Yamaha F9.9FMSH v4 Owner's Manual PDF
Summary of Content for Yamaha F9.9FMSH v4 Owner's Manual PDF
F9.9F T9.9G
OWNERS MANUAL
LIT-18626-08-78 6AU-28199-14
U.S.A.Edition Read this manual carefully before operating this outboard motor.
DIC183
ZMU01690
Read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.
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Important manual information EMU31283
To the owner Thank you for choosing a Yamaha outboard motor. This Owners Manual contains infor- mation needed for proper operation, mainte- nance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owners Manual particularly important information is distinguished in the following ways.
: This is the safety alert symbol. It is used to alert you to potential personal injury haz- ards. Obey all safety messages that follow this symbol to avoid possible injury or death.
WARNING EWM00781
A WARNING indicates a hazardous situa- tion which, if not avoided, could result in death or serious injury.
NOTICE ECM00701
A NOTICE indicates special precautions that must be taken to avoid damage to the outboard motor or other property.
TIP: A TIP provides key information to make pro- cedures easier or clearer.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between
your machine and this manual. If there is any question concerning this manual, please con- sult your Yamaha dealer.
TIP: The F9.9FMH, F9.9FER, T9.9GPH, T9.9GPR, T9.9GEH and the standard acces- sories are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model. EMU25111
F9.9F, T9.9G OWNERS MANUAL
2009 by Yamaha Motor Corporation, USA
1st edition, December 2009 All rights reserved.
Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA
is expressly prohibited. Printed in Japan
P/N LIT-18626-08-78
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Table of contents
Safety information.............................1 Outboard motor safety .................... 1
Propeller ............................................. 1 Rotating parts ..................................... 1 Hot parts............................................. 1 Electric shock ..................................... 1 Power tilt............................................. 1 Engine shut-off cord (lanyard) ............ 1 Gasoline ............................................. 1 Gasoline exposure and spills ............. 2 Carbon monoxide ............................... 2 Modifications ...................................... 2
Boating safety ................................. 2 Alcohol and drugs............................... 2 Personal flotation devices .................. 2 People in the water............................. 2 Passengers ........................................ 2 Overloading ........................................ 2 Avoid collisions................................... 3 Weather.............................................. 3 Accident reporting .............................. 3 Boat education and training................ 3 Passenger training ............................. 4 Boating safety publications................. 4 Laws and regulations ......................... 4
Boating organizations...................... 4 Basic boating rules
(Rules of the road) ....................... 4 Steering and sailing rules and sound
signals............................................. 5 Rules when encountering vessels...... 5 Other special situations ...................... 6
General information ..........................9 Identification numbers record.......... 9
Outboard motor serial number ........... 9 Key number ........................................ 9
Read manuals and labels.............. 10 Warning labels.................................. 10
Specifications and requirements... 14 Specifications ................................ 14 Installation requirements ............... 16
Boat horsepower rating .................... 16 Mounting motor ................................ 16
Remote control requirements........ 16 Battery requirements..................... 16
Specifications of Battery................... 16 Mounting battery............................... 17 Without a rectifier or Rectifier
Regulator ...................................... 17 Propeller selection ........................ 17 Start-in-gear protection ................. 18 Engine oil requirements ................ 18 Fuel requirements ......................... 19
Gasoline ........................................... 19 Ring Free Fuel Additive.................... 19
Muddy or acidic water ................... 20 Anti-fouling paint ........................... 20 Motor disposal requirements......... 20 Emergency equipment .................. 20 Emission control information......... 20
North American models .................... 20 Star labels ........................................ 21
Components .................................... 23 Components diagram.................... 23
Fuel tank........................................... 24 Fuel joint ........................................... 25 Fuel gauge ....................................... 25 Fuel tank cap.................................... 25 Air vent screw................................... 25 Remote control box .......................... 25 Remote control lever ........................ 25 Neutral interlock trigger .................... 26 Neutral throttle lever ......................... 26 Choke switch .................................... 26 Tiller handle...................................... 26 Gear shift lever ................................. 26 Throttle grip ...................................... 27 Throttle indicator............................... 27 Throttle friction adjuster .................... 27 Engine shut-off cord (lanyard)
and clip.......................................... 28 Engine stop button ........................... 28 Choke knob for pull type................... 29 Manual starter handle....................... 29 Starter button.................................... 29 Main switch....................................... 29 Power tilt switch................................ 29
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Table of contents
Steering friction adjuster................... 30 Trim rod (tilt pin) ............................... 31 Tilt lock mechanism.......................... 31 Tilt support knob............................... 31 Tilt support bar ................................. 32 Power tilt unit.................................... 32 Cowling lock lever (pull up type)....... 32 Flushing device ................................ 33 Alert indicator ................................... 33
Instruments and indicators ............ 34 Indicators....................................... 34
Low oil pressure-alert indicator ........ 34 Engine control system.................... 35
Alert system .................................. 35 Low oil pressure alert ....................... 35
Installation .......................................36 Installation ..................................... 36
Mounting the outboard motor ........... 36 Clamping the outboard motor........... 38
Operation ......................................... 39 First-time operation ....................... 39
Fill engine oil .................................... 39 Breaking in engine............................ 39 Getting to know your boat ................ 39
Checks before starting engine ...... 39 Fuel level .......................................... 39 Remove cowling ............................... 40 Fuel system...................................... 40 Controls ............................................ 40 Engine shut-off cord (lanyard) .......... 40 Engine oil.......................................... 41 Engine .............................................. 41 Flushing device ................................ 41 Install cowling ................................... 41 Checking power tilt system............... 42 Battery .............................................. 42
Filling fuel ...................................... 43 Operating engine........................... 44
Sending fuel (portable tank) ............. 44 Starting engine ................................. 45
Checks after starting engine ......... 52 Cooling water ................................... 52
Warming up engine....................... 52 Manual start and electric start
models .......................................... 52 Checks after engine warm-up ....... 53
Shifting ............................................. 53 Stop switches ................................... 53
Shifting .......................................... 53 Stopping boat................................ 54 Stopping engine............................ 55
Procedure......................................... 55 Procedure......................................... 55
Trimming outboard motor.............. 56 Adjusting trim angle for manual tilt
models .......................................... 56 Adjusting trim angle
(power tilt models)......................... 57 Adjusting boat trim............................ 57
Tilting up and down....................... 58 Procedure for tilting up
(manual tilt models)....................... 58 Procedure for tilting up
(power tilt models)......................... 59 Procedure for tilting down
(manual tilt models)....................... 61 Procedure for tilting down
(power tilt models)......................... 61 Shallow water................................ 62
Cruising in shallow water (manual tilt models)....................... 62
Power tilt models .............................. 63 Cruising in other conditions........... 64
Maintenance .................................... 65 Transporting and storing
outboard motor .......................... 65 Dismounting the outboard motor ...... 65 Storing outboard motor..................... 67 Procedure......................................... 67 Lubrication........................................ 68 Flushing power unit .......................... 68 Cleaning the outboard motor ............ 69 Checking painted surface of motor... 69
Periodic maintenance ................... 69 Replacement parts ........................... 70 Maintenance interval guidelines ....... 70
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Table of contents
Maintenance chart 1......................... 71 Maintenance chart 2......................... 73 Greasing........................................... 74 Cleaning and adjusting spark plug ... 76 Checking fuel filter............................ 76 Inspecting idling speed..................... 77 Changing engine oil.......................... 77 Checking wiring and connectors ...... 79 Checking propeller ........................... 79 Removing propeller .......................... 80 Installing propeller ............................ 80 Changing gear oil ............................. 81 Cleaning fuel tank............................. 82 Inspecting and replacing anode(s) ... 83 Checking battery
(for electric start models) .............. 84 Connecting the battery ..................... 84 Disconnecting the battery................. 85
Trouble Recovery............................ 86 Troubleshooting ............................ 86 Temporary action in emergency.... 89
Impact damage................................. 89 Replacing fuse.................................. 89 Power tilt will not operate ................. 90 Starter will not operate ..................... 90 Emergency starting engine............... 91
Engine fails to operate .................. 92 Emergency engine operation ........... 92
Treatment of submerged motor..... 92 Consumer information.................... 93
YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY ............... 93
IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ............. 95
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1
Safety information EMU33622
Outboard motor safety Observe these precautions at all times. EMU36501
Propeller People can be injured or killed if they come in contact with the propeller. The propeller can keep moving even when the motor is in neu- tral, and sharp edges of the propeller can cut even when stationary. Stop the engine when a person is in the wa-
ter near you. Keep people out of reach of the propeller,
even when the engine is off. EMU33630
Rotating parts Hands, feet, hair, jewelry, clothing, PFD straps, etc. can become entangled with inter- nal rotating parts of the engine, resulting in se- rious 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, jewelry, clothing, PFD straps, etc. away from any ex- posed 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 starting or operating the engine. They can cause shock or electrocution.
EMU34790
Power 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 tilt mechanism. The power tilt switches operate even when the main switch is off. Keep people be away from the switches whenever working around the motor. 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 out- board motor accidentally falls. EMU33671
Engine shut-off cord (lanyard) Attach the engine shut-off cord so that the en- gine stops if the operator falls overboard or leaves the helm. This prevents the boat from running away under power and leaving peo- ple stranded, or running over people or ob- jects. 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 become en- tangled, preventing it from functioning. 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 accord- ing to the procedure on page 44 to reduce the risk of fire and explosion.
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Safety information
2
EMU33820
Gasoline exposure and spills Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Dispose of rags properly. If any gasoline spills onto your skin, immedi- ately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gaso- line vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth. EMU33900
Carbon monoxide This product emits exhaust gases which con- tain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking ex- haust outlets. EMU33780
Modifications Do not attempt to modify this outboard motor. Modifications to your outboard motor may re- duce safety and reliability, and render the out- board unsafe or illegal to use. EMU33740
Boating safety This section includes a few of the many im- portant safety precautions that you should fol- low when boating. EMU33710
Alcohol and drugs Never operate after drinking alcohol or taking drugs. Intoxication is one of the most common factors contributing to boating fatalities. 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 boating condi- tions. EMU33731
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 some- one is in the water near the boat, shift into neutral and stop the engine. Stay away from swimming areas. Swimmers can be hard to see. The propeller can keep moving even when the motor is in neutral. Stop the engine when a person is in the water near you. EMU33751
Passengers Consult your boat manufacturers instructions for details about appropriate passenger loca- tions in your boat and be sure all passengers are positioned properly before accelerating and when operating above an idle speed. Standing or sitting in non-designated loca- tions may result in being thrown either over- board or within the boat due to waves, wakes, or sudden changes in speed or direction. Even when people are positioned properly, alert your passengers if you must make any unusual maneuver. Always avoid jumping waves or wakes. EMU33760
Overloading Do not overload the boat. Consult the boat ca- pacity plate or boat manufacturer for maxi- mum 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.
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EMU33772
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, objects, and other boats. Do not follow directly behind other boats or
waterskiers. Avoid sharp turns or other maneuvers that
make it hard for others to avoid you or un- derstand where you are going.
Avoid areas with submerged objects or shallow water.
Ride within your limits and avoid aggressive maneuvers to reduce the risk of loss of con- trol, 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 anoth- er direction.
EMU33790
Weather Stay informed about the weather. Check weather forecasts before boating. Avoid boat- ing in hazardous weather.
EMU33800
Accident reporting Boat operators are required by law to file a Boating Accident Report with their state boat- ing law enforcement agency if their boat is in- volved 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 oth-
er 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 recognized by the United States Coast Guard. Most, but not all, states accept this course to meet their minimum requirements. While it cannot re- place an in-depth course such as one offered by the U.S. Coast Guard, U.S. Power Squad- ron, or other organization, this online course does provide a general overview of the basics in boating safety, requirements, navigation, and operation. Upon successful completion of the course, the user can download a certifi- cate of completion immediately or, for a small charge, request one by mail. To take this free course, go to boatus.org.
ZMU06025
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Safety information
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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 Administra- tors, or your local Power Squadron for a com- plete set of rules governing the waters in which you will be using your boat. EMU33681
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 40511 859-225-9497 www.nasbla.org
National Marine Manufacturers Associa- tion (NMMA) 200 East Randolph Drive Suite 5100 Chicago, IL 60601 www.nmma.org
Marine Retailers Association of America 155 N. Michigan Ave. Chicago, IL 60304 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 driv- ing your boat. These rules are used interna- tionally. (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 encoun- ter another vessel on the water.
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Safety information
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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 main- tain your direction and speed, the other vessel will be able to determine how best to avoid you.
Give-way vessel The vessel that does not have the right-of- way has the duty to take positive and timely action to stay out of the way of the Stand-On vessel. Normally, you should not cross in front of the vessel with the right-of-way. You should slow down or change directions briefly and pass behind the other vessel. You should al- ways 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 ves- sels. 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 fol- lowed: Meeting: (you are approaching another ves- sel head-on) Crossing: (you are traveling across the other 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 shaded 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 col- lision, neither of you has the right-of-way Both of you should alter course to avoid an acci- dent. You should keep the other vessel on
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Safety information
6
your port (left) side. This rule doesnt apply if both of you will clear one another if you con- tinue 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 other 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 direction, provid- ed the other vessel gives you the right-of-way as it should.
Overtaking If you are passing another vessel, you are the Give-Way vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if another 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 other 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 water 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 nav- igate 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 re- gardless of position. Fishing vessels cannot, however, impede the passage of other ves- sels 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-driven vessel has the right-of-way.
2. Sailing vessels should keep clear of any fishing vessel.
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Safety information
7
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, num- bers and lights to show which side of the buoy a boater should pass on when navigating in a particular direction. The markings on these buoys are oriented from the perspective of be- ing entered from seaward (the boater is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open water into port, and black buoys are to port (left) side. When navi- gating out of port, your position with respect to the buoys should be reversed; red buoys should be to port and black buoys to star- board. Many bodies of water used by boaters are en- tirely within the boundaries of a particular state. The Uniform State Waterway Marking System has been devised for these waters. This system uses buoys and signs with dis- tinctive shapes and colors to show regulatory or advisory information. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geograph- ic location. Always consult local boating au- thorities before driving your boat in unfamiliar waters.
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Safety information
8
ZMU01708
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General information
9
EMU25171
Identification numbers record EMU25183
Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto- len. EMU25190
Key number If a main key switch is equipped with the mo- tor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key.
1. Outboard motor serial number location
1. Outboard motor serial number location
1
ZMU05335
1
ZMU05336
1. Key number
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General information
10
EMU33520
Read manuals and labels Before operating or working on this motor: Read this manual. Read any manuals supplied with the boat. Read all labels on the outboard motor and the boat. If you need any additional information, contact your Yamaha dealer. EMU33831
Warning labels If these labels are damaged or missing, contact your Yamaha dealer for replacements. F9.9FMH, T9.9GEH
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General information
11
F9.9FER, T9.9GPH, T9.9GPR
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EMU33843
Symbols The following symbols mean as follows.
Notice/Warning
Read Owners Manual
1 2
3
ZMU05670
ZMU05696
ZMU05664
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General information
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Hazard caused by continuous rotation
Electrical hazard
Remote control lever/gear shift lever operat- ing direction, dual direction
Engine start/ Engine cranking
ZMU05665
ZMU05666
ZMU05667
ZMU05668
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Specifications and requirements
14
EMU34520
Specifications TIP: (AL) stated in the specification data below represents the numerical value for the alumi- num propeller installed. Likewise, (SUS) represents the value for stainless steel propeller installed and (PL) for plastic propeller installed.
TIP: * means, select the engine oil referring to the chart of engine oil paragraph. For further infor- mation, see page 18. EMU2821E
Dimension: Overall length:
F9.9FER 552 mm (21.7 in) F9.9FMH 927 mm (36.5 in) T9.9GEH 1038 mm (40.9 in) T9.9GPH 1038 mm (40.9 in) T9.9GPR 552 mm (21.7 in)
Overall width: F9.9FER 332 mm (13.1 in) F9.9FMH 375 mm (14.8 in) T9.9GEH 370 mm (14.6 in) T9.9GPH 371 mm (14.6 in) T9.9GPR 331 mm (13.0 in)
Overall height S: F9.9FMH 1000 mm (39.4 in)
Overall height L: F9.9FER 1127 mm (44.4 in) F9.9FMH 1127 mm (44.4 in) T9.9GEH 1187 mm (46.7 in) T9.9GPH 1187 mm (46.7 in) T9.9GPR 1187 mm (46.7 in)
Overall height X: T9.9GEH 1255 mm (49.4 in) T9.9GPH 1255 mm (49.4 in) T9.9GPR 1255 mm (49.4 in)
Transom height S: F9.9FMH 435 mm (17.1 in)
Transom height L: F9.9FER 557 mm (21.9 in) F9.9FMH 557 mm (21.9 in) T9.9GEH 552 mm (21.7 in) T9.9GPH 552 mm (21.7 in) T9.9GPR 557 mm (21.9 in)
Transom height X: T9.9GEH 620 mm (24.4 in) T9.9GPH 620 mm (24.4 in) T9.9GPR 625 mm (24.6 in)
Weight (AL) S: F9.9FMH 40.0 kg (88 lb)
Weight (AL) L: F9.9FER 43.0 kg (95 lb) F9.9FMH 41.0 kg (90 lb) T9.9GEH 47.2 kg (104 lb) T9.9GPH 51.8 kg (114 lb) T9.9GPR 49.0 kg (108 lb)
Weight (AL) X: T9.9GEH 50.0 kg (110 lb) T9.9GPH 52.9 kg (117 lb) T9.9GPR 50.2 kg (111 lb)
Performance: Full throttle operating range:
50006000 r/min Maximum output:
7.3 kW@5500 r/min (9.9 HP@5500 r/min)
Idling speed (in neutral): 1050 50 r/min
Engine: Type:
4-stroke L Displacement:
212.0 cm Bore stroke:
56.0 43.0 mm (2.20 1.69 in) Ignition system:
CDI Spark plug (NGK):
BR6HS-10
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Specifications and requirements
15
Spark plug gap: 0.91.0 mm (0.0350.039 in)
Control system: F9.9FER Remote control F9.9FMH Tiller T9.9GEH Tiller T9.9GPH Tiller T9.9GPR Remote control
Starting system: F9.9FER Electric F9.9FMH Manual T9.9GEH Manual and electric T9.9GPH Electric T9.9GPR Electric
Starting carburetion system: Choke valve
Valve clearance (cold engine) IN: 0.150.20 mm (0.00590.0079 in)
Valve clearance (cold engine) EX: 0.200.25 mm (0.00790.0098 in)
Min. cold cranking amps (CCA/SAE): F9.9FER 245.0 A T9.9GEH 245.0 A T9.9GPH 245.0 A T9.9GPR 245.0 A
Min. marine cranking amps (MCA/ABYC): F9.9FER 323.0 A T9.9GEH 323.0 A T9.9GPH 323.0 A T9.9GPR 323.0 A
Min. reserve capacity (RC/SAE): F9.9FER 52 minutes T9.9GEH 52 minutes T9.9GPH 52 minutes T9.9GPR 52 minutes
Alternator output: F9.9FMH 80 W
Maximum generator output: F9.9FER 6 A T9.9GEH 6 A T9.9GPR 6 A
Drive unit: Gear positions:
Forward-neutral-reverse Gear ratio:
F9.9FER 2.08(27/13) F9.9FMH 2.08(27/13) T9.9GEH 2.92(38/13) T9.9GPH 2.92(38/13) T9.9GPR 2.92(38/13)
Trim and tilt system: F9.9FER Manual tilt F9.9FMH Manual tilt T9.9GEH Manual tilt T9.9GPH Power tilt T9.9GPR Power tilt
Propeller mark: F9.9FER N F9.9FMH N T9.9GEH R T9.9GPH R T9.9GPR R
Fuel and oil: Recommended fuel:
Regular unleaded gasoline Min. pump octane:
86 Fuel tank capacity:
12.0 L (3.17 US gal, 2.64 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
Total engine oil quantity (oil pan capacity): Without oil filter replacement:
0.8 L (0.85 US qt, 0.70 Imp.qt)
U6AU13E0.book Page 15 Wednesday, March 11, 2009 9:09 AM
Specifications and requirements
16
Recommended gear oil: Hypoid gear oil SAE#90
Gear oil quantity: F9.9FER 0.150 L (0.159 US qt, 0.132 Imp.qt) F9.9FMH 0.150 L (0.159 US qt, 0.132 Imp.qt) T9.9GEH 0.370 L (0.391 US qt, 0.326 Imp.qt) T9.9GPH 0.370 L (0.391 US qt, 0.326 Imp.qt) T9.9GPR 0.370 L (0.391 US qt, 0.326 Imp.qt)
Tightening torque for engine: Spark plug:
25.0 Nm (2.55 kgf-m, 18.4 ft-lb) Propeller nut:
F9.9FER 17.0 Nm (1.73 kgf-m, 12.5 ft-lb) F9.9FMH 17.0 Nm (1.73 kgf-m, 12.5 ft-lb) T9.9GEH 21.0 Nm (2.14 kgf-m, 15.5 ft-lb) T9.9GPH 21.0 Nm (2.14 kgf-m, 15.5 ft-lb) T9.9GPR 21.0 Nm (2.14 kgf-m, 15.5 ft-lb)
Engine oil drain bolt: 24.0 Nm (2.45 kgf-m, 17.7 ft-lb)
EMU33554
Installation requirements EMU33563
Boat horsepower rating
WARNING EWM01560
Overpowering a boat can cause severe in- stability.
Before installing the outboard motor(s), con- firm that the total horsepower of your motor(s) does not exceed the boats maximum horse- power rating. See the boats capacity plate or contact the manufacturer.
EMU33571
Mounting motor
WARNING EWM01570
Improper mounting of the outboard mo- tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards.
Because the motor is very heavy, spe- cial equipment and training is required to mount it safely.
Your dealer or other person experienced in proper rigging should mount the motor using correct equipment and complete rigging in- structions. For further information, see page 36. EMU33581
Remote control requirements
WARNING EWM01580
If the engine starts in gear, the boat can move suddenly and unexpectedly, pos- sibly causing a collision or throwing passengers overboard.
If the engine ever starts in gear, the start-in-gear protection device is not working correctly and you should dis- continue using the outboard. Contact your Yamaha dealer.
The remote control unit must be equipped with a start-in-gear protection device(s). This device prevents the engine from starting un- less it is in neutral. EMU25694
Battery requirements EMU25713
Specifications of Battery Use a fully charged battery that meets the fol- lowing specifications. The engine cannot be started if battery voltage is too low.
U6AU13E0.book Page 16 Wednesday, March 11, 2009 9:09 AM
Specifications and requirements
17
NOTICE ECM01061
Do not use a battery that does not meet the specified capacity. If a battery that does not meet specifications is used, the elec- tric system could perform poorly or be overloaded, causing electric system dam- age.
EMU36290
Mounting battery Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. WARNING! Do not put flammable items, or loose heavy or metal objects in the same compartment as the battery. Fire, explosion or sparks could result. [EWM01820]
EMU25730
Without a rectifier or Rectifier Regula- tor
NOTICE ECM01090
A battery cannot be connected to models that do not have a rectifier or Rectifier Regulator.
If you wish to use a battery with the models without a rectifier or Rectifier Regulator, install 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 op- tional Rectifier Regulator. EMU34192
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 propellers for ev- ery Yamaha outboard motor and every appli- cation. 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 appropri- ate. 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 propeller 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.
Minimum cold cranking amps (CCA/SAE):
F9.9FER 245.0 A T9.9GEH 245.0 A T9.9GPH 245.0 A T9.9GPR 245.0 A
Minimum marine cranking amps (MCA/ABYC):
F9.9FER 323.0 A T9.9GEH 323.0 A T9.9GPH 323.0 A T9.9GPR 323.0 A
Minimum reserve capacity (RC/SAE): F9.9FER 52 minutes T9.9GEH 52 minutes T9.9GPH 52 minutes T9.9GPR 52 minutes
U6AU13E0.book Page 17 Wednesday, March 11, 2009 9:09 AM
Specifications and requirements
18
For instructions on propeller removal and in- stallation, see page 79.
EMU25760
Start-in-gear protection Yamaha outboard motors affixed with the pic- tured label or Yamaha-approved remote con- trol 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 en- gine.
EMU31444
Engine oil requirements
If the recommended engine oil grades are not available, select an alternative from the fol- lowing chart according to the average temper- atures in your area.
1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark)
1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark)
ZMU04606
-x 1 2 3
ZMU04604
-x 1 2 3
1. Start-in-gear protection label
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
Total engine oil quantity (oil pan capaci- ty):
Without oil filter replacement: 0.8 L (0.85 US qt, 0.70 Imp.qt)
ZMU01713
1
U6AU13E0.book Page 18 Wednesday, March 11, 2009 9:09 AM
Specifications and requirements
19
EMU36360
Fuel requirements EMU36781
Gasoline Use a good quality gasoline that meets the minimum octane rating. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Yamaha recomends that you use alcohol-free (see Gasohol) gas- oline whenever possible.
NOTICE ECM01981
Do not use leaded gasoline. Leaded gas- oline can seriously damage the engine.
Avoid getting water and contaminants in the fuel tank. Contaminated fuel can cause poor performance or engine dam- age. Use only fresh gasoline that has been stored in clean containers.
Gasohol There are two types of gasohol: gasohol con- taining ethanol (E10) and that containing methanol. Ethanol can be used if the ethanol content does not exceed 10% and the fuel meets the minimum octane ratings. E85 is a fuel containing 85% ethanol and must not be used in your outboard motor. All ethanol blends containing more than 10% ethanol can cause fuel system damage or cause engine starting and running problems. Yamaha does not recommend gasohol containing methanol because it can cause fuel system damage or engine performance problems. It is recommended that you install a water- separating marine fuel filter assembly (10 mi- cron minimum) between your boats fuel tank and outboard motor when using ethanol. Eth- anol is known to allow moisture to be ab- sorbed into boat fuel tanks and systems. Moisture in the fuel can cause corrosion of metallic fuel system components, starting and running complaints and require additional fuel system maintenance. EMU27270
Ring Free Fuel Additive Gasoline is a precise blend of many different substances, each chosen to give certain char- acteristics. Gasoline blends have been changing in recent years in response to con- cerns about pollution and resulting emissions regulations. One of the most obvious changes has been the elimination of lead from most fu- els. As gasoline has changed, the amount of addi- tives such as aromatics and oxygenates has increased. These additives are important for the engines in passenger cars, but they can have detrimental effects in marine engines, because of increased deposits in the combus- tion chamber. When enough deposits collect,
Recommended gasoline: Regular unleaded gasoline with a mini- mum Octane rating of 86 (Pump Oc- tane Number) = (R+M)/2
U6AU13E0.book Page 19 Wednesday, March 11, 2009 9:09 AM
Specifications and requirements
20
piston rings begin sticking. Performance drops and engine wear increases dramatical- ly. While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free Fuel Additive has repeatedly proven its ability to clean com- bustion deposits from inside the engine, nota- bly the critical piston-ring-land area, and fuel system components. Follow product labeling for use instructions. EMU36880
Muddy or acidic water Yamaha strongly recommends that you have your dealer install the optional chromium-plat- ed water pump kit if you use the outboard mo- tor in muddy or acidic water conditions. However, depending on the model it might not be required. EMU36330
Anti-fouling paint A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bot- tom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
EMU36341
Motor disposal requirements Never illegally discard (dump) the motor. Yamaha recommends consulting the dealer about discarding the motor. EMU36351
Emergency equipment Keep the following items onboard in case there is trouble with the motor. A tool kit with assorted screwdrivers, pliers,
wrenches (including metric sizes), and electrical tape.
Waterproof flashlight with extra batteries. An extra engine shut-off cord (lanyard) with
clip. Spare parts, such as an extra set of spark
plugs. Consult your Yamaha dealer for details. EMU25221
Emission control information EMU25230
North American models This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for ma- rine SI engines. See the label affixed to your engine for details. EMU25242
Approval label of emission control certifi- cate This label is attached to the bottom cowling. New Technology; (4-stroke/HPDI) EM
1. Approval label location
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Specifications and requirements
21
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 Califor- nia Air Resources Board (CARB) star label. 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 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low-Emission engines.
1. Manufactured date label location
ZMU07059
EMISSION CONTROL INFORMATION EM THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EXHAUST REGULATIONS FOR SI MARINE ENGINES. REFER TO THE OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. MEETS U.S. EPA EVAP STANDARDS USING CERTIFIED COMPONENTS. FAMILY: DISPLACEMENT: liters SPARK PLUG: FUEL: GASOLINE
FELs(HC+NOx / CO): / g/kW-hr MAX POWER: kW IDLE SPEED: rpm IN NETRAL SPARK PLUG GAP (mm): VALVE LASH (mm) IN: EX:
YAMAHA MOTOR CO.,LTD.
Manufactured:
ZMU04346
1. Star labels location
ZMU01702
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Specifications and requirements
22
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 meeting these standards have 90% lower emissions than One Star-Low-Emission engines.
ZMU01703
ZMU01704
ZMU05663
U6AU13E0.book Page 22 Wednesday, March 11, 2009 9:09 AM
Components
23
EMU2579M
Components diagram TIP: * May not be exactly as shown; also may not be included as standard equipment on all models. F9.9F
1. Top cowling 2. Cowling lock lever 3. Anti-cavitation plate 4. Propeller 5. Cooling water inlet 6. Drain screw 7. Trim rod 8. Clamp bracket 9. Flushing device 10.Choke knob 11.Fuel joint 12.Manual starter handle* 13.Alert indicator 14.Engine stop button/Engine shut-off switch* 15.Gear shift lever* 16.Tiller handle*
17.Throttle grip* 18.Throttle friction adjuster* 19.Tilt lock lever 20.Steering friction adjuster* 21.Clamp screw 22.Restraint cable attachment
U6AU13E0.book Page 23 Wednesday, March 11, 2009 9:09 AM
Components
24
T9.9G
EMU25802
Fuel tank If your model was equipped with a portable fuel tank, its function is as follows.
WARNING EWM00020
The fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Com- mercial users should conform to relevant licensing or approval authority regula- tions.
1. Top cowling 2. Cowling lock lever 3. Anti-cavitation plate 4. Propeller 5. Cooling water inlet 6. Drain screw 7. Clamp bracket 8. Power tilt switch* 9. Flushing device 10.Choke knob 11.Fuel joint 12.Manual starter handle* 13.Alert indicator 14.Starter button* 15.Engine stop button/Engine shut-off switch* 16.Gear shift lever* 17.Tiller handle* 18.Throttle grip* 19.Throttle friction adjuster* 20.Tilt lock lever* 21.Steering friction adjuster*
22.Clamp screw 23.Restraint cable attachment 24.Tilt support knob* 25.Remote control box (side mount type)*
U6AU13E0.book Page 24 Wednesday, March 11, 2009 9:09 AM
Components
25
EMU25830
Fuel joint This joint is used to connect the fuel line. EMU25841
Fuel gauge This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the ap- proximate amount of fuel remaining in the tank. EMU25850
Fuel tank cap This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise. EMU25860
Air vent screw This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise. EMU26181
Remote control box The remote control lever actuates both the shifter and the throttle. The electrical switches 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 lever back from neutral engages reverse. The en- gine will continue to run at idle until the lever is moved about 35 (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.
1. Air vent screw 2. Fuel gauge 3. Fuel joint 4. Fuel tank cap
ZMU01992
3 24 1
1. Power 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 4. Shift 5. Fully closed 6. Throttle 7. Fully open
U6AU13E0.book Page 25 Wednesday, March 11, 2009 9:09 AM
Components
26
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 either forward or reverse, put the remote control le- ver in the neutral position and lift the neutral throttle lever.
TIP: The neutral throttle lever will operate only when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position.
EMU26221
Choke switch To activate the choke system, press in the main switch while the key is turned to the (on) or (start) position. The choke sys- tem will then supply the rich fuel mixture re- quired to start the engine. When the key is released, the choke will switch off automati- cally.
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.
1. Neutral interlock trigger
1. Fully open 2. Fully closed
U6AU13E0.book Page 26 Wednesday, March 11, 2009 9:09 AM
Components
27
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 in- dicator shows the relative amount of fuel con- sumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation.
EMU25975
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! Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident. [EWM00032]
1. Forward 2. Neutral 3. Reverse
1. Throttle indicator
ZMU05338
1
ZMU05369
U6AU13E0.book Page 27 Wednesday, March 11, 2009 9:09 AM
Components
28
When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting. EMU25993
Engine shut-off cord (lanyard) and clip The clip must be attached to the engine shut- off switch for the engine to run. The cord should be attached to a secure place on the operators clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power. WARNING! At- tach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. Avoid acci- dentally pulling the cord during 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 ob- jects in the boat to be thrown forward. [EWM00122]
EMU26001
Engine stop button To open the ignition circuit and stop the en- gine, push this button.
ZMU05342
1. Cord 2. Clip 3. Engine shut-off switch
1. Cord 2. Clip 3. Engine shut-off switch
U6AU13E0.book Page 28 Wednesday, March 11, 2009 9:09 AM
Components
29
EMU26011
Choke knob for pull type To supply the engine with the rich fuel mixture required to start, pull out this knob.
EMU26070
Manual starter handle To start the engine, first gently pull the handle out until resistance is felt. From that position, then pull the handle straight out quickly to crank the engine.
EMU26080
Starter button To start the engine with the electric starter, push the starter button.
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) position, the electrical circuits are on, and the key can- not 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.
EMU26102
Power tilt switch The power tilt system adjusts the outboard motor angle in relation to the transom. Push- ing the switch (up) tilts the outboard mo-
U6AU13E0.book Page 29 Wednesday, March 11, 2009 9:09 AM
Components
30
tor up. Pressing the switch (down) tilts the outboard motor down. When the switch is released, the outboard motor will stop in its current position.
TIP: For instructions on using the power tilt switch, see pages 56 and 58.
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.
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.
U6AU13E0.book Page 30 Wednesday, March 11, 2009 9:09 AM
Components
31
TIP: Steering movement is blocked when the
adjuster lever is set to the A position. Check the tiller handle for smooth move-
ment when the lever is turned to the star- board side B.
Do not apply lubricants such as grease to the friction areas of the steering friction ad- juster.
EMU26261
Trim rod (tilt pin) The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.
EMU30530
Tilt lock mechanism The tilt lock mechanism is used to prevent the outboard motor from lifting out of the water when in reverse gear.
To lock it, set the tilt lock lever in the lock po- sition. To release, push the tilt lock lever in the release position. EMU26321
Tilt support knob To keep the outboard motor in the tilted up po- sition, push the tilt support knob under the swivel bracket.
NOTICE ECM00660
Do not use the tilt support lever or knob when trailering the boat. The outboard mo- tor could shake loose from the tilt support and fall. If the motor cannot be trailered in
1. Nut
Nut tightening torque: 6.0 Nm (0.61 kgf-m, 4.4 ft-lb)
1. Tilt lock lever
U6AU13E0.book Page 31 Wednesday, March 11, 2009 9:09 AM
Components
32
the normal running position, use an addi- tional support device to secure it in the tilt position.
EMU26332
Tilt support bar The tilt support bar keeps the outboard motor in the tilted up position.
NOTICE ECM01660
Do not use the tilt support bar when traile- ring the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the nor- mal running position, use an additional support device to secure it in the tilt posi- tion.
EMU26361
Power tilt unit This unit tilts the outboard motor up and down and is controlled with the power tilt switch.
NOTICE ECM00630
Do not step on or exert pressure on the power tilt motor. The power tilt unit could be damaged as a result.
NOTICE ECM00660
Do not use the tilt support lever or knob when trailering the boat. The outboard mo- tor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an addi- tional support device to secure it in the tilt position.
EMU26383
Cowling lock lever (pull up type) To remove the engine top cowling, pull up the cowling lock lever(s) and lift off the cowling. When installing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling by moving the cowling lock lever(s) downward.
1. Power tilt unit 2. Power tilt motor
U6AU13E0.book Page 32 Wednesday, March 11, 2009 9:09 AM
Components
33
EMU26460
Flushing device This device is used to clean the cooling water passages of the motor using a garden hose and tap water.
TIP: For details on usage, see page 68.
EMU26303
Alert indicator If the engine develops a condition which is cause for alert, the indicator lights up. For de- tails on how to read the alert indicator, see page 35.
1. Flushing device
1. Low oil pressure-alert indicator
U6AU13E0.book Page 33 Wednesday, March 11, 2009 9:09 AM
Instruments and indicators
34
EMU36014
Indicators EMU36024
Low oil pressure-alert indicator If oil pressure drops too low, this indicator will light up. For further information, see page 35.
NOTICE ECM00022
Do not continue to run the engine if the low oil pressure-alert indicator is on and the engine oil level is lower. Serious en- gine damage will occur.
The low oil pressure-alert indicator does not indicate the engine oil level. Use the oil dipstick to check the remaining oil quantity. For further information, see page 41.
1. Low oil pressure-alert indicator
U6AU13E0.book Page 34 Wednesday, March 11, 2009 9:09 AM
Engine control system
35
EMU26803
Alert system
NOTICE ECM00091
Do not continue to operate the engine if a alert device has activated. Consult your Yamaha dealer if the problem cannot be lo- cated and corrected.
EMU3016A
Low oil pressure alert If the oil pressure drops too low, the alert de- vice will activate. The engine speed will automatically de-
crease to about 2000 r/min. If equipped with a low oil pressure-alert indicator, it will light or blink.
The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel).
If the alert system has activated, stop the en- gine as soon as it is safe to do so. Check the oil level and add oil as needed. If the oil level is correct and the alert device does not switch off, consult your Yamaha dealer.
U6AU13E0.book Page 35 Wednesday, March 11, 2009 9:09 AM
Installation
36
EMU26902
Installation The information presented in this section is in- tended as reference only. It is not possible to provide complete instructions for every possi- ble boat and motor combination. Proper 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 capacity 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 conditions such as poor handling, loss of control, or fire hazards. For permanently mount- ed models, your dealer or other person experienced in proper rigging should mount the motor.
EMU34801
Mounting the outboard motor
NOTICE ECM01680
Do not hold the top cowling when mount- ing or dismounting the outboard motor. The top cowling could come off, causing the outboard motor to fall.
1. Be sure to mount the outboard motor while the boat is on land. If the boat is on the water, move it to an area on land.
2. To prevent steering movement, turn the adjuster lever to A (if equipped with the adjuster lever). To hold the steering bracket easily, raise the tiller handle to the vertical position (if equipped with the tiller handle).
3. Hold the handgrip and steering bracket as shown in the illustration and lift up the outboard motor using two people.
1. Steering bracket 2. Handgrip
U6AU13E0.book Page 36 Wednesday, March 11, 2009 9:09 AM
Installation
37
4. Mount the outboard motor on the center line (keel line) of the boat, and ensure that the boat itself is well balanced. Oth- erwise the boat will be hard to steer. For boats without a keel or which are asym- metrical, consult your dealer.
EMU26923
Mounting height To run your boat at optimum efficiency, the water resistance (drag) of the boat and out- board motor must be made as little as possi- ble. The mounting height of the outboard motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine
speed will rise abnormally and cause the en- gine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in) below it.
NOTICE ECM01631
Check that the idle hole stays high enough to keep out water getting inside engine even if the boat is in stationary with maximum load.
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 air- borne water spray while the boat is cruising. If the motor is operated contin- uously in the presence of airborne water spray, enough water could enter the en- gine through the intake opening on the cowling to cause severe engine dam- age. Eliminate the cause of the airborne water spray.
TIP: The optimum mounting height of the out-
board motor is affected by the boat and mo- tor combination and the desired use. Test
1. Center line (keel line)
ZMU017601
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Installation
38
runs at different heights can help determine the optimum mounting height. Consult your Yamaha dealer or boat manufacturer for further information on determining the prop- er mounting height.
For instructions on setting the trim angle of the outboard motor, see page 56.
EMU26972
Clamping the outboard motor 1. Place the outboard motor on the transom
so that it is positioned as close to the cen- ter as possible. Tighten the transom clamp screws evenly and securely. Oc- casionally check the clamp screws for tightness during operation of the out- board motor because they could become loose due to engine vibration. WARNING! Loose clamp screws could allow the outboard motor to fall off or move on the transom. This could cause loss of control and serious inju- ry. Make sure the transom screws are tightened securely. Occasionally check the screws for tightness during operation. [EWM00641]
2. If the restraint cable attachment is equipped on your engine, a restraint ca- ble or chain should be used. Attach one end to the restraint cable attachment and the other to a secure mounting point on
the boat. Otherwise the engine could be completely lost if it accidentally falls off the transom.
3. Secure the clamp bracket to the transom using the bolts provided with the out- board (if packed). For details, consult your Yamaha dealer. WARNING! Avoid using bolts, nuts or washers other than those contained in the engine packaging. If used, they must be of at least the same quality of material and strength and must be tightened se- curely. After tightening, test run the engine and check their tightness. [EWM00651]
ZMU02012
1. Bolts
ZMU02013
1
ZMU03806
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Operation
39
EMU36381
First-time operation EMU36391
Fill engine oil The engine is shipped from the factory without engine oil. If your dealer did not fill the oil, you must fill it before starting the engine. NOTICE: Check that the engine is filled with oil be- fore first-time operation to avoid severe engine damage. [ECM01781]
The engine is shipped with the following stick- er, which should be removed after engine oil is filled for the first time. For more information on checking the engine oil level, see page 41.
EMU30174
Breaking in engine Your new engine requires a period of break-in to allow mating surfaces of moving parts to wear in evenly. Correct break-in will help en- sure proper performance and longer engine life. NOTICE: Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage. [ECM00801]
EMU27085
Procedure for 4-stroke models Your new engine requires a period of 10 hours break-in to allow mating surfaces of moving parts to wear in evenly.
TIP: Run the engine in the water, under load (in gear with a propeller installed) as follows. For 10 hours for breaking in engine avoid extend- ed 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 8 hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.
4. After the first 10 hours: Operate the engine normally.
EMU36400
Getting to know your boat Different boats handle differently. Operate cautiously while you learn how your boat han- dles under different conditions and with differ- ent trim angles (see page 56). EMU36412
Checks before starting engine
WARNING EWM01920
If any item in the checks before starting engine is not working properly, have it in- spected and repaired before operating the outboard motor. Otherwise an accident could occur.
NOTICE ECM00120
Do not start the engine out of water. Over- heating and serious engine damage can occur.
EMU36560
Fuel level Be sure you have plenty of fuel for your trip. A good rule is to use 1/3 of your fuel to get to the destination, 1/3 to return, and to keep 1/3 as
ZMU01710
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Operation
40
an emergency reserve. With the boat level on a trailer or in the water, check the fuel level. For fuel filling instructions, see page 43. EMU36570
Remove cowling For the following checks, remove the top cowling from the engine. To remove the en- gine top cowling, release the lock lever and lift off the cowling.
EMU36442
Fuel system
WARNING EWM00060
Gasoline and its vapors are highly flam- mable and explosive. Keep away from sparks, cigarettes, flames, or other sourc- es of ignition.
WARNING EWM00910
Leaking fuel can result in fire or explosion. Check for fuel leakage regularly. If any fuel leakage is found, the fuel sys-
tem must be repaired by a qualified me- chanic. Improper repairs can make the outboard unsafe to operate.
EMU36451
Check for fuel leaks Check for fuel leaks or gasoline fumes in
the boat. Check for fuel leakage from the fuel system. Check the fuel tank and fuel lines for
cracks, swellings, or other damages.
EMU36901
Controls Tiller handle models: Move the tiller handle fully to the left and
right to make sure operation is smooth. Turn the throttle grip from the fully closed to
the fully open position. Make sure that it turns smoothly and that it completely re- turns to the fully closed position.
Look for loose or damaged connections of the throttle and shift cables.
Remote control models: Turn the steering wheel full-right and full-
left. Make sure operation is smooth and un- restricted throughout the whole range with no binding or excessive free play.
Operate the throttle levers several times to make sure there is no hesitation in their travel. Operation should be smooth over the complete range of motion, and each le- ver should return completely to the idle po- sition.
Look for loose or damaged connections of the throttle and shift cables.
EMU36481
Engine shut-off cord (lanyard) Inspect the engine shut-off cord for damage, such as cuts, breaks, and wear.
1. Cord 2. Clip 3. Engine shut-off switch
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41
EMU27166
Engine oil 1. Put the outboard motor in an upright po-
sition (not tilted). NOTICE: If the motor is not level, the oil level indicated on the dipstick may not be accurate. [ECM01790]
2. Remove oil dipstick and wipe it clean. 3. Insert the dipstick and remove it again.
Be sure to completely insert the dipstick into the dipstick guide, otherwise the oil level measurement will be incorrect.
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.
EMU27153
Engine Check the engine and engine mounting. Look for loose or damaged fasteners. Check the propeller for damage. Check for engine oil leaks. EMU36490
Flushing device Check that flushing devices garden hose connector is securely screwed on to the fitting on the bottom cowling. NOTICE: If the flush- ing device is not properly connected, cool- ing water can leak out and the engine can overheat during operation. [ECM01800]
EMU36953
Install cowling 1. Be sure that a cowling lock lever is re-
leased.
1. Cord 2. Clip 3. Engine shut-off switch
1. Oil dipstick
ZMU05368
1
1. Lower level mark 2. Oil dipstick 3. Upper level mark
1. Fitting 2. Flushing device
ZMU02082
1 3
2
U6AU13E0.book Page 41 Wednesday, March 11, 2009 9:09 AM
Operation
42
2. Be sure that the rubber seal is seated all the way around the top cowling.
3. Place the top cowling on bottom cowling. 4. Check to be sure the rubber seal fits cor-
rectly all the way around the engine. 5. Move the lever to lock the cowling as
shown. NOTICE: If the cowling is not installed correctly, water spray under the cowling can damage the engine, or the cowling can blow off at high speeds. [ECM01990]
After installing, check the fitting of the top cowling by pushing it with both hands. If the top cowling is loose, have it repaired by your Yamaha dealer.
EMU34782
Checking power tilt system
WARNING EWM01970
Never get under the lower unit while it is tilted, even when the tilt support knob is locked. Severe injury could occur if the outboard motor accidentally falls.
Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted.
Be sure no one is near the outboard mo- tor before performing this check.
1. Check the power tilt unit for any sign of oil leaks.
2. Operate each of the power tilt switches to check that all switches work.
3. Tilt the outboard motor up and check that the tilt rod is pushed out completely.
4. Check that the tilt rod is free of corrosion or other flaws.
5. Tilt the outboard motor down. Check that the tilt rod operates smoothly.
EMU36582
Battery Check that the battery is in good condition, and fully charged. Check that the battery con- nections are clean, secure and covered by in- sulating covers. The electrical contacts of the
ZMU06136
1. Tilt rod
U6AU13E0.book Page 42 Wednesday, March 11, 2009 9:09 AM
Operation
43
battery and cables must be clean and proper- ly connected or the battery will not start the engine. Refer to the battery manufacturers instruc- tions for checks for your particular battery. EMU27437
Filling fuel
WARNING EWM01830
Gasoline and its vapors are highly flam- mable and explosive. Always refuel ac- cording to this procedure to reduce the risk of fire and explosion.
Gasoline is poisonous and can cause in- jury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gas- oline in your eyes, see your doctor im- mediately. If gasoline spills on your skin, wash with soap and water. If gaso- line spills on your clothing, change your clothes.
1. Be sure the engine is stopped. 2. Disconnect the fuel line from the fuel tank
and tighten the air vent screw on the fuel tank cap.
3. Remove the portable tank from the boat. 4. Be sure you are in a well-ventilated out-
door area, either securely moored or trail- ered.
5. Do not smoke and keep away from sparks, flames, static electric discharge, or other sources of ignition.
6. If you use a portable container to store and dispense fuel, use only an approved GASOLINE container.
7. Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
8. Fill the fuel tank, but do not overfill. Fuel can expand and overflow if the tempera- ture increases.
9. Tighten the filler cap securely.
ZMU06598
Fuel tank capacity: 12.0 L (3.17 US gal, 2.64 Imp.gal)
ZMU04484
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Operation
44
10. Wipe up any spilled gasoline immediately with dry rags. Dispose rags properly ac- cording to local laws or regulations.
EMU27451
Operating engine EMU27466
Sending 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 loosening the air vent screw.
This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which could cause brain damage or death when inhaled. Symp- toms include nausea, dizziness, and drowsiness. Keep cockpit and cabin ar- eas well ventilated. Avoid blocking ex- haust 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.
TIP: Wipe up any spilled gasoline immediately with dry rags. Dispose rags properly according to local laws or regulations. 3. Squeeze the primer pump, with the arrow
pointing up, until you feel it become firm. During engine operation place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank.
ZMU02024
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45
EMU27493
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 water near you.
EMU34813
Manual start models (tiller control)
WARNING EWM01840
Failure to attached engine shut-off cord could result in a runaway boat if opera- tor is ejected. Attach the engine shut-off cord to a secure place on your 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, preventing it from functioning.
Avoid accidentally pulling the cord dur- ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
Starting procedure (cold engine) 1. Place the gear shift lever in neutral.
TIP: The start-in-gear protection device prevents the engine from starting except when in neu- tral. 2. Attach the engine shut-off cord to a se-
cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.
3. Place the throttle grip in the (start) position.
1. Arrow
U6AU13E0.book Page 45 Wednesday, March 11, 2009 9:09 AM
Operation
46
4. Pull out the choke knob fully.
5. Pull the manual starter handle slowly until you feel resistance. Then give a strong pull straight out to crank and start the en- gine.
6. After the engine starts, slowly return the manual starter handle to its original posi- tion before releasing it.
7. Slowly return the throttle grip to the fully closed position.
8. Return the choke knob to the home posi- tion gradually.
TIP: If the choke knob is left in the (start)
position while the engine is running, the en- gine will run poorly or stall.
When the engine is cold, for example, when the ambient temperature is low in winter, it needs to be warmed up. For further infor- mation, see page 52.
Do not turn the throttle grip unnecessarily to open and close the throttle before starting the engine, otherwise the engine may be difficult to start. If the engine is difficult to start, place the throttle grip in the (warm engine) position and try again.
Starting procedure (warm engine) 1. Place the gear shift lever in neutral.
ZMU02030
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47
2. Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.
3. Place the throttle grip in the (start) position.
4. Pull the manual starter handle slowly until you feel resistance. Then give a strong pull straight out to crank and start the en- gine.
TIP: If the engine does not start, place the throt-
tle grip in the (warm engine) position and try again.
It is not necessary to use the choke when starting a warm engine.
5. After the engine starts, slowly return the manual starter handle to its original posi- tion before releasing it.
6. Slowly return the throttle grip to the fully closed position.
ZMU02030
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48
EMU34923
Electric start models (tiller control)
WARNING EWM01840
Failure to attached engine shut-off cord could result in a runaway boat if opera- tor is ejected. Attach the engine shut-off cord to a secure place on your 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, preventing it from functioning.
Avoid accidentally pulling the cord dur- ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
Starting procedure (cold engine) 1. Place the gear shift lever in neutral.
TIP: The start-in-gear protection device prevents the engine from starting except when in neu- tral. 2. Attach the engine shut-off cord to a se-
cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.
3. Place the throttle grip in the (start) position.
4. Pull out the choke knob fully.
5. Push the starter button to start the en- gine.
U6AU13E0.book Page 48 Wednesday, March 11, 2009 9:09 AM
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49
6. Immediately after the engine starts, re- lease the starter button to allow it to re- turn to its original position. NOTICE: Never push the starter button 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 sec- onds, the battery will be quickly dis- charged, thus making it impossible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, release the starter button, wait 10 seconds, then crank the engine again. [ECM00161]
7. Slowly return the throttle grip to the fully closed position.
8. Return the choke knob to the home posi- tion gradually.
TIP: If the choke knob is left in the (start)
position while the engine is running, the en- gine will run poorly or stall.
When the engine is cold, for example, when the ambient temperature is low in winter, it needs to be warmed up. For further infor- mation, see page 52.
Starting procedure (warm engine) 1. Place the gear shift lever in neutral.
2. Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.
3. Place the throttle grip in the (start) position.
ZMU02030
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50
4. Push the starter button to start the en- gine.
TIP: If the engine does not start, place the throt-
tle grip in the (warm engine) position and try again.
It is not necessary to use the choke when starting a warm engine.
5. Immediately after the engine starts, re- lease the starter button to allow it to re- turn to its original position.
6. Slowly return the throttle grip to the fully closed position.
EMU34932
Electric start models (remote control)
WARNING EWM01840
Failure to attached engine shut-off cord could result in a runaway boat if opera- tor is ejected. Attach the engine shut-off cord to a secure place on your 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, preventing it from functioning.
Avoid accidentally pulling the cord dur- ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
1. Place the remote control lever in neutral.
ZMU02030
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51
TIP: The start-in-gear protection device prevents the engine from starting except when in neu- tral. 2. Attach the engine shut-off cord to a se-
cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.
3. Turn the main switch to (on).
4. Open the throttle slightly without shifting using the neutral throttle lever.
TIP: The neutral throttle lever can only be used when the remote control lever is in neutral. 5. Press in and hold the main switch to op-
erate the remote choke system. (The re- mote choke system operates only when the main switch is pressed in fully.)
TIP: It is not necessary to use the choke when starting a warm engine. 6. Turn the main switch to (start) to
start the engine.
OFF
ON
ZMU01880
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52
7. Immediately after the engine starts, re- lease the main switch and allow it to re- turn to (on). The remote choke system stops operating when the main switch is released. NOTICE: Never turn the main switch to (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter mo- tor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it im- possible to start the engine. The start- er can also be damaged. If the engine will not start after 5 seconds of crank- ing, return the main switch to (on), wait 10 seconds, then crank the engine again. [ECM00192]
8. Return the neutral throttle lever to the original position.
TIP: When the engine is cold, for example, when the ambient temperature is low in winter, it needs to be warmed up. For further informa- tion, see page 52. EMU36510
Checks after starting engine EMU36520
Cooling water Check for a steady flow of water from the cool- ing water pilot hole. A continuous flow of water from the pilot hole shows that the water pump
is pumping water through the cooling passag- es. If the cooling passages are frozen, it may take a while for water to start flowing out of the pilot hole.
NOTICE ECM01810
If water is not flowing out of the pilot hole at all times while the engine is running, overheating and serious damage could occur. Stop the engine and check 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.
Check that no water leaks from the joints be- tween the exhaust cover, cylinder head, and body cylinder. EMU27670
Warming up engine EMU27715
Manual start and electric start models 1. After starting the engine, allow it to idle for
3 minutes to warm up. Failure to do so will shorten engine life.
2. Be sure the low oil pressure-alert indica- tor goes off after starting the engine. NOTICE: If the low oil pressure-alert indicator blinks after the engine starts, stop the engine. Otherwise serious engine damage could occur. Check the oil level and add oil if necessary.
U6AU13E0.book Page 52 Wednesday, March 11, 2009 9:09 AM
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53
Consult your Yamaha dealer if the cause for the low oil pressure-alert in- dicator cannot be found. [ECM01830]
EMU36530
Checks after engine warm-up EMU36540
Shifting While tightly moored, and without applying throttle, confirm that the engine shifts smooth- ly into forward and reverse, and back to neu- tral. EMU36980
Stop switches Turn the main switch to , or press the
engine stop button and make sure the en- gine stops.
Confirm that removing the clip from the en- gine shut-off switch stops the engine.
Confirm that the engine cannot be started with the clip removed from the engine shut- off switch.
EMU34561
Shifting
WARNING EWM00180
Before shifting, make sure there are no swimmers or obstacles in the water near you.
NOTICE ECM01610
Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral. If this occurs, stop the en- gine, shift to neutral, then restart the en- gine 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 for- ward 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.
1. Neutral interlock trigger
U6AU13E0.book Page 53 Wednesday, March 11, 2009 9:09 AM
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54
TIP: Tiller handle models: The gear shift lever op- erates only when the throttle grip is in the fully closed position. To shift from in gear (forward/reverse) to neu- tral 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 neutral po- sition.
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 impact the steering wheel or other parts of the boat. This could increase the risk of se- rious 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.
ZMU02030
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55
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 di- rection. EMU27821
Stopping engine Before stopping the engine, first let it cool off for a few minutes at idle or low speed. Stop- ping the engine immediately after operating at high speed is not recommended. EMU27833
Procedure 1. Push and hold the engine stop button un-
til the engine comes to a complete stop.
2. After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to the closed position, if equipped.
3. Disconnect the fuel line if you are using an external fuel tank.
TIP: If the outboard motor is equipped with an en- gine shut-off cord, the engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch. EMU27853
Procedure 1. Turn the main switch to (off).
2. After stopping the engine, disconnect the fuel line or close the fuel cock if there is a fuel joint or a fuel cock on the boat.
3. Tighten the air vent screw on the fuel tank cap (if equipped).
4. Remove the key if the boat will be left un- attended.
TIP: The engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch, then turning the main switch to (off).
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56
EMU27862
Trimming outboard motor
WARNING EWM00740
Excessive trim for the operating condi- tions (either trim up or trim down) can cause boat instability and can make steer- ing the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.
The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help im- prove performance and fuel economy while reducing strain on the engine. Correct trim an- gle depends upon the combination of boat, engine, and propeller. Correct trim is also af- fected by variables such as the load in the boat, sea conditions, and running speed.
EMU27872
Adjusting trim angle for manual tilt models There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim an- gle. 1. Stop the engine. 2. Tilt the outboard motor up, and then re-
move the trim rod from the clamp bracket.
3. Reposition the rod in the desired hole. To raise the bow (trim-out), move the rod away from the transom. To lower the bow (trim-in), move the rod to- ward the transom. Make test runs with the trim set to different an- gles to find the position that works best for your boat and operating conditions.
WARNING EWM00400
Stop the engine before adjusting the trim angle.
Use care to avoid being pinched when removing or installing the rod.
Use caution when trying a trim position for the first time. Increase speed gradu- ally and watch for any signs of instability or control problems. Improper trim an- gle can cause loss of control.
TIP: The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim rod one hole.
1. Trim operating angle
1. Trim rod
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57
EMU27904
Adjusting trim angle (power tilt mod- els)
WARNING EWM00753
Be sure all people are clear of the out- board motor when adjusting the trim 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 instability or control problems. Improper trim an- gle 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.
Tilt the engine to the desired angle using the power tilt switch.
TIP: Stay within the trim operating angle when trimming the outboard motor using the power tilt system. 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 an- gles to find the position that works best for your boat and operating conditions. EMU27912
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. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.
Bow Up Too much trim-out puts the bow of the boat too high in the water. Performance and econ- omy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces perfor- mance further, and the boat may porpoise (hop in the water), which could throw the op- erator and passengers overboard.
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58
Bow Down Too much trim-in causes the boat to plow through the water, decreasing fuel economy and making it hard to increase speed. Operat- ing with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of bow steering and making opera- tion difficult and dangerous.
TIP: Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating. EMU27934
Tilting up and down If the engine will be stopped for some time or if the boat is moored in shallows, the outboard motor should be tilted up to protect the propel- ler and lower casing from damage by collision with obstructions, and also to reduce salt cor- rosion.
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 mo- tor is trimmed or tilted.
WARNING EWM00250
Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, discon- nect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.
NOTICE ECM00241
Before tilting the outboard motor, stop the engine by following the procedure on page 55. 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.
EMU2797B
Procedure for tilting up (manual tilt models) 1. Place the remote control lever / gear shift
lever in neutral.
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59
2. Disconnect the fuel line from the out- board motor.
3. Place the tilt lock lever (if equipped) in the release/up position.
4. Pull up the shallow water lever (if equipped).
5. Hold the rear of the top cowling with one hand and tilt the engine up fully.
6. Push the tilt support knob into the clamp bracket. Or the tilt support bar will turn to the lock position automatically. NOTICE:
Do not use the tilt support lever or knob when trailering the boat. The out- board motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal run- ning position, use an additional sup- port device to secure it in the tilt position. For more detailed informa- tion, see page 65. [ECM01641]
EMU32723
Procedure for tilting up (power tilt models) 1. Place the remote control lever / gear shift
lever in neutral.
N
ZMU03196
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Operation
60
2. Press the power tilt switch (up) until the outboard motor has tilted up com- pletely.
3. Push the tilt support knob into the clamp bracket to support the engine. WARNING! After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever. Oth- erwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit or in the power tilt unit loses pressure. [EWM00262] NOTICE: Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running po- sition, use an additional support de- vice to secure it in the tilt position. For more detailed information, see page 65. [ECM01641]
4. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power tilt switch
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61
(down) to retract the trim rods. NOTICE: Be sure to retract the trim rods completely during mooring. This protects the rods from marine growth and corrosion which could damage the power trim and tilt mechanism. [ECM00251]
EMU30192
Procedure for tilting down (manual tilt models) 1. Place the tilt lock lever in the lock posi-
tion.
2. Slightly tilt the engine up until the tilt sup- port bar is automatically released.
3. Slowly tilt the engine down. EMU33120
Procedure for tilting down (power tilt models) 1. Push the power tilt switch (up) until
the outboard motor is supported by the tilt rod and the tilt support knob becomes free.
2. Pull out the tilt support knob.
3. Push the power tilt switch (down) to lower the outboard motor to the desired position.
DN
ZMU01936
UP
DN
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62
EMU28061
Shallow water EMU28073
Cruising in shallow water (manual tilt models)
WARNING EWM01781
Run the boat at the lowest possible speed when using the shallow water cruising system. The tilt lock mecha- nism does not work while the shallow water cruising system is being used. Hit- ting an underwater obstacle could cause the outboard motor to lift out of the water, resulting in loss of control.
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 acci- dent and personal injury.
NOTICE ECM00260
Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set- ting up for and cruising in shallow water. Otherwise severe damage from overheat- ing can result.
EMU28125
Procedure 1. Place the remote control lever / gear shift
lever in neutral.
2. Place the tilt lock lever in the release/up position.
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63
3. Slightly tilt the outboard motor up. The tilt support bar will lock automatically, sup- porting the outboard motor in a partially raised position. This outboard motor has 2 positions for shallow water cruising.
4. To return the outboard motor to the nor- mal running position, place the remote control lever / gear shift lever in neutral.
5. Place the tilt lock lever in the lock/down position, then slightly tilt the outboard mo- tor up until the tilt support bar automati- cally returns to the free position.
6. Slowly lower the outboard motor to the normal position.
EMU32861
Power tilt models The outboard motor can be tilted up partially to allow operation in shallow water.
NOTICE ECM00260
Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set- ting up for and cruising in shallow water. Otherwise severe damage from overheat- ing can result.
EMU32942
Procedure for power tilt models 1. Place the remote control lever / gear shift
lever in neutral.
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64
2. Slightly tilt the outboard motor up to the desired position using the power tilt switch. WARNING! Using the power tilt switch on the bottom cowling while the boat is moving or engine is on could increase the risk of falling over- board and could distract the operator, increasing the risk of collision with an- other boat or an obstacle. [EWM01960]
3. To return the outboard motor to the nor- mal running position, press the power tilt switch and slowly tilt the outboard motor down.
EMU28195
Cruising in other conditions Cruising in salt water After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh wa- ter. Cruising in muddy, turbid, or acidic water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (see page 20) if you use the outboard motor in acidic water or water with a lot of sediment in it, such as muddy or turbid (cloudy) water. Af- ter operating in such water, flush the cooling passages with fresh water to prevent corro- sion. Also rinse the outside of the outboard motor with fresh water.
UP
ZMU01935
UP
DN
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65
EMU28227
Transporting and storing out- board motor
WARNING EWM00693
USE CARE when transporting fuel tank, whether in a boat or car.
DO NOT fill fuel container to maximum capacity. Gasoline will expand consider- ably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.
WARNING EWM01860
Leaking fuel is a fire hazard. When trans- porting and storing the outboard motor, close the fuel cock to prevent fuel from leaking. Never get under the engine while it is tilted. Severe injury could occur if the outboard motor accidentally falls.
NOTICE ECM00660
Do not use the tilt support lever or knob when trailering the boat. The outboard mo- tor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an addi- tional 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 posi- tion using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details.
EMU34821
Dismounting the outboard motor
NOTICE ECM01680
Do not hold the top cowling when mount- ing or dismounting the outboard motor. The top cowling could come off, causing the outboard motor to fall.
1. Stop the engine and land the boat. 2. Disconnect the fuel line from the out-
board motor.
3. For electric start models, disconnect the battery cables from the battery terminals.
4. To prevent steering movement, turn the adjuster lever to A (if equipped with the adjuster lever). To hold the steering bracket easily, raise the tiller handle to the vertical position (if equipped with the tiller handle).
U6AU13E0.book Page 65 Wednesday, March 11, 2009 9:09 AM
Maintenance
66
5. Loosen the clamp screw(s). 6. Hold the handgrip and steering bracket
as shown in the illustration and lift up the outboard motor to dismount it from the boat.
7. When transporting or storing the out- board motor while removed from a boat, keep the outboard motor in the attitude shown or use an outboard motor stand.
1. Steering bracket 2. Handgrip
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67
TIP: When transporting the outboard motor in a horizontal position, place a towel or some- thing similar under the outboard motor to pro- tect it from damage. 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 pri- or to storage. However, you, the owner, with a minimum of tools, can perform the following procedures.
NOTICE ECM01080
To prevent problems which can be caused by oil entering the cylinder from the sump, keep the outboard motor in the attitude shown when transporting and storing it. If storing or transporting the outboard motor on its side (not up- right), put it on a cushion after draining the engine oil.
Do not place the outboard motor on its side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trouble.
Store the outboard motor in a dry, well- ventilated place, not in direct sunlight.
EMU28304
Procedure EMU32044
Flushing in a test tank
NOTICE ECM00300
Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the engine will
be damaged from overheating. Before starting the engine, be sure to supply wa- ter to the cooling water passages.
1. Dismount the outboard motor from the boat. For further details, see page 65.
2. Wash the outboard motor body using fresh water. NOTICE: Do not spray wa- ter into the air intake. [ECM01840] For further information, see page 69.
3. Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer to each gallon of fuel.
TIP: The use of Yamaha Fuel Conditioner and Stabilizer eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead. 4. Disconnect the fuel line from the out-
board motor. 5. Remove the engine top cowling and si-
lencer cover. Remove the propeller. For further details, see page 80.
6. Position the outboard motor on a water tank. For further details, see page 36.
7. Fill the tank with fresh water to above the level of the anti-cavitation plate. NOTICE: If the fresh water level is below the lev-
1. Water surface 2. Lowest water level
ZMU02051
1
2
U6AU13E0.book Page 67 Wednesday, March 11, 2009 9:09 AM
Maintenance
68
el of the anti-cavitation plate, or if the water supply is insufficient, engine seizure may occur. [ECM00291]
8. Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fog- ging of the engine is mandatory to pre- vent excessive engine damage due to rust. Perform the flushing and fogging at the same time. WARNING! Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. [EWM00091]
9. Run the engine at a fast idle for 1015 minutes in neutral position.
10. Just prior to turning off the engine, quickly spray Yamaha Stor-Rite Engine Fogging Oil alternately into each carburetor or the fogging hole of the silencer cover, if equipped. When properly done, the en- gine will smoke excessively and almost stall.
11. Remove the outboard motor from the test tank. For further details, see page 65.
12. Drain the cooling water completely out of the motor. Clean the body thoroughly.
13. 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 76.
2. Change the gear oil. For instructions, see page 81. Inspect the oil for the presence 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 74.
TIP: For long-term storage, fogging the engine with oil is recommended. Contact your Yamaha dealer for information about fogging oil and procedures for your engine. EMU28443
Flushing power unit Perform this procedure right after operation for the most thorough flushing.
NOTICE ECM01530
Do not perform this procedure while the engine is running. The water pump may be damaged and severe damage from over- heating can result.
1. After shutting off the engine, unscrew the garden hose connector from the fitting on the bottom cowling.
1. Fitting 2. Garden hose connector 3. Garden hose adapter
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Maintenance
69
2. Screw the garden hose adapter onto a garden hose, which is connected to a fresh water supply, and then connect it to the garden hose connector.
3. With the engine off, turn on the water tap and let the water flush through the cool- ing passages for about 15 minutes. Turn off the water and disconnect the garden hose adapter from the garden hose con- nector.
4. Reinstall the garden hose connector onto the fitting on the bottom cowling. Tighten the connector securely. NOTICE: Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal operation. Water will leak out of the connector instead of cooling the en- gine, which can cause serious over- heating. Be sure the connector is tightened securely on the fitting after flushing the engine. [ECM00541]
TIP: When flushing the engine with the boat in
the water, tilting up the outboard motor until it is completely out of the water will achieve better results.
For cooling system flushing instructions, see page 65.
EMU28451
Cleaning the outboard motor After use, wash the exterior of the outboard motor with fresh water. Flush the cooling sys- tem with fresh water.
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 available from your Yamaha dealer. EMU37012
Periodic maintenance
WARNING EWM01942
These procedures require mechanical skills, tools, and supplies. If you do not have the proper skills, tools, or supplies to perform a maintenance procedure, have a Yamaha dealer or other qualified mechan- ic do the work. The procedures involve disassembling the motor and exposing dangerous parts. To reduce the risk of injury from moving, hot, or electrical parts: Turn off the engine and keep the key(s)
and engine shut-off cord (lanyard) with you when you perform maintenance un- less otherwise specified.
The power tilt switch operate even when the ignition key is off. Keep people away from the switches whenever working around the motor. When the motor is tilt- ed, keep away from the area under it or
U6AU13E0.book Page 69 Wednesday, March 11, 2009 9:09 AM
Maintenance
70
between it and the clamp bracket. Be sure no one is in this area before operat- ing the power tilt mechanism.
Allow the engine to cool before handling hot parts or fluids.
Always completely reassemble the mo- tor before operation.
Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual. All war- ranty repairs, however, including those to the emission control system, must be per- formed by an authorized Yamaha marine dealership. A service manual is available for purchase through your Yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform mainte- nance not covered by this owners manual. EMU28511
Replacement parts If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and pas- sengers. Yamaha genuine parts and acces- sories are available from your Yamaha dealer. EMU35520
Maintenance interval guidelines The service intervals provided in the Mainte- nance Chart were developed based upon typical use that includes operating at varied speeds, with sufficient time for engine warm up and cool-down, a medium to light load, and an average cruising speed near the 3000 to 4000 rpm range. As with any engine, howev- er, if your normal operating conditions are dif- ferent, you should consider service more often than shown, especially how often you
change your engine and gear oil. Examples might include extended wide-open-throttle use or long periods of trolling or idling, carry- ing heavy loads, or frequent starting and stop- ping or shifting. More frequent maintenance will often pay off many times over in increased engine life and greater owner satisfaction. Consult your Yamaha dealer for additional maintenance recommendations.
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71
EMU34445
Maintenance chart 1 TIP: Refer to the sections in this chapter for explanations of each owner-specific action. The maintenance cycle on these charts assume usage of 100 hours per year and regular
flushing of the cooling water passages. Maintenance frequency should be adjusted when op- erating the engine under adverse conditions such as extended trolling.
Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
Expendable or consumable parts and lubricants will lose their effectiveness over time and through normal usage regardless of the warranty period.
When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should be flushed with clean water after each use.
The symbol indicates the check-ups which you may carry out yourself. The symbol indicates work to be carried out by your Yamaha dealer.
Item Actions
Initial Every
20 hours (3 months)
100 hours (1 year)
300 hours (3 years)
500 hours (5 years)
Anode(s) (external) Inspection or replace- ment as necessary
Anode(s) (cylinder head, thermostat cov- er)
Inspection or replace- ment as necessary
Anodes (exhaust cover, cooling water passage cover, Rectifier Regula- tor cover)
Replacement
Battery (electrolyte lev- el, terminal) Inspection
Battery (electrolyte lev- el, terminal)
Fill, charging or replac- ing as necessary
Cooling water leakage Inspection or replace- ment as necessary
Cowling lock lever Inspection
Engine starting condi- tion/noise Inspection
Engine idling speed/noise Inspection
Engine oil Replacement
Engine oil filter (built into oil pan)
Inspection, cleaning or replacement as neces- sary
Fuel filter (disposal type) Replacement
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Maintenance
72
Fuel line(High pres- sure) Inspection
Fuel line(High pres- sure)
Inspection or replace- ment as necessary
Fuel line(Low pres- sure) Inspection
Fuel line(Low pres- sure)
Inspection or replace- ment as necessary
Fuel pump Inspection or replace- ment as necessary
Fuel/engine oil leakage Inspection
Gear oil Replacement
Greasing points Greasing
Impeller/water pump housing
Inspection or replace- ment as necessary
Impeller/water pump housing Replacement
Power trim and tilt unit Inspection
Propeller/propeller nut/cotter pin
Inspection or replace- ment as necessary
Shift link/shift cable Inspection, adjustment or replacement as nec- essary
Spark plug(s) Inspection or replace- ment as necessary
Spark plug caps/spark plug wires
Inspection or replace- ment as necessary
Water from the cooling water pilot hole Inspection
Throttle link/throttle ca- ble/throttle pick-up tim- ing
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
Main switch/stop switch/choke switch
Inspection or replace- ment as necessary
Item Actions
Initial Every
20 hours (3 months)
100 hours (1 year)
300 hours (3 years)
500 hours (5 years)
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Maintenance
73
EMU34451
Maintenance chart 2
Wire harness connec- tions/wire coupler con- nections
Inspection or replace- ment as necessary
(Yamaha) Fuel tank Inspection and clean- ing as necessary
Item Actions Every
1000 hours
Exhaust guide/exhaust manifold
Inspection or replace- ment as necessary
Timing belt Replacement
Item Actions
Initial Every
20 hours (3 months)
100 hours (1 year)
300 hours (3 years)
500 hours (5 years)
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Maintenance
74
EMU28932
Greasing Yamaha marine grease (Water resistant grease) F9.9F
U6AU13E0.book Page 74 Wednesday, March 11, 2009 9:09 AM
Maintenance
75
T9.9G
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76
EMU28956
Cleaning and adjusting spark plug The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, 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 di- agnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. 1. Remove the spark plug caps from the
spark plugs. 2. Remove the spark plug. If electrode ero-
sion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type. WARNING! When remov- ing or installing a spark plug, be care- ful not to damage the insulator. A damaged insulator could allow exter- nal sparks, which could lead to explo- sion or fire. [EWM00561]
3. Be sure to use the specified spark plug, otherwise the engine may not operate properly. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; replace it if out of spec- ification.
4. When fitting the plug, wipe off any dirt from the threads, and then screw it in to the correct torque.
TIP: If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past finger- tight. Have the spark plug adjusted to the cor- rect torque as soon as possible with a torque- wrench. EMU28990
Checking fuel filter Check the fuel filter periodically. The fuel filter is a one piece, disposable type. If foreign mat- ter is found in the filter, replace it. For replace- ment of the fuel filter, consult your Yamaha dealer.
Standard spark plug: BR6HS-10
1. Spark plug gap 2. Spark plug part number 3. Spark plug I.D. mark (NGK)
Spark plug gap: 0.91.0 mm (0.0350.039 in)
Spark plug torque: 25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
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77
EMU29043
Inspecting idling speed
WARNING EWM00451
Do not touch or remove electrical parts when starting or during operation.
Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.
NOTICE ECM00490
This procedure must be performed while the outboard motor is in the water. A flush- ing attachment or test tank can be used.
If the boat is not equipped with a tachometer for the outboard motor, use a diagnostic ta- chometer for this procedure. Results may vary depending on whether testing is conduct- ed 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 smoothly. 2. Once the engine has warmed up, verify
whether the idle speed is set to specifica- tion. For idle speed specifications, see page 14. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechanic.
EMU38802
Changing engine oil
NOTICE ECM01710
Change the engine oil after the first 20 hours of operation or 3 months, and every 100 hours or at 1-year intervals thereafter. Otherwise the engine will wear quickly.
Extract the engine oil with an oil changer. 1. Put the outboard motor in an upright po-
sition (not tilted). NOTICE: If the motor is not level, the oil level indicated on the dipstick may not be accurate. [ECM01860]
2. Start the engine. Warm it up and keep the idle speed for 5-10 minutes.
3. Stop the engine and leave it for 5-10 min- utes.
4. Remove the top cowling. 5. Remove the oil filler cap. Pull out the dip-
stick and use the oil changer to extract the oil completely.
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Maintenance
78
TIP: If the oil changer is not available, remove the drain screw while holding a container under the drain hole. Let the oil drain completely. Wipe up any spilled oil immediately.
6. Add the correct amount of oil through the filler hole. Put back the filler cap and the dipstick. NOTICE: Overfilling the oil could cause leakage or damage. If the oil level is above the upper level mark, drain until the level meets the speci- fied capacity. [ECM01850]
7. Leave the outboard motor for 5-10 min- utes.
8. Remove oil dipstick and wipe it clean. 9. Insert the dipstick and remove it again.
Be sure to completely insert the dipstick into the dipstick guide, otherwise the oil level measurement will be incorrect.
10. Recheck the oil level using the dipstick to be sure the level falls between the upper and lower marks. Consult your Yamaha dealer if the oil level is out of specified lev- el.
1. Oil changer
1. Drain screw
ZMU06620
1
1. Oil filler cap
Recommended engine oil: 4-stroke outboard motor oil
Total engine oil quantity (oil pan capaci- ty):
Without oil filter replacement: 0.8 L (0.85 US qt, 0.70 Imp.qt)
1. Lower level mark 2. Oil dipstick
ZMU02082
1 3
2
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Maintenance
79
11. Start the engine and make sure that the low oil pressure-alert indicator remains off. Also, make sure that there are no oil leaks. NOTICE: If the low oil pressure- alert indicator comes on or if there are oil leaks, stop the engine and find the cause. Continued operation with a problem could cause severe engine damage. Consult your Yamaha dealer if the problem cannot be located and corrected. [ECM01622]
12. Dispose of used oil according to local regulations.
TIP: For more information on the disposal of
used oil, consult your Yamaha dealer. Change the oil more often when operating
the engine under adverse conditions such as extended trolling.
EMU29113
Checking wiring and connectors Check that each connector is engaged se-
curely. Check that each ground lead is properly se-
cured.
EMU32112
Checking propeller
WARNING EWM01881
You could be seriously injured if the en- gine accidentally starts when you are near the propeller. Before inspecting, remov- ing, or installing the propeller, place the shift control in neutral, turn the main switch to (off) and remove the key, and remove the clip from the engine shut- off switch. Turn off the battery cut-off switch if your boat has one.
Do not use your hand to hold the propeller when loosening or tightening the propeller nut. Put a wood block between the anti-cavi- tation plate and the propeller to prevent the propeller from turning.
Checkpoints Check each of the propeller blades for ero-
sion from cavitation or ventilation, 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.
3. Upper level mark
ZMU01897
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Maintenance
80
Check the propeller shaft oil seal for dam- age.
EMU30662
Removing propeller EMU29197
Spline models 1. Straighten the cotter pin and pull it out us-
ing a pair of pliers. 2. Remove the propeller nut, washer, and
spacer (if equipped). WARNING! Do not use your hand to hold the propeller when loosening the propeller nut. [EWM01890]
3. Remove the propeller, washer (if equipped), and thrust washer.
EMU30672
Installing propeller EMU29233
Spline models
NOTICE ECM00500
Be sure to use a new cotter pin and bend the ends over securely. Otherwise the pro- peller could come off during operation and be lost.
1. Apply Yamaha marine grease or a corro- sion resistant grease to the propeller shaft.
2. Install the spacer (if equipped), thrust washer, washer (if equipped), and pro- peller on the propeller shaft. NOTICE: Be sure to install the thrust washer before installing the propeller, otherwise the lower case and propeller boss could be damaged. [ECM01880]
3. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque.
1. Cotter pin 2. Propeller nut 3. Washer 4. Propeller 5. Thrust washer
1. Cotter pin 2. Propeller nut 3. Washer 4. Spacer 5. Propeller 6. Thrust washer
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Maintenance
81
4. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends. NOTICE: Do not reuse the cotter pin installed. Otherwise the propeller can come off during operation. [ECM01890]
TIP: If the propeller nut does not align with the pro- peller shaft hole after tightening to the speci- fied torque, tighten the nut further to align it with the hole. EMU29287
Changing gear oil
WARNING EWM00800
Be sure the outboard motor is securely fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you.
Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe injury could oc- cur if the outboard motor accidentally falls.
1. Tilt the outboard motor so that the gear oil drain screw is at the lowest point possi- ble.
2. Place a suitable container under the gear case.
3. Remove the gear oil drain screw and gas- ket. NOTICE: If there is an excessive quantity of metal particles on the mag- netic gear oil drain screw, this can in- dicate lower unit problem. Consult your Yamaha dealer. [ECM01900]
TIP: If a magnetic gear oil drain screw is
equipped, remove all metal particles from the screw before installing it.
Always use new gaskets. Do not reuse the removed gaskets.
4. Remove the oil level plug and gasket to allow the oil to drain completely. NOTICE: Inspect the used oil after it has been drained. If the oil is milky, water is getting into the gear case
Propeller nut tightening torque: F9.9FER 17.0 Nm (1.73 kgf-m, 12.5 ft-lb) F9.9FMH 17.0 Nm (1.73 kgf-m, 12.5 ft-lb) T9.9GEH 21.0 Nm (2.14 kgf-m, 15.5 ft-lb) T9.9GPH 21.0 Nm (2.14 kgf-m, 15.5 ft-lb) T9.9GPR 21.0 Nm (2.14 kgf-m, 15.5 ft-lb)
1. Gear oil drain screw 2. Oil level plug
ZMU02064
2
1
U6AU13E0.book Page 81 Wednesday, March 11, 2009 9:09 AM
Maintenance
82
which can cause gear damage. Con- sult a Yamaha dealer for repair of the lower unit seals. [ECM00711]
TIP: For disposal of used oil, consult your Yamaha dealer. 5. Put the outboard motor in a vertical posi-
tion. Using a flexible or pressurized 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 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 con- tainer.
2. Pour a small amount of suitable solvent into the tank. Install the cap and shake the tank. Drain the solvent completely.
Recommended gear oil: Hypoid gear oil SAE#90
Gear oil quantity: F9.9FER 0.150 L (0.159 US qt, 0.132 Imp.qt) F9.9FMH 0.150 L (0.159 US qt, 0.132 Imp.qt) T9.9GEH 0.370 L (0.391 US qt, 0.326 Imp.qt) T9.9GPH 0.370 L (0.391 US qt, 0.326 Imp.qt) T9.9GPR 0.370 L (0.391 US qt, 0.326 Imp.qt)
Tightening torque: 9.0 Nm (0.92 kgf-m, 6.6 ft-lb)
ZMU02065
Tightening torque: 9.0 Nm (0.92 kgf-m, 6.6 ft-lb)
U6AU13E0.book Page 82 Wednesday, March 11, 2009 9:09 AM
Maintenance
83
3. Remove the screws holding the fuel joint assembly. Pull the assembly out of the tank.
4. Clean the filter (located on the end of the suction pipe) in a suitable cleaning sol- vent. Allow the filter to dry.
5. Replace the gasket with a new one. Re- install the fuel joint assembly and tighten the screws firmly.
EMU29312
Inspecting and replacing anode(s) Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.
NOTICE ECM00720
Do not paint anodes, as this would render them ineffective.
TIP: Inspect ground leads attached to external an- odes on equipped models. Consult a Yamaha dealer for inspection and replacement of inter- nal anodes attached to the power unit.
ZMU03231
ZMU02067
U6AU13E0.book Page 83 Wednesday, March 11, 2009 9:09 AM
Maintenance
84
EMU29322
Checking battery (for electric start models)
WARNING EWM01900
Battery electrolytic fluid is poisonous and caustic, and batteries generate explosive hydrogen gas. When working near the bat- tery: Wear protective eye gear and rubber
gloves. Do not smoke or bring any other source
of ignition near the battery. Refer to page 16 for detailed safety infor- mation about batteries.
The procedure for checking the battery varies for different batteries. This procedure con- tains typical checks that apply to many batter- ies, but you should always refer to the battery manufacturers instructions.
NOTICE ECM01920
A poorly maintained battery will quickly deteriorate.
1. Check the electrolyte level.
2. Check the batterys charge. If your boat is equipped with the digital speedometer, the voltmeter and low battery alert func- tions will help you monitor the batterys charge. If the battery needs charging, consult your Yamaha dealer.
3. Check the battery connections. They should be clean, secure, and covered by an insulating cover. WARNING! Bad connections can produce shorting or arcing and cause an explosion. [EWM01910]
EMU29333
Connecting the battery
WARNING EWM00570
Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder.
NOTICE ECM01123
Reversal of the battery cables will damage the electrical parts.
1. Make sure the main switch (on applicable models) is (off) before working on the battery.
2. Connect the red battery cable to the POSITIVE (+) terminal first. Then con- nect the black battery cable to the NEGA- TIVE (-) terminal.
U6AU13E0.book Page 84 Wednesday, March 11, 2009 9:09 AM
Maintenance
85
3. The electrical contacts of the battery and cables must be clean and properly con- nected, or the battery will not start the en- gine.
EMU29371
Disconnecting the battery 1. Turn off the battery cut-off switch (if
equipped) and main switch. NOTICE: If they are left on, the electrical system can be damaged. [ECM01930]
2. Disconnect the negative cable(s) from the negative (-) terminal. NOTICE: Al- ways disconnect all negative (-) ca- bles first to avoid a short circuit and damage to the electrical system. [ECM01940]
3. Disconnect the positive cable(s) and re- move the battery from the boat.
4. Clean, maintain, and store the battery ac- cording to the manufacturers instruc- tions.
1. Red cable 2. Black cable 3. Battery
U6AU13E0.book Page 85 Wednesday, March 11, 2009 9:09 AM
Trouble Recovery
86
EMU29427
Troubleshooting A problem in the fuel, compression, or ignition systems can cause poor starting, loss of pow- er, or other problems. This section describes basic checks and possible remedies, and cov- ers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble-alert indicator is flashing, consult your Yamaha dealer.
Starter will not operate. Q. Is battery capacity weak or low? A. Check battery condition. Use battery of rec- ommended capacity.
Q. Are battery connections loose or corrod- ed? A. Tighten battery cables and clean battery terminals.
Q. Is fuse for electric start relay or electric cir- cuit blown? A. Check for cause of electric overload and repair. Replace fuse with one of correct am- perage.
Q. Are starter components faulty? A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear? A. Shift to neutral.
Engine will not start (starter operates). Q. Is fuel tank empty? A. Fill tank with clean, fresh fuel.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Is starting procedure incorrect? A. See page 45.
Q. Has fuel pump malfunctioned? A. Have serviced by a Yamaha dealer.
Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
Q. Are spark plug cap(s) fitted incorrectly? A. Check and re-fit cap(s).
Q. Is ignition wiring damaged or poorly con- nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.
Q. Are ignition parts faulty? A. Have serviced by a Yamaha dealer.
Q. Is engine shut-off cord (lanyard) not at- tached? A. Attach cord.
Q. Are engine inner parts damaged? A. Have serviced by a Yamaha dealer.
Engine idles irregularly or stalls. Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
Q. Is fuel system obstructed?
U6AU13E0.book Page 86 Wednesday, March 11, 2009 9:09 AM
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87
A. Check for pinched or kinked fuel line or oth- er obstructions in fuel system.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.
Q. Has alert system activated? A. Find and correct cause of alert.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con- nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.
Q. Is specified engine oil not being used? A. Check and replace oil as specified.
Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.
Q. Are carburetor adjustments incorrect? A. Have serviced by a Yamaha dealer.
Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.
Q. Is air vent screw on fuel tank closed? A. Open air vent screw.
Q. Is choke knob pulled out?
A. Return to home position.
Q. Is motor angle too high? A. Return to normal operating position.
Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect? A. Connect correctly.
Q. Is throttle valve adjustment incorrect? A. Have serviced by a Yamaha dealer.
Q. Is battery cable disconnected? A. Connect securely.
Alert buzzer sounds or indicator lights. Q. Is cooling system clogged? A. Check water intake for restriction.
Q. Is engine oil level low? A. Fill oil tank with specified engine oil.
Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec- ommended type.
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Is engine oil contaminated or deteriorated? 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.
U6AU13E0.book Page 87 Wednesday, March 11, 2009 9:09 AM
Trouble Recovery
88
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 outboard at its recommended speed (r/min) range.
Q. Is trim angle incorrect? A. Adjust trim angle to achieve most efficient operation.
Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height.
Q. Has alert system activated? A. Find and correct cause of alert.
Q. Is boat bottom fouled with marine growth? A. Clean boat bottom.
Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
Q. Are weeds or other foreign matter tangled on gear housing?
A. Remove foreign matter and clean lower unit.
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or oth- er 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 broken 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.
Q. Is fuel joint connection incorrect?
U6AU13E0.book Page 88 Wednesday, March 11, 2009 9:09 AM
Trouble Recovery
89
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 dam- aged 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 compo-
nents 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.
EMU30681
Replacing fuse If a fuse has blown, open the fuse holder and remove the fuse with a fuse puller. Replace it with a spare one of the proper amperage.
WARNING EWM00631
Substituting an incorrect fuse or a piece of wire could allow excessive current flow. This could cause electric system damage and a fire hazard.
Consult your Yamaha dealer if the new fuse immediately blows again.
U6AU13E0.book Page 89 Wednesday, March 11, 2009 9:09 AM
Trouble Recovery
90
EMU32130
Power tilt will not operate If the engine cannot be tilted up or down with the power tilt because of a discharged battery or a failure with the power tilt unit, the engine can be tilted manually. 1. Loosen the manual valve screw by turn-
ing it counterclockwise until it stops.
2. Put the engine in the desired position, then tighten the manual valve screw by turning it clockwise.
EMU29533
Starter will not operate If the starter mechanism does not operate (the engine cannot be cranked with the start- er), the engine can be started with an emer- gency starter rope.
WARNING EWM01022
Use this procedure only in an emergen- cy to return to the nearest port for re- pairs.
When the emergency starter rope is used to start the engine, the start-in- gear protection device does not operate. Make sure the remote control lever is in neutral. Otherwise the boat could unex- pectedly start to move, which could re- sult in an accident.
Attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg while operating the boat.
Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre- venting it from functioning.
Avoid accidentally pulling the cord dur- ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
Make sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure some- one.
An unguarded, rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the en- gine. 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.
1. Fuse box 2. Fuse (10 A) 3. Spare fuse (10 A) 4. Fuse puller
1. Manual valve screw
U6AU13E0.book Page 90 Wednesday, March 11, 2009 9:09 AM
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91
Do not touch the ignition coil, spark plug wire, spark plug cap, or other electrical components when starting or operating the motor. You could get an electrical shock.
EMU29562
Emergency starting engine 1. Remove the top cowling. 2. Remove the start-in-gear protection ca-
ble from the starter, if equipped.
3. Remove the starter/flywheel cover after removing the bolt(s).
4. Prepare the engine for starting. For fur- ther information, see page 45. Be sure the engine is in neutral and that the clip is attached to the engine shut-off switch. The main switch must be (on), if equipped.
5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms up.
6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise.
7. Give a strong pull straight out to crank and start the engine. Repeat if neces- sary.
1. Start-in-gear protection cable
OFF
ON
ZMU01880
U6AU13E0.book Page 91 Wednesday, March 11, 2009 9:09 AM
Trouble Recovery
92
EMU29671
Engine fails to operate EMU35321
Emergency engine operation If the battery voltage is low or in the unlikely event of an ignition system malfunction, the engine speed may become erratic or the en- gine may stop. In such a situation, follow the procedure below. Disconnect the yellow cord (emergency cir- cuit) of the CDI unit. Run the engine at low speed and return to port. NOTICE: Follow this procedure only in an emergency and just long enough to return to port for repairs. [ECM00381]
EMU33501
Treatment of submerged motor If the outboard motor is submerged, immedi- ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immediate-
ly. NOTICE: Do not attempt to run the out- board motor until it has been completely inspected. [ECM00401]
1. Yellow cord
U6AU13E0.book Page 92 Wednesday, March 11, 2009 9:09 AM
Consumer information
93
EMU29830
YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY
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Consumer information
94
U6AU14E0.book Page 94 Friday, December 4, 2009 4:32 PM
Consumer information
95
EMU29841
IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA
U6AU13E0.book Page 95 Wednesday, March 11, 2009 9:09 AM
A5-tate_Blank.fm Page 1 Friday, May 16, 2003 9:00 AM
A5-tate_Blank.fm Page 1 Friday, May 16, 2003 9:00 AM
DIC183
December 20091.0 1 CR Printed in Japan
Printe
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