read this manual carefully before operating this outboard ... · pdf fileemu25062 zmu01690...

115

OWNER’S MANUAL

6N6-28199-1H

U.S.A.EditionLIT-18626-07-95

q Read this manual carefully before operating thisoutboard motor.

6N6-9-1H Hyoshi 08.2.21 9:42 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.

6N6-9-1H Hyoshi 08.2.21 9:42 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 115TR and the standard accessoriesare used as a base for the explanations andillustrations in this manual. Therefore someitems may not apply to every model.

EMU25111

115OWNER’S MANUAL

©2008 by Yamaha Motor Corporation, USA1st edition, April 2008

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

is expressly prohibited.Printed in Japan

P/N LIT-18626-07-95

Table of contents

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

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

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

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

Alcohol and drugs ............................. 2Personal flotation devices ................. 2People in the water ........................... 2Passengers ....................................... 2Overloading....................................... 2Avoid collisions ................................. 3Weather ............................................ 3Accident reporting ............................. 3Boat education and training .............. 3Passenger training ............................ 4Boating safety publications ............... 4Laws and regulations ........................ 4

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

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

Steering and sailing rules and sound signals.................................. 5

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

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

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

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

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

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

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

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

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

Remote control requirements........ 14Battery requirements..................... 14

Specifications of Battery..................14Mounting battery .............................14Multiple batteries .............................15

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

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

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

North American models...................17

Components .................................... 19

Components diagram.................... 19

Remote control box .........................19Remote control lever .......................20Neutral interlock trigger ...................20Neutral throttle lever ........................20Choke switch...................................21Throttle friction adjuster...................21Engine shut-off cord (lanyard) and

clip.................................................21Choke knob for pull type .................22Main switch .....................................22Power trim and tilt switch on

remote control ...............................22Power trim and tilt switch on

bottom engine cowling ..................23Trim tab with anode.........................23Tilt support lever for power trim

and tilt model.................................24Top cowling release lever ...............24Flushing device ...............................25

Instruments and indicators............ 26

Digital tachometer ......................... 26

Trim meter .......................................26Hour meter ......................................26Oil level indicator (digital type) ........26Overheat-alert indicator...................27

Digital speedometer ...................... 27

Speedometer...................................27

Table of contents

Fuel gauge ...................................... 28Trip meter / Clock / Voltmeter ......... 28Fuel level-alert indicator .................. 29Low battery voltage-alert

indicator ........................................ 29

Analog tachometer ........................ 29

Oil level indicators (three indicators 2) .................................. 29

Analog trim meter.......................... 30

Engine control system.................... 31

Alert system .................................. 31

Overheat alert ................................. 31Oil level alert and oil filter clogging

alert............................................... 31

Installation ....................................... 33

Installation ..................................... 33

Mounting the outboard motor .......... 33

Operation ......................................... 35

First-time operation ....................... 35

Breaking in engine .......................... 35Getting to know your boat ............... 35

Checks before starting engine ...... 35

Fuel level......................................... 36Remove cowling.............................. 36Fuel system..................................... 36Controls........................................... 36Engine shut-off cord (lanyard)......... 37Oil.................................................... 37Engine............................................. 37Operation after a long period of

storage.......................................... 37Flushing device ............................... 37Install cowling.................................. 38Checking power trim and tilt

system .......................................... 38Battery............................................. 39

Filling fuel and engine oil............... 40

Filling fuel for models without a fuel joint ........................................ 40

Filling oil .......................................... 40Oil level indicator operation............. 42

Operating engine........................... 43

Feeding fuel .................................... 43Starting engine................................ 43

Checks after starting engine ......... 45

Cooling water ..................................45

Warming up engine....................... 45

Choke start models .........................45

Checks after engine warm-up....... 45

Shifting ............................................45Stop switches ..................................45

Shifting.......................................... 46Stopping boat................................ 47Stopping engine............................ 47

Procedure........................................47

Trimming outboard motor.............. 47

Adjusting trim angle (Power trim and tilt) ..........................................48

Adjusting boat trim ..........................48

Tilting up and down....................... 49

Procedure for tilting up (power trim and tilt models)..............................50

Procedure for tilting down (power trim and tilt models).......................51

Shallow water................................ 51

Power trim and tilt models...............51

Cruising in other conditions........... 52

Maintenance .................................... 53

Transporting and storing outboard motor ........................... 53

Storing outboard motor ...................53Procedure........................................53Lubrication (oil injection models) .....54Cleaning and anticorrosion

measures ......................................55Flushing power unit .........................55Cleaning the outboard motor...........56Checking painted surface of

motor.............................................56

Periodic maintenance ................... 56

Replacement parts ..........................57Maintenance interval guidelines......57Maintenance chart 1........................58Maintenance chart 2........................60Greasing..........................................61Cleaning and adjusting spark

plug ...............................................61Checking fuel filter...........................62Inspecting idling speed....................62

Table of contents

Checking water in engine oil tank ... 63Checking wiring and connectors ..... 63Checking propeller .......................... 63Removing propeller ......................... 64Installing propeller ........................... 64Changing gear oil ............................ 65Inspecting and replacing

anode(s)........................................ 66Checking battery (for electric start

models) ......................................... 67Connecting the battery .................... 67Disconnecting the battery ............... 68

Trouble Recovery............................ 69

Troubleshooting ............................ 69Temporary action in emergency..... 72

Impact damage ............................... 72Replacing fuse ................................ 72Power trim and tilt will not

operate.......................................... 73Starter will not operate .................... 73Emergency starting engine ............. 74

Engine fails to operate .................. 75

Low oil level alert activates ............. 75

Top cowling does not unlock......... 76Treatment of submerged motor...... 76

Consumer information.................... 77

Important warranty information for U.S.A. and Canada ................ 77

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ...... 79

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA .............. 82

1

Safety information

EMU33622

Outboard motor safety

Observe these precautions at all times.

EMU36500

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.

●

Shut off 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.

EMU33660

Power trim and tilt

Body parts can be crushed between the mo-

tor and the clamp bracket when the motor istrimmed or tilted. Keep body parts out of thisarea at all times. Be sure no one is in thisarea before operating the power trim and tiltmechanism.The power trim and tilt switches operateeven when the main switch is off. Keep peo-ple be away from the switches wheneverworking around the motor.Never get under the lower unit while it is tilt-ed, even when the tilt support lever is locked.Severe injury could occur if the outboard mo-tor accidentally falls.

EMU33671

Engine shut-off cord (lanyard)

Attach the engine shut-off cord so that theengine 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 43 toreduce the risk of fire and explosion.

Safety information

2

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 ordeath 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. Yamaha

recommends 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.

EMU33730

People in the water

Always watch carefully for people in the wa-ter, such as swimmers, skiers, or divers,whenever the engine is running. Whensomeone is in the water near the boat, shiftinto neutral and shut off the motor.Stay away from swimming areas. Swimmerscan be hard to see.The propeller can keep moving even whenthe motor is in neutral. Shut off the enginewhen a person is in the water near you.

EMU33750

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-

Safety information

3

dling and lead to an accident, capsizing orswamping.

EMU33771

Avoid collisions

Scan constantly

for people, objects, andother boats. Be alert for conditions that limityour visibility or block your vision of others.

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. Avoid

boating 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,

ZMU06025

Safety information

4

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 geographiclocation, 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.

EMU33680

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 4051 859-225-9497859-225-9497www.nasbla.org

National Marine Manufacturers Associa-tion (NMMA)

200 East Randolph DriveSuite 5100Chicago, IL 606001www.nmma.org

Marine Retailers Association of America

155 N. Michigan Ave. Chicago,IL 60601www.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.

Safety information

5

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 othervessel 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 both

vessels 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 toany 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.

Safety information

6

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;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 younavigate 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.

Safety information

7

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 andblack 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.

EMU25190

Key number

If a main key switch is equipped with the mo-tor, the key identification number is stampedon your key as shown in the illustration.Record this number in the space provided forreference in case you need a new key.

1. Outboard motor serial number location

1. Key number

General information

10

EMU33520

Read manuals and labels

Before operating or working on this motor:

●

Read this manual.

●

Read any manuals supplied with the boat.

●

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

EMU33831

Warning labels

If these labels are damaged or missing, contact your Yamaha dealer for replacements.

ZMU06196

3

12

General information

11

1 2

3

ZMU05670

General information

12

EMU33843

Symbols

The following symbols mean as follows.

Notice/Warning

Read Owner’s Manual

Hazard caused by continuous rotation

Electrical hazard

Remote control lever/gear shift lever operat-ing direction, dual direction

Engine start/ Engine cranking

ZMU05696

ZMU05664

ZMU05665

ZMU05666

ZMU05667

ZMU05668

13

Specifications and requirements

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.

EMU2821C

Dimension:

Overall length: 808 mm (31.8 in)

Overall width: 582 mm (22.9 in)

Overall height L: 1472 mm (58.0 in)

Transom height L: 516 mm (20.3 in)

Weight (without propeller) L: 163.0 kg (359 lb)

Performance:

Full throttle operating range: 4500–5500 r/min

Maximum output: 84.6 kW@5000 r/min (115 HP@5000 r/min)

Idling speed (in neutral): 750

±

50 r/min

Engine:

Type: 2-stroke V

Displacement: 1730.0 cm

3

Bore

×

stroke: 90.0

×

68.0 mm (3.54

×

2.68 in)Ignition system:

CDISpark plug with resistor (NGK):

BR8HS-10

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

Control system: Remote control

Starting system: Electric

Starting carburetion system: Choke valve

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

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

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

Maximum generator output: 20.0 A

Drive unit:

Gear positions: Forward-neutral-reverse

Gear ratio: 2.00 (26/13)

Trim and tilt system: Power trim and tilt

Propeller mark: K

Fuel and oil:

Recommended fuel: Regular unleaded gasoline

Min. pump octane: 86

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

Lubrication: Oil injection

Engine oil tank capacity: 0.9 L (0.95 US qt, 0.79 Imp.qt)

Remote oil tank capacity: 10.5 L (11.10 US qt, 9.24 Imp.qt)

Recommended gear oil: Hypoid gear oil SAE#90


14

Gear oil quantity: 0.760 L (0.803 US qt, 0.669 Imp.qt)

Tightening torque for engine:

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

Propeller nut: 55.0 Nm (5.61 kgf-m, 40.6 ft-lb)

EMU33553

Installation requirements

EMU33563

Boat horsepower rating

WARNING

EWM01560

Overpowering a boat can cause severe

instability.

Before installing the outboard motor(s), con-firm that the total horsepower of your mo-tor(s) does not exceed the boats 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 page33.

EMU33581

Remote control requirements

WARNING

EWM01580

●

If the engine starts in gear, the boat can

move suddenly and unexpectedly, pos-sibly causing a collision or throwingpassengers overboard.

●

If the engine ever starts in gear, thestart-in-gear protection device is notworking correctly and you should dis-continue using the outboard. Contact

your Yamaha dealer.

The remote control unit must be equippedwith a start-in-gear protection device(s). Thisdevice prevents the engine from starting un-less it is in neutral.

EMU25694

Battery requirements

EMU25713

Specifications of Battery

Use a fully charged battery that meets thefollowing specifications. The engine cannotbe started if battery voltage is too low.

NOTICE

ECM01061

Do not use a battery that does not meetthe specified capacity. If a battery thatdoes not meet specifications is used, theelectric system could perform poorly orbe overloaded, causing electric system

damage.

EMU36290

Mounting battery

Mount the battery holder securely in a dry,well-ventilated, vibration-free location in the

Minimum cold cranking amps (CCA/SAE):

380.0 AMinimum marine cranking amps (MCA/ABYC):

502.0 AMinimum reserve capacity (RC/SAE):

124 minutes


15

boat.

WARNING! Do not put flammableitems, or loose heavy or metal objects inthe same compartment as the battery.Fire, explosion or sparks could result.

[EWM01820]

EMU36300

Multiple batteries

To connect multiple batteries, such as formultiple engine configurations or for an ac-cessory battery, consult your Yamaha dealerabout battery selection and correct wiring.

EMU34191

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 andevery 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 63.

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.

EMU25661

Engine oil requirements

Use Yamalube 2-M outboard oil. If Ya-malube 2-M is not available, use only anoth-er outboard motor manufacturer’s factory-brand oil with TC-W3 rating.

NOTICE

ECM01290

Serious engine damage can result fromthe use of lower quality oil, includingsome commonly available oil brands with“TC-W3” on their label. To avoid the risk,use only Yamalube 2-M or, if necessary,

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

Recommended engine oil:YAMALUBE 2 STROKE OUTBOARD OIL

ZMU04608

-x1 2 3


16

another outboard motor manufacturer’s

factory-brand TC-W3 oil.

EMU36360

Fuel requirements

EMU36780

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 (seeGasohol) gasoline whenever possible.

NOTICE

ECM01980

●

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 system

damage 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.

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.

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


17

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, theboat 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.

EMU36340

Motor disposal requirements

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

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 yourengine 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

ZMU04619

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


18

1. Manufactured date label location

1ZMU04618

19

Components

EMU2579H

Components diagramTIP:

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

115

EMU26181

Remote control box

The remote control lever actuates both theshifter and the throttle. The electrical switch-es are mounted on the remote control box.

4

7

8

9

10

1

2

3

5

6

12

11

13

14 15 16

17 18 19

ZMU04764

1. Top cowling2. Power trim and tilt switch3. Flushing device4. Tilt support lever5. Anti-cavitation plate6. Trim tab (anode)7. Propeller*8. Cooling water inlet9. Anode10. Clamp bracket11. Top cowling release lever12. Choke knob13. Cooling water pilot hole14. Remote control box (side mount type)*15. Digital tachometer*

16. Digital speedometer*17. Tachometer*18. Trim meter*19. Remote oil tank*

Components

20

EMU26190

Remote control lever

Moving the lever forward from the neutral po-sition engages forward gear. Pulling the le-ver back from neutral engages reverse. Theengine will continue to run at idle until the le-ver is moved about 35° (a detent can be felt).Moving the lever farther opens the throttle,and the engine will begin to accelerate.

EMU26201

Neutral interlock trigger

To shift out of neutral, first pull the neutral in-terlock trigger up.

EMU26211

Neutral throttle lever

To open the throttle without shifting into ei-ther forward or reverse, put the remote con-trol lever in the neutral position and lift theneutral throttle lever.

TIP:

The neutral throttle lever will operate onlywhen the remote control lever is in neutral.The remote control lever will operate onlywhen the neutral throttle lever is in the closedposition.

1. Power trim and tilt switch2. Remote control lever3. Neutral interlock trigger4. Neutral throttle lever5. Main switch / choke switch6. Engine stop lanyard switch7. Throttle friction adjuster

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”4. Shift5. Fully closed

6. Throttle7. Fully open

1. Neutral interlock trigger

Components

21

EMU26221

Choke switch

To activate the choke system, press in themain switch while the key is turned to the“ ” (on) or “ ” (start) position. Thechoke system will then supply the rich fuelmixture required to start the engine. Whenthe key is released, the choke will switch offautomatically.

EMU25973

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.

WARNING! Do not overtightenthe friction adjuster. If there is too much

resistance, it could be difficult to movethe remote control lever or throttle grip,which could result in an accident.

[EWM00032]

To decrease resistance, turn the adjustercounterclockwise.

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

EMU25993

Engine shut-off cord (lanyard) and clip

The clip must be attached to the engine shut-off switch for the engine to run. The 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 be

1. Fully open2. Fully closed

ZMU03160

Components

22

thrown forward.

[EWM00122]

EMU26011

Choke knob for pull type

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

EMU26090

Main switch

The main switch controls the ignition system;its operation is described below.

●

“ ”

(off)

With the main switch in the “ ” (off) posi-tion, the electrical circuits are off, and the keycan be removed.

●

“ ”

(on)

With the main switch in the “ ” (on) posi-tion, the electrical circuits are on, and the keycannot be removed.

●

“ ”

(start)

With the main switch in the “ ” (start) po-sition, the starter motor turns to start the en-gine. When the key is released, it returnsautomatically to the “ ” (on) position.

EMU32052

Power trim and tilt switch on remote control

The power trim and tilt system adjusts theoutboard motor angle in relation to the tran-som. Pressing the switch “ ” (up) trims theoutboard motor up, and then tilts it up. Press-ing the switch “ ” (down) tilts the outboardmotor down and trims it down. When theswitch is released, the outboard motor willstop in its current position. For instructionson using the power trim and tilt switch, seepages 47 and 49.

1. Cord2. Clip3. Engine shut-off switch

ZMU03903

Components

23

EMU26153

Power trim and tilt switch on bottom engine cowling

The power trim and tilt switch is located onthe side of the bottom engine cowling. Press-ing the switch “ ” (up) trims the outboardmotor up, and then tilts it up. Pressing theswitch “ ” (down) tilts the outboard motordown and trims it down. When the switch isreleased, the outboard motor will stop in itscurrent position.For instructions on using the power trim andtilt switch, see page 49.

WARNING

EWM01030

Use the power trim and tilt switch locatedon the bottom engine cowling only whenthe boat is at a complete stop with the en-gine off. Attempting to use this switchwhile the boat is moving could increasethe risk of falling overboard and coulddistract the operator, increasing the riskof collision with another boat or an obsta-

cle.

EMU26244

Trim tab with anode

WARNING

EWM00840

An improperly adjusted trim tab couldcause difficult steering. Always test runafter the trim tab has been installed or re-

placed to be sure steering is correct. Besure you have tightened the bolt after ad-

justing the trim tab.

The trim tab should be adjusted so that thesteering control can be turned to either theright or left by applying the same amount offorce.If the boat tends to veer to the left (port side),turn the trim tab rear end to the port side “A”in the figure. If the boat tends to veer to theright (starboard side), turn the trim tab end tothe starboard side “B” in the figure.

NOTICE

ECM00840

The trim tab also serves as an anode toprotect the engine from electrochemicalcorrosion. Never paint the trim tab as it

will become ineffective as an anode.

UP

DN

ZMU03517

1. Trim tab2. Bolt3. Cap

1

2

3

ZMU02525

A

B

Components

24

EMU26341

Tilt support lever for power trim and tilt model

To keep the outboard motor in the tilted upposition, lock the tilt support lever to theclamp 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.

EMU26400

Top cowling release lever

The top cowling can be removed by operat-ing the cowling release lever. Pulling thefront lever unlocks the top cowling for remov-al.

When installing the top cowling:1. Set the top cowling straight down onto

the engine, being careful to avoid catch-ing spark plug wires or other wires.

2. Align the three cowling hooks with thelocks on the bottom cowling.

3. Press down on the top of the cowling atthe front and both sides of the back untilthe three locks click.

4. To make sure the cowling is lockedproperly push the cowling from eachside. If it lifts, repeat step 3.

NOTICE

ECM00070

●

Make sure the cowling lock connection

Bolt tightening torque:42.0 Nm (4.2 kgf-m, 31 ft-lb)

1. Tilt support lever

AB

ZMU01863

ZMU03979

1

ZMU03518

ZMU03519

Components

25

cable is operating correctly before rein-stalling the top cowling.

●

When the release lever is operated,both the front and rear cowling hooksshould be released at the same time. Ifnot, adjust the rear clamp cable adjust-ers.

●

Make sure the cable operates smoothlyand is free of corrosion.

●

Check that the cable is properly se-cured in the holder.

●

When reinstalling the cowling, ensurethat both the front and rear locks haveoperated properly. If the cowling hasnot been locked properly, some partsmay be damaged by the top cowling

shaking during operation.

EMU26460

Flushing device

This device is used to clean the cooling wa-ter passages of the motor using a gardenhose and tap water.

TIP:

For details on usage, see page 55.

1. Flushing device

1

ZMU04139

26

Instruments and indicators

EMU26493

Digital tachometer

The tachometer shows the engine speedand has the following functions.All segments of the display will light momen-tarily after the main switch is turned on andwill return to normal thereafter.

TIP:

The water separator and engine trouble-alertindicators only operate when the engine isequipped with the appropriate functions.

EMU26621

Trim meter

This meter shows the trim angle of your out-board motor.

●

Memorize the trim angles that work bestfor your boat under different conditions.Adjust the trim angle to the desired usingthe power trim and tilt switch.

●

If the trim angle of your motor exceeds thetrim operating range, the top segment onthe trim meter display will blink.

EMU26651

Hour meter

This meter shows the number of hours theengine has been run. It can be set to showthe total number of hours or the number ofhours for the current trip. The display canalso be turned on and off.

To change the display format, press the“ ” (mode) button. The display can showtotal hours or trip hours, or turn off.To reset the trip hours, simultaneously pressthe “ ” (set) and “ ” (mode) buttons formore than 1 second while the trip hours aredisplayed. This resets the trip counter to 0(zero).The total number of hours the engine hasbeen run cannot be reset.

EMU26551

Oil level indicator (digital type)

This indicator shows the engine oil level. Ifthe oil level falls below the lower limit, the

1. Tachometer2. Trim meter3. Hour meter4. Oil level indicator5. Overheat-alert indicator6. Set button7. Mode button

1

3

56 7

4

2

ZMU01891

ZMU01869

ZMU01870


27

alert indicator will start to blink. For further in-formation, see page 31.

NOTICE

ECM00030

Do not operate the engine without oil. Se-

rious engine damage will occur.

EMU26583

Overheat-alert indicator

If the engine temperature rises too high, thealert indicator will start to blink. For further in-formation on reading the indicator, see page31.

NOTICE

ECM00052

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

gine damage will occur.

EMU26602

Digital speedometer

This gauge shows the boat speed and otherinformation.

All segments of the display will light momen-tarily after the main switch is turned on andwill return to normal thereafter.

EMU36061

Speedometer

The speedometer displays km/h, mph, orknots, according to operator preference. Se-lect the desired units of measurement by set-ting the selector switch on the back of thegauge. See the illustration for settings.

1. Oil level indicator

1ZMU01867

1

ZMU01868

1. Speedometer2. Fuel gauge3. Trip meter/clock/voltmeter4. Alert indicator(s)

1. Cap2. Selector switch (for speed unit)3. Selector switch (for fuel sensor)


28

EMU26712

Fuel gauge

Eight segments indicate the fuel level. Whenall segments are showing, the fuel tank isfull.

The fuel level reading can be inaccurate dueto by the position of the sensor in the fueltank and the attitude of the boat in the water.Operation with bow-up trim or continuousturning can give false readings.Do not adjust the selector switch for fuel sen-sor. Incorrectly setting the selector switch onthe gauge will give false readings. Consultyour Yamaha dealer on how to correctly setthe selector switch.

NOTICE:

Running outof fuel can damage the engine.

[ECM01770]

EMU36071

Trip meter / Clock / Voltmeter

The display shows either the trip meter, theclock, or the voltmeter.To change the display, press the “ ”(mode) button repeatedly until the indicatoron the face of the gauge points to “ ” (tripmeter), “ ” (clock), or “ ” (voltmeter).

EMU26691

Trip meter

This gauge displays the distance the boathas traveled since the gauge was last reset.The trip distance is shown in kilometers ormiles depending upon the unit of measure-ment selected for the speedometer.To reset the trip meter to zero, press the “ ”

(set) and “ ” (mode) buttons at the sametime.The trip distance is kept in memory by bat-tery power. The stored data will be lost if thebattery is disconnected.

EMU26701

Clock

To set the clock:1. Be sure the gauge is in the “ ” (time)

mode.2. Press the “ ” (set) button; the hour dis-

play will begin blinking.3. Press the “ ” (mode) button until the

desired hour is displayed.4. Press the “ ” (set) button again, the

minute display will begin blinking.5. Press the “ ” (mode) button until the

desired minute is displayed.6. Press the “ ” (set) button again to start

the clock.

The clock operates on battery power. Dis-

ZMU01745


29

connecting the battery will stop the clock.Reset the clock after connecting the battery.

EMU36080

Voltmeter

The voltmeter displays the charge of the bat-tery in volts(V).

EMU26721

Fuel level-alert indicator

If the fuel level decreases to one segment,the fuel level alert segment will blink.Do not continue to operate the engine withfull throttle if an alert device has activated.Get back to the port within trolling enginespeed.

NOTICE:

Running out of fuel candamage the engine.

[ECM01770]

EMU26732

Low battery voltage-alert indicator

If battery voltage drops, the display will auto-matically turn on and blink.Get back to the port soon if an alert devicehas activated. For charging the battery, con-sult your Yamaha dealer.

EMU26471

Analog tachometer

This gauge shows the engine speed and hasthe following functions.

EMU26541

Oil level indicators (three indicators 2)

The indicators on the gauge show the statusof the oil level. For details on how to read theindicators, see page 42.

NOTICE

ECM00030

Do not operate the engine without oil. Se-

rious engine damage will occur.

1. Fuel level-alert segment

1. Low battery indicator

1. Tachometer2. Oil level indicator

ZMU04577

1

2


30

EMU26611

Analog trim meter

This gauge shows the trim angle of your out-board motor.

Memorize the trim angles that work best foryour boat under different conditions. Adjustthe trim angle to the desired setting with thepower trim and tilt switch.

1. Oil level indicators

ZMU04580

1

ZMU04581

31

Engine control system

EMU26803

Alert system

NOTICE

ECM00091

Do not continue to operate the engine if aalert device has activated. Consult yourYamaha dealer if the problem cannot be

located and corrected.

EMU2681A

Overheat alert

This engine has an overheat-alert device. Ifthe engine temperature rises too high, thealert device will activate.

●

The engine speed will automatically de-crease to about 2000 r/min.

●

The overheat-alert indicator will light orblink.

●

The buzzer will sound (if equipped on thetiller handle, remote control box, or mainswitch panel).

If the alert system has activated, stop the en-gine and check the cooling water inlets:

●

Check trim angle to be sure that the cool-ing water inlet is submerged.

●

Check the cooling water inlet for clogging.

EMU26848

Oil level alert and oil filter clogging alert

Oil injection models

This engine has an oil level alert system. Ifthe oil level falls below the lower limit, thealert system will activate.

Activation of alert device

●

Engine speed will automatically decreaseto about 2000 r/min.

●

The oil level-alert indicator will light orblink.

ZMU01757

ZMU04766

ZMU02630

Engine control system

32

●

The buzzer will sound (if equipped on thetiller handle, remote control box, or mainswitch panel).

If the alert system has been activated, stopthe engine and check for the cause.

TIP:

The alert for oil filter clogging is similar to thealerts for low oil level and overheating. Tomake troubleshooting easier, check for en-gine overheating first, then oil level, and fi-

nally oil filter clogging.

ZMU03942

ZMU04586

ZMU03025

1. Oil filter

1. Oil filter

1

ZMU03906

1ZMU01952

33

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.

EMU33470

Mounting the outboard 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.

EMU26931

Mounting height (boat bottom)

The mounting height of your outboard motoraffects its efficiency and reliability. If it ismounted too high, propeller ventilation mayoccur, which will reduce propulsion due toexcessive propeller slip, and the water in-takes for the cooling system may not get ad-equate water supply, which can causeengine overheating. If the engine is mountedtoo low, water resistance (drag) will in-crease, thereby reducing engine efficiencyand performance.Most commonly, outboard motor should bemounted so that the anti-cavitation plate is inalignment with the bottom of the boat. Theoptimum mounting height of the outboardmotor is affected by the boat/motor combina-tion and the desired use. Test runs at differ-ent heights can help determine the optimummounting height. Consult your Yamaha deal-er or boat manufacturer for further informa-tion on determining the proper mountingheight.

1. Center line (keel line)

1 ZMU01873

Installation

34

NOTICE

ECM01630

●

During water testing, check the buoy-ancy of the boat, at rest, with its maxi-mum load. Check that the static waterlevel on the exhaust housing is lowenough to prevent water entry into thepower head when water rises due towaves when the outboard is not run-ning.

●

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.

ZMU01762

35

Operation

EMU36380

First-time operation

EMU27020

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

ECM00140

●

Failure to follow the break-in procedurecould result in reduced engine life oreven severe engine damage.

●

Premix fuel must be used during break-in in addition to oil in the oil injection

system.

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.

EMU30311

Procedure for oil injection 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 ontoplane, 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 onlystraight gasoline in the fuel tank. TheYamaha oil injection system providesproper lubrication for normal operation.

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 47).

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-

1. : Gasoline

2. : Engine oil

Operation

36

dent could occur.

NOTICE

ECM00120

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

occur.

EMU37150

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, turn the keyto “ ”(on) and check the fuel level. For fuelfilling instructions, see page 40.

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.

EMU36440

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.

EMU36450

Check for fuel leaks

●

Check under top cowling and in the boatfor fuel leaks or gasoline fumes.

●

Check fuel line connections to be sure theyare tight.

●

Check fuel lines for cracks, swelling, orother damage.

EMU37320

Check the fuel filter

Check that the fuel filter is clean and free ofwater. If any water is found in the fuel, or if asignificant amount of debris is found, the fueltank should be checked and cleaned by aYamaha dealer.

EMU36460

Controls

●

Turn the steering wheel full-right and full-left. Make sure operation is smooth andunrestricted throughout the whole rangewith no binding or excessive free play.

ZMU06101

ZMU04151

Operation

37

●

Operate the throttle levers several times tomake sure there is no hesitation in theirtravel. Operation should be smooth overthe complete range of motion, and each le-ver should return completely to the idle po-sition.

●

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

EMU36481

Engine shut-off cord (lanyard)

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

EMU27120

Oil

●

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

EMU27151

Engine

●

Check the engine and engine mounting.

●

Look for loose or damaged fasteners.

●

Check the propeller for damage.

●

Check for oil leaks.

EMU27171

Operation after a long period of storage

When operating the engine after a long peri-od (12 months) of storage, proceed as fol-

lows:1. Use a 50:1 gasoline-oil mixture to start

the engine.2. Start the engine. Leave it idling.

WARNING! Do not touch or removeelectrical parts when starting or dur-ing operation. Keep hands, hair, andclothes away from the flywheel andother rotating parts while the engineis running.

[EWM00091]

3. Watch for oil flowing through the oil feed

pipes. After any air in the oil lines hasbeen expelled, the oil injection systemshould supply oil normally. If no oil isflowing after 10 minutes of idling, consultyour Yamaha dealer.

NOTICE

ECM00130

Be sure to take the above steps when op-erating the engine after a long period ofstorage. Otherwise engine seizure could

occur.

EMU36490

Flushing device

Check that flushing device’s garden hoseconnector is securely screwed on to the fit-ting on the bottom cowling.

NOTICE:

If theflushing device is not properly connect-ed, cooling water can leak out and the en-gine can overheat during operation.

[ECM01800]

1. Cord2. Clip3. Engine shut-off switch ZMU04141

Operation

38

EMU37520

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 engine.

3. Set the top cowling straight down ontothe engine, being careful to avoid catch-ing spark plug wires or other wires.

4. Align the three cowling hooks with thelocks on the bottom cowling.

5. Press down on the top of the cowling atthe front and both sides of the back untilthe three locks click.

6. Check to be sure it fits properly in therubber seal.

7. Move the lever to lock the cowling asshown.

NOTICE:

If the cowling is notinstalled correctly, water spray under

the 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.

EMU29158

Checking power trim and tilt system

WARNING

EWM01930

●

Never get under the lower unit while itis tilted, even when the tilt support leveris locked. Severe injury could occur ifthe outboard motor accidentally falls.

●

Body parts can be crushed between themotor and the clamp bracket when themotor is trimmed or tilted.

●

Be sure no one is near the outboard

motor before performing this check.

1. Flushing device

1

ZMU04139

ZMU03519

ZMU06126

ZMU04679

Operation

39

1. Check the power trim and tilt unit for anysign of oil leaks.

2. Operate each of the power trim and tiltswitches on the remote control and en-gine bottom cowling to check that allswitches work.

3. Tilt the outboard motor up and checkthat the tilt rod and trim rods are extend-ed completely.

4. Use the tilt support lever to lock the mo-tor in the up position. Operate the tiltdown switch briefly so the motor is sup-ported by the tilt support lever.

5. Check that the tilt rod and trim rods arefree of corrosion or other flaws.

6. Activate the tilt-down switch until the trim

rods have retracted completely into thecylinders.

7. Activate the trim-up switch until the tiltrod is fully extended. Unlock the tilt sup-port lever.

8. Tilt the outboard motor down. Checkthat the tilt rod and trim rods operatesmoothly.

EMU36581

Battery

Check that the battery is in good condition,and fully charged. Check that the batteryconnections are clean, secure and coveredby insulating covers. The electrical contactsof the battery and cables must be clean andproperly connected or the battery will notstart the engine.Refer to the battery manufacturer’s instruc-tions for checks for your particular battery.

1. Tilt rod2. Trim rods

1. Tilt support lever

ZMU03458

1

2

ZMU04155

1

ZMU04156

ZMU02635

Operation

40

EMU27234

Filling fuel and engine oil

EMU30321

Filling fuel for models without a fuel joint

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. Stop the engine.2. Be sure you are in a well-ventilated out-

door area, either securely moored ortrailered.

3. Make sure no one is in the boat.4. Do not smoke and keep away from

sparks, flames, static electric discharge,or other sources of ignition.

5. If you use a portable container to storeand dispense fuel, only use a locally ap-proved GASOLINE container.

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

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

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

ly with dry rags. Dispose rags properly.

According to local laws or regulations.

EMU27282

Filling oil

This engine uses the Yamaha oil injectionsystem, which provides superior lubricationby ensuring the proper oil ratio for all operat-ing conditions. No fuel premixing is needed.Simply pour gasoline into the fuel tank andoil into the oil tank. Convenient indicator seg-ments indicate the status of the oil supply.For details on reading the indicator seg-ments, see page 42.

WARNING

EWM00530

Do not add gasoline into the oil tank. Fire

or explosion could result.

To fill the engine oil tank, proceed as follows:1. Pour engine oil into the remote oil tank.

TIP:

The oil level lines on the remote oil tank indi-cate the amount of additional oil that can beadded to the tank. The top oil level line indi-cates approximately 1.9 L (0.5 US gal, 0.4Imp gal) can be added, and the bottom oillevel line indicates approximately 3.8 L (1 USgal, 0.8 Imp gal) can be added.2. Turn on the main switch. The Yamaha

Engine oil tank capacity:0.9 L (0.95 US qt, 0.79 Imp.qt)

ZMU04142

Operation

41

oil injection system will automaticallyfeed oil from the remote oil tank to theengine oil tank.

3. After the engine oil tank has filled, turnoff the main switch to cancel the oil levelalert.

4. Operate the engine normally.

NOTICE

ECM00570

When the engine is operated for the firsttime or stored for a period of time, a min-imum of 5 liters (5.3 US qt, 4.4 Imp qt) ofoil should be kept in the remote oil tank.Otherwise the oil-feed pump chamber willnot be filled with oil, and no oil will be

supplied.

ON STARTOFF

ZMU04143

ON STARTOFF

ZMU04144

Operation

42

EMU27321

Oil level indicator operation

The various functions of the oil level system are as follows:

EMU27383

Oil level indicator

Electric start models

Oil level-alert indicator (digital

tachometer)

Oil level-alert indicator (analog

tachometer)

Engine oil tank

Remote oil tank

Remarks

Green

more than 300

cm

3

(0.32 US qt, 0.26

Imp qt)

more than

1500 cm

3

(1.6 US qt, 1.31

Imp qt)

●

No refilling necessary.

Yellow

more than 300

cm

3

(0.32 US qt, 0.26

Imp qt)

1500 cm

3

(1.6 US qt, 1.31 Imp qt) or less

●

Add oil; see page 40.

Red–Yellow–Green

300 cm

3

(0.32 US qt, 0.26

Imp qt) or less

more than

1500 cm

3

(1.6 US qt, 1.31 Imp qt)

●

Check oil filter for clog-ging.

●

Check battery cable connection. Buzzer will sound.

●

Engine speed is auto-matically reduced to about 2000 r/min.

Red

300 cm

3

(0.32 US qt, 0.26

Imp qt) or less

1500 cm

3

(1.6 US qt, 1.31 Imp qt) or less

●

Oil has not been added.

●

Buzzer will sound.

●

Engine speed is auto-matically reduced to about 2000 r/min.

●

Buzzer sounds in remote control box and engine speed is limited to about 2000 r/min to help conserve oil.

Operation

43

EMU27451

Operating engine

EMU27482

Feeding fuel

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.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 or a fuel cock on theboat, firmly connect the fuel line to thejoint or open the fuel cock.

3. Squeeze the primer pump, with the ar-row pointing up, until you feel it becomefirm.

EMU27492

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.

EMU27645

Electric start / remote control models

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 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 to

be thrown forward.

1. Place the remote control lever in neutral.

ZMU02025

Operation

44

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. Turn the main switch to “ ” (on).

4. Open the throttle slightly without shifting

using the neutral throttle lever or free ac-celerator. You may need to change thethrottle opening slightly depending onengine temperature. After the enginestarts, return the throttle to the originalposition.

TIP:

●

On remote controls equipped with a neu-tral throttle lever, a good starting point is tolift the lever just until you feel resistance,then lift slightly more.

●

The neutral throttle lever or free accelera-tor can only be used when the remote con-trol lever is in neutral.

5. Press in and hold the main switch to op-erate the remote choke system. The re-mote choke switch automatically returnsto its normal position when you releaseyour hand. Therefore keep the switchpressed in.

TIP:

●

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

●

Push in the main switch fully, or the remotechoke system will not operate.

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

OFF

ON

ZMU01880

N

ZMU02314

Operation

45

7. Immediately after the engine starts, re-lease the main switch and allow it to re-turn to “ ” (on).

NOTICE:

Never turnthe main switch to “ ” (start)while the engine is running. Do notkeep the starter motor turning formore than 5 seconds. If the startermotor is turned continuously formore than 5 seconds, the battery willbe quickly discharged, thus making itimpossible to start the engine. Thestarter can also be damaged. If theengine will not start after 5 secondsof cranking, return the main switch to“ ” (on), wait 10 seconds, thencrank the engine again.

[ECM00192]

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 willshorten 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.

EMU31721

Stop switches

●

Confirm that turning the main switch to the“ ” (off) position stops the engine.

ZMU03262

ONSTARTOFF

ZMU03908

Operation

46

●

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.

EMU31730

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. Pull the neutral interlock trigger up (if

equipped).

2. Move the remote control lever firmly andcrisply forward (for forward gear) orbackward (for reverse gear) about 35° (adetent can felt).

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 remote control lever firmly andcrisply into the neutral position.

1. Neutral interlock trigger

Operation

47

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.

EMU27853

Procedure

1. Turn the main switch to “ ” (off).

2. After stopping the engine, disconnect

the fuel line or close the fuel cock if thereis a fuel joint or a fuel cock on the boat.

3. Tighten the air vent screw on the fueltank cap (if equipped).

4. Remove the key if the boat will be leftunattended.

TIP:

The engine can also be stopped by pullingthe cord and removing the clip from the en-gine shut-off switch, then turning the mainswitch to “ ” (off).

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.

Operation

48

EMU27884

Adjusting trim angle (Power trim and tilt)

WARNING

EWM00753

●

Be sure all people are clear of the out-board motor when adjusting the trimangle. Body parts can be crushed be-tween the motor and the clamp bracketwhen the motor is trimmed or tilted.

●

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 trimangle can cause loss of control.

●

If equipped with a power trim and tiltswitch located on the bottom cowling,use the switch only when the boat is ata complete stop with the engine off. Donot adjust the trim angle with this

switch while the boat is moving.

Adjust the outboard motor trim angle usingthe power trim and tilt switch.

To raise the bow (trim-out), press the switch“ ” (up).To lower the bow (trim-in), press the switch“ ” (down).Make test runs with the trim set to differentangles to find the position that works best foryour boat and operating conditions.

EMU27911

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 thebow up, the boat may have a greater tenden-

1. Trim operating angle

1 ZMU04145

1. Power trim and tilt switch

1. Power trim and tilt switch

UP

DNZMU03522

1

Operation

49

cy to steer to one side or the other. Compen-sate for this as you steer. The trim tab canalso be adjusted to help offset this effect.When the bow of the boat is down, it is easierto accelerate from a standing start ontoplane.

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 speeds

also makes the boat unstable. Resistance atthe 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.

EMU27934

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

EWM00250

Leaking fuel is a fire hazard. If there is afuel joint on the outboard motor, discon-nect the fuel line or close the fuel cock ifthe engine will be tilted for more than a

Operation

50

few minutes. Otherwise fuel may leak.

NOTICE

ECM00241

●

Before tilting the outboard motor, stopthe engine by following the procedureon page 47. Never tilt the outboard mo-tor while the engine is running. Severedamage from overheating can result.

●

Do not tilt up the engine by pushing thetiller handle (if equipped) because this

could break the handle.

EMU32723

Procedure for tilting up (power trim and tilt models)


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

3. Pull the tilt support lever toward you tosupport the engine.

WARNING! Aftertilting the outboard motor, be sure tosupport it with the tilt support knob ortilt support lever. Otherwise the out-board motor could fall back downsuddenly if oil in the power trim andtilt unit or in the power tilt unit losespressure.

[EWM00262]

NOTICE:

Do not usethe tilt support lever or knob whentrailering the boat. The outboard mo-tor could shake loose from the tiltsupport and fall. If the motor cannotbe trailered in the normal running po-sition, use an additional support de-vice to secure it in the tilt position.For more detailed information, seepage 53.

[ECM01641]

4. Models equipped with trim rods: Oncethe outboard motor is supported with thetilt support lever, press the power trim

N

ZMU03196

UP

ZMU04146

ZMU03432

Operation

51

and tilt switch “ ” (down) to retract thetrim rods.

NOTICE:

Be sure to retractthe trim rods completely duringmooring. This protects the rods frommarine growth and corrosion whichcould damage the power trim and tiltmechanism.

[ECM00251]

EMU33120

Procedure for tilting down (power trim and tilt models)

1. Push the power trim and tilt switch “ ”(up) until the outboard motor is support-ed by the tilt rod and the tilt support leverbecomes free.

2. Release the tilt support lever.

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

EMU28061

Shallow water

EMU32851

Power trim and tilt models

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

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.

EMU32922

Procedure for power trim and tilt models


ZMU03452

ZMU03453

DN

ZMU01936

UP

DN

DN

ZMU04147

Operation

52

2. Slightly tilt the outboard motor up to thedesired position using the power trimand tilt switch.

WARNING! Using thepower trim and tilt switch on the bot-tom cowling while the boat is movingor engine is on could increase therisk of falling overboard and coulddistract the operator, increasing therisk of collision with another boat oran obstacle.

[EWM01850]

3. To return the outboard motor to the nor-

mal running position, press the powertrim and tilt switch and slowly tilt the out-board motor down.

EMU28194

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the coolingwater passages with fresh water to preventthem from becoming clogged. Also rinse theoutside of the outboard motor with fresh wa-ter and, if possible, rinse the power head un-der the cowling.

Cruising in muddy, turbid, or acidic water

Yamaha strongly recommends that you usethe optional chromium-plated water pump kit(see page 17) 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.

UP

ZMU01935

UP

DN

UP

ZMU04146

53

Maintenance

EMU28226

Transporting and storing outboard motor

WARNING

EWM00692

●

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

●

DO NOT fill fuel container to 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.

EMU30272

Storing outboard motor

When storing your Yamaha outboard motor

for 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-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.

EMU28303

Procedure

EMU28383

Flushing with the flushing attachment

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 56.

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 and

ZMU04154

Maintenance

54

Stabilizer” 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 top cowling and silencer

cover/cap. Remove the propeller.4. Install the flushing attachment over the

cooling water inlet.

NOTICE:

Do not runthe engine without supplying it withcooling water. Either the engine wa-ter pump will be damaged or the en-gine will be damaged fromoverheating. Before starting the en-gine, be sure to supply water to thecooling water passages. Avoid run-ning the outboard motor at highspeed while on the flushing attach-ment, otherwise overheating couldoccur.

[ECM02000]

5. Cooling system flushing is essential toprevent the cooling system from clog-ging up with salt, sand, or dirt. In addi-tion, fogging/lubricating of the engine ismandatory to prevent excessive enginedamage due to rust. Perform the flush-ing and fogging at the same time.

WARNING! Do not touch or removeelectrical parts when starting or dur-ing operation. Keep hands, hair, and

clothes away from the flywheel andother rotating parts while the engineis running.

[EWM00091]

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

minutes in neutral position while supply-ing fresh water.

7. Just prior to turning off the engine, quick-ly spray “Yamaha Stor-Rite EngineFogging Oil” alternately into each carbu-retor/each intake manifold. When prop-erly done, the engine will smokeexcessively and almost stall.

8. Remove the flushing attachment andwipe off any excess water.

9. Install the silencer cover/cap and topcowling. Install the propeller.

TIP:

A flushing attachment is available from yourYamaha dealer.

EMU28411

Lubrication (oil injection models)

1. Install the spark plug(s) and torque toproper specification. For information onspark plug installation, see page 61.

2. Fill the oil tanks. This prevents the for-mation of condensation. For models witha remote oil tank, it may be necessary tomanually override the control unit tocompletely fill the engine oil tank.

3. Change the gear oil. For instructions,see page 65. Inspect the oil for the pres-ence of water which indicates a leakyseal. Seal replacement should be per-formed by an authorized Yamaha dealerprior to use.

4. Grease all grease fittings. For further de-tails, see page 61.

TIP:

For long-term storage, fogging the enginewith oil is recommended. Contact yourYamaha dealer for information about fogging

1. Flushing attachment

Maintenance

55

oil 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”.

EMU28443

Flushing power unit

Perform this procedure right after operationfor the most thorough flushing.

NOTICE

ECM01530

Do not perform this procedure while theengine is running. The water pump maybe damaged and severe damage from

overheating can result.

1. After shutting off the engine, unscrewthe garden hose connector from the fit-ting on the bottom cowling.

2. Screw the garden hose adapter onto agarden hose, which is connected to afresh water supply, and then connect itto the garden hose connector.

3. With the engine off, turn on the water tapand let the water flush through the cool-ing passages for about 15 minutes. Turnoff the water and disconnect the gardenhose adapter from the garden hose con-nector.

4. Reinstall the garden hose connectoronto the fitting on the bottom cowling.Tighten the connector securely.

NO-TICE:

Do not leave the garden hoseconnector loose on the bottom cowl-ing fitting or let the hose hang freeduring normal operation. Water willleak out of the connector instead of

1. Fitting2. Garden hose connector3. Garden hose

12 3

ZMU04148

Maintenance

56

cooling the engine, which can causeserious overheating. Be sure the con-nector is tightened securely on thefitting after flushing the engine.

[ECM00541]

TIP:

●

When flushing the engine with the boat inthe water, tilting up the outboard motor un-til it is completely out of the water willachieve better results.

●

For cooling system flushing instructions,see page 53.

EMU28450

Cleaning the outboard motor

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

TIP:

For cooling system flushing instructions, seepage 53.

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.

EMU2848A

Periodic maintenance

WARNING

EWM01871

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 the key(s)and engine shut-off cord (lanyard) withyou when you perform maintenanceunless otherwise specified.

●

The power trim and tilt switches oper-ate even when the ignition key is off.Keep people away from the switcheswhenever working around the motor.When the motor is tilted, keep awayfrom the area under it or between it andthe clamp bracket. Be sure no one is inthis area before operating the powertrim and tilt mechanism.

●

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

●

Always completely reassemble the mo-

tor before operation.

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

ZMU02550

Maintenance

57

have 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

58

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

Battery (electrolyte level, terminal)

Inspection

Battery (electrolyte level, terminal)

Fill, charging or replac-ing as necessary

Cooling water leakageInspection or replace-ment as necessary

Cowling clamp Inspection

Engine starting condi-tion/Noise

Inspection

Engine idling speed/Noise

Inspection

Fuel filter (can be dis-assembled)


Fuel line(High pres-sure)

Inspection

Maintenance

59

Fuel line(High pres-sure)


Fuel line(Low pres-sure)

Inspection

Fuel line(Low pres-sure)


Fuel pumpInspection or replace-ment as necessary

Fuel/oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Impeller/water pump housing


Impeller/water pump housing

Replacement

Oil tank water drain Inspection or cleaning

Oil injection pump/oil feed pump

Inspection or Adjust-ment

Power trim & tilt unit/Operation,noise and oil leakage

Inspection

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/high tension cords


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

Item Actions

Initial Every

20 hours (3

months)

100 hours (1

year)

300 hours (3 years)

500 hours (5 years)

Maintenance

60

EMU34451

Maintenance chart 2

Main switch/stop switch/choke switch


(Yamaha) Meter/gauge Inspection

Item ActionsEvery

1000 hours

Guide exhaust/exhaust manifold


Item Actions

Initial Every

20 hours (3

months)

100 hours (1

year)

300 hours (3 years)

500 hours (5 years)

Maintenance

61

EMU28932

Greasing

Yamaha marine grease (Water resistant grease)

115

EMU28955

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 very

white, this could indicate an intake air leak orcarburetion problem in that cylinder. Do notattempt 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 plug

ZMU04149

Maintenance

62

to slowly break down and erode. If electrodeerosion becomes excessive, or if carbon andother deposits are excessive, you should re-place the spark plug with another of the cor-rect type.1. Remove the spark plug caps from the

spark plugs.2. Remove the spark plug. If electrode ero-

sion becomes excessive, or if 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; adjust the gap to spec-ification if necessary.

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

EMU37450

Checking fuel filter

Check the fuel filter periodically. If any wateror foreign matter is found in the filter, clean orreplace it. For cleaning or replacement of thefuel filter, consult your Yamaha dealer.

EMU29041

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

Standard spark plug:BR8HS-10

1. Spark plug gap2. Spark plug I.D. mark (NGK)3. Spark plug part number

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)

ZMU04151

Maintenance

63

parts while the engine is running.

NOTICE

ECM00490

This procedure must be performed whilethe outboard motor is in the water. Aflushing attachment or test tank can be

used.

A diagnostic tachometer should be used forthis procedure. Results may vary dependingon whether testing is conducted with theflushing attachment, in a test tank, or with theoutboard motor in the water.1. Start the engine and allow it to warm up

fully in neutral until it is running smooth-ly.

TIP:

Correct idling speed inspection is only possi-ble if the engine is fully warmed up. If notwarmed up fully, the idle speed will measurehigher than normal. If you have difficulty ver-ifying the idle speed, or the idle speed re-quires adjustment, consult a Yamaha dealeror other qualified mechanic.2. Verify whether the idle speed is set to

specification. For idle speed specifica-tions, see page 13.

EMU29050

Checking water in engine oil tank

Oil injection models

There is a water trap at the bottom of the en-gine oil tank. If water or foreign matter is vis-ible in this trap, consult your Yamaha dealer.

EMU29112

Checking wiring and connectors

●

Check that each grounding wire is properlysecured.

●

Check that each connector is engaged se-curely.

EMU32111

Checking propeller

WARNING

EWM01880

You could be seriously injured if the en-gine accidentally starts when you arenear the propeller.

●

Before inspecting, removing, or install-ing the propeller, place the shift controlin neutral, turn the main switch to “ ”(off) and remove the key, and removethe clip from the engine shut-off switch.

1. Water trap2. Engine oil tank

21

ZMU01895

ZMU03915

Maintenance

64

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 forwear, erosion from cavitation or ventila-tion, or other damage.

●

Check the propeller shaft for damage.

●

Check the splines for wear or damage.

●

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

●

Check the propeller shaft oil seal for dam-age.

EMU30661

Removing propeller

EMU29197

Spline models

1. Straighten the cotter pin and pull it 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.

EMU30671

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 propeller

ZMU01897

1. Cotter pin2. Propeller nut3. Washer4. Spacer5. Propeller6. Thrust washer

Maintenance

65

shaft.2. Install the spacer (if equipped), thrust

washer, washer (if equipped), and pro-peller on the propeller shaft.

NOTICE:

Be sure to install the thrust 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 securelyfastened to the transom or a stable

stand. 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 has

Propeller nut tightening torque:55.0 Nm (5.61 kgf-m, 40.6 ft-lb)

ZMU03545

1. Gear oil drain screw2. Oil level plug

ZMU03273

2

1

Maintenance

66

been 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 oildrain screw.

EMU29312

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

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:0.760 L (0.803 US qt, 0.669 Imp.qt)

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

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

ZMU03274

ZMU01901

ZMU03461

Maintenance

67

EMU29322

Checking battery (for electric start models)

WARNING

EWM01900

Battery electrolytic fluid is poisonousand caustic, and batteries generate ex-plosive hydrogen gas. When workingnear the battery:

●

Wear protective eye gear and rubbergloves.

●

Do not smoke or bring any other sourceof ignition near the battery.

Refer to page 14 for detailed safety infor-

mation about batteries.

The procedure for checking the battery var-ies for different batteries. This procedurecontains typical checks that apply to manybatteries, but you should always refer to thebattery manufacturer’s instructions.

NOTICE

ECM01920

A poorly maintained battery will quickly

deteriorate.

1. Check the electrolyte level.

2. Check the battery’s charge. If your boatis equipped with the digital speedome-ter, the voltmeter and low battery alertfunctions will help you monitor the bat-tery’s charge. If the battery needs charg-

ing, consult your Yamaha dealer.3. Check the battery connections. They

should be clean, secure, and covered byan insulating cover.

WARNING! Badconnections can produce shorting orarcing and cause an explosion.

[EWM01910]

EMU29333

Connecting the battery

WARNING

EWM00570

Mount the battery holder securely in adry, well-ventilated, vibration-free loca-tion in the boat. Install a fully charged bat-

tery in the holder.

NOTICE

ECM01123

Reversal of the battery cables will dam-

age the electrical parts.

1. Make sure the main switch (on applica-ble models) is “ ” (off) before workingon the battery.

2. Connect the red battery cable to thePOSITIVE (+) terminal first. Then con-nect the black battery cable to the NEG-ATIVE (-) terminal.

3. The electrical contacts of the battery and

1. Red cable2. Black cable3. Battery

Maintenance

68

cables must be clean and properly con-nected, or the battery will not start theengine.

EMU29371

Disconnecting the battery

1. Turn off the battery cut-off switch (ifequipped) and main switch.

NOTICE:

Ifthey are left on, the electrical systemcan be damaged.

[ECM01930]

2. Disconnect the negative cable(s) from

the negative (-) terminal.

NOTICE:

Al-ways disconnect all negative (-) ca-bles first to avoid a short circuit anddamage to the electrical system.

[ECM01940]

3. Disconnect the positive cable(s) and re-

move the battery from the boat.4. Clean, maintain, and store the battery

according to the manufacturer’s instruc-tions.

69

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 43.

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

70

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

71

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

72

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.

EMU29463

Replacing fuse

If the fuse has blown on an electric startmodel, open the fuse holder and replace thefuse with a new one of the proper amperage.

WARNING

EWM00631

Substituting an incorrect fuse or a pieceof wire could allow excessive currentflow. This could cause electric system

damage and a fire hazard.

Trouble Recovery

73

Consult your Yamaha dealer if the new fuseimmediately blows again.

EMU29524

Power trim and tilt will not operate

If the engine cannot be tilted up or down withthe power trim and tilt because of a dis-charged battery or a failure with the powertrim and tilt unit, the engine can be tiltedmanually.1. Loosen the manual valve screw by turn-

ing it counterclockwise until it stops.

2. Put the engine in the desired position,then tighten the manual valve screw byturning it clockwise.

EMU29533

Starter will not operate

If the starter mechanism does not operate(the engine cannot be cranked with the start-er), the engine can be started with an emer-gency starter rope.

WARNING

EWM01022

●

Use this procedure only in an emergen-cy to return to the nearest port for re-pairs.

●

When the emergency starter rope 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, whichcould 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-

1. Fuse holder2. Fuse (20 A, 30 A)

1. Manual valve screw

1

2

ZMU04152

ZMU03464

1

Trouble Recovery

74

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 43. 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.

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 crank

ZMU03920

ZMU02334

ON STARTOFF

ZMU01906

ZMU03921

Trouble Recovery

75

and start the engine. Repeat if neces-sary.

EMU29671

Engine fails to operate

EMU29742

Low oil level alert activates

If the oil level is allowed to drop too low, thered segment will appear on the oil level indi-cator, the buzzer will sound, and enginespeed will be limited to about 2000 r/min. Ifthis happens, a reserve amount of oil can bepumped from the remote oil tank to the en-gine oil tank using the emergency switch.

WARNING

EWM01050

Be sure to stop the engine before per-

forming this procedure.

NOTICE

ECM00901

●

If the emergency switch is held up toolong, too much oil will be pumped intothe engine oil tank, overflowing it. Re-lease the switch when oil reaches theupper level line on the engine oil tank.

●

Do not use this emergency procedureunless the oil level-alert indicators are

working.

1. Remove the top cowling.2. Turn on the main switch.

3. Lift the emergency switch to pump re-serve oil into the engine oil tank from theremote oil tank.

4. After using the emergency switch, turnoff the main switch, then turn it back on.This resets the alert system to normal

ZMU03466

1. Emergency switch

1. Engine oil tank2. Remote oil tank

ON STARTOFF

ZMU01906

1

ZMU04153

1 2ZMU01908

Trouble Recovery

76

operation. The yellow segment will con-tinue to be displayed on the oil level indi-cator.

5. Start the engine and return to the near-est port for more oil.

TIP:

●

The maximum reserve oil capacity is 1500cm

3

(1.6 US qt, 1.31 Imp qt).

●

The oil-feed pump will not operate if theengine is tilted up more than 35°. Put theengine in the upright position (not tilted)before using the emergency switch.

EMU29751

Top cowling does not unlock

If the top cowling stays locked when the re-lease lever is operated, the cable may bedamaged or incorrectly adjusted.1. Pull the cowling release lever to unlock

the front lock.

2. Pull the emergency cowling release wirecoming out of the hole on the side of thepilot hole in the bottom cowling to re-lease the port side rear lock.

3. Lift the port side of the top cowling to pullout the emergency cowling release wirefrom the port side of the bottom cowling.

4. Pull the emergency cowling release wire

to release the starboard side rear lock.

NOTICE:

Be sure the problem withthe cowling lock is repaired before re-installing the cowling.

[ECM00391]

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]

1. Cowling release lever2. Starboard-side cowling release wire3. Port-side cowling release wire

1

2

3

ZMU03544

77

Consumer information

EMU29811

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


78


79

EMU29820

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


80


81


82

EMU29841

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

6N6-9-1H Hyoshi 08.2.21 9:42 ページ 3

Printed in JapanApril 2008-0.3 × 1 ! Printed on recycled paper

6N6-9-1H Hyoshi 08.2.21 9:42 ページ 4

read this manual carefully before operating this outboard ... · pdf fileemu25062 zmu01690...

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