8OWNERS MANUAL

6M8-F8199-1B

U.S.A.EditionLIT-18626-06-91

U6M81BMC 06.2.9 16:00 1

EMU25060

ZMU01690

Read this owners manual carefully before operating your outboard motor.

U6M81BMC 06.2.9 16:00 2

Important manual information

EMU31280

To the owner

Thank you for choosing a Yamaha outboardmotor. This Owners 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 Owners Manual particularly importantinformation is distinguished in the followingways.

The Safety Alert Symbol meansATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

WARNING

EWM00780

Failure to follow WARNING instructionscould result in severe injury or death tothe machine operator, a bystander, or aperson inspecting or repairing the out-

board motor.

CAUTION:

ECM00700

A CAUTION indicates special precautionsthat must be taken to avoid damage to the

outboard motor.

NOTE:

A NOTE provides key information to make

procedures easier or clearer.

Yamaha continually seeks advancements 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. Ifthere is any question concerning this manu-

al, please consult your Yamaha dealer.NOTE:

The 8MH and the standard accessories areused as a base for the explanations and illus-trations in this manual. Therefore some

items may not apply to every model.

EMU25130

8OWNERS MANUAL

2006 by Yamaha Motor Corporation, USA1st Edition, January 2006

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

is expressly prohibited.Printed in France

P/N LIT-18626-06-91

Table of contents

General information .......................... 1

Identification numbers record.......... 1

Outboard motor serial number .......... 1

Emission control information ........... 1

North American models..................... 1

Safety information ........................... 2Important labels............................... 3

Warning labels .................................. 3

Basic boating rules (Rules of the road) ........................ 4

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

Rules when encountering vessels .... 4Other special situations..................... 6

Fueling instructions ......................... 7

Gasoline............................................ 8Engine oil .......................................... 8

Propeller selection........................... 8Start-in-gear protection ................... 9

Basic components .......................... 10

Main components.......................... 10

Fuel tank ......................................... 10Fuel joint ......................................... 11Fuel gauge ...................................... 11Fuel tank cap .................................. 11Air vent screw ................................. 11Tiller handle .................................... 11Gear shift lever................................ 11Throttle grip ..................................... 11Throttle indicator ............................. 12Throttle friction adjuster................... 12Engine stop lanyard switch ............. 12Engine stop button .......................... 13Choke knob for pull type ................. 13Manual starter handle ..................... 13Steering friction adjuster ................. 13Trim rod (tilt pin) .............................. 14Shallow water lever ......................... 14Tilt support knob ............................. 14Top cowling lock lever(s)

(turn type) ..................................... 14

Operation ......................................... 16

Installation ..................................... 16

Mounting the outboard motor .......... 16Clamping the outboard motor ......... 17

Breaking in engine ........................ 18

Gasoline and engine oil mixing chart (25:1)....................................18

Procedure for pre-mixed models.....18

Preoperation checks ..................... 19

Fuel .................................................19Oil ....................................................19Controls...........................................19Engine .............................................19

Filling fuel and engine oil .............. 19

Filling fuel for portable tank .............19Gasoline and oil mixing (100:1).......19

Operating engine .......................... 20

Feeding fuel (portable tank) ............20Starting engine ................................21

Warming up engine....................... 23

Choke start models .........................23

Shifting.......................................... 23

Forward (tiller handle and remote control models) .............................23

Reverse (manual tilt and hydro tilt models) .........................................24

Stopping engine............................ 24

Procedure........................................24

Trimming outboard motor.............. 25

Adjusting trim angle for manual tilt models ..........................................26

Adjusting boat trim ..........................26

Tilting up and down....................... 27

Procedure for tilting up (manual tilt models) .........................................28

Procedure for tilting down (manual tilt models).....................................29

Cruising in shallow water .............. 29

Cruising in shallow water (manual tilt models).....................................29

Cruising in other conditions........... 30

Maintenance .................................... 31

Specifications................................ 31Transporting and storing outboard

motor ........................................... 32

Clamp screw mounting models .......32Storing outboard motor ...................32Procedure........................................33Lubrication (except oil injection

Table of contents

models) ......................................... 34Cleaning and anticorrosion

measures ...................................... 34Cleaning the outboard motor .......... 34Checking painted surface of

motor............................................. 34

Periodic maintenance.................... 34

Replacement parts .......................... 35Maintenance chart .......................... 36Greasing ......................................... 37Cleaning and adjusting spark

plug ............................................... 37Checking fuel system...................... 38Checking fuel filter .......................... 39Inspecting idling speed ................... 39Checking wiring and connectors ..... 39Exhaust leakage ............................. 40Water leakage................................. 40Checking propeller .......................... 40Removing the propeller ................... 41Installing the Propeller .................... 41Changing gear oil ............................ 41Cleaning fuel tank ........................... 42Inspecting and replacing

anode(s)........................................ 43Checking top cowling ...................... 43Coating the boat bottom.................. 44

Trouble Recovery............................ 45

Troubleshooting ............................ 45Temporary action in emergency.... 48

Impact damage ............................... 48Starter will not operate .................... 48Emergency starting engine ............. 49

Treatment of submerged motor..... 50

Procedure ....................................... 50

Consumer information.................... 52

Important warranty information for U.S.A. and Canada ..................... 52

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ...... 54

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE

USA OR CANADA ...................... 57

1

General information

EMU25170

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.

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. Outboard motor serial number location

1

ZMU02836

1. Approval label location

1

ZMU02839

ZMU02896

General information

2

EMU25362

Safety information

Before mounting or operating the outboardmotor, read this entire manual. Reading itshould give you an understanding of themotor and its operation.

Before operating the boat, read any own-ers or operators manuals supplied with itand all labels. Be sure you understandeach item before operating.

Do not overpower the boat with this out-board motor. Overpowering the boat couldresult in loss of control. The rated power ofthe outboard should be equal to or lessthan the rated horsepower capacity of theboat. If the rated horsepower capacity ofthe boat is unknown, consult the dealer orboat manufacturer.

Do not modify the outboard. Modificationscould make the motor unfit or unsafe touse.

Incorrect propeller selection and incorrectuse may not only cause engine damage,but also adversely affect fuel consumption.Consult your dealer for correct use.

Never operate after drinking alcohol or tak-ing drugs. About 50% of all boating fatali-ties involve intoxication.

Have an approved personal flotation de-vice (PFD) on board for every occupant. Itis a good idea to wear a PFD wheneverboating. At a minimum, children and non-swimmers should always wear PFDs, andeveryone should wear PFDs when thereare potentially hazardous boating condi-tions.

Gasoline is highly flammable, and its va-pors are flammable and explosive. Handleand store gasoline carefully. Make surethere are no gas fumes or leaking fuel be-fore starting the engine.

This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which may cause brain dam-age or death when inhaled. Symptoms in-clude nausea, dizziness, and drowsiness.Keep cockpit and cabin areas well ventilat-ed. Avoid blocking exhaust outlets.

Check throttle, shift, and steering for prop-er operation before starting the engine.

Attach the engine stop switch lanyard cordto a secure place on your clothing, or yourarm or leg while operating. If you acciden-tally leave the helm, the cord will pull fromthe switch, stopping the engine.

Know the marine laws and regulationswhere you will be boatingand obeythem. For basic boating rules, see Rulesof the road on page 4.

1. Manufactured date label location

1

ZMU02838

Manufactured:

ZMU04346

General information

3

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

Tell someone where you are going: leavea Float Plan with a responsible person. Besure to cancel the Float Plan when you re-turn.

Use common sense and good judgmentwhen boating. Know your abilities, and besure you understand how your boat han-dles under the different boating conditionsyou may encounter. Operate within yourlimits, and the limits of your boat. Alwaysoperate at safe speeds, and keep a carefulwatch for obstacles and other traffic.

Always watch carefully for swimmers dur-ing the engine operation.

Stay away from swimming areas.

When a swimmer is in the water near youshift into neutral and shut off the engine.

Do not illegally discard empty containersused to replace or replenish oil. For thecorrect processing of empty containers,consult the dealer where you purchasedthe oil.

When replacing oils used to lubricate theproduct (engine or gear oil), be sure towipe away any spilt oil. Never pour oil with-out using a funnel or similar device. If nec-essary, verify the necessary replacementprocedure with the dealer.

Never illegally discard (dump) the product.Yamaha recommends consulting the deal-er on discarding the product.

Be informed about boating safety. Additionalpublications and information can be obtainedfrom many organizations, including the fol-lowing:

United States Coast Guard

Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Af-

fairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647

National Marine Manufacturers Associa-tion (NMMA)

401 N. Michigan Ave. Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave. Chicago, Il 60601

EMU25382

Important labels

EMU25395

Warning labels

EMU25401

Label

WARNING

EWM01260

Be sure shift control is in neutral before

ZMU02841

ZMU02842

General information

4

starting engine. (except 2HP)

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

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

while engine is running.

EMU25431

Label

WARNING

EWM01300

This engine is equipped with a neutralstarting device.

The engine will not start unless the shift

control is in neutral position.

EMU25500

Basic boating rules (Rules of the road)

Just as there are rules which apply when youare driving on streets and high ways, thereare waterway rules which apply when youare driving your boat. These rules are usedinternationally, and are also enforced by theUnited States Coast Guard and local agen-cies. You should be aware of these rules,and follow them whenever you encounteranother vessel on the water.Several sets of rules prevail according togeographic location, but are all basically thesame as the International Rules of the Road.The rules presented here in your OwnersManual are condensed, and have been pro-vided for your convenience only. Consultyour local U.S. Coast Guard Auxiliary or De-partment of Motor Vehicles for a completeset of rules governing the waters in whichyou will be using your boat.

EMU25510

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

The general prudential rule

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

EMU25520

Rules when encountering vessels

There are three main situations which youmay encounter with other vessels which

General information

5

could lead to a collision unless the SteeringRules are followed:

Meeting:

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

Crossing:

(you are traveling across the oth-er vessels path)

Overtaking:

(you are passing or 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 doesntapply if both of you will clear one another ifyou continue on your set course and speed.

Crossing

When two power driven vessels are crossingeach others 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.

General information

6

EMU25530

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 which are fishing with nets, linesor trawls are considered to be fishing ves-sels under the International Rules. Vesselswith trolling lines are not considered fishingvessels. Fishing vessels have the right-of-way regardless of position. Fishing vesselscannot, however, impede the passage ofother vessels 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 which can navi-gate only in such a channel.

Reading buoys and other markers

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

General information

7

EMU25540

Fueling instructionsWARNING

EWM00010

GASOLINE AND ITS VAPORS ARE HIGH-LY FLAMMABLE AND EXPLOSIVE!

Do not smoke when refueling, and keep

away from sparks, flames, or othersources of ignition.

Stop engine before refueling.

Refuel in a well-ventilated area. Refuelportable fuel tanks off the boat.

Take care not to spill gasoline. If gaso-line spills, wipe it up immediately with

ZMU01708

General information

8

dry rags.

Do not overfill the fuel tank.

Tighten the filler cap securely after re-fueling.

If you should swallow some gasoline,inhale a lot of gasoline vapor, or getgasoline in your eyes, get immediatemedical attention.

If any gasoline spills onto your skin, im-mediately wash with soap and water.Change clothing if gasoline spills on it.

Touch the fuel nozzle to the filler open-ing or funnel to help prevent electro-

static sparks.

CAUTION:

ECM00010

Use only new clean gasoline which hasbeen stored in clean containers and is notcontaminated with water or foreign mat-

ter.

EMU25570

Gasoline

If knocking or pinging occurs, use a differentbrand of gasoline or premium unleaded fuel.

Gasohol

There are two types of gasohol: gasohol con-taining ethanol and that containing metha-nol. Gasohol containing ethanol can be usedif ethanol content does not exceed 10% andthe fuel meets minimum octane ratings.Yamaha does not recommended gasoholcontaining methanol because it can causefuel system damage or engine performanceproblems.

EMU25650

Engine oil

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

EMU25742

Propeller selection

The performance of your outboard motor willbe critically affected by your choice of propel-ler, as an incorrect choice could adverselyaffect performance and could also seriouslydamage the motor. Engine speed dependson the propeller size and boat load. If enginespeed is too high or too low for good engineperformance, this will have an adverse effecton the engine.Yamaha outboard motors are fitted with pro-pellers chosen to perform well over a rangeof applications, but there may be uses wherea propeller with a different pitch would bemore appropriate. For a greater operatingload, a smaller-pitch propeller is more suit-able as it enables the correct engine speedto be maintained. Conversely, a larger-pitchpropeller is more suitable for a smaller oper-ating load.Yamaha dealers stock a range of propellers,and can advise you and install a propeller onyour outboard that is best suited to your ap-plication.

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

Recommended engine oil:YAMALUBE 2-stroke outboard motor oil

General information

9

NOTE:

Select a propeller which will allow the engineto reach the middle or upper half of the oper-ating range at full throttle with the maximumboat load. If operating conditions such aslight boat loads then allow the engine r/min torise above the maximum recommendedrange, reduce the throttle setting to maintain

the engine in the proper operating range.

For instructions on propeller removal and in-stallation, see page 40.

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.

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

ZMU04605

-x1 2 3

10

Basic components

EMU25797

Main componentsNOTE:

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

els.

8

EMU25802

Fuel tank

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

WARNING

EWM00020

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

13

4

52

6

16

7

8

9101112

14

15

13

ZMU04490

1. Manual starter handle2. Engine stop button/Engine stop lanyard switch3. Choke knob4. Throttle grip5. Throttle friction adjuster6. Clamp screw7. Cooling water inlet8. Anti-cavitation plate9. Trim rod10. Shallow water lever11. Rope attachment12. Tilt support knob13. Cooling water pilot hole14. Gear shift lever

15. Top cowling16. Fuel tank*

Basic components

11

tions.

EMU25830

Fuel joint

This joint is used to connect the fuel line.

EMU25841

Fuel gauge

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

EMU25850

Fuel tank cap

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

EMU25860

Air vent screw

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

EMU25911

Tiller handle

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

EMU25922

Gear shift lever

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

EMU25941

Throttle grip

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

1. Air vent screw2. Fuel gauge3. Fuel joint4. Fuel tank cap

ZMU01992

3 24 1

1. Neutral 2. Forward 3. Reverse

ZMU02846

1 23

ZMU02847

N FR

Basic components

12

EMU25961

Throttle indicator

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

EMU25971

Throttle friction adjuster

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

WARNING

EWM00031

Do not overtighten the friction adjuster. If

there is too much resistance, it could bedifficult to move the remote control leveror throttle grip, which could result in an

accident.

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

EMU25990

Engine stop lanyard switch

The lock plate must be attached to the en-gine stop switch for the engine to run. Thelanyard should be attached to a secure placeon the operators clothing, or arm or leg.Should the operator fall overboard or leavethe helm, the lanyard will pull out the lockplate, stopping ignition to the engine. Thiswill prevent the boat from running away un-der power.

WARNING

EWM00120

Attach the engine stop switch lanyardto a secure place on your clothing, oryour arm or leg while operating.

Do not attach the lanyard to clothingthat could tear loose. Do not route thelanyard where it could become entan-gled, preventing it from functioning.

Avoid accidentally pulling the lanyardduring normal operation. Loss of en-gine power means the loss of moststeering control. Also, without engine

1. Throttle indicator

ZMU02848

ZMU02849

1

ZMU02850

Basic components

13

power, the boat could slow rapidly. Thiscould cause people and objects in the

boat to be thrown forward.

NOTE:

The engine cannot be started with the lock

plate removed.

EMU26001

Engine stop button

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

EMU26011

Choke knob for pull type

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

EMU26070

Manual starter handle

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

EMU26122

Steering friction adjuster

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

1. Lock plate2. Lanyard

ZMU02851

12

ZMU02852

ZMU02860

Basic components

14

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

WARNING

EWM00040

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to steer, which could result in an

accident.

EMU26261

Trim rod (tilt pin)

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

EMU26280

Shallow water lever

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

EMU26320

Tilt support knob

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

EMU26372

Top cowling lock lever(s) (turn type)

To remove the engine top cowling, turn thelock lever(s) and lift off the cowling. When in-stalling the cowling, check to be sure it fitsproperly in the rubber seal. Then lock thecowling again by returning the lever(s) to thelock position.

ZMU04508

ZMU02853

ZMU02854

ZMU02855

Basic components

15

1. Top cowling lock lever(s)

ZMU02862

1

16

Operation

EMU26901

Installation

CAUTION:

ECM00110

Incorrect engine height or obstructionsto smooth water flow (such as the designor condition of the boat, or accessoriessuch as transom ladders or depth findertransducers) can create airborne waterspray while the boat is cruising. Severeengine damage may result if the motor isoperated continuously in the presence of

airborne water spray.

NOTE:

During water testing check the buoyancy ofthe boat, at rest, with its maximum load.Check that the static water level on the ex-haust housing is low enough to prevent wa-ter entry into the powerhead, when waterrises due to waves when the outboard is not

running.

EMU26910

Mounting the outboard motor

WARNING

EWM00820

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.

The information presented in this sec-tion is intended as reference only. It isnot possible to provide complete in-structions for every possible boat andmotor combination. Proper mountingdepends in part on experience and the

specific boat and motor combination.

WARNING

EWM00830

Improper mounting of the outboard mo-tor could result in hazardous conditionssuch as poor handling, loss of control, orfire hazards. Observe the following:

For permanently mounted models, yourdealer or other person experienced inproper rigging should mount the motor.If you are mounting the motor yourself,you should be trained by an experi-enced person.

For portable models, your dealer or oth-er person experienced in proper out-board motor mounting should show

you how to mount your motor.

Mount the outboard motor on the center line(keel line) of the boat, and ensure that theboat itself is well balanced. Otherwise theboat will be hard to steer. For boats withouta keel or which are asymmetrical, consultyour dealer.

EMU26920

Mounting height

To run your boat at optimum efficiency, thewater resistance (drag) of the boat and out-board motor must be made as little as possi-ble. The mounting height of the outboard

1. Center line (keel line)

ZMU017601

Operation

17

motor greatly affects the water resistance. Ifthe mounting height is too high, cavitationtends to occur, thus reducing the propulsion;and if the propeller tips cut the air, the enginespeed will rise abnormally and cause the en-gine to overheat. If the mounting height is toolow, the water resistance will increase andthereby reduce engine efficiency. Mount theoutboard motor so that the anti-cavitationplate is between the bottom of the boat anda level 25 mm (1 in.) below it.

NOTE:

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

For instructions on setting the trim angle of

the outboard motor, see page 25.

EMU26970

Clamping the outboard motor

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

come loose due to engine vibration.

WARNING

EWM00640

Loose clamp screws could allow the out-board motor to fall off or move on thetransom. This could cause loss of controland serious injury. Make sure the tran-som screws are tightened securely. Oc-casionally check the screws for tightness

during operation.

2. If the engine restraint cable attachmentis equipped on your engine, an enginerestraint cable or chain should be used.Attach one end to the engine restraintcable attachment and the other to a se-cure mounting point on the boat. Other-wise the engine could be completely lostif it accidentally falls off the transom.

3. Secure the clamp bracket to the transomusing the bolts provided with the out-

ZMU02011025mm(01in.) ZMU02012

ZMU02013

Operation

18

board (if packed). For details, consultyour Yamaha dealer.

WARNING

EWM00650

Avoid using bolts, nuts or washers otherthan those contained in the engine pack-aging. If used, they must be of at least thesame quality of material and strength andmust be tightened securely. After tighten-ing, test run the engine and check their

tightness.

EMU30173

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.

CAUTION:

ECM00800

Failure to follow the break-in procedurecould result in reduced engine life or

even severe engine damage.

EMU27050

Gasoline and engine oil mixing chart (25:1)

CAUTION:

ECM00150

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

aged.

EMU27074

Procedure for pre-mixed models

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

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

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

1. Bolts

ZMU02637

1

1. : Gasoline2. : Engine oil

Operation

19

cool.4. Remaining seven hours:

Run the engine at any speed. However,avoid operating at full throttle for morethan 5 minutes at a time.

5. After the first 10 hours:Operate the engine normally. Use thestandard premix ratio of gasoline and oil.For details on mixing fuel and oil, seepage 19.

EMU27102

Preoperation checks

WARNING

EWM00080

If any item in the preoperation check isnot working properly, have it inspectedand repaired before operating the out-board motor. Otherwise an accident

could occur.

CAUTION:

ECM00120

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

occur.

EMU27111

Fuel

Check to be sure you have plenty of fuelfor your trip.

Make sure there are no fuel leaks or gaso-line fumes.

Check fuel line connections to be sure theyare tight (if equipped Yamaha fuel tank orboat tank).

Be sure the fuel tank is positioned on a se-cure, flat surface, and that the fuel line isnot twisted or flattened, or likely to contactsharp objects (if equipped Yamaha fueltank or boat tank).

EMU27120

Oil

Check to be sure you have plenty of oil for

your trip.

EMU27130

Controls

Check throttle, shift, and steering for prop-er operation before starting the engine.

The controls should work smoothly, with-out binding or unusual free play.

Look for loose or damaged connections.

Check operation of the starter and stopswitches when the outboard motor is in thewater.

EMU27140

Engine

Check the engine and engine mounting.

Look for loose or damaged fasteners.

Check the propeller for damage.

EMU27233

Filling fuel and engine oil

EMU27242

Filling fuel for portable tank

WARNING

EWM00060

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

sources of ignition.

1. Remove the fuel tank cap.2. Fill the fuel tank carefully.3. Close the cap securely after refueling.

Wipe up any spilled fuel.

EMU27404

Gasoline and oil mixing (100:1)

If equipped with a portable fuel tank

Fuel tank capacity (if equipped Yamaha fuel tank):

12 L (3.17 US gal) (2.64 Imp.gal)

Gasoline to engine oil ratio

Break-in period See page 18After break-in 100:1

Operation

20

1. Pour oil into the portable fuel tank, andthen add gasoline.

2. Replace the fuel tank cap and closetightly.

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

4. Make sure that the oil and gasoline aremixed.

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

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

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

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

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

built-in fuel tank.

CAUTION:

ECM00810

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

Use a thoroughly blended fuel-oil mix-ture.

If the mixture is not thoroughly mixed,or if the mixing ratio is incorrect, thefollowing problems could occur. Lowoil ratio: Lack of oil could cause majorengine trouble, such as piston seizure.

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

and heavy carbon deposits.

NOTE:

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

ed to the tank.

EMU27450

Operating engine

EMU27461

Feeding fuel (portable tank)WARNING

EWM00420

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

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

This product emits exhaust gaseswhich contain carbon monoxide, a col-orless, odorless gas which could cause

1. Engine oil2. Gasoline

Operation

21

brain damage or death when inhaled.Symptoms include nausea, dizziness,and drowsiness. Keep cockpit and cab-in areas well ventilated. Avoid blocking

exhaust outlets.

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

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

3. If a steering friction adjuster is providedon your outboard motor, securely attachthe fuel line to the fuel line clamp.

NOTE:

During engine operation place the tank hori-zontally, otherwise fuel cannot be drawn

from the fuel tank.

4. Squeeze the primer pump with the outletend up until you feel it become firm.

EMU27490

Starting engine

EMU27505

Manual start models (tiller control)

1. Place the gear shift lever in neutral.

NOTE:

The start-in-gear protection device preventsthe engine from starting except when in neu-

tral.

2. Attach the engine stop switch lanyard toa secure place on your clothing, or yourZMU02024

ZMU02025

Operation

22

arm or leg. Then install the lock plate onthe other end of the lanyard into the en-gine stop switch.

WARNING

EWM00120

Attach the engine stop switch lanyardto a secure place on your clothing, oryour arm or leg while operating.

Do not attach the lanyard to clothingthat could tear loose. Do not route thelanyard where it could become entan-gled, preventing it from functioning.

Avoid accidentally pulling the lanyardduring normal operation. Loss of en-gine power means the loss of moststeering control. Also, without enginepower, the boat could slow rapidly. Thiscould cause people and objects in the

boat to be thrown forward.

3. Place the throttle grip in the (start) position.

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

NOTE:

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

If the choke knob is left in the (start) position while the engine is running,

the engine will run poorly or stall.

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

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

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

ZMU02860

Operation

23

NOTE:

When the engine is cold, it needs to bewarmed up. For further information, seepage 23.

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

the engine still fails to start, see page 45.

EMU27670

Warming up engine

EMU27681

Choke start models

1. After starting the engine, allow it to idlefor 3 minutes to warm up. Failure to doso will shorten engine life. Gradually re-turn the choke knob to its home positionas the engine warms up.

2. Check for a steady flow of water from thecooling water pilot hole.

CAUTION:

ECM00511

A continuous flow of water from the cool-ing water pilot hole shows that the waterpump is pumping water through the cool-ing passages. If water is not flowing outof the hole at all times while the engine isrunning, overheating and serious dam-

age could occur. Stop the engine andcheck whether the cooling water inlet onthe lower case or the cooling water pilothole is blocked. Consult your Yamahadealer if the problem cannot be located

and corrected.

EMU27740

ShiftingWARNING

EWM00180

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

you.

CAUTION:

ECM00220

To change the boat direction or shiftingposition from forward to reverse or vice-versa, first close the throttle so that the

engine idles (or runs at low speeds).

EMU27764

Forward (tiller handle and remote control models)

Tiller handle models1. Place the throttle grip in the fully closed

position.

ZMU02030

ZMU02856

Operation

24

2. Move the gear shift lever quickly andfirmly from neutral to forward.

Remote control models1. Pull up the neutral interlock trigger (if

equipped) and move the remote controllever quickly and firmly from neutral toforward.

EMU27796

Reverse (manual tilt and hydro tilt models)

WARNING

EWM00190

When operating in reverse, go slowly. Donot open the throttle more than half. Oth-erwise the boat could become unstable,which could result in loss of control and

an accident.

Tiller handle models1. Place the throttle grip in the fully closed

position.

2. On models equipped with a tilt lock le-ver, check that it is in the lock/down po-sition.

3. Move the gear shift lever quickly andfirmly from neutral to reverse.

Remote control models1. Check that the tilt lock lever is in the lock

position.2. Pull up the neutral interlock trigger (if

equipped) and move the remote controllever quickly and firmly from neutral toreverse.

EMU27820

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.

EMU27832

Procedure

1. Push and hold the engine stop button

ZMU02030

NF

ZMU02866

ZMU02030

ZMU02867

RN

Operation

25

until the engine comes to a completestop.

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

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

NOTE:

If the outboard motor is equipped with an en-gine stop switch lanyard, the engine can also

be stopped by pulling the lanyard and remov-ing the lock plate from the engine stop

switch.

EMU27861

Trimming outboard motor

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.

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.

Operation

26

EMU27872

Adjusting trim angle for manual tilt models

There are 4 or 5 holes provided in the clampbracket to adjust the outboard motor trim an-gle.1. Stop the engine.2. Tilt the outboard motor up, and then re-

move the trim rod from the clamp brack-et.

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

WARNING

EWM00400

Stop the engine before adjusting thetrim angle.

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

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

angle can cause loss of control.

NOTE:

The outboard motor trim angle can bechanged approximately 4 degrees by shifting

the trim rod one hole.

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 of

1. Trim operating angle

ZMU02858

1

1. Trim rod

ZMU02859

1

Operation

27

the boat is up about 3 to 5 degrees. With thebow up, the boat may have a greater tenden-cy to steer to one side or the other. Compen-sate for this as you steer. The trim tab 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 plowthrough the water, decreasing fuel economy

and making it hard to increase speed. Oper-ating with excessive trim-in at higher speedsalso makes the boat unstable. Resistance atthe bow is greatly increased, heightening thedanger of bow steering and making opera-tion difficult and dangerous.

NOTE:

Depending on the type of boat, the outboardmotor trim angle may have little effect on the

trim of the boat when operating.

EMU27921

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 casing from damage by colli-sion with obstructions, and also to reducesalt corrosion.

WARNING

EWM00220

Be sure all people are clear of the out-board motor when tilting up and down,also be careful not to pinch any bodyparts between the drive unit and engine

bracket.

WARNING

EWM00230

Leaking fuel is a fire hazard. Tighten theair vent screw and place the fuel cock inthe closed position if the outboard motor

Operation

28

will be tilted for more than a few minutes.

Otherwise fuel may leak.

CAUTION:

ECM00231

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

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

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

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

motor is turned 180 (facing the rear).

EMU27978

Procedure for tilting up (manual tilt models)

1. Place the gear shift lever in neutral.

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

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

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

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

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

ZMU02854

ZMU02887

Operation

29

EMU28013

Procedure for tilting down (manual tilt models)

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

knob, pull it out.

3. Slowly tilt the engine down.

EMU28060

Cruising in shallow water

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

EMU28071

Cruising in shallow water (manual tilt models)

WARNING

EWM00710

Place the gear shift in neutral before us-ing the shallow water cruising system.

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

Do not rotate the outboard motor 180and operate the boat in reverse. Placethe gear shift in reverse to operate theboat in reverse.

Use extra care when operating in re-

verse. Too much reverse thrust cancause the outboard motor to lift out ofthe water, increasing the chance of ac-cident and personal injury.

Return the outboard motor to its normalposition as soon as the boat is back in

deeper water.

CAUTION:

ECM00260

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

ing can result.

EMU28110

Procedure

1. Place the gear shift lever in neutral.

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

ZMU02888

ZMU02868

Operation

30

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

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

EMU28192

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 with salt de-posits.NOTE:

For cooling system flushing instructions, see

page 32.

Cruising in turbid water

Yamaha strongly recommends that you usethe optional chromium-plated water pump kit(not available for some models) if you usethe outboard motor in turbid or muddy waterconditions.

ZMU02854

31

Maintenance

EMU31480

SpecificationsNOTE:

(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.

EMU28218

Dimension:

Overall length: 802 mm (31.6 in)

Overall width: 343 mm (13.5 in)

Overall height S: 977 mm (38.5 in)

Transom height S: 436 mm (17.2 in)

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

Performance:

Full throttle operating range: 45005500 r/min

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

Idling speed (in neutral): 900

50 r/min

Engine:

Type: 2-stroke L

Displacement: 165.0 cm

3

(10.07 cu.in)Bore

stroke: 50.0

42.0 mm (1.97

1.65 in)Ignition system:

CDISpark plug with resistor (NGK):

BR7HS-10

Spark plug gap: 0.91.0 mm (0.0350.039 in)

Control system: Tiller

Starting system: Manual

Starting carburetion system: Choke valve

Alternator output: 80 W

Drive unit:

Gear positions: Forward-neutral-reverse

Gear ratio: 2.08 (27/13)

Trim and tilt system: Manual tilt

Propeller mark: N

Fuel and oil:

Recommended fuel: Regular unleaded gasoline

Min. pump octane: 86

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

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

Lubrication: Pre-mixed fuel and oil

Recommended gear oil: Hypoid gear oil SAE#90

Gear oil quantity: 160.0 cm

3

(5.41 US oz) (5.64 Imp.oz)

Tightening torque for engine:

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

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

Maintenance

32

EMU28222

Transporting and storing outboard motor

WARNING

EWM00690

Leaking fuel is a fire hazard. Whentransporting and storing the outboardmotor, close the air vent screw and fuelcock to prevent fuel from leaking.

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

EWM00700

Never get under the lower unit while it istilted, even if a motor support bar is used.Severe injury could occur if the outboard

motor accidentally falls.

CAUTION:

ECM00660

Do not use the tilt support lever or 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.

EMU28235

Clamp screw mounting models

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

NOTE:

Place a towel or something similar under the

outboard motor to protect it from damage.

EMU30272

Storing outboard motor

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

ZMU02870

ZMU02869

Maintenance

33

lowing procedures.

CAUTION:

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.

EMU28302

Procedure

EMU28372

Flushing in a test tank

1. Wash the outboard motor body usingfresh water. For further information, seepage 34.

2. Fill the fuel tank with fresh fuel and addone ounce of Yamaha Fuel Conditionerand Stabilizer (Part No. LUB-FUELC-12-00) to each gallon of fuel.

NOTE:

The use of Yamaha Fuel Conditioner andStabilizer eliminates the need to drain thefuel system. Consult your Yamaha dealer orother qualified mechanic if the fuel system is

to be drained instead.

3. Remove the engine top cowling and si-lencer cover.

4. Install the outboard motor on the testtank.

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

CAUTION:

ECM00300

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

es.

CAUTION:

ECM00290

If the fresh water level is below the levelof the anti-cavitation plate, or if the watersupply is insufficient, engine seizure may

occur.

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

WARNING

EWM00090

Do not touch or remove electrical parts

1. Water surface2. Lowest water level

ZMU02051

1

2

Maintenance

34

when starting or during operation.

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

parts while the engine is running.

7. Run the engine at a fast idle for 1015minutes in neutral position.

8. Just prior to turning off the engine, quick-ly spray Yamaha Stor-Rite EngineFogging Oil (Part No. LUB-STRRT-12-00) alternately into each carburetor orthe fogging hole of the silencer cover, ifequipped. When properly done, the en-gine will smoke excessively and almoststall.

9. Remove the outboard motor from thetest tank.

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

11. Install the silencer cover/cap and topcowling.

EMU28400

Lubrication (except oil injection models)

1. Grease the spark plug threads and in-stall the spark plug(s) and torque toproper specification. For information onspark plug installation, see page 37.

2. Change the gear oil. For instructions,see page 41. Inspect the oil for the pres-ence of water that indicates a leaky seal.Seal replacement should be performedby an authorized Yamaha dealer prior touse.

3. Grease all grease fittings. For further de-tails, see page 37.

EMU28421

Cleaning and anticorrosion measures

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

2. Spray the outboard motor exterior withYamaha Silicone Protectant (Part No.LUB-SILCNE-13-00).

3. Wax the cowling with a non-abrasivewax such as Yamaha Silicone Wax(Part No. ACC-11000-15-02).

EMU28450

Cleaning the outboard motor

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

NOTE:

For cooling system flushing instructions, see

page 32.

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.

EMU28486

Periodic maintenance

WARNING

EWM01070

Be sure to turn off the engine when youperform maintenance unless otherwisespecified. If you or the owner is not famil-iar with machine servicing, this workshould be done by your Yamaha dealer or

other qualified mechanic.

Maintenance

35

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 whohave the mechanical skills, tools, and otherequipment necessary to perform mainte-nance not covered by this owners manual.

EMU28510

Replacement parts

If replacement parts are necessary, use onlygenuine Yamaha parts or parts of the sametype and of equivalent strength and materi-als. Any part of inferior quality may malfunc-tion, and the resulting loss of control couldendanger the operator and passengers.Yamaha genuine parts and accessories areavailable from your Yamaha dealer.

Maintenance

36

EMU28522

Maintenance chart

Frequency of maintenance operations may be adjusted according to the operating condi-tions, but the following table gives general guidelines. Refer to the sections in this chapter forexplanations of each owner-specific action.NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushed with clean

water after each use.

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

Item Actions

Initial Every

10 hours (1 month)

50 hours (3

months)

100 hours (6 months)

200 hours (1

year)

Anode(s) (external) Inspection / replace-ment

Anode(s) (internal) Inspection / replace-ment

Cooling water pas-sages Cleaning

Cowling clamp Inspection

Fuel filter (disposable) Inspection / replace-ment

Fuel system InspectionFuel tank (Yamaha por-table tank) Inspection / cleaningGear oil ChangeGreasing points GreasingIdling speed (carbure-tor models) Inspection

Propeller and cotter pin Inspection / replace-ment

Shift link / shift cable Inspection / adjustmentThermostat Inspection / replace-

mentThrottle link / throttle cable / throttle pick-up timing

Inspection / adjustment

Water pump Inspection / replace-ment

Spark plug(s) Cleaning / adjustment / replacement

Maintenance

37

EMU28931

Greasing

Yamaha marine grease (Water resistant grease)

8

EMU28952

Cleaning and adjusting spark plugWARNING

EWM00560

When removing or installing a spark plug,be careful not to damage the insulator. Adamaged insulator could allow externalsparks, which could lead to explosion or

fire.

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

ZMU02872

Maintenance

38

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

Before fitting the spark plug, measure theelectrode gap with a wire thickness gauge;adjust the gap to specification if necessary.

When fitting the plug, always clean the gas-ket surface and use a new gasket. Wipe offany dirt from the threads and screw in thespark plug to the correct torque.

NOTE:

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 a

torque-wrench.

EMU28962

Checking 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.

Check the fuel lines for leaks, crack, or mal-function. If a problem is found, your Yamahadealer or other qualified mechanic should re-pair it immediately.

Standard spark plug:BR7HS-10

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

Spark plug gap:0.91.0 mm (0.0350.039 in)

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

Maintenance

39

Checkpoints

Fuel system parts leakage

Fuel line joint leakage

Fuel line cracks or other damage

Fuel connector leakage

EMU28990

Checking fuel filter

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

parts while the engine is running.

CAUTION:

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.

NOTE:

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 dealer

or other qualified mechanic.

2. Verify whether the idle speed is set tospecification. For idle speed specifica-tions, see page 31.

EMU29112

Checking wiring and connectors

Check that each grounding wire is properlysecured.

Check that each connector is engaged se-curely.

ZMU04491

ZMU02874

Maintenance

40

EMU29120

Exhaust leakage

Start the engine and check that no exhaustleaks from the joints between the exhaustcover, cylinder head, and body cylinder.

EMU29130

Water leakage

Start the engine and check that no waterleaks from the joints between the exhaustcover, cylinder head, and body cylinder.

EMU29171

Checking propeller

WARNING

EWM00321

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

Before inspecting, removing, or install-ing the propeller, remove the sparkplug caps from the spark plugs. Also,place the shift control in neutral, turnthe main switch to (off) and re-move the key, and remove the lanyardfrom the engine stop switch. Turn offthe battery cut-off switch if your boathas one.

Do not use your hand to hold the pro-peller when loosening or tightening thepropeller nut. Put a wood block be-tween the anti-cavitation plate and thepropeller to prevent the propeller 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 / shear pin for wear ordamage.

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

ZMU02875

ZMU02876

ZMU01897

Maintenance

41

Check the propeller shaft oil seal for dam-age.

NOTE:

If the shear pin equipped: it is designed tobreak if the propeller hits a hard underwaterobstacle to help protect the propeller anddrive mechanism. The propeller will thenspin freely on the shaft. If this happens, the

shear pin must be replaced.

EMU30660

Removing the propeller

EMU29194

Spline models

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

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

3. Remove the propeller and thrust wash-er.

EMU30670

Installing the Propeller

EMU29231

Spline models

CAUTION:

ECM00340

Be sure to install the thrust washer be-

fore installing the propeller, otherwisethe lower case and propeller bosscould be damaged.

Be sure to use a new cotter pin andbend the ends over securely. Otherwisethe propeller could come off during op-

eration and be lost.

1. Apply Yamaha marine grease or a cor-rosion resistant grease to the propellershaft.

2. Install the spacer (if equipped), thrustwasher, and propeller on the propellershaft.

3. Install the spacer (if equipped) and thewasher. 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.

NOTE:

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

align it with the hole.

EMU29282

Changing gear oil

WARNING

EWM00800

Be sure the outboard motor is securelyfastened to the transom or a stable

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

ZMU02877

2345

1

ZMU02063

Maintenance

42

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.

NOTE:

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

Always use new gaskets. Do not reuse the

removed gaskets.

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

CAUTION:

ECM00710

Inspect the used oil after it has beendrained. If the oil is milky, water is gettinginto the gear case which can cause gear

damage. Consult a Yamaha dealer for re-

pair of the lower unit seals.

NOTE:

For disposal of used oil, consult your

Yamaha dealer.

5. With the outboard motor in a vertical po-sition, and using a flexible or pressur-ized filling device, inject the gear oil intothe gear 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.

EMU29302

Cleaning fuel tank

WARNING

EWM00920

Gasoline is highly flammable, and its va-pors are flammable and explosive.

If you have any question about properlydoing this procedure, consult your

1. Gear oil drain screw2. Oil level plug

ZMU028791

2

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:160.0 cm

3

(5.41 US oz) (5.64 Imp.oz)

ZMU02880

Maintenance

43

Yamaha dealer.

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

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

Wipe up any spilled fuel immediately.

Reassemble the fuel tank carefully. Im-proper assembly can result in a fuelleak, which could result in a fire or ex-plosion hazard.

Dispose of old gasoline according to lo-

cal regulations.

1. Empty the fuel tank into an approvedcontainer.

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

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

4. Clean the filter (located on the end of thesuction pipe) in a suitable cleaning sol-vent. Allow the filter to dry.

5. Replace the gasket with a new one. Re-install the fuel joint assembly and tightenthe screws firmly.

EMU29312

Inspecting and replacing anode(s)

Yamaha outboard motors are protected from

corrosion by sacrificial anodes. Inspect theexternal anodes periodically. Remove scalesfrom the surfaces of the anodes. Consult aYamaha dealer for replacement of externalanodes.

CAUTION:

ECM00720

Do not paint anodes, as this would render

them ineffective.

NOTE:

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.

EMU29390

Checking top cowling

Check the fitting of the top cowling by push-ing it with both hands. If it is loose have it re-paired by your Yamaha dealer.

ZMU02881

ZMU02882

Maintenance

44

EMU29400

Coating the boat bottom

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.

ZMU01943

45

Trouble Recovery

EMU29424

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 warning indicator isflashing, 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 21.

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 stop switch lanyard not at-tached?A. Attach lanyard.

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

Engine idles irregularly or stalls.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replacewith recommended type.

Trouble Recovery

46

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 fuel filter clogged?A. Clean or replace filter.

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

Q. Has warning system activated?A. Find and correct cause of warning.

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.

Q. Is ignition wiring damaged or poorly con-nected?A. Check wires for wear or breaks. Tightenall loose connections. Replace worn or bro-ken wires.

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

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

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

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

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

Q. Is choke knob pulled out?

A. Return to home position.

Q. Is motor angle too high?A. Return to normal operating position.

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

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

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

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

Warning buzzer sounds or indicatorlights.

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?

Trouble Recovery

47

A. Have serviced by a Yamaha dealer.

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 warning system activated?A. Find and correct cause of warning.

Q. Is boat bottom fouled with marine growth?A. Clean boat bottom.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replacewith recommended type.

Q. Are weeds or other foreign matter tangledon 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 filter clogged?A. Clean or replace filter.

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

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.

Q. Is ignition wiring damaged or poorly con-nected?A. Check wires for wear or breaks. Tightenall loose connections. Replace worn or bro-ken wires.

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

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

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

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

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

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

Trouble Recovery

48

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.

EMU29432

Temporary action in emergency

EMU29440

Impact damage

WARNING

EWM00870

The outboard motor can be seriously

damaged by a collision while operating ortrailering. 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.

EMU29532

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

EWM01021

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

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

Trouble Recovery

49

could result in an accident.

Attach the engine stop switch lanyardto a secure place on your clothing, oryour arm or leg while operating theboat.

Do not attach the lanyard to clothingthat could tear loose. Do not route thecord where it could become entangled,preventing it from functioning.

Avoid accidentally pulling the lanyardduring normal operation. Loss of en-gine power means the loss of moststeering control. Also, without enginepower, the boat could slow rapidly. Thiscould cause people and objects in theboat to be thrown forward.

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

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

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

electrical shock.

EMU29561

Emergency starting engine

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

ble from the starter,