63B-9-1A hyoshi 4/12/02 3:31 PM Page 1 (2,1)

40B

50B

OWNER’S MANUAL

U.S.A.Edition

LIT-18626-04-92

63B-9-1A hyoshi 4/12/02 3:31 PM Page 2 (1,1)

63B-9-1A-1 2/28/02 5:11 PM Page 1

E

EMU01449

TO THE OWNER

Thank you for choosing a Yamaha outboard motor. This Owner’s manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.

c C

A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

In this Owner’s Manual particularly important information is distinguished in the following ways.

Q

The Safety Alert Symbol means

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

* 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.

w

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.

NOTE:

The 40TR, 50TR and their standard accessories are used as a base for the explanations and illustrations in this manual.

Therefore, some items may not apply to every model.

EMU01446

40B, 50B

OWNER'S MANUAL

©2002 by Yamaha Motor Corporation, USA

1st Edition, March 2002

All rights reserved.

Any reprinting or unauthorized use without the written permission of

Yamaha Motor Corporation, USA is expressly prohibited.

Printed in Japan

P/N LIT-18626-04-92

63B-9-1A-1 2/28/02 5:11 PM Page 2

63B-9-1A-1 2/28/02 5:11 PM Page 3

EMA20010

CONTENTS

GENERAL INFORMATION

E

BASIC COMPONENTS

OPERATION

MAINTENANCE

TROUBLE RECOVERY

INDEX

READ THIS OWNER’S MANUAL CAREFULLY

BEFORE OPERATING YOUR OUTBOARD MOTOR.

6

4

5

1

2

3

63B-9-1A-1 2/28/02 5:11 PM Page 4

63B-9-1A-1 3/1/02 11:04 AM Page 5

E

EMB00010

Chapter 1

GENERAL

INFORMATION

1

IDENTIFICATION NUMBERS

RECORD ....................................................1-1

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

Key number...........................................1-1

EMISSION CONTROL INFORMATION...1-2

2

SAFETY INFORMATION..........................1-3

3

IMPORTANT LABELS ..............................1-5

BASIC BOATING RULES .........................1-6

FUELING INSTRUCTIONS.....................1-10

Gasoline ..............................................1-11

Engine oil ............................................1-11

BATTERY REQUIREMENT ...................1-12

4

PROPELLER SELECTION .......................1-13

START-IN-GEAR PROTECTION ............1-14 5

6

63B-9-1A-1 2/28/02 5:11 PM Page 6

E

EMU00005

IDENTIFICATION NUMBERS

RECORD

EMU00007

OUTBOARD MOTOR SERIAL

NUMBER

1 q

YAMAHA

123

401012

YAMAHA MOTOR CO., LTD.

MADE IN JAPAN

PAYS D'ORIGINE JAPON

The outboard motor serial number is stamped on the label attached to the port side of the clamp-bracket.

Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen.

1 Outboard motor serial number

EMU00008

KEY NUMBER

If main key switch is equipped, your key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference if you need a new key.

1 Key number

904011

1-1

63B-9-1A-1 2/28/02 5:11 PM Page 7 q w

000909

EMU01385

EMISSION CONTROL

INFORMATION

E

EMU01386

NORTH AMERICAN MODELS

This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details.

Approval label of Emission control certificate

This label is attached to the bottom cowling.

1 Emission control information label

EMISSION CONTROL INFORMATION

ENGINE FAMILY :

THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.

FELs :

SPARK PLUG : g/kw-hr IDLE SPEED :

SPARK PLUG GAP (mm) : rpm IN NEUTRAL

Existing Technology ; N/A

Manufactured date label

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

2 Manufactured date label

Manufactured:

1-2

63B-9-1A-1 2/28/02 5:11 PM Page 8

E

EMU00917

Q SAFETY

INFORMATION

8 Before mounting or operating the outboard motor, read this entire manual.

Reading it should give you an understanding of the motor and its operation.

8 Before operating the boat, read any owner’s or operator’s manuals supplied with it and all labels. Be sure you understand each item before operating.

8 Do not overpower the boat with this outboard motor. Overpowering the boat could result in loss of control. The rated power of the outboard should be equal to or less than the rated horsepower capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer.

8 Do not modify the outboard. Modifications could make the motor unfit or unsafe to use.

8 Never operate after drinking alcohol or taking drugs. About 50% of all boating fatalities involve intoxication.

8 Have an approved personal flotation device (PFD) on board for every occupant. It is a good idea to wear a PFD whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear

PFDs when there are potentially hazardous boating conditions.

8 Gasoline is highly flammable, and its vapors are flammable and explosive.

Handle and store gasoline carefully.

Make sure there are no gas fumes or leaking fuel before starting the engine.

8 This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.

8 Check throttle, shift, and steering for proper operation before starting the engine.

8 Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating. If you accidentally leave the helm, the lanyard will pull from the switch, stopping the engine.

8 Know the marine laws and regulations where you will be boating - and obey them. Refer to “RULES OF THE ROAD” section for basic boating rules.

8 Stay informed about the weather.

Check weather forecasts before boating.

Avoid boating in hazardous weather.

8 Tell someone where you are going: leave a Float Plan with a responsible person. Be sure to cancel the Float Plan when you return.

8 Use common sense and good judgment when boating. Know your abilities, and be sure you understand how your boat handles under the different boating conditions you may encounter. Operate within your limits, and the limits of your boat. Always operate at safe speeds, and keep a careful watch for obstacles and other traffic.

8 Always watch carefully for swimmers during the engine operation.

8 Stay away from swimming areas.

1-3

63B-9-1A-1 2/28/02 5:11 PM Page 9

8 When a swimmer is in the water near you shift into neutral and shut off the engine.

8 Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the following:

United States Coast Guard

Consumer Affairs Staff (G-BC)

Office of Boating, Public, and Consumer

Affairs

U.S. Coast Guard Headquarters

Washington, D.C. 20593-0001

Boating Safety Hotline: 1-800-368-5647

National Marine Manufacturers

Association (NMMA)

401 N. Michigan Ave.

Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave.

Chicago, Il 60601

E

1-4

63B-9-1A-1 2/28/02 5:11 PM Page 10 q

202016*

EMB30011

IMPORTANT LABELS

WARNING LABELS

1

WARNING

●Be sure shift control is in neutral

before starting engine. (except 2HP)

●Do not touch or remove electrical parts

when starting or during operation.

●Keep hands,hair,and clothes away from flywheel

and other rotating parts while engine is running.

6A1-83625-41

E

1-5

63B-9-1A-1 2/28/02 5:11 PM Page 11

E

EMB40010

BASIC BOATING RULES

(Rules of the road)

Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast

Guard and local agencies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water.

Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the

Road. The rules presented here in your

Owner’s Manual are condensed, and have been provided for your convenience only.

Consult your local U.S. Coast Guard Auxiliary or Department of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat.

STEERING AND SAILING RULES AND

SOUND SIGNALS

Whenever two vessels on the water meet one another, one vessel has the right-ofway; it is called the “stand-on” vessel.

The vessel which does not have the rightof-way is called the “give-way” or “burdened” vessel. These rules determine which vessel has the right-of-way, and what each vessel should do.

Stand-on vessel

The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision.

When you maintain your direction and speed, the other vessel will be able to determine how best to avoid you.

Give-way vessel

The vessel which does not have the rightof-way has the duty to take positive and timely action to stay out of the way of the

Stand-On vessel. Normally, you should not cross in front of the vessel with the right-of-way. You should slow down or change directions briefly and pass behind the other vessel. You should always move in such a way that the operator of the other vessel can see what you are doing.

“The general prudential rule”

This rule is called Rule 2 in the International Rules and says,

‘In obeying and construing these rules due regard shall be had to all dangers of navigation and collision, and to any special circumstances, which may render a departure from the above rules necessary in order to avoid immediate danger.’

In other words, follow the standard rules except when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become

“Give-Way” vessels.

1-6

63B-9-1A-1 2/28/02 5:11 PM Page 12

E

RULES WHEN ENCOUNTERING

VESSELS

There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed: will clear one another if you continue on your set course and speed.

Meeting (you are approaching another vessel head-on)

Crossing (you are travelling across the other vessel’s path)

Overtaking (you are passing or being passed by another vessel)

102044

In the following illustration, your boat is in the center. You should give the right-ofway to any vessels shown in white area

(you are the Give-Way vessel). Any vessels in the shaded area must yield to you

(they are the Give-Way vessels). Both you and the meeting vessel must alter course to avoid each other.

Crossing

When two power driven vessels are crossing each other’s path close enough to run the risk of collision, the vessel which has the other on the starboard

(right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; you are the Give-Way vessel. If the other vessel is on your port (left) side, remember that you should maintain course and direction, provided the other vessel gives you the right-of-way as it should.

102045

Meeting

If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of-way! Both of you should alter course to avoid an accident. You should keep the other vessel on your port (left) side. This rule doesn’t apply if both of you

102046

Overtaking

If you are passing another vessel, you are the “Give-Way” vessel. This means that the other vessel is expected to maintain

1-7

63B-9-1A-1 2/28/02 5:11 PM Page 13

E its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.

OTHER SPECIAL SITUATIONS

There are three other rules you should be aware of when driving your boat around other vessels.

Narrow channels and bends

When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a power-driven vessel is preparing to go around a bend that may obstruct the view of other water vessels, the operator should sound a prolonged blast on the whistle (4 to 6 seconds). If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still proceed around the bend with caution. If you navigate such waters with your boat, you will need to carry a portable air horn, available from local marine supply stores.

Fishing vessel right-of-way

All vessels which are fishing with nets, lines or trawls are considered to be “fishing vessels” under the International

Rules. Vessels with trolling lines are not considered fishing vessels. Fishing vessels have the right-of-way regardless of position. Fishing vessels cannot, however, impede the passage of other vessels in narrow channels.

Sailing vessel right-of-way

Sailing vessels should normally be given the right-of-way. The exceptions to this are:

1.

When the sailing vessel is overtaking the power-driven vessel, the powerdriven vessel has the right-of-way.

2.

Sailing vessels should keep clear of any fishing vessel.

3.

In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel which can navigate only in such a channel.

Reading buoys and other markers

The waters of the United states are marked for safe navigation by the lateral system of buoyage. Simply put, buoys and markers have an arrangement of shapes, colors, numbers and lights to show which side of the buoy a boater should pass on when navigating in a particular direction. The markings on these buoys are oriented from the perspective of being entered from seaward (the boater is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open water into port, and black buoys are to port (left) side. When navigating out of port, your position with respect to the buoys should be reversed; red buoys should be to port and black buoys to starboard.

Many bodies of water used by boaters are entirely within the boundaries of a particular state. The Uniform State Waterway

Marking System has been devised for these waters. This system uses buoys and signs with distinctive shapes and colors to show regulatory or advisory informa-

1-8

63B-9-1A-1 2/28/02 5:11 PM Page 14 tion. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information.

Remember, markings may vary by geographic location. Always consult local boating authorities before driving your boat in unfamiliar waters.

" 7"

MA

IN

CH

A

N

N

E

L

" 6"

R B " L " or

R G " L "

C " 1"

S

E

C

O

N

D

A

R

Y

N

E

L

C

H

A

N

N " 2"

MAIN CHANNEL BUOYS

" 1" " 3" " 5" " 7"

LIGHTED BUOY (Port Hand)`

Odd number. increasing toward head of navigation.Leave to port (left) proceeding upstream.

1

White Light

OR

1

Green Light

" 5" old new

" 4"

BUOY

COLOR CODE

BLACK

" 3"

" A"

RED

GREEN

" 2" " 4" " 6"

LIGHTED BUOY (Starboard Hand)`

Even number,increasing toward head of navigation. Leave to starboard (right) proceeding upstream.

2

White Light

OR

2

Red Light

" 2" old new

" 1"

C " 1"

Proceeding toward head of navigation from seaward

SECONDARY CHANNEL BUOYS

STARTS NEW NUMBERING SYSTEM

CAN BUOY

Odd number. Leave to port.

1

OR

1

" A"

LIGHTED SAFE WATER BUOY

No number. Marks midchannel, pass on either side. Letter has no lateral significance, used for identification and location purposes.

Top Mark

White Light

White Light

A A

OR old new old

N " 2"

NUN BUOY

Even number. Leave to starboard new

2

R B " L " R G " L "

LIGHTED PREFERRED CHANNEL TO

PORT BUOY

N o n u m b e r . T o p m o s t b a n d r e d - p r e f e r r e d channel is to left of buoy. Letter has no lateral significance, used for identification and location purposes.

Red or

White Light

Red Light

L L

No change old new

102052

1-9

E

63B-9-1A-1 2/28/02 5:11 PM Page 15

1-10

E

EMU00016

FUELING INSTRUCTIONS w

GASOLINE AND ITS VAPORS ARE HIGH-

LY FLAMMABLE AND EXPLOSIVE!

8 Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition.

8 Stop engine before refueling.

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

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

8 Do not overfill the fuel tank.

8 Tighten the filler cap securely after refueling.

8 If you should swallow some gasoline inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention.

8 If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it.

8 Touch the fuel nozzle to the filler open- ing or funnel to help prevent electrostatic sparks.

c C

Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign matter.

63B-9-1A-1 2/28/02 5:11 PM Page 16

E

EMU01804

GASOLINE

Recommended gasoline:

Regular unleaded gasoline with a minimum octane rating of 86

(Pump Octane Number) = (R+M)/2

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

EMU00027

Gasohol

There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or engine performance problems.

1-11

EMU00858

ENGINE OIL

Recommended engine oil:

YAMALUBE 2 STROKE OUTBOARD OIL

If the recommended engine oil is not available, another 2-stroke engine oil with a NMMA-certified TC-W3 rating may be used.

63B-9-1A-1 3/1/02 11:05 AM Page 17

E

EMU01775

BATTERY REQUIREMENT c C

Do not use a battery that does not meet the specified capacity. If a battery which does not meet specifications is used, the electric system could perform poorly or be overloaded, causing electric system damage.

For electric start models, choose a battery which meets the following specifications.

EMU01859

Minimum cold cranking amps

(CCA/SAE): 245 amps at -18°C (-0.4°F)

Minimum marine cranking amps

(MCA/ABYC): 323 amps at 0°C (32°F)

Minimum reserve capacity (RC/SAE):

52 minutes

1-12

63B-9-1A-1 2/28/02 5:11 PM Page 18

EMU01395

PROPELLER SELECTION

E

The performance of your outboard motor will be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine.

Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable for a smaller operating load.

Yamaha dealers stock a range of propellers, and can advise you and install a propeller on your outboard that is best suited to your application.

1-13

63B-9-1A-1 2/28/02 5:11 PM Page 19

10-3/4x17-G

1 23

602011

E

NOTE:

At full throttle and under a maximum boat load, the engine’s rpm should be within the upper half of the full throttle operating range, as listed in “SPECIFICA-

TIONS” on page 4-1. Select a propeller which fulfills this requirement.

If operating under conditions which allow the engine’s rpm to rise above the maximum recommended range (such as light boat loads), reduce the throttle setting to maintain the rpm in the proper operating range.

1 Propeller diameter (in inches)

2 Propeller pitch (in inches)

3 Type of propeller (propeller mark)

Refer to the section “CHECKING PRO-

PELLER” for instructions on propeller removal and installation.

EMU01209

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 Neutral.

Always select Neutral before starting the engine.

1-14

63B-9-1A-1 2/28/02 5:11 PM Page 20

-MEMO-

E

63B-9-1A-2 3/7/02 3:33 PM Page 1

E

EMC00010

Chapter 2

BASIC COMPONENTS

1

MAIN COMPONENTS..............................2-1

OPERATIONS OF CONTROLS AND

OTHER FUNCTIONS ................................2-2

Fuel tank ................................................2-2

Remote control .....................................2-3

Power trim/tilt switch ...........................2-7

Warning indicator.................................2-8

Digital tachometer................................2-9

Trim tab ...............................................2-12

Tilt support lever ................................2-13

Top cowling lock lever .......................2-13

WARNING SYSTEM ..............................2-14

Overheat warning...............................2-14

Oil level warning / oil filter clogging warning ...............................2-15

2

3

4

5

6

63B-9-1A-2 2/28/02 5:12 PM Page 2

E

EMU01206

!3

!2

!1

!0

o i u

1 Oil filler access cap

2 Warning indicator lamp

3 Clamp bracket

4 Battery lead

5 Anode

6 Cooling water inlet

7 Propeller

8 Trim tab (Anode)

MAIN COMPONENTS q w

!4

e r

!5

t y

2-1

9 Anti-cavitation plate

0 Anode q Trim angle adjusting rod w Tilt support lever e Top cowling

* r Remote control box

* t Digital tachometer

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

63B-9-1A-2 2/28/02 5:12 PM Page 3 q e r w

902051*

E

EMC20010

OPERATIONS OF CONTROLS

AND

OTHER FUNCTIONS

EMC21012

FUEL TANK

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

1 Fuel hose joint

2 Fuel meter(If equipped)

3 Fuel tank cap

4 Air vent screw(If equipped)

EMC31010

Fuel hose joint

This connector is provided for connecting or disconnecting fuel hose.

EMC41110

Fuel meter

This meter is on the fuel tank cap. It shows current fuel quantity in the fuel tank approximately.

EMC51010

Fuel tank cap

This cap is for filling fuel. To remove it, turn it counterclockwise.

EMC61010

Air vent screw

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

2-2

63B-9-1A-2 2/28/02 5:12 PM Page 4 y q u w e r t

701011*

E

EMU00096*

REMOTE CONTROL

Both the shifter and the throttle are actuated by the remote control lever. Additionally, the remote control also has the electrical switches.

1 Remote control lever

2 Neutral interlock trigger

3 Neutral throttle lever

4 Main switch

5 Engine stop lanyard switch

6 Power trim and tilt switch (if equipped)

7 Throttle friction adjusting screw y u w

F

r

N

q r t t

R

e u y

701031

EMC50010

Remote control lever

Moving the lever forward from the Neutral position engages Forward gear.

Pulling the lever back from Neutral engages Reverse. The engine will continue to run at idle until the lever is moved about 35° (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.

1 Neutral

2 Forward

3 Reverse

4 Shift

5 Fully closed

6 Throttle

7 Fully open

2-3

63B-9-1A-2 2/28/02 5:12 PM Page 5

E

EMC50110

Neutral interlock trigger

To shift out of Neutral, the neutral interlock trigger of the remote control lever must first be pulled up.

N

q w

OFF

ON

START

701036

701033*

701021

EMC50210

Neutral throttle lever

To open the throttle without shifting into either Forward or Reverse, place the remote control lever in the Neutral position and lift the neutral throttle lever.

NOTE:

The neutral throttle lever will operate only when the remote control lever is in Neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position.

1 Fully open

2 Fully closed

EMC48110

Main switch

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

8 OFF

Electrical circuits switched off.

(The key can be removed.)

8 ON

Electrical circuits switched on.

(The key cannot be removed.)

8 START

Starter-motor will turn and start engine.

(When the key is released, it returns automatically to “ON”.)

2-4

63B-9-1A-2 2/28/02 5:12 PM Page 6

UP

DN

UP

DN

701034

E

EMU01331

Power Trim/Tilt Switch

The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the remote control lever grip. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.

NOTE:

Refer to the sections “ADJUSTING TRIM

ANGLE” and “TILTING UP/DOWN” in

Chapter 3 for instructions on usage.

2-5

63B-9-1A-2 2/28/02 5:12 PM Page 7

E

EMC28210

Engine stop lanyard switch

The lock-plate on the end of the lanyard must be attached to the engine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg.

Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away under power.

w

8 Attach the engine stop switch lanyard to a secure place on your clothing, your arm or leg while operating.

8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard in such a way that it could become entangled, preventing it from functioning.

8 Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly.

This could cause people and objects in the boat to be thrown forward.

q

NOTE:

The engine cannot be started with the lock-plate removed.

1 Lock-plate

2 Lanyard w

000569

2-6

63B-9-1A-2 2/28/02 5:12 PM Page 8

701035

E

EMC87011

Throttle friction adjusting screw

A friction device in the remote control box provides resistance to movement of the remote control lever.

This is adjustable for operator preference.

An adjusting screw is located at the front of the remote control box.

Resistance

Increase

Decrease

Screw

Turn clockwise

Turn counterclockwise w

Do not overtighten the friction adjusting screw.

If there is too much resistance, it may be difficult to move the lever, which could result in an accident.

UP

DN

302013*

EMU01125

POWER TRIM/TILT SWITCH

The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the side of the bottom engine cowling. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.

2-7

63B-9-1A-2 2/28/02 5:12 PM Page 9

E w

Use the power trim/tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the engine off. Attempting to use the cowling-mounted power trim/tilt switch while the boat is moving could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obstacle.

NOTE:

Refer to the section “Adjusting Trim

Angle” and “Tilting Up/Down” for instructions on usage.

q

303012*

EMU00120

WARNING INDICATOR

If the engine develops a condition which is cause for warning, the indicator on the front of the bottom cowling lights up.

The three indicators mounted on the bottom cowling also indicate level of the engine oil. Refer to the section “WARN-

ING SYSTEM” for details of this function.

1 Warning indicator q

303016

2-8

63B-9-1A-2 2/28/02 5:12 PM Page 10 q e t y w u r

001078

E

EMU01614

DIGITAL TACHOMETER

This gauge contains the tachometer, trim meter, hour meter, oil level indicator, and the overheat warning indicator.

1 Tachometer

2 Trim meter

3 Hour meter

4 Oil level indicator

5 Overheat warning indicator

6 Set button

7 Mode button

NOTE:

All segments of the display will light momentarily after the main switch is turned on and will return to normal thereafter.

001082

EMU00136

Tachometer

This meter shows the engine speed.

001049

2-9

63B-9-1A-2 2/28/02 5:12 PM Page 11

001050

E

EMU01109

Trim Meter

This meter shows the trim angle of your outboard motor.

NOTE:

8 Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired setting by operating the power trim and tilt switch.

8 If the trim angle of your motor exceeds the trim operating range, the top segment on the trim meter display will start to blink.

001087

EMU01620

Hour Meter

This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off.

8 Changing the display format

Pressing the MODE button changes the display format in the following circular pattern:

Total hours - Trip hours - Display off

8 Resetting the trip hours

Simultaneously pressing the SET and

MODE buttons for more than 1 second while the trip hours are displayed resets the trip counter to 0 (zero).

NOTE:

The total number of hours the engine has been run cannot be reset.

2-10

63B-9-1A-2 2/28/02 5:12 PM Page 12 q

001051

E

EMU00138

Oil-Level Indicator

This indicator shows the engine oil level.

If the oil level falls below the lower limit, the warning indicator will start to blink.

Refer to the sections “FILLING OIL” and

“OIL LEVEL WARNING” for details.

1 Oil-level indicator c C

Do not operate the engine without oil.

Serious engine damage will occur.

q

001052

EMU01553

Overheat Warning Indicator

If the engine temperature rises too high, the warning indicator will start to blink.

Refer to “OVERHEAT WARNING” for details.

1 Overheat warning indicator c C

Do not continue to operate the engine if a warning device has activated. If necessary, refer to the “TROUBLESHOOTING” section in this manual. Consult your dealer if the problem cannot be located and corrected.

2-11

63B-9-1A-2 2/28/02 5:12 PM Page 13 q w

A

B

603011

E

EMD04011*

TRIM TAB

The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force.

w

An improperly adjusted trim tab may cause difficult steering. Always test run after the trim tab has been installed or replaced to be sure steering is correct. Be sure you have tightened the bolt after adjusting the trim tab.

1 Trim tab

2 Bolt

3 Cap (If equipped)

The rear end of trim tab Boat tends to veer

To the left

(port side)

To the right

(starboard side)

Turn the left(port side),

“A” in the figure

Turn the right(starboard side),”B” in the figure c C

The trim tab also serves as an anode to protect the engine from electroche mical corrosion.

Never paint the trim tab as it will become ineffective as an anode.

2-12

63B-9-1A-2 2/28/02 5:12 PM Page 14

E

EMD60010

TILT SUPPORT LEVER

Power trim & tilt/Hydro tilt model

To keep the outboard motor in the tiltedup position, lock the tilt support lever to the clamp bracket.

403011 q

301013*

EMD62011

TOP COWLING LOCK LEVER

To remove the engine top cowling, turn the lock lever. Then lift off the cowling.

When replacing the cowling, check to be sure it fits properly in the rubber seal.

Then lock the cowling again by moving the lever upward.

1 Top cowling lock lever

2-13

63B-9-1A-2 2/28/02 5:12 PM Page 15

E

EMD80010

WARNING SYSTEM

303012 c C

Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected.

EMD82012*

OVERHEAT WARNING

This engine has an overheat warning device.

If the engine temperature rises too high, the warning device will activate.

001053

701054

( 2 ); Included ( — ); N/A

Warning device activation

Tiller control model

Remote control model

The engine speed will automatically decrease to about

2,000 r/min.

The overheat warning indicator will come on.

The buzzer will sound.

2

2

* 1

2

If the warning system has been activated, stop the engine and check the water inlet for clogging.

605021

*1.Digital tachometer

2-14

63B-9-1A-2 2/28/02 5:12 PM Page 16

303012

303022

E

EMD84012*

OIL LEVEL WARNING / OIL FILTER

CLOGGING WARNING

This engine has an oil level warning system.

If oil level falls below lower limit, the warning device will activate.

( 2 ); Included ( — ); N/A

Warning device activation

Tiller control model

Remote control model

The engine speed will automatically decrease to about

2,000 r/min.

The oil level warning indicator will come on.

The buzzer will sound.

2

2

2

If the warning system has been activated, stop the engine and check for the cause.

NOTE:

The warning for oil filter clogging is similar to the warnings for low oil level and overheating.

For easy troubleshooting, it is advisable to check for engine overheating first, then oil level and finally oil filter clogging.

001094

1 Oil filter q

213024

2-15

63B-9-1A-3 3/7/02 3:39 PM Page 1

E

EMF00010

Chapter 3

OPERATION

1

INSTALLATION ........................................3-1

Mounting the outboard motor............3-2

FILLING FUEL AND ENGINE OIL ............3-4

Filling fuel..............................................3-4

Filling oil ................................................3-5

PRE-OPERATION CHECKS ......................3-8

Operation after a long period of storage...................................................3-9

BREAKING IN ENGINE ..........................3-10

2

3

STARTING ENGINE ...............................3-12

WARMING UP ENGINE .........................3-15

SHIFTING ................................................3-16

Forward ...............................................3-16

Reverse................................................3-16

STOPPING ENGINE ...............................3-17

4

TRIMMING OUTBOARD MOTOR.........3-18

Adjusting trim angle ..........................3-19

TILTING UP/DOWN ...............................3-21 5

CRUISING IN OTHER CONDITIONS.....3-32

Cruising in salt water .........................3-32

Cruising in turbid water .....................3-32

6

63B-9-1A-3 2/28/02 5:13 PM Page 2

E

EMF10010

INSTALLATION c C

Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat or accessories such as transom ladders/depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operated continuously in the presence of airborne water spray.

NOTE:

During water testing check the buoyancy of the boat, at rest, with its maximum load. Check that the static water level on the exhaust housing is low enough to prevent water entry into the powerhead, when water rises due to waves when the outboard is not running.

3-1

63B-9-1A-3 2/28/02 5:13 PM Page 3 q

104011

3-2

E

EMF12012

MOUNTING THE OUTBOARD

MOTOR

w

Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Observe the following:

8 The information presented in this sec- tion is intended as reference only. It is not possible to provide complete instructions for every possible boat/motor combination. Proper mounting depends in part on experience and the specific boat/motor combination.

8 Your dealer or other person experi- enced in proper rigging should mount the motor. If you are mounting the motor yourself, you should be trained by an experienced person. [permanent mounted type]

8 Your dealer or other person experi- enced in proper outboard motor mounting should show you how to mount your motor. [portable type]

Mount the outboard motor on the center line (keel line) of the boat, and ensure that the boat itself is well balanced. Otherwise, the boat will be hard to steer. For boats without a keel or which are asymmetrical, consult your dealer.

1 Center line (keel line)

63B-9-1A-3 2/28/02 5:13 PM Page 4

E w

Overpowering a boat may cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.

104014

EMU01299

Mounting Height

To run your boat at optimum efficiency, the water-resistance (drag) of the boat and outboard motor must be made as little as possible. The mounting-height of the outboard motor greatly affects the water-resistance. If the mounting-height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting-height is too low, the water-resistance will increase and thereby reduce engine efficiency.

Mount the engine so that the anti-cavitation plate is in alignment with the bottom of the boat .

NOTE:

8 The optimum mounting height of the outboard motor is affected by the boat/motor combination. Test runs at different heights can help determine the optimum mounting height.

8 Refer to the section “TRIMMING OUT-

BOARD MOTOR” for instructions on setting the trim angle of the outboard.

3-3

63B-9-1A-3 2/28/02 5:13 PM Page 5

E

902055

EMF20010

FILLING FUEL AND

ENGINE OIL

EMF30011

FILLING FUEL

1) Remove the fuel tank cap.

2) Fill the fuel tank carefully.

3) Close the cap securely after refueling.

Wipe up any spilled fuel.

Fuel tank capacity:

Refer to SPECIFICATIONS, page 4-1.

EMU01019

Ring Free Fuel Additive

Gasoline is a precise blend of many different substances, each chosen to give certain characteristics. Gasoline blends have been changing in recent years in response to concerns about pollution and resulting emissions regulations. One of the most obvious changes has been the elimination of lead from most fuels.

As gasoline has changed, the amount of additives such as aromatics and oxygenates has increased. These additives are important for the engines in passenger cars, but they can have detrimental effects in marine engines, because of increased deposits in the combustion chamber. When enough deposits collect, piston rings begin sticking. Performance drops and engine wear increases dramatically.

While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free has repeatedly proven its ability to clean combustion deposits from inside the engine, notably the critical piston-ringland area, and fuel system components.

Follow product labeling for use instruc-

3-4 tions.

63B-9-1A-3 2/28/02 5:13 PM Page 6

E

EMU01800

FILLING OIL

This engine uses the oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operating conditions. No fuel premixing is needed (except during break-in). Simply pour gasoline into the fuel tank and oil into the oil tank. Convenient indicator segments indicate the status of the oil supply. For details on reading the indicator segments, see “Oil level indicator” in this chapter.

To fill the engine oil tank, proceed as follows: w

Do not add gasoline into the oil tank. Fire or explosion could result.

Engine oil tank capacity:

See Chapter 4, “Specifications.”

3-5

63B-9-1A-3 2/28/02 5:13 PM Page 7

E

EMF34110

Procedure

Electric start model

1) Turn the oil filler access cap on top of the top cowling counterclockwise and open it.

203014

2) Open the oil tank filler cap by pulling a tab on the cap.

q

203015 w

203016*

3) Slowly fill the engine oil into the engine oil tank.

4) After filling, replace the all caps securely.

1 Oil filler access cap

2 Oil tank filler cap

3-6

63B-9-1A-3 2/28/02 5:13 PM Page 8

E

EMD33110

Oil level indicator

Electric start model

The various oil-level system functions are as follows:

Oil level warning indicator

(Digital tachometer)

Oil level warning indicator lamp

(Analog tachometer/Bottom cowling)

Green

Engine oil tank more than 4 50 cm 3

(0.48 US qt,

0.40 Imp qt)

Remarks

No refilling necessary.

Yellow

Red from 450 cm 3

(0.48 US qt,

0.40 Imp qt) down to 200 cm 3

(0.21 US qt,

0.18 Imp qt)

200 cm 3

(0.21 US qt,

0.18 Imp qt) or less

Add oil, refer to oil filling.

Buzzer sounds in remote control box and engine speed is limited to about 2,000 r/min to help conserve oil.

Check oil filter for clogging.

3-7

63B-9-1A-3 2/28/02 5:13 PM Page 9

3-8

E

EMF40012

PRE-OPERATION CHECKS w

If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur.

EMF41110

Fuel

8 Check to be sure you have plenty of fuel for your trip.

8 Make sure there are no fuel leaks or gasoline fumes.

8 Check fuel line connections to be sure they are tight.

8 Be sure the fuel tank is positioned on a secure, flat surface, and that the fuel hose is not twisted or flattened, or likely to contact sharp objects.

EMF42110

Oil

8 Check to be sure you have plenty of oil for your trip.

EMF43010

Controls

8 Check throttle, shift, and steering for proper operation before starting the engine.

8 The controls should work smoothly, without binding or unusual free play.

8 Look for loose or damaged connections.

8 Check operation of the starter and stop switches when the outboard motor is in the water.

63B-9-1A-3 2/28/02 5:13 PM Page 10

E

EMF43510

Engine

8 Check the engine and engine mounting.

8 Look for loose or damaged fasteners.

8 Check the propeller for damage.

c C

Do not start the engine out of water.

Overheating and serious engine damage can occur.

EMU01790

OPERATION AFTER A LONG PERIOD

OF STORAGE

When operating the engine after a long period (12 months) of storage, proceed as follows:

1) Use a 50:1 gasoline-oil mixture to start the engine.

2) Start the engine. Leave it idling.

w

8 Do not touch or remove electrical parts when starting or during operation.

8 Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.

212011*

3) Watch for oil flowing through the oil feed pipes. After any air in the oil lines has been expelled, the oil injection system should supply oil normally. If no oil is flowing after 10 minutes of idling, consult your Yamaha dealer.

c C

Be sure to take the above steps when operating the engine after a long period of storage. Otherwise engine seizure could occur.

3-9

63B-9-1A-3 2/28/02 5:13 PM Page 11

EMU01776

BREAKING IN ENGINE

E

Your new engine requires a period of break-in to allow mating surfaces of moving parts to wear in evenly. Correct breakin will help ensure proper performance and longer engine life.

c C

8 Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage.

8 Premix fuel must be used during break- in, in addition to oil in the oil injection system.

Break-in time: 10 hours

Gasoline to engine oil premix ratio during break-in: 50:1

3-10

63B-9-1A-3 2/28/02 5:13 PM Page 12

3-11

E

EMU01784

Run the engine under load (in gear with a propeller installed) as follows.

1) First 10 minutes:

Run the engine at the lowest possible-speed. A fast idle in neutral is best.

2) Next 50 minutes:

Do not exceed half throttle (approximately 3,000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 r/min or less.

3) Second hour:

Accelerate at full throttle onto plane, then reduce engine speed to threequarter throttle (approximately 4,000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three-quarter throttle or less to let the engine cool.

4) Third through tenth hours:

Avoid operating at full throttle for more than 5 minutes at a time. Let the engine cool between full-throttle runs.

Vary engine speed occasionally.

5) After the first 10 hours:

Operate the engine normally. Use only straight gasoline in the fuel tank.

The oil injection system provides proper lubrication for normal operation.

63B-9-1A-3 2/28/02 5:13 PM Page 13

E

EMU01147

STARTING ENGINE

902053

304034 w

8 Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions.

Be sure there are no swimmers in the water near you.

8 When the air vent screw is loosened, gasoline (petrol) vapor will be released.

Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw.

8 This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled.

Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.

902061

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.

NOTE:

During engine operation place the tank horizontally, or fuel cannot be drawn into the engine.

902025

3) Squeeze the primer bulb with the outlet end up until you feel it become firm.

3-12

63B-9-1A-3 2/28/02 5:13 PM Page 14

N

701015

E

EMF65010

PROCEDURE FOR REMOTE

CONTROL MODEL

4) Place the remote control lever in the

Neutral position.

NOTE:

8 The start-in-gear protection device prevents the engine from starting except when in Neutral.

8 It is not necessary to open the free accelerator lever or Neutral throttle lever while starting.

000293

5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock plate on the other end of the lanyard in the engine stop switch.

w

8 Attach the engine stop switch lanyard to a secure place on your clothing, your arm or leg while operating.

8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard where it could become entangled, preventing from functioning.

8 Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly.

This could cause people and objects in the boat to be thrown forward.

6) Turn the main switch to “ON”.

3-13

63B-9-1A-3 2/28/02 5:13 PM Page 15

OFF

ON

START

701022

E

EMF63910

Electric start model

7) Turn the main switch to “START”, and hold it for a maximum of 5 seconds.

8) Immediately the engine starts, release the main switch to return it to “ON”.

c C

8 Do not turn the main switch to

“START” when the engine is running.

8 Do not keep the starter-motor turning for more than 5 seconds with the main switch in the “START” position. If the engine does not start within 5 seconds, return the main switch to “ON”, wait

10 seconds, and then crank the engine again. (If the starter-motor is run continuously for more than 5 seconds, the battery will rapidly become exhausted and it will be impossible for it to start the engine.)

3-14

63B-9-1A-3 2/28/02 5:13 PM Page 16

309014

EMG00210

WARMING UP ENGINE

E

1) Before beginning operation, allow the engine to warm up at idling speed for

3 minutes. (Failure to do this will shorten engine life.)

2) Check for a steady flow of water from the cooling-water pilot hole.

c C

A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages. If water is not flowing out of the pilot hole at all times while the engine is running, do not continue to run the engine. Overheating and serious damage could occur. Stop the engine and check to see if the water inlet on the lower casing is blocked. If the problem cannot be found and corrected, consult your Yamaha dealer.

NOTE:

After the engine starts, warm-up operation is automatically controlled by the

Prime Start system. Automatic control is cancelled if the throttle is opened more than halfway.

3-15

63B-9-1A-3 3/1/02 11:06 AM Page 17

F N

N

R

701043

E

EMG20111

SHIFTING w

Before shifting, make sure there are no swimmers or obstacles in the water near you.

c C

To change the shifting position from forward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speeds).

EMU00264

FORWARD

Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from Neutral to

Forward.

EMU00269

REVERSE

w

When operating in reverse, go slowly. Do not open the throttle more than half. Otherwise, the boat may become unstable, which could result in loss of control and an accident.

Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from Neutral to

Reverse.

701044

3-16

63B-9-1A-3 2/28/02 5:13 PM Page 18

E

EMG38010

STOPPING ENGINE

Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended.

OFF

ON

START

701023

EMG35310

PROCEDURE

Main switch equipped model

1) Turn the main switch to “OFF”.

NOTE:

The engine can also be stopped by pulling the lanyard from the engine stop switch (then turning the main switch to

“OFF”).

2) If the fuel joints are provided, disconnect the fuel line from the motor after stopping the engine.

304036

3) Tighten the air vent screw on the fuel tank cap after stopping the engine, if it is equipped.

4) Remove the key if the boat will be left unattended.

902052

3-17

63B-9-1A-3 2/28/02 5:13 PM Page 19 q

000862

EMU01412

TRIMMING OUTBOARD

MOTOR

E

The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.

w

Excessive trim for the operating conditions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.

NOTE:

Refer to the section “ADJUSTING TRIM

ANGLE” for instructions on usage.

1 Trim operating angle

3-18

63B-9-1A-3 2/28/02 5:13 PM Page 20

UP

DN

q

UP

DN

701034

E

ADJUSTING TRIM ANGLE

EMU01401

Power Trim/Tilt Model w

8 Be sure all people are clear of the out- board motor when adjusting the trim/tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket.

8 Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems.

8 Use the power trim/tilt switch located on the bottom engine cowling (if equipped) only when the boat is at a complete stop with the engine off.

The outboard motor trim angle can be adjusted operating the power trim/tilt switch 1.

To raise the bow (“trim-out”), push the switch UP.

To lower the bow (“trim-in”), push the switch DN.

Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.

NOTE:

To adjust the trim angle while the boat is moving, use the power trim and tilt switch located on the remote control device or tiller handle, if so equipped.

3-19

63B-9-1A-3 2/28/02 5:13 PM Page 21 q w e

105011

105013

105015

E

EMG62010

Bow up

When the boat is on plane, a bow-up attitude result in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. When trimmed out, the boat may have more tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adjusted to help offset this effect.

Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag.

Excessive trim-up can cause the propeller to ventilate, which reduces performance further. When trimmed-out too much, a boat may “porpoise” (hop in the water), which could throw the operator and passengers overboard.

EMG62110

Bow down

When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.

Too much trim-in causes the boat to

“plow” through the water, decreasing fuel economy and making in hard to increase speed.

Operating with excessive trim-in at higher speeds also makes the boat unstable.

Resistance at the bow is greatly increased, heightening the danger of

“bow steering” and making operation difficult and dangerous.

1 Bow up

2 Bow down

3 Optimum angle

3-20

63B-9-1A-3 2/28/02 5:13 PM Page 22

000817

E

EMH10110

TILTING UP/DOWN

If the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion.

c C

8 Before tilting the motor, follow the pro- cedures under “STOPPING ENGINE”.

Never tilt the motor while the engine is running. Severe damage from overheating can result.

8 Do not tilt up the engine by pushing the steering handle as this could break the handle.

8 Keep the power unit higher than the propeller at all times. Otherwise, water can run into the cylinder, causing damage.

w

Be sure all people are clear of the outboard motor when adjusting the tilt angle, also be careful not to pinch any body parts between the drive unit and engine bracket.

w

Leaking fuel is a fire hazard. Disconnect the fuel line if the engine will be tilted for more than a few minutes. Otherwise, fuel may leak. (If the fuel connector is provided on the motor.)

3-21

63B-9-1A-3 2/28/02 5:13 PM Page 23

UP

DN

UP

DN

E

EMG63210

PROCEDURE FOR TILTING UP

Power trim and tilt model

1) Remove the fuel-line connection from the motor.

304036

2) Push the power trim and tilt switch

“UP” until the outboard has tilted up completely.

701034

UP

DN

302013*

403011

3) Turn the tilt-support lever toward engine bracket and support the engine.

w

After tilting the engine, be sure to support it with the tilt-support lever. Otherwise, the engine could fall back down suddenly if oil in the power trim and tilt unit should lose pressure.

3-22

63B-9-1A-3 2/28/02 5:13 PM Page 24

411035

E

EMG64110

PROCEDURE FOR TILTING DOWN

Power trim and tilt model

1) Push the power trim and tilt switch

“UP” until the engine is supported by the tilt rod.

2) Release the tilt-support lever.

3) Push the power trim and tilt switch

“DN” (Down) to lower the engine to the desired position.

3-23

EMH60010

CRUISING IN OTHER

CONDITIONS

CRUISING IN SALT WATER

After operating in salt water, wash out the cooling-water passages with fresh water to prevent them from becoming cloggedup with salt deposits.

NOTE:

Refer to cooling system flushing instructions in “TRANSPORTING AND STORING

OUTBOARD MOTOR”.

CRUISING IN TURBID WATER

It is strongly recommended that the optional chromium-plated water-pump kit be installed if the outboard is to be used in turbid (muddy) water conditions.

63B-9-1A-4 3/7/02 3:45 PM Page 1

E

EMK00010

Chapter 4

MAINTENANCE

1

SPECIFICATIONS .....................................4-1

TRANSPORTING AND STORING

OUTBOARD MOTOR ...............................4-3

Trailering outboard motor...................4-3

Storing outboard motor ......................4-4

PERIODIC MAINTENANCE......................4-9

Replacement parts ...............................4-9

Maintenance chart..............................4-10

Greasing ..............................................4-11

Cleaning and adjusting spark plug...4-12

Checking fuel system .........................4-14

Cleaning fuel filter ..............................4-15

Adjusting idling speed .......................4-16

Checking water drain under engine oil tank ....................................4-17

Replacing fuse ...................................4-18

Checking wiring and connectors ......4-18

Exhaust leakage..................................4-18

Water leakage .....................................4-18

Checking power trim and tilt system ...........................................4-19

Checking propeller .............................4-20

Changing gear oil ...............................4-22

Cleaning fuel tank...............................4-23

Inspecting and replacing anode .......4-24

Checking battery.................................4-25

Checking bolts and nuts ....................4-28

Motor exterior.....................................4-28

Coating the boat bottom ...................4-28

2

3

4

5

6

63B-9-1A-4 3/7/02 3:45 PM Page 2

E

EMK10011*

SPECIFICATIONS

Model

Unit

Item

DIMENSIONS

8Overall Length

8Overall Width

8Overall Height

8Transom height

8Weight*

PERFORMANCE

L

L

L mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.)

8Full throttle operating range

8Maximum output

8Idling speed r/min kW (HP) r/min

ENGINE

8Engine type

Number of cylinder

Displacement

Bore × stroke

8Ignition system

8Spark plug

Spark plug gap cm 3 (cu.in.) mm (in.)

NGK mm (in.)

8Control system

8Starting system

8Battery

Min. cold cranking amps (CCA/SAE) amps at -18°C (-0.4°F)

Min. marine cranking amps (MCA/ABYC)

Min. reserve capacity (RC/SAE)

8Alternator output

8Starting carburetion system amps at 0°C (32°F) minutes

V-Amp (W)

DRIVE UNIT

8Gear positions

Gear ratio

8Trim and tilt system

8Propeller mark

FUEL AND OIL

8Fuel

Fuel tank capacity

8Recommended engine oil

L (US gal, Imp gal)

Lubrication

Engine oil capacity (engine oil tank)

8Recommended gearcase oil

Gear oil quantity

L (US qt, Imp qt) cm 3 (US oz, Imp oz)

TIGHTNING TORQUE

8Spark plug

8Propeller nut

N•m (kgf•m, lb•ft)

N•m (kgf•m, lb•ft)

* Listed weight does not include propeller.

4-1

646 (25.4)

360 (14.2)

1,319 (51.9)

533 (21.0)

86 (190)

25 (2.5, 18)

35 (3.5, 25)

40TRB

4,500–5,500

29.4 (40) at 5,000 r/min

750–850

2-stroke, L

3

698 (42.6)

67.0 × 66.0 (2.6 × 2.6)

C.D.I system

B7HS-10

0.9–1.0 (0.035–0.039)

Remote control

Electric start

245

323

52

12-6

Prime start system

Forward-Neutral-Reverse

1.85 (24/13)

Power trim and tilt

G

Regular-unleaded gasoline (P.O.N.: minimum 86)

—

YAMALUBE 2 STROKE OUTBOARD OIL, or an equivalent

TC-W3 certified outboard oil oil injection system

1.5 (1.6, 1.3)

Hypoid gear oil (SAE 90)

430 (14.5, 15.1)

63B-9-1A-4 3/7/02 3:45 PM Page 3

50TRB

670 (26.4)

360 (14.2)

1,319 (51.9)

533 (21.0)

86 (190)

4,500–5,500

36.8 (50) at 5,000 r/min

750–850

2-stroke, L

3

698 (42.6)

67.0 × 66.0 (2.6 × 2.6)

C.D.I system

B8HS-10

0.9–1.0 (0.035–0.039)

Remote control

Electric start

245

323

52

12-6

Prime start system

Forward-Neutral-Reverse

1.85 (24/13)

Power trim and tilt

G

Regular-unleaded gasoline (P.O.N.: minimum 86)

—

YAMALUBE 2 STROKE OUTBOARD OIL, or an equivalent TC-W3 certified outboard oil oil injection system

1.5 (1.6, 1.3)

Hypoid gear oil (SAE 90)

430 (14.5, 15.1)

25 (2.5, 18)

35 (3.5, 25)

—

4-2

—

E

63B-9-1A-4 2/28/02 5:14 PM Page 4

4-3

E

EMU01369*

TRANSPORTING AND

STORING OUTBOARD MOTOR w

Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking.

TRAILERING OUTBOARD MOTOR

The motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the motor in the tilt position using a motor support device such as a transom saver bar.

c C

Do not use the tilt support lever/knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor can not be trailered in the down position, use an additional support device to secure it in the up position.

w

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

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

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.

63B-9-1A-4 2/28/02 5:14 PM Page 5

4-4

E

EMU01796

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. This is especially important for your oil injection-equipped outboard motor due to the lean oil ratios used at idle prior to shutting the engine off for the season. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, the following procedures can be performed by you, the owner, with a minimum of tools.

EMK21010

Filling Fuel Tank

Fill the fuel tank with fresh fuel and add one ounce of “Yamaha Fuel Conditioner and Stabilizer” (Part No. LUB-FUELC-12-

00) to each gallon of fuel.

NOTE:

The use of “Yamaha Fuel Conditioner and

Stabilizer” eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead.

63B-9-1A-4 2/28/02 5:14 PM Page 6 q w

605024

E

EMK22511

Flushing Cooling System and Fogging

Engine

Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging of the engine is mandatory to prevent expensive engine damage due to rust. Perform the flushing and fogging at the same time.

8 Flushing in a water tank

1) Remove the engine top cowling and silencer cover.

2) Install the outboard motor on the water tank, and fill the tank with fresh water to above the level of the anticavitation plate.

1 Water surface

2 Lowest water level c C

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.

w

8 Do not tough or remove electrical parts when starting or during operation.

8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running.

3) Run the engine at a fast idle for 10~15 minutes.

4-5

63B-9-1A-4 2/28/02 5:14 PM Page 7

605014

E

4) Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite

Engine Fogging Oil” (Part No. LUB-

STRRT-12-00) alternately into each carburetor. When properly done, the engine will smoke excessively and almost stall.

8 Flushing with the flushing attachment

1) Remove the top cowling and silencer cover. Remove the propeller.

2) Install a flushing attachment to the lower unit. (Flushing attachment available from your Yamaha dealer).

c C

Avoid running the outboard at high speed while on the flushing attachment, or overheating could occur.

w

8 Do not touch or remove electrical parts when starting or during operation.

8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running.

3) Run the engine at a fast idle for 10~15 minutes.

4) Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite

Engine Fogging Oil” (Part No. LUB-

STRRT-12-00) alternately into each carburetor. When properly done, the engine will smoke excessively and almost stall.

5) Remove the flushing attachment and wipe off any excess water.

6) Install the silencer cover and top cowling. Install the propeller.

4-6

63B-9-1A-4 2/28/02 5:14 PM Page 8

E

EMK26112

Lubrication

1) Remove the spark plugs, and spray a

10 second spray of “Yamaha Stor-

Rite Engine Fogging Oil” into each cylinder. Grease the spark plug threads and reinstall the spark plugs and torque to proper specification.

(Refer to “CLEANING AND ADJUST-

ING SPARK PLUG”.)

2) Turn the engine over with the stop lanyard disconnected to work the fogging oil into the piston rings.

3) Fill the oil tanks. This prevents the formation of condensation. For models with a remote tank, it may be necessary to manually override the control unit to completely fill the engine main tank. (Refer to Oil level warning section).

4) Change the lower unit oil. (Refer to

“CHANGING GEAR OIL”). Inspect the oil for the presence of water which indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealership prior to use.

5) Grease all grease fittings. (Refer to

“GREASING”)

4-7

EMK27011

Cleaning and Anti-corrosion Measure

1) Wash down the exterior of the outboard with fresh water and dry off completely.

2) Spray the engine’s exterior with

“Yamaha Silicone Protectant” (Part

No. LUB-SILCNE-13-00).

3) Wax the cowling with a non-abrasive wax such as “Yamaha Silicone Wax”

(Part No. ACC-11000-15-02).

63B-9-1A-4 2/28/02 5:14 PM Page 9

UPPER LEVEL

LOWER LEVEL

901015

4-8

E

EMK29010

Battery Care w

Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing.

Antidote:

EXTERNAL; Flush with water.

INTERNAL; Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

EYES; Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases: Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in a closed space. Always wear eye protection when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

NOTE:

Batteries vary among manufacturers.

Therefore the following procedures may not always apply. Consult your battery manufacturer’s instructions.

1) Disconnect and remove the battery from the boat. Always disconnect the black negative lead first to prevent the risk of shorting.

2) Clean the battery casing and terminals. Fill each cell to the upper level with distilled water.

3) Store the battery on a level surface in a cool, dry, well-ventilated place out of direct sunlight.

4) Once a month, check the specific gravity of the electrolyte and recharge as required to prolong battery life.

63B-9-1A-4 2/28/02 5:14 PM Page 10

4-9

E

EMU01569

PERIODIC MAINTENANCE w

Be sure to turn off the engine when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual. All warranty repairs, however, including those to the emission control system, must be performed by an authorized

Yamaha marine dealership.

A service manual is available for purchase through a Yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform maintenance not covered by this owner’s manual.

EMK33011

REPLACEMENT PARTS

If replacement parts are necessary, use only genuine Yamaha parts or equivalents of the same type and of equivalent strength and materials. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers.

Yamaha genuine parts and accessories are available from a Yamaha dealer.

63B-9-1A-4 2/28/02 5:14 PM Page 11

E

EMK30114*

MAINTENANCE CHART

Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines.

The mark ( ●) indicates the check-ups which you may carry out yourself.

The mark ( 1) indicates work to be carried out by your Yamaha dealer.

Interval Initial Every

10 hours

Refer page

Item

50 hours

(3 months)

100 hours

(6 months)

200 hours

(1 year)

Carburetor

Fuel filter

Fuel system

Fuel tank *2

Throttle link

Idling speed

Cleaning

Cleaning

Inspection

Cleaning

Inspection/Adjustment

Inspection/Adjustment

Spark plug

Oil tank water drain

Oil pump

Cleaning/Adjustment/

Replacement

Cleaning

Inspection/Adjustment

Power trim and tilt system*1 Inspection

Wiring & Connector Inspection/Reconnect

Exhaust leakage Inspection

Water leakage

Grease points

Inspection

Greasing

Gear oil

Bolts & Nuts

Cowling clamp

Change

Retightening

Inspection

Anode

Propeller

Inspection

Inspection

Motor exterior Inspection

Cooling water passages*3 Cleaning

●

●

●

1

●

●

●

●

1

●

●

●

●

●

●

1

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

●

1

●

●

●

●

●

●

1

●

—

4-16

4-15

4-24

—

4-17

4-13

4-23

4-29

—

4-25

4-21

4-29

4-5

4-18

—

4-20

4-19

4-19

4-19

4-11

Battery Inspection

● (every month)

4-26

*1. for Power trim and tilt model

*2. If equipped

*3. When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.

4-10

63B-9-1A-4 2/28/02 5:14 PM Page 12

EMU00366

GREASING

Yamaha marine grease

(Water resistant grease)

E

4-11

63B-9-1A-4 2/28/02 5:14 PM Page 13

4-12

E

EMU01202

CLEANING AND ADJUSTING SPARK

PLUG

w

When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire.

The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself.

Instead, take the outboard motor to a

Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type.

Standard spark plug:

Refer to “SPECIFICATIONS”, page 4-1.

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

Spark plug gap:

Refer to “SPECIFICATIONS”, page 4-1.

63B-9-1A-4 2/28/02 5:14 PM Page 14 w q

903022

E

When fitting the plug, always clean the gasket surface and use a new gasket.

Wipe off any dirt from the threads and screw in the spark plug to the correct torque.

Spark plug torque:

Refer to “SPECIFICATIONS”, page 4-1.

NOTE:

If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.

Initial of spark plug

I.D. mark

B

C/BK

D

Plug wrench size

21 mm (13/16 in.)

16 mm (5/8 in.)

18.3 mm (23/32 in.)

1 Spark plug gap

2 Spark plug I.D. mark (NGK)

4-13

63B-9-1A-4 2/28/02 5:14 PM Page 15

106015

E

EMK38010

CHECKING FUEL SYSTEM

w

Gasoline (petrol) and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition.

Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by Yamaha dealer or other qualified mechanic.

Checking points

8 Fuel system parts leakage.

8 Fuel hose joint leakage.

8 Fuel hose cracks or other damage.

8 Fuel connector leakage.

w

Leaking fuel can result in fire or explosion.

8 Check for fuel leakage regularly.

8 If any fuel leakage is found, the fuel system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate.

4-14

63B-9-1A-4 2/28/02 5:14 PM Page 16

207035

E

EMK50011

CLEANING FUEL FILTER

w

Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive.

8 If you have any question about properly doing this procedure, consult your

Yamaha dealer.

8 Do not perform this procedure on a hot or running engine. Allow the engine to cool.

8 There will be fuel in the fuel filter. Keep away from sparks, cigarettes, flames or other sources of ignition.

8 This procedure will allow some fuel to spill. Catch fuel in a rag. Wipe up any spilled fuel immediately.

8 The fuel filter must be reassembled carefully with O-ring, filter cup, and hoses in place. Improper assembly can result in a fuel leak, which could result in a fire or explosion hazard.

To clean the fuel filter:

1) Remove the nut holding the fuel filter assembly if equipped.

2) Unscrew the filter cup, catching any spilled fuel in a rag.

3) Remove the filter element, and wash it in solvent.

Allow it to dry. Inspect the filter element and O-ring to make sure they are in good condition. Replace them if necessary.

4) Reinstall the filter element in the cup.

Make sure the O-ring in position in the cup. Firmly screw the cup onto the filter housing.

4-15

63B-9-1A-4 2/28/02 5:14 PM Page 17 q w e r

207013

E

5) Attach the filter assembly to the bracket with that the fuel hoses are attached to the filter assembly.

6) Run the engine and check the filter and lines for leaks.

1 Filter element

2 O-ring

3 Filter cup

4 Filter housing

EMK54110

ADJUSTING IDLING SPEED

w

8 Do not touch or remove electrical parts when starting or during operation.

8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running.

c C

This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used.

Procedure

NOTE:

A diagnostic tachometer should be used for this procedure.

1) Start the engine and allow it to warm up fully in Neutral until it is running smoothly. If the outboard is mounted on a boat, be sure the boat is tightly moored.

4-16

63B-9-1A-4 2/28/02 5:14 PM Page 18 q q w

E

2) Adjust the throttle stop-screw to set the idling speed to specification (see

“SPECIFICATIONS”) by turning the stop-screw clockwise to increase the idling speed, and turning it counterclockwise to decrease the idling speed.

NOTE:

Correct idling-speed adjustment is only possible if the engine is fully warmed-up.

If not warmed up fully, the speed setting will tend to be too high. If you have difficulty obtaining the specified idle, consult a Yamaha dealer or other qualified mechanic.

1 Throttle stop-screw

204014*

213012

EMK58010

CHECKING WATER DRAIN UNDER

ENGINE OIL TANK

A translucent water drain hose is connected from the bottom of the oil tank to the filler neck. If water or foreign matter collects in this hose, immediately remove the hose at the filler neck and drain the contaminants.

1 Hose

2 Filler neck side

4-17

63B-9-1A-4 2/28/02 5:14 PM Page 19 q w

205015*

E

EMU01329

REPLACING FUSE

If the fuse has blown on an Electric start model, open the fuse holder and replace the fuse with a new one of proper amperage.

w

Be sure to use the specified fuse. An incorrect fuse or a piece of wire may allow excessive current flow. This could cause electrical system damage and a fire hazard.

NOTE:

If the new fuse blows again immediately, consult a Yamaha dealer.

1 Fuse holder

2 Fuse (20A)

EMK78010

CHECKING WIRING AND

CONNECTORS

1) Check that each grounding wire is properly secured.

2) Check that each connector is engaged securely.

EXHAUST LEAKAGE

Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head and crank case.

WATER LEAKAGE

Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head and crank case.

4-18

63B-9-1A-4 2/28/02 5:14 PM Page 20 q

E

EMU00992

CHECKING POWER TRIM AND TILT

SYSTEM

w

8 Never get under the lower unit while it is tilted, even when the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls.

8 Make sure no one is under the out- board before performing this test.

1) Check the power trim and tilt unit for any sign of oil leaks.

2) Operate each of the power trim and tilt switches on remote control and engine bottom cowling (If equipped) to check that all switches work.

3) Tilt up the motor and check that the trim and tilt rod 1 is pushed out completely.

4) Check that the trim and tilt rod is free of corrosion or other flaws.

5) Operate the motor to trim and tilt down. Check that the trim and tilt rod operates smoothly.

NOTE:

If any operation is abnormal, consult a

Yamaha dealer.

Recommended fluid;

Yamaha power trim & tilt fluid or

ATF (DEXRONII )

4-19

63B-9-1A-4 2/28/02 5:14 PM Page 21

210012

602051

602054

E

EML08011*

CHECKING PROPELLER

w

You could be seriously injured if the engine accidentally starts while you are near the propeller.

8 Before inspecting, removing or installing the propeller, remove the spark plug caps from the spark plugs.

Also, put the shift control in Neutral, put the main switch in the “OFF” position and remove the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one.

8 Do not use your hand to hold the pro- peller when loosening or tightening the propeller nut. Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning.

1) Check each of the propeller blades for wear, erosion from cavitation or ventilation, or other damage.

2) Check the splines for wear and damage.

3) Check for fish line winding around the propeller shaft. Check the propeller shaft oil seal for damage.

Removal

1) Using pliers, straighten the cotter-pin and pull it out.

2) Remove the propeller nut.

3) Remove the propeller.

4-20

63B-9-1A-4 2/28/02 5:14 PM Page 22

1

6

2

34

5

602041

E

1 Thrust washer

2 Propeller

3 Spacer

4 Washer

5 Propeller nut

6 Cotter pin

Installation

1) Apply Yamaha Marine grease (waterresistant grease) to the propellershaft.

2) Slide the propeller over the propellershaft.

c C

Be sure to install the thrust washer before installing propeller, otherwise, lower case and propeller boss may be damaged.

3) Tighten the propeller nut to the specified torque.

Tightening torque:

Refer to “SPECIFICATIONS” page 4-1.

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

NOTE:

When the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, then tighten it more to align the hole.

c C

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.

602053

4-21

63B-9-1A-4 2/28/02 5:14 PM Page 23 w q

000565

E

EMU01460

CHANGING GEAR OIL

w

8 Be sure the outboard is securely fas- tened to the transom or a stable stand.

You could be severely injured if the outboard falls on you.

8 Never get under the lower unit while it is tilted, even when the tilt-support lever/knob is locked. Severe injury could occur if the outboard accidentally falls.

1) Tilt the outboard motor so that the oil drain plug is at the lowest point possible.

2) Place a suitable container under the gear-case.

3) Remove the oil drain plug 1.

NOTE:

The oil drain plug is magnetic. Remove all metal particles from the plug before reinstalling it.

4) Remove the oil level plug 2 to allow the oil to drain completely.

c C

Inspect the used oil after it has been drained. If the oil is milky, water is getting into the gear-case which can cause gear damage. Consult a Yamaha dealer for repair of the lower unit seals.

NOTE:

For disposal of used oil consult your

Yamaha dealer.

4-22

63B-9-1A-4 2/28/02 5:14 PM Page 24

601015

E

5) With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the oil drain plug hole.

Gear oil grade/capacity:

Refer to “SPECIFICATIONS,” page 4-1.

6) When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.

7) Insert and tighten the oil drain plug.

4-23

EML22011

CLEANING FUEL TANK

w

Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive.

8 If you have any question about properly doing this procedure, consult your

Yamaha dealer.

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

8 Remove the fuel tank from the boat before cleaning it. Work only outdoors in an area with good ventilation.

8 Wipe up any spilled fuel immediately.

8 Reassemble the fuel tank carefully.

Improper assembly can result in a fuel leak, which could result in a fire or explosion hazard.

8 Dispose of old gasoline (petrol)accord- ing to local regulations.

63B-9-1A-4 2/28/02 5:14 PM Page 25

E

To clean the fuel tank

1) Empty the fuel tank into an approved gasoline (petrol) container.

2) Pour a small amount of suitable solvent in the tank. Reinstall the cap and shake the tank. Drain the solvent completely.

To clean the fuel filter

1) Remove the screws holding the fuel hose joint assembly . Pull the assembly out of the tank.

2) Clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allow the filter to dry.

3) Replace the gasket with a new one.

Reinstall the fuel hose joint assembly and tighten the screws firmly.

902054

604012

EML24010

INSPECTING AND REPLACING

ANODE

Yamaha outboard motor is protected from corrosion by a sacrificial anode(s).

Check the anode periodically. Remove the scales from surfaces of the anode.

For the replacement of the anode, consult a Yamaha dealer.

c C

Do not paint the anode, for this would render it ineffective.

405011

4-24

63B-9-1A-4 2/28/02 5:14 PM Page 26

4-25

E

EML26010

CHECKING BATTERY

(for Electric start model)

w

Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic.

Always follow these preventive measures:

8 Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury.

8 Wear protective eye gear when han- dling or working near batteries.

Antidote (EXTERNAL):

8 SKIN—Flush with water.

8 EYES—Flush with water for 15 minutes and get immediate medical attention.

Antidote (INTERNAL):

8 Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention.

Batteries also generate explosive hydrogen gas; therefore, you should always follow these preventive measures:

8 Charge batteries in a well-ventilated area.

8 Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.).

8 DO NOT SMOKE when charging or han- dling batteries.

8 KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

c C

A poorly maintained battery will quickly deteriorate.

63B-9-1A-4 2/28/02 5:14 PM Page 27

E

1) Check the electrolyte level at least once a month. Fill to the manufacturer’s recommended level when necessary. Top up only with distilled water

(or pure de-ionized water suitable to use in batteries).

c C

Ordinary tap-water contains minerals harmhul to a battery, and should not be used for topping-up.

2) Keep the battery always in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month or more, remove the battery from the boat and store it in a cool, dark place.

Completely recharge the battery before using it.

3) If the battery will be stored for longer than a month, check the specific gravity of the fluid at least once a month and recharge the battery when it is low.

4-26

63B-9-1A-4 2/28/02 5:14 PM Page 28 e

UPPER LEVEL

LOWER LEVEL w q

901012

E

EMU01279

Connecting the Battery w

Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder.

c C

8 Make sure the main switch (on applica- ble models) is “OFF” before working on the battery.

8 Reversal of the battery leads will dam- age the rectifier.

8 Connect the RED lead first when installing the battery and disconnect the RED lead last when removing it.

Otherwise, the electrical system can be damaged.

8 The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine.

Connect the RED lead to the POSITIVE (+) terminal first.

Then connect the BLACK lead to the NEG-

ATIVE (-) terminal.

1 Red lead

2 Black lead

3 Battery

EMU01280

Disconnecting the Battery

Disconnect the BLACK lead from the NEG-

ATIVE (-) terminal first. Then disconnect the RED lead from the POSITIVE (+) terminal.

4-27

63B-9-1A-4 2/28/02 5:14 PM Page 29

E

EML40010

CHECKING BOLTS AND NUTS

1) Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torques.

2) Check the tightening torques of other bolts and nuts.

EML42011

MOTOR EXTERIOR

Cleaning the Outboard Motor

After use, wash the exterior of the outboard with fresh water. Flush the cooling system with fresh water.

102024

Cleaning cooling-water passages

NOTE:

Refer to cooling system flushing instructions in “TRANSPORTING AND STORING

OUTBOARD MOTOR”.

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. Consult a

Yamaha dealer for touch-up paint.

102025

4-28

EML44010

COATING THE BOAT BOTTOM

A clean hull improves boat performance.

The boat bottom should be kept as clean of marine growths as possible. If necessary, the boat bottom can be coated with an 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.

63B-9-1A-4 2/28/02 5:14 PM Page 30

-MEMO-

E

63B-9-1A-5 2/28/02 5:14 PM Page 1

E

EMN00010

Chapter 5

TROUBLE RECOVERY

1

TROUBLESHOOTING ..............................5-1

TEMPORARY ACTION IN

EMERGENCY ............................................5-5

Impact damage.....................................5-5

Power trim/tilt will not operate ...........5-5

Starter will not operate ........................5-6

Engine fails to operate .........................5-8

Treatment of submerged motor .......5-10

2

3

4

5

6

63B-9-1A-5 2/28/02 5:14 PM Page 2

E

EMU01204¯

TROUBLESHOOTING

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.)

If your outboard motor requires repair, bring it to a Yamaha dealer.

Trouble

A. Starter will not operate.

B. Engine will not start (Starter operates).

Possible Cause

1. Battery capacity weak or low.

2. Battery connections loose or corroded.

3. Fuse for electric start circuit blown.

4. Starter components faulty.

5. Shift lever in gear.

1. Fuel tank empty.

2. Fuel contaminated or stale.

3. Fuel filter clogged.

4. Starting procedure incorrect.

5. Fuel pump malfunctions.

6. Spark plug(s) fouled or incorrect type.

7. Spark plug cap(s) fitted incorrectly.

8. Poor connections or damaged ignition wiring.

9. Ignition parts faulty.

10. Engine stop switch lanyard not attached.

11. Engine inner parts damaged.

Remedy

1. Check battery condition. Use battery of recommended capacity.

2. Tighten battery cables and clean battery terminals.

3. Check for cause of electric overload and repair. Replace fuse with one of correct amperage.

4. Have serviced by a Yamaha dealer.

5. Shift to neutral.

1. Fill tank with clean, fresh fuel.

2. Fill tank with clean, fresh fuel.

3. Clean or replace filter.

4. Read "STARTING ENGINE" section.

5. Have serviced by a Yamaha dealer.

6. Inspect spark plug(s). Clean or replace with recommended type.

7. Check and re-fit cap(s).

8. Check wires for wear or breaks.

Tighten all loose connections.

Replace worn or broken wires.

9. Have serviced by a Yamaha dealer.

10. Attach lanyard.

11. Have serviced by a Yamaha dealer.

5-1

63B-9-1A-5 2/28/02 5:14 PM Page 3

E

Trouble

C. Engine idles irregularly or stalls.

Possible Cause

1. Spark plug(s) fouled or incorrect type.

2. Fuel system obstructed.

3. Fuel contaminated or stale.

4. Fuel filter clogged.

5. Failed ignition parts.

6. Warning system activated.

7. Spark plug gap incorrect.

8. Poor connections or damaged ignition wiring.

9. Specified engine oil not used.

10. Thermostat faulty or clogged.

11. Carburetor adjustments incorrect.

12. Fuel pump damaged.

Remedy

1. Inspect spark plug(s). Clean or replace with recommended type.

2. Check for pinched or kinked fuel line or other obstructions in fuel system.

3. Fill tank with clean, fresh fuel.

4. Clean or replace filter.

5. Have serviced by a Yamaha dealer.

6. Find and correct cause of warning.

7. Inspect and adjust as specified.

8. Check wires for wear or breaks.

Tighten all loose connections.

Replace worn or broken wires.

9. Check and replace oil as specified.

10. Have serviced by a Yamaha dealer.

11. Have serviced by a Yamaha dealer.

12. Have serviced by a Yamaha dealer.

13. Open the air vent screw.

13. Air vent screw on the fuel tank closed.

14. Choke knob pulled out.

15. Motor angle too high.

16. Carburetor clogged.

17. Fuel joint connection incorrect.

18. Throttle valve adjustment incorrect.

19. Battery lead disconnected.

14. Return to home position.

15. Return to normal operating position.

16. Have serviced by a Yamaha dealer.

17. Connect correctly.

18. Have serviced by a Yamaha dealer.

19. Connect securely.

5-2

63B-9-1A-5 2/28/02 5:14 PM Page 4

E

Trouble

D. Warning buzzer sounds or indicator lamp lights.

E. Engine power loss.

Possible Cause

1. Cooling system clogged.

2. Engine oil level low.

3. Heat range of spark plug incorrect.

4. Specified engine oil not used.

5. Engine oil contaminated or deteriorated.

6. Oil filter clogged.

7. Oil feed/injection pump malfunctions.

8. Load on boat improperly distributed.

9. Water pump/thermostat faulty.

1. Propeller damaged.

2. Propeller pitch or diameter incorrect.

3. Trim angle incorrect.

4. Motor mounted at incorrect height on transom.

5. Warning system activated.

6. Boat bottom fouled with marine growth.

7. Spark plug(s) fouled or incorrect type.

8. Weeds or other foreign matter tangled on gear housing.

9. Fuel system obstructed.

10. Fuel filter clogged.

11. Fuel contaminated or stale.

12. Spark plug gap incorrect.

Remedy

1. Check water intake for restriction.

2. Fill oil tank with specified engine oil.

3. Inspect spark plug and replace it with recommended type.

4. Check and replace oil with specified type.

5. Replace oil with fresh, specified type.

6. Have serviced by a Yamaha dealer.

7. Have serviced by a Yamaha dealer.

8. Distribute load to place boat on an even plane.

9. Have serviced by a Yamaha dealer.

1. Have propeller repaired or replaced.

2. Install correct propeller to operate outboard at its recommended speed (r/min) range.

3. Adjust trim angle to achieve most efficient operation.

4. Have motor adjusted to proper transom height.

5. Find and correct cause of warning.

6. Clean boat bottom.

7. Inspect spark plug(s). Clean or replace with recommended type.

8. Remove foreign matter and clean lower unit.

9. Check for pinched or kinked fuel line or other obstructions in fuel system.

10. Clean or replace filter.

11. Fill tank with clean, fresh fuel.

12. Inspect and adjust as specified.

5-3

63B-9-1A-5 2/28/02 5:14 PM Page 5

E

Trouble Possible Cause

13. Poor connections or damaged ignition wiring.

14. Failed ignition parts.

15. Specified engine oil not used.

E. Engine power loss.

16. Thermostat faulty or clogged.

17. Air vent screw closed.

18. Fuel pump damaged.

19. Fuel joint connection incorrect.

20. Heat range of spark plug incorrect.

F. Engine vibrates excessively.

1. Propeller damaged.

2. Propeller shaft damaged.

3. Weeds or other foreign matter tangled on propeller.

4. Motor mounting bolt loose.

5. Steering pivot loose or damaged.

Remedy

13. Check wires for wear or breaks.

Tighten all loose connections.

Replace worn or broken wires.

14. Have serviced by a Yamaha dealer.

15. Check and replace oil with specified type.

16. Have serviced by a Yamaha dealer.

17. Open the air vent screw.

18. Have serviced by a Yamaha dealer.

19. Connect correctly.

20. Inspect spark plug and replace it with recommended type.

1. Have propeller repaired or replaced.

2. Have serviced by a Yamaha dealer.

3. Remove and clean propeller.

4. Tighten bolt.

5. Tighten or have serviced by a

Yamaha dealer.

5-4

63B-9-1A-5 2/28/02 6:25 PM Page 6 q

607011

EMN20010

TEMPORARY ACTION IN

EMERGENCY

E

EMU01492

IMPACT DAMAGE

w

The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate.

If the outboard motor hits any object in the water, follow the procedure below.

1) Stop the engine immediately.

2) Inspect the control system and all components for damage. Also, inspect the boat for damage.

3) Whether damage is found or not, return to the nearest harbor slowly and carefully.

4) Have a Yamaha dealer inspect the outboard motor before operating it again.

411011*

EMG65110

POWER TRIM / TILT WILL NOT

OPERATE

If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit, the engine can be tilted manually. Loosen the manual valve screw counterclockwise until it stops. Put the engine in the desired position, then tighten the manual valve screw clockwise.

1 Manual valve screw

5-5

63B-9-1A-5 2/28/02 5:15 PM Page 7

5-6

E

EMN30310

STARTER WILL NOT OPERATE

If the starter mechanism does not operate

(engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.

w

8 Use this procedure only in an emer- gency and only to return to port for repairs.

8 When the emergency starter rope is used to start the engine, the start-ingear protection device does not operate. Make sure the transmission is in neutral. Otherwise, the boat could unexpectedly start to move, which could result in an accident.

8 Be sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure someone.

8 An unguarded rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the flywheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.

8 Do not touch the ignition coil, high voltage wire, spark plug cap or other electrical components when starting of operating the motor. You could be shocked.

63B-9-1A-5 2/28/02 5:15 PM Page 8

E

Procedure

1) Remove the top cowling.

2) Remove the starter/flywheel cover by removing the bolts.

NOTE:

On a model equipped with the start-ingear protection device (cable), disconnect the cable from the starter.

208026

OFF ON START

701024

3) Prepare the engine for starting. See

“STARTING ENGINE” for procedures.

Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch.

The main switch must be on if the main switch is equipped on the electric start model.

NOTE:

Prime start model

If the engine will not start with this procedure, refer to “ENGINE FAILS TO OPER-

ATE”.

208052

5-7

4) To start the engine with emergency starter rope, insert the knotted end of the rope into the notch in the flywheel rotor and wind the rope several turns clockwise. Then, give a strong pull straight out to crank the engine.

Repeat if necessary.

63B-9-1A-5 2/28/02 5:15 PM Page 9

E

EMN32411

ENGINE FAILS TO OPERATE

Cold engine fails to start (for Prime start model)

If a cold engine fails to start, use the following procedure.

1) Adjust the trim angle so that the drive shaft is at right angles to the water surface or is trimmed in.

2) Open the emergency starter valve located behind the silencer cover on the front side.

OPEN

CLOSE

214011

3) Squeeze the priming pump two or three times to feed fuel.

N

902025

701014

4) Turn the neutral throttle lever on the remote control box upwards. (It is necessary to change the throttle opening slightly depending on the engine temperature.) c C

The operation of the neutral throttle lever is possible only when the remote control lever is in the “Neutral” position.

5-8

63B-9-1A-5 2/28/02 5:15 PM Page 10

N

OFF

ON

START

701022

E

5) Set the MAIN SWITCH to “ON”.

6) Set the MAIN SWITCH to “START”.

NOTE:

When the starter mechanism malfunctions, refer to “STARTER WILL NOT OPERATE”.

c C

8 Do not turn the main switch to

“START”when the engine is running.

8 Do not keep the starter-motor turning for more than 5 seconds with the main switch in the “START” position. If the engine does not start within 5 seconds, return the main switch to “ON”, wait 10 seconds, and then crank the engine again. (If the starter-motor is run continuously for more than 5 seconds, the battery will rapidly become exhausted and it will be impossible for the startermotor to start the engine.)

701013

CLOSE

OPEN

214012

5-9

7) Return the neutral throttle lever slowly to its home position so that the engine does not stall.

8) After the engine starts, return the emergency starter valve (if used) to

“CLOSE”.

w

When starting or operating the engine, do not touch the ignition coil, high voltage wire, spark plug cap or other electrical parts carrying high voltage. Keep loose clothing and other objects away from the engine when starting it with an emergency starter rope. An unguarded rotating flywheel is very dangerous. Do not attempt to replace the top cowling when the engine is running. Proceed at once to the nearest port to get the engine repaired. Take care to prevent water splashing onto the flywheel.

63B-9-1A-5 2/28/02 5:15 PM Page 11

107012

107013

E

EMN50011

TREATMENT OF SUBMERGED

MOTOR

If the outboard motor is submerged, immediately take it a Yamaha dealer. Otherwise, some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure bellow for taking care to minimize engine damage.

1) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.

2) Remove the spark plugs and face the spark plug holes downward to allow any water, mud or contaminants to drain.

3) Drain the fuel from the carburetor.

4) Feed fogging oil or engine oil through the carburetors and spark plug holes while cranking with the manual starter or emergency starter rope.

5) Take the outboard motor to a Yamaha dealer as soon as possible.

c C

Do not attempt to run the motor until it has been completely inspected.

107014

5-10

63B-9-1A-5 2/28/02 5:15 PM Page 12

-MEMO-

E

63B-9-1A-6 2/28/02 5:15 PM Page 1

E

EMP00010

Chapter 6

INDEX

1

INDEX ........................................................6-1 2

3

4

5

6

63B-9-1A-6 3/7/02 4:06 PM Page 2

E

EMP10010

INDEX

A

Adjusting idling speed ..........................4-16

Adjusting trim angle ..............................3-19

Air vent screw...........................................2-2

B

Basic boating rules ..................................1-6

Battery care...............................................4-8

Battery requirement ..............................1-12

Bow down...............................................3-20

Bow up ....................................................3-20

Breaking in engine .................................3-10

C

Changing gear oil...................................4-22

Checking battery ....................................4-25

Checking bolts and nuts........................4-28

Checking fuel system ............................4-14

Checking painted surface of motor......4-28

Checking power trim and tilt system...4-19

Checking propeller.................................4-20

Checking water drain under engine oil tank.....................................................4-17

Checking wiring and connectors..........4-18

Cleaning and adjusting spark plug ......4-12

Cleaning and anti-corrosion measure ...4-7

Cleaning cooling water passages ........4-28

Cleaning fuel filter..................................4-15

Cleaning fuel tank ..................................4-23

Cleaning the outboard motor ...............4-28

Coating the boat bottom .......................4-28

Cold engine fails to start .........................5-8

Connecting the battery..........................4-27

Cruising in other conditions .................3-32

Cruising in salt water.............................3-32

Cruising in turbid water ........................3-32

D

Digital tachometer ...................................2-9

Disconnecting the battery .....................4-27

E

Emission control information.................1-2

Engine fails to operate.............................5-8

Engine oil ................................................1-11

Engine stop lanyard switch.....................2-6

Exhaust leakage .....................................4-18

F

Filling fuel .................................................3-4

Filling fuel tank .........................................4-4

Filling fuel and engine oil........................3-4

Filling oil....................................................3-5

Flushing cooling system and fogging engine........................................................4-5

Forward...................................................3-16

Fuel hose joint ..........................................2-2

Fuel meter.................................................2-2

Fuel tank....................................................2-2

Fuel tank cap.............................................2-2

Fueling instrucions ................................1-10

G

Gasohol...................................................1-11

Gasoline ..................................................1-11

Greasing..................................................4-11

H

I

Hour meter..............................................2-10

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

Impact damage ........................................5-5

Important labels .......................................1-5

Inspecting and replacing anode ...........4-24

Installation ................................................3-1

K

Key number ..............................................1-1

L

Lubrication................................................4-7

M

Main components ....................................2-1

Main switch ..............................................2-4

Maintenance chart .................................4-10

Motor exterior ........................................4-28

Mounting height ......................................3-3

6-1

63B-9-1A-6 3/7/02 4:06 PM Page 3

E

Mounting the outboard motor ...............3-2

N

Neutral interlock trigger ..........................2-4

Neutral throttle lever ...............................2-4

O

Oil level indicator............................2-11, 3-7

Oil level warning/oil filter clogging warning ...................................................2-15

Operation after a long period of storage ......................................................3-9

Operations of controls and other functions ...................................................2-2

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

Overheating warning.............................2-14

Overheat warning indicator..................2-11

P

Periodic maintenance..............................4-9

Power trim/tilt switch .......................2-5, 2-7

Power trim/tilt will not operate...............5-5

Pre-operation checks ...............................3-8

Propeller selection .................................1-13

R

Remote control.........................................2-3

Remote control lever ...............................2-3

Replacement parts ...................................4-9

Replacing fuse........................................4-18

Reverse ...................................................3-16

Ring free fuel additive .............................3-4

S

Safety information ...................................1-3

Shifting....................................................3-16

Specifications ...........................................4-1

Start-in-gear protection.........................1-14

Starter will not operate............................5-6

Starting engine.......................................3-12

Stopping engine.....................................3-17

Storing outboard motor ..........................4-4

T

Tachometer...............................................2-9

Temporary action in emergency ............5-5

Throttle friction adjusting screw ............2-7

Tilt support lever....................................2-13

Tilting up/down ......................................3-21

Top cowling lock lever ..........................2-13

Trailering outboard motor ......................4-3

Transporting and storing outboard motor.........................................................4-3

Treatment of submerged motor ..........5-10

Trim meter ................................................2-9

Trim tab...................................................2-12

Trimming outboard motor....................3-18

Troubleshooting.......................................5-1

W

Warming up engine...............................3-15

Warning indicator ....................................2-8

Warning system .....................................2-14

Water leakage.........................................4-18

6-2

63B-9-1A-6 2/28/02 5:15 PM Page 4

EMU01599

IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND

CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha.

Yamaha is ready to stand behind your purchase with strong warranty coverage. To be sure you receive all the benefits of warranty, please take the following steps:

1. Be sure your new Yamaha is registered for warranty. Your boat dealer should do this at the time of sale. Make sure your dealer gives you a copy of the completed Yamaha registration card for your records. If you are unsure whether or not your Yamaha is registered, complete the Warranty Registration card found inside the cover of the Owner's Manual.

Mail it to the distributor for the country in which you live (see step 6 for the correct address). If your Yamaha is not properly registered, a warranty repair could be unnecessarily delayed while registration records are checked.

2. Read the Limited Warranty statement which follows these instructions. This warranty applies to Yamaha outboard motors sold in the United States, whether purchased separately or when supplied as original equipment by a boat builder. The terms also apply to original equipment packages sold in Canada, with coverage provided by Yamaha Motor

Canada (see ``Warranty Guide'' for Canadian models). This warranty explains the conditions of the warranty, including the obligations that your dealer and you as the owner have under the warranty. For example, your Yamaha outboard must receive a proper pre-delivery inspection (PDI) by the selling dealer. Failure to take this important step could jeopardize warranty coverage!

3. If you need warranty repairs, you must take your Yamaha outboard to an authorized

Yamaha outboard dealer. Be aware that not all selling boat dealers are authorized Yamaha dealers. Only authorized dealers have the factory training, special tools, and Yamaha support needed to perform warranty repairs.

4. If you are away from home, or your selling dealer is not an authorized Yamaha dealer, use the following toll-free numbers to find the nearest Yamaha dealer.

United States Dealer Locations: 1-800-692-6242

Canada Dealer Locations: 1-800-267-8577

63B-9-1A-6 2/28/02 5:15 PM Page 5

5. Your warranty applies specifically to repairs made in the country of purchase. If your

U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian purchased Yamaha needs service while in the United States, Yamaha will assist the local dealer whenever possible. However, some products available in one country may not be sold or serviced in the other.

6. If you need any additional information about your Yamaha or warranty coverage which your dealer cannot provide, please contact us directly.

Yamaha Motor Corporation, U.S.A.

P.O. Box 6555

Cypress, CA 90630

Attention: Customer Relations Department

Telephone No.

(714) 761-7439

Fax No.

(714) 761-7559

Yamaha Motor Canada Ltd.

480 Gordon Baker Road

Toronto, Ontario

M2H 3B4

Attention: Customer Relations Department

Telephone No.

(416) 498-1911

Fax No.

(416) 491-3122

63B-9-1A-6 2/28/02 5:15 PM Page 6

EMU00912*

YAMAHA MOTOR CORPORATION, U.S.A.

OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. is proud of its heritage and reputation for producing products with high standards of quality and workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Outboard Limited Warranty is your assurance of this commitment.

This warranty provides you with protection against the expense of repairs for your outboard motor that are required as a result of defects in materials or workmanship. When maintained and utilized in the prescribed manner, you can count on your Yamaha outboard to provide reliable service.

This warranty provides you with specific coverage and notes your responsibilities in maintaining and operating your outboard. Please take the time to read and become familiar with this warranty.

PERIOD OF WARRANTY. Any new Yamaha outboard motor purchased and registered with Yamaha Motor Corporation, U.S.A. for pleasure use in the United States, will be warranted against defects in material or workmanship for a period of two (2) years from date of purchase, subject to exclusions noted herein. Any Yamaha outboard motor purchased and utilized for commercial applications will be warranted for a period of one (1) year from the date of purchase, subject to exclusions noted herein. Yamaha peripheral equipment included with the motor, such as gauges, fuel tanks and hoses, remote control boxes, propellers, and wiring external from the motor unit, will be warranted for one (1) year from the date of purchase for either pleasure or commercial use. Replacement parts used in warranty repairs will be warranted for the balance of the applicable warranty period.

The second year of warranty (if applicable) shall be limited to covering the cost of parts and labor for major components only. The major components covered are:

Power Unit Section

8 Power Head

8 Intake Manifold and Reed Valve Assembly

8 Carburetor Assembly and its Related Components

8 Fuel and Oil Pump Assemblies

8 Ignition System (Standard and Microcomputer)

8 Precision Blend ® System

Bracket Section

8 Bracket System

8 Power Trim and Tilt Assembly

Lower Unit Section

8 Exhaust System

8 Upper Casing

8 Lower Unit Assembly

The warranty described here applies to outboard motor purchased and registered for use in the United States only excluding its territories. For warranty provisions outside the United States, contact the particular country’s local Yamaha distributor.

WARRANTY REGISTRATION. To be eligible for warranty coverage, the outboard motor must first be registered with Yamaha Motor Corporation, U.S.A. A warranty registration form is provided in the Owner`s Manual with each outboard. This form must be completed and mailed to Yamaha by either the selling dealer or the purchaser. Warranty registration can also be accomplished by any authorized

Yamaha outboard dealer. Upon receipt of the registration, an Owner`s Warranty Card will be sent by Yamaha to the registered purchaser.

OBTAINING REPAIRS UNDER WARRANTY. To receive repairs under this warranty, a valid Owner`s Warranty Card must be presented to an authorized Yamaha outboard dealer.

During the period of warranty, any authorized Yamaha outboard dealer will, free of charge, repair or replace, at Yamaha`s option, any parts adjudged defective by Yamaha due to faulty workmanship or material from the factory. All replaced parts will become the property of Yamaha Motor Corporation, U.S.A.

CUSTOMER`S RESPONSIBILITY. Under the terms of this warranty, the customer will be responsible for ensuring that the outboard motor is properly operated, maintained and stored as specified in the applicable Owner’s Manual.

The owner of the outboard motor shall give notice to an authorized Yamaha marine dealer of any and all apparent defects within ten

(10) days of discovery and make the motor available at that time for inspection and repairs at the dealer’s place of business.

4.

5.

6.

GENERAL EXCLUSIONS FROM WARRANTY. This warranty will not cover the repair of damage if the damage is a result of abuse or neglect of the product. Examples of abuse and neglect include, but are not limited to:

1.

2.

Racing or competition use, modification of original parts, abnormal strain.

Lack of proper maintenance and off-season storage as described in the Owner`s Manual, improper mounting of the motor, installa-

3.

tion of parts or accessories that are not equivalent in design and quality to genuine Yamaha parts.

Operation of the motor at an rpm other than specified, improper propeller selection, use of lubricants, oils, and fuel/oil mixtures that are not suitable for outboard motor use.

Damage as a result of accidents, collisions, contact with foreign materials, or submersion.

Growth of marine organisms on motor surfaces.

Normal deterioration.

63B-9-1A-6 2/28/02 5:15 PM Page 7

SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs, shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes are not covered by warranty. Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yamaha outboard dealer are excluded from warranty coverage.

Specific parts excluded from the second year of warranty (if applicable) are:

8 Top and Bottom Cowling

8 Electric Components (other than ignition system)

8 Rubber Components (such as hoses, tubes, rubber seals, fittings, and clamps)

TRANSFER OF WARRANTY. Transfer of the warranty from the original purchaser to any subsequent purchaser is possible by having the motor inspected by an authorized Yamaha outboard dealer and requesting the dealer to submit a change of registration to Yamaha

Motor Corporation, U.S.A. within ten (10) days of the transfer.

EMISSION CONTROL SYSTEM WARRANTY. Yamaha warrants to the ultimate purchaser and each subsequent purchaser, that this engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean

Air Act and this engine is free from defects in materials and workmanship which cause said engine to fail to conform with applicable regulations for one (1) year from date of purchase.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND

TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND

EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION

MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUEN-

TIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE

TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A.

Post Office Box 6555

Cypress, California 90630

WARRANTY QUESTIONS AND ANSWERS

Q.

What costs are my responsibility during the warranty period?

A.

The customer`s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages.

Q.

What are some examples of ``abnormal’’ strain, neglect, or abuse?

A.

These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or careless transportation, and/or tie down. If you have any specific questions on operation or maintenance, please contact your Yamaha outboard dealer for advice.

Q.

Does the warranty cover incidental costs such as towing or transportation due to a failure?

A.

No. The warranty is limited to repair of the machine itself.

Q.

May I perform any or all of the recommended maintenance shown in the Owner’s Manual instead of having the dealer do them?

A.

Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s and Service Manuals. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha outboard dealer.

Q.

Will the warranty be void or canceled if I do not operate or maintain my new outboard exactly as specified in the Owner’s Manual?

A.

No. The warranty on a new outboard cannot be ’’voided`` or ’’canceled``. However, if a particular failure is caused by operation or maintenance other than as shown in the Owner’s Manual, that failure may not be covered under warranty.

Q.

What responsibility does a Yamaha outboard dealer have under this warranty?

A.

Each Yamaha outboard dealer is expected to:

1. Completely set up each outboard he sells prior to delivery.

2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date.

In addition, each Yamaha outboard dealer is held responsible for his setup, service and warranty repair work.

Q.

Is the warranty transferable to second owners?

A.

Yes. The remainder of any existing warranty can be transferred upon request. The unit has to be inspected and re-registered by an authorized Yamaha outboard dealer for the policy to remain effective.

63B-9-1A-6 2/28/02 5:15 PM Page 8

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United

States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A.

CUSTOMER RELATIONS DEPARTMENT

P.O.Box 6555

Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include any important information such as names, addresses, model, engine serial number, dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is complied from the purchase registrations sent to Yamaha Motor

Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new outboard, please advise us of your new address by sending a postcard listing your outboard model name, engine serial number, dealer number (or dealer’s name) as it is shown on your warranty identification, your name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A.

WARRANTY DEPARTMENT

P.O.Box 6555

Cypress, California 90630

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

63B-9-1A-6 2/28/02 5:15 PM Page 9

EMU01178

IMPORTANT WARRANTY INFORMATION

IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha.

This model was manufactured as a U.S.A. specification model, and the warranty statement shown in this manual is for market. To receive the benefits of the warranty that applies to the country in which you use your Yamaha, please note the following information.

1.

The warranty on this model is the same as equivalent models sold in the country where you will receive service. If you need more information about your warranty coverage or your Yamaha outside the U.S.A. or Canada, please contact an authorized Yamaha dealer in your country.

2.

Keep a copy of your sales contract or invoice for the purchase of your Yamaha and present it if you need warranty repairs. This document should show the date of purchase, which is important evidence the repairing dealer will need to be sure your Yamaha is covered by warranty.

3.

If your Yamaha needs warranty repairs, contact an authorized Yamaha dealer in the country where you are. He will explain how to get warranty service in that country.

4.

This Yamaha model may not be sold in some countries. Therefore, in some cases your local dealer may not have all the parts or service information he may need, which may unavoidably delay repairs. If this happens, we thank you for your understanding and assure you we will attempt to resolve the situation as quickly as possible.

63B-9-1A-6 2/28/02 5:15 PM Page 10

63B-9-1A hyoshi 4/12/02 3:31 PM Page 2 (2,1)

63B-9-1A hyoshi 4/12/02 3:31 PM Page 1 (1,1)

Printed in Japan

March 2002-0.5 × 1 !

63B-28199-1A

(40VETO, 50HETO)

(E)

Printed on recycled paper

OWN

Warranty card 2/27/02 11:47 AM Page 1

OUTBOARD MOTOR WARRANTY REGISTRATION

ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD

Please complete and mail this card. This information is necessary to accurately register your unit for warranty.

Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.

OUTBOARD MOTOR MODEL AND SERIAL NUMBER (From I.D. label on clamp bracket)

MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation)

(For Dealer Use Only)

(A l’usage du concessionnaire)

YAMAHA DEALER NUMBER

NO. DU CONCESSIONNAIRE

YAMAHA

YAMAHA MOTOR CO., LTD.

MADE IN JAPAN

PAYS D'ORIGINE JAPON

DEALER NAME

NOM DU

CONCESSIONNAIRE

DATE SOLD

DATE DE

LIVRAISON

OWNER’S NAME

NOM DU

PROPRIÉTAIRE

ADDRESS

ADRESSE

PHONE NUMBER ( )

NUMÉRO DE TÉLÉPHONE

MONTH

MOIS

CITY

VILLE

DAY

JOUR

USAGE

(Check One)

UTILISATION

(En cocher un.)

PLEASURE

LOISIR

COMMERCIAL

COMMERCIAL

YEAR

ANNÉE

FIRST

PRÉNOM

STREET

RUE

STATE/PROVINCE

PROVINCE

LAST

NOM DE FAMILLE

ZIP

CODE POSTAL

Warranty card 2/27/02 11:47 AM Page 2

ATTN: WARRANTY DEPARTMENT

PLACE

POSTAGE

HERE