance, turn the lever to the starboard side B.

WARNING

EWM00040

Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an

accident.

ZMU04037

ON STARTOFF

ZMU03590

Components

27

If the resistance does not increase even when the lever is turned to the port side A, make sure that the nut is tightened to the specified torque.

TIP:

Steering movement is blocked when the adjuster lever is set to the A position.

Check the tiller handle for smooth move- ment when the lever is turned to the star- board side B.

Do not apply lubricants such as grease to the friction areas of the steering friction ad- juster.

EMU26122

Steering friction adjuster

A friction device provides adjustable resis-

tance to the steering mechanism, and can be set according to operator preference. An ad- justing screw or bolt is located on the swivel bracket.

To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.

WARNING

EWM00040

Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an

accident.

EMU26143

Power trim and tilt switch on remote control or tiller handle

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 52 and 55.

1. Nut

Nut tightening torque: 3.7 Nm (0.4 kgf-m, 2.7 ft-lb)

ZMU02810

B

A

ZMU02908

Components

28

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 55.

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

ZMU04038

Components

29

EMU26312

Tilt lock mechanism

The tilt lock mechanism is used to prevent the outboard motor from lifting out of the wa- ter when in reverse gear.

To lock it, set the tilt lock lever in the (lock) position. To release, push the tilt lock lever in the (release) position.

EMU26321

Tilt support knob

To keep the outboard motor in the tilted up position, push the tilt support knob under the swivel 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.

EMU26372

Top cowling lock lever(s) (turn type)

To remove the engine top cowling, turn the lock lever(s) and lift off the cowling. When in- stalling the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by returning the lever(s) to the lock position.

1. Trim tab 2. Bolt

Bolt tightening torque: 18.0 Nm (1.8 kgf-m, 13 ft-lb)

1. Tilt lock lever

ZMU02822

1

2

A

B

1 ZMU04039

1. Top cowling lock lever(s)

ZMU04040

1

ZMU04041

Components

30

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 64.

EMU26303

Alert indicator

If the engine develops a condition which is cause for alert, the indicator lights up. For details on how to read the alert indicator, see page 35.

1. Flushing device

1. Alert indicator

1

ZMU04042

1

ZMU04043

31

Instruments and indicators

EMU36014

Indicators

EMU36023

Low oil pressure-alert indicator

If oil pressure drops too low, this indicator will light up. For further information, see page 35.

NOTICE

ECM00022

Do not continue to run the engine if the low oil pressure-alert indicator is on and the engine oil level is lower. Seri- ous engine damage will occur.

The low oil pressure-alert indicator does not indicate the engine oil level. Use the oil dipstick to check the re- maining oil quantity. For further infor-

mation, see page 41.

EMU36032

Overheat-alert indicator

If the engine temperature rises too high, this indicator will light up. For further information on reading the indicator, see page 35.

NOTICE

ECM00052

Do not continue to run the engine if the overheat-alert indicator is on. Serious en-

gine damage will occur.

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.

ZMU04044

1. Tachometer 2. Trim meter 3. Hour meter 4. Low oil pressure-alert indicator 5. Overheat-alert indicator 6. Set button 7. Mode button

ZMU04105

1

5

2

4

3

6 7 ZMU03601

Instruments and indicators

32

EMU36050

Tachometer

The tachometer displays engine speed in hundreds of revolutions per minute (r/min). For example, if the tachometer display reads 22 then the engine speed is 2200 r/min.

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.

EMU26524

Low oil pressure-alert indicator

If oil pressure drops too low, the alert indica- tor will start to blink. For further information, see page 35.

NOTICE

ECM00022

Do not continue to run the engine if the low oil pressure-alert indicator is on and the engine oil level is lower. Seri- ous engine damage will occur.

The low oil pressure-alert indicator does not indicate the engine oil level. Use the oil dipstick to check the re- maining oil quantity. For further infor-

mation, see page 41.

ZMU01740

ZMU01741

Instruments and indicators

33

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 35.

NOTICE

ECM00052

Do not continue to run the engine if the overheat-alert indicator is on. Serious en-

gine damage will occur.

EMU26471

Analog tachometer

This gauge shows the engine speed and has the following functions.

EMU26506

Low oil pressure-alert indicator

If oil pressure drops too low, this indicator will flash. For further information, see page 35.

NOTICE

ECM00022

Do not continue to run the engine if the low oil pressure-alert indicator is on and the engine oil level is lower. Seri- ous engine damage will occur.

The low oil pressure-alert indicator does not indicate the engine oil level. Use the oil dipstick to check the re- maining oil quantity. For further infor-

mation, see page 41.

1. Low oil pressure-alert indicator

1. Overheat-alert indicator

ZMU017361

ZMU01737

1

1. Tachometer 2. Alert indicator(s)

ZMU04578

1

2

Instruments and indicators

34

EMU26574

Overheat-alert indicator

If the engine temperature rises too high, this indicator will flash. For further information on reading the indicator, see page 35.

NOTICE

ECM00052

Do not continue to run the engine if the overheat-alert indicator is on. Serious en-

gine damage will occur.

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. Low oil pressure-alert indicator

1. Overheat-alert indicator

ZMU06156

1

ZMU06157

1

ZMU04581

35

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.

EMU3016A

Low oil pressure alert

If the oil pressure drops too low, the alert de- vice will activate.

The engine speed will automatically de- crease to about 2000 r/min. If equipped with a low oil pressure-alert indicator, it will light or blink.

ZMU05028

ZMU04044

Engine control system

36

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 as soon as it is safe to do so. Check the oil level and add oil as needed. If the oil level is correct and the alert device does not switch off, consult your Yamaha dealer.

ZMU04994

ZMU04105

37

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)

ZMU017601

Installation

38

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

39

Operation

EMU36380

First-time operation

EMU36390

Fill engine oil

The engine is shipped from the factory with- out engine oil. If your dealer did not fill the oil, you must fill it before starting the engine.

NO- TICE:

Check that the engine is filled with oil before first-time operation to avoid se- vere engine damage.

[ECM01780]

The engine is shipped with the following sticker, which should be removed after en- gine oil is filled for the first time. For more in- formation on checking the engine oil level, see page 41.

EMU30174

Breaking in engine

Your new engine requires a period of break- in to allow mating surfaces of moving parts to wear in evenly. Correct break-in will help en- sure proper performance and longer engine life.

NOTICE:

Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage.

[ECM00801]

EMU27084

Procedure for 4-stroke models

Your new engine requires a period of 10 hours break-in to allow mating surfaces of moving parts to wear in evenly. Correct break-in will help ensure proper performance and longer engine life.

TIP:

Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage. Run the engine in the water, under load (in gear with a propel- ler installed) as follows. For ten hours for breaking in engine avoid extended idling, rough water and crowded areas. 1. For the first hour of operation:

Run the engine at varying speeds up to 2000 r/min or approximately half throttle.

2. For the second hour of operation: Increase engine speed as much as nec- essary to put the boat on plane (but avoid full-throttle operation), then back off on the throttle while keeping the boat at a planing speed.

3. Remaining eight hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.

4. After the first 10 hours: Operate the engine normally.

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 52).

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-

dent could occur.

NOTICE

ECM00120

Do not start the engine out of water. Over-

ZMU01710

Operation

40

heating and serious engine damage can

occur.

EMU36420

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 43.

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.

EMU36442

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.

EMU36900

Controls

Tiller handle models:

Turn the tiller handle fully to the left and right to make sure operation is smooth.

Turn the throttle grip from the fully closed to the fully open position. Make sure that it turns smoothly and that it completely re- turns to the fully closed position.

Look for loose or damaged connections of the throttle and shift cables under the en- gine cowling.

Remote control models:

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.

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.

ZMU06085

Operation

41

EMU27165

Engine oil

1. Put the outboard motor in an upright po- sition (not tilted).

NOTICE:

If the motor is not level, the oil level indicated on the dipstick may not be accurate.

[ECM01790]

2. Remove the top cowling. 3. Remove oil dipstick and wipe it clean. 4. Insert the dipstick and remove it again.

Be sure to completely insert the dipstick into the dipstick guide, otherwise the oil level measurement will be incorrect.

5. Check the oil level using the dipstick to

be sure the level falls between the upper and lower marks. Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark.

EMU27140

Engine

Check the engine and engine mounting.

Look for loose or damaged fasteners.

Check the propeller for damage.

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-

1. Cord 2. Clip 3. Engine shut-off switch

1. Cord 2. Clip 3. Engine shut-off switch

1. Oil dipstick

1. Lower level mark 2. Oil dipstick 3. Upper level mark

1

ZMU04046

ZMU02082

1 3

2

Operation

42

gine can overheat during operation.

[ECM01800]

EMU36952

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. Place the cowling on top of the seal. 4. Check to be sure the rubber seal fits cor-

rectly all the way around the engine. 5. 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.

EMU34581

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. Check the power trim and tilt unit for any sign of oil leaks.

2. Operate each of the power trim and tilt

1. Fitting 2. Flushing device

2 1

ZMU06051

ZMU06110

1. Trim and tilt rod

1

ZMU04088

Operation

43

switches to check that all switches work. 3. Tilt the outboard motor up and check

that the trim and tilt rod is pushed out completely.

4. Check that the trim and tilt rod is free of corrosion or other flaws.

5. Tilt the outboard motor down. Check that the trim and tilt rod operates 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.

EMU27436

Filling fuel

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. Remove the portable tank from the boat. 3. Be sure you are in a well-ventilated out-

door area, either securely moored or trailered.

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, use only an approved 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.

EMU27451

Operating engine

EMU27464

Feeding fuel (portable tank)

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

Fuel tank capacity: 25 L (6.60 US gal, 5.50 Imp.gal)

ZMU04047

Operation

44

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 on the motor, firmly connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank.

3. Squeeze the primer pump, with the ar- row pointing up, until you feel it become firm. During engine operation place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank.

ZMU02022

1. Arrow

ZMU04048

ZMU02024

Operation

45

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.

EMU27545

Starting engine

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 gear shift lever in neutral.

TIP:

The start-in-gear protection device prevents the engine from starting except when in neu- tral. 2. Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

3. Place the throttle grip in the (start) position.

4. Pull the manual starter handle slowly un- til you feel resistance. Then give a strong pull straight out to crank and start the engine. Repeat if necessary.

Operation

46

5. After the engine starts, slowly return the manual starter handle to its original po- sition before releasing it.

TIP:

When the engine is cold, it needs to be warmed up. For further information, see page 49.

If the engine is warm and fails to start, open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 80.

6. Slowly return the throttle grip to the fully closed position.

EMU27595

Electric start / prime start models

WARNING

EWM01840

Failure to attached engine shut-off cord could result in a runaway boat if opera- tor is ejected. Attach the engine shut- off cord to a secure place on your cloth- ing, or your arm or leg while operating. Do not attach the cord to 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 gear shift lever in neutral.

TIP:

The start-in-gear protection device prevents the engine from starting except when in neu- tral. 2. Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

3. Place the throttle grip in the (start) position. After the engine starts, return the throttle to the fully closed po- sition.

ZMU04050

Operation

47

4. Turn the main switch to (start), and hold it for a maximum of 5 seconds.

5. 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]

TIP:

When the engine is cold, it needs to be warmed up. For further information, see

page 49.

If the engine is warm and fails to start, open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 80.

EMU27664

Electric start and 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.

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-

Operation

48

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. Turn the main switch to (start),

and hold it for a maximum of 5 seconds.

5. 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]

TIP:

When the engine is cold, it needs to be warmed up. For further information, see page 49.

If the engine is warm and fails to start, open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 80.

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.

Operation

49

Check that no water leaks from the joints be- tween the exhaust cover, cylinder head, and body cylinder.

EMU27670

Warming up engine

EMU27715

Manual start and electric start models

1. After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life.

2. Be sure the low oil pressure-alert indica- tor goes off after starting the engine.

NOTICE:

If the low oil pressure-alert indicator blinks after the engine starts, stop the engine. Otherwise se- rious engine damage could occur. Check the oil level and add oil if nec- essary. Consult your Yamaha dealer if the cause for the low oil pressure- alert indicator cannot be found.

[ECM01830]

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.

EMU36980

Stop switches

Turn the main switch to , or press the engine stop button and make sure the en- gine stops.

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.

EMU34530

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).

1. Neutral interlock trigger

Operation

50

2. Move the remote control lever / gear shift lever firmly and crisply forward (for forward gear) or backward (for reverse gear) [about 35 (a detent can felt) for re- mote control models]. Be sure to check that the tilt lock lever is in the lock/down position (if equipped) before operating in reverse.

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 / gear shift lever firmly and crisply into the neu- tral position.

ZMU04053

Operation

51

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.

EMU27845

Procedure

1. Push and hold the engine stop button or turn the main switch to (off).

2. After stopping the engine, disconnect the fuel line if there is a fuel joint on the outboard motor.

ON STARTOFF

ZMU03630

Operation

52

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.

EMU27885

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

ZMU04057

ZMU04058

1. Trim operating angle

1 ZMU04059

Operation

53

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.

EMU27892

Adjusting trim angle for hydro tilt models

WARNING

EWM00491

Stop the engine before adjusting the trim angle.

Be sure all people are clear of the out- board motor when adjusting the trim angle, also be careful not to pinch any body parts between the drive unit and clamp bracket.

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.

1. Stop the engine. 2. Place the tilt lock lever in the release po-

sition.

1. Power trim and tilt switch

1. Power trim and tilt switch

UP

DN

ZMU04060

1

1. Power trim and tilt switch

Operation

54

3. Hold the rear of the top cowling with one hand and tilt the engine to the desired angle.

4. Place the tilt lock lever back into the lock position to support the engine.

To raise the bow (trim-out), tilt the engine up. To lower the bow (trim-in), tilt the engine 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- 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.

ZMU04061

Operation

55

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

few minutes. Otherwise fuel may leak.

NOTICE

ECM00241

Before tilting the outboard motor, stop the engine by following the procedure

on page 51. 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.

EMU27999

Procedure for tilting up (hydro tilt models)

1. Place the remote control lever / gear shift lever in neutral.

2. Place the tilt lock lever in the release po- sition.

N

ZMU03087

Operation

56

3. Hold the rear of the top cowling with one hand, tilt the engine up, and turn the tilt support lever toward you or tilt support knob into the clamp bracket, and then place the tilt lock lever back into the lock position to support the outboard motor.

NOTICE:

Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position. For more detailed information, see page 62.

[ECM01641]

EMU32723

Procedure for tilting up (power trim and tilt models)

1. Place the remote control lever / gear shift lever in neutral.

2. Press the power trim and tilt switch (up) until the outboard motor has tilted up completely.

ZMU04064

ZMU04065

N

ZMU03196

UP

ZMU01935

UP

DN

Operation

57

3. Push the tilt support knob into the clamp bracket 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 outboard motor could fall back down suddenly if oil in the power trim and tilt unit or in the pow- er tilt unit loses pressure.

[EWM00262]

NO- TICE:

Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the nor- mal running position, use an addi- tional support device to secure it in the tilt position. For more detailed in- formation, see page 62.

[ECM01641]

4. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim 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]

EMU34480

Procedure for tilting down (hydro tilt models)

1. Release the tilt lock lever.

2. Hold the rear of the top cowling with one hand, tilt the outboard motor up slightly and pull out the tilt support knob or re- turn the tilt support lever.

UP

ZMU04067 ZMU04068

ZMU04069

Operation

58

3. Slowly tilt the outboard motor down. 4. Place the tilt lock lever in the lock posi-

tion.

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 knob becomes free.

2. Pull out the tilt support knob.

3. Push the power trim and tilt switch (down) to lower the outboard motor to the desired position.

ZMU04070

ZMU04071

ZMU04072

DN

ZMU01936

UP

DN

DN

ZMU04073

Operation

59

EMU28061

Shallow water

EMU28081

Hydro tilt models

The outboard motor can be tilted up partially to allow operation in shallow water.

WARNING

EWM00271

Run the boat at the lowest possible speed when using the shallow water cruising system.

Use extra care when operating in re- verse. Too much reverse thrust can cause the outboard motor to lift out of the water, increasing the chance of ac-

cident and personal injury.

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.

EMU28175

Procedure for hydro tilt models

1. Place the remote control lever / gear shift lever in neutral.

2. Pull the tilt lock lever up to the release position.

3. Slightly tilt the outboard motor up to the desired position and push the tilt lock le- ver down to the lock position.

4. To return the outboard motor to the nor- mal running position, pull the tilt lock le- ver up to the release position and slowly tilt the outboard motor down.

5. Push the tilt lock lever down to the lock position.

ZMU04074

N

ZMU03087

ZMU04075

Operation

60

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.

EMU32912

Procedure for power trim and tilt models

1. Place the remote control lever / gear shift lever in neutral.

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]

ZMU04076

N

ZMU03525

UP

ZMU01935

UP

DN

UP

ZMU04077

Operation

61

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.

62

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.

EMU28241

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

ECM01080

To prevent problems which can be caused by oil entering the cylinder from the sump, keep the outboard motor in the attitude shown when transporting and storing it. If storing or transporting the outboard motor on its side (not up- right), put it on a cushion after draining the engine oil.

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.

ZMU04078

Maintenance

63

EMU28303

Procedure

EMU28376

Flushing in a test tank

NOTICE

ECM00300

Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the en- gine will be damaged from overheating. Before starting the engine, be sure to supply water to the cooling water passag-

es.

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 65.

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 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 engine top cowling and si-

lencer cover. 4. Install the outboard motor on the test

tank.

5. Fill the tank with fresh water to above the level of the anti-cavitation plate.

NO- TICE:

If the fresh water level is below the level of the anti-cavitation plate, or if the water supply is insufficient, engine seizure may occur.

[ECM00291]

6. Cooling system flushing is essential to

prevent the cooling system from clog- ging up with salt, sand, or dirt. In addi- tion, fogging of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flushing and fogging at the same time.

WARNING! Do not touch or remove electrical parts when starting or during opera- tion. Keep hands, hair, and clothes away from the flywheel and other ro- tating parts while the engine is run- ning.

[EWM00091]

7. Run the engine at a fast idle for 1015

minutes in neutral position. 8. Just prior to turning off the engine, quick-

ly spray Yamaha Stor-Rite Engine Fogging Oil alternately into each carbu- retor or the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke excessively and almost stall.

ZMU04079

1. Water surface 2. Lowest water level

ZMU02051

1

2

Maintenance

64

9. Remove the outboard motor from the test tank.

10. Drain the cooling water completely out of the motor. Clean the body thoroughly.

11. Install the silencer cover/cap and top cowling.

EMU28402

Lubrication

1. Install the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 70.

2. Change the gear oil. For instructions, see page 75. Inspect the oil for the pres- ence of water that indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use.

3. Grease all grease fittings. For further de- tails, see page 70.

TIP:

For long-term storage, fogging the engine with oil is recommended. Contact your Yamaha dealer for information about fogging 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

1. Fitting 2. Garden hose connector 3. Garden hose adapter

12

3

ZMU04080

Maintenance

65

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 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 62.

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 62.

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

ZMU02550

Maintenance

66

Yamaha marine dealership.

A service manual is available for purchase through your Yamaha dealer for owners who 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

67

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

Engine oil Replacement

Engine Oil lter (car- tridge)

Replacement

Maintenance

68

Fuel lter (disposal type)

Replacement

Fuel line(High pres- sure)

Inspection

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

Power trim & tilt unit 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

Timing belt Inspection or replace- ment as necessary

Valve clearance Inspection and adjust- ment

Item Actions

Initial Every

20 hours (3

months)

100 hours (1

year)

300 hours (3 years)

500 hours (5 years)

Maintenance

69

EMU34451

Maintenance chart 2

EMU28910

TIP:

When using lead or high-sulfur gasoline, inspecting valve clearance may be required more frequently than every 500 hours.

Water inlet Inspection

Main switch/stop switch/choke switch

Inspection or replace- ment as necessary

Wire harness connec- tions/Wire coupler con- nections

Inspection or replace- ment as necessary

(Yamaha) Meter/gauge Inspection

(Yamaha) Fuel tank Inspection and clean- ing as necessary

Item Actions Every

1000 hours

Guide exhaust/exhaust manifold

Inspection or replace- ment as necessary

Timing belt Replacement

Item Actions

Initial Every

20 hours (3

months)

100 hours (1

year)

300 hours (3 years)

500 hours (5 years)

Maintenance

70

EMU28932

Greasing

Yamaha marine grease (Water resistant grease)

F40B

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 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

ZMU04081

Maintenance

71

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.

EMU28990

Checking fuel filter

Check the fuel filter periodically. The fuel fil- ter is a one piece, disposable type. If foreign matter is found in the filter, replace it. For re- placement 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

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.

Standard spark plug: DPR6EA-9

1. Spark plug gap 2. Spark plug I.D. mark (NGK) 3. Spark plug part number

Spark plug gap: 0.80.9 mm (0.0310.035 in)

Spark plug torque: 18.0 Nm (1.84 kgf-m, 13.3 ft-lb)

ZMU04083

Maintenance

72

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.

EMU29077

Changing engine oil

Change the engine oil several minutes after the engine has been stopped, so that the oil is still warm, but not hot.

WARNING

EWM01950

Be sure the outboard motor is securely

fastened to the transom or a stable stand.

NOTICE

ECM01710

Change the engine oil after the first 20 hours of operation or 3 months, and ev- ery 100 hours or at 1-year intervals there- after. Otherwise the engine will wear

quickly.

1. Put the outboard motor in an upright po- sition (not tilted).

NOTICE:

If the motor is not level, the oil level indicated on the dipstick may not be accurate.

[ECM01860]

2. Prepare a suitable container that holds a larger amount than the engine oil capac- ity. Loosen and remove the drain screw while holding the container under the drain hole. Then remove the oil filler cap. Let the oil drain completely. Wipe up any spilled oil immediately.

3. Put a new gasket on the oil drain screw. Apply a light coat of oil to the gasket and install the drain screw.

TIP:

If a torque wrench is not available when you are installing the drain screw, finger tighten the screw just until the gasket comes into contact with the surface of the drain hole.

1. Drain screw

Drain screw tightening torque: 18.0 Nm (1.84 kgf-m, 13.3 ft-lb)

ZMU04084

1

ZMU04085

Maintenance

73

Then tighten 1/4 to 1/2 turn more. Tighten the drain screw to the correct torque with a torque wrench as soon as possible. 4. Add the correct amount of oil through the

filler hole. Install the filler cap.

NOTICE:

Overfilling the oil could cause leak- age or damage. If the oil level is above the upper level mark, drain un- til the level meets the specified ca- pacity.

[ECM01850]

5. Start the engine and watch to make sure the low oil pressure-alert indicator (if equipped) turns off. Make sure that there are no oil leaks.

NOTICE:

If the low oil pressure-alert indicator does not turn off or if there are oil leaks, stop the engine and find the cause. Continued operation with a problem could cause severe engine damage. Consult your Yamaha dealer if the problem cannot be located and cor- rected.

[ECM00682]

6. Turn off the engine and wait 3 minutes.

Recheck the oil level using the dipstick to be sure the level falls between the up- per and lower marks. Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark.

7. Dispose of used oil according to local regulations.

TIP:

For more information on the disposal of used oil, consult your Yamaha dealer.

Change the oil more often when operating the engine under adverse conditions such as extended trolling.

EMU29112

Checking wiring and connectors

Check that each grounding wire is properly secured.

Check that each connector is engaged se- curely.

Recommended engine oil: 4-stroke outboard motor oil

Engine oil quantity (excluding oil filter): 2.0 L (2.11 US qt, 1.76 Imp.qt)

1. Oil ller cap

1

ZMU04086

ZMU02058

ZMU04087

Maintenance

74

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. 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.

ZMU01897

1. Cotter pin 2. Propeller nut 3. Washer 4. Spacer 5. Propeller 6. Thrust washer

Maintenance

75

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 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]

Propeller nut tightening torque: 40.0 Nm (4.08 kgf-m, 29.5 ft-lb)

ZMU02063

Maintenance

76

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 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.

EMU29302

Cleaning fuel tank

WARNING

EWM00920

Gasoline is highly flammable, and its va- pors are flammable and explosive.

If you have any question about properly doing this procedure, consult your Yamaha dealer.

Keep away from sparks, cigarettes, flames, or other sources of ignition when cleaning the fuel tank.

Remove the fuel tank from the boat be- fore cleaning it. Work only outdoors in an area with good ventilation.

Wipe up any spilled fuel immediately.

Reassemble the fuel tank carefully. Im-

1. Gear oil drain screw 2. Oil level plug

Recommended gear oil: Hypoid gear oil SAE#90

Gear oil quantity: 0.430 L (0.455 US qt, 0.378 Imp.qt)

1

2

ZMU04090

Tightening torque: 9 Nm (0.9 kgf-m, 6.6 ft-lb)

Tightening torque: 9 Nm (0.9 kgf-m, 6.6 ft-lb)

ZMU04091

Maintenance

77

proper assembly can result in a fuel leak, which could result in a fire or ex- plosion hazard.

Dispose of old gasoline according to lo-

cal regulations.

1. Empty the fuel tank into an approved container.

2. Pour a small amount of suitable solvent into the tank. Install the cap and shake the tank. Drain the solvent completely.

3. Remove the screws holding the fuel joint assembly. Pull the assembly out of the tank.

4. Clean the filter (located on the end of the suction pipe) in a suitable cleaning sol- vent. Allow the filter to dry.

5. Replace the gasket with a new one. Re- install the fuel joint assembly and tighten the screws firmly.

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.

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

ZMU02066

ZMU02820

ZMU04092

Maintenance

78

of ignition near the battery. Refer to page 15 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 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-

1. Red cable 2. Black cable 3. Battery

Maintenance

79

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.

80

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 45.

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

81

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

82

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

83

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.

EMU29473

Replacing fuse

If a fuse has blown, remove the electrical cover, open the fuse holder and remove the fuse with a fuse puller (if equipped). Replace it with a spare 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.

Consult your Yamaha dealer if the new fuse immediately blows again.

Trouble Recovery

84

EMU29512

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 clockwise until it stops.

2. Put the engine in the desired position, then tighten the manual valve screw by turning it counterclockwise.

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-

1. Fuse box 2. Fuse (20 A) 3. Spare fuse (20 A) 4. Fuse puller

1. Fuse puller

1 2

3

4

ZMU04094

1

ZMU04093

1. Manual valve screw

1

ZMU04095

Trouble Recovery

85

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- 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.

EMU30362

Emergency starting engine

1. Remove the top cowling. 2. Disconnect the start-in-gear protection

cable 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 45. 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.

ZMU04096

ZMU04097

ZMU04098

Trouble Recovery

86

5. 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.

6. Pull the rope slowly until resistance is felt.

7. Give a strong pull straight out to crank and start the engine. Repeat if neces- sary.

EMU33501

Treatment of submerged motor

If the outboard motor is submerged, immedi- ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi- ately.

NOTICE:

Do not attempt to run the outboard motor until it has been com- pletely inspected.

[ECM00401]

ZMU02334

ON STARTOFF

ZMU01906

ZMU04100

87

Consumer information

EMU29811

Important warranty information for U.S.A. and Canada

Consumer information

88

Consumer information

89

EMU29830

YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY

Consumer information

90

Consumer information

91

EMU29841

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA

67C-9-1B Hyoshi 08.2.28 13:13 3

Printed in Japan April 20080.1 1 ! Printed on recycled paper

67C-9-1B Hyoshi 08.2.28 13:13 4

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Manualsnet FAQs

If you want to find out how the F40BTLR Yamaha works, you can view and download the Yamaha F40BTLR v2 Owner's Manual on the Manualsnet website.

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