owner’s manual - yamaha motor company owner’s manual 6m8-f8199-1e u.s.a.edition lit-18626-08-33...

8

OWNER’S MANUAL

6M8-F8199-1E

U.S.A.EditionLIT-18626-08-33

U6M81EMC 09.4.2 10:05 AM ページ 1

EMU25062

ZMU01690

Read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.

U6M81EMC 09.4.2 10:05 AM ページ 2

Important manual information

EMU31283

To the owner

Thank you for choosing a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understandingof these simple instructions will help you ob-tain maximum enjoyment from your newYamaha. If you have any question about theoperation or maintenance of your outboardmotor, please consult a Yamaha dealer.In this Owner’s Manual particularly importantinformation is distinguished in the followingways.

: This is the safety alert symbol. It isused to alert you to potential personal injuryhazards. Obey all safety messages that fol-low this symbol to avoid possible injury ordeath.

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 precautionsthat 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 inproduct design and quality. Therefore, whilethis manual contains the most current prod-uct information available at the time of print-ing, there may be minor discrepanciesbetween your machine and this manual. If

there is any question concerning this manu-al, please consult your Yamaha dealer.

TIP:

The 8MH and the standard accessories areused as a base for the explanations and illus-trations in this manual. Therefore someitems may not apply to every model.

EMU25131

8OWNER’S MANUAL

©2009 by Yamaha Motor Corporation, USA1st Edition, March 2009

All rights reserved.Any reprinting or unauthorized usewithout the written permission ofYamaha Motor Corporation, USA

is expressly prohibited.Printed in France

P/N LIT-18626-08-33

Table of contents

Safety information............................. 1

Outboard motor safety .................... 1

Propeller............................................ 1Rotating parts.................................... 1Hot parts ........................................... 1Electric shock.................................... 1Engine shut-off cord (lanyard)........... 1Gasoline............................................ 1Gasoline exposure and spills ............ 1Carbon monoxide.............................. 1Modifications ..................................... 2

Boating safety ................................. 2

Alcohol and drugs ............................. 2Personal flotation devices ................. 2People in the water ........................... 2Passengers ....................................... 2Overloading....................................... 2Avoid collisions ................................. 2Weather ............................................ 3Accident reporting ............................. 3Boat education and training .............. 3Passenger training ............................ 3Boating safety publications ............... 3Laws and regulations ........................ 3

Boating organizations...................... 4Basic boating rules (Rules of the

road) .............................................. 4

Steering and sailing rules and sound signals.................................. 4

Rules when encountering vessels .... 5Other special situations..................... 6

General information .......................... 9

Identification numbers record.......... 9

Outboard motor serial number .......... 9

Read manuals and labels.............. 10

Warning labels ................................ 10

Specifications and requirements.................................... 13

Specifications ................................ 13Installation requirements ............... 14

Boat horsepower rating................... 14Mounting motor ............................... 14

Propeller selection......................... 14Start-in-gear protection ................. 15

Engine oil requirements ................ 15Fuel requirements ......................... 15

Gasoline ..........................................15Ring Free Fuel Additive...................16

Muddy or acidic water ................... 16Anti-fouling paint ........................... 16Motor disposal requirements......... 16Emergency equipment .................. 16Emission control information......... 16

North American models...................16

Components .................................... 18

Components diagram.................... 18

Fuel tank .........................................18Fuel joint..........................................19Fuel gauge ......................................19Fuel tank cap...................................19Air vent screw..................................19Tiller handle.....................................19Gear shift lever ................................19Throttle grip .....................................19Throttle indicator .............................20Throttle friction adjuster...................20Engine shut-off cord (lanyard) and

clip.................................................20Engine stop button ..........................21Choke knob for pull type .................21Manual starter handle .....................21Steering friction adjuster .................21Trim rod (tilt pin) ..............................22Shallow water lever .........................22Tilt support knob..............................22Cowling lock lever(s) (turn type)......22

Installation ....................................... 23

Installation..................................... 23

Mounting the outboard motor ..........23Clamping the outboard motor..........24

Operation ......................................... 26

First-time operation....................... 26

Breaking in engine ..........................26Getting to know your boat ...............26

Checks before starting engine ...... 26

Fuel level .........................................27Remove cowling..............................27Fuel system.....................................27Controls...........................................27

Table of contents

Engine shut-off cord (lanyard)......... 27Oil.................................................... 27Engine............................................. 28Install cowling.................................. 28

Filling fuel and engine oil............... 28

Filling fuel for portable tank............. 28Gasoline and oil mixing (100:1) ...... 29

Operating engine........................... 30

Sending fuel (portable tank) ............ 30Starting engine................................ 31

Checks after starting engine ......... 33

Cooling water .................................. 33

Warming up engine ....................... 33

Choke start models ......................... 33

Checks after engine warm-up ....... 34

Shifting ............................................ 34Stop switches.................................. 34

Shifting .......................................... 34Stopping boat ................................ 35Stopping engine ............................ 35

Procedure ....................................... 35

Trimming outboard motor.............. 36

Adjusting trim angle for manual tilt models .......................................... 36

Adjusting boat trim .......................... 37

Tilting up and down ....................... 38

Procedure for tilting up (manual tilt models) ......................................... 38

Procedure for tilting down (manual tilt models) .................................... 39

Shallow water................................ 39

Cruising in shallow water (manual tilt models) .................................... 39

Cruising in other conditions........... 40

Maintenance..................................... 41

Transporting and storing outboard motor ............................ 41

Clamp screw mounting models ....... 41Storing outboard motor ................... 41Procedure ....................................... 42Lubrication ...................................... 43Cleaning and anticorrosion

measures ...................................... 43Cleaning the outboard motor .......... 43Checking painted surface of

motor.............................................43

Periodic maintenance ................... 43

Replacement parts ..........................44Maintenance interval guidelines......44Maintenance chart 1........................45Maintenance chart 2........................47Greasing..........................................48Cleaning and adjusting spark

plug ...............................................48Checking fuel filter...........................49Inspecting idling speed....................49Checking wiring and connectors .....50Checking propeller ..........................50Removing propeller .........................51Installing propeller ...........................51Changing gear oil ............................51Cleaning fuel tank ...........................53Inspecting and replacing

anode(s)........................................53

Trouble Recovery............................ 55

Troubleshooting ............................ 55Temporary action in emergency ... 58

Impact damage ...............................58Starter will not operate ....................58Emergency starting engine .............59

Treatment of submerged motor .... 60

Consumer information ................... 61

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ..... 61

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA .............. 64

1

Safety information

EMU33622

Outboard motor safety

Observe these precautions at all times.

EMU36501

Propeller

People can be injured or killed if they comein contact with the propeller. The propellercan keep moving even when the motor is inneutral, and sharp edges of the propeller cancut even when stationary.

�

Stop the engine when a person is in thewater near you.

�

Keep people out of reach of the propeller,even when the engine is off.

EMU33630

Rotating parts

Hands, feet, hair, jewelry, clothing, PFDstraps, etc. can become entangled with inter-nal rotating parts of the engine, resulting inserious injury or death.Keep the top cowling in place whenever pos-sible. Do not remove or replace the cowlingwith the engine running.Only operate the engine with the cowling re-moved according to the specific instructionsin the manual. Keep hands, feet, hair, jewel-ry, clothing, PFD straps, etc. away from anyexposed moving parts.

EMU33640

Hot parts

During and after operation, engine parts arehot enough to cause burns. Avoid touchingany parts under the top cowling until the en-gine has cooled.

EMU33650

Electric shock

Do not touch any electrical parts while start-ing or operating the engine. They can causeshock or electrocution.

EMU33671

Engine shut-off cord (lanyard)

Attach the engine shut-off cord so that the

engine stops if the operator falls overboardor leaves the helm. This prevents the boatfrom running away under power and leavingpeople stranded, or running over people orobjects.Always attach the engine shut-off cord to asecure place on your clothing or your arm orleg while operating. Do not remove it to leavethe helm while the boat is moving. Do not at-tach the cord to clothing that could tearloose, or route the cord where it could be-come entangled, preventing it from function-ing.Do not route the cord where it is likely to beaccidentally pulled out. If the cord is pulledduring operation, the engine will shut off andyou will lose most steering control. The boatcould slow rapidly, throwing people and ob-jects forward.

EMU33810

Gasoline

Gasoline and its vapors are highly flam-mable and explosive.

Always, refuel ac-cording to the procedure on page 30 toreduce the risk of fire and explosion.

EMU33820

Gasoline exposure and spills

Take care not to spill gasoline. If gasolinespills, 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. Changeclothing if gasoline spills on it.If you swallow gasoline, inhale a lot of gaso-line vapor, or get gasoline in your eyes, getimmediate medical attention. Never siphonfuel by mouth.

EMU33900

Carbon monoxide

This product emits exhaust gases whichcontain carbon monoxide, a colorless, odor-less gas which may cause brain damage or

Safety information

2

death when inhaled. Symptoms include nau-sea, dizziness, and drowsiness. Keep cock-pit and cabin areas well ventilated. Avoidblocking exhaust outlets.

EMU33780

Modifications

Do not attempt to modify this outboard mo-tor. Modifications to your outboard motormay reduce safety and reliability, and renderthe outboard unsafe or illegal to use.

EMU33740

Boating safety

This section includes a few of the many im-portant safety precautions that you shouldfollow when boating.

EMU33710

Alcohol and drugs

Never operate after drinking alcohol or tak-ing drugs. Intoxication is one of the mostcommon factors contributing to boating fatal-ities.

EMU33720

Personal flotation devices

Have an approved personal flotation device(PFD) on board for every occupant. Yamaharecommends that you must wear a PFDwhenever boating. At a minimum, childrenand non-swimmers should always wearPFDs, and everyone should wear PFDswhen there are potentially hazardous boat-ing conditions.

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. Whensomeone is in the water near the boat, shiftinto neutral and stop the engine.Stay away from swimming areas. Swimmerscan be hard to see.The propeller can keep moving even whenthe motor is in neutral. Stop the engine when

a person is in the water near you.

EMU33751

Passengers

Consult your boat manufacturer’s instruc-tions for details about appropriate passengerlocations in your boat and be sure all pas-sengers are positioned properly before ac-celerating and when operating above an idlespeed. Standing or sitting in non-designatedlocations may result in being thrown eitheroverboard or within the boat due to waves,wakes, or sudden changes in speed or direc-tion. Even when people are positioned prop-erly, alert your passengers if you must makeany unusual maneuver. Always avoid jump-ing waves or wakes.

EMU33760

Overloading

Do not overload the boat. Consult the boatcapacity plate or boat manufacturer for max-imum weight and number of passengers. Besure that weight is properly distributed ac-cording to the boat manufacturers instruc-tions. Overloading or incorrect weightdistribution can compromise the boats han-dling and lead to an accident, capsizing orswamping.

EMU33772

Avoid collisions

Scan constantly for people, objects, and oth-er boats. Be alert for conditions that limit yourvisibility or block your vision of others.

ZMU06025

Safety information

3

Operate defensively at safe speeds andkeep a safe distance away from people, ob-jects, and other boats.

�

Do not follow directly behind other boats orwaterskiers.

�

Avoid sharp turns or other maneuvers thatmake it hard for others to avoid you or un-derstand where you are going.

�

Avoid areas with submerged objects orshallow water.

�

Ride within your limits and avoid aggres-sive maneuvers to reduce the risk of lossof control, ejection, and collision.

�

Take early action to avoid collisions. Re-member, boats do not have brakes, andstopping the engine or reducing throttlecan reduce the ability to steer. If you arenot sure that you can stop in time beforehitting an obstacle, apply throttle and turnin another direction.

EMU33790

Weather

Stay informed about the weather. Checkweather forecasts before boating. Avoidboating in hazardous weather.

EMU33800

Accident reporting

Boat operators are required by law to file aBoating Accident Report with their stateboating law enforcement agency if their boatis involved in any of the following accidents:1. There is loss of life or probable loss of

life.2. There is personal injury that requires

medical attention beyond first aid.3. There is property damage to boats or

other property over a certain amount.4. There is complete loss of a boat.Contact local law enforcement personnel if areport is necessary.

EMU33870

Boat education and training

Operators should take a boating safetycourse. This may be required in your state.Many of the organizations listed in the nextsection 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 providedby the BoatU.S. Foundation, is approved bythe National Association of State BoatingLaw Administrators (NASBLA) and recog-nized by the United States Coast Guard.Most, but not all, states accept this course tomeet their minimum requirements. While itcannot replace an in-depth course such asone offered by the U.S. Coast Guard, U.S.Power Squadron, or other organization, thisonline course does provide a general over-view of the basics in boating safety, require-ments, navigation, and operation. Uponsuccessful completion of the course, theuser can download a certificate of comple-tion immediately or, for a small charge, re-quest one by mail. To take this free course,go to boatus.org.

EMU33880

Passenger training

Make sure at least one other passenger istrained to operate the boat in the event of anemergency.

EMU33890

Boating safety publications

Be informed about boating safety. Additionalpublications and information can be obtainedfrom many boating organizations.

EMU33590

Laws and regulations

Know the marine laws and regulations whereyou will be boating- and obey them. Severalsets of rules prevail according to geographic

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4

location, but all are basically the same as theInternational Rules of the Road. The rulespresented in the following section are con-densed- and have been provided for yourconvenience only.Contact the U.S. Coast Guard, the NationalAssociation of State Boating Law Adminis-trators, or your local Power Squadron for acomplete set of rules governing the waters inwhich you will be using your boat.

EMU33681

Boating organizations

The following organizations provide boatingsafety training and information about boatingsafety and laws.

United States Coast Guard

Consumer Affairs Staff (G-BC)Office of Boating, Public, and Consumer Af-fairsU.S. Coast Guard HeadquartersWashington, D.C. 20593-0001Boating Safety Hotline: 1-800-368-5647www.uscgboating.org

United States Power Squadrons

1-888-FOR-USPS (1-888-367-8777)www.usps.org

Boat Owners Association of The UnitedStates

1-800-336-BOAT (1-800-336-2628)www.boatus.com

National Association of State BoatingLaw Administrators (NASBLA)

1500 Leestown Road, Suite 330Lexington, KY 40511 859-225-9497www.nasbla.org

National Marine Manufacturers Associa-tion (NMMA)

200 East Randolph DriveSuite 5100Chicago, IL 60601www.nmma.org

Marine Retailers Association of America

155 N. Michigan Ave. Chicago,IL 60304www.mraa.com

EMU33690

Basic boating rules (Rules of the road)

Just as there are rules that apply when youare driving on streets and highways, thereare waterway rules that apply when you aredriving your boat. These rules are used inter-nationally. (For USA: and are also enforcedby the United States Coast Guard and localagencies.) You should be aware of theserules, and follow them whenever you en-counter another vessel on the water.

EMU33700

Steering and sailing rules and sound signals

Whenever two vessels on the water meetone another, one vessel has the right-of-way; it is called the “stand-on” vessel. Thevessel that does not have the right-of-way iscalled the “give-way” or “burdened”vessel.These rules determine which vessel has theright-of-way, and what each vessel shoulddo.

Stand-on vessel

The vessel with the right-of-way has the dutyto continue its course and speed, except toavoid an immediate collision. When youmaintain your direction and speed, the other

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5

vessel will be able to determine how best toavoid you.

Give-way vessel

The vessel that does not have the right-of-way has the duty to take positive and timelyaction to stay out of the way of the Stand-Onvessel. Normally, you should not cross infront of the vessel with the right-of-way. Youshould slow down or change directions brief-ly and pass behind the other vessel. Youshould always move in such a way that theoperator of the other vessel can see whatyou are doing.

“ The general prudential rule ”

This rule is called Rule 2 in the InternationalRules and says,“ In obeying and construing these rules dueregard shall be had to all dangers of naviga-tion and collision, and to any special circum-stances, which may render a departure fromthe above rules necessary in order to avoidimmediate danger.”In other words, follow the standard rules ex-cept when a collision will occur unless bothvessels try to avoid each other. If that is thecase, both vessels become “ Give-Way ”vessels.

EMU25521

Rules when encountering vessels

There are three main situations that you mayencounter with other vessels which couldlead to a collision unless the Steering Rulesare followed:

Meeting:

(you are approaching another ves-sel head-on)

Crossing:

(you are traveling across the oth-er vessel’s path)

Overtaking:

(you are passing or beingpassed by another vessel)In the following illustration, your boat is in thecenter. You should give the right-of-way to

any vessels shown in white area (you are theGive-Way vessel). Any vessels in the shad-ed area must yield to you (they are the Give-Way vessels). Both you and the meetingvessel must alter course to avoid each other.

Meeting

If you are meeting another power vesselhead on, and are close enough to run the riskof collision, neither of you has the right-of-way Both of you should alter course to avoidan accident. You should keep the other ves-sel on your port (left) side. This rule doesn’tapply if both of you will clear one another ifyou continue on your set course and speed.

Crossing

When two power driven vessels are crossingeach other’s path close enough to run therisk of collision, the vessel which has the oth-er on the starboard (right) side must keep outof the way of the other. If the other vessel ison your right, you must keep out of its way;

Safety information

6

you are the Give-Way vessel. If the othervessel is on your port (left) side, rememberthat you should maintain course and direc-tion, provided the other vessel gives you theright-of-way as it should.

Overtaking

If you are passing another vessel, you arethe “Give-Way” vessel. This means that theother vessel is expected to maintain itscourse and speed. You must stay out of itsway until you are clear of it. Likewise, if an-other vessel is passing you, you shouldmaintain your speed and direction so that theother vessel can steer itself around you.

EMU25531

Other special situations

There are three other rules you should beaware of when driving your boat around oth-er vessels.

Narrow channels and bends

When navigating in narrow channels, youshould keep to the right when it is safe andpractical to do so. If the operator of a power-driven vessel is preparing to go around abend that may obstruct the view of other wa-ter vessels, the operator should sound a pro-longed blast on the whistle (4 to 6 seconds).If another vessel is around the bend, it tooshould sound the whistle. Even if no reply isheard, however, the vessel should still pro-ceed around the bend with caution. If you

navigate such waters with your boat, you willneed to carry a portable air horn, availablefrom local marine supply stores.

Fishing vessel right-of-way

All vessels that are fishing with nets, lines ortrawls are considered to be “fishing vessels”under the International Rules. Vessels withtrolling lines are not considered fishing ves-sels. Fishing vessels have the right-of-wayregardless of position. Fishing vessels can-not, however, impede the passage of othervessels in narrow channels.

Sailing vessel right-of-way

Sailing vessels should normally be given theright-of-way. The exceptions to this are:1. When the sailing vessel is overtaking

the power-driven vessel, the power-driv-en vessel has the right-of-way.

2. Sailing vessels should keep clear of anyfishing vessel.

3. In a narrow channel, a sailing vesselshould not hamper the safe passage ofa power-driven vessel that can navigateonly in such a channel.

Reading buoys and other markers

The waters of the United States are markedfor safe navigation by the lateral system ofbuoyage. Simply put, buoys and markershave an arrangement of shapes, colors,numbers and lights to show which side of thebuoy a boater should pass on when navigat-ing in a particular direction. The markings onthese buoys are oriented from the perspec-tive of being entered from seaward (the boat-er is going towards the port). This means thatred buoys are passed on the starboard(right) side when proceeding from open wa-ter into port, and black buoys are to port (left)side. When navigating out of port, your posi-tion with respect to the buoys should be re-versed; red buoys should be to port and

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7

black buoys to starboard.Many bodies of water used by boaters areentirely within the boundaries of a particularstate. The Uniform State Waterway MarkingSystem has been devised for these waters.This system uses buoys and signs with dis-tinctive shapes and colors to show regulato-ry or advisory information. These markersare white with black letters and orangeboarders. They signify speed zones, restrict-ed areas, danger areas, and general infor-mation.Remember, markings may vary by geo-graphic location. Always consult local boat-ing authorities before driving your boat inunfamiliar waters.

Safety information

8

ZMU01708

9

General information

EMU25171

Identification numbers record

EMU25183

Outboard motor serial number

The outboard motor serial number isstamped on the label attached to the portside of the clamp bracket.Record your outboard motor serial number inthe spaces provided to assist you in orderingspare parts from your Yamaha dealer or forreference in case your outboard motor is sto-len.

1. Outboard motor serial number location

1

ZMU02836

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.

8

1

2

3

ZMU06306

General information

11

1 2

3

ZMU05697

General information

12

EMU35132

Symbols

The following symbols mean as follows.

Notice/Warning

Read Owner’s Manual

Hazard caused by continuous rotation

Electrical hazard

ZMU05696

ZMU05664

ZMU05665

ZMU05666

13

Specifications and requirements

EMU31480

SpecificationsTIP:

“(AL)” stated in the specification data belowrepresents the numerical value for the alumi-num propeller installed.Likewise, “(SUS)” represents the value forstainless steel propeller installed and “(PL)”for plastic propeller installed.

EMU2821E

Dimension:

Overall length: 802 mm (31.6 in)

Overall width: 343 mm (13.5 in)

Overall height S: 977 mm (38.5 in)

Transom height S: 436 mm (17.2 in)

Weight (AL) S: 27.0 kg (60 lb)

Performance:

Full throttle operating range: 4500–5500 r/min

Maximum output: 5.9 kW@5000 r/min (8 HP@5000 r/min)

Idling speed (in neutral): 900

±

50 r/min

Engine:

Type: 2-stroke L

Displacement: 165.0 cm

3

Bore

×

stroke: 50.0

×

42.0 mm (1.97

×

1.65 in)Ignition system:

CDISpark plug (NGK):

B7HS-10

Spark plug gap: 0.9–1.0 mm (0.035–0.039 in)

Control system: Tiller

Starting system: Manual

Starting carburetion system: Choke valve

Alternator output: 80 W

Drive unit:

Gear positions: Forward-neutral-reverse

Gear ratio: 2.08 (27/13)

Trim and tilt system: Manual tilt

Propeller mark: N

Fuel and oil:

Recommended fuel: Regular unleaded gasoline

Min. pump octane: 86

Fuel tank capacity: 12 L (3.17 US gal, 2.64 Imp.gal)

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

Fuel:oil ratio:Regular gasoline:

100 :1Lubrication:

Pre-mixed fuel and oilRecommended gear oil:

Hypoid gear oil SAE#90Gear oil quantity:

0.160 L (0.169 US qt, 0.141 Imp.qt)

Tightening torque for engine:

Spark plug: 25.0 Nm (2.55 kgf-m, 18.4 ft-lb)


14

Propeller nut: 17.0 Nm (1.73 kgf-m, 12.5 ft-lb)

EMU33554

Installation requirements

EMU33563

Boat horsepower rating

WARNING

EWM01560

Overpowering a boat can cause severe

instability.

Before installing the outboard motor(s), con-firm that the total horsepower of your mo-tor(s) does not exceed the boats maximumhorsepower rating. See the boat’s capacityplate or contact the manufacturer.

EMU33571

Mounting motor

WARNING

EWM01570

�

Improper mounting of the outboard mo-tor could result in hazardous condi-tions such as poor handling, loss ofcontrol, 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 inproper rigging should mount the motor usingcorrect equipment and complete rigging in-structions. For further information, see page23.

EMU34192

Propeller selection

Next to selecting an outboard, choosing theright propeller is one of the most importantpurchasing decisions a boater can make.The type, size, and design of your propellerhave a direct impact on acceleration, topspeed, fuel economy, and even engine life.Yamaha designs and manufactures propel-lers for every Yamaha outboard motor and

every application.Your outboard motor came with a Yamahapropeller chosen to perform well over arange of applications, but there may be useswhere a different propeller would be moreappropriate.Your Yamaha dealer can help you select theright propeller for your boating needs. Selecta propeller that will allow the engine to reachthe middle or upper half of the operatingrange at full throttle with the maximum boat-load. Generally, chose a larger pitch propel-ler for a smaller operating load and a smallerpitch propeller for a heavier load. If you carryloads that vary widely, chose the propellerthat lets the engine run in the proper rangefor your maximum load but remember thatyou may need to reduce your throttle settingto stay within the recommended enginespeed range when carrying lighter loads.For instructions on propeller removal and in-stallation, see page 50.

1. Propeller diameter in inches2. Propeller pitch in inches3. Type of propeller (propeller mark)

ZMU04604

-x1 2 3


15

EMU25770

Start-in-gear protection

Yamaha outboard motors or Yamaha-ap-proved remote control units are equippedwith start-in-gear protection device(s). Thisfeature permits the engine to be started onlywhen it is in neutral. Always select neutralbefore starting the engine.

EMU25651

Engine oil requirements

If the recommended engine oil is not avail-able, another 2-stroke engine oil with anNMMA-certified TC-W3 rating may be used.

EMU36360

Fuel requirements

EMU36781

Gasoline

Use a good quality gasoline that meets theminimum octane rating. If knocking or ping-ing occurs, use a different brand of gasolineor premium unleaded fuel. Yamaha re-comends that you use alcohol-free (see

Gasohol) gasoline whenever possible.

NOTICE

ECM01981

�

Do not use leaded gasoline. Leadedgasoline can seriously damage the en-gine.

�

Avoid getting water and contaminantsin the fuel tank. Contaminated fuel cancause poor performance or enginedamage. 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 containingmethanol. Ethanol can be used if the ethanolcontent does not exceed 10% and the fuelmeets the minimum octane ratings. E85 is afuel containing 85% ethanol and must not beused in your outboard motor. All ethanolblends containing more than 10% ethanolcan cause fuel system damage or cause en-gine starting and running problems. Yamahadoes not recommend gasohol containingmethanol because it can cause fuel systemdamage or engine performance problems.It is recommended that you install a water-separating marine fuel filter assembly (10micron minimum) between your boat’s fueltank and outboard motor when using etha-nol. Ethanol is known to allow moisture to beabsorbed into boat fuel tanks and systems.Moisture in the fuel can cause corrosion ofmetallic fuel system components, startingand running complaints and require addition-al fuel system maintenance.

1. Propeller diameter in inches2. Propeller pitch in inches3. Type of propeller (propeller mark)

Recommended engine oil:YAMALUBE 2-stroke outboard motor oil

ZMU04605

-x1 2 3

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


16

EMU27270

Ring Free Fuel Additive

Gasoline is a precise blend of many differentsubstances, each chosen to give certaincharacteristics. Gasoline blends have beenchanging in recent years in response to con-cerns about pollution and resulting emis-sions regulations. One of the most obviouschanges has been the elimination of leadfrom most fuels.As gasoline has changed, the amount of ad-ditives such as aromatics and oxygenateshas increased. These additives are impor-tant for the engines in passenger cars, butthey can have detrimental effects in marineengines, because of increased deposits inthe combustion chamber. When enough de-posits collect, piston rings begin sticking.Performance drops and engine wear in-creases dramatically.While many additives available may reducedeposits, Yamaha recommends the use of

Ring Free Fuel Additive

, available fromyour Yamaha dealer.

Ring Free Fuel Addi-tive

has repeatedly proven its ability to cleancombustion deposits from inside the engine,notably the critical piston-ring-land area, andfuel system components. Follow product la-beling for use instructions.

EMU36880

Muddy or acidic water

Yamaha strongly recommends that you haveyour dealer install the optional chromium-plated water pump kit if you use the outboardmotor in muddy or acidic water conditions.However, depending on the model it mightnot be required.

EMU36330

Anti-fouling paint

A clean hull improves boat performance. Theboat bottom should be kept as clean of ma-rine growth as possible. If necessary, the

boat bottom can be coated with an anti-foul-ing paint approved for your area to inhibitmarine growth.Do not use anti-fouling paint which includescopper or graphite. These paints can causemore rapid engine corrosion.

EMU36341

Motor disposal requirements

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

EMU36351

Emergency equipment

Keep the following items onboard in casethere is trouble with the motor.

�

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

�

Waterproof flashlight with extra batteries.

�

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

�

Spare parts, such as an extra set of sparkplugs.

Consult your Yamaha dealer for details.

EMU25221

Emission control information

EMU25230

North American models

This engine conforms to U.S. EnvironmentalProtection Agency (EPA) regulations for ma-rine SI engines. See the label affixed to your


17

engine for details.

EMU30390

Approval label of emission control certif-icate

This label is attached to the bottom cowling.Existing Technology; N/A

EMU25262

Manufactured date label

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

1. Approval label location

1

ZMU06311

EMISSION CONTROL INFORMATIONENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.FELs :SPARK PLUG :DISPLACEMENT :ADVERTISED POWER :

IDLE SPEED :SPARK PLUG GAP (mm) :FUEL : GASOLINEVALVE LASH (mm) : IN : N/A EX : N/A

cmkW

g/kW-hr rpm IN NEUTRAL

3

ZMU05230

1. Manufactured date label location

1

ZMU02838

Manufactured:

ZMU04346

18

Components

EMU2579M

Components diagramTIP:

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

8

EMU25802

Fuel tank

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

WARNING

EWM00020

The fuel tank supplied with this engine isits dedicated fuel reservoir and must notbe used as a fuel storage container. Com-mercial users should conform to relevantlicensing or approval authority regula-

13

45

2

6

16

7

8

9101112

14

15

13

17

ZMU04490

1. Manual starter handle2. Engine stop button/Engine shut-off switch3. Choke knob4. Throttle grip5. Throttle friction adjuster6. Clamp screw7. Cooling water inlet8. Anti-cavitation plate9. Trim rod10. Shallow water lever11. Restraint cable attachment12. Tilt support knob13. Cooling water pilot hole14. Gear shift lever15. Top cowling

16. Fuel tank*17. Clip

Components

19

tions.

EMU25830

Fuel joint

This joint is used to connect the fuel line.

EMU25841

Fuel gauge

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

EMU25850

Fuel tank cap

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

EMU25860

Air vent screw

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

EMU25911

Tiller handle

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

EMU25922

Gear shift lever

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

EMU25941

Throttle grip

The throttle grip is on the tiller handle. Turnthe grip counterclockwise to increase speedand clockwise to decrease speed.

1. Fuel tank cap2. Fuel gauge3. Air vent screw4. Fuel joint

ZMU04499

4 21 3

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”

ZMU02846

1 23

ZMU02847

N FR

Components

20

EMU25961

Throttle indicator

The fuel consumption curve on the throttleindicator shows the relative amount of fuelconsumed for each throttle position. Choosethe setting that offers the best performanceand fuel economy for the desired operation.

EMU25976

Throttle friction adjuster

A friction device provides adjustable resis-tance to movement of the throttle grip or theremote control lever, and can be set accord-ing to operator preference.To increase resistance, turn the adjusterclockwise. To decrease resistance, turn theadjuster counterclockwise.

WARNING! Donot overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to move the remote control lever

or throttle grip, which could result in anaccident.

[EWM00032]

When constant speed is desired, tighten theadjuster to maintain the desired throttle set-ting.

EMU25994

Engine shut-off cord (lanyard) and clip

The clip must be attached to the engine shut-off switch for the engine to run. The cordshould be attached to a secure place on theoperator’s clothing, or arm or leg. Should theoperator fall overboard or leave the helm, thecord will pull out the clip, stopping ignition tothe engine. This will prevent the boat fromrunning away under power.

WARNING! At-tach the engine shut-off cord to a secureplace on your clothing, or your arm or legwhile operating. Do not attach the cord toclothing that could tear loose. Do notroute the cord where it could become en-tangled, preventing it from functioning.Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power, theboat could slow rapidly. This could causepeople and objects in the boat to bethrown forward.

[EWM00122]

1. Throttle indicator

ZMU02848

ZMU02849

1

ZMU02850

Components

21

EMU26001

Engine stop button

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

EMU26011

Choke knob for pull type

To supply the engine with the rich fuel mix-ture required to start, pull out this knob.

EMU26070

Manual starter handle

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

EMU26122

Steering friction adjuster

A friction device provides adjustable resis-tance to the steering mechanism, and can beset according to operator preference. An ad-justing screw or bolt is located on the swivelbracket.

To increase resistance, turn the adjusterclockwise.To decrease resistance, turn the adjustercounterclockwise.

WARNING

EWM00040

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could be

1. Clip2. Cord3. Engine shut-off switch

ZMU02851

1

2

3

ZMU02852

ZMU02860

ZMU04508

Components

22

difficult to steer, which could result in an

accident.

EMU26261

Trim rod (tilt pin)

The position of the trim rod determines theminimum trim angle of the outboard motor inrelation to the transom.

EMU26280

Shallow water lever

Pushing this lever down will tilt the motor uppartially to provide more clearance when op-erating in shallow water.

EMU26321

Tilt support knob

To keep the outboard motor in the tilted upposition, push the tilt support knob under theswivel bracket.

NOTICE

ECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboardmotor could shake loose from the tilt sup-port and fall. If the motor cannot be trail-ered in the normal running position, usean additional support device to secure it

in the tilt position.

EMU26373

Cowling lock lever(s) (turn type)

To remove the engine top cowling, turn thecowling lock lever(s) and lift off the cowling.When installing the cowling, check to be sureit fits properly in the rubber seal. Then lockthe cowling again by returning the cowlinglock lever(s) to the lock position.

ZMU02853

ZMU02854

1. Cowling lock lever(s)

ZMU02855

ZMU02862

1

23

Installation

EMU26902

Installation

The information presented in this section isintended as reference only. It is not possibleto provide complete instructions for everypossible boat and motor combination. Prop-er mounting depends in part on experienceand 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 horsepowerthan the maximum rating on the capac-ity plate of the boat. If the boat does nothave a capacity plate, consult the boatmanufacturer.

�

Improper mounting of the outboard mo-tor could result in hazardous condi-tions such as poor handling, loss ofcontrol, or fire hazards. For permanent-ly mounted models, your dealer or oth-er person experienced in proper

rigging should mount the motor.

EMU26911

Mounting the outboard motor

WARNING

EWM01720

Your dealer or other person experiencedin proper outboard motor mountingshould show you how to mount your out-

board motor.

The outboard motor should be mounted sothat the boat is well balanced. Otherwise, theboat could be hard to steer. For single-en-gine boats, mount the outboard motor on thecenterline (keel line) of the boat.

EMU26923

Mounting height

To run your boat at optimum efficiency, thewater resistance (drag) of the boat and out-board motor must be made as little as possi-ble. The mounting height of the outboardmotor greatly affects the water resistance. Ifthe mounting height is too high, cavitationtends to occur, thus reducing the propulsion;and if the propeller tips cut the air, the enginespeed will rise abnormally and cause the en-gine to overheat. If the mounting height is toolow, the water resistance will increase andthereby reduce engine efficiency. Mount theoutboard motor so that the anti-cavitationplate is between the bottom of the boat anda level 25 mm (1 in) below it.

1. Center line (keel line)

ZMU017601

Installation

24

NOTICE

ECM01631

�

Check that the idle hole stays highenough to keep out water getting insideengine even if the boat is in stationarywith maximum load.

�

Incorrect engine height or obstructionsto the smooth flow of water (such as thedesign or condition of the boat, or ac-cessories such as transom ladders ordepth finder transducers) can createairborne water spray while the boat iscruising. If the motor is operated con-tinuously in the presence of airbornewater spray, enough water could enterthe engine through the intake openingon the cowling to cause severe enginedamage. Eliminate the cause of the air-

borne water spray.

TIP:

�

The optimum mounting height of the out-board motor is affected by the boat andmotor combination and the desired use.Test runs at different heights can help de-termine the optimum mounting height.Consult your Yamaha dealer or boat man-ufacturer for further information on deter-mining the proper mounting height.

�

For instructions on setting the trim angle ofthe outboard motor, see page 36.

EMU26972

Clamping the outboard motor

1. Place the outboard motor on the tran-som so that it is positioned as close tothe center as possible. Tighten the tran-som clamp screws evenly and securely.Occasionally check the clamp screwsfor tightness during operation of the out-board motor because they could be-come loose due to engine vibration.

WARNING! Loose clamp screwscould allow the outboard motor to falloff or move on the transom. Thiscould cause loss of control and seri-ous injury. Make sure the transomscrews are tightened securely. Occa-sionally check the screws for tight-ness during operation.

[EWM00641]

2. If the restraint cable attachment isequipped on your engine, a restraint ca-ble or chain should be used. Attach oneend to the restraint cable attachmentand the other to a secure mounting pointon the boat. Otherwise the engine couldbe completely lost if it accidentally fallsoff the transom.

ZMU02011

0–25mm(0–1in)

ZMU02012

Installation

25

3. Secure the clamp bracket to the transomusing the bolts provided with the out-board (if packed). For details, consultyour Yamaha dealer.

WARNING! Avoidusing bolts, nuts or washers otherthan those contained in the enginepackaging. If used, they must be of atleast the same quality of material andstrength and must be tightened se-curely. After tightening, test run theengine and check their tightness.

[EWM00651]

1. Bolts

ZMU02013

ZMU02637

1

26

Operation

EMU36381

First-time operation

EMU30174

Breaking in engine

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

NOTICE:

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

[ECM00801]

EMU27060

Gasoline and engine oil mixing chart(50:1)

NOTICE

ECM00150

Be sure to mix gasoline and oil complete-ly, otherwise the engine may be dam-

aged.

EMU27074

Procedure for pre-mixed models

Run the engine under load (in gear with apropeller installed) for 10 hours as follows.1. First 10 minutes:

Run the engine at the lowest possiblespeed. A fast idle in neutral is best.

2. Next 50 minutes:Do not exceed half throttle (approxi-mately 3000 r/min). Vary engine speedoccasionally. If you have an easy-plan-ing boat, accelerate at full throttle onto

plane, then immediately reduce thethrottle to 3000 r/min or less.

3. Next two hours:Accelerate at full throttle onto plane,then reduce engine speed to three-quar-ter throttle (approximately 4000 r/min).Vary engine speed occasionally. Run atfull throttle for one minute, then allowabout 10 minutes of operation at three-quarter throttle or less to let the enginecool.

4. Remaining seven hours:Run the engine at any speed. However,avoid operating at full throttle for morethan 5 minutes at a time.

5. After the first 10 hours:Operate the engine normally. Use thestandard premix ratio of gasoline and oil.For details on mixing fuel and oil, seepage 28.

EMU36400

Getting to know your boat

Different boats handle differently. Operatecautiously while you learn how your boathandles under different conditions and withdifferent trim angles (see page 36).

EMU36412

Checks before starting engine

WARNING

EWM01920

If any item in the checks before startingengine is not working properly, have it in-spected and repaired before operatingthe outboard motor. Otherwise an acci-

dent could occur.

NOTICE

ECM00120

Do not start the engine out of water. Over-heating and serious engine damage can

occur.

1. : Gasoline

2. : Engine oil

Operation

27

EMU37141

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 tothe destination, 1/3 to return, and to keep 1/3 as an emergency reserve. With the boatlevel on a trailer or in the water, check thefuel level. For fuel filling instructions, seepage 28.

EMU36570

Remove cowling

For the following checks, remove the topcowling from the engine. To remove the en-gine top cowling, release the lock lever andlift off the cowling.

EMU36442

Fuel system

WARNING

EWM00060

Gasoline and its vapors are highly flam-mable and explosive. Keep away fromsparks, cigarettes, flames, or other

sources of ignition.

WARNING

EWM00910

Leaking fuel can result in fire or explo-sion.

�

Check for fuel leakage regularly.

�

If any fuel leakage is found, the fuelsystem must be repaired by a qualifiedmechanic. Improper repairs can make

the outboard unsafe to operate.

EMU36451

Check for fuel leaks

�

Check for fuel leaks or gasoline fumes inthe boat.

�

Check for fuel leakage from the fuel sys-tem.

�

Check the fuel tank and fuel lines forcracks, swellings, or other damages.

EMU36891

Controls

�

Move the tiller handle fully to the left andright to make sure operation is smooth.

�

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

�

Look for loose or damaged connections ofthe throttle and shift cables.

EMU36482

Engine shut-off cord (lanyard)

Inspect the engine shut-off cord for damage,such as cuts, breaks, and wear.

EMU27120

Oil

�

Check to be sure you have plenty of oil foryour trip.

ZMU06089

1. Clip2. Cord3. Engine shut-off switch

ZMU02851

1

2

3

Operation

28

EMU27141

Engine

�

Check the engine and engine mounting.

�

Look for loose or damaged fasteners.

�

Check the propeller for damage.

EMU36953

Install cowling

1. Be sure that a cowling lock lever is re-leased.

2. Be sure that the rubber seal is seated allthe way around the top cowling.

3. Place the top cowling on bottom cowl-ing.

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 asshown.

NOTICE:

If the cowling is notinstalled correctly, water spray underthe cowling can damage the engine,or the cowling can blow off at highspeeds.

[ECM01990]

After installing, check the fitting of the topcowling by pushing it with both hands. If thetop cowling is loose, have it repaired by yourYamaha dealer.

EMU27234

Filling fuel and engine oil

EMU27247

Filling fuel for portable tank

WARNING

EWM01830

�

Gasoline and its vapors are highly flam-mable and explosive. Always refuel ac-cording to this procedure to reduce therisk of fire and explosion.

�

Gasoline is poisonous and can causeinjury or death. Handle gasoline withcare. Never siphon gasoline by mouth.If you should swallow some gasoline orinhale a lot of gasoline vapor, or getsome gasoline in your eyes, see yourdoctor immediately. If gasoline spillson your skin, wash with soap and wa-ter. If gasoline 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 onthe fuel tank cap.

ZMU06114

Operation

29

3. Remove the portable tank from the boat.4. Be sure you are in a well-ventilated out-

door area, either securely moored ortrailered.

5. Do not smoke and keep away fromsparks, flames, static electric discharge,or other sources of ignition.

6. If you use a portable container to storeand dispense fuel, use only an approvedGASOLINE container.

7. Touch the fuel nozzle to the filler open-ing or funnel to help prevent electrostaticsparks.

8. Fill the fuel tank, but do not overfill. Fuelcan expand and overflow if the tempera-ture increases.

9. Tighten the filler cap securely.10. Wipe up any spilled gasoline immediate-

ly with dry rags. Dispose rags properlyaccording to local laws or regulations.

EMU27406

Gasoline and oil mixing (100:1)

NOTICE

ECM00811

�

Avoid using any oil other than the spec-ified type.

�

Use a thoroughly blended fuel-oil mix-ture.

�

If the mixture is not thoroughly mixed,or if the mixing ratio is incorrect, thefollowing problems could occur.

�

Low oil ratio: Lack of oil could causemajor engine trouble, such as pistonseizure.

�

High oil ratio: Too much oil could causefouled spark plugs, smoky exhaust,

and heavy carbon deposits.

Fuel tank capacity:12 L (3.17 US gal, 2.64 Imp.gal)

ZMU06621

Gasoline to engine oil ratio

Break-in period See page 26After break-in 100:1

ZMU04484

Operation

30

If equipped with a portable fuel tank1. Pour oil into the portable fuel tank, and

then add gasoline.

2. Replace the fuel tank cap and closetightly.

3. Shake the fuel tank to mix the fuel thor-oughly.

4. Make sure that the oil and gasoline aremixed.

If equipped with a built-in fuel tank1. Pour oil into a clean fuel can, and then

add gasoline.2. Replace the fuel can cap and close tight-

ly.3. Shake the fuel can to mix the fuel thor-

oughly.4. Make sure that the oil and gasoline are

mixed.5. Pour the gasoline and oil mixture into the

built-in fuel tank.

TIP:

If using a permanently installed tank, pourthe oil gradually as the gasoline is being add-ed to the tank.

EMU27451

Operating engine

EMU27466

Sending fuel (portable tank)

WARNING

EWM00420

�

Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in thewater near you.

�

When the air vent screw is loosened,gasoline vapor will be released. Gaso-line is highly flammable, and its vaporsare flammable and explosive. Refrainfrom smoking, and keep away fromopen flames and sparks while loosen-ing the air vent screw.

�

This product emits exhaust gaseswhich contain carbon monoxide, a col-orless, odorless gas which could causebrain damage or death when inhaled.

1. : Gasoline

2. : Engine oil

1. Engine oil2. Gasoline

100:11 L

(0.26 US gal, 0.22 Imp gal)

12 L


14 L


24 L


0.01 L

(0.01 US qt, 0.01 Imp qt)

0.12 L

(0.13 US qt, 0.11 Imp qt)

0.14 L

(0.15 US qt, 0.12 Imp qt)

0.24 L

(0.25 US qt, 0.21 Imp qt)

ZMU04910

Operation

31

Symptoms include nausea, dizziness,and drowsiness. Keep cockpit and cab-in areas well ventilated. Avoid blocking

exhaust outlets.

1. If there is an air vent screw on the fueltank cap, loosen it 2 or 3 turns.

2. If there is a fuel joint on the motor, firmlyconnect the fuel line to the joint. Thenfirmly connect the other end of the fuelline to the joint on the fuel tank.

TIP:

Wipe up any spilled gasoline immediatelywith dry rags. Dispose rags properly accord-ing to local laws or regulations.3. Squeeze the primer pump, with the ar-

row pointing up, until you feel it becomefirm. During engine operation place thetank horizontally, otherwise fuel cannotbe drawn from the fuel tank.

EMU27493

Starting engine

WARNING

EWM01600

Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in the wa-

ter near you.

EMU27508

Manual start models (tiller control)

WARNING

EWM01840

�

Failure to attached engine shut-off cordcould result in a runaway boat if opera-tor is ejected. Attach the engine shut-off cord to a secure place on your cloth-ing, or your arm or leg while operating.Do not attach the cord to clothing thatcould tear loose. Do not route the cord

ZMU02024

1. Arrow

Operation

32

where it could become entangled, pre-venting it from functioning.

�

Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power,the boat could slow rapidly. This couldcause people and objects in the boat to

be thrown forward.

1. Place the gear shift lever in neutral.

TIP:

The start-in-gear protection device preventsthe 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 armor leg. Then install the clip on the otherend of the cord into the engine shut-offswitch.

3. Place the throttle grip in the “ ”

(start) position.

4. Pull out / turn the choke knob fully. Afterthe engine starts, replace / return theknob to the home position.

TIP:

�

It is not necessary to use the choke whenstarting a warm engine.

�

If the choke knob is left in the “ ”(start) position while the engine is running,the engine will run poorly or stall.

5. Pull the manual starter handle slowly un-til you feel resistance. Then give astrong pull straight out to crank and startthe engine. Repeat if necessary.

ZMU02860

Operation

33

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

7. Slowly return the throttle grip to the fullyclosed position.

TIP:

�

When the engine is cold, it needs to bewarmed up. For further information, seepage 33.

�

If the engine does not start on the first try,repeat the procedure. If the engine fails tostart after 4 or 5 tries, open the throttle asmall amount (between 1/8 and 1/4) andtry again. Also if the engine is warm andfails to start, open the throttle a sameamount and try to start the engine again. Ifthe engine still fails to start, see page 55.

EMU36510

Checks after starting engine

EMU36520

Cooling water

Check for a steady flow of water from thecooling water pilot hole. A continuous flow ofwater from the pilot hole shows that the wa-ter pump is pumping water through the cool-ing passages. If the cooling passages arefrozen, it may take a while for water to startflowing out of the pilot hole.

NOTICE

ECM01810

If water is not flowing out of the pilot holeat all times while the engine is running,overheating and serious damage couldoccur. Stop the engine and check wheth-er the cooling water inlet on the lowercase or the cooling water pilot hole isblocked. Consult your Yamaha dealer ifthe problem cannot be located and cor-

rected.

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

EMU27670

Warming up engine

EMU27683

Choke start models

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

ZMU02030

ZMU02856

Operation

34

shorten engine life. Gradually return thechoke knob to its home position as the en-gine warms up.

EMU36530

Checks after engine warm-up

EMU36540

Shifting

While tightly moored, and without applyingthrottle, confirm that the engine shiftssmoothly into forward and reverse, and backto neutral.

EMU36970

Stop switches

�

Press the engine stop button and makesure the engine stops.

�

Confirm that removing the clip from the en-gine shut-off switch stops the engine.

�

Confirm that the engine cannot be startedwith the clip removed from the engineshut-off switch.

EMU34550

Shifting

WARNING

EWM00180

Before shifting, make sure there are noswimmers or obstacles in the water near

you.

NOTICE

ECM01610

Warm up the engine before shifting intogear. Until the engine is warm, the idlespeed may be higher than normal. Highidle speed can prevent you from shiftingback to neutral. If this occurs, stop theengine, shift to neutral, then restart the

engine and allow it to warm up.

To shift out of neutral1. Move the gear shift lever firmly and

crisply forward (for forward gear) orbackward (for reverse gear). Be sure tocheck that the tilt lock lever is in the lock/

down position (if equipped) before oper-ating in reverse.

To shift from in gear (forward/reverse) toneutral1. Close the throttle so that the engine

slows to idle speed.

2. After the engine is at idle speed in gearmove the gear shift lever firmly andcrisply into the neutral position.

ZMU05921

N FR

ZMU02030

Operation

35

EMU31742

Stopping boat

WARNING

EWM01510

�

Do not use the reverse function to slowdown or stop the boat as it could causeyou to lose control, be ejected, or im-pact the steering wheel or other parts ofthe boat. This could increase the risk ofserious injury. It could also damage theshift mechanism.

�

Do not shift into reverse while travelingat planing speeds. Loss of control, boatswamping, or damage to the boat could

occur.

The boat is not equipped with a separatebraking system. Water resistance stops it af-ter the throttle lever is moved back to idle.The stopping distance varies depending ongross weight, water surface conditions, andwind direction.

EMU27821

Stopping engine

Before stopping the engine, first let it cool offfor a few minutes at idle or low speed. Stop-ping the engine immediately after operatingat high speed is not recommended.

EMU27833

Procedure

1. Push and hold the engine stop buttonuntil the engine comes to a completestop.

2. After stopping the engine, tighten the airvent screw on the fuel tank cap and setthe fuel cock lever or knob to the closedposition, if equipped.

3. Disconnect the fuel line if you are usingan external fuel tank.

TIP:

If the outboard motor is equipped with an en-gine shut-off cord, the engine can also bestopped by pulling the cord and removing theclip from the engine shut-off switch.

Operation

36

EMU27862

Trimming outboard motor

WARNING

EWM00740

Excessive trim for the operating condi-tions (either trim up or trim down) cancause boat instability and can makesteering the boat more difficult. This in-creases the possibility of an accident. Ifthe boat begins to feel unstable or is hardto steer, slow down and/or readjust the

trim angle.

The trim angle of the outboard motor helpsdetermine the position of the bow of the boatin the water. Correct trim angle will help im-prove performance and fuel economy whilereducing strain on the engine. Correct trimangle depends upon the combination ofboat, engine, and propeller. Correct trim isalso affected by variables such as the load inthe boat, sea conditions, and running speed.

EMU27872

Adjusting trim angle for manual tilt models

There are 4 or 5 holes provided in the clampbracket 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 brack-et.

1. Trim operating angle

ZMU02858

1

Operation

37

3. Reposition the rod in the desired hole.To raise the bow (“trim-out”), move the rodaway from the transom.To lower the bow (“trim-in”), move the rod to-ward the transom.Make test runs with the trim set to differentangles to find the position that works best foryour boat and operating conditions.

WARNING

EWM00400

�

Stop the engine before adjusting thetrim angle.

�

Use care to avoid being pinched whenremoving or installing the rod.

�

Use caution when trying a trim positionfor the first time. Increase speed gradu-ally and watch for any signs of instabil-ity or control problems. Improper trim

angle can cause loss of control.

TIP:

The outboard motor trim angle can bechanged approximately 4 degrees by shiftingthe trim rod one hole.

EMU27912

Adjusting boat trim

When the boat is on plane, a bow-up attituderesults in less drag, greater stability and effi-ciency. This is generally when the keel line ofthe 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 ofthe boat is down, it is easier to acceleratefrom a standing start onto plane.

Bow Up

Too much trim-out puts the bow of the boattoo high in the water. Performance and econ-omy are decreased because the hull of theboat is pushing the water and there is moreair drag. Excessive trim-out can also causethe propeller to ventilate, which reduces per-formance further, and the boat may “por-poise” (hop in the water), which could throwthe operator and passengers overboard.

Bow Down

Too much trim-in causes the boat to “plow”through the water, decreasing fuel economyand making it hard to increase speed. Oper-ating with excessive trim-in at higher speedsalso makes the boat unstable. Resistance at

1. Trim rod

ZMU02859

1

Operation

38

the bow is greatly increased, heightening thedanger of “bow steering” and making opera-tion difficult and dangerous.

TIP:

Depending on the type of boat, the outboardmotor trim angle may have little effect on thetrim of the boat when operating.

EMU27922

Tilting up and down

If the engine will be stopped for some time orif the boat is moored in shallows, the out-board motor should be tilted up to protect thepropeller and lower casing from damage bycollision with obstructions, and also to re-duce salt corrosion.

WARNING

EWM00221

Be sure all people are clear of the out-board motor when tilting up and down.Body parts can be crushed between themotor and the clamp bracket when the

motor is trimmed or tilted.

WARNING

EWM00230

Leaking fuel is a fire hazard. Tighten theair vent screw and place the fuel cock inthe closed position if the outboard motorwill be tilted for more than a few minutes.

Otherwise fuel may leak.

NOTICE

ECM00231

�

Before tilting the outboard motor, fol-low the procedure under “Stopping en-gine” in this chapter. Never tilt theoutboard motor while the engine is run-ning. Severe damage from overheatingcan result.

�

Do not tilt up the engine by pushing thetiller handle because this could breakthe handle.

�

Keep the power unit higher than thepropeller at all times. Otherwise watercould run into the cylinder and causedamage.

�

The outboard motor cannot be tiltedwhen in reverse or when the outboard

motor is turned 180° (facing the rear).

EMU32662

Procedure for tilting up (manual tilt models)


2. Disconnect the fuel line from the out-board motor.

Operation

39

3. Place the tilt lock lever (if equipped) inthe release/up position.

4. Pull up the shallow water lever (ifequipped).

5. Hold the rear of the top cowling with onehand and tilt the engine up fully.

6. Push the tilt support knob into the clampbracket. Or the tilt support bar will turn tothe lock position automatically.

NO-TICE:

Do not use the tilt support leveror knob when trailering the boat. Theoutboard motor could shake loosefrom the tilt support and fall. If themotor cannot be trailered in the nor-mal running position, use an addi-tional support device to secure it inthe tilt position. For more detailed in-formation, see page 41.

[ECM01641]

EMU28013

Procedure for tilting down (manual tilt models)

1. Slightly tilt the engine up.2. On models equipped with a tilt support

knob, pull it out.

3. Slowly tilt the engine down.

EMU28061

Shallow water

EMU28073

Cruising in shallow water (manual tilt models)

WARNING

EWM01781

�

Run the boat at the lowest possiblespeed when using the shallow watercruising system. The tilt lock mecha-nism does not work while the shallowwater cruising system is being used.Hitting an underwater obstacle couldcause the outboard motor to lift out of

ZMU02854

ZMU02887

ZMU02888

Operation

40

the water, resulting in loss of control.

�

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

cident and personal injury.

NOTICE

ECM00260

Do not tilt the outboard motor up so thatthe cooling water inlet on the lower unit isabove the surface of the water when set-ting up for and cruising in shallow water.Otherwise severe damage from overheat-

ing can result.

EMU28110

Procedure


2. Slightly tilt the outboard motor up. Pullup the shallow water lever.

3. The shallow water lever will lock, sup-porting the outboard motor in a partiallyraised position.

4. When lowering the outboard motor,slightly tilt it up and push the shallow wa-ter lever down. Slowly lower the out-board motor to the normal position.

EMU28195

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the coolingwater passages with fresh water to preventthem from becoming clogged. Also rinse theoutside of the outboard motor with fresh wa-ter.

Cruising in muddy, turbid, or acidic water

Yamaha strongly recommends that you usethe optional chromium-plated water pump kit(see page 16) if you use the outboard motorin acidic water or water with a lot of sedimentin it, such as muddy or turbid (cloudy) water.After operating in such water, flush the cool-ing passages with fresh water to prevent cor-rosion. Also rinse the outside of the outboardmotor with fresh water.

ZMU02868

ZMU02854

41

Maintenance

EMU28227

Transporting and storing outboard motor

WARNING

EWM00693

�

USE CARE when transporting fuel tank,whether in a boat or car.

�

DO NOT fill fuel container to maximumcapacity. Gasoline will expand consid-erably as it warms up and can build uppressure in the fuel container. This cancause 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 fromleaking. Never get under the engine whileit is tilted. Severe injury could occur if the

outboard motor accidentally falls.

NOTICE

ECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboardmotor could shake loose from the tilt sup-port and fall. If the motor cannot be trail-ered in the normal running position, usean additional support device to secure it

in the tilt position.

The outboard motor should be trailered andstored in the normal running position. If thereis insufficient road clearance in this position,then trailer the outboard motor in the tilt po-sition using a motor support device such asa transom saver bar. Consult your Yamahadealer for further details.

EMU28236

Clamp screw mounting models

When transporting or storing the outboardmotor while removed from a boat, keep theoutboard motor in the attitude shown.

TIP:

Place a towel or something similar under theoutboard motor to protect it from damage.

EMU30272

Storing outboard motor

When storing your Yamaha outboard motorfor prolonged periods of time (2 months orlonger), several important procedures mustbe performed to prevent excessive damage.It is advisable to have your outboard motorserviced by an authorized Yamaha dealerprior to storage. However, you, the owner,with a minimum of tools, can perform the fol-

ZMU02870

ZMU02869

Maintenance

42

lowing procedures.

NOTICE

ECM01411

�

Do not place the outboard motor on itsside before the cooling water hasdrained from it completely, otherwisewater may enter the cylinder throughthe exhaust port and cause engine trou-ble.

�

Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

EMU28304

Procedure

EMU28376

Flushing in a test tank

NOTICE

ECM00300

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

es.

1. Wash the outboard motor body usingfresh water.

NOTICE:

Do not spray wa-ter into the air intake.

[ECM01840]

For fur-ther information, see page 43.

2. Fill the fuel tank with fresh fuel and addone ounce of “Yamaha Fuel Conditionerand Stabilizer” to each gallon of fuel.

TIP:

The use of “Yamaha Fuel Conditioner andStabilizer” eliminates the need to drain thefuel system. Consult your Yamaha dealer orother qualified mechanic if the fuel system isto be drained instead.3. Remove the engine top cowling and si-

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

tank.

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

NO-TICE:

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

[ECM00291]

6. Cooling system flushing is essential to

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

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

[EWM00091]

7. Run the engine at a fast idle for 10–15

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

ly spray “Yamaha Stor-Rite EngineFogging Oil” alternately into each carbu-retor or the fogging hole of the silencercover, if equipped. When properly done,the engine will smoke excessively andalmost stall.

1. Water surface2. Lowest water level

ZMU02051

1

2

Maintenance

43

9. Remove the outboard motor from thetest tank.

10. Drain the cooling water completely outof the motor. Clean the body thoroughly.

11. Install the silencer cover/cap and topcowling.

EMU28402

Lubrication

1. Install the spark plug(s) and torque toproper specification. For information onspark plug installation, see page 48.

2. Change the gear oil. For instructions,see page 51. Inspect the oil for the pres-ence of water that indicates a leaky seal.Seal replacement should be performedby an authorized Yamaha dealer prior touse.

3. Grease all grease fittings. For further de-tails, see page 48.

TIP:

For long-term storage, fogging the enginewith oil is recommended. Contact yourYamaha dealer for information about foggingoil and procedures for your engine.

EMU28423

Cleaning and anticorrosion measures

1. Wash down the exterior of the outboardmotor with fresh water and dry off com-pletely.

NOTICE:

Do not spray waterinto the air intake.

[ECM01840]

2. Spray the outboard motor exterior with

“Yamaha Silicone Protectant”.3. Wax the cowling with a non-abrasive

wax such as “Yamaha Silicone Wax”.

EMU28451

Cleaning the outboard motor

After use, wash the exterior of the outboardmotor with fresh water. Flush the coolingsystem with fresh water.

EMU28460

Checking painted surface of motor

Check the motor for scratches, nicks, or flak-ing paint. Areas with damaged paint aremore likely to corrode. If necessary, cleanand paint the areas. A touch-up paint is avail-able from your Yamaha dealer.

EMU37081

Periodic maintenance

WARNING

EWM01981

These procedures require mechanicalskills, tools, and supplies. If you do nothave the proper skills, tools, or suppliesto perform a maintenance procedure,have a Yamaha dealer or other qualifiedmechanic do the work.The procedures involve disassemblingthe motor and exposing dangerous parts.To reduce the risk of injury from moving,hot, or electrical parts:

�

Turn off the engine and keep engineshut-off cord (lanyard) with you whenyou perform maintenance unless other-wise specified.

�

Allow the engine to cool before han-dling hot parts or fluids.

�

Always completely reassemble the mo-

tor before operation.

Maintenance, replacement, or repair ofthe emission control devices and sys-

Maintenance

44

tems may be performed by any marineengine repair establishment or individual.All warranty repairs, however, includingthose to the emission control system,must be performed by an authorizedYamaha marine dealership.

A service manual is available for purchasethrough your Yamaha dealer for owners whohave the mechanical skills, tools, and otherequipment necessary to perform mainte-nance not covered by this owner’s manual.

EMU28511

Replacement parts

If replacement parts are necessary, use onlygenuine Yamaha parts or parts of equivalentdesign and quality. Any part of inferior qualitymay malfunction, and the resulting loss ofcontrol could endanger the operator andpassengers. Yamaha genuine parts and ac-cessories are available from your Yamahadealer.

EMU35520

Maintenance interval guidelines

The service intervals provided in the Mainte-nance Chart were developed based upon“typical” use that includes operating at variedspeeds, with sufficient time for engine warmup and cool-down, a medium to light load,and an average cruising speed near the3000 to 4000 rpm range. As with any engine,however, if your normal operating conditionsare different, you should consider servicemore often than shown, especially how oftenyou change your engine and gear oil. Exam-ples might include extended wide-open-throttle use or long periods of trolling oridling, carrying heavy loads, or frequentstarting and stopping or shifting. More fre-quent maintenance will often pay off manytimes over in increased engine life and great-er owner satisfaction. Consult your Yamahadealer for additional maintenance recom-

mendations.

Maintenance

45

EMU34445

Maintenance chart 1TIP:

�

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 regularflushing of the cooling water passages. Maintenance frequency should be adjusted whenoperating the engine under adverse conditions such as extended trolling.

�

Disassembly or repairs may be necessary depending on the outcome of maintenancechecks.

�

Expendable or consumable parts and lubricants will lose their effectiveness over time andthrough normal usage regardless of the warranty period.

�

When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine shouldbe flushed with clean water after each use.

The “ ” symbol indicates the check-ups which you may carry out yourself.The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

20 hours (3

months)

100 hours (1

year)

300 hours (3 years)

500 hours (5 years)

Anode(s) (external)Inspection or replace-ment as necessary

Anode(s) (cylinder head, thermostat cover)

Inspection or replace-ment as necessary

Anodes (exhaust cover, cooling water passage cover, Rectifier Regula-tor cover)

Replacement

Cooling water leakageInspection or replace-ment as necessary

Cowling lock lever Inspection

Engine starting condi-tion/noise

Inspection

Engine idling speed/noise

Inspection

Fuel filter (disposal type)

Replacement

Fuel line(High pres-sure)

Inspection

Fuel line(High pres-sure)


Fuel line(Low pres-sure)

Inspection

Maintenance

46

Fuel line(Low pres-sure)


Fuel pumpInspection or replace-ment as necessary

Fuel/engine oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Impeller/water pump housing


Impeller/water pump housing

Replacement

Propeller/propeller nut/cotter pin


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

Spark plug(s)Inspection or replace-ment as necessary

Spark plug caps/spark plug wires


Water from the cooling water pilot hole

Inspection

Throttle link/throttle cable/throttle pick-up timing

Inspection, adjustment or replacement as nec-essary

ThermostatInspection or replace-ment as necessary

Water inlet Inspection

Main switch/stop switch/choke switch


Wire harness connec-tions/wire coupler con-nections


(Yamaha) Fuel tankInspection and clean-ing as necessary

Item Actions

Initial Every

20 hours (3

months)

100 hours (1

year)

300 hours (3 years)

500 hours (5 years)

Maintenance

47

EMU34451

Maintenance chart 2

Item ActionsEvery

1000 hours

Exhaust guide/exhaust manifold


Maintenance

48

EMU28932

Greasing

Yamaha marine grease (Water resistant grease)

8

EMU28956

Cleaning and adjusting spark plug

The spark plug is an important engine com-ponent and is easy to inspect. The conditionof the spark plug can indicate somethingabout the condition of the engine. For exam-ple, if the center electrode porcelain is verywhite, this could indicate an intake air leak orcarburetion problem in that cylinder. Do not

attempt to diagnose any problems yourself.Instead, take the outboard motor to aYamaha dealer. You should periodically re-move and inspect the spark plug becauseheat and deposits will cause the spark plugto slowly break down and erode.1. Remove the spark plug caps from the

spark plugs.

ZMU02872

Maintenance

49

2. Remove the spark plug. If electrode ero-sion becomes excessive, or if carbonand other deposits are excessive, youshould replace the spark plug with an-other of the correct type.

WARNING!When removing or installing a sparkplug, be careful not to damage the in-sulator. A damaged insulator couldallow external sparks, which couldlead to explosion or fire.

[EWM00561]

3. Be sure to use the specified spark plug,otherwise the engine may not operateproperly. Before fitting the spark plug,measure the electrode gap with a wirethickness gauge; replace it if out of spec-ification.

4. When fitting the plug, wipe off any dirtfrom the threads, and then screw it in to

the correct torque.

TIP:

If a torque-wrench is not available when youare fitting a spark plug, a good estimate ofthe correct torque is 1/4 to 1/2 a turn past fin-ger-tight. Have the spark plug adjusted to thecorrect torque as soon as possible with atorque-wrench.

EMU28990

Checking fuel filter

Check the fuel filter periodically. The fuel fil-ter is a one piece, disposable type. If foreignmatter is found in the filter, replace it. For re-placement of the fuel filter, consult yourYamaha dealer.

EMU29043

Inspecting idling speed

WARNING

EWM00451

�

Do not touch or remove electrical partswhen starting or during operation.

�

Keep hands, hair, and clothes awayfrom the flywheel and other rotating

parts while the engine is running.

NOTICE

ECM00490

This procedure must be performed while

Standard spark plug:B7HS-10

1. Spark plug gap2. Spark plug part number3. Spark plug I.D. mark (NGK)

Spark plug gap:0.9–1.0 mm (0.035–0.039 in)

Spark plug torque:25.0 Nm (2.55 kgf-m, 18.4 ft-lb)

ZMU02874

Maintenance

50

the outboard motor is in the water. Aflushing attachment or test tank can be

used.

If the boat is not equipped with a tachometerfor the outboard motor, use a diagnostic ta-chometer for this procedure. Results mayvary depending on whether testing is con-ducted with the flushing attachment, in a testtank, or with the outboard motor in the water.1. Start the engine and allow it to warm up

fully in neutral until it is running smooth-ly.

2. Once the engine has warmed up, verifywhether the idle speed is set to specifi-cation. For idle speed specifications,see page 13. If you have difficulty verify-ing the idle speed, or the idle speed re-quires adjustment, consult a Yamahadealer or other qualified mechanic.

EMU29113

Checking wiring and connectors

�

Check that each connector is engaged se-curely.

�

Check that each ground lead is properlysecured.

EMU32112

Checking propeller

WARNING

EWM01881

You could be seriously injured if the en-gine accidentally starts when you are

near the propeller. Before inspecting, re-moving, or installing the propeller, placethe shift control in neutral, turn the mainswitch 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 propellerwhen loosening or tightening the propellernut. Put a wood block between the anti-cavi-tation plate and the propeller to prevent thepropeller from turning.

Checkpoints

�

Check each of the propeller blades for ero-sion from cavitation or ventilation, or otherdamage.

�

Check the propeller shaft for damage.

�

Check the splines for wear or damage.

�

Check for fish line tangled around the pro-peller shaft.

ZMU02875

ZMU01897

Maintenance

51

�

Check the propeller shaft oil seal for dam-age.

EMU30662

Removing propeller

EMU29197

Spline models

1. Straighten the cotter pin and pull it outusing a pair of pliers.

2. Remove the propeller nut, washer, andspacer (if equipped).

WARNING! Donot use your hand to hold the propel-ler when loosening the propeller nut.

[EWM01890]

3. Remove the propeller, washer (ifequipped), and thrust washer.

EMU30672

Installing propeller

EMU29233

Spline models

NOTICE

ECM00500

Be sure to use a new cotter pin and bendthe ends over securely. Otherwise thepropeller could come off during opera-

tion and be lost.

1. Apply Yamaha marine grease or a cor-

rosion resistant grease to the propellershaft.

2. Install the spacer (if equipped), thrustwasher, washer (if equipped), and pro-peller on the propeller shaft.

NOTICE:

Be sure to install the thrust washerbefore installing the propeller, other-wise the lower case and propellerboss could be damaged.

[ECM01880]

3. Install the spacer (if equipped) and the

washer. Tighten the propeller nut to thespecified torque.

4. Align the propeller nut with the propellershaft hole. Insert a new cotter pin in thehole and bend the cotter pin ends.

NO-TICE:

Do not reuse the cotter pin in-stalled. Otherwise the propeller cancome off during operation.

[ECM01890]

TIP:

If the propeller nut does not align with thepropeller shaft hole after tightening to thespecified torque, tighten the nut further toalign it with the hole.

EMU29287

Changing gear oil

WARNING

EWM00800

�

Be sure the outboard motor is securely

1. Cotter pin2. Propeller nut3. Washer4. Propeller5. Thrust washer

ZMU02877

23

45

1

Propeller nut tightening torque:17.0 Nm (1.73 kgf-m, 12.5 ft-lb)

ZMU02063

Maintenance

52

fastened to the transom or a stablestand. You could be severely injured ifthe outboard motor falls on you.

�

Never get under the lower unit while itis tilted, even when the tilt support leveror knob is locked. Severe injury couldoccur if the outboard motor accidental-

ly falls.

1. Tilt the outboard motor so that the gearoil drain screw is at the lowest point pos-sible.

2. Place a suitable container under thegear case.

3. Remove the gear oil drain screw andgasket.

NOTICE:

If there is an exces-sive quantity of metal particles on themagnetic gear oil drain screw, thiscan indicate lower unit problem. Con-sult your Yamaha dealer.

[ECM01900]

TIP:

�

If a magnetic gear oil drain screw isequipped, remove all metal particles fromthe screw before installing it.

�

Always use new gaskets. Do not reuse theremoved gaskets.

4. Remove the oil level plug and gasket toallow the oil to drain completely.

NO-

TICE:

Inspect the used oil after it hasbeen drained. If the oil is milky, wateris getting into the gear case whichcan cause gear damage. Consult aYamaha dealer for repair of the lowerunit seals.

[ECM00711]

TIP:

For disposal of used oil, consult yourYamaha dealer.5. Put the outboard motor in a vertical po-

sition. Using a flexible or pressurized fill-ing device, inject the gear oil into thegear oil drain screw hole.

6. Put a new gasket on the oil level plug.When the oil begins to flow out of the oillevel plug hole, insert and tighten the oillevel plug.

7. Put a new gasket on the gear oil drainscrew. Insert and tighten the gear oil

1. Gear oil drain screw2. Oil level plug

ZMU02879

1

2

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:0.160 L (0.169 US qt, 0.141 Imp.qt)

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

ZMU02880

Maintenance

53

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 properlydoing this procedure, consult yourYamaha dealer.

�

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

�

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

�

Wipe up any spilled fuel immediately.

�

Reassemble the fuel tank carefully. Im-proper assembly can result in a fuelleak, 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 approvedcontainer.

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

3. Remove the screws holding the fuel jointassembly. Pull the assembly out of thetank.

4. Clean the filter (located on the end of thesuction 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 tightenthe screws firmly.

EMU29313

Inspecting and replacing anode(s)

Yamaha outboard motors are protected fromcorrosion by sacrificial anodes. Inspect theexternal anodes periodically. Remove scalesfrom the surfaces of the anodes. Consult aYamaha dealer for replacement of externalanodes.

NOTICE

ECM00720

Do not paint anodes, as this would render

them ineffective.

TIP:

Inspect ground leads attached to external

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

ZMU02881

Maintenance

54

anodes on equipped models. Consult aYamaha dealer for inspection and replace-ment of internal anodes attached to the pow-er unit.

55

Trouble Recovery

EMU29427

Troubleshooting

A problem in the fuel, compression, or igni-tion systems can cause poor starting, loss ofpower, or other problems. This section de-scribes basic checks and possible remedies,and covers all Yamaha outboard motors.Therefore some items may not apply to yourmodel.If your outboard motor requires repair, bringit to your Yamaha dealer.If the engine trouble-alert indicator is flash-ing, consult your Yamaha dealer.

Starter will not operate.

Q. Is battery capacity weak or low?A. Check battery condition. Use battery ofrecommended capacity.

Q. Are battery connections loose or corrod-ed?A. Tighten battery cables and clean batteryterminals.

Q. Is fuse for electric start relay or electric cir-cuit blown?A. Check for cause of electric overload andrepair. 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 31.

Q. Has fuel pump malfunctioned?A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replacewith 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. Tightenall loose connections. Replace worn or bro-ken wires.

Q. Are ignition parts faulty?A. Have serviced by a Yamaha dealer.

Q. Is engine shut-off cord (lanyard) not at-tached?A. Attach cord.

Q. Are engine inner parts damaged?A. Have serviced by a Yamaha dealer.

Engine idles irregularly or stalls.


Trouble Recovery

56

Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line orother obstructions in fuel system.

Q. Is fuel contaminated or stale?A. Fill tank with clean, fresh fuel.


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 specified engine oil not being used?A. Check and replace oil as specified.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Are carburetor adjustments incorrect?A. Have serviced by a Yamaha dealer.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw on fuel tank closed?A. Open air vent screw.

Q. Is choke knob pulled out?

A. Return to home position.

Q. Is motor angle too high?A. Return to normal operating position. Q. Is carburetor clogged?A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect?A. Connect correctly.

Q. Is throttle valve adjustment incorrect?A. Have serviced by a Yamaha dealer.

Q. Is battery cable disconnected?A. Connect securely.

Alert buzzer sounds or indicator lights.

Q. Is cooling system clogged?A. Check water intake for restriction.

Q. Is engine oil level low?A. Fill oil tank with specified engine oil.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is engine oil contaminated or deteriorat-ed?A. Replace oil with fresh, specified type.

Q. Is oil filter clogged?A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunc-tioned?A. Have serviced by a Yamaha dealer.

Trouble Recovery

57

Q. Is load on boat improperly distributed?A. Distribute load to place boat on an evenplane.

Q. Is water pump or thermostat faulty?A. Have serviced by a Yamaha dealer.

Q. Is there excess water in fuel filter cup?A. Drain filter cup.

Engine power loss.

Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller pitch or diameter incorrect?A. Install correct propeller to operate out-board at its recommended speed (r/min)range.

Q. Is trim angle incorrect?A. Adjust trim angle to achieve most efficientoperation.

Q. Is motor mounted at incorrect height ontransom?A. Have motor adjusted to proper transomheight.

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 weeds or other foreign matter tangled

on gear housing?A. Remove foreign matter and clean lowerunit.

Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line orother obstructions in fuel system.


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. Have electrical parts failed?A. Have serviced by a Yamaha dealer.

Q. Is specified fuel not being used?A. Replace fuel with specified type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw closed?A. Open the air vent screw.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Trouble Recovery

58

Q. Is fuel joint connection incorrect?A. Connect correctly.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is high pressure fuel pump drive belt bro-ken?A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shiftlever 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 tangledon 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 Yamahadealer.

EMU29433

Temporary action in emergency

EMU29440

Impact damage

WARNING

EWM00870

The outboard motor can be seriouslydamaged by a collision while operating or

trailering. Damage could make the out-

board motor unsafe to operate.

If the outboard motor hits an object in the wa-ter, follow the procedure below.

1. Stop the engine immediately.2. Inspect the control system and all com-

ponents for damage. Also inspect theboat for damage.

3. Whether damage is found or not, returnto the nearest harbor slowly and careful-ly.

4. Have a Yamaha dealer inspect the out-board motor before operating it again.

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 isused to start the engine, the start-in-gear protection device does not oper-ate. Make sure the remote control leveris in neutral. Otherwise the boat couldunexpectedly start to move, which

Trouble Recovery

59

could result in an accident.

�

Attach the engine shut-off cord to a se-cure place on your clothing, or yourarm or leg while operating the boat.

�

Do not attach the cord to clothing thatcould tear loose. Do not route the cordwhere it could become entangled, pre-venting it from functioning.

�

Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power,the boat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

�

Make sure no one is standing behindyou when pulling the starter rope. Itcould whip behind you and injuresomeone.

�

An unguarded, rotating flywheel is verydangerous. Keep loose clothing andother objects away when starting theengine. Use the emergency starter ropeonly as instructed. Do not touch the fly-wheel or other moving parts when theengine is running. Do not install thestarter mechanism or top cowling afterthe engine is running.

�

Do not touch the ignition coil, sparkplug wire, spark plug cap, or other elec-trical components when starting or op-erating the motor. You could get an

electrical shock.

EMU29562

Emergency starting engine

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

ble from the starter, if equipped.3. Remove the starter/flywheel cover after

removing the bolt(s).

4. Prepare the engine for starting. For fur-ther information, see page 31. Be surethe engine is in neutral and that the clipis attached to the engine shut-off switch.The main switch must be “ ” (on), ifequipped.

5. If equipped the choke knob, pull out itwhen the engine is cold. After the enginestarts, gradually return the choke knobto its home position as the engine warmsup.

ZMU02883

ZMU02884

Trouble Recovery

60

6. Insert the knotted end of the emergencystarter rope into the notch in the flywheelrotor and wind the rope several turnsaround the flywheel clockwise.

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

EMU33501

Treatment of submerged motor

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

NOTICE:

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

[ECM00401]

ZMU02860

ZMU02885

61

Consumer information

EMU29820

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY


62


63


64

EMU29841

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

U6M81EMC 09.4.2 10:05 AM ページ 3

Printed in FranceApril 2009–PDF × 1 !

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owner’s manual - yamaha motor company owner’s manual 6m8-f8199-1e u.s.a.edition lit-18626-08-33...

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