Yamaha F40BTLR v3 Owner's Manual PDF
Summary of Content for Yamaha F40BTLR v3 Owner's Manual PDF
F40B
OWNERS MANUAL
67C-28199-19
U.S.A.Edition LIT-18626-07-40
67C-9-19 Hyoshi 07.3.9 14:32 1
EMU25061
ZMU01690
Read this owners manual carefully before operating or working on your 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-9-19 Hyoshi 07.3.9 14:32 2
Important manual information
EMU31281
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.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
WARNING
EWM00780
Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the out-
board motor.
CAUTION:
ECM00700
A CAUTION indicates special precautions that must be taken to avoid damage to the
outboard motor.
NOTE:
A NOTE provides key information to make
procedures 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.
NOTE:
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
2007 by Yamaha Motor Corporation, USA 1st edition, April 2007
All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA
is expressly prohibited. Printed in Japan
P/N LIT-18626-07-40
Table of contents
General information .......................... 1
Identification numbers record.......... 1
Outboard motor serial number .......... 1 Key number....................................... 1
Emission control information ........... 1
North American models..................... 1 Star labels ......................................... 2
Read manuals and labels................ 4
Warning labels .................................. 4
Safety information............................. 6
Safety information ........................... 6
Rotating parts.................................... 6 Hot parts ........................................... 6 Electric shock.................................... 6 Power trim and tilt ............................. 6 Engine shut-off cord.......................... 6 Gasoline............................................ 6 Gasoline exposure and spills ............ 6 Carbon monoxide.............................. 7 Modifications ..................................... 7
Boating safety ................................. 7
Alcohol and drugs ............................. 7 Personal flotation devices ................. 7 People in the water ........................... 7 Passengers ....................................... 7 Overloading....................................... 7 Avoid collisions ................................. 7 Weather ............................................ 8 Accident reporting ............................. 8 Boat education and training .............. 8 Passenger training ............................ 8 Boating safety publications ............... 8 Laws and regulations ........................ 8
Boating organizations...................... 9 Basic boating rules (Rules of the
road) .............................................. 9
Steering and sailing rules and sound signals............................................. 9
Rules when encountering vessels.......................................... 10
Other special situations................... 11
Basic requirements......................... 14
Fueling instructions ....................... 14
Gasoline.......................................... 14 Engine oil ........................................ 14
Installation requirements............... 15
Boat horsepower rating ...................15 Mounting motor ...............................15 Remote control requirements..........15 Battery requirement.........................15 Without a rectifier or Rectifier
Regulator ......................................16 Propeller selection...........................16
Start-in-gear protection ................. 17
Basic components .......................... 18
Main components ......................... 18
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
control or tiller handle....................24 Power trim and tilt switch on bottom
engine cowling ..............................25 Trim tab with anode.........................25 Tilt lock mechanism.........................26 Tilt support knob..............................26 Top cowling lock lever(s)
(turn type)......................................26 Flushing device ...............................27 Warning indicator ............................27 Tachometer .....................................27 Digital tachometer ...........................27 Low oil pressure-warning
Table of contents
indicator ........................................ 28 Low oil pressure-warning
indicator ........................................ 28 Overheat-warning indicator ............. 28 Overheat-warning indicator (digital
type).............................................. 28 Trim meter....................................... 29 Trim meter (digital type) .................. 29 Hour meter (digital type).................. 29
Warning system ............................ 30
Overheat warning............................ 30 Low oil pressure warning ................ 30
Operation ......................................... 32
Installation ..................................... 32
Mounting the outboard motor .......... 32
Breaking in engine ........................ 33
Procedure for 4-stroke models........ 33
Pre-operation checks .................... 34
Fuel ................................................. 34 Controls........................................... 34 Stop switches.................................. 34 Engine............................................. 34 Checking the engine oil level .......... 34
Filling fuel ...................................... 35
Ring Free Fuel Additive .................. 35
Operating engine........................... 36
Feeding fuel (portable tank) ............ 36 Starting engine................................ 37
Warming up engine ....................... 40
Manual start and electric start models .......................................... 40
Shifting .......................................... 41 Stopping boat ................................ 42 Stopping engine ............................ 43
Procedure ....................................... 43
Trimming outboard motor.............. 43
Adjusting trim angle (Power trim and tilt) .......................................... 44
Adjusting trim angle for hydro tilt models .......................................... 45
Adjusting boat trim .......................... 45
Tilting up and down ....................... 46
Procedure for tilting up (hydro tilt models) ......................................... 47
Procedure for tilting up (power trim
and tilt models)..............................47 Procedure for tilting down (hydro tilt
models) .........................................49 Procedure for tilting down (power
trim and tilt models).......................49
Cruising in shallow water .............. 50
Hydro tilt models .............................50 Power trim and tilt models...............51
Cruising in other conditions........... 52
Maintenance .................................... 54
Specifications................................ 54 Transporting and storing outboard
motor ........................................... 55
Storing outboard motor ...................55 Procedure........................................56 Lubrication.......................................57 Cleaning and anticorrosion
measures ......................................57 Battery care.....................................57 Flushing power unit .........................58 Cleaning the outboard motor...........59 Checking painted surface of
motor.............................................59
Periodic maintenance ................... 59
Replacement parts ..........................60 Severe operating conditions............60 Maintenance chart 1........................61 Maintenance chart 2........................63 Greasing..........................................64 Cleaning and adjusting spark
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
system...........................................68 Checking propeller ..........................69 Removing propeller .........................70 Installing propeller ...........................70 Changing gear oil ............................71
Table of contents
Cleaning fuel tank ........................... 72 Inspecting and replacing
anode(s)........................................ 72 Checking battery (for electric start
models) ......................................... 73 Connecting the battery .................... 74 Disconnecting the battery ............... 74 Checking top cowling ...................... 74 Coating the boat bottom.................. 75
Trouble Recovery............................ 76
Troubleshooting ............................ 76 Temporary action in emergency.... 79
Impact damage ............................... 79 Replacing fuse ................................ 79 Power trim and tilt will not
operate.......................................... 80 Starter will not operate .................... 80 Emergency starting engine ............. 81
Treatment of submerged motor..... 82
Procedure ....................................... 82
Consumer information.................... 83
Important warranty information for U.S.A. and Canada ..................... 83
YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY ................................ 85
IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ...................... 87
1
General information
EMU25170
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.
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
1. Outboard motor serial number location
1
ZMU04028
1. Key number
1. Approval label location
ZMU05759
1
General information
2
EMU25262
Manufactured date label
This label is attached to the clamp bracket or the swivel bracket.
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.
1. Manufactured date label location
ZMU05159
1
ZMU04029
1. Star labels location
1
ZMU04977
ZMU01702
General information
3
EMU25300
Three StarsUltra Low Emission
The three-star label identifies engines that meet the Air Resources Boards 2008 ex- haust emission standards. Engines meeting 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.
ZMU01703
ZMU01704
ZMU05663
General information
4
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.
EMU33830
Warning labels
If these labels are damaged or missing, contact your Yamaha dealer for replacements.
3
12
12
ZMU05783
General information
5
1 2
3
ZMU05670
6
Safety information
EMU33621
Safety information
Observe these precautions at all times.
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.
EMU33670
Engine shut-off cord
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 36 to reduce the risk of fire and explosion.
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.
Safety information
7
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- dling and lead to an accident, capsizing or swamping.
EMU33770
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.
Safety information
8
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, 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-
Safety information
9
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.
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
Safety information
10
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.
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.
Safety information
11
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.
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.
Safety information
12
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
13
ZMU01708
14
Basic requirements
EMU25540
Fueling instructions
WARNING
EWM00010
GASOLINE AND ITS VAPORS ARE HIGH- LY FLAMMABLE AND EXPLOSIVE!
Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition.
Stop engine before refueling.
Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat.
Take care not to spill gasoline. If gaso- line spills, wipe it up immediately with dry rags.
Do not overfill the fuel tank.
Tighten the filler cap securely after re- fueling.
If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention.
If any gasoline spills onto your skin, im- mediately wash with soap and water. Change clothing if gasoline spills on it.
Touch the fuel nozzle to the filler open- ing or funnel to help prevent electro-
static sparks.
CAUTION:
ECM00010
Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign mat-
ter.
EMU33960
Gasoline
If knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel.
Gasohol
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.
EMU31440
Engine oil
NOTE:
If the recommended engine oil grades are not available, select an alternative from the following chart according to the average
temperatures in your area.
Recommended gasoline: Regular unleaded gasoline with a min- imum octane rating of 86 (Pump Oc- tane Number) = (R+M)/2
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 (excluding oil filter): 2.0 L (2.11 US qt) (1.76 Imp.qt)
Basic requirements
15
CAUTION:
ECM01050
All 4-stroke engines are shipped from the
factory without engine oil.
EMU33551
Installation requirements
EMU33560
Boat horsepower rating
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.
WARNING
EWM01560
Overpowering a boat can cause severe
instability.
EMU33570
Mounting motor
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 32.
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.
EMU33580
Remote control requirements
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.
WARNING
EWM01580
If the engine starts in gear, the boat can move suddenly and unexpectedly, pos- sibly causing a collision or throwing passengers overboard.
If the engine ever starts in gear, the start-in-gear protection device is not working correctly and you should dis- continue using the outboard. Contact
your Yamaha dealer.
EMU25693
Battery requirement
CAUTION:
ECM01061
Do not use a battery that does not meet the specified capacity. If a battery that does not meet specifications is used, the
ZMU01710
Basic requirements
16
electric system could perform poorly or be overloaded, causing electric system
damage.
For electric start models, choose a battery which meets the following specifications.
EMU25712
Battery specifications
The engine cannot be started if battery volt- age is too low.
EMU25730
Without a rectifier or Rectifier Regulator
CAUTION:
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.
EMU34190
Propeller selection
Next to selecting an outboard, choosing the right propeller is one of the most important
purchasing decisions a boater can make. The type, size, and design of your propeller have a direct impact on acceleration, top speed, fuel economy, and even engine life. Yamaha designs and manufactures propel- lers for every Yamaha outboard motor and every application. Your outboard motor came with a Yamaha propeller chosen to perform well over a range of applications, but there may be uses where a different propeller would be more appropriate. Your Yamaha dealer can help you select the right propeller for your boating needs. Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat- load. Generally, chose a larger pitch propel- ler for a smaller operating load and a smaller pitch propeller for a heavier load. If you carry loads that vary widely, chose the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle setting to stay within the recommended engine speed range when carrying lighter loads. For instructions on propeller removal and in- stallation, see page 69.
Minimum cold cranking amps (CCA/ SAE):
380.0 A Minimum marine cranking amps (MCA/ ABYC):
502.0 A Minimum reserve capacity (RC/SAE):
124 minutes
1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark)
ZMU04604
-x 1 2 3
Basic requirements
17
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.
18
Basic components
EMU2579B
Main components NOTE:
* 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
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. Warning 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)*
Basic components
19
its dedicated fuel reservoir and must not be used as a fuel storage container. Com- 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.
EMU26180
Remote control
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 / choke switch 6. Engine shut-off switch 7. Throttle friction adjuster
1. Neutral
2. Forward
3. Reverse
Basic components
20
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.
NOTE:
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.
4. Shift 5. Fully closed 6. Throttle 7. Fully open
1. Neutral interlock trigger
1. Fully open 2. Fully closed
Basic components
21
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.
EMU25971
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. To decrease resistance, turn the adjuster counterclockwise.
WARNING
EWM00031
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.
1. Forward
2. Neutral
3. Reverse
1. Throttle indicator
Basic components
22
When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting.
EMU25991
Engine shut-off switch
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
EWM00121
Attach the engine shut-off cord to a se- cure 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 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.
NOTE:
The engine cannot be started with the clip re-
moved.
EMU26001
Engine stop button
To open the ignition circuit and stop the en- gine, push this button.
ZMU03169
1. Cord 2. Clip
1. Clip 2. Cord
1
2
ZMU03171
Basic components
23
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
Basic components
24
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.
NOTE:
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.
EMU26142
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.
NOTE:
For instructions on using the power trim and
tilt switch, see pages 43 and 46.
1. Nut
Nut tightening torque: 3.7 Nm (2.7 ft-lb) (0.4 kgf-m)
ZMU02810
B
A
ZMU02908
Basic components
25
EMU26152
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.
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.
NOTE:
For instructions on using the power trim and
tilt switch, see page 46.
EMU26243
Trim tab with anode
The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force.
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.
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.
CAUTION:
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
Basic components
26
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.
CAUTION:
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 (13 ft-lb) (1.8 kgf-m)
1. Tilt lock lever
ZMU02822
1
2
A
B
1 ZMU04039
1. Top cowling lock lever(s)
ZMU04040
1
ZMU04041
Basic components
27
EMU26460
Flushing device
This device is used to clean the cooling wa- ter passages of the motor using a garden hose and tap water.
NOTE:
For details on usage, see page 58.
EMU26302
Warning indicator
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.
EMU26470
Tachometer
This gauge shows the engine speed and has the following functions.
EMU26492
Digital tachometer
The tachometer shows the engine speed and has the following functions.
NOTE:
All segments of the display will light momen- tarily after the main switch is turned on and
will return to normal thereafter.
NOTE:
The water separator and engine trouble-
1. Flushing device
1. Warning indicator
1
ZMU04042
1
ZMU04043
1. Tachometer 2. Warning indicator(s)
1. Tachometer 2. Trim meter 3. Hour meter 4. Low oil pressure-warning indicator 5. Overheat-warning indicator 6. Set button 7. Mode button
ZMU04578
1
2
1
5
2
4
3
6 7 ZMU03601
Basic components
28
warning indicators only operate when the en- gine is equipped with the appropriate func-
tions.
EMU26504
Low oil pressure-warning indicator
If oil pressure drops too low, this indicator will flash. For further information, see page 30.
CAUTION:
ECM00021
Do not continue to run the engine if the low oil pressure-warning indicator is on and the engine oil level is lower. Seri- ous engine damage will occur.
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-
mation, see page 34.
EMU26523
Low oil pressure-warning indicator
If oil pressure drops too low, the warning in- dicator will start to blink. For further informa- tion, see page 30.
CAUTION:
ECM00021
Do not continue to run the engine if the low oil pressure-warning indicator is on and the engine oil level is lower. Seri- ous engine damage will occur.
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-
mation, see page 34.
EMU26573
Overheat-warning indicator
If the engine temperature rises too high, this indicator will flash. For further information on reading the indicator, see page 30.
CAUTION:
ECM00051
Do not continue to run the engine if the overheat-warning indicator is on. Serious
engine damage will occur.
EMU26582
Overheat-warning indicator (digital type)
If the engine temperature rises too high, the
ZMU04754
1. Low oil pressure-warning indicator
ZMU017361
ZMU04715
Basic components
29
warning indicator will start to blink. For fur- ther information on reading the indicator, see page 30.
CAUTION:
ECM00051
Do not continue to run the engine if the overheat-warning indicator is on. Serious
engine damage will occur.
EMU26610
Trim meter
This gauge shows the trim angle of your out- board motor.
NOTE:
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.
EMU26620
Trim meter (digital type)
This meter shows the trim angle of your out- board motor.
NOTE:
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.
EMU26650
Hour meter (digital type)
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.
Changing the display format
Pressing the (mode) button chang-
1. Overheat-warning indicator
ZMU01737
1
ZMU04581
ZMU01740
ZMU01741
Basic components
30
es the display format in the following pat- tern:
Total hours
Trip hours
Display off
Resetting the trip hours
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).
NOTE:
The total number of hours the engine has
been run cannot be reset.
EMU26801
Warning system
CAUTION:
ECM00090
Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem can-
not be located and corrected.
EMU26817
Overheat warning
This engine has an overheat-warning de- vice. If the engine temperature rises too high, the warning device will activate.
Activation of warning device
The engine speed will automatically de- crease to about 2000 r/min.
If equipped with an overheat-warning indi- cator, it will light or blink.
The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel).
If the warning system has activated, stop the engine and check the cooling water inlet for clogging.
EMU30168
Low oil pressure warning
If the oil pressure drops too low, the warning device will activate.
ZMU05028
ZMU04044
Basic components
31
Activation of warning device
The engine speed will automatically de- crease to about 2000 r/min.
If equipped with a low oil pressure-warning indicator, it will light or blink.
The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel).
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
level is correct and the warning device does not switch off, consult your Yamaha dealer.
CAUTION:
ECM00101
Do not continue to run the engine if the low oil pressure-warning indicator is on.
Serious engine damage could occur.
ZMU04994
ZMU04105
32
Operation
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
Operation
33
CAUTION:
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.
EMU30173
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.
CAUTION:
ECM00800
Failure to follow the break-in procedure could result in reduced engine life or
even severe engine damage.
EMU27083
Procedure for 4-stroke models
Your new engine requires a period of ten- 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.
NOTE:
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.
ZMU01762
Operation
34
EMU27104
Pre-operation checks
WARNING
EWM00081
If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the out- board motor. Otherwise an accident
could occur.
CAUTION:
ECM00120
Do not start the engine out of water. Over- heating and serious engine damage can
occur.
EMU27111
Fuel
Check to be sure you have plenty of fuel for your trip.
Make sure there are no fuel leaks or gaso- line fumes.
Check fuel line connections to be sure they are tight (if equipped Yamaha fuel tank or boat tank).
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).
EMU27130
Controls
Check throttle, shift, and steering for prop- er operation before starting the engine.
The controls should work smoothly, with- out binding or unusual free play.
Look for loose or damaged connections.
Check operation of the starter and stop switches when the outboard motor is in the water.
EMU31721
Stop switches
Confirm that turning the main switch to the
(off) position stops the engine.
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.
EMU27140
Engine
Check the engine and engine mounting.
Look for loose or damaged fasteners.
Check the propeller for damage.
EMU27163
Checking the engine oil level
1. Put the outboard motor in an upright po- sition (not tilted).
2. Remove oil dipstick and wipe it clean. 3. Completely insert the dipstick and re-
move it again. 4. 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.
1. Oil dipstick
1
ZMU04046
Operation
35
NOTE:
Be sure to completely insert the dipstick into
the dipstick guide.
EMU27433
Filling fuel
WARNING
EWM00060
Gasoline and its vapors are highly flam- mable and explosive. Keep away from sparks, cigarettes, flames, or other
sources of ignition.
1. Remove the fuel tank cap. 2. Carefully fill the fuel tank. 3. Securely close the cap after filling the
tank. Wipe up any spilled fuel.
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.
1. Lower level mark 2. Oil dipstick 3. Upper level mark
Fuel tank capacity: 25 L (6.60 US gal) (5.50 Imp.gal)
ZMU02082
1 3
2
ZMU04047
Operation
36
EMU27450
Operating engine
EMU27463
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 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. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp.
NOTE:
During engine operation place the tank hori- zontally, otherwise fuel cannot be drawn
from the fuel tank.
4. Squeeze the primer pump, with the ar- row pointing up, until you feel it become firm.
ZMU02022
ZMU04048
ZMU02024
Operation
37
EMU27491
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.
EMU27543
Starting engine
1. Place the gear shift lever in neutral.
NOTE:
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.
WARNING
EWM00121
Attach the engine shut-off cord to a se- cure 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 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.
3. Place the throttle grip in the (start) position.
1. Arrow
Operation
38
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.
5. After the engine starts, slowly return the manual starter handle to its original po- sition before releasing it.
NOTE:
When the engine is cold, it needs to be warmed up. For further information, see page 40.
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 76.
6. Slowly return the throttle grip to the fully closed position.
EMU27593
Electric start / prime start models
1. Place the gear shift lever in neutral.
NOTE:
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.
WARNING
EWM00121
Attach the engine shut-off cord to a se- cure 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 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.
3. Place the throttle grip in the (start) position. After the engine starts, return the throttle to the fully closed po- sition.
ZMU04050
Operation
39
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).
CAUTION:
ECM00191
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 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
again.
NOTE:
When the engine is cold, it needs to be warmed up. For further information, see page 40.
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 76.
EMU27663
Electric start and remote control models
1. Place the remote control lever in neutral.
NOTE:
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.
WARNING
EWM00121
Attach the engine shut-off cord to a se- cure 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 entangled, pre- venting it from functioning.
Avoid accidentally pulling the cord dur-
Operation
40
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.
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).
CAUTION:
ECM00191
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 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
again.
NOTE:
When the engine is cold, it needs to be warmed up. For further information, see page 40.
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 76.
EMU27670
Warming up engine
EMU27710
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 warning in- dicator goes off after starting the engine.
3. Check for a steady flow of water from the cooling water pilot hole.
CAUTION:
ECM00210
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.
A continuous flow of water from the pi- lot hole shows that the water pump is pumping water through the cooling
Operation
41
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-
lem cannot be located and corrected.
EMU34530
Shifting
WARNING
EWM00180
Before shifting, make sure there are no swimmers or obstacles in the water near
you.
CAUTION:
ECM01610
Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral. If this occurs, stop the engine, shift to neutral, then restart the
engine and allow it to warm up.
To shift out of neutral 1. Pull the neutral interlock trigger up (if
equipped).
2. Move the remote control lever / 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.
ZMU04051
1. Neutral interlock trigger
ZMU04053
Operation
42
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.
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.
Operation
43
EMU27820
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.
3. Tighten the air vent screw on the fuel tank cap (if equipped).
4. Remove the key if the boat will be left unattended.
NOTE:
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).
EMU27861
Trimming outboard motor
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
ON STARTOFF
ZMU03630
ZMU04057
ZMU04058
Operation
44
also affected by variables such as the load in the boat, sea conditions, and running speed.
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.
EMU27883
Adjusting trim angle (Power trim and tilt)
WARNING
EWM00752
Be sure all people are clear of the out- board motor when adjusting the tilt an-
gle. Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted.
Use caution when trying a trim position for the first time. Increase speed gradu- ally and watch for any signs of instabil- ity or control problems. Improper trim angle can cause loss of control.
If equipped with a power trim and tilt switch located on the bottom cowling, use the switch only when the boat is at a complete stop with the engine off. Do not adjust the trim angle with this
switch while the boat is moving.
Adjust the outboard motor trim angle using the power trim and tilt switch.
1. Trim operating angle
1 ZMU04059
1. Power trim and tilt switch
1. Power trim and tilt switch
UP
DN
ZMU04060
1
Operation
45
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.
EMU27891
Adjusting trim angle for hydro tilt models
WARNING
EWM00490
Stop the engine before adjusting the trim angle.
Be sure all people are clear of the out- board motor when adjusting the tilt an- gle, 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.
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.
1. Power trim and tilt switch
ZMU04061
Operation
46
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.
NOTE:
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.
CAUTION:
ECM00241
Before tilting the outboard motor, stop the engine by following the procedure
Operation
47
on page 43. 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.
EMU27998
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.
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.
CAUTION:
ECM01640
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-
formation, see page 55.
EMU32722
Procedure for tilting up (power trim and tilt models)
1. Place the remote control lever / gear
N
ZMU03087
ZMU04064
ZMU04065
Operation
48
shift lever in neutral.
2. Press the power trim and tilt switch (up) until the outboard motor has tilted up completely.
3. Push the tilt support knob into the clamp bracket to support the engine.
WARNING
EWM00261
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
N
ZMU03196
UP
ZMU01935
UP
DN
UP
ZMU04067
ZMU04068
Operation
49
power tilt unit loses pressure.
CAUTION:
ECM01640
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-
formation, see page 55.
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.
CAUTION:
ECM00250
Be sure to retract the trim rods complete- ly during mooring. This protects the rods from marine growth and corrosion which could damage the power trim and tilt
mechanism.
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.
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.
ZMU04069
ZMU04070
ZMU04071
Operation
50
3. Push the power trim and tilt switch (down) to lower the outboard motor to the desired position.
EMU28060
Cruising in shallow water
The outboard motor can be tilted up partially to allow operation in shallow water.
EMU28080
Hydro tilt models
The outboard motor can be tilted up partially to allow operation in shallow water.
WARNING
EWM00270
Place the gear shift in neutral before us- ing the shallow water cruising system.
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.
Return the outboard motor to its normal position as soon as the boat is back in
deeper water.
CAUTION:
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.
ZMU04072
DN
ZMU01936
UP
DN
DN
ZMU04073
Operation
51
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.
EMU32850
Power trim and tilt models
The outboard motor can be tilted up partially to allow operation in shallow water.
WARNING
EWM00660
Place the gear shift in neutral before setting up for shallow water cruising.
Return the outboard motor to its normal position as soon as the boat is back in
ZMU04074
N
ZMU03087
ZMU04075
ZMU04076
Operation
52
deeper water.
CAUTION:
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.
EMU32910
Procedure for power trim and tilt
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.
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.
EMU28193
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-
N
ZMU03525
UP
ZMU01935
UP
DN
UP
ZMU04077
Operation
53
ter and, if possible, rinse the power head un- der the cowling.
Cruising in muddy or turbid water
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.
Cruising in acidic water
Water in some areas can be acidic. After op- erating in such water, flush the cooling pas- sages with fresh water to prevent corrosion. Also rinse the outside of the outboard motor with fresh water.
54
Maintenance
EMU34520
Specifications NOTE:
(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.
NOTE:
* means, select the engine oil referring to the chart of engine oil paragraph. For further
information, see page 14.
EMU28219
Dimension:
Overall length: F40BMH 1332 mm (52.4 in) F40BTR 700 mm (27.6 in)
Overall width: 378 mm (14.9 in)
Overall height L: 1340 mm (52.8 in)
Transom height L: 533 mm (21.0 in)
Weight (without propeller) L: F40BMH 87.0 kg (192 lb) F40BTR 89.0 kg (196 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 with resistor (NGK):
DPR6EA-9 Spark plug gap:
0.80.9 mm (0.0310.035 in) Control system:
F40BMH Tiller F40BER Remote control F40BTR Remote control
Starting system: F40BMH Manual F40BER Electric 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): 380.0 A
Min. marine cranking amps (MCA/ABYC): 502.0 A
Min. reserve capacity (RC/SAE): 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: F40BMH Hydro tilt F40BER Hydro tilt F40BTR Power trim and tilt
Propeller mark:
Maintenance
55
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 (excluding oil filter): 2.0 L (2.11 US qt) (1.76 Imp.qt)
Recommended gear oil: Hypoid gear oil SAE#90
Gear oil quantity: 430.0 cm
3
(14.54 US oz) (15.17 Imp.oz)
Tightening torque for engine:
Spark plug: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)
Propeller nut: 40.0 Nm (29.5 ft-lb) (4.08 kgf-m)
Engine oil drain bolt: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)
Engine oil filter: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)
EMU28223
Transporting and storing outboard motor
WARNING
EWM00690
Leaking fuel is a fire hazard. When transporting and storing the outboard
motor, close the air vent screw and fuel cock to prevent fuel from leaking.
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
EWM00700
Never get under the lower unit while it is tilted, even if a motor support bar is used. Severe injury could occur if the outboard
motor accidentally falls.
CAUTION:
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
Maintenance
56
prior to storage. However, you, the owner, with a minimum of tools, can perform the fol- lowing procedures.
CAUTION:
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.
EMU28303
Procedure
EMU28373
Flushing in a test tank
1. Wash the outboard motor body using fresh water. For further information, see page 59.
2. Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer to each gallon of fuel.
NOTE:
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.
CAUTION:
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.
ZMU04078
ZMU04079
1. Water surface 2. Lowest water level
ZMU02051
1
2
Maintenance
57
Before starting the engine, be sure to supply water to the cooling water passag-
es.
CAUTION:
ECM00290
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.
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
EWM00090
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.
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.
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 64.
2. Change the gear oil. For instructions, see page 71. 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 64.
NOTE:
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.
EMU28422
Cleaning and anticorrosion measures
1. Wash down the exterior of the outboard motor with fresh water and dry off com- pletely.
2. Spray the outboard motor exterior with Yamaha Silicone Protectant.
3. Wax the cowling with a non-abrasive wax such as Yamaha Silicone Wax.
EMU28431
Battery care
WARNING
EWM00330
Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive mea- sures:
Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury.
Wear protective eye gear when han-
Maintenance
58
dling or working near batteries. Antidote (EXTERNAL):
SKIN - Flush with water.
EYES - Flush with water for 15 minutes and get immediate medical attention.
Antidote (INTERNAL):
Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention.
Batteries also generate explosive hydro- gen gas; therefore, you should always follow these preventive measures:
Charge batteries in a well-ventilated ar- ea.
Keep batteries away from fire, sparks, or open flames (for example: welding equipment, lighted cigarettes, and so on.)
DO NOT SMOKE when charging or han- dling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
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
the boat. Always disconnect the black negative cable first to prevent the risk of shorting.
2. Clean the battery casing and terminals. Fill each cell to the upper level with dis- tilled water.
3. Store the battery on a level surface in a cool, dry, well-ventilated place out of di- rect sunlight.
4. Once a month, check the specific gravity of the electrolyte and recharge as re-
quired to prolong battery life.
EMU28442
Flushing power unit
Perform this procedure right after operation for the most thorough flushing.
CAUTION:
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.
1. Fitting 2. Garden hose connector 3. Garden hose adapter
12
3
ZMU04080
Maintenance
59
3. With the engine off, turn on the water tap and let the water flush through the cool- ing passages for about 15 minutes. Turn off the water and disconnect the garden hose adapter from the garden hose con- nector.
4. Reinstall the garden hose connector onto the fitting on the bottom cowling. Tighten the connector securely.
CAUTION:
ECM00540
Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal opera- tion. Water will leak out of the connector instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fit-
ting after flushing the engine.
NOTE:
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 55.
EMU28450
Cleaning the outboard motor
After use, wash the exterior of the outboard motor with fresh water. Flush the cooling system with fresh water.
NOTE:
For cooling system flushing instructions, see
page 55.
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.
EMU28488
Periodic maintenance
WARNING
EWM01071
Be sure to turn off the engine when you perform maintenance unless otherwise specified. If you are not familiar with ma- chine servicing, this work should be done by your Yamaha dealer or other qualified
mechanic.
Maintenance, replacement, or repair of the emission control devices and sys- tems may be performed by any marine engine repair establishment or individual. All warranty repairs, however, including those to the emission control system, must be performed by an authorized Yamaha marine dealership.
A service manual is available for purchase through your Yamaha dealer for owners who
ZMU02550
Maintenance
60
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.
EMU34150
Severe operating conditions
Severe operating conditions involve one or more of the following types of operation on a regular basis:
Operating continuously at or near maxi- mum engine speed (rpm) for many hours
Operating continuously at a low engine speed (rpm) for many hours
Brief periods of rapid acceleration and de- celeration followed by engine shut off be- fore the engine has reached proper operating temperature
Frequent quick acceleration and decelera- tion
Frequent shifting
Frequently starting and stopping the en- gine(s)
Operation that fluctuates often between light and heavy cargo loads
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.
Maintenance
61
EMU34442
Maintenance chart 1 NOTE:
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 years)
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
Anode(s) (exhaust cover, cover joint)
Replacement
Battery Inspection or charging, replacement as neces- sary
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
Maintenance
62
Engine Oil lter (car- tridge)
Replacement
Fuel lter (disposal type)
Replacement
Fuel pump Inspection or replace- ment as necessary
Fuel/oil leakage Inspection
Fuel pipe Inspection or replace- ment as necessary
Fuel pipe Replacement
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, adjustment or replacement as nec- essary
Spark plug caps/high tention cordes
Inspection or replace- ment as necessary
Pilot water 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
Water inlet Inspection
Item Actions
Initial Every
20 hours (3
months)
100 hours (1 years)
300 hours (3 years)
500 hours (5 years)
Maintenance
63
EMU34450
Maintenance chart 2
EMU28910
NOTE:
When using lead or high-sulfur gasoline, inspecting valve clearance may be required more
frequently than every 500 hours.
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 years)
300 hours (3 years)
500 hours (5 years)
Maintenance
64
EMU28932
Greasing
Yamaha marine grease (Water resistant grease)
F40B
EMU28953
Cleaning and adjusting spark plug
WARNING
EWM00560
When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or
fire.
WARNING
EWM01550
The engine will still be very hot when it has just been turned off. Take extremely care so that neither you nor anyone else gets burnt. To avoid burns, work on the
engine when it has cooled down.
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
ZMU04081
Maintenance
65
other deposits are excessive, you should re- place the spark plug with another of the cor- rect type.
Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification if necessary.
When fitting the plug, always clean the gas- ket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque.
NOTE:
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.
EMU28962
Checking 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.
Check the fuel lines for leaks, crack, or mal- function. If a problem is found, your Yamaha dealer or other qualified mechanic should re- pair it immediately.
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 (13.3 ft-lb) (1.84 kgf-m)
ZMU04082
Maintenance
66
Checkpoints
Fuel system parts leakage
Fuel line joint leakage
Fuel line cracks or other damage
Fuel connector leakage
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.
CAUTION:
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.
NOTE:
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 54.
EMU29074
Changing engine oil
WARNING
EWM00760
Avoid draining the engine oil immedi- ately after stopping the engine. The oil is hot and should be handled with care to avoid burns.
Be sure the outboard motor is securely fastened to the transom or a stable
stand.
CAUTION:
ECM00970
Do not overfill the oil, and be sure the outboard motor is upright (not tilted) when checking and changing the en- gine oil.
If the oil level is above the upper level mark, drain until the level meets the specified capacity. Overfilling the oil
could cause leakage or damage.
CAUTION:
ECM01240
Change the engine oil after the first 10 hours of operation, and every 100 hours
ZMU04083
Maintenance
67
or at 6-month intervals thereafter. Other-
wise the engine will wear quickly.
NOTE:
Change the engine oil when the oil is still
warm.
1. Put the outboard motor in an upright po- sition (not tilted).
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.
NOTE:
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. 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.
5. Start the engine and watch to make sure the low oil pressure-warning indicator (if equipped) turns off. Make sure that there are no oil leaks.
CAUTION:
ECM00681
If the low oil pressure-warning indicator does not turn off or if there are oil leaks,
1. Drain screw
ZMU04084
1
ZMU04085
Drain screw tightening torque: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)
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
Maintenance
68
stop the engine and find the cause. Con- tinued operation with a problem could cause severe engine damage. Consult your Yamaha dealer if the problem can-
not be located and corrected.
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.
NOTE:
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.
EMU29120
Exhaust leakage
Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head, and body cylinder.
EMU29130
Water leakage
Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head, and body cylinder.
EMU29140
Engine oil leakage
Check for oil leaks on the around the engine.
NOTE:
If any leaks are found, consult your Yamaha
dealer.
EMU34580
Checking power trim and tilt system
WARNING
EWM00431
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.
Make sure no one is under the outboard motor before performing this test. Body parts can be crushed between the mo- tor and the clamp bracket when the mo-
tor is trimmed or tilted.
1. Check the power trim and tilt unit for any sign of oil leaks.
ZMU02058
ZMU04087
Maintenance
69
2. Operate each of the power trim and tilt 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.
NOTE:
Consult your Yamaha dealer if any operation
is abnormal.
EMU32110
Checking propeller
WARNING
EWM01610
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, 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
boat has one.
Do not use your hand to hold the pro- peller when loosening or tightening the propeller nut. Put a wood block be- tween the anti-cavitation 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.
1. Trim and tilt rod
1
ZMU04088
ZMU04089
ZMU01897
Maintenance
70
Check the propeller shaft oil seal for dam- age.
EMU30661
Removing propeller
EMU29196
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).
3. Remove the propeller, washer (if equipped), and thrust washer.
EMU30671
Installing propeller
EMU29232
Spline models
CAUTION:
ECM00340
Be sure to install the thrust washer be- fore installing the propeller, otherwise the lower case and propeller boss could be damaged.
Be sure to use a new cotter pin and bend the ends over securely. Otherwise the propeller could come off during op-
eration 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.
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.
NOTE:
If the propeller nut does not align with the
1. Cotter pin 2. Propeller nut 3. Washer 4. Spacer 5. Propeller 6. Thrust washer
Propeller nut tightening torque: 40.0 Nm (29.5 ft-lb) (4.08 kgf-m)
ZMU02063
Maintenance
71
propeller shaft hole after tightening to the specified torque, tighten the nut further to
align it with the hole.
EMU29282
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.
NOTE:
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.
CAUTION:
ECM00710
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-
pair of the lower unit seals.
NOTE:
For disposal of used oil, consult your
Yamaha dealer.
5. With the outboard motor in a vertical po- sition, and using a flexible or pressur- ized filling 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
1. Gear oil drain screw 2. Oil level plug
1
2
ZMU04090
Recommended gear oil: Hypoid gear oil SAE#90
Gear oil quantity: 430.0 cm
3
(14.54 US oz) (15.17 Imp.oz)
ZMU04091
Maintenance
72
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- 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.
CAUTION:
ECM00720
Do not paint anodes, as this would render
them ineffective.
NOTE:
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.
ZMU02066
Maintenance
73
EMU29320
Checking battery (for electric start models)
WARNING
EWM00330
Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive mea- sures:
Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury.
Wear protective eye gear when han- dling or working near batteries.
Antidote (EXTERNAL):
SKIN - Flush with water.
EYES - Flush with water for 15 minutes and get immediate medical attention.
Antidote (INTERNAL):
Drink large quantities of water or milk
followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention.
Batteries also generate explosive hydro- gen gas; therefore, you should always follow these preventive measures:
Charge batteries in a well-ventilated ar- ea.
Keep batteries away from fire, sparks, or open flames (for example: welding equipment, lighted cigarettes, and so on.)
DO NOT SMOKE when charging or han- dling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
CAUTION:
ECM00360
A poorly maintained battery will quickly deteriorate.
Ordinary tap water contains minerals harmful to a battery, and should not be
used for topping up.
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).
2. Always keep the battery in a good state
ZMU02820
ZMU04092
Maintenance
74
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.
3. If the battery will be stored for longer than a month, check the specific gravity of the fluid at least once a month and re- charge the battery when it is low.
NOTE:
Consult a Yamaha dealer when charging or
re-charging batteries.
EMU29332
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.
CAUTION:
ECM01122
Make sure the main switch (on applica- ble models) is (off) before work- ing on the battery.
Reversal of the battery cables will dam- age the electrical parts.
Connect the red battery cable first when installing the battery and discon- nect the black battery cable first when removing it.
The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start
the engine.
Connect the red battery cable to the POSI- TIVE (+) terminal first. Then connect the black battery cable to the NEGATIVE (-) ter- minal.
EMU29370
Disconnecting the battery
Disconnect the BLACK cable from the NEG- ATIVE (-) terminal first. Then disconnect the RED cable from the POSITIVE (+) terminal.
EMU29391
Checking top cowling
CAUTION:
ECM01650
Be sure the cowling is closed securely and that there are no gaps. A loose or im- properly fitting cover could allow water
into the engine.
Check the fitting of the top cowling by push- ing it with both hands. If it is loose have it re- paired by your Yamaha dealer.
1. Red cable 2. Black cable 3. Battery
ZMU02068
Maintenance
75
EMU29400
Coating the boat bottom
A clean hull improves boat performance. The boat bottom should be kept as clean of ma- rine growth as possible. If necessary, the boat bottom can be coated with an anti-foul- ing paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
ZMU01943
76
Trouble Recovery
EMU29425
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-warning indicator is flashing, 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 37.
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 not attached? 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.
Q. Is fuel system obstructed?
Trouble Recovery
77
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 warning system activated? A. Find and correct cause of warning.
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.
Warning 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
78
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 warning system activated? A. Find and correct cause of warning.
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
79
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.
EMU29471
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
EWM00630
Be sure to use the specified fuse. An in- correct fuse or a piece of wire could allow excessive current flow. This could cause
electric system damage and a fire hazard.
NOTE:
Consult your Yamaha dealer if the new fuse
immediately blows again.
Trouble Recovery
80
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
81
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 37. 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
82
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.
EMU29760
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. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the proce- dure below in order to minimize engine dam- age.
EMU29783
Procedure
1. Thoroughly wash away mud, salt, sea- weed, and so on, with fresh water.
2. Remove the spark plug(s), then face the spark plug holes downward to allow any water, mud, or contaminants to drain.
3. Drain the fuel from the carburetor, fuel filter, and fuel line. Drain the engine oil completely.
4. Fill the sump with the fresh engine oil.
5. Feed engine fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking the engine with the manual starter or emergency starter rope.
6. Take the outboard motor to a Yamaha dealer as soon as possible.
CAUTION:
ECM00400
Do not attempt to run the outboard motor
until it has been completely inspected.
ZMU02334
ON STARTOFF
ZMU01906
ZMU04100
Engine oil capacity: 2.0 L (2.11 US qt) (1.76 Imp.qt)
83
Consumer information
EMU29811
Important warranty information for U.S.A. and Canada
Consumer information
84
Consumer information
85
EMU29830
YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY
Consumer information
86
Consumer information
87
EMU29841
IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA
67C-9-19 Hyoshi 07.3.9 14:32 3
Printed in Japan April 20070.6 1 ! Printed on recycled paper
67C-9-19 Hyoshi 07.3.9 14:32
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