U6E028E0.book Page 1 Tuesday, February 10, 2009 3:19 PM
4AC
5C
OWNER’S MANUAL
Read this manual carefully before operating this
outboard motor.
6E0-28199-28-E0
U6E028E0.book Page 1 Tuesday, February 10, 2009 3:19 PM
Read this manual carefully before operating this outboard motor. Keep this
manual onboard in a waterproof bag when boating. This manual should stay
with the outboard motor if it is sold.
U6E028E0.book Page 1 Tuesday, February 10, 2009 3:19 PM
Important manual information
EMU25105
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.
: This is the safety alert symbol. It is used
to alert you to potential personal injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.
EWM00781
WARNING
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
ECM00701
NOTICE
A NOTICE indicates special precautions
that must be taken to avoid damage to the
outboard motor or other property.
TIP:
A TIP provides key information to make 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.
To ensure long product life, Yamaha recommends that you use the product and perform
the specified periodic inspections and maintenance by correctly following the instructions in
the owner’s manual. Any damage resulting
from neglect of these instructions is not covered by warranty.
Some countries have laws or regulations restricting users from taking the product out of
the country where it was purchased, and it
may be impossible to register the product in
the destination country. Additionally, the warranty may not apply in certain regions. When
planning to take the product to another country, consult the dealer where the product was
purchased for further information.
If the product was purchased used, please
consult your closest dealer for customer reregistration, and to be eligible for the specified
services.
TIP:
The 4ACMH, 5CMH and the standard accessories are used as a base for the explanations
and illustrations in this manual. Therefore
some items may not apply to every model.
EMU25121
4AC, 5C
OWNER’S MANUAL
©2009 by Yamaha Motor Co., Ltd.
1st Edition, February 2009
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
U6E028E0.book Page 1 Tuesday, February 10, 2009 3:19 PM
Table of contents
Safety information............................. 1
Outboard motor safety .................... 1
Propeller .............................................
Rotating parts .....................................
Hot parts.............................................
Electric shock .....................................
Engine shut-off cord (lanyard) ............
Gasoline .............................................
Gasoline exposure and spills .............
Carbon monoxide ...............................
Modifications ......................................
1
1
1
1
1
1
1
1
2
Boating safety ................................. 2
Alcohol and drugs...............................
Personal flotation devices ..................
People in the water.............................
Passengers ........................................
Overloading ........................................
Avoid collisions...................................
Weather..............................................
Passenger training .............................
Boating safety publications.................
Laws and regulations .........................
2
2
2
2
2
2
3
3
3
3
General information .......................... 4
Identification numbers record .......... 4
Outboard motor serial number ........... 4
EC Declaration of Conformity
(DoC)............................................
CE Marking .....................................
C-Tick label .....................................
Read manuals and labels................
4
4
4
6
Warning labels.................................... 6
Specifications and requirements... 10
Specifications ................................ 10
Installation requirements ............... 11
Boat horsepower rating .................... 11
Mounting motor ................................ 11
Propeller selection ........................
Start-in-gear protection .................
Engine oil requirements ................
Fuel requirements .........................
11
12
12
12
Gasoline ........................................... 12
Muddy or acidic water ................... 13
Anti-fouling paint ........................... 13
Motor disposal requirements......... 13
Emergency equipment .................. 13
Components .................................... 14
Components diagram.................... 14
Fuel tank...........................................
Fuel tank...........................................
Fuel joint ...........................................
Fuel gauge .......................................
Fuel tank cap....................................
Air vent screw ...................................
Fuel cock ..........................................
Open.................................................
Tiller handle ......................................
Gear shift lever .................................
Throttle grip ......................................
Throttle indicator...............................
Throttle friction adjuster ....................
Engine shut-off cord (lanyard) and
clip.................................................
Engine stop button ...........................
Choke knob ......................................
Manual starter handle.......................
Steering friction adjuster...................
Trim rod (tilt pin) ...............................
Tilt support bar .................................
Cowling lock lever(s) (turn type) .......
15
16
16
16
16
16
16
17
17
17
18
18
18
19
19
19
19
20
20
20
20
Installation ....................................... 21
Installation..................................... 21
Battery requirements ..................... 11
Mounting the outboard motor ........... 21
Clamping the outboard motor ........... 22
Without a rectifier or Rectifier
Regulator ...................................... 11
Operation ......................................... 24
First-time operation ....................... 24
Breaking in engine............................ 24
Getting to know your boat ................ 24
Checks before starting engine ...... 24
Fuel level .......................................... 25
U6E028E0.book Page 2 Tuesday, February 10, 2009 3:19 PM
Table of contents
Remove cowling ...............................
Fuel system ......................................
Controls ............................................
Engine shut-off cord (lanyard) ..........
Oil .....................................................
Engine ..............................................
Install cowling ...................................
25
25
25
25
25
26
26
Filling fuel and engine oil............... 26
Filling fuel for portable tank .............. 26
Filling fuel for built-in tank................. 27
Gasoline and oil mixing (100:1)........ 28
Operating engine........................... 30
Sending fuel (portable tank) ............. 30
Sending fuel ..................................... 31
Starting engine ................................. 32
Checks after starting engine ......... 33
Cooling water ................................... 33
Warming up engine ....................... 34
Choke start models .......................... 34
Checks after engine warm-up ....... 34
Shifting ............................................. 34
Stop switches ................................... 34
Shifting .......................................... 34
Stopping boat ................................ 35
Stopping engine ............................ 35
Procedure......................................... 35
Trimming outboard motor .............. 36
Adjusting trim angle for manual tilt
models .......................................... 37
Adjusting boat trim............................ 37
Tilting up and down ....................... 38
Procedure for tilting up
(manual tilt models)....................... 38
Procedure for tilting down
(manual tilt models)....................... 40
Shallow water................................ 40
Cruising in shallow water
(manual tilt models)....................... 40
Cruising in other conditions ........... 41
Maintenance..................................... 42
Transporting and storing outboard
motor .......................................... 42
Clamp screw mounting models ........ 42
Storing outboard motor.....................
Procedure.........................................
Lubrication........................................
Cleaning the outboard motor ............
Checking painted surface of motor...
42
43
44
44
44
Periodic maintenance ................... 44
Replacement parts ...........................
Severe operating conditions.............
Maintenance chart 1.........................
Maintenance chart 2.........................
Greasing ...........................................
Cleaning and adjusting spark plug ...
Checking fuel filter ............................
Inspecting idling speed .....................
Checking wiring and connectors ......
Checking propeller ...........................
Removing propeller ..........................
Installing propeller ............................
Changing gear oil .............................
Cleaning fuel tank.............................
Inspecting and replacing anode(s) ...
44
44
45
47
47
48
48
49
49
49
50
50
51
52
53
Trouble Recovery............................ 54
Troubleshooting ............................ 54
Temporary action in emergency ... 57
Impact damage................................. 57
Starter will not operate ..................... 57
Emergency starting engine............... 58
Treatment of submerged motor .... 59
U6E028E0.book Page 1 Tuesday, February 10, 2009 3:19 PM
Safety information
EMU33622
Outboard motor safety
Observe these precautions at all times.
EMU36501
Propeller
People can be injured or killed if they come in
contact with the propeller. The propeller can
keep moving even when the motor is in neutral, and sharp edges of the propeller can cut
even when stationary.
● Stop the engine when a person is in the water near you.
● Keep people out of reach of the propeller,
even when the engine is off.
EMU33630
Rotating parts
Hands, feet, hair, jewelry, clothing, PFD
straps, etc. can become entangled with internal rotating parts of the engine, resulting in serious injury or death.
Keep the top cowling in place whenever possible. Do not remove or replace the cowling
with the engine running.
Only operate the engine with the cowling removed according to the specific instructions in
the manual. Keep hands, feet, hair, jewelry,
clothing, PFD straps, etc. away from any exposed moving parts.
EMU33640
Hot parts
During and after operation, engine parts are
hot enough to cause burns. Avoid touching
any parts under the top cowling until the engine has cooled.
EMU33650
Electric shock
Do not touch any electrical parts while starting
or operating the engine. They can cause
shock or electrocution.
EMU33671
Engine shut-off cord (lanyard)
Attach the engine shut-off cord so that the engine stops if the operator falls overboard or
leaves the helm. This prevents the boat from
1
running away under power and leaving people stranded, or running over people or objects.
Always attach the engine shut-off cord to a
secure place on your clothing or your arm or
leg while operating. Do not remove it to leave
the helm while the boat is moving. Do not attach the cord to clothing that could tear loose,
or route the cord where it could become entangled, preventing it from functioning.
Do not route the cord where it is likely to be
accidentally pulled out. If the cord is pulled
during operation, the engine will shut off and
you will lose most steering control. The boat
could slow rapidly, throwing people and objects forward.
EMU33810
Gasoline
Gasoline and its vapors are highly flammable and explosive. Always, refuel according to the procedure on page 30 to reduce the
risk of fire and explosion.
EMU33820
Gasoline exposure and spills
Take care not to spill gasoline. If gasoline
spills, wipe it up immediately with dry rags.
Dispose of rags properly.
If any gasoline spills onto your skin, immediately wash with soap and water. Change
clothing if gasoline spills on it.
If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get
immediate medical attention. Never siphon
fuel by mouth.
EMU33900
Carbon monoxide
This product emits exhaust gases which 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.
U6E028E0.book Page 2 Tuesday, February 10, 2009 3:19 PM
Safety information
EMU33780
Modifications
Do not attempt to modify this outboard motor.
Modifications to your outboard motor may reduce safety and reliability, and render the outboard unsafe or illegal to use.
EMU33740
Boating safety
This section includes a few of the many important safety precautions that you should follow when boating.
EMU33710
Alcohol and drugs
Never operate after drinking alcohol or taking
drugs. Intoxication is one of the most common
factors contributing to boating fatalities.
EMU33720
Personal flotation devices
Have an approved personal flotation device
(PFD) on board for every occupant. Yamaha
recommends that you must wear a PFD
whenever boating. At a minimum, children
and non-swimmers should always wear
PFDs, and everyone should wear PFDs when
there are potentially hazardous boating conditions.
and when operating above an idle speed.
Standing or sitting in non-designated locations may result in being thrown either overboard or within the boat due to waves, wakes,
or sudden changes in speed or direction.
Even when people are positioned properly,
alert your passengers if you must make any
unusual maneuver. Always avoid jumping
waves or wakes.
EMU33760
Overloading
Do not overload the boat. Consult the boat capacity plate or boat manufacturer for maximum weight and number of passengers. Be
sure that weight is properly distributed according to the boat manufacturers instructions. Overloading or incorrect weight
distribution can compromise the boats handling and lead to an accident, capsizing or
swamping.
EMU33772
Avoid collisions
Scan constantly for people, objects, and other
boats. Be alert for conditions that limit your
visibility or block your vision of others.
EMU33731
People in the water
Always watch carefully for people in the water, such as swimmers, skiers, or divers,
whenever the engine is running. When someone is in the water near the boat, shift into
neutral and stop the engine.
Stay away from swimming areas. Swimmers
can be hard to see.
The propeller can keep moving even when
the motor is in neutral. Stop the engine when
a person is in the water near you.
EMU33751
Passengers
Consult your boat manufacturer’s instructions
for details about appropriate passenger locations in your boat and be sure all passengers
are positioned properly before accelerating
ZMU06025
Operate defensively at safe speeds and keep
a safe distance away from people, objects,
and other boats.
● Do not follow directly behind other boats or
waterskiers.
2
U6E028E0.book Page 3 Tuesday, February 10, 2009 3:19 PM
Safety information
●
●
●
●
Avoid sharp turns or other maneuvers that
make it hard for others to avoid you or understand where you are going.
Avoid areas with submerged objects or
shallow water.
Ride within your limits and avoid aggressive
maneuvers to reduce the risk of loss of control, ejection, and collision.
Take early action to avoid collisions. Remember, boats do not have brakes, and
stopping the engine or reducing throttle can
reduce the ability to steer. If you are not
sure that you can stop in time before hitting
an obstacle, apply throttle and turn in another direction.
EMU33790
Weather
Stay informed about the weather. Check
weather forecasts before boating. Avoid boating in hazardous weather.
EMU33880
Passenger training
Make sure at least one other passenger is
trained to operate the boat in the event of an
emergency.
EMU33890
Boating safety publications
Be informed about boating safety. Additional
publications and information can be obtained
from many boating organizations.
EMU33600
Laws and regulations
Know the marine laws and regulations where
you will be boating- and obey them. Several
sets of rules prevail according to geographic
location, but all are basically the same as the
International Rules of the Road.
3
U6E028E0.book Page 4 Tuesday, February 10, 2009 3:19 PM
General information
EMU25171
Identification numbers record
EMU25183
Outboard motor serial number
The outboard motor serial number is stamped
on the label attached to the port side of the
clamp bracket.
Record your outboard motor serial number in
the spaces provided to assist you in ordering
spare parts from your Yamaha dealer or for
reference in case your outboard motor is stolen.
●
●
●
●
Name of Engine Manufacture
Model name
Product code of model (Approved model
code)
Code of conformed directives
EMU25203
CE Marking
Outboard motors affixed with this “CE”marking conform with the directives of; 98/37/EC,
94/25/EC - 2003/44/EC and 2004/108/EC.
1. CE marking location
1. Outboard motor serial number location
ZMU06040
EMU25213
C-Tick label
EMU37290
EC Declaration of Conformity
(DoC)
This outboard motor conforms to certain portions of the European Parliament directive relating to machinery.
Each conformed outboard motor accompanied with EC DoC.EC DoC contains the following information;
Engines affixed with this label conform to certain portion(s) of the Australian Radio Communications Act.
4
U6E028E0.book Page 5 Tuesday, February 10, 2009 3:19 PM
General information
1. C-Tick label location
ZMU01697
5
U6E028E0.book Page 6 Tuesday, February 10, 2009 3:19 PM
General information
EMU33520
Read manuals and labels
Before operating or working on this motor:
● Read this manual.
● Read any manuals supplied with the boat.
● Read all labels on the outboard motor and the boat.
If you need any additional information, contact your Yamaha dealer.
EMU33831
Warning labels
If these labels are damaged or missing, contact your Yamaha dealer for replacements.
4AC, 5C
4
1
2
3
ZMU06033
6
U6E028E0.book Page 7 Tuesday, February 10, 2009 3:19 PM
General information
1
2
3
4
ZMU05924
EMU35281
Contents of labels
The above warning labels mean as follows.
1
EWM01691
WARNING
Emergency starting does not have startin-gear protection. Ensure shift control is
in neutral before starting engine.
2
EWM01681
WARNING
●
●
7
Keep hands, hair, and clothing away
from rotating parts while the engine is
running.
Do not touch or remove electrical parts
when starting or during operation.
3
EWM01671
WARNING
●
●
●
Read Owner’s Manuals and labels.
Wear an approved personal flotation device (PFD).
Attach engine shut-off cord (lanyard) to
your PFD, arm, or leg so the engine
stops if you accidentally leave the helm,
which could prevent a runaway boat.
U6E028E0.book Page 8 Tuesday, February 10, 2009 3:19 PM
General information
4
Hazard caused by continuous rotation
EWM01701
WARNING
Gasoline is highly flammable and explosive. Shut off engine before refueling.
Tighten tank cap and air vent screw when
not in use.
EMU33843
Symbols
The following symbols mean as follows.
ZMU05665
Notice/Warning
Electrical hazard
ZMU05696
Read Owner’s Manual
ZMU05666
Remote control lever/gear shift lever operating direction, dual direction
ZMU05664
ZMU05667
8
U6E028E0.book Page 9 Tuesday, February 10, 2009 3:19 PM
General information
Engine start/ Engine cranking
ZMU05668
9
U6E028E0.book Page 10 Tuesday, February 10, 2009 3:19 PM
Specifications and requirements
EMU31480
Specifications
TIP:
“(AL)” stated in the specification data below
represents the numerical value for the aluminum propeller installed.
Likewise, “(SUS)” represents the value for
stainless steel propeller installed and “(PL)”
for plastic propeller installed.
EMU2821E
Dimension:
Overall length:
677 mm (26.7 in)
Overall width:
322 mm (12.7 in)
Overall height S:
1011 mm (39.8 in)
Overall height L:
1138 mm (44.8 in)
Transom height S:
444 mm (17.5 in)
Transom height L:
571 mm (22.5 in)
Weight (AL) S:
21.0 kg (46 lb)
Weight (AL) L:
21.5 kg (47 lb)
Performance:
Full throttle operating range:
4500–5500 r/min
Maximum output:
4ACMH 2.9 kW@5000 r/min (4
HP@5000 r/min)
5CMH 3.7 kW@5000 r/min (5
HP@5000 r/min)
Idling speed (in neutral):
1150 ±50 r/min
Engine:
Type:
2-stroke S
Displacement:
4ACMH 83.0 cm³
5CMH 103.0 cm³
Bore × stroke:
4ACMH 50.0 × 42.0 mm (1.97 × 1.65 in)
5CMH 54.0 × 45.0 mm (2.13 × 1.77 in)
Ignition system:
CDI
Spark plug (NGK):
B7HS
BR7HS
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Control system:
Tiller
Starting system:
Manual
Starting carburetion system:
Choke valve
Alternator output:
40/60 W
Drive unit:
Gear positions:
Forward-neutral-reverse
Gear ratio:
2.08 (27/13)
Trim and tilt system:
Manual tilt
Propeller mark:
B
BA
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Fuel tank capacity:
5CMH 12.0 L (3.17 US gal, 2.64 Imp.gal)
Fuel tank capacity (built in type):
2.8 L (0.74 US gal, 0.62 Imp.gal)
Recommended engine oil:
YAMALUBE 2-stroke outboard motor oil
Fuel:oil ratio:
10
U6E028E0.book Page 11 Tuesday, February 10, 2009 3:19 PM
Specifications and requirements
Regular gasoline:
100 :1
Lubrication:
Pre-mixed fuel and oil
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
0.100 L (0.106 US qt, 0.088 Imp.qt)
Tightening torque for engine:
Spark plug:
25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
Noise and vibration level:
Operator sound pressure level (ICOMIA
39/94 and 40/94):
4ACMH 81.6 dB(A) (*CE)
Vibration on tiller handle (ICOMIA 38/94):
4ACMH 3.4 m/s² (*CE)
EMU33554
Installation requirements
EMU33563
Boat horsepower rating
EWM01560
WARNING
Overpowering a boat can cause severe instability.
Before installing the outboard motor(s), confirm that the total horsepower of your motor(s)
does not exceed the boats maximum horsepower rating. See the boat’s capacity plate or
contact the manufacturer.
EMU33571
Mounting motor
EWM01570
WARNING
●
●
Improper mounting of the outboard motor could result in hazardous conditions
such as poor handling, loss of control,
or fire hazards.
Because the motor is very heavy, special equipment and training is required
to mount it safely.
11
Your dealer or other person experienced in
proper rigging should mount the motor using
correct equipment and complete rigging instructions. For further information, see page
21.
EMU25694
Battery requirements
EMU25730
Without a rectifier or Rectifier Regulator
ECM01090
NOTICE
A battery cannot be connected to models
that do not have a rectifier or Rectifier
Regulator.
If you wish to use a battery with the models
without a rectifier or Rectifier Regulator, install
an optional Rectifier Regulator.
Using a maintenance-free battery with the
above models can shorten the life of the battery significantly.
Install an optional Rectifier Regulator or use
accessories rated to withstand 18 volts or
higher with the above models. Consult your
Yamaha dealer for details on installing an optional Rectifier Regulator.
EMU34192
Propeller selection
Next to selecting an outboard, choosing the
right propeller is one of the most important
purchasing decisions a boater can make. The
type, size, and design of your propeller have
a direct impact on acceleration, top speed,
fuel economy, and even engine life. Yamaha
designs and manufactures propellers for every Yamaha outboard motor and every application.
Your outboard motor came with a Yamaha
propeller chosen to perform well over a range
of applications, but there may be uses where
a different propeller would be more appropriate.
U6E028E0.book Page 12 Tuesday, February 10, 2009 3:19 PM
Specifications and requirements
Your Yamaha dealer can help you select the
right propeller for your boating needs. Select
a propeller that will allow the engine to reach
the middle or upper half of the operating
range at full throttle with the maximum boatload. Generally, chose a larger pitch propeller
for a smaller operating load and a smaller
pitch propeller for a heavier load. If you carry
loads that vary widely, chose the propeller
that lets the engine run in the proper range for
your maximum load but remember that you
may need to reduce your throttle setting to
stay within the recommended engine speed
range when carrying lighter loads.
For instructions on propeller removal and installation, see page 49.
x
1
EMU25651
Engine oil requirements
Recommended engine oil:
YAMALUBE 2-stroke outboard motor
oil
If the recommended engine oil is not available, another 2-stroke engine oil with an
NMMA-certified TC-W3 rating may be used.
EMU36360
Fuel requirements
EMU36771
Gasoline
Use a good quality gasoline that meets the
minimum octane rating. If knocking or pinging
occurs, use a different brand of gasoline or
premium unleaded fuel. Yamaha recomends
that you use alcohol-free (see Gasohol) gasoline whenever possible.
Recommended gasoline:
Regular unleaded gasoline
2 3
ECM01981
NOTICE
●
ZMU04604
●
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
EMU25770
Start-in-gear protection
Yamaha outboard motors 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 in neutral. Always select neutral before
starting the engine.
Do not use leaded gasoline. Leaded gasoline can seriously damage the engine.
Avoid getting water and contaminants in
the fuel tank. Contaminated fuel can
cause poor performance or engine damage. Use only fresh gasoline that has
been stored in clean containers.
Gasohol
There are two types of gasohol: gasohol containing ethanol (E10) and that containing
methanol. Ethanol can be used if the ethanol
content does not exceed 10% and the fuel
meets the minimum octane ratings. All ethanol blends containing more than 10% ethanol
can cause fuel system damage or cause engine starting and running problems. Yamaha
12
U6E028E0.book Page 13 Tuesday, February 10, 2009 3:19 PM
Specifications and requirements
does not recommend gasohol containing
methanol because it can cause fuel system
damage or engine performance problems.
EMU36880
Muddy or acidic water
Yamaha strongly recommends that you have
your dealer install the optional chromium-plated water pump kit if you use the outboard motor in muddy or acidic water conditions.
However, depending on the model it might not
be required.
EMU36330
Anti-fouling paint
A clean hull improves boat performance. The
boat bottom should be kept as clean of marine
growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint
approved for your area to inhibit marine
growth.
Do not use anti-fouling paint which includes
copper or graphite. These paints can cause
more rapid engine corrosion.
EMU36341
Motor disposal requirements
Never illegally discard (dump) the motor.
Yamaha recommends consulting the dealer
about discarding the motor.
EMU36351
Emergency equipment
Keep the following items onboard in case
there is trouble with the motor.
13
A tool kit with assorted screwdrivers, pliers,
wrenches (including metric sizes), and
electrical tape.
● Waterproof flashlight with extra batteries.
● An extra engine shut-off cord (lanyard) with
clip.
● Spare parts, such as an extra set of spark
plugs.
Consult your Yamaha dealer for details.
●
U6E028E0.book Page 14 Tuesday, February 10, 2009 3:19 PM
Components
EMU2579M
Components diagram
TIP:
* May not be exactly as shown; also may not be included as standard equipment on all models.
4AC
1. Air vent screw
2. Fuel tank cap
3. Top cowling
4. Cowling lock lever
5. Steering friction adjuster
6. Anti-cavitation plate
7. Propeller
8. Cooling water inlet
9. Trim rod
10.Clamp bracket
11.Clamp screw
12.Tiller handle
13.Throttle friction adjuster
14.Manual starter handle
15.Choke knob
16.Engine stop button/Engine shut-off switch
17.Restraint cable attachment
18.Tilt support bar
19.Fuel cock
20.Gear shift lever
14
U6E028E0.book Page 15 Tuesday, February 10, 2009 3:19 PM
Components
5C
1. Air vent screw
2. Fuel tank cap
3. Top cowling
4. Cowling lock lever
5. Steering friction adjuster
6. Anti-cavitation plate
7. Propeller
8. Cooling water inlet
9. Trim rod
10.Clamp bracket
11.Clamp screw
12.Tiller handle
13.Throttle friction adjuster
14.Manual starter handle
15.Choke knob
16.Engine stop button/Engine shut-off switch
17.Restraint cable attachment
18.Tilt support bar
19.Gear shift lever
20.Fuel cock
21.Fuel tank*
15
EMU25802
Fuel tank
If your model was equipped with a portable
fuel tank, its function is as follows.
EWM00020
WARNING
The fuel tank supplied with this engine is
its dedicated fuel reservoir and must not
be used as a fuel storage container. Commercial users should conform to relevant
licensing or approval authority regulations.
U6E028E0.book Page 16 Tuesday, February 10, 2009 3:19 PM
Components
EMU25860
3
4
1
2
Air vent screw
This screw is on the fuel tank cap. To loosen
the screw, turn it counterclockwise.
EMU25872
Fuel cock
The fuel cock turns on and off the supply of
fuel from the fuel tank to the engine.
ZMU01992
1.
2.
3.
4.
Air vent screw
Fuel gauge
Fuel joint
Fuel tank cap
EMU25821
Fuel tank
If your model included a fuel tank, its parts
and functions are as follows.
1. Air vent screw
2. Fuel tank cap
EMU25830
Fuel joint
This joint is used to connect the fuel line.
EMU25841
Fuel gauge
This gauge is located on either the fuel tank
cap or on the fuel joint base. It shows the approximate amount of fuel remaining in the
tank.
1. Fuel cock
1. Fuel cock
EMU25881
Close
To stop fuel flow to the engine, turn the lever
or knob to close position.
Always turn the lever or knob to close position
when the engine is not running.
EMU25850
Fuel tank cap
This cap seals the fuel tank. When removed,
the tank can be filled with fuel. To remove the
cap, turn it counterclockwise.
16
U6E028E0.book Page 17 Tuesday, February 10, 2009 3:19 PM
Components
EMU25901
Open
The fuel cock has two open positions, one for
selecting fuel flow from the built-in fuel tank,
and one for an external tank.
Fuel flows to the carburetor with the lever or
knob in either open position. These are the
normal running positions.
1. Close position
1. “OPEN” position for the built-in tank
2. “OPEN” position for the portable tank
EMU25911
Tiller handle
1. Close position
EMU25891
Open
With the lever/knob in this position, fuel flows
to the carburetor.
Normal running is done with the lever/knob in
this position.
To change direction, move the tiller handle to
the left or right as necessary.
EMU25922
Gear shift lever
1. Open position
17
Pulling the gear shift lever towards you puts
the engine in forward gear so that the boat
moves ahead. Pushing the lever away from
you puts the engine in reverse gear so that the
boat moves astern.
U6E028E0.book Page 18 Tuesday, February 10, 2009 3:19 PM
Components
1. Forward “ ”
2. Neutral “ ”
3. Reverse “ ”
EMU25941
Throttle grip
The throttle grip is on the tiller handle. Turn
the grip counterclockwise to increase speed
and clockwise to decrease speed.
1. Throttle indicator
EMU25975
Throttle friction adjuster
A friction device provides adjustable resistance to movement of the throttle grip or the
remote control lever, and can be set according to operator preference.
To increase resistance, turn the adjuster
clockwise. To decrease resistance, turn the
adjuster counterclockwise. WARNING! Do
not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to move the remote control lever
or throttle grip, which could result in an
accident. [EWM00032]
EMU25961
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.
When constant speed is desired, tighten the
adjuster to maintain the desired throttle setting.
18
U6E028E0.book Page 19 Tuesday, February 10, 2009 3:19 PM
Components
EMU25993
Engine shut-off cord (lanyard) and
clip
The clip must be attached to the engine shutoff switch for the engine to run. The cord
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
cord will pull out the clip, stopping ignition to
the engine. This will prevent the boat from
running away under power. WARNING! Attach the engine shut-off cord to a secure
place on your clothing, or your arm or leg
while operating. Do not attach the cord to
clothing that could tear loose. Do not route
the cord where it could become entangled,
preventing it from functioning. Avoid accidentally pulling the cord 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.
EMU26020
Choke knob
To supply the engine with the rich fuel mixture
required to start, turn this knob to the right.
[EWM00122]
EMU26070
Manual starter handle
To start the engine, first gently pull the handle
out until resistance is felt. From that position,
then pull the handle straight out quickly to
crank the engine.
1. Cord
2. Clip
3. Engine shut-off switch
EMU26001
Engine stop button
To open the ignition circuit and stop the engine, push this button.
19
U6E028E0.book Page 20 Tuesday, February 10, 2009 3:19 PM
Components
EMU26122
EMU26332
Steering friction adjuster
Tilt support bar
A friction device provides adjustable resistance to the steering mechanism, and can be
set according to operator preference. An adjusting screw or bolt is located on the swivel
bracket.
The tilt support bar keeps the outboard motor
in the tilted up position.
ECM01660
NOTICE
To increase resistance, turn the adjuster
clockwise.
To decrease resistance, turn the adjuster
counterclockwise.
EWM00040
WARNING
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to steer, which could result in an
accident.
EMU26261
Trim rod (tilt pin)
The position of the trim rod determines the
minimum trim angle of the outboard motor in
relation to the transom.
Do not use the tilt support bar when trailering the boat. The outboard motor could
shake loose from the tilt support and fall.
If the motor cannot be trailered in the normal running position, use an additional
support device to secure it in the tilt position.
EMU26373
Cowling lock lever(s) (turn type)
To remove the engine top cowling, turn the
cowling lock lever(s) and lift off the cowling.
When installing the cowling, check to be sure
it fits properly in the rubber seal. Then lock the
cowling again by returning the cowling lock lever(s) to the lock position.
1. Cowling lock lever(s)
20
U6E028E0.book Page 21 Tuesday, February 10, 2009 3:19 PM
Installation
EMU26902
Installation
The information presented in this section is intended as reference only. It is not possible to
provide complete instructions for every possible boat and motor combination. Proper
mounting depends in part on experience and
the specific boat and motor combination.
EWM01590
1
WARNING
●
●
Overpowering a boat could 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.
Improper mounting of the outboard motor could result in hazardous conditions
such as poor handling, loss of control,
or fire hazards. For permanently mounted models, your dealer or other person
experienced in proper rigging should
mount the motor.
EMU26911
Mounting the outboard motor
EWM01720
WARNING
ZMU01760
1. Center line (keel line)
EMU26923
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
outboard motor so that the anti-cavitation
plate is between the bottom of the boat and a
level 25 mm (1 in) below it.
Your dealer or other person experienced
in proper outboard motor mounting
should show you how to mount your outboard motor.
The outboard motor should be mounted so
that the boat is well balanced. Otherwise, the
boat could be hard to steer. For single-engine
boats, mount the outboard motor on the centerline (keel line) of the boat.
21
0–25mm
(0–1in)
ZMU02011
U6E028E0.book Page 22 Tuesday, February 10, 2009 3:19 PM
Installation
allow the outboard motor to fall off or
move on the transom. This could
cause loss of control and serious injury. Make sure the transom screws are
tightened securely. Occasionally
check the screws for tightness during
operation. [EWM00641]
ECM01631
NOTICE
●
●
Check that the idle hole stays high
enough to keep out water getting inside
engine even if the boat is in stationary
with maximum load.
Incorrect engine height or obstructions
to the smooth flow of water (such as the
design or condition of the boat, or accessories such as transom ladders or
depth finder transducers) can create airborne water spray while the boat is
cruising. If the motor is operated continuously in the presence of airborne water
spray, enough water could enter the engine through the intake opening on the
cowling to cause severe engine damage. Eliminate the cause of the airborne
water spray.
ZMU02012
2.
TIP:
●
●
The optimum mounting height of the outboard motor is affected by the boat and motor combination and the desired use. Test
runs at different heights can help determine
the optimum mounting height. Consult your
Yamaha dealer or boat manufacturer for
further information on determining the proper mounting height.
For instructions on setting the trim angle of
the outboard motor, see page 36.
If the restraint cable attachment is
equipped on your engine, a restraint cable or chain should be used. Attach one
end to the restraint cable attachment and
the other to a secure mounting point on
the boat. Otherwise the engine could be
completely lost if it accidentally falls off
the transom.
EMU26972
Clamping the outboard motor
1.
Place the outboard motor on the transom
so that it is positioned as close to the center as possible. Tighten the transom
clamp screws evenly and securely. Occasionally check the clamp screws for
tightness during operation of the outboard motor because they could become
loose due to engine vibration.
WARNING! Loose clamp screws could
ZMU02013
3.
Secure the clamp bracket to the transom
using the bolts provided with the outboard (if packed). For details, consult
your Yamaha dealer. WARNING! Avoid
using bolts, nuts or washers other
than those contained in the engine
22
U6E028E0.book Page 23 Tuesday, February 10, 2009 3:19 PM
Installation
packaging. If used, they must be of at
least the same quality of material and
strength and must be tightened securely. After tightening, test run the
engine and check their tightness.
[EWM00651]
23
U6E028E0.book Page 24 Tuesday, February 10, 2009 3:19 PM
Operation
EMU36381
First-time operation
1.
EMU30174
Breaking in engine
Your new engine requires a period of break-in
to allow mating surfaces of moving parts to
wear in evenly. Correct break-in will help ensure proper performance and longer engine
life. NOTICE: Failure to follow the break-in
procedure could result in reduced engine
life or even severe engine damage. [ECM00801]
2.
EMU31241
3.
Gasoline and engine oil mixing chart (25:1,
50:1)
For models without CE marking (25:1)
4.
1.
2.
: Gasoline
: Engine oil
For models with CE marking (50:1)
5.
First 10 minutes:
Run the engine at the lowest possible
speed. A fast idle in neutral is best.
Next 50 minutes:
Do not exceed half throttle (approximately 3000 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
3000 r/min or less.
Next two hours:
Accelerate at full throttle onto plane, then
reduce engine speed to three-quarter
throttle (approximately 4000 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.
Remaining seven hours:
Run the engine at any speed. However,
avoid operating at full throttle for more
than 5 minutes at a time.
After the first 10 hours:
Operate the engine normally. Use the
standard premix ratio of gasoline and oil.
For details on mixing fuel and oil, see
page 26.
EMU36400
Getting to know your boat
1.
2.
: Gasoline
: Engine oil
ECM00150
NOTICE
Be sure to mix gasoline and oil completely, otherwise the engine may be damaged.
EMU27074
Procedure for pre-mixed models
Run the engine under load (in gear with a propeller installed) for 10 hours as follows.
Different boats handle differently. Operate
cautiously while you learn how your boat handles under different conditions and with different trim angles (see page 36).
EMU36412
Checks before starting engine
EWM01920
WARNING
If any item in the checks before starting
engine is not working properly, have it inspected and repaired before operating the
outboard motor. Otherwise an accident
could occur.
24
U6E028E0.book Page 25 Tuesday, February 10, 2009 3:19 PM
Operation
ECM00120
●
NOTICE
Do not start the engine out of water. Overheating and serious engine damage can
occur.
EMU37141
Fuel level
Be sure you have plenty of fuel for your trip. A
good rule is to use 1/3 of your fuel to get to the
destination, 1/3 to return, and to keep 1/3 as
an emergency reserve. With the boat level on
a trailer or in the water, check the fuel level.
For fuel filling instructions, see page 26.
EMU36570
EMU36451
Check for fuel leaks
● Check for fuel leaks or gasoline fumes in
the boat.
● Check for fuel leakage from the fuel system.
● Check the fuel tank and fuel lines for
cracks, swellings, or other damages.
EMU36891
Controls
●
Remove cowling
For the following checks, remove the top
cowling from the engine. To remove the engine top cowling, release the lock lever and lift
off the cowling.
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.
●
●
Move the tiller handle fully to the left and
right to make sure operation is smooth.
Turn the throttle grip from the fully closed to
the fully open position. Make sure that it
turns smoothly and that it completely returns to the fully closed position.
Look for loose or damaged connections of
the throttle and shift cables.
EMU36481
Engine shut-off cord (lanyard)
Inspect the engine shut-off cord for damage,
such as cuts, breaks, and wear.
ZMU06089
EMU36442
Fuel system
EWM00060
WARNING
Gasoline and its vapors are highly flammable and explosive. Keep away from
sparks, cigarettes, flames, or other sources of ignition.
EWM00910
WARNING
Leaking fuel can result in fire or explosion.
● Check for fuel leakage regularly.
25
1. Cord
2. Clip
3. Engine shut-off switch
EMU27120
Oil
●
Check to be sure you have plenty of oil for
your trip.
U6E028E0.book Page 26 Tuesday, February 10, 2009 3:19 PM
Operation
EMU27141
Engine
●
●
●
Check the engine and engine mounting.
Look for loose or damaged fasteners.
Check the propeller for damage.
EMU36953
Install cowling
1.
2.
3.
4.
5.
Be sure that a cowling lock lever is released.
Be sure that the rubber seal is seated all
the way around the top cowling.
Place the top cowling on bottom cowling.
Check to be sure the rubber seal fits correctly all the way around the engine.
Move the lever to lock the cowling as
shown. NOTICE: If the cowling is not
installed correctly, water spray under
the cowling can damage the engine, or
the cowling can blow off at high
speeds. [ECM01990]
EMU27234
Filling fuel and engine oil
EMU27247
Filling fuel for portable tank
EWM01830
WARNING
●
●
ZMU06114
After installing, check the fitting of the top
cowling by pushing it with both hands. If the
top cowling is loose, have it repaired by your
Yamaha dealer.
1.
2.
Gasoline and its vapors are highly flammable and explosive. Always refuel according to this procedure to reduce the
risk of fire and explosion.
Gasoline is poisonous and can cause injury or death. Handle gasoline with care.
Never siphon gasoline by mouth. If you
should swallow some gasoline or inhale
a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your
skin, wash with soap and water. If gasoline spills on your clothing, change your
clothes.
Be sure the engine is stopped.
Disconnect the fuel line from the fuel tank
and tighten the air vent screw on the fuel
tank cap.
26
U6E028E0.book Page 27 Tuesday, February 10, 2009 3:19 PM
Operation
ZMU04484
ZMU06621
9. Tighten the filler cap securely.
10. Wipe up any spilled gasoline immediately
with dry rags. Dispose rags properly according to local laws or regulations.
EMU37532
Filling fuel for built-in tank
EWM01950
WARNING
Be sure the outboard motor is securely
fastened to the transom or a stable stand.
3.
4.
Remove the portable tank from the boat.
Be sure you are in a well-ventilated outdoor area, either securely moored or trailered.
Do not smoke and keep away from
sparks, flames, static electric discharge,
or other sources of ignition.
If you use a portable container to store
and dispense fuel, use only an approved
GASOLINE container.
Touch the fuel nozzle to the filler opening
or funnel to help prevent electrostatic
sparks.
Fill the fuel tank, but do not overfill. Fuel
can expand and overflow if the temperature increases.
5.
6.
7.
8.
Fuel tank capacity:
5CMH 12.0 L (3.17 US gal,
2.64 Imp.gal)
27
EWM01830
WARNING
●
●
1.
2.
Gasoline and its vapors are highly flammable and explosive. Always refuel according to this procedure to reduce the
risk of fire and explosion.
Gasoline is poisonous and can cause injury or death. Handle gasoline with care.
Never siphon gasoline by mouth. If you
should swallow some gasoline or inhale
a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your
skin, wash with soap and water. If gasoline spills on your clothing, change your
clothes.
Be sure the engine is stopped.
Disconnect the fuel line from the portable
fuel tank and tighten the air vent screw on
the fuel tank cap (if equipped portable
fuel tank).
U6E028E0.book Page 28 Tuesday, February 10, 2009 3:19 PM
Operation
ZMU06621
9. Tighten the filler cap securely.
10. Wipe up any spilled gasoline immediately
with dry rags. Dispose rags properly according to local laws or regulations.
EMU27406
Gasoline and oil mixing (100:1)
ECM00811
NOTICE
●
●
3.
4.
5.
6.
7.
8.
Remove the portable tank from the boat.
Be sure you are in a well-ventilated outdoor area, either securely moored or trailered.
Do not smoke and keep away from
sparks, flames, static electric discharge,
or other sources of ignition.
If you use a portable container to store
and dispense fuel, only use a locally approved GASOLINE container.
Touch the fuel nozzle to the filler opening
or funnel to help prevent electrostatic
sparks.
Fill the fuel tank, but do not overfill. Fuel
can expand and overflow if the temperature increases.
●
●
●
Avoid using any oil other than the specified type.
Use a thoroughly blended fuel-oil mixture.
If the mixture is not thoroughly mixed, or
if the mixing ratio is incorrect, the following problems could occur.
Low oil ratio: Lack of oil could cause major engine trouble, such as piston seizure.
High oil ratio: Too much oil could cause
fouled spark plugs, smoky exhaust, and
heavy carbon deposits.
Gasoline to engine oil
ratio
Break-in period
See page 24
After break-in
100:1
Fuel tank capacity:
2.8 L (0.74 US gal, 0.62 Imp.gal)
28
U6E028E0.book Page 29 Tuesday, February 10, 2009 3:19 PM
Operation
4.
1L
(0.26 US gal,
0.22 Imp gal)
100:1
12 L
14 L
(3.2 US gal,
(3.7 US gal,
2.6 Imp gal)
3.1 Imp gal)
24 L
(6.3 US gal,
5.3 Imp gal)
0.01 L
(0.01 US qt,
0.01 Imp qt)
0.12 L
(0.13 US qt,
0.11 Imp qt)
0.24 L
(0.25 US qt,
0.21 Imp qt)
0.14 L
(0.15 US qt,
0.12 Imp qt)
Make sure that the oil and gasoline are
mixed.
If equipped with a built-in fuel tank
1. Pour oil into a clean fuel can, and then
add gasoline.
ZMU04910
1.
2.
: Gasoline
: Engine oil
If equipped with a portable fuel tank
1. Pour oil into the portable fuel tank, and
then add gasoline.
1. Engine oil
2. Gasoline
2.
3.
4.
5.
1. Engine oil
2. Gasoline
2.
3.
29
Replace the fuel tank cap and close tightly.
Shake the fuel tank to mix the fuel thoroughly.
Replace the fuel can cap and close tightly.
Shake the fuel can to mix the fuel thoroughly.
Make sure that the oil and gasoline are
mixed.
Pour the gasoline and oil mixture into the
built-in fuel tank.
TIP:
If using a permanently installed tank, pour the
oil gradually as the gasoline is being added to
the tank.
U6E028E0.book Page 30 Tuesday, February 10, 2009 3:19 PM
Operation
EMU27451
Operating engine
EMU27466
Sending fuel (portable tank)
EWM00420
WARNING
●
●
●
Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.
When the air vent screw is loosened,
gasoline vapor will be released. Gasoline is highly flammable, and its vapors
are flammable and explosive. Refrain
from smoking, and keep away from
open flames and sparks while loosening
the air vent screw.
This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which could cause brain
damage or death when inhaled. Symptoms include nausea, dizziness, and
drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.
1.
If there is an air vent screw on the fuel
tank cap, loosen it 2 or 3 turns.
2.
If there is a fuel joint on the motor, firmly
connect the fuel line to the joint. Then
firmly connect the other end of the fuel
line to the joint on the fuel tank.
ZMU02024
TIP:
Wipe up any spilled gasoline immediately with
dry rags. Dispose rags properly according to
local laws or regulations.
3. Squeeze the primer pump, with the arrow
pointing up, until you feel it become firm.
During engine operation place the tank
horizontally, otherwise fuel cannot be
drawn from the fuel tank.
1. Arrow
30
U6E028E0.book Page 31 Tuesday, February 10, 2009 3:19 PM
Operation
EMU27474
Sending fuel
EWM00420
WARNING
●
●
●
Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.
When the air vent screw is loosened,
gasoline vapor will be released. Gasoline is highly flammable, and its vapors
are flammable and explosive. Refrain
from smoking, and keep away from
open flames and sparks while loosening
the air vent screw.
This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which could cause brain
damage or death when inhaled. Symptoms include nausea, dizziness, and
drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.
1.
For the built in tank, loosen the air vent
screw on the fuel tank cap by one turn.
For the external fuel tank, loosen it on the
fuel tank cap by 2 or 3 turns.
2.
Select the fuel tank using the fuel cock or
open the fuel cock.
31
3.
If you are using an external fuel tank, connect the fuel joints securely and squeeze
the primer pump, with the arrow pointing
up, until you feel it become firm (if
equipped the fuel joint).
U6E028E0.book Page 32 Tuesday, February 10, 2009 3:19 PM
Operation
EMU27493
Starting engine
EWM01600
WARNING
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.
TIP:
The start-in-gear protection device prevents
the engine from starting except when in neutral.
2. Attach the engine shut-off cord to a secure place on your clothing, or your arm
or leg. Then install the clip on the other
end of the cord into the engine shut-off
switch.
EMU27508
Manual start models (tiller control)
EWM01840
WARNING
●
●
1.
Failure to attached engine shut-off cord
could result in a runaway boat if operator is ejected. Attach the engine shut-off
cord to a secure place on your clothing,
or your arm or leg while operating. Do
not attach the cord to clothing that could
tear loose. Do not route the cord where
it could become entangled, preventing it
from functioning.
Avoid accidentally pulling the cord 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.
Place the throttle grip in the “
(start) position.
”
4.
Pull out / turn the choke knob fully. After
the engine starts, replace / return the
knob to the home position.
Place the gear shift lever in neutral.
32
U6E028E0.book Page 33 Tuesday, February 10, 2009 3:19 PM
Operation
ZMU02030
TIP:
TIP:
It is not necessary to use the choke when
starting a warm engine.
● If the choke knob is left in the “
” (start)
position while the engine is running, the engine will run poorly or stall.
5. Pull the manual starter handle slowly until
you feel resistance. Then give a strong
pull straight out to crank and start the engine. Repeat if necessary.
●
●
●
When the engine is cold, it needs to be
warmed up. For further information, see
page 34.
If the engine does not start on the first try,
repeat the procedure. If the engine fails to
start after 4 or 5 tries, open the throttle a
small amount (between 1/8 and 1/4) and try
again. Also if the engine is warm and fails to
start, open the throttle a same amount and
try to start the engine again. If the engine
still fails to start, see page 54.
EMU36510
Checks after starting engine
EMU36520
Cooling water
6.
7.
33
After the engine starts, slowly return the
manual starter handle to its original position before releasing it.
Slowly return the throttle grip to the fully
closed position.
Check for a steady flow of water from the cooling water pilot hole. A continuous flow of water
from the pilot hole shows that the water pump
is pumping water through the cooling passages. If the cooling passages are frozen, it may
take a while for water to start flowing out of the
pilot hole.
ECM01810
NOTICE
If water is not flowing out of the pilot hole
at all times while the engine is running,
overheating and serious damage could
occur. Stop the engine and check whether
the cooling water inlet on the lower case or
U6E028E0.book Page 34 Tuesday, February 10, 2009 3:19 PM
Operation
the cooling water pilot hole is blocked.
Consult your Yamaha dealer if the problem cannot be located and corrected.
EMU34610
Shifting
EWM00180
WARNING
Before shifting, make sure there are no
swimmers or obstacles in the water near
you.
ECM01610
NOTICE
Check that no water leaks from the joints between the exhaust cover, cylinder head, and
body cylinder.
EMU27670
Warming up engine
EMU27683
Choke start models
After starting the engine, allow it to idle for 3
minutes to warm up. Failure to do so will
shorten engine life. Gradually return the
choke knob to its home position as the engine
warms up.
Warm up the engine before shifting into
gear. Until the engine is warm, the idle
speed may be higher than normal. High
idle speed can prevent you from shifting
back to neutral. If this occurs, stop the engine, shift to neutral, then restart the engine and allow it to warm up.
To shift out of neutral
Move the gear shift lever firmly and crisply forward (for forward gear) or backward (for reverse gear).
EMU36530
Checks after engine warm-up
EMU36540
Shifting
While tightly moored, and without applying
throttle, confirm that the engine shifts smoothly into forward and reverse, and back to neutral.
EMU36970
Stop switches
●
●
●
Press the engine stop button and make
sure the engine stops.
Confirm that removing the clip from the engine shut-off switch stops the engine.
Confirm that the engine cannot be started
with the clip removed from the engine shutoff switch.
To shift from in gear (forward/reverse) to neutral
1. Close the throttle so that the engine
slows to idle speed.
34
U6E028E0.book Page 35 Tuesday, February 10, 2009 3:19 PM
Operation
●
2.
After the engine is at idle speed in gear
move the gear shift lever firmly and crisply into the neutral position.
Do not shift into reverse while traveling
at planing speeds. Loss of control, boat
swamping, or damage to the boat could
occur.
The boat is not equipped with a separate
braking system. Water resistance stops it after the throttle lever is moved back to idle. The
stopping distance varies depending on gross
weight, water surface conditions, and wind direction.
EMU27821
Stopping engine
Before stopping the engine, first let it cool off
for a few minutes at idle or low speed. Stopping the engine immediately after operating at
high speed is not recommended.
EMU27833
Procedure
1.
Push and hold the engine stop button until the engine comes to a complete stop.
2.
After stopping the engine, tighten the air
vent screw on the fuel tank cap and set
the fuel cock lever or knob to the closed
position, if equipped.
TIP:
The outboard motor can turn 360° in its bracket (full-pivot system). The boat can also be
backed up by simply turning the outboard motor around 180° with the steering handle facing toward you.
EMU31742
Stopping boat
EWM01510
WARNING
●
Do not use the reverse function to slow
down or stop the boat as it could cause
you to lose control, be ejected, or impact
the steering wheel or other parts of the
boat. This could increase the risk of serious injury. It could also damage the
shift mechanism.
35
U6E028E0.book Page 36 Tuesday, February 10, 2009 3:19 PM
Operation
EMU27862
Trimming outboard motor
EWM00740
WARNING
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.
The trim angle of the outboard motor helps
determine the position of the bow of the boat
in the water. Correct trim angle will help improve performance and fuel economy while
reducing strain on the engine. 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.
3.
Disconnect the fuel line if you are using
an external fuel tank.
TIP:
If the outboard motor is equipped with an engine shut-off cord, the engine can also be
stopped by pulling the cord and removing the
clip from the engine shut-off switch.
1
ZMU02043
1. Trim operating angle
36
U6E028E0.book Page 37 Tuesday, February 10, 2009 3:19 PM
Operation
EMU27872
Adjusting trim angle for manual tilt
models
There are 4 or 5 holes provided in the clamp
bracket to adjust the outboard motor trim angle.
1. Stop the engine.
2. Tilt the outboard motor up, and then remove the trim rod from the clamp bracket.
TIP:
The outboard motor trim angle can be
changed approximately 4 degrees by shifting
the trim rod one hole.
EMU27911
Adjusting boat trim
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. With the
bow up, the boat may have a greater 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.
When the bow of the boat is down, it is easier
to accelerate from a standing start onto plane.
1. Trim rod
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.
EWM00400
WARNING
●
●
●
Stop the engine before adjusting the
trim angle.
Use care to avoid being pinched when
removing or installing the rod.
Use caution when trying a trim position
for the first time. Increase speed gradually and watch for any signs of instability
or control problems. Improper trim angle can cause loss of control.
37
Bow Up
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-out can also cause the
propeller to ventilate, which reduces performance further, and the boat may “porpoise”
(hop in the water), which could throw the operator and passengers overboard.
U6E028E0.book Page 38 Tuesday, February 10, 2009 3:19 PM
Operation
EWM00221
WARNING
Be sure all people are clear of the outboard motor when tilting up and down,
Body parts can be crushed between the
motor and the clamp bracket when the motor is trimmed or tilted.
EWM00230
WARNING
Bow Down
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.
Leaking fuel is a fire hazard. Tighten the
air vent screw and place the fuel cock in
the closed position if the outboard motor
will be tilted for more than a few minutes.
Otherwise fuel may leak.
ECM00231
NOTICE
●
●
●
●
TIP:
Depending on the type of boat, the outboard
motor trim angle may have little effect on the
trim of the boat when operating.
EMU27922
Tilting up and down
If the engine will be stopped for some time or
if the boat is moored in shallows, the outboard
motor should be tilted up to protect the propeller and lower casing from damage by collision
with obstructions, and also to reduce salt corrosion.
Before tilting the outboard motor, follow
the procedure under “Stopping engine”
in this chapter. Never tilt the outboard
motor while the engine is running. Severe damage from overheating can result.
Do not tilt up the engine by pushing the
tiller handle because this could break
the handle.
Keep the power unit higher than the propeller at all times. Otherwise water could
run into the cylinder and cause damage.
The outboard motor cannot be tilted
when in reverse or when the outboard
motor is turned 180° (facing the rear).
EMU34620
Procedure for tilting up (manual tilt
models)
1.
Place the gear shift lever in neutral and
face the outboard motor forward.
38
U6E028E0.book Page 39 Tuesday, February 10, 2009 3:19 PM
Operation
5.
3.
Tighten the steering friction adjuster by
turning it clockwise to prevent the motor
from turning freely.
Tighten the air vent screw.
4.
Close the fuel cock.
ECM01670
2.
Hold the rear of the top cowling or the
rear handle (if equipped) with one hand
and tilt the outboard motor up fully until
the tilt support bar automatically locks.
NOTICE
Do not use the tilt support bar when trailering the boat. The outboard motor could
shake loose from the tilt support and fall.
If the motor cannot be trailered in the normal running position, use an additional
support device to secure it in the tilt position. For more detailed information, see
page 42.
TIP:
If the motor is not facing forward, the tilt support bar cannot automatically turn to the
locked position. If the tilt support bar does not
automatically lock, swing the motor a little to
the left and right.
39
U6E028E0.book Page 40 Tuesday, February 10, 2009 3:19 PM
Operation
EMU28033
Procedure for tilting down (manual tilt
models)
1.
2.
Slightly tilt the outboard motor up.
If equipped with the tilt support bar: Slowly tilt the outboard motor down while pulling the tilt support bar lever up.
●
●
ting an underwater obstacle could
cause the outboard motor to lift out of
the water, resulting in loss of control.
Do not rotate the outboard motor 180°
and operate the boat in reverse. Place
the gear shift in reverse to operate the
boat in reverse.
Use extra care when operating in reverse. Too much reverse thrust can
cause the outboard motor to lift out of
the water, increasing the chance of accident and personal injury.
ECM00260
NOTICE
3.
4.
5.
If equipped with the tilt support knob: Pull
the knob out, and then slowly tilt the outboard motor down.
If equipped with the tilt support lever:
Slowly tilt the outboard motor down while
pulling the tilt support lever up.
Loosen the steering friction adjuster by
turning it counterclockwise, and adjust
the steering friction according to operator
preference. WARNING! If there is too
much resistance it could be difficult to
steer, which could result in an accident. [EWM00721]
Do not tilt the outboard motor up so that
the cooling water inlet on the lower unit is
above the surface of the water when setting up for and cruising in shallow water.
Otherwise severe damage from overheating can result.
EMU28061
Shallow water
EMU35691
EMU28102
Cruising in shallow water (manual tilt
models)
Procedure
1. Place the gear shift lever in neutral and
face the outboard motor forward.
EWM00711
WARNING
●
Run the boat at the lowest possible
speed when using the shallow water
cruising system. The tilt lock mechanism does not work while the shallow
water cruising system is being used. Hit-
40
U6E028E0.book Page 41 Tuesday, February 10, 2009 3:19 PM
Operation
EMU28195
Cruising in other conditions
2.
Slightly tilt the outboard motor up until the
tilt support bar automatically turns to the
lock position to support the engine. The
outboard motor is equipped with 2 or 3
positions for shallow water cruising.
3.
To lower the outboard motor to the normal running position, first slightly tilt the
outboard motor up. Then pull up the tilt
support bar lever and slowly tilt the engine down.
41
Cruising in salt water
After operating in salt water, flush the cooling
water passages with fresh water to prevent
them from becoming clogged. Also rinse the
outside of the outboard motor with fresh water.
Cruising in muddy, turbid, or acidic water
Yamaha strongly recommends that you use
the optional chromium-plated water pump kit
(see page 13) if you use the outboard motor in
acidic water or water with a lot of sediment in
it, such as muddy or turbid (cloudy) water. After operating in such water, flush the cooling
passages with fresh water to prevent corrosion. Also rinse the outside of the outboard
motor with fresh water.
U6E028E0.book Page 42 Tuesday, February 10, 2009 3:19 PM
Maintenance
EMU28227
Transporting and storing outboard motor
EWM00693
WARNING
●
●
EMU28235
Clamp screw mounting models
When transporting or storing the outboard
motor while removed from a boat, keep the
outboard motor in the attitude shown.
USE CARE when transporting fuel tank,
whether in a boat or car.
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.
EWM01860
WARNING
Leaking fuel is a fire hazard. When transporting and storing the outboard motor,
close the fuel cock to prevent fuel from
leaking. Never get under the engine while
it is tilted. Severe injury could occur if the
outboard motor accidentally falls.
ECM00660
NOTICE
Do not use the tilt support lever or knob
when trailering the boat. The outboard motor could shake loose from the tilt support
and fall. If the motor cannot be trailered in
the normal running position, use an additional support device to secure it in the tilt
position.
The outboard motor should be trailered and
stored in the normal running position. If there
is insufficient road clearance in this position,
then trailer the outboard motor in the tilt position using a motor support device such as a
transom saver bar. Consult your Yamaha
dealer for further details.
TIP:
Place a towel or something similar under the
outboard motor to protect it from damage.
EMU30272
Storing outboard motor
When storing your Yamaha outboard motor
for prolonged periods of time (2 months or
longer), several important procedures must
be performed to prevent excessive damage.
It is advisable to have your outboard motor
serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a
minimum of tools, can perform the following
procedures.
42
U6E028E0.book Page 43 Tuesday, February 10, 2009 3:19 PM
Maintenance
ECM01411
6.
Cooling system flushing is essential to
prevent the cooling system from clogging
up with salt, sand, or dirt. In addition, fogging/lubricating of the engine is mandatory to prevent excessive engine damage
due to rust. Perform the flushing and fogging at the same time. WARNING! Do
not touch or remove electrical parts
when starting or during operation.
Keep hands, hair, and clothes away
from the flywheel and other rotating
parts while the engine is running.
7.
Run the engine at a fast idle for a few
minutes in neutral position.
Just prior to turning off the engine, quickly
spray “Fogging Oil” alternately into each
carburetor or the fogging hole of the silencer cover, if equipped. When properly
done, the engine will smoke excessively
and almost stall.
If “Fogging Oil” is not available, run the
engine at a fast idle until the fuel system
empties and the engine stops.
Remove the outboard motor from the test
tank.
Install the silencer cover or fogging hole
cap, and the top cowling.
Drain the cooling water completely out of
the motor. Clean the body thoroughly.
If “Fogging Oil” is not available, remove
the spark plug(s). Pour a teaspoonful of
clean engine oil into each cylinder. Crank
several times manually. Replace the
spark plug(s).
Drain the fuel from both the built-in and
portable fuel tanks, on equipped models.
NOTICE
●
●
Do not place the outboard motor on its
side before the cooling water has
drained from it completely, otherwise
water may enter the cylinder through the
exhaust port and cause engine trouble.
Store the outboard motor in a dry, wellventilated place, not in direct sunlight.
EMU28304
Procedure
EMU28315
Flushing in a water tank
1. Wash the outboard motor body using
fresh water. NOTICE: Do not spray water into the air intake. [ECM01840] For further
information, see page 44.
2. Place the fuel cock in the closed position
and disconnect the fuel line if equipped.
Tighten the air vent screw, if equipped.
3. Remove the engine top cowling and silencer cover.
4. Install the outboard motor on the test
tank.
[EWM00091]
8.
9.
10.
2
1
11.
12.
13.
ZMU02704
1. Lowest water level
2. Water surface
5.
43
Fill the tank with fresh water to above the
level of the anti-cavitation plate. NOTICE:
If the fresh water level is below the level of the anti-cavitation plate, or if the
water supply is insufficient, engine
seizure may occur. [ECM00291]
14.
TIP:
Portable fuel tank equipped models: Store the
portable fuel tank in a dry, well-ventilated
place, not in direct sunlight.
U6E028E0.book Page 44 Tuesday, February 10, 2009 3:19 PM
Maintenance
EMU28402
EMU37074
Periodic maintenance
Lubrication
1.
2.
3.
Install the spark plug(s) and torque to
proper specification. For information on
spark plug installation, see page 48.
Change the gear oil. For instructions, see
page 51. Inspect the oil for the presence
of water that indicates a leaky seal. Seal
replacement should be performed by an
authorized Yamaha dealer prior to use.
Grease all grease fittings. For further details, see page 47.
TIP:
For long-term storage, fogging the engine
with oil is recommended. Contact your
Yamaha dealer for information about fogging
oil and procedures for your engine.
EMU28451
Cleaning the outboard motor
After use, wash the exterior of the outboard
motor with fresh water. Flush the cooling system with fresh water.
EWM01981
WARNING
These procedures require mechanical
skills, tools, and supplies. If you do not
have the proper skills, tools, or supplies to
perform a maintenance procedure, have a
Yamaha dealer or other qualified mechanic do the work.
The procedures involve disassembling
the motor and exposing dangerous parts.
To reduce the risk of injury from moving,
hot, or electrical parts:
● Turn off the engine and keep engine
shut-off cord (lanyard) with you when
you perform maintenance unless otherwise specified.
● Allow the engine to cool before handling
hot parts or fluids.
● Always completely reassemble the motor before operation.
EMU28511
Replacement parts
If replacement parts are necessary, use only
genuine Yamaha parts or parts of equivalent
design and quality. Any part of inferior quality
may malfunction, and the resulting loss of
control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from your Yamaha
dealer.
EMU28460
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
your Yamaha dealer.
EMU34151
Severe operating conditions
Severe operating conditions involve one or
more of the following types of operation on a
regular basis:
● Operating continuously at or near maximum engine speed (rpm) for many hours
● Operating continuously at a low engine
speed (rpm) for many hours
44
U6E028E0.book Page 45 Tuesday, February 10, 2009 3:19 PM
Maintenance
●
●
●
●
●
Operating without sufficient time for engine
to warm up and cool down
Frequent quick acceleration and deceleration
Frequent shifting
Frequently starting and stopping the engine(s)
Operation that fluctuates often between
light and heavy cargo loads
Outboard motors operating under any of
these above conditions require more frequent
maintenance. Yamaha recommends that you
do this service twice as often as specified in
the maintenance chart. For example, if a particular service should be done at 50 hours, do
it instead at 25 hours. This will help prevent
more rapid deterioration of engine components.
EMU34445
Maintenance chart 1
TIP:
Refer to the sections in this chapter for explanations of each owner-specific action.
The maintenance cycle on these charts assume usage of 100 hours per year and regular
flushing of the cooling water passages. Maintenance frequency should be adjusted when operating the engine under adverse conditions such as extended trolling.
● Disassembly or repairs may be necessary depending on the outcome of maintenance
checks.
● Expendable or consumable parts and lubricants will lose their effectiveness over time and
through normal usage regardless of the warranty period.
● When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should
be flushed with clean water after each use.
The “ ” symbol indicates the check-ups which you may carry out yourself.
The “ ” symbol indicates work to be carried out by your Yamaha dealer.
●
●
Initial
Item
Actions
Anode(s) (external)
Inspection or replacement as necessary
Cooling water leakage
Inspection or replacement as necessary
Cowling lock lever
Inspection
Engine starting condition/noise
Inspection
Engine idling
speed/noise
Inspection
Fuel filter (inside builtin fuel tank)
Inspection and cleaning as necessary
Fuel filter (disposal
type)
Replacement
Fuel line(High pressure)
Inspection
45
20 hours 100 hours
(3 months) (1 year)
Every
300 hours
(3 years)
500 hours
(5 years)
U6E028E0.book Page 46 Tuesday, February 10, 2009 3:19 PM
Maintenance
Initial
Item
Actions
Fuel line(High pressure)
Inspection or replacement as necessary
Fuel line(Low pressure)
Inspection
Fuel line(Low pressure)
Inspection or replacement as necessary
Fuel pump
Inspection or replacement as necessary
Fuel/engine oil leakage
Inspection
Gear oil
Replacement
Greasing points
Greasing
Impeller/water pump
housing
Inspection or replacement as necessary
Impeller/water pump
housing
Replacement
Propeller/propeller
nut/cotter pin
Inspection or replacement as necessary
Shift link/shift cable
Inspection, adjustment
or replacement as necessary
Spark plug(s)
Inspection or replacement as necessary
Spark plug caps/spark
plug wires
Inspection or replacement as necessary
Water from the cooling
water pilot hole
Inspection
Throttle link/throttle cable/throttle pick-up timing
Inspection, adjustment
or replacement as necessary
Thermostat
Inspection or replacement as necessary
Water inlet
Inspection
Main switch/stop
switch/choke switch
Inspection or replacement as necessary
Wire harness connections/wire coupler connections
Inspection or replacement as necessary
(Yamaha) Fuel tank
Inspection and cleaning as necessary
Fuel tank (built-in tank)
Inspection and cleaning as necessary
20 hours 100 hours
(3 months) (1 year)
Every
300 hours
(3 years)
500 hours
(5 years)
46
U6E028E0.book Page 47 Tuesday, February 10, 2009 3:19 PM
Maintenance
EMU34451
Maintenance chart 2
Every
Item
Actions
1000 hours
Exhaust guide/exhaust
manifold
Inspection or replacement as necessary
EMU28941
Greasing
Yamaha grease A (water resistant grease)
Yamaha grease D (corrosion resistant grease; for propeller shaft)
4AC, 5C
47
U6E028E0.book Page 48 Tuesday, February 10, 2009 3:19 PM
Maintenance
EMU28956
Cleaning and adjusting spark plug
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.
1. Remove the spark plug caps from the
spark plugs.
2. Remove the spark plug. 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. WARNING! 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. [EWM00561]
Standard spark plug:
B7HS
BR7HS
3.
Be sure to use the specified spark plug,
otherwise the engine may not operate
properly. Before fitting the spark plug,
measure the electrode gap with a wire
thickness gauge; replace it if out of specification.
1. Spark plug gap
2. Spark plug part number
3. Spark plug I.D. mark (NGK)
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
4.
When fitting the plug, wipe off any dirt
from the threads, and then screw it in to
the correct torque.
Spark plug torque:
25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
TIP:
If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of the
correct torque is 1/4 to 1/2 a turn past fingertight. Have the spark plug adjusted to the correct torque as soon as possible with a torquewrench.
EMU28990
Checking fuel filter
Check the fuel filter periodically. The fuel filter
is a one piece, disposable type. If foreign matter is found in the filter, replace it. For replacement of the fuel filter, consult your Yamaha
dealer.
48
U6E028E0.book Page 49 Tuesday, February 10, 2009 3:19 PM
Maintenance
EMU29113
Checking wiring and connectors
●
●
Check that each connector is engaged securely.
Check that each ground lead is properly secured.
EMU32112
Checking propeller
EWM01881
WARNING
EMU29043
Inspecting idling speed
EWM00451
WARNING
●
●
Do not touch or remove electrical parts
when starting or during operation.
Keep hands, hair, and clothes away from
the flywheel and other rotating parts
while the engine is running.
ECM00490
NOTICE
This procedure must be performed while
the outboard motor is in the water. A flushing attachment or test tank can be used.
If the boat is not equipped with a tachometer
for the outboard motor, use a diagnostic tachometer for this procedure. Results may
vary depending on whether testing is conducted with the flushing attachment, in a test tank,
or with the outboard motor in the water.
1. Start the engine and allow it to warm up
fully in neutral until it is running smoothly.
2. Once the engine has warmed up, verify
whether the idle speed is set to specification. For idle speed specifications, see
page 10. If you have difficulty verifying
the idle speed, or the idle speed requires
adjustment, consult a Yamaha dealer or
other qualified mechanic.
49
You could be seriously injured if the engine accidentally starts when you are near
the propeller. Before inspecting, removing, or installing the propeller, place the
shift control in neutral, turn the main
switch to “
” (off) and remove the key,
and remove the clip from the engine shutoff switch. Turn off the battery cut-off
switch if your boat has one.
Do not use your hand to hold the propeller
when loosening or tightening the propeller
nut. Put a wood block between the anti-cavitation plate and the propeller to prevent the
propeller from turning.
Checkpoints
● Check each of the propeller blades for erosion from cavitation or ventilation, or other
damage.
● Check the propeller shaft for damage.
● Check the splines for wear or damage.
● Check for fish line tangled around the propeller shaft.
U6E028E0.book Page 50 Tuesday, February 10, 2009 3:19 PM
Maintenance
EMU30672
Installing propeller
EMU30372
Spline models
ECM00500
NOTICE
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.
●
Check the propeller shaft oil seal for damage.
EMU30662
1.
2.
Removing propeller
EMU29197
Spline models
1. Straighten the cotter pin and pull it out using a pair of pliers.
2. Remove the propeller nut, washer, and
spacer (if equipped). WARNING! Do not
use your hand to hold the propeller
when loosening the propeller nut.
[ECM01880]
3.
[EWM01890]
4.
1.
2.
3.
4.
5.
3.
Apply Yamaha marine grease or a corrosion resistant grease to the propeller
shaft.
Install the spacer (if equipped), thrust
washer, and propeller on the propeller
shaft. NOTICE: Be sure to install the
thrust washer before installing the
propeller, otherwise the lower case
and propeller boss could be damaged.
Install the spacer (if equipped) and the
washer. Tighten the propeller nut until
there is no forward-and-backward movement.
Align the propeller nut with the propeller
shaft hole. Insert a new cotter pin in the
hole and bend the cotter pin ends.
NOTICE: Do not reuse the cotter pin
installed. Otherwise the propeller can
come off during operation. [ECM01890]
Cotter pin
Propeller nut
Washer
Propeller
Thrust washer
Remove the propeller, washer
equipped), and thrust washer.
(if
50
U6E028E0.book Page 51 Tuesday, February 10, 2009 3:19 PM
Maintenance
TIP:
TIP:
If the propeller nut does not align with the propeller shaft hole after tightening it, loosen the
nut until it aligns with the hole.
If a magnetic gear oil drain screw is
equipped, remove all metal particles from
the screw before installing it.
● Always use new gaskets. Do not reuse the
removed gaskets.
4. Remove the oil level plug and gasket to
allow the oil to drain completely.
NOTICE: Inspect the used oil after it
has been drained. If the oil is milky,
water is getting into the gear case
which can cause gear damage. Consult a Yamaha dealer for repair of the
lower unit seals. [ECM00711]
EMU29287
Changing gear oil
EWM00800
WARNING
●
●
Be sure the outboard motor is securely
fastened to the transom or a stable
stand. You could be severely injured if
the outboard motor falls on you.
Never get under the lower unit while it is
tilted, even when the tilt support lever or
knob is locked. Severe injury could occur if the outboard motor accidentally
falls.
1.
2.
3.
Tilt the outboard motor so that the gear oil
drain screw is at the lowest point possible.
Place a suitable container under the gear
case.
Remove the gear oil drain screw and gasket. NOTICE: If there is an excessive
quantity of metal particles on the magnetic gear oil drain screw, this can indicate lower unit problem. Consult
your Yamaha dealer. [ECM01900]
●
TIP:
For disposal of used oil, consult your Yamaha
dealer.
5. Put the outboard motor in a vertical position. Using a flexible or pressurized filling
device, inject the gear oil into the gear oil
drain screw hole.
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
0.100 L (0.106 US qt, 0.088 Imp.qt)
6.
1. Gear oil drain screw
2. Oil level plug
51
Put a new gasket on the oil level plug.
When the oil begins to flow out of the oil
level plug hole, insert and tighten the oil
level plug.
U6E028E0.book Page 52 Tuesday, February 10, 2009 3:19 PM
Maintenance
Tightening torque:
9.0 Nm (0.92 kgf-m, 6.6 ft-lb)
7.
Put a new gasket on the gear oil drain
screw. Insert and tighten the gear oil
drain screw.
Tightening torque:
9.0 Nm (0.92 kgf-m, 6.6 ft-lb)
EMU29302
Cleaning fuel tank
EWM00920
WARNING
Gasoline is highly flammable, and its vapors are flammable and explosive.
● If you have any question about properly
doing this procedure, consult your
Yamaha dealer.
● Keep away from sparks, cigarettes,
flames, or other sources of ignition
when cleaning the fuel tank.
● Remove the fuel tank from the boat before cleaning it. Work only outdoors in
an area with good ventilation.
● Wipe up any spilled fuel immediately.
● Reassemble the fuel tank carefully. Improper assembly can result in a fuel
leak, which could result in a fire or explosion hazard.
● Dispose of old gasoline according to local regulations.
1.
2.
Empty the fuel tank into an approved container.
Pour a small amount of suitable solvent
into the tank. Install the cap and shake
the tank. Drain the solvent completely.
ZMU03231
3.
Remove the screws holding the fuel joint
assembly. Pull the assembly out of the
tank.
4.
Clean the filter (located on the end of the
suction pipe) in a suitable cleaning solvent. Allow the filter to dry.
Replace the gasket with a new one. Reinstall the fuel joint assembly and tighten
the screws firmly.
5.
52
U6E028E0.book Page 53 Tuesday, February 10, 2009 3:19 PM
Maintenance
EMU29312
Inspecting and replacing anode(s)
Yamaha outboard motors are protected from
corrosion by sacrificial anodes. Inspect the
external anodes periodically. Remove scales
from the surfaces of the anodes. Consult a
Yamaha dealer for replacement of external
anodes.
ECM00720
NOTICE
Do not paint anodes, as this would render
them ineffective.
TIP:
Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha
dealer for inspection and replacement of internal anodes attached to the power unit.
53
U6E028E0.book Page 54 Tuesday, February 10, 2009 3:19 PM
Trouble Recovery
EMU29427
Troubleshooting
A problem in the fuel, compression, or ignition
systems can cause poor starting, loss of power, or other problems. This section describes
basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore
some items may not apply to your model.
If your outboard motor requires repair, bring it
to your Yamaha dealer.
If the engine trouble-alert indicator is flashing,
consult your Yamaha dealer.
Starter will not operate.
Q. Is battery capacity weak or low?
A. Check battery condition. Use battery of recommended capacity.
Q. Are battery connections loose or corroded?
A. Tighten battery cables and clean battery
terminals.
Q. Is fuse for electric start relay or electric circuit blown?
A. Check for cause of electric overload and
repair. Replace fuse with one of correct amperage.
Q. Are starter components faulty?
A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear?
A. Shift to neutral.
Engine will not start (starter operates).
Q. Is fuel tank empty?
A. Fill tank with clean, fresh fuel.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged?
A. Clean or replace filter.
Q. Is starting procedure incorrect?
A. See page 32.
Q. Has fuel pump malfunctioned?
A. Have serviced by a Yamaha dealer.
Q. Are spark plug(s) fouled or of incorrect
type?
A. Inspect spark plug(s). Clean or replace with
recommended type.
Q. Are spark plug cap(s) fitted incorrectly?
A. Check and re-fit cap(s).
Q. Is ignition wiring damaged or poorly connected?
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires.
Q. Are ignition parts faulty?
A. Have serviced by a Yamaha dealer.
Q. Is engine shut-off cord (lanyard) not attached?
A. Attach cord.
Q. Are engine inner parts damaged?
A. Have serviced by a Yamaha dealer.
Engine idles irregularly or stalls.
Q. Are spark plug(s) fouled or of incorrect
type?
A. Inspect spark plug(s). Clean or replace with
recommended type.
Q. Is fuel system obstructed?
54
U6E028E0.book Page 55 Tuesday, February 10, 2009 3:19 PM
Trouble Recovery
A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged?
A. Clean or replace filter.
Q. Have ignition parts failed?
A. Have serviced by a Yamaha dealer.
Q. Has alert system activated?
A. Find and correct cause of alert.
Q. Is spark plug gap incorrect?
A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly connected?
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires.
Q. Is specified engine oil not being used?
A. Check and replace oil as specified.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer.
Q. Are carburetor adjustments incorrect?
A. Have serviced by a Yamaha dealer.
Q. Is fuel pump damaged?
A. Have serviced by a Yamaha dealer.
Q. Is air vent screw on fuel tank closed?
A. Open air vent screw.
Q. Is choke knob pulled out?
55
A. Return to home position.
Q. Is motor angle too high?
A. Return to normal operating position.
Q. Is carburetor clogged?
A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect?
A. Connect correctly.
Q. Is throttle valve adjustment incorrect?
A. Have serviced by a Yamaha dealer.
Q. Is battery cable disconnected?
A. Connect securely.
Alert buzzer sounds or indicator lights.
Q. Is cooling system clogged?
A. Check water intake for restriction.
Q. Is engine oil level low?
A. Fill oil tank with specified engine oil.
Q. Is heat range of spark plug incorrect?
A. Inspect spark plug and replace it with recommended type.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Is engine oil contaminated or deteriorated?
A. Replace oil with fresh, specified type.
Q. Is oil filter clogged?
A. Have serviced by a Yamaha dealer.
Q. Has oil feed/injection pump malfunctioned?
A. Have serviced by a Yamaha dealer.
U6E028E0.book Page 56 Tuesday, February 10, 2009 3:19 PM
Trouble Recovery
Q. Is load on boat improperly distributed?
A. Distribute load to place boat on an even
plane.
A. Remove foreign matter and clean lower
unit.
Q. Is water pump or thermostat faulty?
A. Have serviced by a Yamaha dealer.
Q. Is fuel system obstructed?
A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is there excess water in fuel filter cup?
A. Drain filter cup.
Q. Is fuel filter clogged?
A. Clean or replace filter.
Engine power loss.
Q. Is propeller damaged?
A. Have propeller repaired or replaced.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is propeller pitch or diameter incorrect?
A. Install correct propeller to operate outboard
at its recommended speed (r/min) range.
Q. Is trim angle incorrect?
A. Adjust trim angle to achieve most efficient
operation.
Q. Is motor mounted at incorrect height on
transom?
A. Have motor adjusted to proper transom
height.
Q. Has alert system activated?
A. Find and correct cause of alert.
Q. Is boat bottom fouled with marine growth?
A. Clean boat bottom.
Q. Are spark plug(s) fouled or of incorrect
type?
A. Inspect spark plug(s). Clean or replace with
recommended type.
Q. Are weeds or other foreign matter tangled
on gear housing?
Q. Is spark plug gap incorrect?
A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly connected?
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires.
Q. Have electrical parts failed?
A. Have serviced by a Yamaha dealer.
Q. Is specified fuel not being used?
A. Replace fuel with specified type.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer.
Q. Is air vent screw closed?
A. Open the air vent screw.
Q. Is fuel pump damaged?
A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect?
56
U6E028E0.book Page 57 Tuesday, February 10, 2009 3:19 PM
Trouble Recovery
A. Connect correctly.
If the outboard motor hits an object in the water, follow the procedure below.
Q. Is heat range of spark plug incorrect?
A. Inspect spark plug and replace it with recommended type.
Q. Is high pressure fuel pump drive belt broken?
A. Have serviced by a Yamaha dealer.
Q. Is engine not responding properly to shift
lever position?
A. Have serviced by a Yamaha dealer.
1.
2.
Engine vibrates excessively.
Q. Is propeller damaged?
A. Have propeller repaired or replaced.
3.
Q. Is propeller shaft damaged?
A. Have serviced by a Yamaha dealer.
4.
Q. Are weeds or other foreign matter tangled
on propeller?
A. Remove and clean propeller.
Q. Is motor mounting bolt loose?
A. Tighten bolt.
Q. Is steering pivot loose or damaged?
A. Tighten or have serviced by a Yamaha
dealer.
EMU29533
Starter will not operate
If the starter mechanism does not operate
(the engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.
EWM01022
WARNING
●
EMU29433
Temporary action in emergency
●
EMU29440
Impact damage
EWM00870
WARNING
The outboard motor can be seriously damaged by a collision while operating or
trailering. Damage could make the outboard motor unsafe to operate.
57
Stop the engine immediately.
Inspect the control system and all components for damage. Also inspect the boat
for damage.
Whether damage is found or not, return
to the nearest harbor slowly and carefully.
Have a Yamaha dealer inspect the outboard motor before operating it again.
●
Use this procedure only in an emergency to return to the nearest port for repairs.
When the emergency starter rope is
used to start the engine, the start-ingear protection device does not operate.
Make sure the remote control lever is in
neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.
Attach the engine shut-off cord to a secure place on your clothing, or your arm
or leg while operating the boat.
U6E028E0.book Page 58 Tuesday, February 10, 2009 3:19 PM
Trouble Recovery
●
●
●
●
●
Do not attach the cord to clothing that
could tear loose. Do not route the cord
where it could become entangled, preventing it from functioning.
Avoid accidentally pulling the cord 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.
Make sure no one is standing behind
you when pulling the starter rope. It
could whip behind you and injure someone.
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.
Do not touch the ignition coil, spark plug
wire, spark plug cap, or other electrical
components when starting or operating
the motor. You could get an electrical
shock.
4.
5.
6.
7.
Prepare the engine for starting. For further information, see page 32. Be sure
the engine is in neutral and that the clip is
attached to the engine shut-off switch.
The main switch must be “ ” (on), if
equipped.
If equipped the choke knob, pull out it
when the engine is cold. After the engine
starts, gradually return the choke knob to
its home position as the engine warms
up.
Insert the knotted end of the emergency
starter rope into the notch in the flywheel
rotor and wind the rope several turns
around the flywheel clockwise.
Give a strong pull straight out to crank
and start the engine. Repeat if necessary.
EMU29562
Emergency starting engine
1.
2.
3.
Remove the top cowling.
Remove the start-in-gear protection cable from the starter, if equipped.
Remove the starter/flywheel cover after
removing the bolt(s).
58
U6E028E0.book Page 59 Tuesday, February 10, 2009 3:19 PM
Trouble Recovery
EMU33501
Treatment of submerged motor
If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise
some corrosion may begin almost immediately. NOTICE: Do not attempt to run the outboard motor until it has been completely
inspected. [ECM00401]
59
U6E028E0.book Page 60 Tuesday, February 10, 2009 3:19 PM
U6E028E0.book Page 1 Tuesday, February 10, 2009 3:19 PM
YAMAHA MOTOR CO., LTD.
Printed in Japan
March 2009–0.3 × 1 CR
Printed on recycled paper