U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM
E8D
OWNER’S MANUAL
677-28199-20-E0
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM
Read this owner’s manual carefully before operating your outboard motor.
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM
Important manual information
EMU25100
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.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
EWM00780
WARNING
Failure to follow WARNING instructions
could result in severe injury or death to the
machine operator, a bystander, or a person inspecting or repairing the outboard
motor.
ECM00700
CAUTION:
A CAUTION indicates special precautions
that must be taken to avoid damage to the
outboard motor.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
Yamaha continually seeks advancements in
product design and quality. Therefore, while
this manual contains the most current product
information available at the time of printing,
there may be minor discrepancies between
your machine and this manual. If there is any
question concerning this manual, please consult your Yamaha dealer.
NOTE:
The E8DMH 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.
EMU25120
E8D
OWNER’S MANUAL
©2004 by Yamaha Motor Co., Ltd.
1st Edition, February 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM
Table of contents
General information ...................... 1
Identification numbers record ...... 1
Outboard motor serial number ....... 1
EC label....................................... 1
Safety information ....................... 1
Important labels........................... 2
Warning labels................................ 2
Fueling instructions ..................... 3
Gasoline ......................................... 3
Engine oil........................................ 3
Propeller selection....................... 3
Start-in-gear protection ............... 4
Basic components ........................5
Main components........................ 5
Fuel tank......................................... 5
Fuel joint......................................... 6
Fuel tank cap.................................. 6
Air vent screw................................. 6
Tiller handle.................................... 6
Gear shift lever ............................... 6
Throttle grip .................................... 6
Throttle indicator............................. 6
Throttle friction adjuster.................. 7
Engine stop lanyard switch............. 7
Engine stop button ......................... 8
Choke knob for pull type................. 8
Manual starter handle..................... 8
Steering friction adjuster................. 8
Trim rod (tilt pin) ............................. 8
Tilt lock mechanism........................ 9
Tilt support bar ............................... 9
Top cowling lock lever(s)
(turn type).................................... 9
Operation ..................................... 10
Installation ................................. 10
Mounting the outboard motor ....... 10
Clamping the outboard motor....... 11
Breaking in engine .................... 12
Gasoline and engine oil mixing
chart (25:1)................................ 12
Procedure for pre-mixed
models ...................................... 12
Preoperation checks ................. 13
Fuel .............................................. 13
Oil ................................................. 13
Controls ........................................ 13
Engine .......................................... 13
Filling fuel and engine oil .......... 13
Filling fuel for portable tank .......... 13
Gasoline and oil mixing ................ 13
Operating engine ...................... 14
Feeding fuel (portable tank) ......... 14
Starting engine ............................. 15
Warming up engine................... 17
Choke start models ...................... 17
Shifting ...................................... 18
Forward (tiller handle and
remote control models) ............. 18
Reverse (manual tilt and
hydro tilt models)....................... 18
Stopping engine ........................ 19
Procedure..................................... 19
Trimming outboard motor.......... 19
Adjusting trim angle for
manual tilt models ..................... 20
Adjusting boat trim........................ 20
Tilting up and down................... 21
Procedure for tilting up
(manual tilt models)................... 22
Procedure for tilting down
(manual tilt models)................... 23
Cruising in shallow water .......... 23
Cruising in shallow water
(manual tilt models)................... 23
Cruising in other conditions....... 24
Maintenance ................................ 26
Specifications............................ 26
Transporting and storing
outboard motor ...................... 26
Clamp screw mounting models .... 27
Storing outboard motor................. 27
Procedure..................................... 28
U67720E0.book Page 2 Friday, March 26, 2004 10:36 AM
Table of contents
Lubrication
(except oil injection models)...... 29
Cleaning the outboard motor........ 29
Checking painted
surface of motor ........................ 29
Periodic maintenance................ 29
Replacement parts .......................
Maintenance chart........................
Greasing.......................................
Cleaning and adjusting
spark plug .................................
Checking fuel system ...................
Inspecting fuel filter ......................
Cleaning fuel filter.........................
Inspecting idling speed.................
Checking wiring and
connectors ................................
Exhaust leakage...........................
Water leakage ..............................
Checking propeller .......................
Removing the propeller ................
Installing the Propeller..................
Changing gear oil .........................
Cleaning fuel tank.........................
Inspecting and replacing
anode(s)....................................
Checking top cowling ...................
Coating the boat bottom ...............
29
30
31
31
32
33
33
33
34
34
34
34
35
35
36
37
37
38
38
Trouble Recovery ........................ 39
Troubleshooting ........................ 39
Temporary action in
emergency ............................. 42
Impact damage............................. 42
Starter will not operate ................. 42
Emergency starting engine........... 43
Treatment of
submerged motor ................... 44
Procedure..................................... 44
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM
General information
EMU25170
Identification numbers record
EMU25182
Outboard motor serial number
The outboard motor serial number is stamped
on the label attached to the port side of the
clamp bracket or the upper part of the swivel
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. EC label location
ZMU01696
EMU25370
1. Outboard motor serial number location
Safety information
●
●
●
EMU25202
EC label
Engines affixed with this label conform to certain portions of the European Parliament directive relating to machinery. Refer to the
label and the EC Declaration of Conformity for
more details.
1
Before mounting or operating the outboard
motor, read this entire manual. Reading it
should give you an understanding of the
motor and its operation.
Before operating the boat, read any owner’s or operator’s manuals supplied with it
and all labels. Be sure you understand each
item before operating.
Do not overpower the boat with this outboard motor. Overpowering the boat could
result in loss of control. The rated power of
the outboard should be equal to or less than
the rated horsepower capacity of the boat.
If the rated horsepower capacity of the boat
is unknown, consult the dealer or boat manufacturer.
U67720E0.book Page 2 Friday, March 26, 2004 10:36 AM
General information
●
●
●
●
●
●
●
●
●
●
Do not modify the outboard. Modifications
could make the motor unfit or unsafe to use.
Never operate after drinking alcohol or taking drugs. About 50% of all boating fatalities
involve intoxication.
Have an approved personal flotation device
(PFD) on board for every occupant. It is a
good idea to wear a PFD whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and
everyone should wear PFDs when there
are potentially hazardous boating conditions.
Gasoline is highly flammable, and its vapors are flammable and explosive. Handle
and store gasoline carefully. Make sure
there are no gas fumes or leaking fuel before starting the engine.
This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness.
Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.
Check throttle, shift, and steering for proper
operation before starting the engine.
Attach the engine stop switch lanyard to a
secure place on your clothing, or your arm
or leg while operating. If you accidentally
leave the helm, the lanyard will pull from the
switch, stopping the engine.
Know the marine laws and regulations
where you will be boating - and obey them.
Stay informed about the weather. Check
weather forecasts before boating. Avoid
boating in hazardous weather.
Tell someone where you are going: leave a
Float Plan with a responsible person. Be
sure to cancel the Float Plan when you return.
●
●
●
●
Use common sense and good judgment
when boating. Know your abilities, and be
sure you understand how your boat handles under the different boating conditions
you may encounter. Operate within your
limits, and the limits of your boat. Always
operate at safe speeds, and keep a careful
watch for obstacles and other traffic.
Always watch carefully for swimmers during
the engine operation.
Stay away from swimming areas.
When a swimmer is in the water near you
shift into neutral and shut off the engine.
EMU25380
Important labels
EMU25395
Warning labels
EMU25401
Label
EWM01260
WARNING
●
●
●
Be sure shift control is in neutral before
starting engine. (except 2HP)
Do not touch or remove electrical parts
when starting or during operation.
Keep hands, hair, and clothes away from
flywheel and other rotating parts while
engine is running.
2
U67720E0.book Page 3 Friday, March 26, 2004 10:36 AM
General information
EMU25431
EMU30330
Label
Gasoline
EWM01300
WARNING
●
●
This engine is equipped with a neutral
starting device.
The engine will not start unless the shift
control is in neutral position.
EMU25540
Fueling instructions
EWM00010
WARNING
GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE!
● Do not smoke when refueling, and keep
away from sparks, flames, or other
sources of ignition.
● Stop engine before refueling.
● Refuel in a well-ventilated area. Refuel
portable fuel tanks off the boat.
● Take care not to spill gasoline. If gasoline spills, wipe it up immediately with
dry rags.
● Do not overfill the fuel tank.
● Tighten the filler cap securely after refueling.
● If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical
attention.
● If any gasoline spills onto your skin, immediately wash with soap and water.
Change clothing if gasoline spills on it.
● Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
ECM00010
CAUTION:
Use only new clean gasoline which has
been stored in clean containers and is not
contaminated with water or foreign matter.
3
Recommended gasoline:
Regular unleaded gasoline
If knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel. If
unleaded gasoline is not available, then premium gasoline can be used.
EMU25650
Engine oil
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.
EMU25741
Propeller selection
The performance of your outboard motor will
be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously
damage the motor. Engine speed depends on
the propeller size and boat load. If engine
speed is too high or too low for good engine
performance, this will have an adverse effect
on the engine.
Yamaha outboard motors are fitted with propellers chosen to perform well over a range of
applications, but there may be uses where a
propeller with a different pitch would be more
appropriate. For a greater operating load, a
smaller-pitch propeller is more suitable as it
enables the correct engine speed to be maintained. Conversely, a larger-pitch propeller is
more suitable for a smaller operating load.
Yamaha dealers stock a range of propellers,
and can advise you and install a propeller on
your outboard that is best suited to your application.
U67720E0.book Page 4 Friday, March 26, 2004 10:36 AM
General information
1
x
1
2 3
ZMU04604
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
ZMU01713
1. Start-in-gear protection label
NOTE:
Select a propeller which will allow the engine
to reach the middle or upper half of the operating range at full throttle with the maximum
boat load. If operating conditions such as light
boat loads then allow the engine r/min to rise
above the maximum recommended range, reduce the throttle setting to maintain the engine in the proper operating range.
For instructions on propeller removal and installation, see page 34.
EMU25760
Start-in-gear protection
Yamaha outboard motors affixed with the pictured label 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.
4
U67720E0.book Page 5 Friday, March 26, 2004 10:36 AM
Basic components
EMU25795
Main components
NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all models.
1.
2.
3.
4.
Manual starter handle
Tiller handle
Choke knob
Engine stop button/Engine stop lanyard
switch
5. Tilt lock lever
6. Clamp screw
7. Trim rod
8. Propeller
9. Cooling water inlet
10.Anti-cavitation plate
11.Clamp bracket
12.Rope attachment
13.Gear shift lever
14.Top cowling
15.Fuel tank
5
EMU25802
Fuel tank
If your model was equipped with a portable
fuel tank, its function is as follows.
EWM00020
WARNING
The fuel tank supplied with this engine is
its dedicated fuel reservoir and must not
be used as a fuel storage container. Commercial users should conform to relevant
licensing or approval authority regulations.
U67720E0.book Page 6 Friday, March 26, 2004 10:36 AM
Basic components
EMU25922
Gear shift lever
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.
1. Fuel joint
2. Fuel tank cap
3. Air vent screw
EMU25830
Fuel joint
This joint is used to connect the fuel line.
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
Air vent screw
This screw is on the fuel tank cap. To loosen
the screw, turn it counterclockwise.
EMU25911
1. Forward “ ”
2. Neutral “ ”
3. Reverse “ ”
EMU25941
Throttle grip
The throttle grip is on the tiller handle. Turn
the grip counterclockwise to increase speed
and clockwise to decrease speed.
Tiller handle
To change direction, move the tiller handle to
the left or right as necessary.
EMU25961
Throttle indicator
The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the
setting that offers the best performance and
fuel economy for the desired operation.
6
U67720E0.book Page 7 Friday, March 26, 2004 10:36 AM
Basic components
EMU25990
Engine stop lanyard switch
The lock plate must be attached to the engine
stop switch for the engine to run. The lanyard
should be attached to a secure place on the
operator’s clothing, or arm or leg. Should the
operator fall overboard or leave the helm, the
lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat
from running away under power.
1. Throttle indicator
EWM00120
WARNING
EMU25970
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.
EWM00030
WARNING
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to move throttle lever or grip,
which could result in an accident.
●
●
●
Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg while operating.
Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entangled, preventing it from functioning.
Avoid accidentally pulling the lanyard
during normal operation. Loss of engine
power means the loss of most steering
control. Also, without engine power, the
boat could slow rapidly. This could
cause people and objects in the boat to
be thrown forward.
NOTE:
The engine cannot be started with the lock
plate removed.
When constant speed is desired, tighten the
adjuster to maintain the desired throttle setting.
1. Lock plate
2. Lanyard
7
U67720E0.book Page 8 Friday, March 26, 2004 10:36 AM
Basic components
EMU26001
Engine stop button
To open the ignition circuit and stop the engine, push this button.
EMU26122
Steering friction adjuster
EMU26011
Choke knob for pull type
To supply the engine with the rich fuel mixture
required to start, pull out this knob.
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.
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.
To increase resistance, turn the adjuster
clockwise.
To decrease resistance, turn the adjuster
counterclockwise.
EWM00040
WARNING
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to steer, which could result in an
accident.
EMU26261
Trim rod (tilt pin)
The position of the trim rod determines the
minimum trim angle of the outboard motor in
relation to the transom.
8
U67720E0.book Page 9 Friday, March 26, 2004 10:36 AM
Basic components
EMU30460
EMU26372
Tilt lock mechanism
Top cowling lock lever(s) (turn type)
The tilt lock mechanism is used to prevent the
outboard motor from lifting out of the water
when in reverse gear.
To remove the engine top cowling, turn the
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 lever(s) to the
lock position.
1. Tilt lock lever
To lock it, set the tilt lock lever in the “
”
(lock) position. To release, push the tilt lock lever in the “
” (release) position.
EMU26330
Tilt support bar
The tilt support bar keeps the outboard motor
in the tilted up position.
9
1. Top cowling lock lever(s)
U67720E0.book Page 10 Friday, March 26, 2004 10:36 AM
Operation
EMU26901
EWM00830
Installation
ECM00110
CAUTION:
Incorrect engine height or obstructions to
smooth water flow (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. Severe engine
damage may result if the motor is operated continuously in the presence of airborne water spray.
NOTE:
During water testing check the buoyancy of
the boat, at rest, with its maximum load.
Check that the static water level on the exhaust housing is low enough to prevent water
entry into the powerhead, when water rises
due to waves when the outboard is not running.
EMU26910
WARNING
Improper mounting of the outboard motor
could result in hazardous conditions such
as poor handling, loss of control, or fire
hazards. Observe the following:
● For permanently mounted models, your
dealer or other person experienced in
proper rigging should mount the motor.
If you are mounting the motor yourself,
you should be trained by an experienced
person.
● For portable models, your dealer or other person experienced in proper outboard motor mounting should show you
how to mount your motor.
Mount the outboard motor on the center line
(keel line) of the boat, and ensure that the
boat itself is well balanced. Otherwise the
boat will be hard to steer. For boats without a
keel or which are asymmetrical, consult your
dealer.
Mounting the outboard motor
EWM00820
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.
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.
1
ZMU01760
1. Center line (keel line)
EMU26920
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
10
U67720E0.book Page 11 Friday, March 26, 2004 10:36 AM
Operation
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.
0–25mm
(0–1in.)
●
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.
ZMU02011
NOTE:
●
EWM00640
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 19.
ZMU02012
2.
If the engine restraint cable attachment is
equipped on your engine, an engine restraint cable or chain should be used. Attach one end to the engine 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.
EMU26970
Clamping the outboard motor
1.
11
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.
ZMU02013
U67720E0.book Page 12 Friday, March 26, 2004 10:36 AM
Operation
3.
Secure the clamp bracket to the transom
using the bolts provided with the outboard (if packed). For details, consult
your Yamaha dealer.
ECM00150
CAUTION:
Be sure to mix gasoline and oil completely, otherwise the engine may be damaged.
EWM00650
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.
EMU30172
Breaking in engine
Your new engine requires a period of break-in
to allow mating surfaces of moving parts to
wear in evenly. Correct break-in will help ensure proper performance and longer engine
life.
ECM00800
CAUTION:
Failure to follow the break-in procedure
could result in reduced engine life or even
severe engine damage.
EMU27050
Gasoline and engine oil mixing chart
(25:1)
1.
2.
: Gasoline
: Engine oil
EMU27073
Procedure for pre-mixed models
Run the engine under load (in gear with a propeller installed) as follows.
1. First 10 minutes:
Run the engine at the lowest possible
speed. A fast idle in neutral is best.
2. Next 50 minutes:
Do not exceed half throttle (approximately 3000 r/min). Vary engine speed occasionally. If you have an easy-planing
boat, accelerate at full throttle onto plane,
then immediately reduce the throttle to
3000 r/min or less.
3. Second hour:
Accelerate at full throttle onto plane, then
reduce engine speed to three-quarter
throttle (approximately 4000 r/min). Vary
engine speed occasionally. Run at full
throttle for one minute, then allow about
10 minutes of operation at three-quarter
throttle or less to let the engine cool.
4. Third through tenth hours:
Avoid operating at full throttle for more
than 5 minutes at a time. Let the engine
cool between full-throttle runs. Vary engine speed occasionally.
5. After the first 10 hours:
Operate the engine normally. Use the
standard premix ratio of gasoline and oil.
For details on mixing fuel and oil, see
page 13.
12
U67720E0.book Page 13 Friday, March 26, 2004 10:36 AM
Operation
EMU27101
EMU27140
Preoperation checks
EWM00080
WARNING
If any item in the preoperation check is not
working properly, have it inspected and
repaired before operating the outboard
motor. Otherwise an accident could occur.
Engine
●
●
●
Check the engine and engine mounting.
Look for loose or damaged fasteners.
Check the propeller for damage.
EMU27233
Filling fuel and engine oil
EMU27242
Filling fuel for portable tank
EWM00060
ECM00120
CAUTION:
Do not start the engine out of water. Overheating and serious engine damage can
occur.
WARNING
Gasoline and its vapors are highly flammable and explosive. Keep away from
sparks, cigarettes, flames, or other sources of ignition.
EMU27110
Fuel
●
●
●
●
Check to be sure you have plenty of fuel for
your trip.
Make sure there are no fuel leaks or gasoline fumes.
Check fuel line connections to be sure they
are tight (if equipped Yamaha fuel tank or
boat tank).
Be sure the fuel tank is positioned on a secure, flat surface, and that the fuel line is not
twisted or flattened, or likely to contact
sharp objects (if equipped Yamaha fuel
tank or boat tank).
EMU27120
Oil
●
Check to be sure you have plenty of oil for
your trip.
EMU27130
Controls
●
●
●
●
Check throttle, shift, and steering for proper
operation before starting the engine.
The controls should work smoothly, without
binding or unusual free play.
Look for loose or damaged connections.
Check operation of the starter and stop
switches when the outboard motor is in the
water.
13
1.
2.
3.
Remove the fuel tank cap.
Fill the fuel tank carefully.
Close the cap securely after refueling.
Wipe up any spilled fuel.
Fuel tank capacity (if equipped Yamaha
fuel tank):
24.0 L (6.34 US gal) (5.28 Imp.gal)
EMU27392
Gasoline and oil mixing
Gasoline to engine oil
ratio
Break-in period
After break-in
25:1
50:1
If equipped with a portable fuel tank
1. Pour oil into the portable fuel tank, and
then add gasoline.
U67720E0.book Page 14 Friday, March 26, 2004 10:36 AM
Operation
ECM00810
CAUTION:
●
●
●
●
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.
NOTE:
If using a permanently installed tank, pour the
oil gradually as the gasoline is being added to
the tank.
1. Engine oil
2. Gasoline
2.
Replace the fuel tank cap and close tightly.
3. 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.
EMU27450
Operating engine
EMU27461
Feeding fuel (portable tank)
EWM00420
WARNING
●
●
●
Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.
When the air vent screw is loosened,
gasoline vapor will be released. Gasoline is highly flammable, and its vapors
are flammable and explosive. Refrain
from smoking, and keep away from
open flames and sparks while loosening
the air vent screw.
This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which could cause brain
damage or death when inhaled. Symptoms include nausea, dizziness, and
14
U67720E0.book Page 15 Friday, March 26, 2004 10:36 AM
Operation
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.
3.
If a steering friction adjuster is provided
on your outboard motor, securely attach
the fuel line to the fuel line clamp.
NOTE:
During engine operation place the tank horizontally, otherwise fuel cannot be drawn from
the fuel tank.
4.
Squeeze the primer pump with the outlet
end up until you feel it become firm.
ZMU02295
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.
ZMU02025
EMU27490
Starting engine
EMU27505
Manual start models (tiller control)
1. Place the gear shift lever in neutral.
NOTE:
The start-in-gear protection device prevents
the engine from starting except when in neutral.
ZMU02024
15
U67720E0.book Page 16 Friday, March 26, 2004 10:36 AM
Operation
2.
Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg. Then install the lock plate on
the other end of the lanyard into the engine stop switch.
EWM00120
WARNING
●
●
●
Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg while operating.
Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entangled, preventing it from functioning.
Avoid accidentally pulling the lanyard
during normal operation. Loss of engine
power means the loss of most steering
control. Also, without engine power, the
boat could slow rapidly. This could
cause people and objects in the boat to
be thrown forward.
4.
Pull out / turn the choke knob fully. After
the engine starts, replace / return the
knob to the home position.
NOTE:
●
●
5.
3.
Place the throttle grip in the “
(start) position.
”
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.
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.
16
U67720E0.book Page 17 Friday, March 26, 2004 10:36 AM
Operation
EMU27670
Warming up engine
EMU27680
Choke start models
1.
2.
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.
ZMU02030
NOTE:
●
●
When the engine is cold, it needs to be
warmed up. For further information, see
page 17.
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 39.
17
After starting the engine, allow it to idle for
3 minutes to warm up. Failure to do so will
shorten engine life. Gradually return the
choke knob to its home position as the
engine warms up.
Check for a steady flow of water from the
cooling water pilot hole.
ECM00510
CAUTION:
A flow of water from the hole on the exhaust cover shows that the water pump is
pumping water through the cooling passages. If water is not flowing out of the
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.
U67720E0.book Page 18 Friday, March 26, 2004 10:36 AM
Operation
EMU27740
Shifting
EWM00180
WARNING
Before shifting, make sure there are no
swimmers or obstacles in the water near
you.
Remote control models
Pull up the neutral interlock trigger (if
equipped) and move the remote control lever
quickly and firmly from neutral to forward.
EMU27795
Reverse (manual tilt and hydro tilt
models)
EWM00190
ECM00220
WARNING
CAUTION:
To change the boat direction or shifting
position from forward to reverse or viceversa, first close the throttle so that the engine idles (or runs at low speeds).
EMU27763
Forward (tiller handle and remote
control models)
Tiller control models
1. Place the throttle grip in the fully closed
position.
When operating in reverse, go slowly. Do
not open the throttle more than half. Otherwise the boat could become unstable,
which could result in loss of control and
an accident.
Tiller control models
1. Place the throttle grip in the fully closed
position.
ZMU02030
2.
On models equipped with a tilt lock lever,
check that it is in the lock/down position.
3.
Move the gear shift lever quickly and firmly from neutral to reverse.
ZMU02030
2.
Move the gear shift lever quickly and firmly from neutral to forward.
18
U67720E0.book Page 19 Friday, March 26, 2004 10:36 AM
Operation
ZMU02301
Remote control models
1. Check that the tilt lock lever is in the lock
position.
2. Pull up the neutral interlock trigger (if
equipped) and move the remote control
lever quickly and firmly from neutral to reverse.
3.
Disconnect the fuel line if you are using
an external fuel tank.
EMU27820
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.
EMU27832
Procedure
1.
Push and hold the engine stop button until the engine comes to a complete stop.
NOTE:
If the outboard motor is equipped with an engine stop switch lanyard, the engine can also
be stopped by pulling the lanyard and removing the lock plate from the engine stop switch.
EMU27861
Trimming outboard motor
2.
19
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.
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.
U67720E0.book Page 20 Friday, March 26, 2004 10:36 AM
Operation
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.
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
●
●
●
1
ZMU02043
1. Trim operating angle
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.
EMU27871
Adjusting trim angle for manual tilt
models
NOTE:
There are 4 or 5 holes provided in the clamp
bracket to adjust the outboard motor trim angle.
1. Stop the engine.
2. Remove the trim rod from the clamp
bracket while slightly tilting the outboard
motor up.
EMU27911
The outboard motor trim angle can be
changed approximately 4 degrees by shifting
the trim rod one hole.
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
20
U67720E0.book Page 21 Friday, March 26, 2004 10:36 AM
Operation
bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can
also be adjusted to help offset this effect.
When the bow of the boat is down, it is easier
to accelerate from a standing start onto plane.
also makes the boat unstable. Resistance at
the bow is greatly increased, heightening the
danger of “bow steering” and making operation difficult and dangerous.
NOTE:
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.
Depending on the type of boat, the outboard
motor trim angle may have little effect on the
trim of the boat when operating.
EMU27920
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 casing from damage by collision with
obstructions, and also to reduce salt corrosion.
EWM00220
WARNING
Be sure all people are clear of the outboard motor when tilting up and down,
also be careful not to pinch any body parts
between the drive unit and engine bracket.
EWM00230
WARNING
Bow Down
Too much trim-in causes the boat to “plow”
through the water, decreasing fuel economy
and making it hard to increase speed. Operating with excessive trim-in at higher speeds
21
Leaking fuel is a fire hazard. Tighten the
air vent screw and place the fuel cock in
the closed position if the outboard motor
will be tilted for more than a few minutes.
Otherwise fuel may leak.
U67720E0.book Page 22 Friday, March 26, 2004 10:36 AM
Operation
ECM00230
CAUTION:
●
●
●
●
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).
3.
Place the tilt lock lever (if equipped) in the
release/up position.
4.
Pull up the shallow water lever (if
equipped).
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.
EMU27975
Procedure for tilting up (manual tilt
models)
1.
Place the gear shift lever in neutral.
5.
6.
2.
Disconnect the fuel line from the outboard motor.
22
U67720E0.book Page 23 Friday, March 26, 2004 10:36 AM
Operation
EMU28031
Procedure for tilting down (manual tilt
models)
1.
2.
Slightly tilt the outboard motor up.
If the tilt support bar equipped: Slowly tilt
the outboard motor down while pulling
the tilt support bar lever up.
●
●
●
3.
If the tilt support knob equipped: pull out
it, then slowly tilt the engine down.
Loosen the steering friction adjuster by
turning it counterclockwise, and adjust
the steering friction according to operator
preference.
4.
EWM00720
WARNING
If there is too much resistance it could be
difficult to steer, which could result in an
accident.
nism 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
the water, resulting in loss of control.
Do not rotate the outboard motor 180°
and operate the boat in reverse. Place
the gear shift in reverse to operate the
boat in reverse.
Use extra care when operating in reverse. Too much reverse thrust can
cause the outboard motor to lift out of
the water, increasing the chance of accident and personal injury.
Return the outboard motor to its normal
position as soon as the boat is back in
deeper water.
ECM00260
CAUTION:
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.
EMU28060
Cruising in shallow water
The outboard motor can be tilted up partially
to allow operation in shallow water.
EMU28071
Cruising in shallow water (manual tilt
models)
EWM00710
WARNING
●
●
Place the gear shift in neutral before using the shallow water cruising system.
Run the boat at the lowest possible
speed when using the shallow water
cruising system. The tilt lock mecha-
23
EMU30450
Procedure
1. Place the gear shift lever in neutral.
U67720E0.book Page 24 Friday, March 26, 2004 10:36 AM
Operation
2.
3.
4.
To return the outboard motor to the normal running position, place the gear shift
lever in neutral, then place the tilt lock lever in the lock position.
5.
Slightly tilt the outboard motor up. Slowly
tilt the outboard motor down while pulling
the tilt support bar lever up.
6.
Slowly lower the outboard motor to the
normal position.
Place the tilt lock lever in the release position.
Slightly tilt the outboard motor up. The tilt
support bar will lock automatically, supporting the outboard motor in a partially
raised position.
EMU28190
Cruising in other conditions
Cruising in salt water
After operating in salt water, wash out the
cooling water passages with fresh water to
prevent them from becoming clogged with salt
deposits.
NOTE:
The outboard motor is equipped with 2 or 3
positions for shallow water cruising.
NOTE:
For cooling system flushing instructions, see
page 26.
24
U67720E0.book Page 25 Friday, March 26, 2004 10:36 AM
Operation
Cruising in turbid water
Yamaha strongly recommends that you use
the optional chromium-plated water pump kit
if you use the outboard motor in turbid (muddy) water conditions.
25
U67720E0.book Page 26 Friday, March 26, 2004 10:36 AM
Maintenance
EMU28215
Specifications
Drive unit:
Gear positions:
Forward-neutral-reverse
Gear ratio:
2.08 (27/13)
Trim and tilt system:
Manual tilt
Propeller mark:
C
Dimension:
Overall length:
718 mm (28.3 in)
Overall width:
328 mm (12.9 in)
Overall height S:
1044 mm (41.1 in)
Overall height L:
1184 mm (46.6 in)
Transom height S:
442 mm (17.4 in)
Transom height L:
582 mm (22.9 in)
Weight (AL) S:
28.0 kg (62 lb)
Weight (AL) L:
29.0 kg (64 lb)
Fuel and oil:
Recommended fuel:
Unleaded regular gasoline
Fuel tank capacity:
24.0 L (6.34 US gal) (5.28 Imp.gal)
Recommended engine oil:
YAMALUBE 2-stroke outboard motor oil
Fuel:oil ratio:
Regular gasoline:
50 :1
Lubrication:
Pre-mixed fuel and oil
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
230.0 cm³ (7.78 US oz) (8.11 Imp.oz)
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):
1250 ±50 r/min
Tightening torque for engine:
Engine:
Type:
2-stroke L
Displacement:
165.0 cm³ (10.07 cu.in)
Bore × stroke:
50.0 × 42.0 mm (1.97 × 1.65 in)
Ignition system:
CDI
Spark plug (NGK):
B7HS-10
Spark plug with resistor (NGK):
BR7HS-10
Spark plug gap:
0.9–1.0 mm (0.035–0.039 in)
Control system:
Tiller
Starting system:
Manual
Starting carburetion system:
Choke valve
Spark plug:
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
EMU28222
Transporting and storing
outboard motor
EWM00690
WARNING
●
●
●
Leaking fuel is a fire hazard. When transporting and storing the outboard motor,
close the air vent screw and fuel cock to
prevent fuel from leaking.
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.
26
U67720E0.book Page 27 Friday, March 26, 2004 10:36 AM
Maintenance
EWM00700
WARNING
Never get under the lower unit while it is
tilted, even if a motor support bar is used.
Severe injury could occur if the outboard
motor accidentally falls.
ECM00660
CAUTION:
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.
EMU28235
Clamp screw mounting models
When transporting or storing the outboard
motor while removed from a boat, keep the
outboard motor in the attitude shown.
NOTE:
Place a towel or something similar under the
outboard motor to protect it from damage.
EMU30272
Storing outboard motor
When storing your Yamaha outboard motor
for prolonged periods of time (2 months or
longer), several important procedures must
be performed to prevent excessive damage.
It is advisable to have your outboard motor
serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a
minimum of tools, can perform the following
procedures.
ECM01411
CAUTION:
●
●
27
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.
U67720E0.book Page 28 Friday, March 26, 2004 10:36 AM
Maintenance
5.
EMU28301
Procedure
Cooling system flushing is essential to
prevent the cooling system from clogging
up with salt, sand, or dirt. In addition, fogging/lubricating of the engine is mandatory to prevent excessive engine damage
due to rust. Perform the flushing and fogging at the same time.
EMU28332
Flushing in a test tank
ECM00300
CAUTION:
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.
3.
4.
Wash the outboard motor body using
fresh water. For further information, see
page 29.
Disconnect the fuel line from the motor or
shut off the fuel cock, if equipped.
Remove the engine top cowling and silencer cover. Remove the propeller.
Install the outboard motor on the test
tank. Fill the tank with fresh water to
above the level of the anti-cavitation
plate.
EWM00090
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.
6.
7.
8.
1
2
ZMU02051
1. Water surface
2. Lowest water level
9.
10.
11.
12.
ECM00290
CAUTION:
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.
13.
Run the engine at a fast idle for a few
minutes in neutral position.
Just prior to turning off the engine, quickly
spray “Fogging Oil” alternately into each
carburetor or the fogging hole of the silencer cover, if equipped. When properly
done, the engine will smoke excessively
and almost stall.
Remove the outboard motor from the test
tank.
Install the silencer cover/cap of fogging
hole and top cowling.
If the “Fogging Oil” is not available, run
the engine at a fast idle until the fuel system becomes empty and the engine
stops.
Drain the cooling water completely out of
the motor. Clean the body thoroughly.
If the “Fogging Oil” is not available, remove the spark plug(s). Pour a teaspoonful of clean engine oil into each cylinder.
Crank several times manually. Replace
the spark plug(s).
Drain the fuel from the fuel tank.
28
U67720E0.book Page 29 Friday, March 26, 2004 10:36 AM
Maintenance
EMU28460
NOTE:
Checking painted surface of motor
Store the fuel tank in a dry, well-ventilated
place, not in direct sunlight.
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.
EMU28400
Lubrication (except oil injection
models)
1.
2.
3.
Grease the spark plug threads and install
the spark plug(s) and torque to proper
specification. For information on spark
plug installation, see page 31.
Change the gear oil. For instructions, see
page 36. 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 31.
EMU28450
Cleaning the outboard motor
After use, wash the exterior of the outboard
motor with fresh water. Flush the cooling system with fresh water.
NOTE:
For cooling system flushing instructions, see
page 26.
29
EMU28474
Periodic maintenance
EWM01070
WARNING
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If you or the owner is not familiar with machine servicing, this work
should be done by your Yamaha dealer or
other qualified mechanic.
EMU28510
Replacement parts
If replacement parts are necessary, use only
genuine Yamaha parts or parts of the same
type and of equivalent strength and materials.
Any part of inferior quality may malfunction,
and the resulting loss of control could endanger the operator and passengers. Yamaha
genuine parts and accessories are available
from your Yamaha dealer.
U67720E0.book Page 30 Friday, March 26, 2004 10:36 AM
Maintenance
EMU28521
Maintenance chart
Frequency of maintenance operations may be adjusted according to the operating conditions,
but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action.
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) (internal)
Actions
Every
10 hours
50 hours 100 hours 200 hours
(1 month) (3 months) (6 months) (1 year)
Inspection /
replacement
Inspection /
replacement
Cooling water
passages
Cleaning
Cowling clamp
Inspection
Fuel filter (can be
disassembled)
Inspection / cleaning
Fuel system
Inspection
Fuel tank (Yamaha
portable tank)
Inspection / cleaning
Gear oil
Change
Greasing points
Greasing
Idling speed
(carburetor models)
Inspection / adjustment
Propeller and cotter pin
Inspection /
replacement
Shift link / shift cable
Inspection / adjustment
Throttle link / throttle
cable / throttle pick-up
timing
Inspection / adjustment
Water pump
Inspection
Spark plug(s)
Cleaning / adjustment /
replacement
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean
water after each use.
30
U67720E0.book Page 31 Friday, March 26, 2004 10:36 AM
Maintenance
EMU28940
Greasing
Yamaha grease A (water resistant grease)
Yamaha grease D (corrosion resistant grease; for propeller shaft)
EMU28951
Cleaning and adjusting spark plug
EWM00560
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.
31
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
U67720E0.book Page 32 Friday, March 26, 2004 10:36 AM
Maintenance
should periodically remove and inspect the
spark plug because heat and deposits will
cause the spark plug to slowly break down
and erode. If electrode erosion becomes excessive, or if carbon and other deposits are
excessive, you should replace the spark plug
with another of the correct type.
Standard spark plug:
B7HS-10
BR7HS-10
Before fitting the spark plug, measure the
electrode gap with a wire thickness gauge;
adjust the gap to specification if necessary.
tight. Have the spark plug adjusted to the correct torque as soon as possible with a torquewrench.
EMU28962
Checking fuel system
EWM00060
WARNING
Gasoline and its vapors are highly flammable and explosive. Keep away from
sparks, cigarettes, flames, or other sources of ignition.
EWM00910
WARNING
Leaking fuel can result in fire or explosion.
● Check for fuel leakage regularly.
● If any fuel leakage is found, the fuel system must be repaired by a qualified mechanic. Improper repairs can make the
outboard unsafe to operate.
Check the fuel lines for leaks, crack, or malfunction. If a problem is found, your Yamaha
dealer or other qualified mechanic should repair it immediately.
1. Spark plug gap
2. Spark plug I.D. mark (NGK)
Spark plug gap:
0.9–1.0 mm (0.035–0.039 in)
When fitting the plug, always clean the gasket
surface and use a new gasket. Wipe off any
dirt from the threads and screw in the spark
plug to the correct torque.
Spark plug torque:
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
NOTE:
If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of the
correct torque is 1/4 to 1/2 a turn past finger-
Checkpoints
● Fuel system parts leakage
● Fuel line joint leakage
● Fuel line cracks or other damage
● Fuel connector leakage
32
U67720E0.book Page 33 Friday, March 26, 2004 10:36 AM
Maintenance
EMU28980
Inspecting fuel filter
3.
Remove the filter element, and wash it in
solvent. Allow it to dry. Inspect the filter element and O-ring to make sure they are
in good condition. Replace them if necessary. If any water is found in the fuel, the
Yamaha portable fuel tank or other fuel
tanks should be checked and cleaned.
EWM00310
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.
● Do not perform this procedure on a hot
or running engine. Allow the engine to
cool.
● There will be fuel in the fuel filter. Keep
away from sparks, cigarettes, flames or
other sources of ignition.
● This procedure will allow some fuel to
spill. Catch fuel in a rag. Wipe up any
spilled fuel immediately.
● The fuel filter must be reassembled
carefully with the O-ring, filter cup, and
hoses in place. Improper assembly or
replacement could result in a fuel leak,
which could result in a fire or explosion
hazard.
1.
2.
3.
4.
4.
EMU29001
Cleaning fuel filter
1.
5.
Remove the nut holding the fuel filter assembly if equipped.
6.
Filter cup
Filter element
O-ring
Filter housing
Reinstall the filter element in the cup.
Make sure the O-ring is in position in the
cup. Firmly screw the cup onto the filter
housing.
Attach the filter assembly to the bracket
so that the fuel hoses are attached to the
filter assembly.
Run the engine and check the filter and
lines for leaks.
EMU29040
Inspecting idling speed
EWM00450
WARNING
●
●
2.
33
Unscrew the filter cup, catching any
spilled fuel in a rag.
●
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.
2-hp models: The propeller rotates
whenever the engine is running. Do not
move the throttle control lever from the
U67720E0.book Page 34 Friday, March 26, 2004 10:36 AM
Maintenance
start position during warm-up. The boat
could unexpectedly start to move, which
could result in an accident.
ECM00490
CAUTION:
This procedure must be performed while
the outboard motor is in the water. A flushing attachment or test tank can be used.
A diagnostic tachometer should be used 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-hp model: Warm the engine with the
throttle in the start position or less. If the
outboard is mounted on a boat, be sure
the boat is tightly moored.
NOTE:
Correct idling speed inspection is only possible if the engine is fully warmed up. If not
warmed up fully, the idle speed will measure
higher than normal. If you have difficulty verifying the idle speed, or the idle speed requires
adjustment, consult a Yamaha dealer or other
qualified mechanic.
2.
EMU29120
Exhaust leakage
Start the engine and check that no exhaust
leaks from the joints between the exhaust
cover, cylinder head, and body cylinder.
EMU29130
Water leakage
Start the engine and check that no water
leaks from the joints between the exhaust
cover, cylinder head, and body cylinder.
EMU29171
Checking propeller
EWM00321
WARNING
You could be seriously injured if the engine accidentally starts when you are near
the propeller.
● Before inspecting, removing, or installing the propeller, remove the spark plug
caps from the spark plugs. Also, place
the shift control in neutral, turn the main
switch to “
” (off) and remove the key,
and remove the lanyard from the engine
stop switch. Turn off the battery cut-off
switch if your boat has one.
● 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.
Verify whether the idle speed is set to
specification. For idle speed specifications, see page 26.
EMU29111
Checking wiring and connectors
●
●
Check that each grounding wire is properly
secured.
Check that each connector is engaged securely.
ZMU01896
Checkpoints
34
U67720E0.book Page 35 Friday, March 26, 2004 10:36 AM
Maintenance
●
●
●
●
Check each of the propeller blades for
wear, erosion from cavitation or ventilation,
or other damage.
Check the propeller shaft for damage.
Check the splines / shear pin for wear or
damage.
Check for fish line tangled around the propeller shaft.
1. Cotter pin
2. Propeller
3. Shear pin
2.
3.
Remove the propeller nut and washer, if
equipped.
Remove the shear pin and the propeller.
EMU30381
Installing the Propeller
ECM00500
●
Check the propeller shaft oil seal for damage.
NOTE:
If the shear pin equipped: it is designed to
break if the propeller hits a hard underwater
obstacle to help protect the propeller and
drive mechanism. The propeller will then spin
freely on the shaft. If this happens, the shear
pin must be replaced.
CAUTION:
Be sure to use a new cotter pin and bend
the ends over securely. Otherwise the propeller could come off during operation and
be lost.
1.
2.
EMU29180
Removing the propeller
1.
Straighten the cotter pin and pull it out using a pair of pliers.
3.
4.
5.
Apply Yamaha Marine grease or Corrosion resistant grease to the propeller
shaft.
Insert the shear pin into the hole in the
propeller shaft.
Align the shear pin with the groove in the
propeller boss, and slide the propeller
over the propeller shaft.
Tighten the propeller nut until there is no
forward-and-backward movement.
Align the propeller nut hole with the propeller shaft hole.
NOTE:
When the propeller nut does not align with the
propeller shaft hole after tightening it, loosen
the nut to align it with the hole.
35
U67720E0.book Page 36 Friday, March 26, 2004 10:36 AM
Maintenance
6.
Insert a new cotter pin in the holes, and
then bend the cotter pin ends.
ZMU02714
NOTE:
There is a holder on the bottom cowling for
spare shear and cotter pins. Be sure to replace any used pins.
EMU29280
1. Gear oil drain screw
2. Oil level plug
NOTE:
If the magnetic gear oil drain screw equipped:
remove all metal particles from the screw before installing it.
4.
Changing gear oil
EWM00800
WARNING
●
●
1.
2.
3.
Be sure the outboard motor is securely
fastened to the transom or a stable
stand. You could be severely injured if
the outboard motor falls on you.
Never get under the lower unit while it is
tilted, even when the tilt support lever or
knob is locked. Severe injury could occur if the outboard motor accidentally
falls.
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.
Remove the oil level plug to allow the oil
to drain completely.
ECM00710
CAUTION:
Inspect the used oil after it has been
drained. If the oil is milky, water is getting
into the gear case which can cause gear
damage. Consult a Yamaha dealer for repair of the lower unit seals.
NOTE:
For disposal of used oil consult your Yamaha
dealer.
5.
With the outboard motor in a vertical position, and 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:
230.0 cm³ (7.78 US oz) (8.11 Imp.oz)
36
U67720E0.book Page 37 Friday, March 26, 2004 10:36 AM
Maintenance
2.
3.
6.
7.
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.
When the oil begins to flow out of the oil
level plug hole, insert and tighten the oil
level plug.
Insert and tighten the gear oil drain
screw.
ZMU02324
EMU29302
Cleaning fuel tank
EWM00920
4.
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.
37
Empty the fuel tank into an approved container.
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.
EMU29312
Inspecting and replacing anode(s)
Yamaha outboard motors are protected from
corrosion by sacrificial anodes. Inspect the
external anodes periodically. Remove scales
from the surfaces of the anodes. Consult a
Yamaha dealer for replacement of external
anodes.
ECM00720
CAUTION:
Do not paint anodes, as this would render
them ineffective.
NOTE:
Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha
dealer for inspection and replacement of internal anodes attached to the power unit.
U67720E0.book Page 38 Friday, March 26, 2004 10:36 AM
Maintenance
EMU29390
Checking top cowling
Check the fitting of the top cowling by pushing
it with both hands. If it is loose have it repaired
by your Yamaha dealer.
EMU29400
Coating the boat bottom
A clean hull improves boat performance. The
boat bottom should be kept as clean of marine
growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint
approved for your area to inhibit marine
growth.
Do not use anti-fouling paint which includes
copper or graphite. These paints can cause
more rapid engine corrosion.
ZMU01943
38
U67720E0.book Page 39 Friday, March 26, 2004 10:36 AM
Trouble Recovery
EMU29422
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 warning indicator is flashing, consult your Yamaha dealer.
Starter will not operate.
Q. Is battery capacity weak or low?
A. Check battery condition. Use battery of recommended capacity.
Q. Are battery connections loose or corroded?
A. Tighten battery cables and clean battery
terminals.
Q. Is fuse for electric start relay or electric circuit blown?
A. Check for cause of electric overload and
repair. Replace fuse with one of correct amperage.
Q. Are starter components faulty?
A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear?
A. Shift to neutral.
Engine will not start (starter operates).
Q. Is fuel tank empty?
A. Fill tank with clean, fresh fuel.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
39
Q. Is fuel filter clogged?
A. Clean or replace filter.
Q. Is starting procedure incorrect?
A. See page 15.
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 stop switch lanyard not attached?
A. Attach lanyard.
Q. Are engine inner parts damaged?
A. Have serviced by a Yamaha dealer.
Engine idles irregularly or stalls.
Q. Are spark plug(s) fouled or of incorrect
type?
A. Inspect spark plug(s). Clean or replace with
recommended type.
Q. Is fuel system obstructed?
U67720E0.book Page 40 Friday, March 26, 2004 10:36 AM
Trouble Recovery
A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged?
A. Clean or replace filter.
Q. Have ignition parts failed?
A. Have serviced by a Yamaha dealer.
Q. Has warning system activated?
A. Find and correct cause of warning.
Q. Is spark plug gap incorrect?
A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly connected?
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires.
Q. Is specified engine oil not being used?
A. Check and replace oil as specified.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer.
Q. Are carburetor adjustments incorrect?
A. Have serviced by a Yamaha dealer.
Q. Is fuel pump damaged?
A. Have serviced by a Yamaha dealer.
Q. Is air vent screw on fuel tank closed?
A. Open air vent screw.
Q. Is choke knob pulled out?
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.
Warning buzzer sounds or indicator lights.
Q. Is cooling system clogged?
A. Check water intake for restriction.
Q. Is engine oil level low?
A. Fill oil tank with specified engine oil.
Q. Is heat range of spark plug incorrect?
A. Inspect spark plug and replace it with recommended type.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Is engine oil contaminated or deteriorated?
A. Replace oil with fresh, specified type.
Q. Is oil filter clogged?
A. Have serviced by a Yamaha dealer.
Q. Has oil feed/injection pump malfunctioned?
A. Have serviced by a Yamaha dealer.
40
U67720E0.book Page 41 Friday, March 26, 2004 10:36 AM
Trouble Recovery
Q. Is load on boat improperly distributed?
A. Distribute load to place boat on an even
plane.
A. Remove foreign matter and clean lower
unit.
Q. Is water pump or thermostat faulty?
A. Have serviced by a Yamaha dealer.
Q. Is fuel system obstructed?
A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is there excess water in fuel filter cup?
A. Drain filter cup.
Q. Is fuel filter clogged?
A. Clean or replace filter.
Engine power loss.
Q. Is propeller damaged?
A. Have propeller repaired or replaced.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is propeller pitch or diameter incorrect?
A. Install correct propeller to operate outboard
at its recommended speed (r/min) range.
Q. Is trim angle incorrect?
A. Adjust trim angle to achieve most efficient
operation.
Q. Is motor mounted at incorrect height on
transom?
A. Have motor adjusted to proper transom
height.
Q. Has warning system activated?
A. Find and correct cause of warning.
Q. Is boat bottom fouled with marine growth?
A. Clean boat bottom.
Q. Are spark plug(s) fouled or of incorrect
type?
A. Inspect spark plug(s). Clean or replace with
recommended type.
Q. Are weeds or other foreign matter tangled
on gear housing?
Q. Is spark plug gap incorrect?
A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly connected?
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires.
Q. Have ignition parts failed?
A. Have serviced by a Yamaha dealer.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer.
Q. Is air vent screw closed?
A. Open the air vent screw.
Q. Is fuel pump damaged?
A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect?
A. Connect correctly.
Q. Is heat range of spark plug incorrect?
41
U67720E0.book Page 42 Friday, March 26, 2004 10:36 AM
Trouble Recovery
A. Inspect spark plug and replace it with recommended type.
Q. Is high pressure fuel pump drive belt broken?
A. Have serviced by a Yamaha dealer.
Q. Is engine not responding properly to shift
lever position?
A. Have serviced by a Yamaha dealer.
Engine vibrates excessively.
Q. Is propeller damaged?
A. Have propeller repaired or replaced.
1.
2.
3.
Q. Is propeller shaft damaged?
A. Have serviced by a Yamaha dealer.
4.
Q. Are weeds or other foreign matter tangled
on propeller?
A. Remove and clean propeller.
Q. Is motor mounting bolt loose?
A. Tighten bolt.
Q. Is steering pivot loose or damaged?
A. Tighten or have serviced by a Yamaha
dealer.
EMU29431
EMU29531
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.
EWM01020
WARNING
●
●
Temporary action in emergency
EMU29440
Impact damage
EWM00870
WARNING
The outboard motor can be seriously damaged by a collision while operating or
trailering. Damage could make the outboard motor unsafe to operate.
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 and only to return to port for repairs.
When the emergency starter rope is
used to start the engine, the start-ingear protection device does not operate.
Make sure the remote control lever is in
neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.
Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg while operating.
If the outboard motor hits an object in the water, follow the procedure below.
42
U67720E0.book Page 43 Friday, March 26, 2004 10:36 AM
Trouble Recovery
●
●
●
●
●
Do not attach the lanyard to clothing
that could tear loose. Do not route the
cord where it could become entangled,
preventing it from functioning.
Avoid accidentally pulling the lanyard
during normal operation. Loss of engine
power means the loss of most steering
control. Also, without engine power, the
boat could slow rapidly. This could
cause people and objects in the boat to
be thrown forward.
Be 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.
EMU29561
Emergency starting engine
1.
2.
3.
43
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).
4.
5.
6.
7.
Prepare the engine for starting. For further information, see page 15. Be sure
the engine is in neutral and that the engine stop switch lanyard lock plate is attached to the engine stop switch. The
main switch must be “ ” (on), if
equipped.
If equipped the choke knob, pull out it
when the engine is cold. After the engine
starts, gradually return the choke knob to
its home position as the engine warms
up.
Insert the knotted end of the emergency
starter rope into the notch in the flywheel
rotor and wind the rope several turns
around the flywheel clockwise.
Give a strong pull straight out to crank
and start the engine. Repeat if necessary.
U67720E0.book Page 44 Friday, March 26, 2004 10:36 AM
Trouble Recovery
EMU29760
Treatment of submerged motor
4.
If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise
some corrosion may begin almost immediately.
If you cannot immediately take the outboard
motor to a Yamaha dealer, follow the procedure below in order to minimize engine damage.
Feed fogging oil or engine oil through the
carburetor(s) and spark plug holes while
cranking with the manual starter or emergency starter rope.
EMU29771
Procedure
1.
Thoroughly wash away mud, salt, seaweed, and so on, with fresh water.
ZMU01911
5.
Take the outboard motor to a Yamaha
dealer as soon as possible.
ECM00400
CAUTION:
Do not attempt to run the outboard motor
until it has been completely inspected.
ZMU01909
2.
Remove the spark plugs and face the
spark plug holes downward to allow any
water, mud, or contaminants to drain.
ZMU01910
3.
Drain the fuel from the carburetor, fuel filter, and fuel line.
44
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM
YAMAHA MOTOR CO., LTD.
Printed in Japan
April 2004–0.1 × 1 CR
Printed on recycled paper