60H-9-E1 Hyoshi 4/9/02 1:09 PM Page 1 (2,1)
E115A
115B
140B
150A
L150A
175A
200A
L200A
OWNER’S MANUAL
60H-28199-E1
67K-9-14-1 2/28/02 11:23 AM Page 2
60H-9-E1-1 3/1/02 9:25 PM Page 1
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EMU01449
TO THE OWNER
Thank you for choosing a Yamaha outboard
motor. This Owner’s manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you
obtain maximum enjoyment from your new
Yamaha. If you have any question about
the operation or maintenance of your outboard motor, please consult a Yamaha
dealer.
In this Owner’s Manual particularly important information is distinguished in the following ways.
Q
The Safety Alert Symbol means
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
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Failure to follow WARNING instructions
could result in severe injury or death to
the machine operator, a bystander, or a
person inspecting or repairing the outboard motor.
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A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
* Yamaha continually seeks advancements
in product design and quality. Therefore,
while this manual contains the most current product information available at the
time of printing, there may be minor discrepancies between your machine and
this manual. If there is any question concerning this manual, please consult your
Yamaha dealer.
NOTE:
The E115AE, E115AMH, E115AWH,
200AET, L200AET, and their standard
accessories are used as a base for the
explanations and illustrations in this manual. Therefore, some items may not apply to
every model.
EMU01447
E115A, 115B, 140B, 150A, L150A,
175A, 200A, L200A
OWNER’S MANUAL
©2002 by Yamaha Motor Co., Ltd.
1st Edition, March 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
60H-9-E1-1 3/1/02 9:25 PM Page 2
60H-9-E1-1 3/1/02 9:25 PM Page 3
EMU00003
CONTENTS
E
GENERAL INFORMATION
1
BASIC COMPONENTS
2
OPERATION
3
MAINTENANCE
4
TROUBLE RECOVERY
5
INDEX
6
READ THIS OWNER’S MANUAL CAREFULLY
BEFORE OPERATING YOUR OUTBOARD MOTOR.
60H-9-E1-1 3/1/02 9:25 PM Page 4
60H-9-E1-1 3/4/02 11:30 AM Page 5
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EMU00004
Chapter 1
GENERAL
INFORMATION
IDENTIFICATION NUMBERS
RECORD ............................................... 1-1
Outboard motor serial number ............ 1-1
Key number ........................................ 1-1
LABELS ................................................ 1-2
EC label .............................................. 1-2
EPA label ............................................ 1-2
EMISSION CONTROL
INFORMATION ..................................... 1-3
1
2
3
SAFETY INFORMATION ...................... 1-4
FUELING INSTRUCTIONS ................... 1-6
Gasoline............................................... 1-7
Engine oil ............................................ 1-7
BATTERY REQUIREMENT .................. 1-8
4
PROPELLER SELECTION .................... 1-8
START-IN-GEAR PROTECTION .......... 1-9
5
6
60H-9-E1-1 3/1/02 9:25 PM Page 6
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EMU00005
IDENTIFICATION NUMBERS
RECORD
EMU00007
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
OUTBOARD MOTOR SERIAL
NUMBER
The outboard motor serial number is
stamped on the label attached to the port
side of the clamp-bracket.
Record your outboard motor serial number
in the spaces provided to assist you in
ordering spare parts from your Yamaha
dealer or for reference in case your outboard motor is stolen.
1
1 Outboard motor serial number
401012
EMU00008
KEY NUMBER
If a main key switch is equipped with the
motor, the key identification number is
stamped on your key as shown in the illustration. Record this number in the space
provided for reference in case you need a
new key.
YAMAHA
q
123
000319
1 Key number
1-1
60H-9-E1-1 3/1/02 9:25 PM Page 7
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EMU01532
LABELS
YAMAHA MOTOR CO.,LTD.
2500 SHINGAI,IWATA,
SHIZUOKA,JAPAN
NOMINAL
POWER
MASS
KW
Kg
000769
EMU01526
EC LABEL
Engines affixed with this label conform to
certain portions of the European Parliament
directive relating to machinery. Refer to the
label and the EC Declaration of Conformity
for more details.
EMU01527
EPA LABEL
EMISSION CONTROL INFORMATION
ENGINE FAMILY :
THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.
rpm IN NEUTRAL
g/kw-hr
IDLE SPEED :
FELs :
SPARK PLUG GAP (mm) :
SPARK PLUG :
Engines affixed with this label conform to
U.S. Environmental Protection Agency
(EPA) regulations for marine SI engines.
Refer to the label for more details.
000762
1-2
60H-9-E1-1 3/1/02 9:25 PM Page 8
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EMU01385
EMISSION CONTROL
INFORMATION
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EMU01390
U.S. INSULAR AREAS
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001336
Engines affixed with the label pictured
below conform to U.S. Environmental
Protection Agency (EPA) regulations for
marine SI engines. See the label affixed to
your engine for details.
1 Emission control information label
EMISSION CONTROL INFORMATION
ENGINE FAMILY :
THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.
rpm IN NEUTRAL
g/kw-hr
IDLE SPEED :
FELs :
SPARK PLUG GAP (mm) :
SPARK PLUG :
000762
Approval label of Emission control certificate
This label is attached to the bottom cowling.
Existing Technology ; N/A
2 Manufactured date label
Manufactured:
1-3
Manufactured date label
This label is attached to the clamp bracket
or the swivel bracket.
60H-9-E1-1 3/1/02 9:25 PM Page 9
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EMU00918
QSAFETY INFORMATION
8 Before mounting or operating the outboard motor, read this entire manual.
Reading it should give you an understanding of the motor and its operation.
8 Before operating the boat, read any
owner’s or operator’s manuals supplied
with it and all labels. Be sure you understand each item before operating.
8 Do not overpower the boat with this outboard motor. Overpowering the boat
could result in loss of control. The rated
power of the outboard should be equal to
or less than the rated horsepower capacity of the boat. If the rated horsepower
capacity of the boat is unknown, consult
the dealer or boat manufacturer.
8 Do not modify the outboard. Modifications
could make the motor unfit or unsafe to
use.
8 Never operate after drinking alcohol or
taking drugs. About 50% of all boating
fatalities involve intoxication.
8 Have an approved personal flotation
device (PFD) on board for every occupant. It is a good idea to wear a PFD
whenever boating. At a minimum, children and non-swimmers should always
wear PFDs, and everyone should wear
PFDs when there are potentially hazardous boating conditions.
8 Gasoline (Petrol) is highly flammable, and
its vapors are flammable and explosive.
Handle and store gasoline (Petrol) carefully. Make sure there are no gas fumes
or leaking fuel before starting the engine.
1-4
60H-9-E1-1 3/1/02 9:25 PM Page 10
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8 This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which may cause brain
damage or death when inhaled.
Symptoms include nausea, dizziness,
and drowsiness. Keep cockpit and cabin
areas well ventilated. Avoid blocking
exhaust outlets.
8 Check throttle, shift, and steering for
proper operation before starting the
engine.
8 Attach the engine stop switch lanyard to a
secure place on your clothing, or your
arm or leg while operating. If you accidentally leave the helm, the lanyard will pull
from the switch, stopping the engine.
8 Know the marine laws and regulations
where you will be boating - and obey
them.
8 Stay informed about the weather. Check
weather forecasts before boating. Avoid
boating in hazardous weather.
8 Tell someone where you are going: leave
a Float Plan with a responsible person.
Be sure to cancel the Float Plan when
you return.
8 Use common sense and good judgment
when boating. Know your abilities, and be
sure you understand how your boat handles under the different boating conditions
you may encounter. Operate within your
limits, and the limits of your boat. Always
operate at safe speeds, and keep a careful watch for obstacles and other traffic.
8 Always watch carefully for swimmers during the engine operation.
8 Stay away from swimming areas.
8 When a swimmer is in the water near you
shift into neutral and shut off the engine.
1-5
60H-9-E1-1 3/1/02 9:25 PM Page 11
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EMU00016
FUELING INSTRUCTIONS
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GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE!
8 Do not smoke when refueling, and
keep away from sparks, flames, or
other sources of ignition.
8 Stop engine before refueling.
8 Refuel in a well-ventilated area. Refuel
portable fuel tanks off the boat.
8 Take care not to spill gasoline. If gasoline spills, wipe it up immediately with
dry rags.
8 Do not overfill the fuel tank.
8 Tighten the filler cap securely after
refueling.
8 If you should swallow some gasoline
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.
8 If any gasoline spills onto your skin,
immediately wash with soap and
water. Change clothing if gasoline
spills on it.
8 Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
cC
Use only new clean gasoline which has
been stored in clean containers and is
not contaminated with water or foreign
matter.
1-6
60H-9-E1-1 3/1/02 9:25 PM Page 12
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EMU01799
GASOLINE
Recommended gasoline:
Regular unleaded gasoline
If knocking or pinging occurs, use a different brand of gasoline or premium unleaded
fuel. If unleaded gasoline is not available,
then premium gasoline can be used.
EMU01356
ENGINE OIL
Recommended engine oil:
YAMALUBE, TWO STROKE MOTOR
OIL FOR MARINE
If the recommended engine oil is not available, another 2-stroke engine oil with a
NMMA-certified TC-W3 rating may be used.
1-7
60H-9-E1-1 3/4/02 11:31 AM Page 13
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EMU01775
BATTERY REQUIREMENT
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EL
LEV EL
ER
V
UPP ER LE
W
O
L
901015
Do not use a battery that does not meet
the specified capacity. If a battery which
does not meet specifications is used, the
electric system could perform poorly or
be overloaded, causing electric system
damage.
For electric start models, choose a battery
which meets the following specifications.
EMU01857
Minimum cold cranking amps (CCA/EN):
430 amps at -18°C (-0.4°F)
Minimum rated capacity (20HR/IEC):
70 A·h
EMU01395
PROPELLER SELECTION
The performance of your outboard motor
will be critically affected by your choice of
propeller, as an incorrect choice could
adversely affect performance and could
also seriously damage the motor. Engine
speed depends on the propeller size and
boat load. If engine speed is too high or too
low for good engine performance, this will
have an adverse effect on the engine.
Yamaha outboard motors are fitted with
propellers chosen to perform well over a
range of applications, but there may be
uses where a propeller with a different pitch
would be more appropriate. For a greater
operating load, a smaller-pitch propeller is
more suitable as it enables the correct
engine speed to be maintained. Conversely,
a larger-pitch propeller is more suitable for
a smaller operating load.
1-8
60H-9-E1-1 3/1/02 9:25 PM Page 14
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13 x 17 - K
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000933
14-1/2 x 17 - M
q
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602022
Yamaha dealers stock a range of propellers, and can advise you and install a
propeller on your outboard that is best suited to your application.
NOTE:
At full throttle and under a maximum boat
load, the engine’s rpm should be within the
upper half of the full throttle operating
range, as listed in “SPECIFICATIONS” on
page 4-1. Select a propeller which fulfills
this requirement.
If operating under conditions which allow
the engine’s rpm to rise above the maximum recommended range (such as light
boat loads), reduce the throttle setting to
maintain the rpm in the proper operating
range.
1 Propeller diameter (in inches)
2 Propeller pitch (in inches)
3 Type of propeller (propeller mark)
Refer to the section “CHECKING PROPELLER” for instructions on propeller
removal and installation.
13-3/4 x 17 - ML
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602033
EMU01208
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START-IN-GEAR PROTECTION
000376
1-9
Yamaha outboard motors which have the
pictured label 1 affixed to them or Yamaha
approved remote control units are equipped
with start-in-gear protection device(s). This
feature permits the engine to be started
only when it is Neutral. Always select
Neutral before starting the engine.
60H-9-E1-2 3/1/02 9:36 PM Page 1
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EMU00037
Chapter 2
BASIC COMPONENTS
1
MAIN COMPONENTS ........................... 2-1
OPERATIONS OF CONTROLS AND
OTHER FUNCTIONS ............................ 2-5
Fuel tank ............................................. 2-5
Gear shift lever ................................... 2-6
Engine stop lanyard switch ................. 2-6
Choke knob ......................................... 2-7
Manual injection knob ......................... 2-7
Recoil starter handle ........................... 2-7
Main switch ......................................... 2-8
Tiller handle ........................................ 2-8
Remote control ................................. 2-10
Steering friction adjusting screw ....... 2-16
Trim tab ............................................. 2-17
Trim angle adjusting rod ................... 2-17
Tachometer ....................................... 2-18
Trim meter ........................................ 2-18
Digital hour meter ............................. 2-18
Tilt lock mechanism .......................... 2-19
Tilt support lever ............................... 2-20
Top cowling lock levers ..................... 2-20
WARNING SYSTEM ........................... 2-21
Overheat warning ............................. 2-21
2
3
4
5
6
60H-9-E1-2 3/1/02 9:36 PM Page 2
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EMU01206
MAIN COMPONENTS
E115AMH, E115AWH
!4
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!3
!2
!0
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!1
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1
2
3
4
5
6
7
8
9
0
Top cowling
Tilt support lever
Tilt lock lever
Trim angle adjusting rod
Anti-cavitation plate
Trim tab (Anode)
Propeller
Cooling water inlet
Anode
Engine stop switch
2-1
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*
Main switch
Tiller handle
Manual injection knob
Recoil starter handle
May not be exactly as shown; also may not be
included as standard equipment on all models.
60H-9-E1-2 3/1/02 9:36 PM Page 3
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EMU01206
MAIN COMPONENTS
E115AE, 115BE
!1
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!0
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1
2
3
4
5
6
7
8
9
0
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Top cowling
Tilt support lever
Tilt lock lever
Trim angle adjusting rod
Anti-cavitation plate
Trim tab (Anode)
Propeller
Cooling water inlet
Anode
Cowling lock lever
Choke knob
*
May not be exactly as shown; also may not be
included as standard equipment on all models.
2-2
60H-9-E1-2 3/1/02 9:36 PM Page 4
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EMU01206
MAIN COMPONENTS
E115AET, 115BET, 140BET, 150AET, L150AET, 175AET, 200AET, L200AET
1
2
2
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0
9
8
3
7
4
6
1
2
3
4
5
6
7
8
9
0
q
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Top cowling
Cowling lock levers
Anti-cavitation plate
Trim tab(Anode)
Propeller
Cooling water inlet
Anode
Clamp bracket
Tilt support lever
Power trim/tilt switch
Fuel joint
Choke knob
2-3
5
*
May not be exactly as shown; also may not be
included as standard equipment on all models.
60H-9-E1-2 3/1/02 9:36 PM Page 5
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EMU01206
MAIN COMPONENTS
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3
4
5
2
HOUR
6
1
x1000 r/min
7
YAMAHA
YAMAHA
YAMAHA
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*1
*2
*3
*4
*5
*6
*7
*8
Remote control box (side mount type)
Remote control box (binnacle mount type)
Switch panel (for use with 2)
Tachometer
Trim meter
Digital hour meter
Remote control cable
Fuel tank
i
*
May not be exactly as shown; also may not be
included as standard equipment on all models.
2-4
60H-9-E1-2 3/1/02 9:36 PM Page 6
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EMU00039
OPERATIONS OF CONTROLS
AND
OTHER FUNCTIONS
EMU01465
FUEL TANK
If your model included a portable fuel tank,
its parts and functions are as follows.
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1
2
3
4
Fuel hose joint
Fuel meter (if equipped)
Fuel tank cap
Air vent screw (if equipped)
EMU00042
Fuel Hose Joint
This connector is provided for connecting or
disconnecting fuel hose.
902016
EMU00045
Fuel Tank Cap
This cap is for filling fuel. To remove it, turn
it counterclockwise.
EMU00046
Air Vent Screw
This screw is on the fuel tank cap. To
loosen it, turn it counterclockwise.
2-5
60H-9-E1-2 3/1/02 9:36 PM Page 7
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EMU00051
2
1
3
GEAR SHIFT LEVER (for Tiller
control model)
Turning the gear-shift lever towards you
engages the clutch with the forward gear so
that the boat moves ahead. Turning the
lever away from you engages the reverse
gear so that the boat moves astern.
507014
1 Neutral
2 Forward
3 Reverse
EMU00931
ENGINE STOP LANYARD SWITCH
(for Tiller control model)
The lock-plate 1 must be attached to the
engine stop lanyard switch for the engine to
run. The lanyard 2 should be attached to a
secure place on the operator’s clothing, or
arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull
out the lock plate, stopping ignition to the
engine. This will prevent the boat from running away under power.
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000974
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8 Attach the lanyard to a secure place
on your clothing, your arm or leg while
operating.
8 Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard in such a way that it could
become entangled, preventing it from
functioning.
8 Avoid accidentally pulling the lanyard
during normal operation. Loss of
engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly.
This could cause people and objects
in the boat to be thrown forward.
2-6
60H-9-E1-2 3/1/02 9:36 PM Page 8
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NOTE:
The engine cannot be started with the lockplate removed.
EMU00055
CHOKE KNOB
305034
Pulling out this knob (setting it to ON) supplies a rich mixture required to start the
engine.
NOTE:
The choke knob for Remote control model
has the same function as the choke switch
on the remote control box.
EMU01703
MANUAL INJECTION KNOB
E115AMH, E115AWH
001310
The manual injection knob is used to supply
a rich fuel mixture to the carburetor when
starting the engine. To use the manual
injection knob, fully pull out the knob firmly.
Release the knob to allow it to automatically
return to its home position. For further information, see Chapter 3, “Starting engine.”
EMU00059
RECOIL STARTER HANDLE (If
equipped)
Pull the handle gently until resistance is felt.
Then vigorously pull the handle straight out
to crank the engine to start it.
209015
2-7
60H-9-E1-2 3/1/02 9:36 PM Page 9
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EMU01292
MAIN SWITCH
E115AWH
ON
OFF
START
000530
The main switch controls the ignition system; its operation is described below.
8 OFF
Electrical circuits switched off.
(The key can be removed.)
8 ON
Electrical circuits switched on.
(The key cannot be removed.)
8 START
Starter-motor will turn and start engine.
(When the key is released, it returns automatically to “ON”.)
EMU00062
TILLER HANDLE (for Tiller control
model)
Moving the tiller handle sideways to adjust
the steering direction. In addition, this handle contains the functions as follows.
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000952
1 Throttle control grip
2 Throttle indicator
3 Throttle friction adjusting knob/screw
EMU00065
Throttle Control Grip
The throttle control grip is on the tiller handle. Turn the grip counterclockwise to
increase speed and clockwise to decrease
speed.
000529
2-8
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EMU00067
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Throttle Indicator
The fuel consumption curve on the throttle
indicator shows the relative amount of fuel
consumed for each throttle position.
Choose the setting that offers the best performance and fuel economy for the desired
operation.
000559
1 Throttle indicator
EMU01293
Throttle friction adjusting screw/ knob
A friction device in the tiller handle provide
resistance to movement of the throttle grip.
This is adjustable for operator preference.
An adjusting screw/knob is located within
the tiller handle.
Resistance
502025
Knob/Screw
Increase
Turn clockwise
Decrease
Turn counterclockwise
When constant speed is desired, tighten the
adjusting screw/bolt to maintain the desired
throttle setting.
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Do not over tighten the friction adjusting
screw/ knob.
If there is too much resistance, it may be
difficult to move the throttle grip, which
could result in an accident.
2-9
60H-9-E1-2 3/1/02 9:36 PM Page 11
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A
EMU01691
REMOTE CONTROL
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Both the shifter and the throttle are actuated
by the remote control lever. Additionally, the
remote control also has the electrical
switches.
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000322
B
1
2
3
4
5
6
7
8
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C
OFF
t
å Side mount remote control box
∫ Binnacle mount remote control box
ç Switch panel (for use with ∫)
Remote control lever
Neutral interlock trigger
Neutral throttle lever
Free accelerator
Main switch / choke switch
Engine stop lanyard switch
Power trim and tilt switch
Throttle friction adjusting screw
001276
ON
ON
START OFF
START
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001277
2-10
60H-9-E1-2 3/1/02 9:36 PM Page 12
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EMU00098
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F
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701031
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Remote Control Lever
Moving the lever forward from the Neutral
position engages Forward gear. Pulling the
lever back from Neutral engages Reverse.
The engine will continue to run at idle until
the lever is moved about 35° (a detent can
be felt). Moving the lever farther opens the
throttle, and the engine will begin to accelerate.
1
2
3
4
5
6
7
Neutral
Forward
Reverse
Shift
Fully closed
Throttle
Fully open
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702032
EMU00099
Neutral Interlock Trigger
To shift out of Neutral, the neutral interlock
trigger of the remote control lever must first
be pulled up.
UP
DN
EMU00100
000323
N
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000324
2-11
Neutral Throttle Lever
To open the throttle without shifting into
either Forward or Reverse, place the
remote control lever in the Neutral position
and lift the neutral throttle lever.
NOTE:
The neutral throttle lever will operate only
when the remote control lever is in Neutral.
The remote control lever will operate only
when the neutral throttle lever is in the
closed position.
1 Fully open
2 Fully closed
60H-9-E1-2 3/1/02 9:36 PM Page 13
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EMU00101
OFF
ON
START
701021
OFF
ON
ON
START OFF
START
Main switch
The main switch controls the ignition system; its operation is described below.
8 OFF
Electrical circuits switched off.
(The key can be removed.)
8 ON
Electrical circuits switched on.
(The key cannot be removed.)
8 START
Starter-motor will turn and start engine.
(When the key is released, it returns automatically to “ON”.)
001242
EMU00102
Choke Switch
While the main switch is being pressed in at
“ON” or “START”, the choke system will
switch on, to supply a rich mixture required
to start the engine. (When the key is
released, it will switch off automatically.)
701055
OFF
ON
START
703031
2-12
60H-9-E1-2 3/1/02 9:36 PM Page 14
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EMU00934
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000569
OFF
ON
ON
START OFF
START
q
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000715
Engine Stop Lanyard Switch
The lock-plate 1 must be attached to the
engine stop lanyard switch for the engine to
run. The lanyard 2 should be attached to a
secure place on the operator’s clothing, or
arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull
out the lock plate, stopping ignition to the
engine. This will prevent the boat from running away under power.
w
8 Attach the lanyard to a secure place
on your clothing, your arm or leg while
operating.
8 Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard in such a way that it could
become entangled, preventing it from
functioning.
8 Avoid accidentally pulling the lanyard
during normal operation. Loss of
engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly.
This could cause people and objects
in the boat to be thrown forward.
NOTE:
The engine cannot be started with the lockplate removed.
2-13
60H-9-E1-2 3/1/02 9:36 PM Page 15
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EMU01112
UP
DN
UP
DN
701034
DN
UP
Power Trim/Tilt Switches
The power trim/tilt adjusts the motor angle
in relation to the transom. The power trim/tilt
switch is located on the remote control lever
grip. Individual-engine switches are also on
the control cover. Pushing the switch “UP”
trims the motor up, then tilts the motor up.
Pressing the switch “DN” tilts the motor
down and trims the motor down. When the
switch button is released, the motor will
stop in its current position.
NOTE:
8 On the dual engine control, the switch on
the remote control grip controls both
engines at the same time.
8 Refer to the sections “Adjusting Trim
Angle” and “Tilting Up/Down” in Chapter 3
for instructions on usage.
000921
2-14
60H-9-E1-2 3/1/02 9:36 PM Page 16
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EMU00106
Free Accelerator
To open the throttle without shifting into
either Forward or Reverse, push the free
accelerator button and turn the remote control lever.
NOTE:
8 The free accelerator button can be operated only when the remote control lever is
in the Neutral position.
8 After the button is pushed, the remote
control lever must be moved at least 35°
to begin opening the throttle.
8 After operating the free accelerator,
return the remote control lever to the
Neutral position. The free accelerator button will return automatically to its set position. The remote control will then engage
Forward and Reverse normally.
q
35°
e
q
2-15
001278
1 Fully-open
2 Fully-closed
3 Free accelerator
60H-9-E1-2 3/1/02 9:36 PM Page 17
E
EMU01155
Throttle Friction Adjusting Screw
A friction device in the remote control box
provides adjustable resistance to movement
of the remote control lever, and can be set
according to operator preference. An
adjusting screw is located on the front of the
remote control box.
701035
Resistance
Screw
Increase
Turn clockwise
Decrease
Turn counterclockwise
w
Do not overtighten the friction adjusting
screw. If there is too much resistance, it
may be difficult to move the lever, which
could result in an accident.
702035
EMU00109
STEERING FRICTION ADJUSTING
SCREW (for Tiller control model)
000550
A friction device provides resistance to
steering movement. This is adjustable for
operator
preference.
An
adjusting
screw/bolt is located at right(starboard) side
of the through tube end on the clamp bracket.
2-16
60H-9-E1-2 3/1/02 9:36 PM Page 18
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EMU01552
TRIM TAB
The trim tab should be adjusted so that the
steering control can be turned to either the
right or left by applying the same amount of
force.
w
An improperly adjusted trim tab may
cause difficult steering. Always test run
after the trim tab has been installed or
replaced to be sure steering is correct.
Be sure you have tightened the bolt after
adjusting the trim tab.
e
w
1 Trim tab
2 Bolt
3 Cap (if equipped)
q
Boat tends to veer
The fin of trim tab
To the left (port side)
Turn to the left
(A in the figure)
To the right
(starboard side)
Turn to the right
(B in the figure)
603014
cC
The trim tab also serves as an anode to
protect the engine from electrochemical
corrosion. Never paint the trim tab as it
will become ineffective as an anode.
A
B
000625
EMU01297
TRIM ANGLE ADJUSTING ROD
The position of the trim angle adjusting rod
determines the minimum trim angle of the
outboard motor in relation to the transom.
001290
2-17
60H-9-E1-2 3/1/02 9:36 PM Page 19
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EMU00124
TACHOMETER
3
This meter shows the engine speed.
4
5
2
6
1
x1000 r/min
7
YAMAHA
801023
EMU00132
TRIM METER (for Power trim/tilt
model)
YAMAHA
801011
This meter shows the trim angle of your outboard.
NOTE:
Memorize the trim angles that work best for
your boat under different conditions. Adjust
the trim angle to the desired setting by
operating the power trim/tilt switch.
EMU00133
DIGITAL HOUR METER
This meter indicates the time elapsed time
by counting the time of engine use.
HOUR
1 Hours
2 Minutes(×6)
YAMAHA
q
w
001326
NOTE:
The time counting method can be selected
that it counts while the main switch is “ON”
or the engine is running by operator’s preference. Consult your Yamaha dealer for
selecting the time counting method.
2-18
60H-9-E1-2 3/1/02 9:36 PM Page 20
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EMU01610
DIGITAL HOUR METER
200A, L200A
000130
Located on the engine inside the top cowling, this device measures the total number
of hours the engine has been run since
manufacture. When the main switch is
turned on, initially all segments of the display will light. The indicator will then display
the number of hours normally.
NOTE:
The number of hours is only measured
when the engine is running. When the main
switch is turned on but the engine is not
running, the digital hour meter will display
the hours run but will not add any further
time to the total.
EMU00153
TILT LOCK MECHANISM (for Manual
tilt model)
q
001286
The tilt-lock mechanism is used to prevent
reverse thrust from the propeller lifting the
outboard motor when reversing.
To lock it, set the tilt-lock lever in the Lock
position.
To release it, place the tilt-lock lever in the
Tilt position.
1 Tilt-lock lever
2-19
60H-9-E1-2 3/1/02 9:36 PM Page 21
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EMU00157
TILT SUPPORT LEVER
To keep the outboard motor in the tilted-up
position, lock the tilt support lever to the
clamp bracket.
001288
EMU00160
TOP COWLING LOCK LEVERS
To remove the engine top cowling, turn the
front lock lever and rear lock lever(s). Then
lift off the cowling. When replacing the cowling, check to be sure it fits properly in the
rubber seal. Then lock the cowling again by
returning the levers to the locked position.
q
001375
1 Top cowling lock lever
q
001376
2-20
60H-9-E1-2 3/1/02 9:36 PM Page 22
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EMU00169
WARNING SYSTEM
cC
Do not continue to operate the engine if
the warning device has activated.
Consult your Yamaha dealer if the problem cannot be located and corrected.
EMU00171
OVERHEAT WARNING
This engine has an overheat warning
device. If the engine temperature rises too
high, the warning device will activate.
(1); Included (—); N/A
701054
ON
OFF
ON
START OFF
START
703026
605015
2-21
Warning device
activation
Tiller
control
model
Remote
control
model
The engine speed
will automatically
decrease to about
2,000 r/min.
1
1
The overheat warning
indicator will come on.
—
—
The buzzer will sound.
—
1
If the warning system has been activated,
stop the engine and check the water inlet
for clogging.
NOTE:
In case of dual engine drive:
Should the overheat warning system of one
engine operate, it slows down and the
buzzer sounds. This will cause the other
engine to slow down and the buzzer to
sound. For the other engine, the warning
system can be released by shifting the
remote control lever into the neutral.
60H-9-E1-3 3/1/02 9:38 PM Page 1
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EMU00174
Chapter 3
OPERATION
INSTALLATION .................................... 3-1
Mounting the outboard motor .............. 3-2
BREAKING IN (RUNNING IN)
ENGINE ................................................. 3-5
Running in the engine ......................... 3-5
PRE-OPERATION CHECKS ................ 3-7
FILLING FUEL AND ENGINE OIL ........ 3-8
Filling fuel ............................................ 3-8
Gasoline (petrol) and oil mixing .......... 3-9
STARTING ENGINE ........................... 3-11
1
2
3
WARMING UP ENGINE ...................... 3-19
SHIFTING ............................................ 3-20
Forward ............................................. 3-20
Reverse ............................................ 3-21
STOPPING ENGINE ........................... 3-22
TRIMMING OUTBOARD MOTOR ...... 3-23
Adjusting trim angle .......................... 3-24
TILTING UP/DOWN ............................ 3-27
CRUISING IN OTHER
CONDITIONS ...................................... 3-31
Cruising in salt water ........................ 3-31
Cruising in turbid water ..................... 3-31
4
5
6
60H-9-E1-3 3/1/02 9:38 PM Page 2
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EMU00175
INSTALLATION
cC
Incorrect engine height or obstructions
to smooth water flow (such as the
design or condition of the boat or accessories such as transom ladders/depth
finder transducers) can create airborne
water spray while the boat is cruising.
Severe engine damage may result if the
motor is operated continuously in the
presence of airborne water spray.
NOTE:
During water testing check the buoyancy of
the boat, at rest, with its maximum load.
Check that the static water level on the
exhaust housing is low enough to prevent
water entry into the powerhead, when water
rises due to waves when the outboard is not
running.
3-1
60H-9-E1-3 3/1/02 9:38 PM Page 3
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EMU01478
MOUNTING THE OUTBOARD
MOTOR
w
8 Overpowering a boat may cause
severe instability. Do not install an
outboard motor with more horsepower
than the maximum rating on the
capacity plate of the boat. If the boat
does not have a capacity plate, consult
the boat manufacturer.
8 The information presented in this section is intended as reference only. It is
not possible to provide complete
instructions
for
every
possible
boat/motor
combination.
Proper
mounting depends in part on experience and the specific boat/motor combination.
w
Improper mounting of the outboard
motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Observe the following:
8 For permanently mounted models,
your dealer or other person experienced in proper rigging should mount
the motor. If you are mounting the
motor yourself, you should be trained
by an experienced person.
8 For portable models, your dealer or
other person experienced in proper
outboard motor mounting should
show you how to mount your motor.
3-2
60H-9-E1-3 3/1/02 9:38 PM Page 4
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Mount the outboard motor on the center line
(keel line) of the boat, and ensure that the
boat itself is well balanced. Otherwise, the
boat will be hard to steer. For boats without
a keel or which are asymmetrical, consult
your dealer.
1 Center line (keel line)
q
q
104016
000371
EMU01298
0–25 mm
(0–1 in.)
001180
3-3
Mounting Height
To run your boat at optimum efficiency, the
water-resistance (drag) of the boat and outboard motor must be made as little as possible. The mounting-height of the outboard
motor greatly affects the water-resistance. If
the mounting-height is too high, cavitation
tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the
engine speed will rise abnormally and
cause the engine to overheat. If the mounting-height is too low, the water-resistance
will increase and thereby reduce engine
efficiency. Mount the engine so that the
anti-cavitation plate is between the bottom
of the boat and a level 25 mm (1 in.) below
it.
60H-9-E1-3 3/1/02 9:38 PM Page 5
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NOTE:
8 The optimum mounting height of the outboard motor is affected by the boat/motor
combination and the desired use. Test
runs at different heights can help determine the optimum mounting height.
8 Refer to the section “TRIMMING OUTBOARD MOTOR” for instructions on setting the trim angle of the outboard.
3-4
60H-9-E1-3 3/1/02 9:38 PM Page 6
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EMU01534
BREAKING IN (RUNNING IN)
ENGINE
Your new engine requires a period of breakin (running-in) to allow mating surfaces of
moving parts to wear-in evenly. Correct
break-in (running-in) will help ensure proper
performance and longer engine life.
cC
Failure to follow the break-in (running-in)
procedure may result in reduced engine
life or even severe engine damage.
Break-in (running-in) time:10 hours
Break-in (running-in) premix ratio:
Refer to “GASOLINE/PETROL AND
OIL MIXING”.
EMU01538
Run the engine under load (in gear with a
propeller installed) as follows.
1) First 10 minutes:
Run the engine at the lowest possible
speed. A fast idle in neutral is best.
N
F
35˚
000776
2)
45˚
000987
3-5
Next 50 minutes:
Do not exceed half throttle (approximately 3,000 r/min). Vary engine speed
occasionally. If you have an easy-planing boat, accelerate at full throttle onto
plane, then immediately reduce the
throttle to 3,000 r/min or less.
60H-9-E1-3 3/1/02 9:38 PM Page 7
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3)
Second hour:
Accelerate at full throttle onto plane,
then reduce engine speed to threequarter throttle (approximately 4,000
r/min). Vary engine speed occasionally.
Run at full throttle for one minute, then
allow about 10 minutes of operation at
three-quarter throttle or less to let the
engine cool.
4)
Third through tenth hours:
Avoid operating at full throttle for more
than 5 minutes at a time. Let the engine
cool between full-throttle runs. Vary
engine speed occasionally.
5)
After the first 10 hours:
Operate the engine normally. Use the
standard premix ratio of gasoline:oil.
Refer to “GASOLINE/PETROL AND
OIL MIXING” for details.
000989
000984
000991
3-6
60H-9-E1-3 3/1/02 9:38 PM Page 8
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EMU00204
PRE-OPERATION CHECKS
w
If any item in the pre-operation check is
not working properly, have it inspected
and repaired before operating the outboard motor. Otherwise, an accident
could occur.
cC
Do not start the engine out of water.
Overheating and serious engine damage
can occur.
EMU00206
Fuel
8 Check to be sure you have plenty of fuel
for your trip.
8 Make sure there are no fuel leaks or
gasoline fumes.
8 Check fuel line connections to be sure
they are tight.
8 Be sure the fuel tank is positioned on a
secure, flat surface, and that the fuel
hose is not twisted or flattened, or likely to
contact sharp objects.
EMU00207
Oil
8 Check to be sure you have plenty of oil
for your trip.
3-7
60H-9-E1-3 3/1/02 9:38 PM Page 9
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EMU00209
Controls
8 Check throttle, shift, and steering for
proper operation before starting the
engine.
8 The controls should work smoothly, without binding or unusual free play.
8 Look for loose or damaged connections.
8 Check operation of the starter and stop
switches when the outboard motor is in
the water.
EMU00210
Engine
8 Check the engine and engine mounting.
8 Look for loose or damaged fasteners.
8 Check the propeller for damage.
EMU00186
FILLING FUEL AND ENGINE
OIL
EMU01537
FILLING FUEL
902021
1)
2)
3)
Remove the fuel tank cap.
Fill the fuel tank carefully.
Close the cap securely after refueling.
Wipe up any spilled fuel.
Fuel tank capacity:
Refer to “SPECIFICATIONS,” page 4-1.
3-8
60H-9-E1-3 3/1/02 9:38 PM Page 10
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EMU01481
GASOLINE (PETROL) AND OIL
MIXING
q
Pre-mix models
Gasoline (Petrol) : Engine oil
w
1)
Break-in period
25 : 1
After break-in
50 : 1
Pour oil and gasoline into the fuel tank,
in that order.
1 Engine oil
2 Gasoline (Petrol)
2)
3)
Mix the fuel thoroughly by shaking.
Make sure the oil is mixed with the
gasoline.
cC
902031
3-9
8 Avoid using any oil other than the designated type.
8 Use a thoroughly blended fuel-oil mixture.
8 If the mixture is not thoroughly blended, or if the mixing ratio is incorrect,
the following problems could occur:
8 Low oil ratio: Lack of oil could
cause major engine trouble, such
as piston seizure.
8 High oil ratio: Too much oil could
cause fouled spark plugs, smoky
exhaust,
and
heavy
carbon
deposits.
60H-9-E1-3 3/1/02 9:38 PM Page 11
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Mixing ratio
25 : 1
Gasoline
(Petrol)
Engine oil
1L
12 L
14 L
24 L
(0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal,
0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.3 Imp gal)
0.04 L
0.48 L
0.56 L
0.96 L
(0.04 US qt, (0.51 US qt, (0.59 US qt, (1.01 US qt,
0.04 Imp qt) 0.42 Imp qt) 0.49 Imp qt) 0.84 Imp qt)
Mixing ratio
50 : 1
Gasoline
(Petrol)
Engine oil
12 L
14 L
24 L
1L
(0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal,
0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.3 Imp gal)
0.02 L
0.24 L
0.28 L
0.48 L
(0.02 US qt, (0.26 US qt, (0.30 US qt, (0.51 US qt,
0.02 Imp qt) 0.21 Imp qt) 0.24 Imp qt) 0.42 Imp qt)
NOTE:
If using a permanently installed tank, pour
the oil gradually as the fuel is being added
to the tank.
3-10
60H-9-E1-3 3/1/02 9:38 PM Page 12
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EMU01461
STARTING ENGINE
w
902043
001309
8 Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions. Be sure there are no swimmers
in the water near you.
8 When the air vent screw is loosened,
gasoline (petrol) vapor will be
released. Gasoline (petrol) is highly
flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames
and sparks while loosening the air
vent screw.
8 This product emits exhaust gases
which contain carbon monoxide, a colorless, odorless gas which may cause
brain damage or death when inhaled.
Symptoms include nausea, dizziness,
and drowsiness. Keep cockpit and
cabin areas well ventilated. Avoid
blocking exhaust outlets.
1)
902023
If there is an air vent screw on the fuel
tank cap, loosen it 2 or 3 turns.
2) If there is a fuel joint on the motor, firmly connect the fuel line to the joint. Then
firmly connect the other end of the fuel
line to the joint on the fuel tank.
NOTE:
During engine operation place the tank horizontally, or fuel cannot be drawn from the
fuel tank.
3)
902025
3-11
Squeeze the primer bulb with the outlet
end up until you feel it become firm.
60H-9-E1-3 3/1/02 9:38 PM Page 13
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EMU01497
PROCEDURE FOR TILLER
CONTROL MODEL
4)
N
507022
Place the gear-shift lever in the neutral
position.
NOTE:
The start-in-gear protection device prevents
the engine from starting except when in
Neutral.
5)
Attach the engine stop switch lanyard
to a secure place on your clothing, or
your arm or leg. Then, install the lock
plate on the other end of the lanyard in
the engine stop switch.
w
000975
8 Attach the engine stop switch lanyard
to a secure place on your clothing,
your arm or leg while operating.
8 Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entangled, preventing it from functioning.
8 Avoid accidentally pulling the lanyard
during normal operation. Loss of
engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly.
This could cause people and objects
in the boat to be thrown forward.
6)
Place the throttle control grip in the
“START” position.
503022
3-12
60H-9-E1-3 3/1/02 9:38 PM Page 14
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EMU01707
001310
Manual start models
7) Fully pull out the manual injection knob
firmly once. Release the knob to allow it
to automatically return to its home position.
NOTE:
8 It is not necessary to use the manual
injection knob when restarting a warm
engine.
8 Pull out the manual injection knob twice
when the engine is brand new, after it has
been disassembled and reassembled for
inspection or repairs, and when starting
after a long period of storage.
8)
9)
209015
000560
3-13
Pull the starter handle slowly until you
feel resistance. Then give a strong pull
straight out to crank and start the
engine. Repeat if necessary.
After the engine starts, return the
starter handle slowly to its original position before releasing it.
NOTE:
8 When starting a cold engine, the engine
needs to be warmed up. For further information, see “Warming up engine” in this
chapter.
8 If the engine doesn’t start after pulling the
starter handle 3 or more times, repeat the
procedure from step 7. If the engine still
fails
to
start,
see
Chapter
5,
“Troubleshooting.”
60H-9-E1-3 3/1/02 9:38 PM Page 15
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EMU01706
Electric start models
E115AWH
7)
001310
Fully pull out the manual injection knob
firmly once. Release the knob to allow it
to automatically return to its home position.
NOTE:
8 It is not necessary to use the manual
injection knob when restarting a warm
engine.
8 Pull out the manual injection knob twice
when the engine is brand new, after it has
been disassembled and reassembled for
inspection or repairs, and when starting
after a long period of storage.
8)
Turn the main switch to START, and
hold it for a maximum of 5 seconds.
START
000531
3-14
60H-9-E1-3 3/1/02 9:38 PM Page 16
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9)
Immediately after the engine starts,
release the main switch to return it to
ON.
cC
8 Do not turn the main switch to START
when the engine is running.
8 Do not keep the starter motor turning
for more than 5 seconds. The battery
will rapidly become exhausted and it
will be impossible for it to start the
engine. If the engine does not start
within 5 seconds, return the main
switch to ON, wait 10 seconds, then
crank the engine again.
10) Return the throttle control grip slowly to
the fully closed position.
000560
3-15
60H-9-E1-3 3/1/02 9:38 PM Page 17
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EMU00248
PROCEDURE FOR REMOTE
CONTROL MODELS
N
4)
701015
Place the remote control lever in the
Neutral position.
NOTE:
The start-in-gear protection device permits
the engine to be started only when it is in
Neutral.
N
702025
5)
Attach the engine stop switch lanyard
to a secure place on your clothing, or
your arm or leg. Then, install the lock
plate on the other end of the lanyard in
the engine stop switch.
w
000293
OFF
ON
ON
START OFF
START
000714
8 Attach the engine stop switch lanyard
to a secure place on your clothing,
your arm or leg while operating.
8 Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entangled, preventing it from functioning.
8 Avoid accidentally pulling the lanyard
during normal operation. Loss of
engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly.
This could cause people and objects
in the boat to be thrown forward.
3-16
60H-9-E1-3 3/1/02 9:38 PM Page 18
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6) Turn the main switch to “ON”.
NOTE:
In case of dual-engine operation, when the
main switch is turned on, the buzzer operates for a few seconds and stops automatically. Should either of the dual engines stall,
the buzzer operates.
ON
OFF
000977
OFF
ON
ON
START OFF
START
001242
EMU00948
N
701014
N
702026
3-17
Electric start models
7) Open the throttle slightly without shifting using the neutral throttle lever or the
free accelerator.
After the engine starts, return the throttle to the original position.
NOTE:
The rotation angle of the neutral throttle
lever or the free accelerator should be
determined upon the engine temperature.
When the engine is cold, it is necessary to
rotate the lever a little farther.
60H-9-E1-3 3/1/02 9:38 PM Page 19
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8)
OFF
ON
START
701056
OFF
ON
START
Press in and hold the main switch to
operate the remote choke system.(The
remote choke switch returns to its
home position when you release your
hand. Therefore, keep the switch
pressed in.)
NOTE:
8 It is not necessary to use the choke when
the engine is warm.
8 Set the choke knob to the home position,
or the remote choke system will not operate.
9)
Turn the main switch to “START”, and
hold it for a maximum of 5 seconds.
10) Immediately after the engine starts,
release the main switch to return it to
“ON”.
703025
cC
8 Do not turn the main switch to
“START” when the engine is running.
8 Do not keep the starter motor turning
for more than 5 seconds. The starter
can be damaged. The battery will also
run down quickly, making it harder to
start the engine. If the engine does not
start within 5 seconds, return the main
switch to “ON,” wait 10 seconds, and
then crank the engine again.
3-18
60H-9-E1-3 3/1/02 9:38 PM Page 20
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EMU01507
WARMING UP ENGINE
1)
001318
2)
Before beginning operation, allow the
engine to warm up at idling speed for 3
minutes. (Failure to do this will shorten
engine life.) Gradually return the choke
knob to the home position as the
engine warms up.
Check for a steady flow of water from
the cooling-water pilot hole.
cC
A continuous flow of water from the pilot
hole shows that the water pump is
pumping water through the cooling passages. If water is not flowing out of the
pilot hole at all times while the engine is
running, do not continue to run the
engine. Overheating and serious damage could occur. Stop the engine and
check to see if the water inlet on the
lower casing is blocked. If the problem
cannot be found and corrected, consult
your Yamaha dealer.
3-19
60H-9-E1-3 3/1/02 9:38 PM Page 21
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EMU00261
SHIFTING
w
Before shifting, make sure there are no
swimmers or obstacles in the water near
you.
000560
cC
To change the shifting position from forward to reverse or vice-versa, close the
throttle first so that the engine idles (or
runs at low speeds).
N
F
EMU00265
FORWARD
Tiller control model
507015
1)
2)
N
F
Place the throttle control grip in the fully
closed position.
Turn the gear-shift lever quickly and
firmly from Neutral to Forward.
Remote control model
Pull up the neutral interlock trigger if
equipped and move the remote control
lever quickly and firmly from Neutral to
Forward.
701043
F
N
702015
3-20
60H-9-E1-3 3/1/02 9:38 PM Page 22
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EMU01326
REVERSE
w
When operating in Reverse, go slowly.
Do not open the throttle more than half.
Otherwise, the boat may become unstable, which could result in loss of control
and an accident.
000560
1)
2)
Place the throttle control grip in the fully
closed position (for Tiller control
model).
Check that the tilt-lock lever (for Manual
tilt/Hydro-tilt model) is in the locked
position.
001311
N
Tiller control model
R
3)
Turn the gear-shift lever quickly and
firmly from Neutral to Reverse.
507016
Remote control model
N
R
3)
701044
3-21
Pull up the neutral interlock trigger if
equipped and move the remote control
lever quickly and firmly from Neutral to
Reverse.
60H-9-E1-3 3/1/02 9:38 PM Page 23
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EMU00273
STOPPING ENGINE
Let it cool off for a few minutes at idle or low
speed first. Stopping the engine immediately after operating at high speed is not recommended.
EMU00277
000973
1)
Push and hold the engine stop button
or turn the main switch to “OFF”.
2)
If the fuel joints are provided, disconnect the fuel line from the motor after
stopping the engine.
ON
OFF
START
OFF
701023
001312
3)
902044
Tighten the air vent screw on the fuel
tank cap after stopping the engine, if it
is equipped.
4) Remove the key if the boat will be left
unattended.
NOTE:
The engine can also be stopped by pulling
the lanyard and removing the lock plate
from the engine stop lanyard switch (then
turning the main switch to “OFF”).
3-22
60H-9-E1-3 3/1/02 9:38 PM Page 24
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EMU01412
TRIMMING OUTBOARD
MOTOR
The trim angle of the outboard motor helps
determine the position of the bow of the
boat in the water. The correct trim angle will
help improve performance and fuel economy while reducing strain on the engine. The
correct trim angle depends upon the combination of boat, engine, and propeller.
Correct trim is also affected by variables
such as the load in the boat, sea conditions,
and running speed.
w
Excessive trim for the operating conditions (either trim up or trim down) can
cause boat instability and can make
steering the boat more difficult. This
increases the possibility of an accident.
If the boat begins to feel unstable or is
hard to steer, slow down and/or readjust
the trim angle.
q
000862
NOTE:
Refer to the section “ADJUSTING TRIM
ANGLE” for instructions on usage.
1 Trim operating angle
3-23
60H-9-E1-3 3/1/02 9:38 PM Page 25
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ADJUSTING TRIM ANGLE
EMU00951
q
001325
Manual tilt model
There are 4 or 5 holes provided in the
clamp bracket to adjust the outboard motor
trim angle.
1) Stop the engine.
2) Remove the trim angle adjusting rod 1
from the clamp bracket while tilting the
motor up slightly.
3) Reposition the rod in the desired hole.
To raise the bow (“trim-out”), move the rod
away from the transom.
To lower the bow (“trim-in”), move the rod
toward the transom.
Make test runs with the trim set to different
angles to find the position that works best
for your boat and operating conditions.
w
8 Stop the engine before adjusting the
trim angle.
8 Use care to avoid being pinched when
removing or installing the rod.
8 Use caution when trying a trim position for the first time. Increase speed
gradually and watch for any signs of
instability
or
control
problems.
Improper trim angle can cause loss of
control.
NOTE:
The outboard motor trim angle can be
changed approximately 4 degrees by shifting the trim adjusting-rod one hole.
3-24
60H-9-E1-3 3/1/02 9:38 PM Page 26
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EMU01401
Power Trim/Tilt Model
w
UP
DN
8 Be sure all people are clear of the outboard motor when adjusting the
trim/tilt angle, also be careful not to
pinch any body parts between the
drive unit and clamp bracket.
8 Use caution when trying a trim position for the first time. Increase speed
gradually and watch for any signs of
instability or control problems.
8 Use the power trim/tilt switch located
on the bottom engine cowling (if
equipped) only when the boat is at a
complete stop with the engine off.
UP
DN
q
000350
The outboard motor trim angle can be
adjusted operating the power trim/tilt switch
1.
To raise the bow (“trim-out”), push the
switch UP.
q
DN
UP
To lower the bow (“trim-in”), push the switch
DN.
000351
3-25
Make test runs with the trim set to different
angles to find the position that works best
for your boat and operating conditions.
NOTE:
To adjust the trim angle while the boat is
moving, use the power trim and tilt switch
located on the remote control device or tiller
handle, if so equipped.
60H-9-E1-3 3/1/02 9:38 PM Page 27
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EMU01558
Bow Up
When the boat is on plane, a bow-up attitude results in less drag, greater stability
and efficiency. This is generally when the
keel line of the boat is up about 3 to 5
degrees. When trimmed out, the boat may
have more tendency to steer to one side or
the other. Compensate for this as you steer.
The trim tab can also be adjusted to help
offset this effect.
q
105011
w
Too much trim-out puts the bow of the boat
too high in the water. Performance and
economy are decreased because the hull of
the boat is pushing the water and there is
more air drag.
Excessive trim-up can cause the propeller
to ventilate, which reduces performance further. When trimmed-out too much, a boat
may “porpoise” (hop in the water), which
could throw the operator and passengers
overboard.
EMU01559
Bow Down
When the bow of the boat is down, it is easier to accelerate from a standing start onto
plane.
105013
e
105015
Too much trim-in causes the boat to “plow”
through the water, decreasing fuel economy
and making it hard to increase speed.
Operating with excessive trim-in at higher
speeds also makes the boat unstable.
Resistance at the bow is greatly increased,
heightening the danger of “bow steering”
and making operation difficult and dangerous.
1 Bow up
2 Bow down
3 Optimum angle
3-26
60H-9-E1-3 3/1/02 9:38 PM Page 28
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EMU00285
TILTING UP/DOWN
000817
If the engine will be stopped for some time,
or if the boat is moored in shallows, the
engine should be tilted up to protect the
propeller and casing from damage by collision with obstructions, and also to reduce
salt corrosion.
cC
8 Before tilting the motor, follow the procedures under “STOPPING ENGINE”.
Never tilt the motor while the engine is
running. Severe damage from overheating can result.
8 Do not tilt up the engine by pushing
the steering handle as this could break
the handle.
w
Be sure all people are clear of the outboard motor when adjusting the tilt
angle, also be careful not to pinch any
body parts between the drive unit and
engine bracket.
w
Leaking fuel is a fire hazard. Disconnect
the fuel line if the engine will be tilted for
more than a few minutes. Otherwise, fuel
may leak. (If the fuel connector is provided on the motor.)
3-27
60H-9-E1-3 3/1/02 9:38 PM Page 29
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EMU00286
PROCEDURE FOR TILTING UP
Manual tilt model
1)
Remove the fuel-line connection from
the motor. (If the fuel connector is provided on the motor.)
2)
Place the tilt-lock lever in Release.
3)
Hold the rear of the top cowling with
one hand, tilt the engine up, and turn
the tilt-support lever to the locked position and support the engine.
001312
001313
001314
EMU00297
PROCEDURE FOR TILTING DOWN
Manual tilt models
1)
2)
Return the tilt support lever tilting up
the engine slightly.
Tilt down the engine.
3-28
60H-9-E1-3 3/1/02 9:38 PM Page 30
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EMU01575
PROCEDURE FOR TILTING UP
Power trim and tilt models
1)
Disconnect the fuel line or close the
fuel cock.
2)
Push the power trim and tilt switch “UP”
until the outboard has tilted up completely.
3)
Turn the tilt support lever toward you to
support the engine.
001312
UP
DN
UP
DN
701034
DN
UP
000921
w
001315
3-29
8 After tilting the engine, be sure to support it with the tilt support lever.
Otherwise, the engine could fall back
down suddenly if oil in the power trim
and tilt unit should lose pressure.
8 Never operate the engine while it is
supported by the tilt support lever.
60H-9-E1-3 3/1/02 9:38 PM Page 31
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EMU01576
4)
Once the engine is supported with the
tilt support lever, push the power trim
and tilt switch “DN” (down) to retract the
trim rods.
cC
411043
Be sure to retract the trim rods completely during mooring. This protects the
rods from marine growths and corrosion
which could damage the power trim and
tilt mechanism.
EMU00303
PROCEDURE FOR TILTING DOWN
Power trim/tilt model
1)
2)
3)
411045
Push the power trim/tilt switch “UP”
until the engine is supported by the tilt
rod.
Release the tilt-support lever.
Push the power trim/tilt switch “DN”
(Down) to lower the engine to the
desired position.
3-30
60H-9-E1-3 3/1/02 9:38 PM Page 32
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EMU00316
CRUISING IN OTHER
CONDITIONS
CRUISING IN SALT WATER
After operating in salt water, wash out the
cooling-water passages with fresh water to
prevent them from becoming clogged-up
with salt deposits.
NOTE:
Refer to cooling system flushing instructions
in “TRANSPORTING AND STORING OUTBOARD MOTOR”.
CRUISING IN TURBID WATER
It is strongly recommended that the optional
chromium-plated
water-pump
kit
be
installed if the outboard is to be used in turbid (muddy) water conditions.
3-31
60H-9-E1-4 3/1/02 9:39 PM Page 1
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EMU00317
Chapter 4
MAINTENANCE
1
SPECIFICATIONS ................................ 4-1
TRANSPORTING AND STORING OUTBOARD MOTOR ................................... 4-7
Trailering outboard motor ................... 4-7
Storing outboard motor ....................... 4-8
PERIODIC MAINTENANCE ................ 4-11
Replacement parts ............................ 4-11
Maintenance chart ............................ 4-12
Greasing ........................................... 4-13
Cleaning and adjusting spark plug .... 4-14
Checking fuel system ........................ 4-16
Inspecting fuel filter ........................... 4-17
Adjusting idling speed ....................... 4-20
Replacing fuse .................................. 4-21
Checking wiring and connectors ....... 4-21
Exhaust leakage ............................... 4-21
Water leakage ................................... 4-21
Checking power trim and tilt system . 4-22
Checking propeller ............................ 4-23
Changing gear oil .............................. 4-25
Cleaning fuel tank ............................. 4-26
Inspecting and replacing anode(s) .... 4-27
Checking battery ............................... 4-28
Checking bolts and nuts ................... 4-31
Checking top cowling ........................ 4-31
Motor exterior .................................... 4-31
Coating the boat bottom ................... 4-32
2
3
4
5
6
60H-9-E1-4 3/4/02 11:36 AM Page 2
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EMU01695*
SPECIFICATIONS
Model
Item
Unit
E115AMH
mm (in.)
mm (in.)
mm (in.)
mm (in.)
kg (lb.)
1,458 (57.4)
600 (23.6)
1,558 (61.3) / 1,611 (63.4) / 1,684 (66.3)
516 (20.3) / 569 (22.4) / 642 (25.3)
153 (337) / 155 (342) / 157 (346)
DIMENSIONS
Overall length
Overall width
Overall height
Transom height
Weight
L/Y/X
L/Y/X
L/Y/X
PERFORMANCE
Full throttle operating range
Maximum output
Idling speed (in neutral)
r/min
kW (HP) @ r/min
r/min
4,500–5,500
84.6 (115) @ 5,000
700–800
ENGINE
Type
Displacement
Bore × stroke
Ignition system
Spark plug
Spark plug gap
Control system
Starting system
Battery
Min. cold cranking amps (CCA/EN)
Min. rated capacity (20HR/IEC)
Alternator output
Starting carburetion system
cm3 (cu.in.)
mm (in.)
NGK
mm (in.)
amps at -18°C (-0.4°F)
A·h
V-A (W)
2-stroke, V4
1,730 (105.6)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10
0.9–1.0 (0.035–0.039)
Tiller control
Manual start
—
—
12-10
Manual injection
DRIVE UNIT
Gear positions
Gear ratio
Trim and tilt system
Propeller mark
Forward-Neutral-Reverse
2.00 (26/13)
Manual tilt
K
FUEL AND OIL
Recommended fuel
Fuel tank capacity
Recommended engine oil
Lubrication
Fuel:oil ratio
Recommended gear oil
Gear oil capacity
l (US gal, Imp gal)
Fuel:Oil
cm3 (US oz, Imp oz)
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
760 (25.7, 26.8)
TIGHTENING TORQUE
Spark plug
Propeller nut
4-1
N·m (kgf·m, lb·ft)
N·m (kgf·m, lb·ft)
25 (2.5, 18)
55 (5.6, 40)
60H-9-E1-4 3/1/02 9:39 PM Page 3
E
E115AWH
E115AE
E115AET
1,458 (57.4)
600 (23.6)
1,558 (61.3) / 1,611 (63.4) / 1,684 (66.3)
516 (20.3) / 569 (22.4) / 642 (25.3)
156 (344) / 158 (348) / 160 (353)
828 (32.6)
600 (23.6)
1,435 (56.5) / — / 1,561 (61.5)
516 (20.3) / — / 642 (25.3)
149 (328) / — / 153 (337)
828 (32.6)
600 (23.6)
1,435 (56.5) / — / 1,561 (61.5)
516 (20.3) / — / 642 (25.3)
156 (344) / — / 160 (353)
4,500–5,500
84.6 (115) @ 5,000
700–800
4,500–5,500
84.6 (115) @ 5,000
700–800
4,500–5,500
84.6 (115) @ 5,000
700–800
2-stroke, V4
1,730 (105.6)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10
0.9–1.0 (0.035–0.039)
Tiller control
Manual and electric start
2-stroke, V4
1,730 (105.6)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10
0.9–1.0 (0.035–0.039)
Remote control
Electric start
2-stroke, V4
1,730 (105.6)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10 (EPA models: BR8HS-10)
0.9–1.0 (0.035–0.039)
Remote control
Electric start
430
70
12-10
Manual injection
430
70
12-10
Choke start
430
70
12-10
Choke start
Forward-Neutral-Reverse
2.00 (26/13)
Manual tilt
K
Forward-Neutral-Reverse
2.00 (26/13)
Manual tilt
K
Forward-Neutral-Reverse
2.00 (26/13)
Power trim and tilt
K
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
760 (25.7, 26.8)
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
760 (25.7, 26.8)
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
760 (25.7, 26.8)
25 (2.5, 18)
55 (5.6, 40)
25 (2.5, 18)
55 (5.6, 40)
25 (2.5, 18)
55 (5.6, 40)
4-2
60H-9-E1-4 3/4/02 11:36 AM Page 4
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EMU01695*
SPECIFICATIONS
Model
Item
Unit
115BE
DIMENSIONS
Overall length
Overall width
Overall height
Transom height
Weight
L/Y/X
L/Y/X
L/Y/X
mm (in.)
mm (in.)
mm (in.)
mm (in.)
kg (lb.)
828 (32.6)
600 (23.6)
1,435 (56.5) / — / —
516 (20.3) / — / —
148 (326) / — / —
r/min
kW (HP) @ r/min
r/min
4,500–5,500
84.6 (115) @ 5,000
700–800
PERFORMANCE
Full throttle operating range
Maximum output
Idling speed (in neutral)
ENGINE
Type
Displacement
Bore × stroke
Ignition system
Spark plug
Spark plug gap
Control system
Starting system
Battery
Min. cold cranking amps (CCA/EN)
Min. rated capacity (20HR/IEC)
Alternator output
Starting carburetion system
cm3 (cu.in.)
mm (in.)
NGK
mm (in.)
amps at -18°C (-0.4°F)
A·h
V-A (W)
2-stroke, V4
1,730 (105.6)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10
0.9–1.0 (0.035–0.039)
Remote control
Electric start
430
70
12-10
Choke start
DRIVE UNIT
Gear positions
Gear ratio
Trim and tilt system
Propeller mark
Forward-Neutral-Reverse
2.00 (26/13)
Manual tilt
K
FUEL AND OIL
Recommended fuel
Fuel tank capacity
Recommended engine oil
Lubrication
Fuel:oil ratio
Recommended gear oil
Gear oil capacity
l (US gal, Imp gal)
Fuel:Oil
cm3 (US oz, Imp oz)
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
760 (25.7, 26.8)
TIGHTENING TORQUE
Spark plug
Propeller nut
4-3
N·m (kgf·m, lb·ft)
N·m (kgf·m, lb·ft)
25 (2.5, 18)
55 (5.6, 40)
60H-9-E1-4 3/1/02 10:08 PM Page 5
E
115BET
140BET
150AET
828 (32.6)
600 (23.6)
— / — / 1,561 (61.5)
— / — / 642 (25.3)
— / — / 160 (353)
828 (32.6)
600 (23.6)
1,435 (56.5) / — / 1,561 (61.5)
516 (20.3) / — / 642 (25.3)
156 (344) / — / 160 (353)
828 (32.6)
600 (23.6)
1,577 (62.1) / — / 1,703 (67.0)
516 (20.3) / — / 642 (25.3)
180 (397) / — / 184 (406)
4,500–5,500
84.6 (115) @ 5,000
700–800
4,500–5,500
103 (140) @ 5,000
700–800
4,500–5,500
110.3 (150) @ 5,000
675–725
2-stroke, V4
1,730 (105.6)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10
0.9–1.0 (0.035–0.039)
Remote control
Electric start
2-stroke, V4
1,730 (105.6)
90 × 68 (3.54 × 2.68)
CDI system
B9HS-10
0.9–1.0 (0.035–0.039)
Remote control
Electric start
2-stroke, V6
2,596 (158.4)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10 (EPA models: BR8HS-10)
0.9–1.0 (0.035–0.039)
Remote control
Electric start
430
70
12-10
Choke start
430
70
12-10
Choke start
430
70
12-14
Choke start
Forward-Neutral-Reverse
2.00 (26/13)
Power trim and tilt
K
Forward-Neutral-Reverse
2.00 (26/13)
Power trim and tilt
K
Forward-Neutral-Reverse
1.86 (26/14)
Power trim and tilt
M
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
760 (25.7, 26.8)
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
760 (25.7, 26.8)
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
980 (33.1, 34.5)
25 (2.5, 18)
55 (5.6, 40)
25 (2.5, 18)
55 (5.6, 40)
25 (2.5, 18)
55 (5.6, 40)
4-4
60H-9-E1-4 3/4/02 11:36 AM Page 6
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EMU01695*
SPECIFICATIONS
Model
Item
Unit
L150AET
DIMENSIONS
Overall length
Overall width
Overall height
Transom height
Weight
L/Y/X
L/Y/X
L/Y/X
mm (in.)
mm (in.)
mm (in.)
mm (in.)
kg (lb.)
828 (32.6)
600 (23.6)
— / — / 1,703 (67.0)
— / — / 642 (25.3)
— / — / 186 (410)
r/min
kW (HP) @ r/min
r/min
4,500–5,500
110.3 (150) @ 5,000
675–725
PERFORMANCE
Full throttle operating range
Maximum output
Idling speed (in neutral)
ENGINE
Type
Displacement
Bore × stroke
Ignition system
Spark plug
Spark plug gap
Control system
Starting system
Battery
Min. cold cranking amps (CCA/EN)
Min. rated capacity (20HR/IEC)
Alternator output
Starting carburetion system
cm3 (cu.in.)
mm (in.)
NGK
mm (in.)
amps at -18°C (-0.4°F)
A·h
V-A (W)
2-stroke, V6
2,596 (158.4)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10 (EPA models: BR8HS-10)
0.9–1.0 (0.035–0.039)
Remote control
Electric start
430
70
12-14
Choke start
DRIVE UNIT
Gear positions
Gear ratio
Trim and tilt system
Propeller mark
Forward-Neutral-Reverse
1.86 (26/14)
Power trim and tilt
ML
FUEL AND OIL
Recommended fuel
Fuel tank capacity
Recommended engine oil
Lubrication
Fuel:oil ratio
Recommended gear oil
Gear oil capacity
l (US gal, Imp gal)
Fuel:Oil
cm3 (US oz, Imp oz)
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
870 (29.4, 30.6)
TIGHTENING TORQUE
Spark plug
Propeller nut
4-5
N·m (kgf·m, lb·ft)
N·m (kgf·m, lb·ft)
25 (2.5, 18)
55 (5.6, 40)
60H-9-E1-4 3/1/02 9:39 PM Page 7
E
175AET
200AET
L200AET
828 (32.6)
600 (23.6)
1,577 (62.1) / — / 1,703 (67.0)
516 (20.3) / — / 642 (25.3)
180 (397) / — / 184 (406)
828 (32.6)
600 (23.6)
1,577 (62.1) / — / 1,703 (67.0)
516 (20.3) / — / 642 (25.3)
180 (397) / — / 184 (406)
828 (32.6)
600 (23.6)
— / — / 1,703 (67.0)
— / — / 642 (25.3)
— / — / 186 (410)
4,500–5,500
128.7 (175) @ 5,000
675–725
4,500–5,500
147.1 (200) @ 5,000
675–725
4,500–5,500
147.1 (200) @ 5,000
675–725
2-stroke, V6
2,596 (158.4)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10
0.9–1.0 (0.035–0.039)
Remote control
Electric start
2-stroke, V6
2,596 (158.4)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10
0.9–1.0 (0.035–0.039)
Remote control
Electric start
2-stroke, V6
2,596 (158.4)
90 × 68 (3.54 × 2.68)
CDI system
B8HS-10
0.9–1.0 (0.035–0.039)
Remote control
Electric start
430
70
12-14
Choke start
430
70
12-14
Choke start
430
70
12-14
Choke start
Forward-Neutral-Reverse
1.86 (26/14)
Power trim and tilt
M
Forward-Neutral-Reverse
1.86 (26/14)
Power trim and tilt
M
Forward-Neutral-Reverse
1.86 (26/14)
Power trim and tilt
ML
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
980 (33.1, 34.5)
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
980 (33.1, 34.5)
Regular unleaded gasoline
24 (6.34, 5.28)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
50:1
Hypoid gear oil (SAE90)
870 (29.4, 30.6)
25 (2.5, 18)
55 (5.6, 40)
25 (2.5, 18)
55 (5.6, 40)
25 (2.5, 18)
55 (5.6, 40)
4-6
60H-9-E1-4 3/1/02 9:39 PM Page 8
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EMU01369
TRANSPORTING AND
STORING OUTBOARD MOTOR
w
001329
Leaking fuel is a fire hazard. When transporting and storing the outboard motor,
close the air vent screw and fuel cock to
prevent fuel from leaking.
EMU00326
TRAILERING OUTBOARD MOTOR
The motor should be trailered and stored in
the normal running position. If there is insufficient road clearance in this position, then
trailer the motor in the tilt position using a
motor support device such as a transom
saver bar.
For further details, consult your Yamaha
dealer.
w
8 Never get under the lower unit while it
is tilted, even if a motor support bar is
used. Severe injury could occur if the
outboard accidentally falls.
8 USE CARE when transporting fuel
tank, whether in a boat or car.
8 DO NOT fill fuel container to maximum
capacity. Gasoline will expand considerably as it warms up and can build up
pressure in the fuel container. This
can cause fuel leakage and a potential
fire hazard.
cC
Do not use the tilt support lever/knob
when trailering the boat. The outboard
motor could shake loose from the tilt
support and fall. If the motor can not be
trailered in the down position, use an
additional support device to secure it in
the up position.
4-7
60H-9-E1-4 3/1/02 9:39 PM Page 9
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EMU00329
STORING OUTBOARD MOTOR
When storing your outboard motor for prolonged periods of time (2 months or longer),
several important procedures must be performed to prevent expensive damage.
It is advisable to have your outboard serviced by an authorized Yamaha dealer prior
to storage. However, the following procedures can be performed by the owner with a
minimum of tools.
cC
8 Do not place the engine on its side
before the cooling water has drained
from it completely, or water may enter
the cylinder through the exhaust port
and cause problems.
8 Store the engine in a dry, well-ventilated place, not in direct sunlight.
EMU01508
1)
2)
3)
4)
5)
6)
Wash the motor body using fresh
water. (Refer to “MOTOR EXTERIOR”
for details.)
Remove the fuel-line connection(s)
from the motor or shut off the fuel
valve, if equipped.
Run the engine at idling speed while
supplying fresh water to flush the cooling-water passages. Continue until the
fuel system becomes empty and the
engine stops. (Refer to “FLUSHING
COOLING SYSTEM” for details.)
For electric start models, remove the
battery. (Refer to “DISCONNECTING
THE BATTERY” for details.)
Drain the cooling water completely out
of the motor.
Clean the body thoroughly.
Remove the spark plug(s).
4-8
60H-9-E1-4 3/1/02 9:39 PM Page 10
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7)
8)
9)
Pour a teaspoonful of clean engine oil
into the cylinder(s).
Crank several times manually.
Replace the spark plug(s).
EMU00336
Fuel Tank
1) Drain the fuel from the tank for a long
period of storage.
2) Store the fuel tank in a dry, well-ventilated place, not in direct sunlight.
EMU00345
Flushing Cooling System
cC
Do not run the engine without supplying
the engine cooling water. Either the
engine water pump will be damaged or
the engine will overheat and be damaged. Before starting the engine, supply
water to the cooling water passage.
EMU00348
8 Flushing with the Flushing Attachment
w
q
Before using the flushing attachment,
remove the propeller. Keep yourself and
others away from the propeller shaft.
1)
000420
2)
3)
4)
605014
4-9
Fit the flushing attachment 1 (option)
in position on the lower casing, with
rubber cups covering the cooling water
inlet.
Connect a garden hose between the
flushing attachment and the water tap.
Shift into “NEUTRAL”, and start the
engine while supplying water.
Run the engine at low speed for a few
minutes.
60H-9-E1-4 3/1/02 9:39 PM Page 11
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EMU01545
Battery Care
w
Battery electrolyte is poisonous and
dangerous, causing severe burns, etc. It
contains sulfuric acid. Avoid contact
with skin, eyes, or clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of
water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call
physician immediately.
EYES: Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases: Keep
sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in a
closed space. Always wear eye protection when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
EL
LEV EL
ER
V
UPP ER LE
W
LO
000639
Batteries vary among manufacturers.
Therefore the following procedures may not
always apply. Consult your battery manufacturer’s instructions.
1) Disconnect and remove the battery
from the boat. Always disconnect the
black negative lead first to prevent the
risk of shorting.
2) Clean the battery casing and terminals.
Fill each cell to the upper level with distilled water.
3) Store the battery on a level surface in a
cool, dry, well-ventilated place out of
direct sunlight.
4) Once a month, check the specific gravity of the electrolyte and recharge as
required to prolong battery life.
4-10
60H-9-E1-4 3/7/02 8:58 PM Page 12
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EMU00355
PERIODIC MAINTENANCE
w
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If the owner is not familiar
with machine servicing, this work should
be done by a Yamaha dealer or other
qualified mechanic.
EMU00356
REPLACEMENT PARTS
If replacement parts are necessary, use
only genuine Yamaha parts or equivalents
of the same type and of equivalent strength
and materials. Any part of inferior quality
may malfunction, and the resulting loss of
control could endanger the operator and
passengers.
Yamaha genuine parts and accessories are
available from a Yamaha dealer.
4-11
60H-9-E1-4 3/1/02 9:39 PM Page 13
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EMU01708
MAINTENANCE CHART
Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines.
The mark (●) indicates the check-ups which you may carry out yourself.
The mark (1) indicates work to be carried out by your Yamaha dealer.
Initial
Interval
10 hours
Item
Carburetor
Cleaning
Fuel tank
Cleaning
1
Every
50 hours 100 hours
(3 months) (6 months)
1
200 hours
(1 year)
1
—
●
Fuel filter
Cleaning
●
Fuel system
Inspection
●
Cooling water passages *1
Cleaning
Idling speed
Inspection/adjustment
●
Spark plug
Cleaning/adjustment/
replacement
●
Power trim and tilt system
Inspection
Wiring and connectors
Inspection/reconnection
Exhaust leakage
Inspection
Water leakage
Inspection
Grease points
Greasing
Gear oil
Change
●
Bolts and nuts
Retightening
●
Cowling clamps
Inspection
Anode
Inspection
●
●
●
●
Refer
page
4-26
4-17
1
4-16
●
4-9
●
4-20
●
●
4-14
●
●
●
4-22
●
●
●
4-21
●
●
●
4-21
●
●
●
4-21
●
4-13
●
4-25
●
●
4-31
●
—
●
●
4-27
Propeller
Inspection
●
●
●
4-23
Motor exterior
Inspection
●
●
●
4-31
Battery *2
Inspection
●
(every
month)
Carburetor setting
Inspection/adjustment
1
1
—
Ignition timing
Inspection/adjustment
1
1
—
4-28
*1. When operating in salt water, turbid or muddy water, the engine should be flushed with clean water
after each use.
*2. For electric start models.
4-12
60H-9-E1-4 3/1/02 9:39 PM Page 14
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EMU00909
GREASING
Yamaha grease A (Water resistant grease)
Yamaha grease D (Corrosion resistant grease) *1
103072
*1. For propeller shaft
4-13
60H-9-E1-4 3/1/02 9:39 PM Page 15
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EMU01202
CLEANING AND ADJUSTING SPARK
PLUG
w
000655
When removing or installing a spark
plug, be careful not to damage the insulator. A damaged insulator could allow
external sparks, which could lead to
explosion or fire.
The spark plug is an important engine component and is easy to inspect. The condition
of the spark plug can indicate something
about the condition of the engine. For
example, if the center electrode porcelain is
very white, this could indicate an intake air
leak or carburetion problem in that cylinder.
Do not attempt to diagnose any problems
yourself. Instead, take the outboard motor
to a Yamaha dealer. You should periodically remove and inspect the spark plug
because heat and deposits will cause the
spark plug to slowly break down and erode.
If electrode erosion becomes excessive, or
if carbon and other deposits are excessive,
you should replace the spark plug with
another of the correct type.
Standard spark plug:
Refer to “SPECIFICATIONS”, page 4-1.
Before fitting the spark plug, measure the
electrode gap with a wire thickness gauge;
adjust the gap to specification if necessary.
Spark plug gap:
Refer to “SPECIFICATIONS”, page 4-1.
4-14
60H-9-E1-4 3/1/02 9:39 PM Page 16
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When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off
any dirt from the threads and screw in the
spark plug to the correct torque.
Spark plug torque:
Refer to “SPECIFICATIONS”, page 4-1.
NOTE:
If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of
the correct torque is 1/4 to 1/2 a turn past
finger-tight. Have the spark plug adjusted to
the correct torque as soon as possible with
a torque-wrench.
Initial of spark
plug I.D. mark
000535
Plug wrench size
B
21 mm (13/16 in.)
C/BK
16 mm (5/8 in.)
D
18.3 mm (23/32 in.)
1 Spark plug gap
2 Spark plug I.D. mark (NGK)
w
q
903022
4-15
60H-9-E1-4 3/1/02 9:39 PM Page 17
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EMU01509
V4
CHECKING FUEL SYSTEM
w
Gasoline (petrol) and its vapors are highly flammable and explosive. Keep away
from sparks, cigarettes, flames or other
sources of ignition.
001319
V6
Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should
be repaired immediately by Yamaha dealer
or other qualified mechanic.
Checkpoints
8 Fuel system parts leakage.
8 Fuel hose joint leakage.
8 Fuel hose cracks or other damage.
8 Fuel connector leakage.
001320
w
Leaking fuel can result in fire or explosion.
8 Check for fuel leakage regularly.
8 If any fuel leakage is found, the fuel
system must be repaired by a qualified
mechanic. Improper repairs can make
the outboard unsafe to operate.
4-16
60H-9-E1-4 3/1/02 9:39 PM Page 18
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EMU00370
INSPECTING FUEL FILTER
w
Gasoline (petrol) is highly flammable,
and its vapors are flammable and explosive.
8 If you have any question about properly doing this procedure, consult your
Yamaha dealer.
8 Do not perform this procedure on a
hot or running engine. Allow the
engine to cool.
8 There will be fuel in the fuel filter. Keep
away from sparks, cigarettes, flames
or other sources of ignition.
8 This procedure will allow some fuel to
spill. Catch fuel in a rag. Wipe up any
spilled fuel immediately.
8 The fuel filter must be reassembled
carefully with O-ring, filter cup, and
hoses in place. Improper assembly or
replacement can result in a fuel leak,
which could result in a fire or explosion hazard.
4-17
60H-9-E1-4 3/1/02 9:39 PM Page 19
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EMU00978
115B, 140B
115B, 140B
1)
2)
3)
001333
4)
w
e
r
5)
q
000983
6)
EMU01307
E115A, 150A,
E115A, 150A, L150A, 175A
L150A, 175A
NOTE:
If any water is in the fuel, the red float in the
fuel filter unit will rise. If so, remove the cup
and drain the water.
1)
001334
2)
r
e
Remove the nut holding the fuel filter
assembly if equipped.
Unscrew the filter cup 1, catching any
spilled fuel in a rag.
Remove the filter element 2, and wash
it in solvent.
Allow it to dry. Inspect the filter element
and O-ring 3 to make sure they are in
good condition. Replace them if necessary.
Reinstall the filter element in the cup.
Make sure the O-ring in position in the
cup. Firmly screw the cup onto the filter
housing 4.
Attach the filter assembly to the bracket
with that the fuel hoses are attached to
the filter assembly.
Run the engine and check the filter and
lines for leaks.
w
3)
t
4)
q
001335
5)
Remove the filter cup 1, catching any
spilled fuel in a container.
Remove the filter element 2, wash it in
solvent, and allow it to dry. Inspect the
filter element, O-ring 3, and float 5 to
make sure they are in good condition,
and replace if necessary.
Re-install the filter element in the filter
housing 4 and properly re-insert the
float into the filter cup.
Re-insert the O-ring in its proper position and re-install the filter cup onto the
filter housing firmly.
Run the engine and check the filter and
lines for leaks.
4-18
60H-9-E1-4 3/1/02 9:39 PM Page 20
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EMU01308
200A, L200A
200A, L200A
q
NOTE:
If any water is in the fuel, the float 7 will
rise. If so, remove the cup and drain the
water.
1)
001332
2)
y
t
r
e
w
3)
u
4)
001331
5)
6)
4-19
Loosen and remove the locking tab bolt
and tab 1. Slightly loosen the filter cup
ring nut 2.
Remove the filter cup 3, catching any
spilled fuel in a rag.
Remove the filter element 4, and wash
it in solvent.
Allow it to dry. Inspect the filter element
and O-ring 5 to make sure they are in
good condition. Replace them if necessary.
Reinstall the filter element. Make sure
the O-ring is in position in the cup.
Insert the cup and O-ring into the filter
housing 6. Screw the ring nut onto the
filter housing until the ring is lightly
seated.
Tighten the ring nut approximately an
additional 1/4 turn until ring nut is tight.
Align one of the four larger ring nut tabs
into the slot of the locking tab. Install
the locking tab bolt and tighten.
Run the engine and check the filter and
lines for leaks.
60H-9-E1-4 3/1/02 9:39 PM Page 21
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EMU00991
ADJUSTING IDLING SPEED
w
8 Do not touch or remove electrical
parts when starting or during operation.
8 Keep hands, hair and clothes away
from flywheel and other rotating parts
while engine is running.
cC
This procedure must be performed while
the outboard motor is in the water. A
flushing attachment or test tank can be
used.
q
001321
A diagnostic tachometer should be used for
this procedure.
1) Start the engine and allow it to warm up
fully in Neutral until it is running
smoothly. If the outboard is mounted on
a boat, be sure the boat is tightly
moored.
2) Adjust the throttle stop-screw 1 to set
the idling speed to specification (see
“SPECIFICATIONS” on page 4-1) by
turning the stop-screw clockwise to
increase the idling speed, and turning it
counterclockwise to decrease the idling
speed.
NOTE:
Correct idling-speed adjustment is only possible if the engine is fully warmed-up. If not
warmed up fully, the speed setting will tend
to be too high. If you have difficulty obtaining the specified idle, consult a Yamaha
dealer or other qualified mechanic.
4-20
60H-9-E1-4 3/1/02 9:39 PM Page 22
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EMU01329
REPLACING FUSE
If the fuse has blown on an Electric start
model, open the fuse holder and replace
the fuse with a new one of proper amperage.
w
Be sure to use the specified fuse. An
incorrect fuse or a piece of wire may
allow excessive current flow. This could
cause electrical system damage and a
fire hazard.
NOTE:
If the new fuse blows again immediately,
consult a Yamaha dealer.
w q
205033
1 Fuse holder
2 Fuse (20A)
EMU00383
CHECKING WIRING AND
CONNECTORS
1)
2)
Check that each grounding wire is
properly secured.
Check that each connector is engaged
securely.
EMU00384
413016
EXHAUST LEAKAGE
Start the engine and check that no exhaust
leaks from the joints between the exhaust
cover, cylinder head and crank case.
EMU00385
WATER LEAKAGE
Start the engine and check that no water
leaks from the joints between the exhaust
cover, cylinder head and crank case.
4-21
60H-9-E1-4 3/1/02 9:39 PM Page 23
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EMU01690
CHECKING POWER TRIM AND TILT
SYSTEM
w
8 Never get under the lower unit while it
is tilted, even when the tilt-support
lever is locked. Severe injury could
occur if the outboard accidentally falls.
8 Make sure no one is under the outboard before performing this test.
1)
q
w
411046
e
411044
Check the power trim and tilt unit for
any sign of oil leaks.
2) Operate each of the power trim and tilt
switches on remote control and engine
bottom cowling (if equipped) to check
that all switches work.
3) Tilt up the motor and check that the tilt
rod 1 and trim rods 2 are pushed out
completely.
4) Use the tilt support lever 3 to lock the
motor in the UP position. Operate the
tilt down switch briefly so the motor is
supported the tilt support lever.
5) Check that the tilt rod and trim rods are
free of corrosion or other flaws.
6) Activate the tilt-down switch until the
trim rods have gone completely into the
cylinders.
7) Activate the trim-up switch until the tilt
rod is fully extended. Unlock the tilt
support lever.
8) Operate the motor to tilt down. Check
that the tilt rod and trim rods operate
smoothly.
NOTE:
If any operation is abnormal, consult a
Yamaha dealer.
411045
4-22
60H-9-E1-4 3/1/02 9:39 PM Page 24
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Recommended fluid:
Yamaha power trim & tilt fluid or ATF
(DEXRON-II).
EMU00388
CHECKING PROPELLER
w
210012
602051
You could be seriously injured if the
engine accidentally starts while you are
near the propeller.
8 Before
inspecting,
removing
or
installing the propeller, remove the
spark plug caps from the spark plugs.
Also, put the shift control in Neutral,
put the main switch in the “OFF” position and remove the key, and remove
the lanyard from the engine stop
switch. Turn off the battery cut-off
switch if your boat has one.
8 Do not use your hand to hold the propeller when loosening or tightening
the propeller nut. Put a wood block
between the cavitation plate and the
propeller to prevent the propeller from
turning.
EMU00390
602054
4-23
Propeller Checking Point
8 Check each of the propeller blades for
wear, erosion from cavitation or ventilation, or other damage.
8 Check the splines for wear and damage.
8 Check for fish line winding around the
propeller shaft.
8 Check the propeller shaft oil seal for damage.
60H-9-E1-4 3/1/02 9:39 PM Page 25
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EMU00976
q
w
e
r
y
t
Removing the Propeller
1) Straighten the cotter-pin 1 and pull it
out using a pair of pliers.
2) Remove the propeller nut 2, washer 3
and spacer 4.
3) Remove the propeller 5 and thrust
washer 6.
000357
EMU01560
Installing the Propeller
cC
8 Be sure to install the thrust washer
before installing propeller, otherwise
the lower case and propeller boss may
be damaged.
8 Be sure to use a new cotter pin and
bend the ends over securely.
Otherwise, the propeller could come
off during operation and be lost.
1)
2)
3)
Apply Yamaha Marine grease or
Corrosion resistant grease to the propeller shaft.
Install the thrust washer and propeller
on the propeller shaft.
Install the spacer and washer. Tighten
the propeller nut to the specified torque.
Tightening torque:
Refer to “SPECIFICATIONS” page 4-1.
4)
602053
Align the propeller nut with the propeller
shaft hole. Insert a new cotter pin in the
hole and bend the cotter pin ends.
NOTE:
If the propeller nut does not align with the
propeller shaft hole after tightening to the
specified torque, then tighten the nut further
to align it with the hole.
4-24
60H-9-E1-4 3/1/02 9:39 PM Page 26
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EMU01460
CHANGING GEAR OIL
w
8 Be sure the outboard is securely fastened to the transom or a stable stand.
You could be severely injured if the
outboard falls on you.
8 Never get under the lower unit while it
is tilted, even when the tilt-support
lever/knob is locked. Severe injury
could occur if the outboard accidentally falls.
1)
Tilt the outboard motor so that the oil
drain plug is at the lowest point possible.
2) Place a suitable container under the
gear-case.
3) Remove the oil drain plug 1.
NOTE:
The oil drain plug is magnetic. Remove all
metal particles from the plug before reinstalling it.
w
4)
Remove the oil level plug 2 to allow
the oil to drain completely.
cC
q
001324
Inspect the used oil after it has been
drained. If the oil is milky, water is getting into the gear-case which can cause
gear damage. Consult a Yamaha dealer
for repair of the lower unit seals.
NOTE:
For disposal of used oil consult your
Yamaha dealer.
4-25
60H-9-E1-4 3/1/02 9:39 PM Page 27
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5)
With the outboard motor in a vertical
position, and using a flexible or pressurized filling device, inject the gear oil
into the oil drain plug hole.
Gear oil grade/capacity:
Refer to “SPECIFICATIONS,” page 4-1.
6)
601033
7)
When the oil begins to flow out of the
oil level plug hole, insert and tighten the
oil level plug.
Insert and tighten the oil drain plug.
EMU01510
CLEANING FUEL TANK
w
Gasoline (petrol) is highly flammable,
and its vapors are flammable and explosive.
8 If you have any question about properly doing this procedure, consult your
Yamaha dealer.
8 Keep away from sparks, cigarettes,
flames or other sources of ignition
when cleaning the fuel tank.
8 Remove the fuel tank from the boat
before cleaning it. Work only outdoors
in an area with good ventilation.
8 Wipe up any spilled fuel immediately.
8 Reassemble the fuel tank carefully.
Improper assembly can result in a fuel
leak, which could result in a fire or
explosion hazard.
8 Dispose of old gasoline (petrol)
according to local regulations.
1)
2)
000638
Empty the fuel tank into an approved
container.
Pour a small amount of suitable solvent
in the tank. Reinstall the cap and shake
the tank. Drain the solvent completely.
4-26
60H-9-E1-4 3/1/02 9:39 PM Page 28
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EMU00402
000274
Cleaning the Fuel Filter
1) Remove the screws holding the fuel
hose joint assembly. Pull the assembly
out of the tank.
2) Clean the filter (located on the end of
the suction pipe) in a suitable cleaning
solvent. Allow the filter to dry.
3) Replace the gasket with a new one.
Reinstall the fuel hose joint assembly
and tighten the screws firmly.
EMU01462
INSPECTING AND REPLACING
ANODE(S)
603024
Yamaha outboard motors are protected
from corrosion by sacrificial anodes.
Check the anodes periodically. Remove
scales from the surfaces of the anodes.
For inspection and replacement of anodes,
consult a Yamaha dealer.
cC
Do not paint anodes, as this would render them ineffective.
405016
4-27
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EMU00404
CHECKING BATTERY (for Electric
start models)
w
EL
LEV EL
ER
V
UPP ER LE
W
LO
901015
Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is
poisonous and highly caustic.
Always follow these preventive measures:
8 Avoid bodily contact with electrolytic
fluid as it can cause severe burns or
permanent eye injury.
8 Wear protective eye gear when handling or working near batteries.
Antidote (EXTERNAL):
8 SKIN - Flush with water.
8 EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
8 Drink large quantities of water or milk
followed by milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive hydrogen gas; therefore, you should always
follow these preventive measures:
8 Charge batteries in a well-ventilated
area.
8 Keep batteries away from fire, sparks,
or open flames (e.g., welding equipment, lighted cigarettes, etc.).
8 DO NOT SMOKE when charging or
handling batteries.
8 KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN.
4-28
60H-9-E1-4 3/1/02 9:39 PM Page 30
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cC
8 A poorly maintained battery will quickly deteriorate.
8 Ordinary tap-water contains minerals
harmful to a battery, and should not be
used for topping-up.
EL
LEV EL
ER
V
UPP ER LE
LOW
000639
1)
2)
3)
4-29
Check the electrolyte level at least once
a month. Fill to the manufacturer’s recommended level when necessary. Top
up only with distilled water (or pure deionized water suitable to use in batteries).
Keep the battery always in a good state
of charge. Installing a voltmeter will
help you monitor your battery. If you will
not use the boat for a month or more,
remove the battery from the boat and
store it in a cool, dark place.
Completely recharge the battery before
using it.
If the battery will be stored for longer
than a month, check the specific gravity
of the fluid at least once a month and
recharge the battery when it is low.
60H-9-E1-4 3/1/02 9:39 PM Page 31
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EMU01279
Connecting the Battery
Electric start models
w
Mount the battery holder securely in a
dry, well-ventilated, vibration-free location in the boat. Install a fully charged
battery in the holder.
cC
q
EL
L E V EL
ER
V
U P P ER LE
LOW
w
e
901012
8 Make sure the main switch (on applicable models) is “OFF” before working
on the battery.
8 Reversal of the battery leads will damage the rectifier.
8 Connect the RED lead first when
installing the battery and disconnect
the RED lead last when removing it.
Otherwise, the electrical system can
be damaged.
8 The electrical contacts of the battery
and cables must be clean and properly
connected, or the battery will not start
the engine.
Connect the RED lead to the POSITIVE (+)
terminal first.
Then connect the BLACK lead to the NEGATIVE (-) terminal.
1 Red lead
2 Black lead
3 Battery
EMU01280
Disconnecting the Battery
Disconnect the BLACK lead from the NEGATIVE (-) terminal first. Then disconnect the
RED lead from the POSITIVE (+) terminal.
4-30
60H-9-E1-4 3/1/02 9:39 PM Page 32
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EMU00408
CHECKING BOLTS AND NUTS
1)
2)
Check that bolts securing the cylinder
head and engine and the nut securing
the flywheel are tightened with their
specified tightening torque.
Check the tightening torque of other
bolts and nuts.
EMU01635
CHECKING TOP COWLING
Check the fitting of the top cowling by pushing it with both hands.
If the fitting is loose have it repaired by a
Yamaha dealer.
EMU00409
MOTOR EXTERIOR
EMU00410
Cleaning the Outboard Motor
After use, wash the exterior of the outboard
with fresh water.
Flush the cooling system with fresh water.
NOTE:
Refer to Flushing Cooling System instructions in “TRANSPORTING AND STORING
OUTBOARD MOTOR”.
102024
EMU00412
Checking Painted Surface of Motor
Check the motor for scratches, nicks, or
flaking paint. Areas with damaged paint are
more likely to corrode. If necessary, clean
and paint the areas. A touch-up paint is
available from a Yamaha dealer.
4-31
60H-9-E1-4 3/1/02 9:39 PM Page 33
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EMU00413
COATING THE BOAT BOTTOM
102025
A clean hull improves boat performance.
The boat bottom should be kept as clean of
marine growths as possible. If necessary,
the boat bottom can be coated with an antifouling paint approved for your area to
inhibit marine growth.
Do not use anti-fouling paint which includes
copper or graphite. These paints can cause
more rapid engine corrosion.
4-32
60H-9-E1-4 3/1/02 9:39 PM Page 34
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-MEMO-
60H-9-E1-5 3/1/02 9:41 PM Page 1
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EMU00414
Chapter 5
TROUBLE RECOVERY
1
TROUBLESHOOTING .......................... 5-1
TEMPORARY ACTION IN
EMERGENCY ....................................... 5-5
Impact damage ................................... 5-5
Running single engine ........................ 5-5
Power trim/tilt will not operate ............. 5-6
Starter will not operate ........................ 5-7
Treatment of submerged motor ........ 5-11
2
3
4
5
6
60H-9-E1-5 3/4/02 11:41 AM Page 2
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EMU01663¯
TROUBLESHOOTING
A problem in the fuel, compression, or ignition systems can cause poor starting, loss of
power, or other problems. The troubleshooting chart describes basic checks and possible
remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not
apply to your model.)
If your outboard motor requires repair, bring it to a Yamaha dealer.
If the engine warning indicator is flashing, consult your Yamaha dealer.
Trouble
Possible Cause
4. Starter components faulty.
5. Shift lever in gear.
1.
2.
3.
4.
5.
6.
Fuel tank empty.
Fuel contaminated or stale.
Fuel filter clogged.
Starting procedure incorrect.
Fuel pump malfunctions.
Spark plug(s) fouled or incorrect type.
1.
2.
3.
4.
5.
6.
7. Spark plug cap(s) fitted incorrectly.
8. Poor connections or damaged ignition
wiring.
7.
8.
2. Battery connections loose or corroded.
A. Starter will not
operate.
B. Engine will not start
(Starter operates).
3. Fuse for electric start circuit blown.
9. Ignition parts faulty.
10. Engine stop switch lanyard not
attached.
11. Engine inner parts damaged.
1. Spark plug(s) fouled or incorrect type.
2. Fuel system obstructed.
C. Engine idles
irregularly or stalls.
5-1
Remedy
1. Check battery condition. Use battery
of recommended capacity.
2. Tighten battery cables and clean
battery terminals.
3. Check for cause of electric overload
and repair. Replace fuse with one of
correct amperage.
4. Have serviced by a Yamaha dealer.
5. Shift to neutral.
1. Battery capacity weak or low.
3.
4.
5.
6.
7.
Fuel contaminated or stale.
Fuel filter clogged.
Failed ignition parts.
Warning system activated.
Spark plug gap incorrect.
9.
10.
Fill tank with clean, fresh fuel.
Fill tank with clean, fresh fuel.
Clean or replace filter.
Read “STARTING ENGINE” section.
Have serviced by a Yamaha dealer.
Inspect spark plug(s). Clean or
replace with recommended type.
Check and re-fit cap(s).
Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.
Have serviced by a Yamaha dealer.
Attach lanyard.
11. Have serviced by a Yamaha dealer.
1. Inspect spark plug(s). Clean or
replace with recommended type.
2. Check for pinched or kinked fuel line
or other obstructions in fuel system.
3. Fill tank with clean, fresh fuel.
4. Clean or replace filter.
5. Have serviced by a Yamaha dealer.
6. Find and correct cause of warning.
7. Inspect and adjust as specified.
60H-9-E1-5 3/4/02 11:41 AM Page 3
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Trouble
C. Engine idles
irregularly or stalls.
Possible Cause
Remedy
8. Poor connections or damaged ignition
wiring.
8. Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.
9. Check and replace oil as specified.
10. Have serviced by a Yamaha dealer.
11. Have serviced by a Yamaha dealer.
12. Have serviced by a Yamaha dealer.
13. Open the air vent screw.
14. Return to home position.
15. Return to normal operating position.
16. Have serviced by a Yamaha dealer.
17. Connect correctly.
18. Have serviced by a Yamaha dealer.
19. Connect securely.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Specified engine oil not used.
Thermostat faulty or clogged.
Carburetor adjustments incorrect.
Fuel pump damaged.
Air vent screw on the fuel tank closed.
Choke knob pulled out.
Motor angle too high.
Carburetor clogged.
Fuel joint connection incorrect.
Throttle valve adjustment incorrect.
Battery lead disconnected.
1. Cooling system clogged.
2. Heat range of spark plug incorrect.
D. Warning buzzer
sounds or indicator
lamp lights.
3. Specified engine oil not used.
4. Engine oil contaminated or
deteriorated.
5. Load on boat improperly distributed.
6. Water pump/thermostat faulty.
1. Propeller damaged.
2. Propeller pitch or diameter incorrect.
3. Trim angle incorrect.
E. Engine power loss.
4. Motor mounted at incorrect height on
transom.
5. Warning system activated.
6. Boat bottom fouled with marine growth.
7. Spark plug(s) fouled or incorrect type.
8. Weeds or other foreign matter tangled
on gear housing.
9. Fuel system obstructed.
10.
11.
12.
13.
Fuel filter clogged.
Fuel contaminated or stale.
Spark plug gap incorrect.
Poor connections or damaged ignition
wiring.
1. Check water intake for restriction.
2. Inspect spark plug and replace it with
recommended type.
3. Check and replace oil with specified
type.
4. Replace oil with fresh, specified type.
5. Distribute load to place boat on an
even plane.
6. Have serviced by a Yamaha dealer.
1. Have propeller repaired or replaced.
2. Install correct propeller to operate
outboard at its recommended speed
(r/min) range.
3. Adjust trim angle to achieve most
efficient operation.
4. Have motor adjusted to proper
transom height.
5. Find and correct cause of warning.
6. Clean boat bottom.
7. Inspect spark plug(s). Clean or
replace with recommended type.
8. Remove foreign matter and clean
lower unit.
9. Check for pinched or kinked fuel line
or other obstructions in fuel system.
10. Clean or replace filter.
11. Fill tank with clean, fresh fuel.
12. Inspect and adjust as specified.
13. Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.
5-2
60H-9-E1-5 3/4/02 11:41 AM Page 4
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Trouble
Possible Cause
14. Failed ignition parts.
15. Specified engine oil not used.
E. Engine power loss.
F. Engine vibrates
excessively.
5-3
16.
17.
18.
19.
20.
Thermostat faulty or clogged.
Air vent screw closed.
Fuel pump damaged.
Fuel joint connection incorrect.
Heat range of spark plug incorrect.
1. Propeller damaged.
2. Propeller shaft damaged.
3. Weeds or other foreign matter tangled
on propeller.
4. Motor mounting bolt loose.
5. Steering pivot loose or damaged.
Remedy
14. Have serviced by a Yamaha dealer.
15. Check and replace oil with specified
type.
16. Have serviced by a Yamaha dealer.
17. Open the air vent screw.
18. Have serviced by a Yamaha dealer.
19. Connect correctly.
20. Inspect spark plug and replace it with
recommended type.
1. Have propeller repaired or replaced.
2. Have serviced by a Yamaha dealer.
3. Remove and clean propeller.
4. Tighten bolt.
5. Tighten or have serviced by a
Yamaha dealer.
60H-9-E1-5 3/1/02 9:41 PM Page 5
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-MEMO-
5-4
60H-9-E1-5 3/1/02 9:41 PM Page 6
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EMU00416
TEMPORARY ACTION IN
EMERGENCY
EMU01492
IMPACT DAMAGE
w
The outboard motor can be seriously
damaged by a collision while operating
or trailering. Damage could make the
outboard motor unsafe to operate.
607011
If the outboard motor hits any object in the
water, follow the procedure below.
1) Stop the engine immediately.
2) Inspect the control system and all components for damage. Also, inspect the
boat for damage.
3) Whether damage is found or not, return
to the nearest harbor slowly and carefully.
4) Have a Yamaha dealer inspect the outboard motor before operating it again.
EMU00418
RUNNING SINGLE ENGINE
Using only one of the engines in case of an
emergency, be sure to keep the unused
one tilted up and operate the other engine
at low speed.
cC
If the boat is operated with one engine in
the water but not running, water may run
into the exhaust pipe due to wave action,
causing engine trouble.
001422
5-5
NOTE:
When you are maneuvering at low speed,
such as near a dock, it is recommended
that both engines be running with one in
neutral gear if possible.
60H-9-E1-5 3/1/02 9:41 PM Page 7
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EMU00419
POWER TRIM/TILT WILL NOT
OPERATE
q
411025
If the engine cannot be tilted up or down
with the power trim and tilt because of a discharged battery or a failure with the power
trim and tilt unit, the engine can be tilted
manually.
1 Manual valve screw
EMU00421
1)
2)
Loosen the manual valve screw counterclockwise until it stops.
Put the engine in the desired position,
then tighten the manual valve screw
clockwise.
5-6
60H-9-E1-5 3/1/02 9:41 PM Page 8
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EMU00423
STARTER WILL NOT OPERATE
If the starter mechanism does not operate
(engine cannot be cranked with the starter),
the engine can be started with an emergency starter rope.
w
8 Use this procedure only in an emergency and only to return to port for
repairs.
8 When the emergency starter rope is
used to start the engine, the start-ingear protection device does not operate. Make sure the gear shift lever/
remote control lever is in neutral.
Otherwise, the boat could unexpectedly start to move, which could result in
an accident.
8 Be sure no one is standing behind you
when pulling the starter rope. It could
whip behind you and injure someone.
8 An unguarded rotating flywheel is very
dangerous. Keep loose clothing and
other objects away when starting the
engine. Use the emergency starter
rope only as instructed. Do not touch
the flywheel or other moving parts
when the engine is running. Do not
install the starter mechanism or top
cowling after the engine is running.
8 Do not touch the ignition coil, high
voltage wire, spark plug cap or other
electrical components when starting of
operating the motor. You could be
shocked.
5-7
60H-9-E1-5 3/1/02 9:41 PM Page 9
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EMU01513
Emergency Starting Engine
1) Remove the top cowling.
2) Remove the start-in-gear protection
cable from the starter if equipped.
3) Remove the starter/flywheel cover after
removing the bolt(s).
001316
OFF
ON
START
OFF
4)
Prepare the engine for starting. Refer to
“STARTING ENGINE” for details. Be
sure the engine is in Neutral and that
the lock plate is attached to the engine
stop lanyard switch. The main switch
must be “ON” if equipped.
5)
Pull out the choke knob when starting a
cold engine. After the engine starts,
gradually return the choke knob to the
home position as the engine warms up.
ON
ON
START OFF
START
305034
5-8
60H-9-E1-5 3/1/02 9:41 PM Page 10
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6)
7)
Insert the knotted end of the emergency starter rope into the notch in the
flywheel rotor and wind the rope 1 or 2
turns clockwise.
Give a strong pull straight out to crank
and start the engine. Repeat if necessary.
208041
EMU01705*
Starting engine after manual injection
failure
E115AMH, E115AWH
1)
Remove the top cowling.
2)
Turn the emergency valve to ON.
3)
Prepare the engine for starting. For
instructions, see Chapter 3, “Starting
Engine.” Be sure the engine is in neutral.
214015
N
507022
5-9
60H-9-E1-5 3/1/02 9:41 PM Page 11
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4)
Squeeze the primer pump once to feed
fuel to the engine.
5)
Pull the starter handle slowly until you
feel resistance. Then give a strong pull
straight out to crank and start the
engine. Repeat if necessary.
6)
Return the emergency valve to OFF
after the engine has started, then
securely reinstall the top cowling.
902025
001317
214016
5-10
60H-9-E1-5 3/1/02 9:41 PM Page 12
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EMU01511
TREATMENT OF SUBMERGED
MOTOR
107012
If the outboard motor is submerged, immediately take it a Yamaha dealer. Otherwise,
some corrosion may begin almost immediately.
If you cannot immediately take the outboard
motor to a Yamaha dealer, follow the procedure below in order to minimize engine
damage.
EMU00447
1)
2)
3)
107013
4)
5)
Thoroughly wash away mud, salt, seaweed, etc. with fresh water.
Remove the spark plugs and face the
spark plug holes downward to allow
any water, mud or contaminants to
drain.
Drain the fuel from the carburetor, fuel
filter and fuel line.
Feed fogging oil or engine oil through
the carburetor(s) and spark plug hole(s)
while cranking with the manual starter
or emergency starter rope.
Take the outboard motor to a Yamaha
dealer as soon as possible.
cC
Do not attempt to run the motor until it
has been completely inspected.
107014
5-11
60H-9-E1-6 3/1/02 9:42 PM Page 1
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EMU00450
Chapter 6
INDEX
1
INDEX......................................................6-1
2
3
4
5
6
60H-9-E1-6 3/1/02 9:42 PM Page 2
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EMU00451
INDEX
A
Adjusting idling speed .......................... 4-20
Adjusting trim angle ............................. 3-24
Air vent screw ........................................ 2-5
B
Battery care ......................................... 4-10
Battery requirement ............................... 1-8
Bow down ............................................ 3-26
Bow up ................................................. 3-26
Breaking in (running in) engine .............. 3-5
C
Changing gear oil ................................ 4-25
Checking battery .................................. 4-28
Checking bolts and nuts ...................... 4-31
Checking fuel system .......................... 4-16
Checking painted surface of motor ...... 4-31
Checking power trim and tilt system .... 4-22
Checking propeller ............................... 4-23
Checking top cowling ........................... 4-31
Checking wiring and connectors .......... 4-21
Checkpoints ......................................... 4-16
Choke knob ........................................... 2-7
Choke switch ....................................... 2-12
Cleaning and adjusting spark plug ...... 4-14
Cleaning fuel tank ................................ 4-26
Cleaning the fuel filter .......................... 4-27
Cleaning the outboard motor ............... 4-31
Coating the boat bottom ...................... 4-32
Connecting the battery ........................ 4-30
Cruising in other conditions ................. 3-31
Cruising in salt water ........................... 3-31
Cruising in turbid water ........................ 3-31
D
Digital hour meter ....................... 2-18, 2-19
Disconnecting the battery .................... 4-30
E
EC label ................................................. 1-2
Emergency starting engine .................... 5-8
6-1
Emission control information ................. 1-3
Engine ................................................... 3-8
Engine oil ............................................... 1-7
Engine stop lanyard switch .................. 2-13
Engine stop lanyard switch .................... 2-6
EPA label ............................................... 1-2
Exhaust leakage .................................. 4-21
F
Filling fuel .............................................. 3-8
Filling fuel and engine oil ....................... 3-8
Flushing cooling system ........................ 4-9
Forward ............................................... 3-20
Free accelerator .................................. 2-15
Fuel ........................................................ 3-7
Fuel hose joint ....................................... 2-5
Fuel tank ................................................ 4-9
Fuel tank ................................................ 2-5
Fuel tank cap ......................................... 2-5
Fueling instructions ................................ 1-6
G
Gasoline (petrol) .................................... 1-7
Gasoline (petrol) and oil mixing ............. 3-9
Gear shift lever ...................................... 2-6
Greasing .............................................. 4-13
I
Identification numbers record ................ 1-5
Impact damage ...................................... 5-5
Inspecting and replacing anode(s) ...... 4-27
Inspecting fuel filter .............................. 4-17
Installation ............................................. 3-1
Installing the propeller ......................... 4-24
K
Key number ........................................... 1-1
L
Labels .................................................... 1-2
M
Main components .................................. 2-1
Main switch ................................... 2-8, 2-12
Maintenance chart ............................... 4-12
Manual injection knob ............................ 2-7
Motor exterior ...................................... 4-31
60H-9-E1-6 3/4/02 11:43 AM Page 3
E
Mounting height ..................................... 3-3
Mounting the outboard motor ................ 3-2
N
Neutral interlock trigger ....................... 2-11
Neutral throttle lever ............................ 2-11
O
Oil ............................................................3-7
Operations of controls and other
functions ................................................ 2-5
Outboard motor serial number ............... 1-1
Overheat warning ................................ 2-21
P
Periodic maintenance .......................... 4-11
Power trim/tilt switches ........................ 2-14
Power trim/tilt will not operate ................ 5-6
Pre-operation checks ............................. 3-7
Propeller checking point ...................... 4-23
Propeller selection ................................. 1-8
R
Recoil starter handle .............................. 2-7
Remote control .................................... 2-10
Remote control lever ........................... 2-11
Removing the propeller ....................... 4-24
Replacement parts .............................. 4-11
Replacing fuse ..................................... 4-21
Reverse ............................................... 3-21
Running in the engine ............................ 3-5
Running single engine ........................... 5-5
S
Safety information .................................. 1-4
Shifting ................................................. 3-20
Specifications ........................................ 4-1
Start-in-gear protection .......................... 1-9
Starter will not operate ........................... 5-7
Starting engine .................................... 3-11
Starting engine after manual injection
failure ..................................................... 5-9
Steering friction adjusting screw........... 2-16
Stopping engine ................................... 3-22
Storing outboard motor .......................... 4-8
T
Tachometer ......................................... 2-18
Temporary action in emergency ............ 5-5
Throttle control grip ................................ 2-8
Throttle friction adjusting screw ........... 2-16
Throttle friction adjusting screw/ knob ... 2-9
Throttle indicator .................................... 2-9
Tiller handle ........................................... 2-8
Tilt lock mechanism ............................. 2-19
Tilt support lever .................................. 2-20
Tilting up/down .................................... 3-27
Top cowling lock levers ....................... 2-20
Trailering outboard motor ...................... 4-7
Transporting and storing outboard
motor ..................................................... 4-7
Treatment of submerged motor ........... 5-11
Trim angle adjusting rod ...................... 2-17
Trim meter ........................................... 2-18
Trim tab ............................................... 2-17
Trimming outboard motor .................... 3-23
Troubleshooting ..................................... 5-1
W
Warming up engine ............................. 3-19
Warning system ................................... 2-21
Water leakage ..................................... 4-21
6-2
60H-9-E1-6 3/1/02 9:42 PM Page 4
60H-9-E1-6 3/1/02 9:42 PM Page 5
60H-9-E1 Hyoshi 4/9/02 1:09 PM Page 1 (1,1)
OWN
YAMAHA MOTOR CO., LTD.
Printed in Japan
March 2002-0.1 × 1 !
60H-28199-E1
(E115AMH, E115AWH, E115AE, E115AET, 115BE, 115BET, 140BET, 150AET, L150AET,
175AET, 200AET, L200AET)
(E)
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