Yamaha 50B Owner`s manual

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
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63B-9-1A-1 2/28/02 5:11 PM Page 1
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EMU01449
TO THE OWNER
Thank you for choosing a Yamaha outboard motor. This Owner’s manual contains information needed for proper operation, maintenance and care. A thorough
understanding of these simple instructions will help you obtain maximum
enjoyment from your new Yamaha. If you
have any question about the operation or
maintenance of your outboard motor,
please consult a Yamaha dealer.
In this Owner’s Manual particularly
important information is distinguished in
the following ways.
Q
The Safety Alert Symbol means
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
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.
cC
A CAUTION indicates special precautions
that must be taken to avoid damage to
the outboard motor.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
* Yamaha continually seeks advancements in product design and quality.
Therefore, while this manual contains
the most current product information
available at the time of printing, there
may be minor discrepancies between
your machine and this manual. If there
is any question concerning this manual,
please consult your Yamaha dealer.
NOTE:
The 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
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EMA20010
CONTENTS
E
GENERAL INFORMATION
1
BASIC COMPONENTS
2
OPERATION
3
MAINTENANCE
4
TROUBLE RECOVERY
5
INDEX
6
READ THIS OWNER’S MANUAL CAREFULLY
BEFORE OPERATING YOUR OUTBOARD MOTOR.
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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
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EMU00005
IDENTIFICATION NUMBERS
RECORD
EMU00007
OUTBOARD MOTOR SERIAL
NUMBER
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
1
401012
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.
YAMAHA
q
123
1 Key number
904011
1-1
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EMU01385
EMISSION CONTROL
INFORMATION
q
EMU01386
NORTH AMERICAN MODELS
w
000909
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.
rpm IN NEUTRAL
g/kw-hr
IDLE SPEED :
FELs :
SPARK PLUG GAP (mm) :
SPARK PLUG :
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
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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.
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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
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EMB30011
IMPORTANT LABELS
q
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.
202016*
6A1-83625-41
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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.
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.’
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.
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.
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will clear one another if you continue on
your set course and speed.
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:
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)
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.
102044
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
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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-
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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.
N
A
A
C
H
C " 1"
M
N
O
AN
N
White Light
C
H
D
A
R
Odd number. increasing toward head of navigation.Leave to port (left) proceeding upstream.
EL
SE
C
RB " L "
or
RG " L "
LIGHTED BUOY (Port Hand)`
N " 2"
Y
IN
" 7"
" 1" " 3" " 5" " 7"
N
EL
MAIN CHANNEL BUOYS
" 6"
1
OR
Green Light
1
" 5"
BUOY
COLOR CODE
" 4"
new
old
BLACK
" 2" " 4" " 6"
LIGHTED BUOY (Starboard Hand)`
RED
" 3"
GREEN
Even number,increasing toward head of navigation. Leave to starboard (right) proceeding upstream.
White Light
" A"
2
OR
Red Light
2
" 2"
new
old
" 1"
" A"
LIGHTED SAFE WATER BUOY
Proceeding toward head
of navigation from seaward
No number. Marks midchannel, pass on either
side. Letter has no lateral significance, used for
identification and location purposes.
SECONDARY CHANNEL BUOYS
Top Mark
STARTS NEW NUMBERING SYSTEM
White Light
C " 1"
CAN BUOY
Odd number. Leave to port.
OR
1
1
OR
new
old
old
N " 2"
White Light
A
A
new
RB " L "
RG " L "
LIGHTED PREFERRED CHANNEL TO
PORT BUOY
NUN BUOY
Even number. Leave to starboard
No number. Topmost band red - preferred
channel is to left of buoy. Letter has no lateral
significance, used for identification and location
purposes.
2
L
old
Red or
White Light
Red Light
L
new
No change
102052
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EMU00016
FUELING INSTRUCTIONS
w
GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE!
8 Do not smoke when refueling, and
keep away from sparks, flames, or
other sources of ignition.
8 Stop engine before refueling.
8 Refuel in a well-ventilated area. Refuel
portable fuel tanks off the boat.
8 Take care not to spill gasoline. If gasoline spills, wipe it up immediately with
dry rags.
8 Do not overfill the fuel tank.
8 Tighten the filler cap securely after
refueling.
8 If you should swallow some gasoline
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.
8 If any gasoline spills onto your skin,
immediately wash with soap and
water. Change clothing if gasoline spills
on it.
8 Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
cC
Use only new clean gasoline which has
been stored in clean containers and is not
contaminated with water or foreign matter.
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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.
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.
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EMU01775
BATTERY REQUIREMENT
cC
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
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EMU01395
PROPELLER SELECTION
The performance of your outboard motor
will be critically affected by your choice of
propeller, as an incorrect choice could
adversely affect performance and could
also seriously damage the motor. Engine
speed depends on the propeller size and
boat load. If engine speed is too high or
too low for good engine performance,
this will have an adverse effect on the
engine.
Yamaha outboard motors are fitted with
propellers chosen to perform well over a
range of applications, but there may be
uses where a propeller with a different
pitch would be more appropriate. For a
greater operating load, a smaller-pitch
propeller is more suitable as it enables
the correct engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable for a smaller operating load.
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.
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NOTE:
At full throttle and under a maximum
boat load, the engine’s rpm should be
within the upper half of the full throttle
operating range, as listed in “SPECIFICATIONS” on page 4-1. Select a propeller
which fulfills this requirement.
If operating under conditions which allow
the engine’s rpm to rise above the maximum recommended range (such as light
boat loads), reduce the throttle setting to
maintain the rpm in the proper operating
range.
10-3/4x17-G
1
23
1 Propeller diameter (in inches)
2 Propeller pitch (in inches)
3 Type of propeller (propeller mark)
602011
Refer to the section “CHECKING PROPELLER” 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.
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-MEMO-
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EMC00010
Chapter 2
BASIC COMPONENTS
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
1
2
3
4
5
6
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EMU01206
MAIN COMPONENTS
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!2
!4
e
r
!1
!5
!0
o
t
i
y
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1
2
3
4
5
6
7
8
9
0
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e
*r
*t
Oil filler access cap
Warning indicator lamp
Clamp bracket
Battery lead
Anode
Cooling water inlet
Propeller
Trim tab (Anode)
Anti-cavitation plate
Anode
Trim angle adjusting rod
Tilt support lever
Top cowling
Remote control box
Digital tachometer
* May not be exactly as shown; also may not
be included as standard equipment on all
models.
2-1
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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.
q
e
r
w
1
2
3
4
Fuel hose joint
Fuel meter(If equipped)
Fuel tank cap
Air vent screw(If equipped)
EMC31010
Fuel hose joint
This connector is provided for connecting
or disconnecting fuel hose.
902051*
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.
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EMU00096*
REMOTE CONTROL
y
q
w
Both the shifter and the throttle are actuated by the remote control lever. Additionally, the remote control also has the
electrical switches.
e
u
r
t
701011*
1
2
3
4
5
6
7
Remote control lever
Neutral interlock trigger
Neutral throttle lever
Main switch
Engine stop lanyard switch
Power trim and tilt switch (if equipped)
Throttle friction adjusting screw
EMC50010
w
F
r
Nq
t
y
r Re
t
y
u
u
701031
Remote control lever
Moving the lever forward from the Neutral position engages Forward gear.
Pulling the lever back from Neutral
engages Reverse. The engine will continue to run at idle until the lever is moved
about 35° (a detent can be felt). Moving
the lever farther opens the throttle, and
the engine will begin to accelerate.
1
2
3
4
5
6
7
2-3
Neutral
Forward
Reverse
Shift
Fully closed
Throttle
Fully open
63B-9-1A-2 2/28/02 5:12 PM Page 5
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EMC50110
Neutral interlock trigger
To shift out of Neutral, the neutral interlock trigger of the remote control lever
must first be pulled up.
EMC50210
701036
N
q
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701033*
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
OFF
ON
START
701021
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”.)
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EMU01331
UP
DN
UP
DN
701034
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.
NOTE:
The engine cannot be started with the
lock-plate removed.
q
1 Lock-plate
2 Lanyard
w
000569
2-6
63B-9-1A-2 2/28/02 5:12 PM Page 8
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.
701035
Resistance
Screw
Increase
Turn clockwise
Decrease
Turn counterclockwise
w
Do not overtighten the friction adjusting
screw.
If there is too much resistance, it may be
difficult to move the lever, which could
result in an accident.
EMU01125
POWER TRIM/TILT SWITCH
UP
DN
302013*
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.
EMU00120
WARNING INDICATOR
q
303012*
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 “WARNING 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
E
EMU01614
DIGITAL TACHOMETER
q
w
e
t
y
r
u 001078
This gauge contains the tachometer, trim
meter, hour meter, oil level indicator, and
the overheat warning indicator.
1
2
3
4
5
6
7
Tachometer
Trim meter
Hour meter
Oil level indicator
Overheat warning indicator
Set button
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
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EMU01109
001050
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.
EMU01620
001087
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
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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.
q 001051
1 Oil-level indicator
cC
Do not operate the engine without oil.
Serious engine damage will occur.
EMU01553
Overheat Warning Indicator
If the engine temperature rises too high,
the warning indicator will start to blink.
Refer to “OVERHEAT WARNING” for
details.
q
1 Overheat warning indicator
001052
cC
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
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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.
A
1 Trim tab
2 Bolt
3 Cap (If equipped)
q
w
B
603011
Boat tends to
veer
The rear end of trim tab
To the left
(port side)
Turn the left(port side),
“A” in the figure
To the right
(starboard side)
Turn the right(starboard
side),”B” in the figure
cC
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
EMD62011
TOP COWLING LOCK LEVER
q
301013*
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
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EMD80010
WARNING SYSTEM
cC
Do not continue to operate the engine if
the warning device has activated. Consult
your Yamaha dealer if the problem cannot be located and corrected.
303012
EMD82012*
OVERHEAT WARNING
This engine has an overheat warning
device.
If the engine temperature rises too high,
the warning device will activate.
(2); Included (—); N/A
Warning device
activation
001053
701054
605021
Tiller
control
model
Remote
control
model
The engine speed
will automatically
decrease to about
2,000 r/min.
2
The overheat warning
indicator will come on.
2*1
The buzzer will sound.
2
If the warning system has been activated,
stop the engine and check the water inlet
for clogging.
*1.Digital tachometer
2-14
63B-9-1A-2 2/28/02 5:12 PM Page 16
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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.
303012
(2); Included (—); N/A
Warning device
activation
303022
Tiller
control
model
Remote
control
model
The engine speed
will automatically
decrease to about
2,000 r/min.
2
The oil level warning
indicator will come on.
2
The buzzer will sound.
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
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EMF00010
Chapter 3
OPERATION
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
1
2
3
STARTING ENGINE ...............................3-12
WARMING UP ENGINE .........................3-15
SHIFTING ................................................3-16
Forward ...............................................3-16
Reverse................................................3-16
STOPPING ENGINE ...............................3-17
TRIMMING OUTBOARD MOTOR.........3-18
Adjusting trim angle ..........................3-19
TILTING UP/DOWN ...............................3-21
CRUISING IN OTHER CONDITIONS.....3-32
Cruising in salt water .........................3-32
Cruising in turbid water.....................3-32
4
5
6
63B-9-1A-3 2/28/02 5:13 PM Page 2
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EMF10010
INSTALLATION
cC
Incorrect engine height or obstructions to
smooth water flow (such as the design or
condition of the boat or accessories such
as transom ladders/depth finder transducers) can create airborne water spray
while the boat is cruising. Severe engine
damage may result if the motor is operated continuously in the presence of airborne water spray.
NOTE:
During water testing check the buoyancy
of the boat, at rest, with its maximum
load. Check that the static water level on
the exhaust housing is low enough to prevent water entry into the powerhead,
when water rises due to waves when the
outboard is not running.
3-1
63B-9-1A-3 2/28/02 5:13 PM Page 3
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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 section is intended as reference only. It is
not possible to provide complete
instructions
for
every
possible
boat/motor combination. Proper mounting depends in part on experience and
the specific boat/motor combination.
8 Your dealer or other person experienced in proper rigging should mount
the motor. If you are mounting the
motor yourself, you should be trained
by an experienced person. [permanent
mounted type]
8 Your dealer or other person experienced 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)
q
104011
3-2
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.
EMU01299
104014
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 OUTBOARD 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
EMF20010
FILLING FUEL AND
ENGINE OIL
EMF30011
FILLING FUEL
1)
2)
3)
902055
Remove the fuel tank cap.
Fill the fuel tank carefully.
Close the cap securely after refueling.
Wipe up any spilled fuel.
Fuel tank capacity:
Refer to SPECIFICATIONS, page 4-1.
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 instructions.
3-4
63B-9-1A-3 2/28/02 5:13 PM Page 6
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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
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EMF34110
Procedure
Electric start model
1)
Turn the oil filler access cap on top of
the top cowling counterclockwise and
open it.
2)
Open the oil tank filler cap by pulling
a tab on the cap.
3)
Slowly fill the engine oil into the
engine oil tank.
After filling, replace the all caps
securely.
203014
203015
4)
q
w
1 Oil filler access cap
2 Oil tank filler cap
203016*
3-6
63B-9-1A-3 2/28/02 5:13 PM Page 8
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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)
Engine oil tank
Green
Yellow
Red
3-7
Remarks
more than 4 50 cm3
(0.48 US qt,
0.40 Imp qt)
No refilling necessary.
from 450 cm3
(0.48 US qt,
0.40 Imp qt)
down to 200 cm3
(0.21 US qt,
0.18 Imp qt)
Add oil,
refer to oil filling.
200 cm3
(0.21 US qt,
0.18 Imp qt) or less
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.
63B-9-1A-3 2/28/02 5:13 PM Page 9
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.
3-8
63B-9-1A-3 2/28/02 5:13 PM Page 10
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EMF43510
Engine
8 Check the engine and engine mounting.
8 Look for loose or damaged fasteners.
8 Check the propeller for damage.
cC
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.
3)
212011*
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.
cC
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
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EMU01776
BREAKING IN ENGINE
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.
cC
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 breakin, 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
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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.
3-11
63B-9-1A-3 2/28/02 5:13 PM Page 13
E
EMU01147
STARTING ENGINE
w
902053
304034
8 Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.
8 When the air vent screw is loosened,
gasoline (petrol) vapor will be released.
Gasoline (petrol) is highly flammable,
and its vapors are flammable and
explosive. Refrain from smoking, and
keep away from open flames and
sparks while loosening the air vent
screw.
8 This product emits exhaust gases
which contain carbon monoxide, a colorless, odorless gas which may cause
brain damage or death when inhaled.
Symptoms include nausea, dizziness,
and drowsiness. Keep cockpit and
cabin areas well ventilated. Avoid
blocking exhaust outlets.
1)
902061
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.
3)
902025
3-12
Squeeze the primer bulb with the outlet end up until you feel it become
firm.
63B-9-1A-3 2/28/02 5:13 PM Page 14
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EMF65010
PROCEDURE FOR REMOTE
CONTROL MODEL
N
4)
701015
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.
5)
Attach the engine stop switch lanyard
to a secure place on your clothing, or
your arm or leg. Then, install the lock
plate on the other end of the lanyard
in the engine stop switch.
w
000293
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)
3-13
Turn the main switch to “ON”.
63B-9-1A-3 2/28/02 5:13 PM Page 15
E
EMF63910
OFF
ON
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”.
START
cC
701022
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
E
EMG00210
WARMING UP ENGINE
1)
2)
309014
Before beginning operation, allow the
engine to warm up at idling speed for
3 minutes. (Failure to do this will
shorten engine life.)
Check for a steady flow of water from
the cooling-water pilot hole.
cC
A continuous flow of water from the pilot
hole shows that the water pump is
pumping water through the cooling passages. If water is not flowing out of the
pilot hole at all times while the engine is
running, do not continue to run the
engine. Overheating and serious damage
could occur. Stop the engine and check
to see if the water inlet on the lower casing is blocked. If the problem cannot be
found and corrected, consult your Yamaha dealer.
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
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EMG20111
SHIFTING
w
Before shifting, make sure there are no
swimmers or obstacles in the water near
you.
cC
F
To change the shifting position from forward to reverse or vice-versa, close the
throttle first so that the engine idles (or
runs at low speeds).
N
EMU00264
FORWARD
701043
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.
N
Pull up the neutral interlock trigger (if
equipped) and move the remote control
lever quickly and firmly from Neutral to
Reverse.
R
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.
EMG35310
ON
OFF
PROCEDURE
START
Main switch equipped model
701023
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.
3)
Tighten the air vent screw on the fuel
tank cap after stopping the engine, if
it is equipped.
Remove the key if the boat will be left
unattended.
304036
4)
902052
3-17
63B-9-1A-3 2/28/02 5:13 PM Page 19
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EMU01412
TRIMMING OUTBOARD
MOTOR
The trim angle of the outboard motor
helps determine the position of the bow
of the boat in the water. The correct trim
angle will help improve performance and
fuel economy while reducing strain on the
engine. The correct trim angle depends
upon the combination of boat, engine,
and propeller. Correct trim is also affected
by variables such as the load in the boat,
sea conditions, and running speed.
w
Excessive trim for the operating conditions (either trim up or trim down) can
cause boat instability and can make
steering the boat more difficult. This
increases the possibility of an accident. If
the boat begins to feel unstable or is hard
to steer, slow down and/or readjust the
trim angle.
NOTE:
Refer to the section “ADJUSTING TRIM
ANGLE” for instructions on usage.
q
000862
1 Trim operating angle
3-18
63B-9-1A-3 2/28/02 5:13 PM Page 20
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ADJUSTING TRIM ANGLE
EMU01401
Power Trim/Tilt Model
w
UP
DN
8 Be sure all people are clear of the outboard motor when adjusting the
trim/tilt angle, also be careful not to
pinch any body parts between the drive
unit and clamp bracket.
8 Use caution when trying a trim position
for the first time. Increase speed gradually and watch for any signs of instability or control problems.
8 Use the power trim/tilt switch located
on the bottom engine cowling (if
equipped) only when the boat is at a
complete stop with the engine off.
UP
DN
q
701034
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
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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.
q
105011
w
Too much trim-out puts the bow of the
boat too high in the water. Performance
and economy are decreased because the
hull of the boat is pushing the water and
there is more air drag.
Excessive trim-up can cause the propeller
to ventilate, which reduces performance
further. When trimmed-out too much, a
boat may “porpoise” (hop in the water),
which could throw the operator and passengers overboard.
EMG62110
Bow down
When the bow of the boat is down, it is
easier to accelerate from a standing start
onto plane.
105013
e
105015
Too much trim-in causes the boat to
“plow” through the water, decreasing
fuel economy and making 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
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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.
000817
cC
8 Before tilting the motor, follow the procedures under “STOPPING ENGINE”.
Never tilt the motor while the engine is
running. Severe damage from overheating can result.
8 Do not tilt up the engine by pushing
the steering handle as this could break
the handle.
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
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EMG63210
PROCEDURE FOR TILTING UP
Power trim and tilt model
1)
Remove the fuel-line connection from
the motor.
2)
Push the power trim and tilt switch
“UP” until the outboard has tilted up
completely.
3)
Turn the tilt-support lever toward
engine bracket and support the
engine.
304036
UP
DN
UP
DN
701034
UP
DN
302013*
w
403011
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
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EMG64110
PROCEDURE FOR TILTING DOWN
Power trim and tilt model
1)
2)
3)
411035
Push the power trim and tilt switch
“UP” until the engine is supported by
the tilt rod.
Release the tilt-support lever.
Push the power trim and tilt switch
“DN” (Down) to lower the engine to
the desired position.
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.
3-23
63B-9-1A-4 3/7/02 3:45 PM Page 1
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EMK00010
Chapter 4
MAINTENANCE
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
1
2
3
4
5
6
63B-9-1A-4 3/7/02 3:45 PM Page 2
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EMK10011*
SPECIFICATIONS
Model
Unit
40TRB
Item
DIMENSIONS
8Overall Length
8Overall Width
8Overall Height
8Transom height
8Weight*
L
L
L
mm (in.)
mm (in.)
mm (in.)
mm (in.)
kg (lb.)
646 (25.4)
360 (14.2)
1,319 (51.9)
533 (21.0)
86 (190)
8Full throttle operating range
8Maximum output
8Idling speed
r/min
kW (HP)
r/min
4,500–5,500
29.4 (40) at 5,000 r/min
750–850
PERFORMANCE
ENGINE
8Engine type
Number of cylinder
Displacement
Bore × stroke
8Ignition system
8Spark plug
Spark plug gap
8Control system
8Starting system
8Battery
Min. cold cranking amps (CCA/SAE)
Min. marine cranking amps (MCA/ABYC)
Min. reserve capacity (RC/SAE)
8Alternator output
8Starting carburetion system
cm3 (cu.in.)
mm (in.)
NGK
mm (in.)
amps at -18°C (-0.4°F)
amps at 0°C (32°F)
minutes
V-Amp (W)
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
DRIVE UNIT
8Gear positions
Gear ratio
8Trim and tilt system
8Propeller mark
Forward-Neutral-Reverse
1.85 (24/13)
Power trim and tilt
G
FUEL AND OIL
8Fuel
Fuel tank capacity
8Recommended engine oil
Lubrication
Engine oil capacity (engine oil tank)
8Recommended gearcase oil
Gear oil quantity
Regular-unleaded gasoline (P.O.N.: minimum 86)
L (US gal, Imp gal)
L (US qt, Imp qt)
cm3 (US oz, Imp oz)
—
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)
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
25 (2.5, 18)
35 (3.5, 25)
63B-9-1A-4 3/7/02 3:45 PM Page 3
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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
—
63B-9-1A-4 2/28/02 5:14 PM Page 4
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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.
cC
Do not use the tilt support lever/knob
when trailering the boat. The outboard
motor could shake loose from the tilt
support and fall. If the motor can not be
trailered in the down position, use an
additional support device to secure it in
the up position.
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.
4-3
63B-9-1A-4 2/28/02 5:14 PM Page 5
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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-1200) 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.
4-4
63B-9-1A-4 2/28/02 5:14 PM Page 6
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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.
q
w
605024
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
cC
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)
4-5
Run the engine at a fast idle for 10~15
minutes.
63B-9-1A-4 2/28/02 5:14 PM Page 7
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4)
Just prior to turning off the engine,
quickly spray “Yamaha Stor-Rite
Engine Fogging Oil” (Part No. LUBSTRRT-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).
cC
605014
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)
4)
5)
6)
4-6
Run the engine at a fast idle for 10~15
minutes.
Just prior to turning off the engine,
quickly spray “Yamaha Stor-Rite
Engine Fogging Oil” (Part No. LUBSTRRT-12-00) alternately into each
carburetor. When properly done, the
engine will smoke excessively and
almost stall.
Remove the flushing attachment and
wipe off any excess water.
Install the silencer cover and top
cowling. Install the propeller.
63B-9-1A-4 2/28/02 5:14 PM Page 8
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EMK26112
Lubrication
1) Remove the spark plugs, and spray a
10 second spray of “Yamaha StorRite 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 ADJUSTING 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”)
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).
4-7
63B-9-1A-4 2/28/02 5:14 PM Page 9
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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)
2)
3)
EL
LEV EL
ER
V
UPP ER LE
W
O
L
4)
901015
4-8
Disconnect and remove the battery
from the boat. Always disconnect the
black negative lead first to prevent the
risk of shorting.
Clean the battery casing and terminals. Fill each cell to the upper level
with distilled water.
Store the battery on a level surface in
a cool, dry, well-ventilated place out
of direct sunlight.
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
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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.
4-9
63B-9-1A-4 2/28/02 5:14 PM Page 11
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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.
Initial
Interval
10 hours
Item
Every
50 hours 100 hours 200 hours
(3 months) (6 months) (1 year)
Refer
page
Carburetor
Cleaning
1
1
1
—
Fuel filter
Cleaning
●
●
●
4-16
Fuel system
Inspection
●
Fuel tank *2
Cleaning
Throttle link
Inspection/Adjustment
Idling speed
Inspection/Adjustment
Spark plug
Cleaning/Adjustment/
Replacement
●
4-15
●
1
●
4-24
—
●
4-17
●
●
●
4-13
●
●
4-18
Oil tank water drain
Cleaning
●
Oil pump
Inspection/Adjustment
1
—
Power trim and tilt system*1 Inspection
●
●
●
4-20
Wiring & Connector
Inspection/Reconnect
●
●
●
4-19
Exhaust leakage
Inspection
●
●
●
4-19
Water leakage
Inspection
●
●
●
4-19
Grease points
Greasing
●
4-11
Gear oil
Change
●
●
4-23
Bolts & Nuts
Retightening
●
Cowling clamp
Inspection
Anode
Inspection
Propeller
Inspection
Motor exterior
Inspection
Cooling water passages*3
Cleaning
Battery
Inspection
●
●
4-29
●
—
●
●
4-25
●
●
●
4-21
●
●
●
4-29
●
●
4-5
● (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
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EMU00366
GREASING
Yamaha marine grease
(Water resistant grease)
4-11
63B-9-1A-4 2/28/02 5:14 PM Page 13
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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.
4-12
63B-9-1A-4 2/28/02 5:14 PM Page 14
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When fitting the plug, always clean the
gasket surface and use a new gasket.
Wipe off any dirt from the threads and
screw in the spark plug to the correct
torque.
Spark plug torque:
Refer to “SPECIFICATIONS”, page 4-1.
NOTE:
If a torque-wrench is not available when
you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a
turn past finger-tight. Have the spark plug
adjusted to the correct torque as soon as
possible with a torque-wrench.
Initial of spark plug
I.D. mark
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)
w
q
903022
4-13
63B-9-1A-4 2/28/02 5:14 PM Page 15
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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.
106015
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
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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.
207035
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
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5)
q
w
6)
r
e
207013
1
2
3
4
Attach the filter assembly to the
bracket with that the fuel hoses are
attached to the filter assembly.
Run the engine and check the filter
and lines for leaks.
Filter element
O-ring
Filter cup
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.
cC
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)
4-16
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.
63B-9-1A-4 2/28/02 5:14 PM Page 18
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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.
q
1 Throttle stop-screw
204014*
EMK58010
CHECKING WATER DRAIN UNDER
ENGINE OIL TANK
w
q
213012
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
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EMU01329
REPLACING FUSE
If the fuse has blown on an Electric start
model, open the fuse holder and replace
the fuse with a new one of proper amperage.
w
Be sure to use the specified fuse. An
incorrect fuse or a piece of wire may
allow excessive current flow. This could
cause electrical system damage and a fire
hazard.
q
w
205015*
NOTE:
If the new fuse blows again immediately,
consult a Yamaha dealer.
1 Fuse holder
2 Fuse (20A)
EMK78010
CHECKING WIRING AND
CONNECTORS
1)
2)
Check that each grounding wire is
properly secured.
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
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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 outboard before performing this test.
1)
q
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 (DEXRON-II)
4-19
63B-9-1A-4 2/28/02 5:14 PM Page 21
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EML08011*
CHECKING PROPELLER
w
210012
602051
You could be seriously injured if the
engine accidentally starts while you are
near the propeller.
8 Before
inspecting,
removing
or
installing the propeller, remove the
spark plug caps from the spark plugs.
Also, put the shift control in Neutral,
put the main switch in the “OFF” position and remove the key, and remove
the lanyard from the engine stop
switch. Turn off the battery cut-off
switch if your boat has one.
8 Do not use your hand to hold the propeller when loosening or tightening the
propeller nut. Put a wood block
between the cavitation plate and the
propeller to prevent the propeller from
turning.
1)
2)
3)
602054
Check each of the propeller blades for
wear, erosion from cavitation or ventilation, or other damage.
Check the splines for wear and damage.
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
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6
4
3
1
5
2
602041
1
2
3
4
5
6
Thrust washer
Propeller
Spacer
Washer
Propeller nut
Cotter pin
Installation
1) Apply Yamaha Marine grease (waterresistant grease) to the propellershaft.
2) Slide the propeller over the propellershaft.
cC
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.
cC
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
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EMU01460
CHANGING GEAR OIL
w
8 Be sure the outboard is securely fastened to the transom or a stable stand.
You could be severely injured if the outboard falls on you.
8 Never get under the lower unit while it
is tilted, even when the tilt-support
lever/knob is locked. Severe injury
could occur if the outboard accidentally
falls.
1)
Tilt the outboard motor so that the oil
drain plug is at the lowest point possible.
2) Place a suitable container under the
gear-case.
3) Remove the oil drain plug 1.
NOTE:
The oil drain plug is magnetic. Remove all
metal particles from the plug before reinstalling it.
w
4)
Remove the oil level plug 2 to allow
the oil to drain completely.
cC
q
000565
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
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5)
With the outboard motor in a vertical
position, and using a flexible or pressurized filling device, inject the gear
oil into the oil drain plug hole.
Gear oil grade/capacity:
Refer to “SPECIFICATIONS,”
page 4-1.
601015
6)
7)
When the oil begins to flow out of the
oil level plug hole, insert and tighten
the oil level plug.
Insert and tighten the oil drain plug.
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)according to local regulations.
4-23
63B-9-1A-4 2/28/02 5:14 PM Page 25
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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
EML24010
INSPECTING AND REPLACING
ANODE
Yamaha outboard motor is protected
from corrosion by a sacrificial anode(s).
604012
Check the anode periodically. Remove the
scales from surfaces of the anode.
For the replacement of the anode, consult
a Yamaha dealer.
cC
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
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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 handling or working near batteries.
Antidote (EXTERNAL):
8 SKIN—Flush with water.
8 EYES—Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
8 Drink large quantities of water or milk
followed by milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive
hydrogen gas; therefore, you should
always follow these preventive measures:
8 Charge batteries in a well-ventilated
area.
8 Keep batteries away from fire, sparks,
or open flames (e.g., welding equipment, lighted cigarettes, etc.).
8 DO NOT SMOKE when charging or handling batteries.
8 KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
cC
A poorly maintained battery will quickly
deteriorate.
4-25
63B-9-1A-4 2/28/02 5:14 PM Page 27
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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).
cC
Ordinary tap-water contains minerals
harmhul to a battery, and should not be
used for topping-up.
2)
3)
4-26
Keep the battery always in a good
state of charge. Installing a voltmeter
will help you monitor your battery. If
you will not use the boat for a month
or more, remove the battery from the
boat and store it in a cool, dark place.
Completely recharge the battery
before using it.
If the battery will be stored for longer
than a month, check the specific gravity of the fluid at least once a month
and recharge the battery when it is
low.
63B-9-1A-4 2/28/02 5:14 PM Page 28
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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.
cC
q
EL
L E V EL
ER
V
U P P ER LE
LOW
8 Make sure the main switch (on applicable models) is “OFF” before working on
the battery.
8 Reversal of the battery leads will damage the rectifier.
8 Connect the RED lead first when
installing the battery and disconnect
the RED lead last when removing it.
Otherwise, the electrical system can be
damaged.
8 The electrical contacts of the battery
and cables must be clean and properly
connected, or the battery will not start
the engine.
Connect the RED lead to the POSITIVE (+)
terminal first.
Then connect the BLACK lead to the NEGATIVE (-) terminal.
w
e
901012
1 Red lead
2 Black lead
3 Battery
EMU01280
Disconnecting the Battery
Disconnect the BLACK lead from the NEGATIVE (-) terminal first. Then disconnect
the RED lead from the POSITIVE (+) terminal.
4-27
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EML40010
CHECKING BOLTS AND NUTS
1)
2)
Check that bolts securing the cylinder
head and engine and the nut securing
the flywheel are tightened with their
specified tightening torques.
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.
EML44010
COATING THE BOAT BOTTOM
102025
A clean hull improves boat performance.
The boat bottom should be kept as clean
of marine growths as possible. If necessary, the boat bottom can be coated with
an 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.
4-28
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63B-9-1A-5 2/28/02 5:14 PM Page 1
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EMN00010
Chapter 5
TROUBLE RECOVERY
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
1
2
3
4
5
6
63B-9-1A-5 2/28/02 5:14 PM Page 2
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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
Possible Cause
1. Battery capacity weak or low.
A. Starter will not
operate.
5. Shift lever in gear.
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.
2.
3.
4.
1.
2.
3.
4.
2. Battery connections loose or
corroded.
3. Fuse for electric start circuit blown.
4. Starter components faulty.
B. Engine will not
start (Starter
operates).
Remedy
Fuel tank empty.
Fuel contaminated or stale.
Fuel filter clogged.
Starting procedure incorrect.
5. Fuel pump malfunctions.
5.
6. Spark plug(s) fouled or incorrect
type.
7. Spark plug cap(s) fitted incorrectly.
8. Poor connections or damaged
ignition wiring.
6.
9. Ignition parts faulty.
9.
10. Engine stop switch lanyard not
attached.
11. Engine inner parts damaged.
5-1
7.
8.
10.
Fill tank with clean, fresh fuel.
Fill tank with clean, fresh fuel.
Clean or replace filter.
Read "STARTING ENGINE"
section.
Have serviced by a Yamaha
dealer.
Inspect spark plug(s). Clean or
replace with recommended type.
Check and re-fit cap(s).
Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.
Have serviced by a Yamaha
dealer.
Attach lanyard.
11. Have serviced by a Yamaha
dealer.
63B-9-1A-5 2/28/02 5:14 PM Page 3
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Trouble
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.
C. Engine idles
irregularly or stalls.
9. Specified engine oil not used.
10. Thermostat faulty or clogged.
11. Carburetor adjustments incorrect.
12. Fuel pump damaged.
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.
5-2
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.
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.
63B-9-1A-5 2/28/02 5:14 PM Page 4
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Trouble
Possible Cause
1. Cooling system clogged.
2. Engine oil level low.
3. Heat range of spark plug incorrect.
4. Specified engine oil not used.
D. Warning buzzer
sounds or
indicator lamp
lights.
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.
E. Engine power loss.
4. Motor mounted at incorrect height
on transom.
5. Warning system activated.
6. Boat bottom fouled with marine
growth.
7. Spark plug(s) fouled or incorrect
type.
8. Weeds or other foreign matter
tangled on gear housing.
9. Fuel system obstructed.
10. Fuel filter clogged.
11. Fuel contaminated or stale.
12. Spark plug gap incorrect.
5-3
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.
63B-9-1A-5 2/28/02 5:14 PM Page 5
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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.
1. Propeller damaged.
2. Propeller shaft damaged.
F. Engine vibrates
excessively.
3. Weeds or other foreign matter
tangled on propeller.
4. Motor mounting bolt loose.
5. Steering pivot loose or damaged.
5-4
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.
63B-9-1A-5 2/28/02 6:25 PM Page 6
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EMN20010
TEMPORARY ACTION IN
EMERGENCY
EMU01492
IMPACT DAMAGE
w
The outboard motor can be seriously
damaged by a collision while operating
or trailering. Damage could make the outboard motor unsafe to operate.
607011
If the outboard motor hits any object in
the water, follow the procedure below.
1) Stop the engine immediately.
2) Inspect the control system and all
components for damage. Also,
inspect the boat for damage.
3) Whether damage is found or not,
return to the nearest harbor slowly
and carefully.
4) Have a Yamaha dealer inspect the
outboard motor before operating it
again.
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.
q
411011*
1 Manual valve screw
5-5
63B-9-1A-5 2/28/02 5:15 PM Page 7
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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 emergency and only to return to port for
repairs.
8 When the emergency starter rope is
used to start the engine, the start-ingear protection device does not operate. Make sure the 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.
5-6
63B-9-1A-5 2/28/02 5:15 PM Page 8
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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
3)
OFF ON START
701024
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 OPERATE”.
4)
208052
5-7
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
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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.
3)
Squeeze the priming pump two or
three times to feed fuel.
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.)
OPEN
CLOSE
214011
902025
N
cC
701014
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
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OFF
ON
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”.
START
cC
701022
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.)
7)
N
8)
Return the neutral throttle lever slowly to its home position so that the
engine does not stall.
After the engine starts, return the
emergency starter valve (if used) to
“CLOSE”.
w
701013
OPEN
CLOSE
214012
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.
5-9
63B-9-1A-5 2/28/02 5:15 PM Page 11
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EMN50011
TREATMENT OF SUBMERGED
MOTOR
107012
107013
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.
cC
Do not attempt to run the motor until it
has been completely inspected.
107014
5-10
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63B-9-1A-6 2/28/02 5:15 PM Page 1
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EMP00010
Chapter 6
INDEX
INDEX........................................................6-1
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
Hour meter..............................................2-10
I
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.
Fax No.
(714) 761-7439
(714) 761-7559
Yamaha Motor Canada Ltd.
480 Gordon Baker Road
Toronto, Ontario
M2H 3B4
Attention: Customer Relations Department
Telephone No.
Fax No.
(416) 498-1911
(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.
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.
Racing or competition use, modification of original parts, abnormal strain.
2.
Lack of proper maintenance and off-season storage as described in the Owner`s Manual, improper mounting of the motor, installation of parts or accessories that are not equivalent in design and quality to genuine Yamaha parts.
3.
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.
4.
Damage as a result of accidents, collisions, contact with foreign materials, or submersion.
5.
Growth of marine organisms on motor surfaces.
6.
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 CONSEQUENTIAL 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.
A.
What costs are my responsibility during the warranty period?
The customer`s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages.
Q.
A.
What are some examples of ``abnormal’’ strain, neglect, or abuse?
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.
A.
Does the warranty cover incidental costs such as towing or transportation due to a failure?
No. The warranty is limited to repair of the machine itself.
Q.
A.
May I perform any or all of the recommended maintenance shown in the Owner’s Manual instead of having the dealer do them?
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.
A.
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?
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.
A.
What responsibility does a Yamaha outboard dealer have under this warranty?
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.
A.
Is the warranty transferable to second owners?
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)
OWN
Printed in Japan
March 2002-0.5 × 1 !
63B-28199-1A
(40VETO, 50HETO)
(E)
Printed on recycled paper
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.
(For Dealer Use Only)
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) (A l’usage du concessionnaire)
YAMAHA DEALER NUMBER
NO. DU CONCESSIONNAIRE
YAMAHA
DEALER NAME
NOM DU
CONCESSIONNAIRE
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
USAGE
(Check One)
UTILISATION
(En cocher un.)
DATE SOLD
DATE DE
LIVRAISON
OWNER’S NAME
NOM DU
PROPRIÉTAIRE
MONTH
MOIS
DAY
JOUR
PHONE NUMBER (
)
NUMÉRO DE TÉLÉPHONE
YEAR
ANNÉE
FIRST
PRÉNOM
ADDRESS
ADRESSE
PLEASURE
LOISIR
COMMERCIAL
COMMERCIAL
LAST
NOM DE FAMILLE
STREET
RUE
CITY
VILLE
STATE/PROVINCE
PROVINCE
ZIP
CODE POSTAL
Warranty card 2/27/02 11:47 AM Page 2
PLACE
POSTAGE
HERE
ATTN: WARRANTY DEPARTMENT