Yamaha F40BTLR v3 Owner's Manual PDF

Pages 96
Year 2008
English en
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Summary of Content for Yamaha F40BTLR v3 Owner's Manual PDF

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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...

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Fuel tank ... 18 Fuel joint... 19 Fuel gauge ... 19 Fuel tank cap... 19 Air vent screw... 19 Remote control ... 19 Remote control lever ... 19 Neutral interlock trigger ... 20 Neutral throttle lever ... 20 Tiller handle... 20 Gear shift lever ... 20 Throttle grip ... 21 Throttle indicator ... 21 Throttle friction adjuster... 21 Engine shut-off switch ... 22 Engine stop button ... 22 Manual starter handle ... 23 Main switch ... 23 Steering friction adjuster ... 23 Steering friction adjuster ... 24 Power trim and tilt switch on remote

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plug ... 64 Checking fuel system ... 65 Checking fuel filter... 66 Inspecting idling speed... 66 Changing engine oil ... 66 Checking wiring and connectors ... 68 Exhaust leakage... 68 Water leakage ... 68 Engine oil leakage... 68 Checking power trim and tilt

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models) ... 73 Connecting the battery ... 74 Disconnecting the battery ... 74 Checking top cowling ... 74 Coating the boat bottom... 75

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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...

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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...

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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...

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Read all labels on the outboard motor and the boat... If you need any additional information, contact your Yamaha dealer...

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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...

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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...

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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, go to boatus... org...

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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...

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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...

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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...

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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...

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There are two types of gasohol: gasohol con- taining ethanol and that containing metha- nol... Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings... E-85 is a fuel blend containing 85% ethanol and therefore must not be used in your outboard motor... All ethanol blends containing more than 10% ethanol can cause fuel system damage or engine performance problems... Yamaha does not recommend gasohol-con- taining methanol because it can cause fuel system damage or engine performance problems...

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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...

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purchasing decisions a boater can make... The type, size, and design of your propeller have a direct impact on acceleration, top speed, fuel economy, and even engine life... Yamaha designs and manufactures propel- lers for every Yamaha outboard motor and every application... Your outboard motor came with a Yamaha propeller chosen to perform well over a range of applications, but there may be uses where a different propeller would be more appropriate... Your Yamaha dealer can help you select the right propeller for your boating needs... Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat- load... Generally, chose a larger pitch propel- ler for a smaller operating load and a smaller pitch propeller for a heavier load... If you carry loads that vary widely, chose the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle setting to stay within the recommended engine speed range when carrying lighter loads... For instructions on propeller removal and in- stallation, see page 69...

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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...

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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... Warning indicator(s)* 12... Steering friction adjuster* 13... Tilt support knob 14... Flushing device

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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...

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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...

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

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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...

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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...

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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...

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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-

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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

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If the engine develops a condition which is cause for warning, the indicator lights up... For details on how to read the warning indicator, see page 30...

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

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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...

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Simultaneously pressing the (set) and (mode) buttons for more than 1 second while the trip hours are displayed resets the trip counter to 0 (zero)...

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If the warning system has activated, stop the engine as soon as it is safe to do so... Check the oil level and add oil as needed... If the oil

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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...

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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-

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Be sure the fuel tank is positioned on a se- cure, flat surface, and that the fuel line is not twisted or flattened, or likely to contact sharp objects (if equipped Yamaha fuel tank or boat tank)...

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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

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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

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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

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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

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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 im- possible 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

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If the low oil pressure warning indicator does not go off after the engine starts, stop the engine... Otherwise serious en- gine damage could occur... Check the oil level and add oil if necessary... Consult your Yamaha dealer if the cause for the low oil pressure warning indicator can- not be found...

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passages... If water is not flowing out of the pilot hole at all times while the en- gine is running, overheating and seri- ous damage could occur... Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked... Consult your Yamaha dealer if the prob-

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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...

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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

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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

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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...

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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...

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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... For more detailed in-

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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

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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... For more detailed in-

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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-

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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...

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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-

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Yamaha strongly recommends that you use the optional chromium-plated water pump kit (available for V4 and large engines) if you use the outboard motor in water with a lot of sediment in it, such as muddy or other turbid (cloudy) water...

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(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)

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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...

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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...

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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...

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Follow the manual of the battery for the han- dling of the battery... Batteries vary among manufacturers... Therefore the following pro- cedures may not always apply... Consult your battery manufacturers instructions... Procedure 1... Disconnect and remove the battery from

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Maintenance, replacement, or repair of the emission control devices and sys- tems may be performed by any marine engine repair establishment or individual... All warranty repairs, however, including those to the emission control system, must be performed by an authorized Yamaha marine dealership...

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Outboard motors operating under any of these above conditions require more fre- quent maintenance... Yamaha recommends that you do this service twice as often as specified in the maintenance chart... For ex- ample, if a particular service should be done at 50 hours, do it instead at 25 hours... This will help prevent more rapid deterioration of engine components...

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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...

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Shift link/shift cable Inspection, adjustment or replacement as nec- essary

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When using lead or high-sulfur gasoline, inspecting valve clearance may be required more

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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

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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

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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

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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...

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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...

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Before inspecting, removing, or install- ing the propeller, remove the spark plug caps from the spark plugs... Also, place the shift control in neutral, turn the main switch to (off) and re- move the key, and remove the cord from the engine shut-off switch... Turn off the battery cut-off switch if your

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Be sure to install the thrust washer be- fore installing the propeller, otherwise the lower case and propeller boss could be damaged...

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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 re-

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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...

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1... Check the electrolyte level at least once a month... Fill to the manufacturers rec- ommended level when necessary... Top up only with distilled water (or pure de- ionized water suitable to use in batter- ies)...

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of charge... Installing a voltmeter will help you monitor your battery... If you will not use the boat for a month or more, re- move the battery from the boat and store it in a cool, dark place... Completely re- charge the battery before using it...

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A clean hull improves boat performance... The boat bottom should be kept as clean of ma- rine growth as possible... If necessary, the boat bottom can be coated with an anti-foul- ing paint approved for your area to inhibit marine growth... Do not use anti-fouling paint which includes copper or graphite... These paints can cause more rapid engine corrosion...

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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-warning indicator is flashing, consult your Yamaha dealer...

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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...

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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...

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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...

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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...

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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...

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If the outboard motor is submerged, immedi- ately take it to a Yamaha dealer... Otherwise some corrosion may begin almost immedi- ately... If you cannot immediately take the outboard motor to a Yamaha dealer, follow the proce- dure below in order to minimize engine dam- age...

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

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Printed in Japan April 20070... 6 1 ! Printed on recycled paper

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