U6M81EMC 09.4.2 10:05 AM ページ 1
8
OWNER’S MANUAL
U.S.A.Edition
LIT-18626-08-33
6M8-F8199-1E
U6M81EMC 09.4.2 10:05 AM ページ 2
EMU25062
ZMU01690
Read this manual carefully before operating this outboard motor. Keep this
manual onboard in a waterproof bag when boating. This manual should stay
with the outboard motor if it is sold.
Important manual information
EMU31283
To the owner
Thank you for choosing a Yamaha outboard
motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding
of these simple instructions will help you obtain maximum enjoyment from your new
Yamaha. If you have any question about the
operation or maintenance of your outboard
motor, please consult a Yamaha dealer.
In this Owner’s Manual particularly important
information is distinguished in the following
ways.
: This is the safety alert symbol. It is
used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death.
EWM00781
WARNING
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
ECM00701
NOTICE
A NOTICE indicates special precautions
that must be taken to avoid damage to the
outboard motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
Yamaha continually seeks advancements in
product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing, there may be minor discrepancies
between your machine and this manual. If
there is any question concerning this manual, please consult your Yamaha dealer.
TIP:
The 8MH and the standard accessories are
used as a base for the explanations and illustrations in this manual. Therefore some
items may not apply to every model.
EMU25131
8
OWNER’S MANUAL
©2009 by Yamaha Motor Corporation, USA
1st Edition, March 2009
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in France
P/N LIT-18626-08-33
Table of contents
Safety information............................. 1
Outboard motor safety .................... 1
Engine oil requirements ................ 15
Fuel requirements ......................... 15
Propeller............................................ 1
Rotating parts.................................... 1
Hot parts ........................................... 1
Electric shock .................................... 1
Engine shut-off cord (lanyard)........... 1
Gasoline ............................................ 1
Gasoline exposure and spills ............ 1
Carbon monoxide.............................. 1
Modifications ..................................... 2
Gasoline .......................................... 15
Ring Free Fuel Additive................... 16
Boating safety ................................. 2
Alcohol and drugs ............................. 2
Personal flotation devices ................. 2
People in the water ........................... 2
Passengers ....................................... 2
Overloading....................................... 2
Avoid collisions ................................. 2
Weather ............................................ 3
Accident reporting ............................. 3
Boat education and training .............. 3
Passenger training ............................ 3
Boating safety publications ............... 3
Laws and regulations ........................ 3
Boating organizations...................... 4
Basic boating rules (Rules of the
road) .............................................. 4
Steering and sailing rules and
sound signals.................................. 4
Rules when encountering vessels .... 5
Other special situations..................... 6
General information .......................... 9
Identification numbers record.......... 9
Outboard motor serial number .......... 9
Read manuals and labels.............. 10
Warning labels ................................ 10
Muddy or acidic water ...................
Anti-fouling paint ...........................
Motor disposal requirements.........
Emergency equipment ..................
Emission control information.........
16
16
16
16
16
North American models................... 16
Components .................................... 18
Components diagram.................... 18
Fuel tank ......................................... 18
Fuel joint.......................................... 19
Fuel gauge ...................................... 19
Fuel tank cap................................... 19
Air vent screw.................................. 19
Tiller handle..................................... 19
Gear shift lever ................................ 19
Throttle grip ..................................... 19
Throttle indicator ............................. 20
Throttle friction adjuster................... 20
Engine shut-off cord (lanyard) and
clip................................................. 20
Engine stop button .......................... 21
Choke knob for pull type ................. 21
Manual starter handle ..................... 21
Steering friction adjuster ................. 21
Trim rod (tilt pin) .............................. 22
Shallow water lever ......................... 22
Tilt support knob.............................. 22
Cowling lock lever(s) (turn type)...... 22
Installation ....................................... 23
Installation..................................... 23
Mounting the outboard motor .......... 23
Clamping the outboard motor.......... 24
Specifications and
requirements.................................... 13
Specifications ................................ 13
Installation requirements ............... 14
Operation ......................................... 26
First-time operation ....................... 26
Boat horsepower rating ................... 14
Mounting motor ............................... 14
Checks before starting engine ...... 26
Propeller selection......................... 14
Start-in-gear protection ................. 15
Breaking in engine .......................... 26
Getting to know your boat ............... 26
Fuel level ......................................... 27
Remove cowling .............................. 27
Fuel system ..................................... 27
Controls ........................................... 27
Table of contents
Engine shut-off cord (lanyard)......... 27
Oil.................................................... 27
Engine ............................................. 28
Install cowling.................................. 28
Filling fuel and engine oil............... 28
Filling fuel for portable tank ............. 28
Gasoline and oil mixing (100:1) ...... 29
Operating engine........................... 30
Sending fuel (portable tank) ............ 30
Starting engine ................................ 31
Checks after starting engine ......... 33
Cooling water .................................. 33
Warming up engine ....................... 33
Choke start models ......................... 33
Checks after engine warm-up ....... 34
Shifting ............................................ 34
Stop switches .................................. 34
Shifting .......................................... 34
Stopping boat ................................ 35
Stopping engine ............................ 35
motor............................................. 43
Periodic maintenance ................... 43
Replacement parts .......................... 44
Maintenance interval guidelines ...... 44
Maintenance chart 1........................ 45
Maintenance chart 2........................ 47
Greasing.......................................... 48
Cleaning and adjusting spark
plug ............................................... 48
Checking fuel filter........................... 49
Inspecting idling speed.................... 49
Checking wiring and connectors ..... 50
Checking propeller .......................... 50
Removing propeller ......................... 51
Installing propeller ........................... 51
Changing gear oil ............................ 51
Cleaning fuel tank ........................... 53
Inspecting and replacing
anode(s)........................................ 53
Trimming outboard motor.............. 36
Trouble Recovery............................ 55
Troubleshooting ............................ 55
Temporary action in emergency ... 58
Adjusting trim angle for manual tilt
models .......................................... 36
Adjusting boat trim .......................... 37
Impact damage ............................... 58
Starter will not operate .................... 58
Emergency starting engine ............. 59
Tilting up and down ....................... 38
Treatment of submerged motor .... 60
Consumer information ................... 61
YAMAHA MOTOR
CORPORATION, U.S.A.
OUTBOARD MOTOR TWO
YEAR LIMITED WARRANTY ..... 61
IMPORTANT WARRANTY
INFORMATION IF YOU USE
YOUR YAMAHA OUTSIDE
THE USA OR CANADA .............. 64
Procedure ....................................... 35
Procedure for tilting up (manual tilt
models) ......................................... 38
Procedure for tilting down (manual
tilt models) .................................... 39
Shallow water................................ 39
Cruising in shallow water (manual
tilt models) .................................... 39
Cruising in other conditions........... 40
Maintenance..................................... 41
Transporting and storing
outboard motor ............................ 41
Clamp screw mounting models ....... 41
Storing outboard motor ................... 41
Procedure ....................................... 42
Lubrication ...................................... 43
Cleaning and anticorrosion
measures ...................................... 43
Cleaning the outboard motor .......... 43
Checking painted surface of
Safety information
EMU33622
Outboard motor safety
Observe these precautions at all times.
EMU36501
Propeller
People can be injured or killed if they come
in contact with the propeller. The propeller
can keep moving even when the motor is in
neutral, and sharp edges of the propeller can
cut even when stationary.
● Stop the engine when a person is in the
water near you.
● Keep people out of reach of the propeller,
even when the engine is off.
EMU33630
Rotating parts
Hands, feet, hair, jewelry, clothing, PFD
straps, etc. can become entangled with internal rotating parts of the engine, resulting in
serious injury or death.
Keep the top cowling in place whenever possible. Do not remove or replace the cowling
with the engine running.
Only operate the engine with the cowling removed according to the specific instructions
in the manual. Keep hands, feet, hair, jewelry, clothing, PFD straps, etc. away from any
exposed moving parts.
EMU33640
Hot parts
During and after operation, engine parts are
hot enough to cause burns. Avoid touching
any parts under the top cowling until the engine has cooled.
EMU33650
Electric shock
Do not touch any electrical parts while starting or operating the engine. They can cause
shock or electrocution.
EMU33671
Engine shut-off cord (lanyard)
Attach the engine shut-off cord so that the
1
engine stops if the operator falls overboard
or leaves the helm. This prevents the boat
from running away under power and leaving
people stranded, or running over people or
objects.
Always attach the engine shut-off cord to a
secure place on your clothing or your arm or
leg while operating. Do not remove it to leave
the helm while the boat is moving. Do not attach the cord to clothing that could tear
loose, or route the cord where it could become entangled, preventing it from functioning.
Do not route the cord where it is likely to be
accidentally pulled out. If the cord is pulled
during operation, the engine will shut off and
you will lose most steering control. The boat
could slow rapidly, throwing people and objects forward.
EMU33810
Gasoline
Gasoline and its vapors are highly flammable and explosive. Always, refuel according to the procedure on page 30 to
reduce the risk of fire and explosion.
EMU33820
Gasoline exposure and spills
Take care not to spill gasoline. If gasoline
spills, wipe it up immediately with dry rags.
Dispose of rags properly.
If any gasoline spills onto your skin, immediately wash with soap and water. Change
clothing if gasoline spills on it.
If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get
immediate medical attention. Never siphon
fuel by mouth.
EMU33900
Carbon monoxide
This product emits exhaust gases which
contain carbon monoxide, a colorless, odorless gas which may cause brain damage or
Safety information
death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid
blocking exhaust outlets.
EMU33780
Modifications
Do not attempt to modify this outboard motor. Modifications to your outboard motor
may reduce safety and reliability, and render
the outboard unsafe or illegal to use.
EMU33740
Boating safety
This section includes a few of the many important safety precautions that you should
follow when boating.
EMU33710
Alcohol and drugs
Never operate after drinking alcohol or taking drugs. Intoxication is one of the most
common factors contributing to boating fatalities.
EMU33720
Personal flotation devices
Have an approved personal flotation device
(PFD) on board for every occupant. Yamaha
recommends that you must wear a PFD
whenever boating. At a minimum, children
and non-swimmers should always wear
PFDs, and everyone should wear PFDs
when there are potentially hazardous boating conditions.
EMU33731
People in the water
Always watch carefully for people in the water, such as swimmers, skiers, or divers,
whenever the engine is running. When
someone is in the water near the boat, shift
into neutral and stop the engine.
Stay away from swimming areas. Swimmers
can be hard to see.
The propeller can keep moving even when
the motor is in neutral. Stop the engine when
a person is in the water near you.
EMU33751
Passengers
Consult your boat manufacturer’s instructions for details about appropriate passenger
locations in your boat and be sure all passengers are positioned properly before accelerating and when operating above an idle
speed. Standing or sitting in non-designated
locations may result in being thrown either
overboard or within the boat due to waves,
wakes, or sudden changes in speed or direction. Even when people are positioned properly, alert your passengers if you must make
any unusual maneuver. Always avoid jumping waves or wakes.
EMU33760
Overloading
Do not overload the boat. Consult the boat
capacity plate or boat manufacturer for maximum weight and number of passengers. Be
sure that weight is properly distributed according to the boat manufacturers instructions. Overloading or incorrect weight
distribution can compromise the boats handling and lead to an accident, capsizing or
swamping.
EMU33772
Avoid collisions
Scan constantly for people, objects, and other boats. Be alert for conditions that limit your
visibility or block your vision of others.
ZMU06025
2
Safety information
Operate defensively at safe speeds and
keep a safe distance away from people, objects, and other boats.
● Do not follow directly behind other boats or
waterskiers.
● Avoid sharp turns or other maneuvers that
make it hard for others to avoid you or understand where you are going.
● Avoid areas with submerged objects or
shallow water.
● Ride within your limits and avoid aggressive maneuvers to reduce the risk of loss
of control, ejection, and collision.
● Take early action to avoid collisions. Remember, boats do not have brakes, and
stopping the engine or reducing throttle
can reduce the ability to steer. If you are
not sure that you can stop in time before
hitting an obstacle, apply throttle and turn
in another direction.
EMU33790
Weather
Stay informed about the weather. Check
weather forecasts before boating. Avoid
boating in hazardous weather.
EMU33800
Accident reporting
Boat operators are required by law to file a
Boating Accident Report with their state
boating law enforcement agency if their boat
is involved in any of the following accidents:
1. There is loss of life or probable loss of
life.
2. There is personal injury that requires
medical attention beyond first aid.
3. There is property damage to boats or
other property over a certain amount.
4. There is complete loss of a boat.
Contact local law enforcement personnel if a
report is necessary.
3
EMU33870
Boat education and training
Operators should take a boating safety
course. This may be required in your state.
Many of the organizations listed in the next
section can provide information about courses in your area.
You may also want to consider an Internetbased program for basic boater education.
The Online Boating Safety Course provided
by the BoatU.S. Foundation, is approved by
the National Association of State Boating
Law Administrators (NASBLA) and recognized by the United States Coast Guard.
Most, but not all, states accept this course to
meet their minimum requirements. While it
cannot replace an in-depth course such as
one offered by the U.S. Coast Guard, U.S.
Power Squadron, or other organization, this
online course does provide a general overview of the basics in boating safety, requirements, navigation, and operation. Upon
successful completion of the course, the
user can download a certificate of completion immediately or, for a small charge, request one by mail. To take this free course,
go to boatus.org.
EMU33880
Passenger training
Make sure at least one other passenger is
trained to operate the boat in the event of an
emergency.
EMU33890
Boating safety publications
Be informed about boating safety. Additional
publications and information can be obtained
from many boating organizations.
EMU33590
Laws and regulations
Know the marine laws and regulations where
you will be boating- and obey them. Several
sets of rules prevail according to geographic
Safety information
location, but all are basically the same as the
International Rules of the Road. The rules
presented in the following section are condensed- and have been provided for your
convenience only.
Contact the U.S. Coast Guard, the National
Association of State Boating Law Administrators, or your local Power Squadron for a
complete set of rules governing the waters in
which you will be using your boat.
EMU33681
Boating organizations
The following organizations provide boating
safety training and information about boating
safety and laws.
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
www.uscgboating.org
National Marine Manufacturers Association (NMMA)
200 East Randolph Drive
Suite 5100
Chicago, IL 60601
www.nmma.org
Marine Retailers Association of America
155 N. Michigan Ave. Chicago,
IL 60304
www.mraa.com
EMU33690
Basic boating rules (Rules of
the road)
Just as there are rules that apply when you
are driving on streets and highways, there
are waterway rules that apply when you are
driving your boat. These rules are used internationally. (For USA: 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.
EMU33700
United States Power Squadrons
1-888-FOR-USPS (1-888-367-8777)
www.usps.org
Boat Owners Association of The United
States
1-800-336-BOAT (1-800-336-2628)
www.boatus.com
National Association of State Boating
Law Administrators (NASBLA)
1500 Leestown Road, Suite 330
Lexington, KY 40511 859-225-9497
www.nasbla.org
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 that does not have the right-of-way is
called the “give-way” or “burdened”vessel.
These rules determine which vessel has the
right-of-way, and what each vessel should
do.
Stand-on vessel
The vessel with the right-of-way has the duty
to continue its course and speed, except to
avoid an immediate collision. When you
maintain your direction and speed, the other
4
Safety information
vessel will be able to determine how best to
avoid you.
Give-way vessel
The vessel that does not have the right-ofway has the duty to take positive and timely
action to stay out of the way of the Stand-On
vessel. Normally, you should not cross in
front of the vessel with the right-of-way. You
should slow down or change directions briefly and pass behind the other vessel. You
should always move in such a way that the
operator of the other vessel can see what
you are doing.
“ The general prudential rule ”
This rule is called Rule 2 in the International
Rules and says,
“ In obeying and construing these rules due
regard shall be had to all dangers of navigation and collision, and to any special circumstances, which may render a departure from
the above rules necessary in order to avoid
immediate danger.”
In other words, follow the standard rules except when a collision will occur unless both
vessels try to avoid each other. If that is the
case, both vessels become “ Give-Way ”
vessels.
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 GiveWay vessels). Both you and the meeting
vessel must alter course to avoid each other.
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-ofway 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 will clear one another if
you continue on your set course and speed.
EMU25521
Rules when encountering vessels
There are three main situations that 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 traveling 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-of-way to
5
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;
Safety information
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.
Overtaking
If you are passing another vessel, you are
the “Give-Way” vessel. This means that the
other vessel is expected to maintain 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.
EMU25531
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 powerdriven 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 that 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 power-driven 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 that 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
6
Safety information
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 information. These markers
are white with black letters and orange
boarders. They signify speed zones, restricted areas, danger areas, and general information.
Remember, markings may vary by geographic location. Always consult local boating authorities before driving your boat in
unfamiliar waters.
7
Safety information
ZMU01708
8
General information
EMU25171
Identification numbers record
EMU25183
Outboard motor serial number
The outboard motor serial number is
stamped on the label attached to the port
side of the clamp bracket.
Record your outboard motor serial number in
the spaces provided to assist you in ordering
spare parts from your Yamaha dealer or for
reference in case your outboard motor is stolen.
1
ZMU02836
1. Outboard motor serial number location
9
General information
EMU33520
Read manuals and labels
Before operating or working on this motor:
● Read this manual.
● Read any manuals supplied with the boat.
● Read all labels on the outboard motor and the boat.
If you need any additional information, contact your Yamaha dealer.
EMU33831
Warning labels
If these labels are damaged or missing, contact your Yamaha dealer for replacements.
8
1
2
3
ZMU06306
10
General information
1
2
3
ZMU05697
11
General information
EMU35132
Symbols
The following symbols mean as follows.
Electrical hazard
Notice/Warning
ZMU05666
ZMU05696
Read Owner’s Manual
ZMU05664
Hazard caused by continuous rotation
ZMU05665
12
Specifications and requirements
EMU31480
Specifications
TIP:
“(AL)” stated in the specification data below
represents the numerical value for the aluminum propeller installed.
Likewise, “(SUS)” represents the value for
stainless steel propeller installed and “(PL)”
for plastic propeller installed.
EMU2821E
Dimension:
Overall length:
802 mm (31.6 in)
Overall width:
343 mm (13.5 in)
Overall height S:
977 mm (38.5 in)
Transom height S:
436 mm (17.2 in)
Weight (AL) S:
27.0 kg (60 lb)
Performance:
Full throttle operating range:
4500–5500 r/min
Maximum output:
5.9 kW@5000 r/min
(8 HP@5000 r/min)
Idling speed (in neutral):
900 ±50 r/min
Engine:
Type:
2-stroke L
Displacement:
165.0 cm3
Bore × stroke:
50.0 × 42.0 mm (1.97 × 1.65 in)
Ignition system:
CDI
Spark plug (NGK):
B7HS-10
13
Spark plug gap:
0.9–1.0 mm (0.035–0.039 in)
Control system:
Tiller
Starting system:
Manual
Starting carburetion system:
Choke valve
Alternator output:
80 W
Drive unit:
Gear positions:
Forward-neutral-reverse
Gear ratio:
2.08 (27/13)
Trim and tilt system:
Manual tilt
Propeller mark:
N
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Min. pump octane:
86
Fuel tank capacity:
12 L (3.17 US gal, 2.64 Imp.gal)
Recommended engine oil:
YAMALUBE 2-stroke outboard motor
oil
Fuel:oil ratio:
Regular gasoline:
100 :1
Lubrication:
Pre-mixed fuel and oil
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
0.160 L (0.169 US qt, 0.141 Imp.qt)
Tightening torque for engine:
Spark plug:
25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
Specifications and requirements
Propeller nut:
17.0 Nm (1.73 kgf-m, 12.5 ft-lb)
EMU33554
Installation requirements
EMU33563
Boat horsepower rating
EWM01560
WARNING
Overpowering a boat can cause severe
instability.
Before installing the outboard motor(s), confirm that the total horsepower of your motor(s) does not exceed the boats maximum
horsepower rating. See the boat’s capacity
plate or contact the manufacturer.
EMU33571
Mounting motor
EWM01570
WARNING
●
●
Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of
control, or fire hazards.
Because the motor is very heavy, special equipment and training is required
to mount it safely.
Your dealer or other person experienced in
proper rigging should mount the motor using
correct equipment and complete rigging instructions. For further information, see page
23.
every application.
Your outboard motor came with a Yamaha
propeller chosen to perform well over a
range of applications, but there may be uses
where a different propeller would be more
appropriate.
Your Yamaha dealer can help you select the
right propeller for your boating needs. Select
a propeller that will allow the engine to reach
the middle or upper half of the operating
range at full throttle with the maximum boatload. Generally, chose a larger pitch propeller for a smaller operating load and a smaller
pitch propeller for a heavier load. If you carry
loads that vary widely, chose the propeller
that lets the engine run in the proper range
for your maximum load but remember that
you may need to reduce your throttle setting
to stay within the recommended engine
speed range when carrying lighter loads.
For instructions on propeller removal and installation, see page 50.
x
1
2 3
ZMU04604
EMU34192
Propeller selection
Next to selecting an outboard, choosing the
right propeller is one of the most important
purchasing decisions a boater can make.
The type, size, and design of your propeller
have a direct impact on acceleration, top
speed, fuel economy, and even engine life.
Yamaha designs and manufactures propellers for every Yamaha outboard motor and
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
14
Specifications and requirements
Gasohol) gasoline whenever possible.
x
1
Recommended gasoline:
Regular unleaded gasoline with a minimum Octane rating of 86 (Pump Octane Number) = (R+M)/2
2 3
ECM01981
NOTICE
ZMU04605
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
EMU25770
Start-in-gear protection
Yamaha outboard motors or Yamaha-approved remote control units are equipped
with start-in-gear protection device(s). This
feature permits the engine to be started only
when it is in neutral. Always select neutral
before starting the engine.
EMU25651
Engine oil requirements
Recommended engine oil:
YAMALUBE 2-stroke outboard motor
oil
If the recommended engine oil is not available, another 2-stroke engine oil with an
NMMA-certified TC-W3 rating may be used.
EMU36360
Fuel requirements
EMU36781
Gasoline
Use a good quality gasoline that meets the
minimum octane rating. If knocking or pinging occurs, use a different brand of gasoline
or premium unleaded fuel. Yamaha recomends that you use alcohol-free (see
15
●
●
Do not use leaded gasoline. Leaded
gasoline can seriously damage the engine.
Avoid getting water and contaminants
in the fuel tank. Contaminated fuel can
cause poor performance or engine
damage. Use only fresh gasoline that
has been stored in clean containers.
Gasohol
There are two types of gasohol: gasohol containing ethanol (E10) and that containing
methanol. Ethanol can be used if the ethanol
content does not exceed 10% and the fuel
meets the minimum octane ratings. E85 is a
fuel containing 85% ethanol and must not be
used in your outboard motor. All ethanol
blends containing more than 10% ethanol
can cause fuel system damage or cause engine starting and running problems. Yamaha
does not recommend gasohol containing
methanol because it can cause fuel system
damage or engine performance problems.
It is recommended that you install a waterseparating marine fuel filter assembly (10
micron minimum) between your boat’s fuel
tank and outboard motor when using ethanol. Ethanol is known to allow moisture to be
absorbed into boat fuel tanks and systems.
Moisture in the fuel can cause corrosion of
metallic fuel system components, starting
and running complaints and require additional fuel system maintenance.
Specifications and requirements
EMU27270
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 Fuel Additive has repeatedly proven its ability to clean
combustion deposits from inside the engine,
notably the critical piston-ring-land area, and
fuel system components. Follow product labeling for use instructions.
EMU36880
Muddy or acidic water
Yamaha strongly recommends that you have
your dealer install the optional chromiumplated water pump kit if you use the outboard
motor in muddy or acidic water conditions.
However, depending on the model it might
not be required.
boat bottom can be coated with an anti-fouling paint approved for your area to inhibit
marine growth.
Do not use anti-fouling paint which includes
copper or graphite. These paints can cause
more rapid engine corrosion.
EMU36341
Motor disposal requirements
Never illegally discard (dump) the motor.
Yamaha recommends consulting the dealer
about discarding the motor.
EMU36351
Emergency equipment
Keep the following items onboard in case
there is trouble with the motor.
● A tool kit with assorted screwdrivers, pliers, wrenches (including metric sizes), and
electrical tape.
● Waterproof flashlight with extra batteries.
● An extra engine shut-off cord (lanyard)
with clip.
● Spare parts, such as an extra set of spark
plugs.
Consult your Yamaha dealer for details.
EMU25221
Emission control information
EMU25230
North American models
EMU36330
Anti-fouling paint
A clean hull improves boat performance. The
boat bottom should be kept as clean of marine growth as possible. If necessary, the
This engine conforms to U.S. Environmental
Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your
16
Specifications and requirements
engine for details.
EMU30390
Approval label of emission control certificate
This label is attached to the bottom cowling.
Existing Technology; N/A
1
1
ZMU02838
1. Manufactured date label location
ZMU06311
1. Approval label location
Manufactured:
EMISSION CONTROL INFORMATION
ENGINE FAMILY :
THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.
REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.
g/kW-hr
FELs :
IDLE SPEED :
rpm IN NEUTRAL
SPARK PLUG :
SPARK PLUG GAP (mm) :
DISPLACEMENT :
cm 3
FUEL : GASOLINE
ADVERTISED POWER :
EX : N/A
VALVE LASH (mm) : IN : N/A
kW
ZMU05230
EMU25262
Manufactured date label
This label is attached to the clamp bracket or
the swivel bracket.
17
ZMU04346
Components
EMU2579M
Components diagram
TIP:
* May not be exactly as shown; also may not be included as standard equipment on all models.
8
15
1
3
14
13
12
11
10
9
4
5
2
17
6
16
8
7
1. Manual starter handle
2. Engine stop button/Engine shut-off switch
3. Choke knob
4. Throttle grip
5. Throttle friction adjuster
6. Clamp screw
7. Cooling water inlet
8. Anti-cavitation plate
9. Trim rod
10. Shallow water lever
11. Restraint cable attachment
12. Tilt support knob
13. Cooling water pilot hole
14. Gear shift lever
15. Top cowling
ZMU04490
16. Fuel tank*
17. Clip
EMU25802
Fuel tank
If your model was equipped with a portable
fuel tank, its function is as follows.
EWM00020
WARNING
The fuel tank supplied with this engine is
its dedicated fuel reservoir and must not
be used as a fuel storage container. Commercial users should conform to relevant
licensing or approval authority regula-
18
Components
tions.
4
1
3
2
ZMU02846
ZMU04499
EMU25922
Gear shift lever
1. Fuel tank cap
2. Fuel gauge
3. Air vent screw
4. Fuel joint
EMU25830
Fuel joint
This joint is used to connect the fuel line.
EMU25841
Pulling the gear shift lever towards you puts
the engine in forward gear so that the boat
moves ahead. Pushing the lever away from
you puts the engine in reverse gear so that
the boat moves astern.
R
3
N
1
F
2
Fuel gauge
This gauge is located on either the fuel tank
cap or on the fuel joint base. It shows the approximate amount of fuel remaining in the
tank.
EMU25850
Fuel tank cap
This cap seals the fuel tank. When removed,
the tank can be filled with fuel. To remove the
cap, turn it counterclockwise.
EMU25860
ZMU02847
1. Neutral “ ”
2. Forward “ ”
3. Reverse “ ”
Air vent screw
This screw is on the fuel tank cap. To loosen
the screw, turn it counterclockwise.
EMU25911
Tiller handle
To change direction, move the tiller handle to
the left or right as necessary.
19
EMU25941
Throttle grip
The throttle grip is on the tiller handle. Turn
the grip counterclockwise to increase speed
and clockwise to decrease speed.
Components
or throttle grip, which could result in an
accident. [EWM00032]
ZMU02848
EMU25961
ZMU02850
Throttle indicator
The fuel consumption curve on the throttle
indicator shows the relative amount of fuel
consumed for each throttle position. Choose
the setting that offers the best performance
and fuel economy for the desired operation.
1
ZMU02849
1. Throttle indicator
EMU25976
Throttle friction adjuster
A friction device provides adjustable resistance to movement of the throttle grip or the
remote control lever, and can be set according to operator preference.
To increase resistance, turn the adjuster
clockwise. To decrease resistance, turn the
adjuster counterclockwise. WARNING! Do
not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to move the remote control lever
When constant speed is desired, tighten the
adjuster to maintain the desired throttle setting.
EMU25994
Engine shut-off cord (lanyard) and
clip
The clip must be attached to the engine shutoff switch for the engine to run. The cord
should be attached to a secure place on the
operator’s clothing, or arm or leg. Should the
operator fall overboard or leave the helm, the
cord will pull out the clip, stopping ignition to
the engine. This will prevent the boat from
running away under power. WARNING! Attach the engine shut-off cord to a secure
place on your clothing, or your arm or leg
while operating. Do not attach the cord to
clothing that could tear loose. Do not
route the cord where it could become entangled, preventing it from functioning.
Avoid accidentally pulling the cord during normal operation. Loss of engine
power means the loss of most steering
control. Also, without engine power, the
boat could slow rapidly. This could cause
people and objects in the boat to be
thrown forward. [EWM00122]
20
Components
EMU26070
Manual starter handle
To start the engine, first gently pull the handle out until resistance is felt. From that position, then pull the handle straight out quickly
to crank the engine.
1
2
3
ZMU02851
1. Clip
2. Cord
3. Engine shut-off switch
EMU26001
Engine stop button
To open the ignition circuit and stop the engine, push this button.
EMU26122
Steering friction adjuster
A friction device provides adjustable resistance to the steering mechanism, and can be
set according to operator preference. An adjusting screw or bolt is located on the swivel
bracket.
ZMU02852
EMU26011
Choke knob for pull type
To supply the engine with the rich fuel mixture required to start, pull out this knob.
ZMU04508
To increase resistance, turn the adjuster
clockwise.
To decrease resistance, turn the adjuster
counterclockwise.
EWM00040
WARNING
ZMU02860
21
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
Components
difficult to steer, which could result in an
accident.
EMU26261
Trim rod (tilt pin)
The position of the trim rod determines the
minimum trim angle of the outboard motor in
relation to the transom.
ZMU02855
ECM00660
NOTICE
ZMU02853
EMU26280
Shallow water lever
Pushing this lever down will tilt the motor up
partially to provide more clearance when operating in shallow water.
Do not use the tilt support lever or knob
when trailering the boat. The outboard
motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use
an additional support device to secure it
in the tilt position.
EMU26373
Cowling lock lever(s) (turn type)
To remove the engine top cowling, turn the
cowling lock lever(s) and lift off the cowling.
When installing the cowling, check to be sure
it fits properly in the rubber seal. Then lock
the cowling again by returning the cowling
lock lever(s) to the lock position.
1
ZMU02854
EMU26321
Tilt support knob
To keep the outboard motor in the tilted up
position, push the tilt support knob under the
swivel bracket.
ZMU02862
1. Cowling lock lever(s)
22
Installation
EMU26902
Installation
The information presented in this section is
intended as reference only. It is not possible
to provide complete instructions for every
possible boat and motor combination. Proper mounting depends in part on experience
and the specific boat and motor combination.
EWM01590
1
WARNING
●
●
Overpowering a boat could cause severe instability. Do not install an outboard motor with more horsepower
than the maximum rating on the capacity plate of the boat. If the boat does not
have a capacity plate, consult the boat
manufacturer.
Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of
control, or fire hazards. For permanently mounted models, your dealer or other person experienced in proper
rigging should mount the motor.
EMU26911
Mounting the outboard motor
EWM01720
WARNING
Your dealer or other person experienced
in proper outboard motor mounting
should show you how to mount your outboard motor.
The outboard motor should be mounted so
that the boat is well balanced. Otherwise, the
boat could be hard to steer. For single-engine boats, mount the outboard motor on the
centerline (keel line) of the boat.
23
ZMU01760
1. Center line (keel line)
EMU26923
Mounting height
To run your boat at optimum efficiency, the
water resistance (drag) of the boat and outboard motor must be made as little as possible. The mounting height of the outboard
motor greatly affects the water resistance. If
the mounting height is too high, cavitation
tends to occur, thus reducing the propulsion;
and if the propeller tips cut the air, the engine
speed will rise abnormally and cause the engine to overheat. If the mounting height is too
low, the water resistance will increase and
thereby reduce engine efficiency. Mount the
outboard motor so that the anti-cavitation
plate is between the bottom of the boat and
a level 25 mm (1 in) below it.
Installation
EMU26972
Clamping the outboard motor
1.
0–25mm
(0–1in)
ZMU02011
ECM01631
NOTICE
●
●
Check that the idle hole stays high
enough to keep out water getting inside
engine even if the boat is in stationary
with maximum load.
Incorrect engine height or obstructions
to the smooth flow of water (such as the
design or condition of the boat, or accessories such as transom ladders or
depth finder transducers) can create
airborne water spray while the boat is
cruising. If the motor is operated continuously in the presence of airborne
water spray, enough water could enter
the engine through the intake opening
on the cowling to cause severe engine
damage. Eliminate the cause of the airborne water spray.
TIP:
●
●
The optimum mounting height of the outboard motor is affected by the boat and
motor combination and the desired use.
Test runs at different heights can help determine the optimum mounting height.
Consult your Yamaha dealer or boat manufacturer for further information on determining the proper mounting height.
For instructions on setting the trim angle of
the outboard motor, see page 36.
Place the outboard motor on the transom so that it is positioned as close to
the center as possible. Tighten the transom clamp screws evenly and securely.
Occasionally check the clamp screws
for tightness during operation of the outboard motor because they could become loose due to engine vibration.
WARNING! Loose clamp screws
could allow the outboard motor to fall
off or move on the transom. This
could cause loss of control and serious injury. Make sure the transom
screws are tightened securely. Occasionally check the screws for tightness during operation. [EWM00641]
ZMU02012
2.
If the restraint cable attachment is
equipped on your engine, a restraint cable or chain should be used. Attach one
end to the restraint cable attachment
and the other to a secure mounting point
on the boat. Otherwise the engine could
be completely lost if it accidentally falls
off the transom.
24
Installation
ZMU02013
3.
Secure the clamp bracket to the transom
using the bolts provided with the outboard (if packed). For details, consult
your Yamaha dealer. WARNING! Avoid
using bolts, nuts or washers other
than those contained in the engine
packaging. If used, they must be of at
least the same quality of material and
strength and must be tightened securely. After tightening, test run the
engine and check their tightness.
[EWM00651]
1
ZMU02637
1. Bolts
25
Operation
EMU36381
First-time operation
EMU30174
Breaking in engine
3.
Your new engine requires a period of breakin to allow mating surfaces of moving parts to
wear in evenly. Correct break-in will help ensure proper performance and longer engine
life. NOTICE: Failure to follow the break-in
procedure could result in reduced engine
life or even severe engine damage. [ECM00801]
EMU27060
Gasoline and engine oil mixing chart
(50:1)
4.
5.
plane, then immediately reduce the
throttle to 3000 r/min or less.
Next two hours:
Accelerate at full throttle onto plane,
then reduce engine speed to three-quarter throttle (approximately 4000 r/min).
Vary engine speed occasionally. Run at
full throttle for one minute, then allow
about 10 minutes of operation at threequarter throttle or less to let the engine
cool.
Remaining seven hours:
Run the engine at any speed. However,
avoid operating at full throttle for more
than 5 minutes at a time.
After the first 10 hours:
Operate the engine normally. Use the
standard premix ratio of gasoline and oil.
For details on mixing fuel and oil, see
page 28.
EMU36400
1.
: Gasoline
2.
: Engine oil
ECM00150
NOTICE
Be sure to mix gasoline and oil completely, otherwise the engine may be damaged.
EMU27074
Procedure for pre-mixed models
Run the engine under load (in gear with a
propeller installed) for 10 hours as follows.
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 3000 r/min). Vary engine speed
occasionally. If you have an easy-planing boat, accelerate at full throttle onto
Getting to know your boat
Different boats handle differently. Operate
cautiously while you learn how your boat
handles under different conditions and with
different trim angles (see page 36).
EMU36412
Checks before starting engine
EWM01920
WARNING
If any item in the checks before starting
engine is not working properly, have it inspected and repaired before operating
the outboard motor. Otherwise an accident could occur.
ECM00120
NOTICE
Do not start the engine out of water. Overheating and serious engine damage can
occur.
26
Operation
the outboard unsafe to operate.
EMU37141
Fuel level
Be sure you have plenty of fuel for your trip.
A good rule is to use 1/3 of your fuel to get to
the destination, 1/3 to return, and to keep 1/
3 as an emergency reserve. With the boat
level on a trailer or in the water, check the
fuel level. For fuel filling instructions, see
page 28.
EMU36570
EMU36451
Check for fuel leaks
Check for fuel leaks or gasoline fumes in
the boat.
● Check for fuel leakage from the fuel system.
● Check the fuel tank and fuel lines for
cracks, swellings, or other damages.
●
EMU36891
Remove cowling
Controls
For the following checks, remove the top
cowling from the engine. To remove the engine top cowling, release the lock lever and
lift off the cowling.
●
●
●
Move the tiller handle fully to the left and
right to make sure operation is smooth.
Turn the throttle grip from the fully closed
to the fully open position. Make sure that it
turns smoothly and that it completely returns to the fully closed position.
Look for loose or damaged connections of
the throttle and shift cables.
EMU36482
Engine shut-off cord (lanyard)
Inspect the engine shut-off cord for damage,
such as cuts, breaks, and wear.
ZMU06089
EMU36442
Fuel system
1
EWM00060
2
WARNING
Gasoline and its vapors are highly flammable and explosive. Keep away from
sparks, cigarettes, flames, or other
sources of ignition.
EWM00910
WARNING
Leaking fuel can result in fire or explosion.
● Check for fuel leakage regularly.
● If any fuel leakage is found, the fuel
system must be repaired by a qualified
mechanic. Improper repairs can make
27
3
ZMU02851
1. Clip
2. Cord
3. Engine shut-off switch
EMU27120
Oil
●
Check to be sure you have plenty of oil for
your trip.
Operation
EMU27141
Engine
●
●
●
Check the engine and engine mounting.
Look for loose or damaged fasteners.
Check the propeller for damage.
EMU36953
Install cowling
1.
2.
3.
4.
5.
Be sure that a cowling lock lever is released.
Be sure that the rubber seal is seated all
the way around the top cowling.
Place the top cowling on bottom cowling.
Check to be sure the rubber seal fits correctly all the way around the engine.
Move the lever to lock the cowling as
shown. NOTICE: If the cowling is not
installed correctly, water spray under
the cowling can damage the engine,
or the cowling can blow off at high
speeds. [ECM01990]
EMU27234
Filling fuel and engine oil
EMU27247
Filling fuel for portable tank
EWM01830
WARNING
●
●
ZMU06114
After installing, check the fitting of the top
cowling by pushing it with both hands. If the
top cowling is loose, have it repaired by your
Yamaha dealer.
1.
2.
Gasoline and its vapors are highly flammable and explosive. Always refuel according to this procedure to reduce the
risk of fire and explosion.
Gasoline is poisonous and can cause
injury or death. Handle gasoline with
care. Never siphon gasoline by mouth.
If you should swallow some gasoline or
inhale a lot of gasoline vapor, or get
some gasoline in your eyes, see your
doctor immediately. If gasoline spills
on your skin, wash with soap and water. If gasoline spills on your clothing,
change your clothes.
Be sure the engine is stopped.
Disconnect the fuel line from the fuel
tank and tighten the air vent screw on
the fuel tank cap.
28
Operation
ZMU04484
ZMU06621
9. Tighten the filler cap securely.
10. Wipe up any spilled gasoline immediately with dry rags. Dispose rags properly
according to local laws or regulations.
EMU27406
Gasoline and oil mixing (100:1)
ECM00811
NOTICE
●
3.
4.
5.
6.
7.
8.
Remove the portable tank from the boat.
Be sure you are in a well-ventilated outdoor area, either securely moored or
trailered.
Do not smoke and keep away from
sparks, flames, static electric discharge,
or other sources of ignition.
If you use a portable container to store
and dispense fuel, use only an approved
GASOLINE container.
Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic
sparks.
Fill the fuel tank, but do not overfill. Fuel
can expand and overflow if the temperature increases.
Fuel tank capacity:
12 L (3.17 US gal, 2.64 Imp.gal)
29
●
●
●
●
Avoid using any oil other than the specified type.
Use a thoroughly blended fuel-oil mixture.
If the mixture is not thoroughly mixed,
or if the mixing ratio is incorrect, the
following problems could occur.
Low oil ratio: Lack of oil could cause
major engine trouble, such as piston
seizure.
High oil ratio: Too much oil could cause
fouled spark plugs, smoky exhaust,
and heavy carbon deposits.
Gasoline to engine
oil ratio
Break-in period
After break-in
See page 26
100:1
Operation
3.
1L
(0.26 US gal,
0.22 Imp gal)
100:1
12 L
14 L
(3.2 US gal,
(3.7 US gal,
2.6 Imp gal)
3.1 Imp gal)
24 L
(6.3 US gal,
5.3 Imp gal)
0.01 L
(0.01 US qt,
0.01 Imp qt)
0.12 L
(0.13 US qt,
0.11 Imp qt)
0.24 L
(0.25 US qt,
0.21 Imp qt)
0.14 L
(0.15 US qt,
0.12 Imp qt)
ZMU04910
1.
: Gasoline
2.
: Engine oil
If equipped with a portable fuel tank
1. Pour oil into the portable fuel tank, and
then add gasoline.
Shake the fuel tank to mix the fuel thoroughly.
4. Make sure that the oil and gasoline are
mixed.
If equipped with a built-in fuel tank
1. Pour oil into a clean fuel can, and then
add gasoline.
2. Replace the fuel can cap and close tightly.
3. Shake the fuel can to mix the fuel thoroughly.
4. Make sure that the oil and gasoline are
mixed.
5. Pour the gasoline and oil mixture into the
built-in fuel tank.
TIP:
If using a permanently installed tank, pour
the oil gradually as the gasoline is being added to the tank.
EMU27451
Operating engine
EMU27466
Sending fuel (portable tank)
EWM00420
WARNING
●
●
1. Engine oil
2. Gasoline
2.
Replace the fuel tank cap and close
tightly.
●
Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.
When the air vent screw is loosened,
gasoline vapor will be released. Gasoline is highly flammable, and its vapors
are flammable and explosive. Refrain
from smoking, and keep away from
open flames and sparks while loosening the air vent screw.
This product emits exhaust gases
which contain carbon monoxide, a colorless, odorless gas which could cause
brain damage or death when inhaled.
30
Operation
Symptoms include nausea, dizziness,
and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking
exhaust outlets.
1.
If there is an air vent screw on the fuel
tank cap, loosen it 2 or 3 turns.
2.
If there is a fuel joint on the motor, firmly
connect the fuel line to the joint. Then
firmly connect the other end of the fuel
line to the joint on the fuel tank.
TIP:
Wipe up any spilled gasoline immediately
with dry rags. Dispose rags properly according to local laws or regulations.
3. Squeeze the primer pump, with the arrow pointing up, until you feel it become
firm. During engine operation place the
tank horizontally, otherwise fuel cannot
be drawn from the fuel tank.
1. Arrow
EMU27493
Starting engine
EWM01600
WARNING
Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the water near you.
EMU27508
Manual start models (tiller control)
EWM01840
WARNING
●
ZMU02024
31
Failure to attached engine shut-off cord
could result in a runaway boat if operator is ejected. Attach the engine shutoff cord to a secure place on your clothing, or your arm or leg while operating.
Do not attach the cord to clothing that
could tear loose. Do not route the cord
Operation
●
1.
(start) position.
where it could become entangled, preventing it from functioning.
Avoid accidentally pulling the cord during normal operation. Loss of engine
power means the loss of most steering
control. Also, without engine power,
the boat could slow rapidly. This could
cause people and objects in the boat to
be thrown forward.
Place the gear shift lever in neutral.
4.
Pull out / turn the choke knob fully. After
the engine starts, replace / return the
knob to the home position.
TIP:
The start-in-gear protection device prevents
the engine from starting except when in neutral.
2. Attach the engine shut-off cord to a secure place on your clothing, or your arm
or leg. Then install the clip on the other
end of the cord into the engine shut-off
switch.
3.
Place the throttle grip in the “
ZMU02860
TIP:
It is not necessary to use the choke when
starting a warm engine.
● If the choke knob is left in the “
”
(start) position while the engine is running,
the engine will run poorly or stall.
5. Pull the manual starter handle slowly until you feel resistance. Then give a
strong pull straight out to crank and start
the engine. Repeat if necessary.
●
”
32
Operation
EMU36510
Checks after starting engine
EMU36520
Cooling water
6.
After the engine starts, slowly return the
manual starter handle to its original position before releasing it.
Slowly return the throttle grip to the fully
closed position.
7.
Check for a steady flow of water from the
cooling water pilot hole. A continuous flow of
water from the pilot hole shows that the water pump is pumping water through the cooling passages. If the cooling passages are
frozen, it may take a while for water to start
flowing out of the pilot hole.
ECM01810
NOTICE
If water is not flowing out of the pilot hole
at all times while the engine is running,
overheating and serious damage could
occur. Stop the engine and check whether the cooling water inlet on the lower
case or the cooling water pilot hole is
blocked. Consult your Yamaha dealer if
the problem cannot be located and corrected.
ZMU02030
TIP:
●
●
When the engine is cold, it needs to be
warmed up. For further information, see
page 33.
If the engine does not start on the first try,
repeat the procedure. If the engine fails to
start after 4 or 5 tries, open the throttle a
small amount (between 1/8 and 1/4) and
try again. Also if the engine is warm and
fails to start, open the throttle a same
amount and try to start the engine again. If
the engine still fails to start, see page 55.
ZMU02856
Check that no water leaks from the joints between the exhaust cover, cylinder head, and
body cylinder.
EMU27670
Warming up engine
EMU27683
Choke start models
After starting the engine, allow it to idle for 3
minutes to warm up. Failure to do so will
33
Operation
down position (if equipped) before operating in reverse.
shorten engine life. Gradually return the
choke knob to its home position as the engine warms up.
EMU36530
R
Checks after engine warm-up
N
F
EMU36540
Shifting
While tightly moored, and without applying
throttle, confirm that the engine shifts
smoothly into forward and reverse, and back
to neutral.
ZMU05921
EMU36970
Stop switches
●
●
●
Press the engine stop button and make
sure the engine stops.
Confirm that removing the clip from the engine shut-off switch stops the engine.
Confirm that the engine cannot be started
with the clip removed from the engine
shut-off switch.
To shift from in gear (forward/reverse) to
neutral
1. Close the throttle so that the engine
slows to idle speed.
EMU34550
Shifting
EWM00180
WARNING
Before shifting, make sure there are no
swimmers or obstacles in the water near
you.
ECM01610
NOTICE
Warm up the engine before shifting into
gear. Until the engine is warm, the idle
speed may be higher than normal. High
idle speed can prevent you from shifting
back to neutral. If this occurs, stop the
engine, shift to neutral, then restart the
engine and allow it to warm up.
ZMU02030
2.
After the engine is at idle speed in gear
move the gear shift lever firmly and
crisply into the neutral position.
To shift out of neutral
1. Move the gear shift lever firmly and
crisply forward (for forward gear) or
backward (for reverse gear). Be sure to
check that the tilt lock lever is in the lock/
34
Operation
EMU31742
Stopping boat
EWM01510
WARNING
●
●
Do not use the reverse function to slow
down or stop the boat as it could cause
you to lose control, be ejected, or impact the steering wheel or other parts of
the boat. This could increase the risk of
serious injury. It could also damage the
shift mechanism.
Do not shift into reverse while traveling
at planing speeds. Loss of control, boat
swamping, or damage to the boat could
occur.
2.
After stopping the engine, tighten the air
vent screw on the fuel tank cap and set
the fuel cock lever or knob to the closed
position, if equipped.
3.
Disconnect the fuel line if you are using
an external fuel tank.
The boat is not equipped with a separate
braking system. Water resistance stops it after the throttle lever is moved back to idle.
The stopping distance varies depending on
gross weight, water surface conditions, and
wind direction.
EMU27821
Stopping engine
Before stopping the engine, first let it cool off
for a few minutes at idle or low speed. Stopping the engine immediately after operating
at high speed is not recommended.
EMU27833
Procedure
1.
Push and hold the engine stop button
until the engine comes to a complete
stop.
TIP:
If the outboard motor is equipped with an engine shut-off cord, the engine can also be
stopped by pulling the cord and removing the
clip from the engine shut-off switch.
35
Operation
EMU27862
Trimming outboard motor
EWM00740
WARNING
Excessive trim for the operating conditions (either trim up or trim down) can
cause boat instability and can make
steering the boat more difficult. This increases the possibility of an accident. If
the boat begins to feel unstable or is hard
to steer, slow down and/or readjust the
trim angle.
The trim angle of the outboard motor helps
determine the position of the bow of the boat
in the water. Correct trim angle will help improve performance and fuel economy while
reducing strain on the engine. Correct trim
angle depends upon the combination of
boat, engine, and propeller. Correct trim is
also affected by variables such as the load in
the boat, sea conditions, and running speed.
1
ZMU02858
1. Trim operating angle
EMU27872
Adjusting trim angle for manual tilt
models
There are 4 or 5 holes provided in the clamp
bracket to adjust the outboard motor trim angle.
1. Stop the engine.
2. Tilt the outboard motor up, and then remove the trim rod from the clamp bracket.
36
Operation
bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. When the bow of
the boat is down, it is easier to accelerate
from a standing start onto plane.
1
ZMU02859
1. Trim rod
3. Reposition the rod in the desired hole.
To raise the bow (“trim-out”), move the rod
away from the transom.
To lower the bow (“trim-in”), move the rod toward the transom.
Make test runs with the trim set to different
angles to find the position that works best for
your boat and operating conditions.
EWM00400
WARNING
●
●
●
Stop the engine before adjusting the
trim angle.
Use care to avoid being pinched when
removing or installing the rod.
Use caution when trying a trim position
for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim
angle can cause loss of control.
Bow Up
Too much trim-out puts the bow of the boat
too high in the water. Performance and economy are decreased because the hull of the
boat is pushing the water and there is more
air drag. Excessive trim-out can also cause
the propeller to ventilate, which reduces performance further, and the boat may “porpoise” (hop in the water), which could throw
the operator and passengers overboard.
TIP:
The outboard motor trim angle can be
changed approximately 4 degrees by shifting
the trim rod one hole.
EMU27912
Adjusting boat trim
When the boat is on plane, a bow-up attitude
results in less drag, greater stability and efficiency. This is generally when the keel line of
the boat is up about 3 to 5 degrees. With the
37
Bow Down
Too much trim-in causes the boat to “plow”
through the water, decreasing fuel economy
and making it hard to increase speed. Operating with excessive trim-in at higher speeds
also makes the boat unstable. Resistance at
Operation
the bow is greatly increased, heightening the
danger of “bow steering” and making operation difficult and dangerous.
Otherwise fuel may leak.
ECM00231
NOTICE
●
●
●
TIP:
Depending on the type of boat, the outboard
motor trim angle may have little effect on the
trim of the boat when operating.
●
EMU27922
Tilting up and down
If the engine will be stopped for some time or
if the boat is moored in shallows, the outboard motor should be tilted up to protect the
propeller and lower casing from damage by
collision with obstructions, and also to reduce salt corrosion.
Before tilting the outboard motor, follow the procedure under “Stopping engine” in this chapter. Never tilt the
outboard motor while the engine is running. Severe damage from overheating
can result.
Do not tilt up the engine by pushing the
tiller handle because this could break
the handle.
Keep the power unit higher than the
propeller at all times. Otherwise water
could run into the cylinder and cause
damage.
The outboard motor cannot be tilted
when in reverse or when the outboard
motor is turned 180° (facing the rear).
EMU32662
Procedure for tilting up (manual tilt
models)
1.
Place the gear shift lever in neutral.
2.
Disconnect the fuel line from the outboard motor.
EWM00221
WARNING
Be sure all people are clear of the outboard motor when tilting up and down.
Body parts can be crushed between the
motor and the clamp bracket when the
motor is trimmed or tilted.
EWM00230
WARNING
Leaking fuel is a fire hazard. Tighten the
air vent screw and place the fuel cock in
the closed position if the outboard motor
will be tilted for more than a few minutes.
38
Operation
ZMU02887
3.
4.
Place the tilt lock lever (if equipped) in
the release/up position.
Pull up the shallow water lever (if
equipped).
EMU28013
Procedure for tilting down (manual
tilt models)
1.
2.
Slightly tilt the engine up.
On models equipped with a tilt support
knob, pull it out.
ZMU02854
5.
6.
39
Hold the rear of the top cowling with one
hand and tilt the engine up fully.
Push the tilt support knob into the clamp
bracket. Or the tilt support bar will turn to
the lock position automatically. NOTICE: Do not use the tilt support lever
or knob when trailering the boat. The
outboard motor could shake loose
from the tilt support and fall. If the
motor cannot be trailered in the normal running position, use an additional support device to secure it in
the tilt position. For more detailed information, see page 41. [ECM01641]
ZMU02888
3.
Slowly tilt the engine down.
EMU28061
Shallow water
EMU28073
Cruising in shallow water (manual tilt
models)
EWM01781
WARNING
●
Run the boat at the lowest possible
speed when using the shallow water
cruising system. The tilt lock mechanism does not work while the shallow
water cruising system is being used.
Hitting an underwater obstacle could
cause the outboard motor to lift out of
Operation
●
the water, resulting in loss of control.
Use extra care when operating in reverse. Too much reverse thrust can
cause the outboard motor to lift out of
the water, increasing the chance of accident and personal injury.
ECM00260
NOTICE
Do not tilt the outboard motor up so that
the cooling water inlet on the lower unit is
above the surface of the water when setting up for and cruising in shallow water.
Otherwise severe damage from overheating can result.
ZMU02854
3.
4.
The shallow water lever will lock, supporting the outboard motor in a partially
raised position.
When lowering the outboard motor,
slightly tilt it up and push the shallow water lever down. Slowly lower the outboard motor to the normal position.
EMU28195
Cruising in other conditions
ZMU02868
EMU28110
Procedure
1. Place the gear shift lever in neutral.
2.
Cruising in salt water
After operating in salt water, flush the cooling
water passages with fresh water to prevent
them from becoming clogged. Also rinse the
outside of the outboard motor with fresh water.
Cruising in muddy, turbid, or acidic water
Yamaha strongly recommends that you use
the optional chromium-plated water pump kit
(see page 16) if you use the outboard motor
in acidic water or water with a lot of sediment
in it, such as muddy or turbid (cloudy) water.
After operating in such water, flush the cooling passages with fresh water to prevent corrosion. Also rinse the outside of the outboard
motor with fresh water.
Slightly tilt the outboard motor up. Pull
up the shallow water lever.
40
Maintenance
EMU28227
Transporting and storing
outboard motor
EWM00693
WARNING
●
●
USE CARE when transporting fuel tank,
whether in a boat or car.
DO NOT fill fuel container to maximum
capacity. Gasoline will expand considerably as it warms up and can build up
pressure in the fuel container. This can
cause fuel leakage and a potential fire
hazard.
EWM01860
WARNING
ZMU02870
EMU28236
Clamp screw mounting models
When transporting or storing the outboard
motor while removed from a boat, keep the
outboard motor in the attitude shown.
Leaking fuel is a fire hazard. When transporting and storing the outboard motor,
close the fuel cock to prevent fuel from
leaking. Never get under the engine while
it is tilted. Severe injury could occur if the
outboard motor accidentally falls.
ECM00660
NOTICE
Do not use the tilt support lever or knob
when trailering the boat. The outboard
motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use
an additional support device to secure it
in the tilt position.
The outboard motor should be trailered and
stored in the normal running position. If there
is insufficient road clearance in this position,
then trailer the outboard motor in the tilt position using a motor support device such as
a transom saver bar. Consult your Yamaha
dealer for further details.
41
ZMU02869
TIP:
Place a towel or something similar under the
outboard motor to protect it from damage.
EMU30272
Storing outboard motor
When storing your Yamaha outboard motor
for prolonged periods of time (2 months or
longer), several important procedures must
be performed to prevent excessive damage.
It is advisable to have your outboard motor
serviced by an authorized Yamaha dealer
prior to storage. However, you, the owner,
with a minimum of tools, can perform the fol-
Maintenance
lowing procedures.
ECM01411
NOTICE
●
●
Do not place the outboard motor on its
side before the cooling water has
drained from it completely, otherwise
water may enter the cylinder through
the exhaust port and cause engine trouble.
Store the outboard motor in a dry, wellventilated place, not in direct sunlight.
EMU28304
1
2
ZMU02051
1. Water surface
2. Lowest water level
Procedure
EMU28376
5.
Flushing in a test tank
ECM00300
NOTICE
Do not run the engine without supplying
it with cooling water. Either the engine
water pump will be damaged or the engine will be damaged from overheating.
Before starting the engine, be sure to
supply water to the cooling water passages.
1.
2.
6.
Wash the outboard motor body using
fresh water. NOTICE: Do not spray water into the air intake. [ECM01840] For further information, see page 43.
Fill the fuel tank with fresh fuel and add
one ounce of “Yamaha Fuel Conditioner
and Stabilizer” to each gallon of fuel.
TIP:
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.
3. Remove the engine top cowling and silencer cover.
4. Install the outboard motor on the test
tank.
7.
8.
Fill the tank with fresh water to above the
level of the anti-cavitation plate. NOTICE: If the fresh water level is below
the level of the anti-cavitation plate,
or if the water supply is insufficient,
engine seizure may occur. [ECM00291]
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 excessive engine damage
due to rust. Perform the flushing and
fogging at the same time. WARNING!
Do not touch or remove electrical
parts when starting or during operation. Keep hands, hair, and clothes
away from the flywheel and other rotating parts while the engine is running. [EWM00091]
Run the engine at a fast idle for 10–15
minutes in neutral position.
Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite Engine
Fogging Oil” alternately into each carburetor or the fogging hole of the silencer
cover, if equipped. When properly done,
the engine will smoke excessively and
almost stall.
42
Maintenance
9.
Remove the outboard motor from the
test tank.
10. Drain the cooling water completely out
of the motor. Clean the body thoroughly.
11. Install the silencer cover/cap and top
cowling.
EMU28402
Lubrication
1.
2.
3.
Install the spark plug(s) and torque to
proper specification. For information on
spark plug installation, see page 48.
Change the gear oil. For instructions,
see page 51. Inspect the oil for the presence of water that indicates a leaky seal.
Seal replacement should be performed
by an authorized Yamaha dealer prior to
use.
Grease all grease fittings. For further details, see page 48.
TIP:
For long-term storage, fogging the engine
with oil is recommended. Contact your
Yamaha dealer for information about fogging
oil and procedures for your engine.
EMU28423
Cleaning and anticorrosion
measures
1.
2.
3.
Wash down the exterior of the outboard
motor with fresh water and dry off completely. NOTICE: Do not spray water
into the air intake. [ECM01840]
Spray the outboard motor exterior with
“Yamaha Silicone Protectant”.
Wax the cowling with a non-abrasive
wax such as “Yamaha Silicone Wax”.
EMU28451
Cleaning the outboard motor
After use, wash the exterior of the outboard
motor with fresh water. Flush the cooling
system with fresh water.
EMU28460
Checking painted surface of motor
Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are
more likely to corrode. If necessary, clean
and paint the areas. A touch-up paint is available from your Yamaha dealer.
EMU37081
Periodic maintenance
EWM01981
WARNING
These procedures require mechanical
skills, tools, and supplies. If you do not
have the proper skills, tools, or supplies
to perform a maintenance procedure,
have a Yamaha dealer or other qualified
mechanic do the work.
The procedures involve disassembling
the motor and exposing dangerous parts.
To reduce the risk of injury from moving,
hot, or electrical parts:
● Turn off the engine and keep engine
shut-off cord (lanyard) with you when
you perform maintenance unless otherwise specified.
● Allow the engine to cool before handling hot parts or fluids.
● Always completely reassemble the motor before operation.
Maintenance, replacement, or repair of
the emission control devices and sys-
43
Maintenance
tems 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 your Yamaha dealer for owners who
have the mechanical skills, tools, and other
equipment necessary to perform maintenance not covered by this owner’s manual.
mendations.
EMU28511
Replacement parts
If replacement parts are necessary, use only
genuine Yamaha parts or parts of equivalent
design and quality. Any part of inferior quality
may malfunction, and the resulting loss of
control could endanger the operator and
passengers. Yamaha genuine parts and accessories are available from your Yamaha
dealer.
EMU35520
Maintenance interval guidelines
The service intervals provided in the Maintenance Chart were developed based upon
“typical” use that includes operating at varied
speeds, with sufficient time for engine warm
up and cool-down, a medium to light load,
and an average cruising speed near the
3000 to 4000 rpm range. As with any engine,
however, if your normal operating conditions
are different, you should consider service
more often than shown, especially how often
you change your engine and gear oil. Examples might include extended wide-openthrottle use or long periods of trolling or
idling, carrying heavy loads, or frequent
starting and stopping or shifting. More frequent maintenance will often pay off many
times over in increased engine life and greater owner satisfaction. Consult your Yamaha
dealer for additional maintenance recom-
44
Maintenance
EMU34445
Maintenance chart 1
TIP:
Refer to the sections in this chapter for explanations of each owner-specific action.
The maintenance cycle on these charts assume usage of 100 hours per year and regular
flushing of the cooling water passages. Maintenance frequency should be adjusted when
operating the engine under adverse conditions such as extended trolling.
● Disassembly or repairs may be necessary depending on the outcome of maintenance
checks.
● Expendable or consumable parts and lubricants will lose their effectiveness over time and
through normal usage regardless of the warranty period.
● When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should
be flushed with clean water after each use.
The “ ” symbol indicates the check-ups which you may carry out yourself.
The “ ” symbol indicates work to be carried out by your Yamaha dealer.
●
●
Initial
Item
Anode(s) (external)
Anode(s) (cylinder
head, thermostat
cover)
Anodes (exhaust cover,
cooling water passage
cover, Rectifier Regulator cover)
Actions
Inspection or replacement as necessary
Inspection or replacement as necessary
Replacement
Cooling water leakage
Inspection or replacement as necessary
Cowling lock lever
Inspection
Engine starting condition/noise
Engine idling speed/
noise
Fuel filter (disposal
type)
Fuel line(High pressure)
Fuel line(High pressure)
Fuel line(Low pressure)
45
Inspection
Inspection
Replacement
Inspection
Inspection or replacement as necessary
Inspection
20 hours
(3
months)
Every
100
hours (1
year)
300
hours (3
years)
500
hours (5
years)
Maintenance
Initial
Item
Fuel line(Low pressure)
Fuel pump
Actions
Inspection
Gear oil
Replacement
Greasing points
Greasing
Impeller/water pump
housing
Impeller/water pump
housing
Propeller/propeller nut/
cotter pin
Inspection or replacement as necessary
Spark plug(s)
Spark plug caps/spark
plug wires
Water from the cooling
water pilot hole
Throttle link/throttle
cable/throttle pick-up
timing
Thermostat
300
hours (3
years)
500
hours (5
years)
Replacement
Inspection or replacement as necessary
Inspection, adjustment
or replacement as necessary
Inspection or replacement as necessary
Inspection or replacement as necessary
Inspection
Inspection, adjustment
or replacement as necessary
Inspection or replacement as necessary
Water inlet
Inspection
Main switch/stop
switch/choke switch
Wire harness connections/wire coupler connections
Inspection or replacement as necessary
(Yamaha) Fuel tank
100
hours (1
year)
Inspection or replacement as necessary
Inspection or replacement as necessary
Fuel/engine oil leakage
Shift link/shift cable
20 hours
(3
months)
Every
Inspection or replacement as necessary
Inspection and cleaning as necessary
46
Maintenance
EMU34451
Maintenance chart 2
Every
Item
Actions
1000 hours
Exhaust guide/exhaust
manifold
47
Inspection or replacement as necessary
Maintenance
EMU28932
Greasing
Yamaha marine grease (Water resistant grease)
8
ZMU02872
EMU28956
Cleaning and adjusting spark plug
The spark plug is an important engine component and is easy to inspect. The condition
of the spark plug can indicate something
about the condition of the engine. For example, if the center electrode porcelain is very
white, this could indicate an intake air leak or
carburetion problem in that cylinder. Do not
attempt to diagnose any problems yourself.
Instead, take the outboard motor to a
Yamaha dealer. You should periodically remove and inspect the spark plug because
heat and deposits will cause the spark plug
to slowly break down and erode.
1. Remove the spark plug caps from the
spark plugs.
48
Maintenance
2.
Remove the spark plug. If electrode erosion becomes excessive, or if carbon
and other deposits are excessive, you
should replace the spark plug with another of the correct type. WARNING!
When removing or installing a spark
plug, be careful not to damage the insulator. A damaged insulator could
allow external sparks, which could
lead to explosion or fire. [EWM00561]
Standard spark plug:
B7HS-10
3.
Be sure to use the specified spark plug,
otherwise the engine may not operate
properly. Before fitting the spark plug,
measure the electrode gap with a wire
thickness gauge; replace it if out of specification.
the correct torque.
Spark plug torque:
25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
TIP:
If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of
the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the
correct torque as soon as possible with a
torque-wrench.
EMU28990
Checking fuel filter
Check the fuel filter periodically. The fuel filter is a one piece, disposable type. If foreign
matter is found in the filter, replace it. For replacement of the fuel filter, consult your
Yamaha dealer.
ZMU02874
EMU29043
1. Spark plug gap
2. Spark plug part number
3. Spark plug I.D. mark (NGK)
Inspecting idling speed
EWM00451
WARNING
●
Spark plug gap:
0.9–1.0 mm (0.035–0.039 in)
4.
When fitting the plug, wipe off any dirt
from the threads, and then screw it in to
●
Do not touch or remove electrical parts
when starting or during operation.
Keep hands, hair, and clothes away
from the flywheel and other rotating
parts while the engine is running.
ECM00490
NOTICE
This procedure must be performed while
49
Maintenance
the outboard motor is in the water. A
flushing attachment or test tank can be
used.
If the boat is not equipped with a tachometer
for the outboard motor, use a diagnostic tachometer for this procedure. Results may
vary depending on whether testing is conducted with the flushing attachment, in a test
tank, or with the outboard motor in the water.
1. Start the engine and allow it to warm up
fully in neutral until it is running smoothly.
2. Once the engine has warmed up, verify
whether the idle speed is set to specification. For idle speed specifications,
see page 13. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha
dealer or other qualified mechanic.
near the propeller. Before inspecting, removing, or installing the propeller, place
the shift control in neutral, turn the main
switch to “
” (off) and remove the key,
and remove the clip from the engine shutoff switch. Turn off the battery cut-off
switch if your boat has one.
Do not use your hand to hold the propeller
when loosening or tightening the propeller
nut. Put a wood block between the anti-cavitation plate and the propeller to prevent the
propeller from turning.
EMU29113
Checking wiring and connectors
●
●
Check that each connector is engaged securely.
Check that each ground lead is properly
secured.
ZMU01897
Checkpoints
● Check each of the propeller blades for erosion from cavitation or ventilation, or other
damage.
● Check the propeller shaft for damage.
● Check the splines for wear or damage.
● Check for fish line tangled around the propeller shaft.
ZMU02875
EMU32112
Checking propeller
EWM01881
WARNING
You could be seriously injured if the engine accidentally starts when you are
50
Maintenance
●
Check the propeller shaft oil seal for damage.
2.
EMU30662
Removing propeller
EMU29197
Spline models
1. Straighten the cotter pin and pull it out
using a pair of pliers.
2. Remove the propeller nut, washer, and
spacer (if equipped). WARNING! Do
not use your hand to hold the propeller when loosening the propeller nut.
3.
[EWM01890]
Propeller nut tightening torque:
17.0 Nm (1.73 kgf-m, 12.5 ft-lb)
1
4.
3 2
5
rosion resistant grease to the propeller
shaft.
Install the spacer (if equipped), thrust
washer, washer (if equipped), and propeller on the propeller shaft. NOTICE:
Be sure to install the thrust washer
before installing the propeller, otherwise the lower case and propeller
boss could be damaged. [ECM01880]
Install the spacer (if equipped) and the
washer. Tighten the propeller nut to the
specified torque.
4
ZMU02877
Align the propeller nut with the propeller
shaft hole. Insert a new cotter pin in the
hole and bend the cotter pin ends. NOTICE: Do not reuse the cotter pin installed. Otherwise the propeller can
come off during operation. [ECM01890]
1. Cotter pin
2. Propeller nut
3. Washer
4. Propeller
5. Thrust washer
3.
Remove the propeller, washer
equipped), and thrust washer.
(if
EMU30672
ZMU02063
Installing propeller
EMU29233
Spline models
ECM00500
NOTICE
Be sure to use a new cotter pin and bend
the ends over securely. Otherwise the
propeller could come off during operation and be lost.
1.
TIP:
If the propeller nut does not align with the
propeller shaft hole after tightening to the
specified torque, tighten the nut further to
align it with the hole.
EMU29287
Changing gear oil
EWM00800
WARNING
Apply Yamaha marine grease or a cor●
51
Be sure the outboard motor is securely
Maintenance
●
1.
2.
3.
fastened to the transom or a stable
stand. You could be severely injured if
the outboard motor falls on you.
Never get under the lower unit while it
is tilted, even when the tilt support lever
or knob is locked. Severe injury could
occur if the outboard motor accidentally falls.
Tilt the outboard motor so that the gear
oil drain screw is at the lowest point possible.
Place a suitable container under the
gear case.
Remove the gear oil drain screw and
gasket. NOTICE: If there is an excessive quantity of metal particles on the
magnetic gear oil drain screw, this
can indicate lower unit problem. Consult your Yamaha dealer. [ECM01900]
TICE: Inspect the used oil after it has
been drained. If the oil is milky, water
is getting into the gear case which
can cause gear damage. Consult a
Yamaha dealer for repair of the lower
unit seals. [ECM00711]
TIP:
For disposal of used oil, consult your
Yamaha dealer.
5. Put the outboard motor in a vertical position. Using a flexible or pressurized filling device, inject the gear oil into the
gear oil drain screw hole.
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
0.160 L (0.169 US qt, 0.141 Imp.qt)
2
1
ZMU02880
ZMU02879
6.
1. Gear oil drain screw
2. Oil level plug
Put a new gasket on the oil level plug.
When the oil begins to flow out of the oil
level plug hole, insert and tighten the oil
level plug.
TIP:
If a magnetic gear oil drain screw is
equipped, remove all metal particles from
the screw before installing it.
● Always use new gaskets. Do not reuse the
removed gaskets.
4. Remove the oil level plug and gasket to
allow the oil to drain completely. NO-
Tightening torque:
9 Nm (0.9 kgf-m, 6.6 ft-lb)
●
7.
Put a new gasket on the gear oil drain
screw. Insert and tighten the gear oil
52
Maintenance
drain screw.
Tightening torque:
9 Nm (0.9 kgf-m, 6.6 ft-lb)
EMU29302
Cleaning fuel tank
EWM00920
WARNING
Gasoline is highly flammable, and its vapors are flammable and explosive.
● If you have any question about properly
doing this procedure, consult your
Yamaha dealer.
● Keep away from sparks, cigarettes,
flames, or other sources of ignition
when cleaning the fuel tank.
● Remove the fuel tank from the boat before cleaning it. Work only outdoors in
an area with good ventilation.
● Wipe up any spilled fuel immediately.
● Reassemble the fuel tank carefully. Improper assembly can result in a fuel
leak, which could result in a fire or explosion hazard.
● Dispose of old gasoline according to local regulations.
1.
2.
3.
Empty the fuel tank into an approved
container.
Pour a small amount of suitable solvent
into the tank. Install the cap and shake
the tank. Drain the solvent completely.
Remove the screws holding the fuel joint
assembly. Pull the assembly out of the
tank.
4.
5.
Clean the filter (located on the end of the
suction pipe) in a suitable cleaning solvent. Allow the filter to dry.
Replace the gasket with a new one. Reinstall the fuel joint assembly and tighten
the screws firmly.
EMU29313
Inspecting and replacing anode(s)
Yamaha outboard motors are protected from
corrosion by sacrificial anodes. Inspect the
external anodes periodically. Remove scales
from the surfaces of the anodes. Consult a
Yamaha dealer for replacement of external
anodes.
ECM00720
NOTICE
Do not paint anodes, as this would render
them ineffective.
ZMU02881
TIP:
Inspect ground leads attached to external
53
Maintenance
anodes on equipped models. Consult a
Yamaha dealer for inspection and replacement of internal anodes attached to the power unit.
54
Trouble Recovery
EMU29427
Troubleshooting
A problem in the fuel, compression, or ignition systems can cause poor starting, loss of
power, or other problems. This section describes basic checks and possible remedies,
and covers all Yamaha outboard motors.
Therefore some items may not apply to your
model.
If your outboard motor requires repair, bring
it to your Yamaha dealer.
If the engine trouble-alert indicator is flashing, consult your Yamaha dealer.
Starter will not operate.
Q. Is battery capacity weak or low?
A. Check battery condition. Use battery of
recommended capacity.
Q. Are battery connections loose or corroded?
A. Tighten battery cables and clean battery
terminals.
Q. Is fuse for electric start relay or electric circuit blown?
A. Check for cause of electric overload and
repair. Replace fuse with one of correct amperage.
Q. Are starter components faulty?
A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear?
A. Shift to neutral.
Engine will not start (starter operates).
Q. Is fuel tank empty?
A. Fill tank with clean, fresh fuel.
Q. Is fuel contaminated or stale?
55
A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged?
A. Clean or replace filter.
Q. Is starting procedure incorrect?
A. See page 31.
Q. Has fuel pump malfunctioned?
A. Have serviced by a Yamaha dealer.
Q. Are spark plug(s) fouled or of incorrect
type?
A. Inspect spark plug(s). Clean or replace
with recommended type.
Q. Are spark plug cap(s) fitted incorrectly?
A. Check and re-fit cap(s).
Q. Is ignition wiring damaged or poorly connected?
A. Check wires for wear or breaks. Tighten
all loose connections. Replace worn or broken wires.
Q. Are ignition parts faulty?
A. Have serviced by a Yamaha dealer.
Q. Is engine shut-off cord (lanyard) not attached?
A. Attach cord.
Q. Are engine inner parts damaged?
A. Have serviced by a Yamaha dealer.
Engine idles irregularly or stalls.
Q. Are spark plug(s) fouled or of incorrect
type?
A. Inspect spark plug(s). Clean or replace
with recommended type.
Trouble Recovery
Q. Is fuel system obstructed?
A. Check for pinched or kinked fuel line or
other obstructions in fuel system.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged?
A. Clean or replace filter.
Q. Have ignition parts failed?
A. Have serviced by a Yamaha dealer.
Q. Has alert system activated?
A. Find and correct cause of alert.
Q. Is spark plug gap incorrect?
A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly connected?
A. Check wires for wear or breaks. Tighten
all loose connections. Replace worn or broken wires.
A. Return to home position.
Q. Is motor angle too high?
A. Return to normal operating position.
Q. Is carburetor clogged?
A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect?
A. Connect correctly.
Q. Is throttle valve adjustment incorrect?
A. Have serviced by a Yamaha dealer.
Q. Is battery cable disconnected?
A. Connect securely.
Alert buzzer sounds or indicator lights.
Q. Is cooling system clogged?
A. Check water intake for restriction.
Q. Is engine oil level low?
A. Fill oil tank with specified engine oil.
Q. Is specified engine oil not being used?
A. Check and replace oil as specified.
Q. Is heat range of spark plug incorrect?
A. Inspect spark plug and replace it with recommended type.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Are carburetor adjustments incorrect?
A. Have serviced by a Yamaha dealer.
Q. Is engine oil contaminated or deteriorated?
A. Replace oil with fresh, specified type.
Q. Is fuel pump damaged?
A. Have serviced by a Yamaha dealer.
Q. Is air vent screw on fuel tank closed?
A. Open air vent screw.
Q. Is choke knob pulled out?
Q. Is oil filter clogged?
A. Have serviced by a Yamaha dealer.
Q. Has oil feed/injection pump malfunctioned?
A. Have serviced by a Yamaha dealer.
56
Trouble Recovery
Q. Is load on boat improperly distributed?
A. Distribute load to place boat on an even
plane.
on gear housing?
A. Remove foreign matter and clean lower
unit.
Q. Is water pump or thermostat faulty?
A. Have serviced by a Yamaha dealer.
Q. Is fuel system obstructed?
A. Check for pinched or kinked fuel line or
other obstructions in fuel system.
Q. Is there excess water in fuel filter cup?
A. Drain filter cup.
Q. Is fuel filter clogged?
A. Clean or replace filter.
Engine power loss.
Q. Is propeller damaged?
A. Have propeller repaired or replaced.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is propeller pitch or diameter incorrect?
A. Install correct propeller to operate outboard at its recommended speed (r/min)
range.
Q. Is trim angle incorrect?
A. Adjust trim angle to achieve most efficient
operation.
Q. Is motor mounted at incorrect height on
transom?
A. Have motor adjusted to proper transom
height.
Q. Is spark plug gap incorrect?
A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly connected?
A. Check wires for wear or breaks. Tighten
all loose connections. Replace worn or broken wires.
Q. Have electrical parts failed?
A. Have serviced by a Yamaha dealer.
Q. Is specified fuel not being used?
A. Replace fuel with specified type.
Q. Has alert system activated?
A. Find and correct cause of alert.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Is boat bottom fouled with marine growth?
A. Clean boat bottom.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer.
Q. Are spark plug(s) fouled or of incorrect
type?
A. Inspect spark plug(s). Clean or replace
with recommended type.
Q. Is air vent screw closed?
A. Open the air vent screw.
Q. Are weeds or other foreign matter tangled
57
Q. Is fuel pump damaged?
A. Have serviced by a Yamaha dealer.
Trouble Recovery
Q. Is fuel joint connection incorrect?
A. Connect correctly.
Q. Is heat range of spark plug incorrect?
A. Inspect spark plug and replace it with recommended type.
trailering. Damage could make the outboard motor unsafe to operate.
If the outboard motor hits an object in the water, follow the procedure below.
Q. Is high pressure fuel pump drive belt broken?
A. Have serviced by a Yamaha dealer.
Q. Is engine not responding properly to shift
lever position?
A. Have serviced by a Yamaha dealer.
Engine vibrates excessively.
Q. Is propeller damaged?
A. Have propeller repaired or replaced.
Q. Is propeller shaft damaged?
A. Have serviced by a Yamaha dealer.
Q. Are weeds or other foreign matter tangled
on propeller?
A. Remove and clean propeller.
Q. Is motor mounting bolt loose?
A. Tighten bolt.
Q. Is steering pivot loose or damaged?
A. Tighten or have serviced by a Yamaha
dealer.
1.
2.
3.
4.
EMU29533
Starter will not operate
If the starter mechanism does not operate
(the engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.
EWM01022
WARNING
●
EMU29433
Temporary action in
emergency
EMU29440
Impact damage
EWM00870
WARNING
The outboard motor can be seriously
damaged by a collision while operating or
Stop the engine immediately.
Inspect the control system and all components for damage. Also inspect the
boat for damage.
Whether damage is found or not, return
to the nearest harbor slowly and carefully.
Have a Yamaha dealer inspect the outboard motor before operating it again.
●
Use this procedure only in an emergency to return to the nearest port for repairs.
When the emergency starter rope is
used to start the engine, the start-ingear protection device does not operate. Make sure the remote control lever
is in neutral. Otherwise the boat could
unexpectedly start to move, which
58
Trouble Recovery
●
●
●
●
●
●
could result in an accident.
Attach the engine shut-off cord to a secure place on your clothing, or your
arm or leg while operating the boat.
Do not attach the cord to clothing that
could tear loose. Do not route the cord
where it could become entangled, preventing it from functioning.
Avoid accidentally pulling the cord during normal operation. Loss of engine
power means the loss of most steering
control. Also, without engine power,
the boat could slow rapidly. This could
cause people and objects in the boat to
be thrown forward.
Make sure no one is standing behind
you when pulling the starter rope. It
could whip behind you and injure
someone.
An unguarded, rotating flywheel is very
dangerous. Keep loose clothing and
other objects away when starting the
engine. Use the emergency starter rope
only as instructed. Do not touch the flywheel or other moving parts when the
engine is running. Do not install the
starter mechanism or top cowling after
the engine is running.
Do not touch the ignition coil, spark
plug wire, spark plug cap, or other electrical components when starting or operating the motor. You could get an
electrical shock.
ZMU02883
4.
Prepare the engine for starting. For further information, see page 31. Be sure
the engine is in neutral and that the clip
is attached to the engine shut-off switch.
The main switch must be “ ” (on), if
equipped.
ZMU02884
EMU29562
Emergency starting engine
1.
2.
3.
59
Remove the top cowling.
Remove the start-in-gear protection cable from the starter, if equipped.
Remove the starter/flywheel cover after
removing the bolt(s).
5.
If equipped the choke knob, pull out it
when the engine is cold. After the engine
starts, gradually return the choke knob
to its home position as the engine warms
up.
Trouble Recovery
ZMU02860
6.
7.
Insert the knotted end of the emergency
starter rope into the notch in the flywheel
rotor and wind the rope several turns
around the flywheel clockwise.
Give a strong pull straight out to crank
and start the engine. Repeat if necessary.
ZMU02885
EMU33501
Treatment of submerged motor
If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise
some corrosion may begin almost immediately. NOTICE: Do not attempt to run the
outboard motor until it has been completely inspected. [ECM00401]
60
Consumer information
EMU29820
YAMAHA MOTOR CORPORATION, U.S.A.
OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY
61
Consumer information
62
Consumer information
63
Consumer information
EMU29841
IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR
YAMAHA OUTSIDE THE USA OR CANADA
64
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