8C
OWNER’S MANUAL
U.S.A.Edition
LIT-18626-05-30
E
EMU01448
TO THE OWNER
Thank you for choosing a Yamaha outboard motor. This Owner’s manual contains information needed for proper operation, maintenance and care. A thorough
understanding of these simple instructions will help you obtain maximum
enjoyment from your new Yamaha. If you
have any question about the operation or
maintenance of your outboard motor,
please consult a Yamaha dealer.
In this Owner’s Manual particularly
important information is distinguished in
the following ways.
Q
The Safety Alert Symbol means
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
w
Failure to follow WARNING instructions
could result in severe injury or death to
the machine operator, a bystander, or a
person inspecting or repairing the outboard motor.
cC
A CAUTION indicates special precautions
that must be taken to avoid damage to
the outboard motor.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
* Yamaha continually seeks advancements in product design and quality.
Therefore, while this manual contains
the most current product information
available at the time of printing, there
may be minor discrepancies between
your machine and this manual. If there
is any question concerning this manual,
please consult your Yamaha dealer.
NOTE:
The 8MH and its standard accessories are
used as a base for the explanations and
illustrations in this manual. Therefore,
some items may not apply to every
model.
EMU01446*
8C
OWNER'S MANUAL
©2003 by Yamaha Motor Corporation, USA
1st Edition, January 2003
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-18626-05-30
EMA20010
CONTENTS
E
GENERAL INFORMATION
1
BASIC COMPONENTS
2
OPERATION
3
MAINTENANCE
4
TROUBLE RECOVERY
5
INDEX
6
READ THIS OWNER’S MANUAL CAREFULLY
BEFORE OPERATING YOUR OUTBOARD MOTOR.
E
EMB00010
Chapter 1
GENERAL
INFORMATION
IDENTIFICATION NUMBERS
RECORD ....................................................1-1
1
2
EMISSION CONTROL INFORMATION...1-2
SAFETY INFORMATION..........................1-3
IMPORTANT LABELS ..............................1-5
3
BASIC BOATING RULES .........................1-6
FUELING INSTRUCTIONS.....................1-10
Gasoline(petrol) ..................................1-11
Engine oil .............................................1-11
PROPELLER SELECTION .......................1-12
4
START-IN-GEAR PROTECTION ............1-13
5
6
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EMU00005
IDENTIFICATION NUMBERS
RECORD
EMU00007
OUTBOARD MOTOR SERIAL NUMBER
M B K INDUSTRIE
PRODUCT ASSEMBLED IN FRANCE
PRODUIT ASSEMBLE EN FRANCE
1
401012
The outboard motor serial number is
stamped on the label attached to the port
side of the clamp-bracket.
Record your outboard motor serial number in the spaces provided to assist you in
ordering spare parts from your Yamaha
dealer or for reference in case your outboard motor is stolen.
1 Outboard motor serial number
1-1
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EMU01385
EMISSION CONTROL
INFORMATION
q
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EMU01386
NORTH AMERICAN MODELS
This
engine
conforms
to
U.S.
Environmental Protection Agency (EPA)
regulations for marine SI engines. See the
label affixed to your engine for details.
Approval label of Emission control
certificate
This label is attached to the bottom cowling.
1 Emission control information label
EMISSION CONTROL INFORMATION
ENGINE FAMILY :
THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.
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
VALVE LASH (mm) : IN
kw
Existing Technology ; N/A
Manufactured date label
This label is attached to the clamp bracket
or the swivel bracket.
2 Manufactured date label
Manufactured:
1-2
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8 This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which may cause brain
damage or death when inhaled.
Symptoms include nausea, dizziness,
8 Before mounting or operating the outand drowsiness. Keep cockpit and cabin
board motor, read this entire manual.
areas well ventilated. Avoid blocking
Reading it should give you an underexhaust outlets.
standing of the motor and its operation.
8 Check throttle, shift, and steering for
8 Before operating the boat, read any
proper operation before starting the
owner’s or operator’s manuals supplied
engine.
with it and all labels. Be sure you under8 Attach the engine stop switch lanyard
stand each item before operating.
to a secure place on your clothing, or
8 Do not overpower the boat with this
your arm or leg while operating. If you
outboard motor. Overpowering the
accidentally leave the helm, the lanyard
boat could result in loss of control. The
will pull from the switch, stopping the
rated power of the outboard should be
engine.
equal to or less than the rated horse8 Know the marine laws and regulations
power capacity of the boat. If the rated
where you will be boating - and obey
horsepower capacity of the boat is
them. Refer to the “RULES OF THE
unknown, consult the dealer or boat
ROAD” section for basic boating rules.
manufacturer.
8 Stay informed about the weather.
8 Do
not
modify
the
outboard.
Check weather forecasts before boating.
Modifications could make the motor
Avoid boating in hazardous weather.
unfit or unsafe to use.
8 Tell someone where you are going:
8 Never operate after drinking alcohol or
leave a Float Plan with a responsible
taking drugs. About 50% of all boating
person. Be sure to cancel the Float Plan
fatalities involve intoxication.
when you return.
8 Have an approved personal flotation
8 Use common sense and good judgment
device (PFD) on board for every occuwhen boating. Know your abilities, and
pant. It is a good idea to wear a PFD
be sure you understand how your boat
whenever boating. At a minimum, chilhandles under the different boating
dren and non-swimmers should always
conditions you may encounter. Operate
wear PFDs, and everyone should wear
within your limits, and the limits of your
PFDs when there are potentially hazboat. Always operate at safe speeds,
ardous boating conditions.
and keep a careful watch for obstacles
8 Gasoline is highly flammable, and its
and other traffic.
vapors are flammable and explosive.
8 Always watch carefully for swimmers
Handle and store gasoline carefully.
during the engine operation.
Make sure there are no gas fumes or
8 Stay away from swimming areas.
leaking fuel before starting the engine.
8 When a swimmer is in the water near
you shift into neutral and shut off the
engine.
1-3
EMU00917
SAFETY
Q INFORMATION
E
8 Be informed about boating safety.
Additional publications and information
can be obtained from many organizations, including the following:
United States Coast Guard
Consumer Affairs Staff (G-BC)
Office of Boating, Public, and Consumer
Affairs
U.S. Coast Guard Headquarters
Washington, D.C. 20593-0001
Boating Safety Hotline: 1-800-368-5647
National Marine Manufacturers
Association (NMMA)
401 N. Michigan Ave.
Chicago, Il 60611
Marine Retailers Association of America
155 N. Michigan Ave.
Chicago, Il 60601
1-4
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EMB30010
IMPORTANT LABELS
q
WARNING LABELS
1
WARNING
6 Be
sure shift control is in neutral
before starting engine. (except 2HP)
6 Do not touch or remove electrical parts
when starting or during operation.
6 Keep hands,hair,and clothes away from flywheel
and other rotating parts while engine is running.
6A1-83625-41
2
WARNING
This engine is equipped with a neutral starting device.
The engine will not start unless the shift control is
in neutral position.
6E0-83627-41
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001733
1-5
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EMB40010
BASIC BOATING RULES
(Rules of the road)
Just as there are rules which apply when
you are driving on streets and high ways,
there are waterway rules which apply
when you are driving your boat. These
rules are used internationally, and are
also enforced by the United States Coast
Guard and local agencies. You should be
aware of these rules, and follow them
whenever you encounter another vessel
on the water.
Several sets of rules prevail according to
geographic location, but are all basically
the same as the International Rules of the
Road. The rules presented here in your
Owner’s Manual are condensed, and have
been provided for your convenience only.
Consult your local U.S. Coast Guard
Auxiliary or Department of Motor
Vehicles for a complete set of rules governing the waters in which you will be
using your boat.
Stand-on Vessel
The vessel with the right-of-way has the
duty to continue its course and speed,
except to avoid an immediate collision.
When you maintain your direction and
speed, the other vessel will be able to
determine how best to avoid you.
Give-way Vessel
The vessel which does not have the rightof-way has the duty to take positive and
timely action to stay out of the way of the
Stand-On vessel. Normally, you should
not cross in front of the vessel with the
right-of-way. You should slow down or
change directions briefly and pass behind
the other vessel. You should always move
in such a way that the operator of the
other vessel can see what you are doing.
“The general prudential rule”
This rule is called Rule 2 in the International Rules and says,
‘In obeying and construing these
rules due regard shall be had to all
dangers of navigation and collision,
and to any special circumstances,
which may render a departure from
the above rules necessary in order to
avoid immediate danger.’
STEERING AND SAILING RULES AND
SOUND SIGNALS
Whenever two vessels on the water meet
one another, one vessel has the right-ofway; it is called the “stand-on” vessel.
The vessel which does not have the rightof-way is called the “give-way” or “burdened” vessel. These rules determine
which vessel has the right-of-way, and
what each vessel should do.
In other words, follow the standard rules
except when a collision will occur unless
both vessels try to avoid each other. If
that is the case, both vessels become
“Give-Way” vessels.
1-6
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RULES WHEN ENCOUNTERING
VESSELS
There are three main situations which you
may encounter with other vessels which
could lead to a collision unless the
Steering Rules are followed:
Meeting
(you are approaching another vessel
head-on)
Crossing
(you are travelling across the other
vessel’s path)
Overtaking
(you are passing or being passed by
another vessel)
In the following illustration, your boat is
in the center. You should give the right-ofway to any vessels shown in white area
(you are the Give-Way vessel). Any vessels in the shaded area must yield to you
(they are the Give-Way vessels). Both you
and the meeting vessel must alter course
to avoid each other.
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.
102044
Crossing
When two power driven vessels are
crossing each other’s path close enough
to run the risk of collision, the vessel
which has the other on the starboard
(right) side must keep out of the way of
the other. If the other vessel is on your
right, you must keep out of its way; you
are the Give-Way vessel. If the other vessel is on your port (left) side, remember
that you should maintain course and
direction, provided the other vessel gives
you the right-of-way as it should.
102045
Meeting
If you are meeting another power vessel
head on, and are close enough to run the
risk of collision, neither of you has the
right-of-way! Both of you should alter
course to avoid an accident. You should
102046
Overtaking
If you are passing another vessel, you are
the “Give-Way” vessel. This means that
the other vessel is expected to maintain
1-7
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its course and speed. You must stay out
of its way until you are clear of it.
Likewise, if another vessel is passing you,
you should maintain your speed and
direction so that the other vessel can steer
itself around you.
OTHER SPECIAL SITUATIONS
There are three other rules you should be
aware of when driving your boat around
other vessels.
Narrow Channels and Bends
When navigating in narrow channels, you
should keep to the right when it is safe
and practical to do so. If the operator of a
power-driven vessel is preparing to go
around a bend that may obstruct the view
of other water vessels, the operator
should sound a prolonged blast on the
whistle (4 to 6 seconds). If another vessel
is around the bend, it too should sound
the whistle. Even if no reply is heard,
however, the vessel should still proceed
around the bend with caution. If you navigate such waters with your boat, you will
need to carry a portable air horn, available from local marine supply stores.
Fishing Vessel Right-of-way
All vessels which are fishing with nets,
lines or trawls are considered to be“fishing vessels” under the International
Rules. Vessels with trolling lines are not
considered fishing vessels. Fishing vessels have the right-of-way regardless of
position. Fishing vessels cannot, however, impede the passage of other vessels in
narrow channels.
Sailing Vessel Right-of-way
Sailing vessels should normally be given
the right-of-way. The exceptions to this
are:
1.
2.
3.
When the sailing vessel is overtaking
the power-driven vessel, the powerdriven vessel has the right-of-way.
Sailing vessels should keep clear of
any fishing vessel.
In a narrow channel, a sailing vessel
should not hamper the safe passage
of a power-driven vessel which can
navigate only in such a channel.
Reading Buoys and Other Markers
The waters of the United states are
marked for safe navigation by the lateral
system of buoyage. Simply put, buoys
and markers have an arrangement of
shapes, colors, numbers and lights to
show which side of the buoy a boater
should pass on when navigating in a particular direction. The markings on these
buoys are oriented from the perspective
of being entered from seaward (the
boater is going towards the port). This
means that red buoys are passed on the
starboard (right) side when proceeding
from open water into port, and black
buoys are to port (left) side. When navigating out of port, your position with
respect to the buoys should be reversed;
red buoys should be to port and black
buoys to starboard.
Many bodies of water used by boaters are
entirely within the boundaries of a particular state. The Uniform State Waterway
Marking System has been devised for
these waters. This system uses buoys and
signs with distinctive shapes and colors
to show regulatory or advisory information. These markers are white with black
letters and orange boarders. They signify
speed zones, restricted areas, danger
areas, and general information.
1-8
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Remember, markings may vary by geographic location. Always consult local
boating authorities before driving your
boat in unfamiliar waters.
N
EL
MAIN CHANNEL BUOYS
A
N
" 6"
A
C
H
C " 1"
M
N
N
O
A
N
White Light
C
H
D
A
R
Odd number. increasing toward head of navigation.Leave to port (left) proceeding upstream.
EL
SE
C
RB " L "
or
RG " L "
LIGHTED BUOY (Port Hand)`
N " 2"
Y
IN
" 7"
" 1" " 3" " 5" " 7"
1
OR
Green Light
1
" 5"
BUOY
COLOR CODE
" 4"
new
old
BLACK
" 2" " 4" " 6"
LIGHTED BUOY (Starboard Hand)`
RED
" 3"
GREEN
Even number,increasing toward head of navigation. Leave to starboard (right) proceeding upstream.
White Light
" A"
2
OR
Red Light
2
" 2"
new
old
" 1"
" A"
LIGHTED SAFE WATER BUOY
Proceeding toward head
of navigation from seaward
No number. Marks midchannel, pass on either
side. Letter has no lateral significance, used for
identification and location purposes.
SECONDARY CHANNEL BUOYS
Top Mark
STARTS NEW NUMBERING SYSTEM
White Light
C " 1"
CAN BUOY
Odd number. Leave to port.
OR
1
1
OR
new
old
old
N " 2"
White Light
A
A
new
RB " L "
RG " L "
LIGHTED PREFERRED CHANNEL TO
PORT BUOY
NUN BUOY
Even number. Leave to starboard
No number. Topmost band red - preferred
channel is to left of buoy. Letter has no lateral
significance, used for identification and location
purposes.
2
L
old
Red or
White Light
Red Light
L
new
No change
102052
1-9
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EMU00016
FUELING INSTRUCTIONS
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GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE!
8 Do not smoke when refueling, and
keep away from sparks, flames, or
other sources of ignition.
8 Stop engine before refueling.
8 Refuel in a well-ventilated area. Refuel
portable fuel tanks off the boat.
8 Take care not to spill gasoline. If gasoline spills, wipe it up immediately with
dry rags.
8 Do not overfill the fuel tank.
8 Tighten the filler cap securely after
refueling.
8 If you should swallow some gasoline
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.
8 If any gasoline spills onto your skin,
immediately wash with soap and
water. Change clothing if gasoline spills
on it.
8 Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
cC
Use only new clean gasoline which has
been stored in clean containers and is not
contaminated with water or foreign matter.
1-10
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EMU00018
GASOLINE (PETROL)
Recommended gasoline:
Regular unleaded gasoline with a
minimum octane rating of 86
(Pump octane number) = (R+M)/2
If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. If unleaded gasoline is not available, then leaded regular gasoline can be
used.
EMU00027
Gasohol
There are two types of gasohol: gasohol
containing ethanol and that containing
methanol. Gasohol containing ethanol
can be used if ethanol content does not
exceed 10% and the fuel meets minimum
octane ratings. Gasohol containing
methanol is not recommended by
Yamaha because it can cause fuel system
damage or engine performance problems.
EMU00858
ENGINE OIL
Recommended oil:
YAMALUBE 2 STROKE OUTBOARD OIL
If the recommended engine oil is not
available, another 2-stroke engine oil with
a NMMA-certified TC-W3 rating may be
used.
1-11
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EMU01395
PROPELLER SELECTION
The performance of your outboard motor
will be critically affected by your choice of
propeller, as an incorrect choice could
adversely affect performance and could
also seriously damage the motor. Engine
speed depends on the propeller size and
boat load. If engine speed is too high or
too low for good engine performance,
this will have an adverse effect on the
engine.
Yamaha outboard motors are fitted with
propellers chosen to perform well over a
range of applications, but there may be
uses where a propeller with a different
pitch would be more appropriate. For a
greater operating load, a smaller-pitch
propeller is more suitable as it enables
the correct engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable for a smaller operating load.
Yamaha dealers stock a range of propellers, and can advise you and install a
propeller on your outboard that is best
suited to your application.
NOTE:
At full throttle and under a maximum
boat load, the engine’s rpm should be
within the upper half of the full throttle
operating range, as listed in “SPECIFICATIONS” on page 4-1. Select a propeller
which fulfills this requirement.
If operating under conditions which allow
the engine’s rpm to rise above the maximum recommended range (such as light
boat loads), reduce the throttle setting to
maintain the rpm in the proper operating
range.
1-12
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1 Propeller diameter (in inches)
2 Propeller pitch (in inches)
3 Type of propeller (propeller mark)
9-1/4 x8 -N
1 23
Refer to the section “CHECKING PROPELLER” for instructions on propeller
removal and installation.
602013
EMU01209
START-IN-GEAR PROTECTION
Yamaha outboard motors or Yamaha
approved remote control units are
equipped with start-in-gear protection
device(s). This feature permits the engine
to be started only when it is Neutral.
Always select Neutral before starting the
engine.
1-13
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EMC00010
Chapter 2
BASIC COMPONENTS
MAIN COMPONENTS..............................2-1
OPERATIONS OF CONTROLS AND
OTHER FUNCTIONS ................................2-2
Fuel tank.................................................2-2
Gear shift lever ......................................2-2
Engine stop button ...............................2-3
Engine stop lanyard switch..................2-3
Throttle control grip..............................2-4
Choke knob ............................................2-4
Recoil starter handle.............................2-4
Tiller handle...........................................2-5
Throttle friction adjustment .................2-5
Steering friction adjustment ................2-6
Trim angle adjusting rod......................2-6
Sallow water lever ................................2-7
Tilt support knob...................................2-7
Top cowling lock lever..........................2-7
1
2
3
4
5
6
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EMU01206
MAIN COMPONENTS
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!4
!3
e
!2
r
t
!1
y
u
!0
!5
o
i
1
2
3
4
5
Recoil starter handle
Choke knob
Throttle control grip
Throttle friction adjustment
Engine stop button/
Engine stop lanyard switch
6 Clamp screw
7 Rope attachment
8 Cooling water inlet
9
0
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t
y
!6
Anti-cavitation plate
Trim angle adjusting rod
Shallow water lever
Tilt support knob
Gear shift-lever
Top cowling
Fuel tank
Fuel hose
* May not be exactly as shown; also may not
be included as standard equipment on all
models.
2-1
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EMC20010
OPERATIONS OF CONTROLS
AND OTHER FUNCTIONS
EMC21012
FUEL TANK
If your model was equipped with a
portable fuel tank, its function is as follows.
q e
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1
2
3
4
Fuel hose joint
Fuel meter(If equipped)
Fuel tank cap
Air vent screw(If equipped)
Fuel hose joint
This connector is provided for connecting
or disconnecting fuel hose.
902065
Fuel meter
This meter is on the fuel tank cap. It
shows current fuel quantity in the fuel
tank approximately.
Fuel tank cap
This cap is for filling fuel. To remove it,
turn it counterclockwise.
Air Vent screw
This screw is on the fuel tank cap. To
loosen it, turn it counterclockwise.
EMC25010
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GEAR SHIFT LEVER
(for Tiller control model):
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Turning the gear-shift lever towards you
engages the clutch with the forward gear
so that the boat moves ahead. Turning
the lever away from you engages the
reverse gear so that the boat moves
astern.
310011
1 Neutral
2 Forward
3 Reverse
2-2
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EMC27011
ENGINE STOP BUTTON (for Tiller
control model)
Pushing this button opens the ignition circuit and stops the engine.
308041
EMU00931
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ENGINE STOP LANYARD SWITCH
(for Tiller control model)
The lock-plate 1 must be attached to the
engine stop lanyard switch for the engine
to run. The lanyard 2 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.
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8 Attach the lanyard to a secure place on
your clothing, your arm or leg while
operating.
8 Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard in such a way that it could
become entangled, preventing it from
functioning.
8 Avoid accidentally pulling the lanyard
during normal operation. Loss of
engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly.
This could cause people and objects in
the boat to be thrown forward.
NOTE:
The engine cannot be started with the
lock-plate removed.
2-3
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EMC40010
THROTTLE CONTROL GRIP
(for Tiller control model)
The throttle control grip is on the tiller
handle. Turn the grip counterclockwise to
increase speed and clockwise to decrease
speed.
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.
q
503013
1 Throttle indicator
EMC42110
CHOKE KNOB
Turning this knob to right (setting it to
ON) supplies a rich mixture required to
start the engine.
305014
EMC44010
RECOIL STARTER HANDLE
(If equipped)
Pull the handle gently until resistance is
felt. Then vigorously pull the handle
straight out to crank the engine to start it.
209015
2-4
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EMC60010
TILLER HANDLE
(for Tiller control model)
Moving the tiller handle sideways to
adjust the steering direction.
503015
EMC64010
THROTTLE FRICTION ADJUSTMENT
(for Tiller control model)
A friction device in the tiller handle provides resistance to movement of the
throttle grip. This is adjustable for operator preference. An adjusting screw/bolt is
located within the tiller handle.
502022
To increase the resistance:
Turn the adjusting screw/bolt clockwise.
To decrease the resistance:
Turn the adjusting screw/bolt counterclockwise.
When constant speed is desired, tighten
the adjusting screw/bolt to maintain the
desired throttle setting.
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Do not overtighten the friction adjusting
screw/bolt. If there is too much resistance, it may be difficult to move the
throttle grip, which could result in an
accident.
2-5
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EMD00010
STEERING FRICTION ADJUSTMENT
(for Tiller control model)
A friction device provides resistance to
steering movement. This is adjustable for
operator preference.
An adjusting screw/bolt is located on the
swivel bracket.
408011
To increase the resistance:
Turn the adjusting screw/bolt clockwise.
To decrease the resistance:
Turn the adjusting screw/bolt counterclockwise.
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Do
not
overtighten
the
friction
screw/bolt. If there is too much resistance, it may be difficult to steer, which
could result in an accident.
EMU01297
TRIM ANGLE ADJUSTING ROD
The position of the trim angle adjusting
rod determines the minimum trim angle
of the outboard motor in relation to the
transom.
404032*
2-6
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EMD08110
SHALLOW WATER LEVER
(If equipped)
Pushing this lever down will tilt the motor
up partially to provide more clearance
when operating in shallow water.
412011*
EMD47010
TILT SUPPORT KNOB
To keep the outboard motor in the tiltedup position, push the tilt support knob
under the swivel bracket.
403022
EMD62011
TOP COWLING LOCK LEVER
To remove the engine top cowling, turn
the lock lever. Then lift off the cowling.
When replacing the cowling, check to be
sure it fits properly in the rubber seal.
Then lock the cowling again by moving
the lever upward.
q
301036*
1 Top cowling lock lever
2-7
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EMF00010
Chapter 3
OPERATION
INSTALLATION ........................................3-1
Mounting the outboard motor ............3-2
Clamping the outboard motor.............3-4
FILLING FUEL AND ENGINE OIL ............3-5
Filling fuel ..............................................3-5
Gasoline (petrol) and oil mixing..........3-6
PRE-OPERATION CHECKS ......................3-7
BREAKING IN (RUNNING IN)
ENGINE .....................................................3-8
1
2
3
STARTING ENGINE ...............................3-10
WARMING UP ENGINE .........................3-13
SHIFTING ................................................3-14
Forward................................................3-14
Reverse ................................................3-14
STOPPING ENGINE ...............................3-15
TRIMMING OUTBOARD MOTOR.........3-16
Adjusting trim angle ...........................3-17
CRUISING IN SHALLOW WATER.........3-19
4
5
TILTING UP/DOWN ...............................3-21
CRUISING IN OTHER CONDITIONS.....3-23
Cruising in salt water..........................3-23
Cruising in turbid water .....................3-23
6
E
EMF10010
INSTALLATION
cC
Incorrect engine height or obstructions to
smooth water flow (such as the design or
condition of the boat or acce- ssories
such as transom ladders/depth finder
transducers) can create airborne water
spray while the boat is cruising.
Severe engine damage may result if the
motor is operated continuously in the
presence of airborne water spray.
NOTE:
During water testing check the buoyancy
of the boat, at rest, with its maximum
load. Check that the static water level on
the exhaust housing is low enough to prevent water entry into the powerhead,
when water rises due to waves when the
outboard is not running.
3-1
E
EMU00176
MOUNTING THE OUTBOARD
MOTOR
w
Improper mounting of the outboard
motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Observe the following:
8 The information presented in this section is intended as reference only. It is
not possible to provide complete
instructions
for
every
possible
boat/motor
combination.
Proper
mounting depends in part on experience and the specific boat/motor combination.
8 Your dealer or other person experienced in proper rigging should mount
the motor. If you are mounting the
motor yourself, you should be trained
by an experienced person. [permanent
mounted type]
8 Your dealer or other person experienced in proper outboard motor
mounting should show you how to
mount your motor. [portable type]
Mount the outboard motor on the center
line (keel line) of the boat, and ensure that
the boat itself is well balanced. Otherwise,
the boat will be hard to steer. For boats
without a keel or which are asymmetrical,
consult your dealer.
1 Center line (keel line)
q
104011
3-2
E
w
Overpowering a boat may cause severe
instability. Do not install an outboard
motor with more horsepower than the
maximum rating on the capacity plate of
the boat. If the boat does not have a
capacity plate, consult the boat manufacturer.
EMU01298
0~25mm
(0~1in.)
104013
Mounting Height
To run your boat at optimum efficiency,
the water-resistance (drag) of the boat
and outboard motor must be made as little as possible. The mounting-height of
the outboard motor greatly affects the
water-resistance. If the mounting-height
is too high, cavitation tends to occur, thus
reducing the propulsion; and if the propeller tips cut the air, the engine speed
will rise abnormally and cause the engine
to overheat. If the mounting-height is too
low, the water-resistance will increase
and thereby reduce engine efficiency.
Mount the engine so that the anti-cavitation plate is between the bottom of the
boat and a level 25 mm (1 in.) below it.
NOTE:
8 The optimum mounting height of the
outboard motor is affected by the
boat/motor combination and the
desired use. Test runs at different
heights can help determine the optimum mounting height.
8 Refer to the section “TRIMMING OUTBOARD MOTOR” for instructions on
setting the trim angle of the outboard.
3-3
E
EMF14010
CLAMPING THE OUTBOARD
MOTOR
1)
409011
Place the outboard on the transom so
that it is positioned as close to the
center as possible. Tighten the transom clamp screws evenly and securely. Check the clamp-screws for tightness occasionally during operation of
the motor as they can work loose due
to engine vibration.
w
Loose clamp screws could allow the
motor to move on the transom or fall off
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.
2)
410012
3-4
An engine restraint cable or chain
should be used. Attach one end to
the engine restraint cable attachment
point 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.
E
FILLING FUEL
AND ENGINE OIL
EMF30010
FILLING FUEL
1)
2)
3)
Remove the fuel tank cap.
Fill the fuel tank carefully.
Close the cap securely after refueling.
Wipe up any spilled fuel.
902076
Fuel tank capacity:
Refer to SPECIFICATIONS, Page 4-1.
Ring Free Fuel Additive
Gasoline is a precise blend of many different substances, each chosen to give certain characteristics. Gasoline blends have
been changing in recent years in
response to concerns about pollution and
resulting emissions regulations. One of
the most obvious changes has been the
elimination of lead from most fuels.
As gasoline has changed, the amount of
additives such as aromatics and oxygenates has increased. These additives
are important for the engines in passenger cars, but they can have detrimental
effects in marine engines, because of
increased deposits in the combustion
chamber. When enough deposits collect,
piston rings begin sticking. Performance
drops and engine wear increases dramatically.
While many additives available may
reduce deposits, Yamaha recommends
the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free
has repeatedly proven its ability to clean
combustion deposits from inside the
engine, notably the critical piston-ringland area, and fuel system components.
Follow product labeling for use instructions.
3-5
E
EMF35010*
GASOLINE (PETROL) AND OIL
MIXING
q
Pre-mix model
Gasoline (Petrol) : Oil
w
1)
Break-in period
25 : 1
After break-in
100 : 1
Pour oil and gasoline into the fuel
tank, in that order.
1 Oil
2 Gasoline (Petrol)
2)
3)
902032
Then mix the fuel thoroughly by shaking.
Make sure the oil is mixed with gasoline.
cC
8 Avoid using any oil other than the designated type.
8 Use a thoroughly blended fuel-oil mixture.
8 If the mixture is not thoroughly blended, 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 exgaust, and
heavy carbon deposits.
Mixing
ratio
Gasoline
(Petrol)
Engine oil
3-6
25 : 1
1L
12 L
14 L
24 L
(0.26 US gal,
(3.2 US gal,
(3.7 US gal,
(6.3 US gal,
0.22 Imp gal)
2.6 Imp gal)
3.1 Imp gal)
5.3 Imp gal)
0.04 L
0.48 L
0.56 L
0.96 L
(0.04 US qt,
(0.51 US qt,
(0.59 US qt,
(1.01 US qt,
0.04 Imp ql)
0.42 Imp qt)
0.49 Imp qt)
0.84 Imp qt)
E
Mixing
ratio
Gasoline
(Petrol)
Engine oil
100 : 1
1L
12 L
14 L
24 L
(0.26 US gal,
(3.2 US gal,
(3.7 US gal,
(6.3 US gal,
0.22 Imp gal)
2.6 Imp gal)
3.1 Imp gal)
5.3 Imp gal)
0.01 L
0.12 L
0.14 L
024 L
(0.01 US qt,
(0.13 US qt,
(0.15 US qt,
(0.25 US qt,
0.01 Imp ql)
0.11 Imp qt)
0.12 Imp qt)
0.21 Imp qt)
NOTE:
If using a permanently installed tank, pour
the oil gradually as the fuel is being
added to the tank.
EMF40012
PRE-OPERATION CHECKS
w
If any item in the pre-operation check is
not working properly, have it inspected
and repaired before operating the outboard motor. Otherwise, an accident
could occur.
EMF41110
Fuel
8 Check to be sure you have plenty of fuel
for your trip.
8 Make sure there are no fuel leaks or
gasoline fumes.
8 Check fuel line connections to be sure
they are tight.
8 Be sure the fuel tank is positioned on a
secure, flat surface, and that the fuel
hose is not twisted or flattened, or likely
to contact sharp objects.
3-7
E
EMF43010
Controls
8 Check throttle, shift, and steering for
proper operation before starting the
engine.
8 The controls should work smoothly,
without binding or unusual free play.
8 Look for loose or damaged connections.
8 Check operation of the starter and stop
switches when the outboard motor is in
the water.
EMF43510
Engine
8 Check the engine and engine mounting.
8 Look for loose or damaged fasteners.
8 Check the propeller for damage.
cC
Do not start the engine out of water.
Overheating and serious engine damage
can occur.
EMF50012
BREAKING IN (RUNNING IN)
ENGINE
Your new engine requires a period of
break-in (running-in) to allow mating surfaces of moving parts to wear-in evenly.
Correct break-in (running-in) will help
ensure proper performance and longer
engine life.
cC
Failure to follow the break-in (running-in)
procedure may result in reduced engine
life or even severe engine damage.
3-8
E
Break-in (running-in) time:10 hours
Break-in (running-in) premix ratio:
Refer to “Gasoline/Petrol and Oil
Mixing”.
EMU00226
Run the engine under load (in gear with a
propeller installed) as follows.
1) First 10 minutes:
Run the engine at the lowest possible-speed. A fast idle in neutral is
best.
2) Next 50 minutes:
Do not exceed half throttle (approximately 3,000 r/min). Vary engine
speed occasionally. If you have an
easy-planing boat, accelerate at full
throttle onto plane, then immediately
reduce the throttle to 3,000 r/min or
less.
3) Second hour:
Accelerate at full throttle onto plane,
then reduce engine speed to threequarter throttle (approximately 4,000
r/min). Vary engine speed occasionally. Run at full throttle for one minute,
then allow about 10 minutes of operation at three-quarter throttle or less to
let the engine cool.
4) Third through tenth hours:
Avoid operating at full throttle for
more than 5 minutes at a time. Let the
engine cool between full-throttle runs.
Vary engine speed occasionally.
5) After the first 10 hours:
Operate the engine normally. Use the
standard premix ratio of gasoline :
Oil. (Refer to “Gasoline/Petrol and Oil
Mixing”.)
3-9
E
EMU01147
STARTING ENGINE
E
F
w
902072
304014*
8 Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.
8 When the air vent screw is loosened,
gasoline (petrol) vapor will be released.
Gasoline (petrol) is highly flammable,
and its vapors are flammable and
explosive. Refrain from smoking, and
keep away from open flames and
sparks while loosening the air vent
screw.
8 This product emits exhaust gases
which contain carbon monoxide, a colorless, odorless gas which may cause
brain damage or death when inhaled.
Symptoms include nausea, dizziness,
and drowsiness. Keep cockpit and
cabin areas well ventilated. Avoid
blocking exhaust outlets.
1)
902073
If there is an air vent screw on the fuel
tank cap, loosen it 2 or 3 turns.
2) If there is a fuel joint on the motor,
firmly connect the fuel line to the
joint. Then firmly connect the other
end of the fuel line to the joint on the
fuel tank.
NOTE:
During engine operation place the tank
horizontally, or fuel cannot be drawn into
the engine.
3)
001671
3-10
Squeeze the primer bulb with the outlet end up until you feel it become
firm.
E
EMU14970
PROCEDURE FOR TILLER CONTROL
MODEL
N
4)
310012
Place the gear-shift lever in the neutral position.
NOTE:
The start-in-gear protection device prevents the engine from starting except
when in Neutral.
5)
Attach the engine stop switch lanyard
to a secure place on your clothing, or
your arm or leg. Then, install the lock
plate on the other end of the lanyard
in the engine stop switch.
w
001367
8 Attach the engine stop switch lanyard
to a secure place on your clothing, your
arm or leg while operating.
8 Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entangled, preventing it from functioning.
8 Avoid accidentally pulling the lanyard
during normal operation. Loss of
engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly.
This could cause people and objects in
the boat to be thrown forward.
6)
3-11
Place the throttle control grip in the
“START” position.
E
EMU00240
305014
Manual Start Model
7) Pull out the choke knob completely.
After the engine starts, return the
knob to the original position.
NOTE:
8 It is not necessary to use the choke
when restarting a warm engine.
8 If the choke knob is left pulled out after
the engine starts, the engine will stall.
8)
209015
Pull the starter handle slowly until
you feel resistance. Then, give a
strong pull straight out to crank and
start the engine. Repeat it, if necessary.
9) After the engine starts, return the
starter handle slowly to the original
position before releasing it.
10) Return the throttle to the fully closed
position.
3-12
E
EMG00010-*
WARMING UP ENGINE
1)
2)
309012
Before beginning operation, allow the
engine to warm up at idling speed for
3 minutes. (Failure to do this will
shorten engine life.)
Check for a steady flow of water from
the cooling-water pilot hole.
cC
A continuous flow of water from the pilot
hole shows that the water pump is
pumping water through the cooling passages. If water is not flowing out of the
pilot hole at all times while the engine is
running, do not continue to run the
engine. Overheating and serious damage
could occur. Stop the engine and check
to see if the water inlet on the lower casing is blocked. If the problem cannot be
found and corrected, consult your
Yamaha dealer.
3-13
E
EMG20111
SHIFTING
w
Before shifting, make sure there are no
swimmers or obstacles in the water near
you.
503012
cC
To change the shifting position from forward to reverse or vice-versa, close the
throttle first so that the engine idles (or
runs at low speeds).
N
F
EMG22110
FORWARD
1)
310013
2)
Place the throttle control grip in the
fully closed position.
Turn the gear shift lever quickly and
firmly from Neutral to Forward.
EMU00267
REVERSE
w
503012
When operating in Reverse, go slowly. Do
not open the throttle more than half.
Otherwise, the boat may become unstable, which could result in loss of control
and an accident.
1)
N
R
2)
310014
3-14
Place the throttle control grip in the
fully closed position.
Turn the gear shift lever quickly and
firmly from Neutral to Reverse.
E
EMG38010
STOPPING ENGINE
Let it cool off for a few minutes at idle or
low speed first. Stopping the engine
immediately after operating at high speed
is not recommended.
EMU00275
1)
Push and hold the engine stop button
until the engine comes to a complete
stop.
2)
After stopping the engine, disconnect
the fuel line from the motor.
304014*
Tighten the air vent screw on the fuel
tank cap after stopping the engine, if
it is equipped.
NOTE:
The engine can also be stopped by
pulling the lanyard and removing the lock
plate from the engine stop lanyard switch.
E
F
3)
902071
3-15
E
EMU01412
TRIMMING OUTBOARD
MOTOR
The trim angle of the outboard motor
helps determine the position of the bow
of the boat in the water. The correct trim
angle will help improve performance and
fuel economy while reducing strain on the
engine. The correct trim angle depends
upon the combination of boat, engine,
and propeller. Correct trim is also affected
by variables such as the load in the boat,
sea conditions, and running speed.
w
q
105024*
Excessive trim for the operating conditions (either trim up or trim down) can
cause boat instability and can make
steering the boat more difficult. This
increases the possibility of an accident. If
the boat begins to feel unstable or is hard
to steer, slow down and/or readjust the
trim angle.
NOTE:
Refer to the section “ADJUSTING TRIM
ANGLE” for instructions on usage.
1 Trim operating angle
3-16
E
ADJUSTING TRIM ANGLE
EMU00951
q
404032*
Manual tilt model
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 angle adjusting rod
1 from the clamp bracket while tilting
the motor up slightly.
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.
w
8 Stop the engine before adjusting the
trim angle.
8 Use care to avoid being pinched when
removing or installing the rod.
8 Use caution when trying a trim position
for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim
angle can cause loss of control.
NOTE:
The outboard motor trim angle can be
changed approximately 4 degrees by
shifting the trim adjusting-rod one hole.
3-17
E
EMU19160
q
001672
w
Trim angle settings and boat handling
When the boat is on plane, a bow-up attitude results in less drag, greater stability
and efficiency. This is generally when the
keel line of the boat is up about 3 to 5
degrees. With the bow up, the boat may
have a greater tendency to steer to one
side or the other. Compensate for this as
you steer. The trim tab can also be adjusted to help offset this effect.
1 Optimum angle (level keel line)
2 Bow up
3 Bow down
001673
e
001674
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.
Bow Down
When the bow of the boat is down, it is
easier to accelerate from a standing start
onto plane. Too much trim-in causes the
boat to “plow” through the water,
decreasing fuel economy and making it
hard to increase speed. Operating with
excessive trim-in at higher speeds also
makes the boat unstable. Resistance at
the bow is greatly increased, heightening
the danger of “bow steering” and making
operation difficult and dangerous.
3-18
E
NOTE:
Depending on the type of boat, the outboard motor trim angle may have little
effect on the trim of the boat when operating.
EMG70011
CRUISING IN SHALLOW
WATER
The outboard motor can be tilted up partially to allow operation in shallow water.
w
8 Place the gear shift in the Neutral position before using the shallow water
cruising system.
8 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 engine to lift out of the
water, resulting in loss of control.
8 Use extra care when operating in
reverse. Too much reverse thrust can
cause the engine to lift out of the
water, increasing the chance of accident and personal injury.
8 Return the engine to its normal position as soon as the boat is back in
deeper water.
cC
Place the gear-shift in the Neutral position before using the shallow water cruising system.
3-19
E
EMG71110
PROCEDURE
N
1)
Place the gear shift lever in Neutral.
2)
Slightly tilt up the engine. Pull up the
shallow water lever.
3)
The shallow water lever will lock, supporting the engine in a partially raised
position.
When lowering the engine, slightly tilt
up the engine and push the shallow
water lever down. Then, slowly lower
the engine to the normal position.
310012
412011*
4)
3-20
E
EMH10110
TILTING UP/DOWN
105031
If the engine will be stopped for some
time, or if the boat is moored in shallows,
the engine should be tilted up to protect
the propeller and casing from damage by
collision with obstructions, and also to
reduce salt corrosion.
cC
8 Before tilting the motor, follow the procedures under “STOPPING ENGINE”.
Never tilt the motor while the engine is
running. Severe damage from overheating can result.
8 Do not tilt up the engine by pushing
the steering handle as this could break
the handle.
8 Keep the power unit higher than the
propeller at all times. Otherwise, water
can run into the cylinder, causing damage.
w
Be sure all people are clear of the outboard motor when adjusting the tilt
angle, also be careful not to pinch any
body parts between the drive unit and
engine bracket.
w
Leaking fuel is a fire hazard. Disconnect
the fuel line if the engine will be tilted for
more than a few minutes. Otherwise, fuel
may leak. (If the fuel connector is provided on the motor.)
3-21
E
EMU00288
PROCEDURE FOR TILTING UP
N
1)
Place the gear shift lever in Neutral.
2)
Remove the fuel line connection from
the motor.
Hold the rear of the top cowling with
one hand and fully tilt the engine up.
310012
3)
304014*
4)
Push the tilt support knob into the
clamp bracket.
PROCEDURE FOR TILTING DOWN
1)
2)
3)
3-22
Slightly tilt up the engine.
Pull out the tilt support knob.
Tilt down the engine slowly to its
home position.
E
EMH60010
CRUISING IN OTHER
CONDITIONS
CRUISING IN SALT WATER
After operating in salt water, wash out the
cooling-water passages with fresh water
to prevent them from becoming cloggedup with salt deposits.
NOTE:
Refer to cooling system flushing instructions in “TRANSPORTING AND STORING
OUTBOARD MOTOR”.
CRUISING IN TURBID WATER
It is strongly recommended that the
optional chromium-plated water-pump kit
be installed if the outboard is to be used
in turbid (muddy) water conditions.
3-23
E
EMK00010
Chapter 4
MAINTENANCE
SPECIFICATIONS .....................................4-1
TRANSPORTING AND STORING
OUTBOARD MOTOR ...............................4-2
Trailering outboard motor ...................4-2
Storing outboard motor .......................4-3
PERIODIC MAINTENANCE......................4-6
Replacement parts ................................4-6
Maintenance chart ................................4-7
Cleaning and adjusting spark plug .....4-8
Checking fuel system .........................4-10
Inspecting and replacing fuel filter ...4-11
Inspecting idling speed ......................4-12
Checking wiring and connectors.......4-13
Exhaust leakage ..................................4-13
Water leakage......................................4-13
Checking top cowling .........................4-13
Greasing...............................................4-14
Checking propeller..............................4-15
Changing gear oil................................4-18
Cleaning fuel tank ...............................4-19
Inspecting and replacing anode ........4-20
Checking bolts and nuts.....................4-21
Motor exterior .....................................4-21
Coating the boat bottom ....................4-21
1
2
3
4
5
6
E
EMU01693*¯
SPECIFICATIONS
Model
Unit
Item
8MH
DIMENSIONS
Overall length
Overall width
Overall height
Transom height
Weight
S
S
S
mm (in.)
mm (in.)
mm (in.)
mm (in.)
kg (lb.)
802 (31.6)
343 (13.5)
977 (38.5)
436 (17.2)
27 (59.4)
PERFORMANCE
Full throttle operating range
Maximum output
Idling speed (in neutral)
r/min
kW (HP) @ r/min
r/min
4,500–5,500
5.9 (8) @ 5,000
850–950
ENGINE
Type
Displacement
Bore × stroke
Ignition system
Spark plug
Spark plug gap
Control system
Starting system
Alternator output
Starting carburetion system
cm3 (cu.in.)
mm (in.)
NGK
mm (in.)
V-A (W)
2-stroke, L2
165 (10.01)
50 × 42 (1.97 × 1.65)
CDI system
BR7HS-10
0.9–1.0 (0.035–0.039)
Tiller control
Manual start
12 (80)
Choke start
DRIVE UNIT
Forward-Neutral-Reverse
2.08 (27/13)
Manual tilt
N
Gear positions
Gear ratio
Trim and tilt system
Propeller mark
FUEL AND OIL
Recommended fuel
Fuel tank capacity
Recommended engine oil
Lubrication
Fuel:oil ratio
Recommended gear oil
Gear oil capacity
P.O.N.
L (US gal, Imp gal)
Fuel:Oil
cm3 (US oz, Imp oz)
Regular unleaded gasoline
Minimum 86
25 (6.6, 5.5)
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TCW3 certified outboard oil
Premix
100:1
Hypoid gear oil (SAE90)
160 (5.41, 5.63)
TIGHTENING TORQUE
Spark plug
Propeller nut
N•m (kgf•m, lb•ft)
N•m (kgf•m, lb•ft)
4-1
25 (2.5, 18)
17 (1.7, 12)
E
EMU01369
TRANSPORTING AND
STORING OUTBOARD MOTOR
w
Leaking fuel is a fire hazard. When transporting and storing the outboard motor,
close the air vent screw and fuel cock to
prevent fuel from leaking.
EMU00326
TRAILERING OUTBOARD MOTOR
q
The motor should be trailered and stored
in the normal running position. If there is
insufficient road clearance in this position,
then trailer the motor in the tilt position
using a motor support device such as a
transom saver bar.
For further details, consult your Yamaha
dealer.
w
102015
8 Never get under the lower unit while it is
tilted, even if a motor support bar is
used. Severe injury could occur if the
outboard accidentally falls.
8 USE CARE when transporting fuel tank,
whether in a boat or car.
8 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.
cC
Do not use the tilt support lever/knob
when trailering the boat. The outboard
motor could shake loose from the tilt support and fall. If the motor can not be trailered in the down position, use an additional support device to secure it in the up
position.
4-2
E
EMU00327
Clamp handle mounting model
When transporting or storing the outboard motor while removed from a boat,
fold the tiller handle and lean the motor
on the tiller handle to keep in a horizontal
position.
102013
cC
Keep the power unit higher than the propeller at all times. Otherwise, cooling
water can run into the cylinder, which
could result in damage.
NOTE:
Place a towel or the like under the outboard motor to protect it from damage.
EMK22010**
STORING OUTBOARD MOTOR
When storing your Yamaha outboard for
prolonged periods of time, (2 months or
longer), several important procedures
must be performed to prevent expensive
damage.
It is advisable to have your outboard serviced by an authorized Yamaha dealer
prior to storage. However, the following
procedures can be performed by you, the
owner, with a minimum of tools.
Filling Fuel Tank
Fill the fuel tank with fresh fuel and add
one ounce of “Yamaha fuel conditioner
and stabilizer” (Part No. LUB-FUELC-1200) to each gallon of fuel.
NOTE:
The use of Yamaha Fuel Conditioner and
Stabilizer eliminates the need to drain the
fuel system. Consult your Yamaha dealer
or other qualified mechanic if the fuel system is to be drained instead.
4-3
E
EMU00338
Flushing Cooling System and Fogging
Engine
Cooling system flushing is essential to
prevent the cooling system from clogging
up with salt, sand, or dirt. In addition, fogging of the engine is mandatory to prevent expensive engine damage due to
rust. Perform the flushing and fogging at
the same time.
w
8 Do not touch or remove electrical parts
when starting or during operation.
8 Keep hands, hair and clothes away
from flywheel and other rotating parts
while engine is running.
EMU00340
8 Flushing in a Water Tank
cC
If the fresh water level is below the level
of the anti-cavitation plate, or if the water
supply is insufficient, engine seizure may
occur.
1)
2)
3)
4)
5)
q
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6)
7)
Remove the engine top cowling.
Install the outboard motor on the
water tank.
Fill the tank with fresh water to above
the level of the anti-cavitation plate.
Run the engine at a fast idle for 10~15
minutes.
Just prior to turning off the engine,
quickly spray “Yamaha Stor-Rite
Engine Fogging Oil” (Part No. LUBSTRRT-12-00) into the silencer cover.
When properly done, the engine will
smoke excessively and almost stall.
Remove the motor from the water
tank.
Install the top cowling.
605011
1 Water surface
2 Lowest water level
4-4
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EMK26010
Lubrication
1) Remove the spark plugs, and spray a
10 second spray of Yamaha Stor-Rite
Engine Fogging Oil into each cylinder.
Grease the spark plug threads and
reinstall the spark plugs and torque to
proper specification.
(Refer to the Periodic Maintenance
section, “Cleanning and adjusting
spark plug.”).
2) Turn the engine over with the stop
lanyard disconnected to work the fogging oil into the piston rings.
3) Change the lower unit oil. (Refer to
the Periodic Maintenance section,
“Changing gear oil.”). Inspect the oil
for the presence of water which indicates a leaky seal. Seal replacement
should be performed by an authorized Yamaha dealership prior to use.
4) Grease all grease fittings. (Refer to
the Periodic Maintenance section,
“Greasing.”)
EMK27010
Cleaning and Anti-corrosion Measure
1) Wash down the exterior of the outboard with fresh water and dry off
completely.
2) Spray the engine’s exterior with
Yamaha Silicone Protectant (Part No.
LUB-SILCNE-13-00).
3) Wax the cowling with a non-abrasive
wax such as Yamaha Silicone Wax
(Part No. ACC-11000-15-02).
4-5
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EMU01569
PERIODIC MAINTENANCE
w
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If the owner is not familiar with
machine servicing, this work should be
done by a Yamaha dealer or other qualified mechanic.
Maintenance, replacement, or repair of
the emission control devices and systems
may be performed by any marine engine
repair establishment or individual. All
warranty repairs, however, including
those to the emission control system,
must be performed by an authorized
Yamaha marine dealership.
A service manual is available for purchase
through a Yamaha dealer for owners who
have the mechanical skills, tools, and
other equipment necessary to perform
maintenance not covered by this owner’s
manual.
EMK33011
REPLACEMENT PARTS
If replacement parts are necessary, use
only genuine Yamaha parts or equivalents of the same type and of equivalent
strength and materials. Any part of inferior quality may malfunction, and the
resulting loss of control could endanger
the operator and passengers.
Yamaha genuine parts and accessories
are available from a Yamaha dealer.
4-6
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EMU19270
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 mark (●) indicates the check-ups which you may carry out yourself.
The mark (1) indicates work to be carried out by your Yamaha dealer.
Item
Spark plug(s)
Greasing points
Gear oil
Fuel system
Fuel filter (disposable)
Fuel tank (Yamaha
portable tank)
Idling speed (carburetor
models)
Anode(s) (external)
Anode(s) (internal)
Cooling water passages
Propeller and cotter pin
Battery
Throttle link / throttle cable
/ throttle pick-up timing
Shift link / shift cable
Thermostat
Water pump
Cowling clamp
Initial
10 hours
50 hours
(1 month)
(3 months)
Actions
Cleaning / adjustment /
replacement
Greasing
Change
Inspection
Inspection / replacement
●
●
●
●/1
Every
100 hours
200 hours
(6 months)
(1 year)
●
●
●
●/1
●
●
●
●/1
●
Inspection / cleaning
●/1
Inspection / adjustment
Inspection
Inspection
Cleaning
Inspection
Inspection
/ replacement
/ replacement
●/1
●/1
●/1
●
●
●
●
1
/ replacement
/ charging
●/1
Inspection / adjustment
1
Inspection / adjustment
Inspection
Inspection
Inspection
1
1
1
●
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with
clean water after each use.
4-7
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EMU01202
CLEANING AND ADJUSTING SPARK
PLUG
w
When removing or installing a spark plug,
be careful not to damage the insulator. A
damaged insulator could allow external
sparks, which could lead to explosion or
fire.
The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
something about the condition of the
engine. For example, if the center electrode porcelain is very white, this could
indicate an intake air leak or carburetion
problem in that cylinder. Do not attempt
to diagnose any problems yourself.
Instead, take the outboard motor to a
Yamaha dealer. You should periodically
remove and inspect the spark plug
because heat and deposits will cause the
spark plug to slowly break down and
erode. If electrode erosion becomes
excessive, or if carbon and other deposits
are excessive, you should replace the
spark plug with another of the correct
type.
Standard spark plug:
Refer to “SPECIFICATIONS”,
page 4-1.
Before fitting the spark plug, measure the
electrode gap with a wire thickness
gauge; adjust the gap to specification if
necessary.
Spark plug gap:
Refer to “SPECIFICATIONS”,
page 4-1.
4-8
E
When fitting the plug, always clean the
gasket surface and use a new gasket.
Wipe off any dirt from the threads and
screw in the spark plug to the correct
torque.
Spark plug torque:
Refer to “SPECIFICATIONS”,
page 4-1.
NOTE:
If a torque-wrench is not available when
you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a
turn past finger-tight. Have the spark plug
adjusted to the correct torque as soon as
possible with a torque-wrench.
Initial of spark plug
I.D. mark
Plug wrench
size
B
21 mm (13/16 in.)
C/BK
16 mm (5/8 in.)
D
18.3 mm (23/32 in.)
1 Spark plug gap
2 Spark plug I.D. mark (NGK)
w
q
903022
4-9
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EMK38010
CHECKING FUEL SYSTEM
w
Gasoline (petrol) and its vapors are highly
flammable and explosive. Keep away
from sparks, cigarettes, flames or other
sources of ignition.
Check the fuel line for leaks, cracks, or
malfunctions. If any problem is found, it
should be repaired immediately by
Yamaha dealer or other qualified mechanic.
Checking points
8 Fuel system parts leakage.
8 Fuel hose joint leakage.
8 Fuel hose cracks or other damage.
8 Fuel connector leakage.
w
Leaking fuel can result in fire or explosion.
8 Check for fuel leakage regularly.
8 If any fuel leakage is found, the fuel
system must be repaired by a qualified
mechanic.
Improper repairs can make the outboard unsafe to operate.
4-10
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EMM52010
INSPECTING AND REPLACING FUEL
FILTER
w
Gasoline (petrol) is highly flammable, and
its vapors are flammable and explosive.
8 If you have any question about properly
doing the procedure, consult your
Yamaha dealer.
8 Do not perform the procedure on a hot
or running engine. Allow the engine to
cool.
8 There will be fuel in the fuel filter.
Keep away from sparks, cigarettes,
flames or other sources of ignition.
8 The procedure will allow some fuel to
spill.
Catch fuel in a rag. Wipe up any spilled
fuel immediately.
8 Improper replacement can result in a
fuel leak, which could result in a fire or
explosion hazard.
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 a Yamaha dealer.
207015*
4-11
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EMU09912
INSPECTING IDLING SPEED
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8 Do not touch or remove electrical parts
when starting or during operation.
8 Keep hands, hair and clothes away
from flywheel and other rotating parts
while engine is running.
cC
This procedure must be performed while
the outboard motor is in the water. A
flushing attachment or test tank can also
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. If the outboard motor is
mounted on a boat, be sure the boat
is tightly moored.
2) Verify whether the idle speed is set to
specification. For idle speed specifications, see “Specifications” in this
chapter.
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.
4-12
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EMK78010
CHECKING WIRING AND
CONNECTORS
1)
2)
Check that each grounding wire is
properly secured.
Check that each connector is engaged
securely.
606011
EXHAUST LEAKAGE
Start the engine and check that no
exhaust leaks from the joints between the
exhaust cover, cylinder head and crank
case.
WATER LEAKAGE
Start the engine and check that no water
leaks from the joints between the exhaust
cover, cylinder head and crank case.
EMU16350
CHECKING TOP COWLING
Check the fitting of the top cowling by
pushing it with both hands.
If the fitting is loose have it repaired by a
Yamaha dealer.
4-13
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EMU00366
GREASING
Yamaha marine grease
(Water resistant grease)
103101
4-14
E
EMU00388
CHECKING PROPELLER
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210012
602051
You could be seriously injured if the
engine accidentally starts while you are
near the propeller.
8 Before
inspecting,
removing
or
installing the propeller, remove the
spark plug caps from the spark plugs.
Also, put the shift control in Neutral,
put the main switch in the “OFF” position and remove the key, and remove
the lanyard from the engine stop
switch. Turn off the battery cut-off
switch if your boat has one.
8 Do not use your hand to hold the propeller when loosening or tightening the
propeller nut. Put a wood block
between the cavitation plate and the
propeller to prevent the propeller from
turning.
EMU00390
602054
Propeller Checking Point
8 Check each of the propeller blades for
wear, erosion from cavitation or ventilation, or other damage.
8 Check the splines for wear and damage.
8 Check for fish line winding around the
propeller shaft.
8 Check the propeller shaft oil seal for
damage.
4-15
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EMU00977
Removing the Propeller
1) Straighten the cotter-pin 1 and pull it
out using a pair of pliers.
602052
2)
q
3)
e
t
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r
000607
4-16
Remove the propeller nut 2 and washer
3.
Remove the propeller 4 and thrust
washer 5.
E
EMU00396
Installing the Propeller
cC
8 Be sure to install the thrust washer
before installing the propeller, otherwise the lower case and propeller boss
may be damaged.
8 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)
3)
Apply Yamaha Marine grease or a
corrosion resistant grease to the propeller-shaft.
Install the thrust washer and propeller
on the propeller-shaft.
Install the washer and tighten the propeller nut to the specified torque.
Tightening torque:
Refer to “SPECIFICATIONS” page 4-1.
4)
602053
Align the propeller nut with the propeller shaft hole. Insert a new cotter
pin in the hole and bend the cotter pin
ends.
NOTE:
When the propeller nut does not align
with the propeller shaft hole after tightening to the specified torque, then tighten
the nut further to align it with the hole.
4-17
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EMU01460¯
CHANGING GEAR OIL
w
8 Be sure the outboard is securely fastened to the transom or a stable stand.
You could be severely injured if the outboard falls on you.
8 Never get under the lower unit while it
is tilted, even when the tilt-support
lever/knob is locked. Severe injury
could occur if the outboard accidentally
falls.
1)
2)
Tilt the outboard motor so that the oil
drain plug is at the lowest point possible.
Place a suitable container under the
gear-case.
102015
3)
4)
Remove the oil drain plug 1.
Remove the oil level plug 2 to allow
the oil to drain completely.
cC
w
q
001418
Inspect the used oil after it has been
drained. If the oil is milky, water is getting into the gear-case which can cause
gear damage. Consult a Yamaha dealer
for repair of the lower unit seals.
NOTE:
For disposal of used oil consult your
Yamaha dealer.
4-18
E
5)
With the outboard motor in a vertical
position, and using a flexible or pressurized filling device, inject the gear
oil into the oil drain plug hole.
Gear oil grade/capacity:
Refer to “SPECIFICATIONS,” page 4-1.
601011
6)
7)
When the oil begins to flow out of the
oil level plug hole, insert and tighten
the oil level plug.
Insert and tighten the oil drain plug.
EML22010
CLEANING FUEL TANK
w
Gasoline (petrol) is highly flammable, and
its vapors are flammable and explosive.
8 If you have any question about properly
doing this procedure, consult your
Yamaha dealer.
8 Keep away from sparks, cigarettes,
flames or other sources of ignition
when cleaning the fuel tank.
8 Remove the fuel tank from the boat
before cleaning it. Work only outdoors
in an area with good ventilation.
8 Wipe up any spilled fuel immediately.
8 Reassemble the fuel tank carefully.
Improper assembly can result in a fuel
leak, which could result in a fire or
explosion hazard.
8 Dispose of old gasoline according to
local regulations.
4-19
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To clean the fuel tank:
1) Empty the fuel tank into an approved
gasoline container.
2) Pour a small amount of suitable solvent in the tank. Reinstall the cap and
shake the tank. Drain the solvent
completely.
902066
To clean the fuel filter:
1) Remove the screws holding the fuel
meter assembly. Pull the assembly
out of the tank.
2) Clean the filter (located on the end of
the suction pipe) in a suitable cleaning solvent. Allow the filter to dry.
3) Replace the gasket with a new one.
Reinstall the fuel meter assembly and
tighten the screws firmly.
EMU14622
INSPECTING AND REPLACING
ANODE(S)
604013
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.
cC
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.
4-20
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EML40010
CHECKING BOLTS AND NUTS
1)
2)
Check that bolts securing the cylinder
head and engine and the nut securing
the flywheel are tightened with their
specified tightening torques.
Check the tightening torques of other
bolts and nuts.
EMU00409
MOTOR EXTERIOR
EMU00410
Cleaning the Outboard Motor
After use, wash the exterior of the outboard with fresh water.
Flush the cooling system with fresh
water.
NOTE:
Refer to Flushing Cooling System instructions in “TRANSPORTING AND STORING
OUTBOARD MOTOR”.
102031
Checking Painted Surface of Motor
Check the motor for scratches, nicks, or
flaking paint. Areas with damaged paint
are more likely to corrode.
If necessary, clean and paint the areas.
Consult a Yamaha dealer for touch-up
paint.
EML44010
COATING THE BOAT BOTTOM
102025
A clean hull improves boat performance.
The boat bottom should be kept as clean
of marine growths as possible.
If necessary, the boat bottom can be coated with an anti-fouling paint approved for
your area to inhibit marine growth.
Do not use anti-fouling paint which
includes copper or graphite. These paints
can cause more rapid engine corrosion.
4-21
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EMN00010
Chapter 5
TROUBLE RECOVERY
TROUBLESHOOTING ..............................5-1
TEMPORARY ACTION IN
EMERGENCY ............................................5-5
Impact damege .....................................5-5
Starter will not operate.........................5-6
Treatment of submerged motor..........5-8
1
2
3
4
5
6
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EMU01663¯
TROUBLESHOOTING
A problem in the fuel, compression, or ignition systems can cause poor starting, loss of
power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items
may not apply to your model.)
If your outboard motor requires repair, bring it to a Yamaha dealer.
If the engine warning indicator is flashing, consult your Yamaha dealer.
Trouble
A. Starter will not
operate.
B. Engine will not
start (Starter
operates).
Possible Cause
1. Starter components faulty.
Remedy
2. Shift lever in gear.
1. Have serviced by a Yamaha
dealer.
2. Shift to neutral.
1.
2.
3.
4.
1.
2.
3.
4.
Fuel tank empty.
Fuel contaminated or stale.
Fuel filter clogged.
Starting procedure incorrect.
5. Fuel pump malfunctions.
5.
6. Spark plug(s) fouled or incorrect
type.
7. Spark plug cap(s) fitted incorrectly.
8. Poor connections or damaged
ignition wiring.
6.
9. Ignition parts faulty.
9.
10. Engine stop switch lanyard not
attached.
11. Engine inner parts damaged.
5-1
7.
8.
10.
Fill tank with clean, fresh fuel.
Fill tank with clean, fresh fuel.
Clean or replace filter.
Read “STARTING ENGINE”
section.
Have serviced by a Yamaha
dealer.
Inspect spark plug(s). Clean or
replace with recommended type.
Check and re-fit cap(s).
Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.
Have serviced by a Yamaha
dealer.
Attach lanyard.
11. Have serviced by a Yamaha
dealer.
E
Trouble
Possible Cause
1. Spark plug(s) fouled or incorrect
type.
2. Fuel system obstructed.
3. Fuel contaminated or stale.
4. Fuel filter clogged.
5. Failed ignition parts.
6. Spark plug gap incorrect.
7. Poor connections or damaged
ignition wiring.
C. Engine idles
irregularly or stalls.
8. Specified engine oil not used.
9. Thermostat faulty or clogged.
10. Carburetor adjustments incorrect.
11. Fuel pump damaged.
12. Air vent screw on the fuel tank
closed.
13. Choke knob pulled out.
14. Motor angle too high.
15. Carburetor clogged.
16. Fuel joint connection incorrect.
17. Throttle valve adjustment incorrect.
5-2
Remedy
1. Inspect spark plug(s). Clean or
replace with recommended type.
2. Check for pinched or kinked fuel
line or other obstructions in fuel
system.
3. Fill tank with clean, fresh fuel.
4. Clean or replace filter.
5. Have serviced by a Yamaha
dealer.
6. Inspect and adjust as specified.
7. Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.
8. Check and replace oil as specified.
9. Have serviced by a Yamaha
dealer.
10. Have serviced by a Yamaha
dealer.
11. Have serviced by a Yamaha
dealer.
12. Open the air vent screw.
13. Return to home position.
14. Return to normal operating
position.
15. Have serviced by a Yamaha
dealer.
16. Connect correctly.
17. Have serviced by a Yamaha
dealer.
E
Trouble
Possible Cause
1. Propeller damaged.
2. Propeller pitch or diameter incorrect.
3. Trim angle incorrect.
4. Motor mounted at incorrect height
on transom.
5. Boat bottom fouled with marine
growth.
6. Spark plug(s) fouled or incorrect
type.
7. Weeds or other foreign matter
tangled on gear housing.
8. Fuel system obstructed.
D. Engine power loss.
9.
10.
11.
12.
Fuel filter clogged.
Fuel contaminated or stale.
Spark plug gap incorrect.
Poor connections or damaged
ignition wiring.
13. Failed ignition parts.
14. Specified engine oil not used.
15. Thermostat faulty or clogged.
16. Air vent screw closed.
17. Fuel pump damaged.
18. Fuel joint connection incorrect.
19. Heat range of spark plug incorrect.
5-3
Remedy
1. Have propeller repaired or
replaced.
2. Install correct propeller to operate
outboard at its recommended
speed (r/min) range.
3. Adjust trim angle to achieve most
efficient operation.
4. Have motor adjusted to proper
transom height.
5. Clean boat bottom.
6. Inspect spark plug(s). Clean or
replace with recommended type.
7. Remove foreign matter and clean
lower unit.
8. Check for pinched or kinked fuel
line or other obstructions in fuel
system.
9. Clean or replace filter.
10. Fill tank with clean, fresh fuel.
11. Inspect and adjust as specified.
12. Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.
13. Have serviced by a Yamaha
dealer.
14. Check and replace oil with
specified type.
15. Have serviced by a Yamaha
dealer.
16. Open the air vent screw.
17. Have serviced by a Yamaha
dealer.
18. Connect correctly.
19. Inspect spark plug and replace it
with recommended type.
E
Trouble
Possible Cause
1. Propeller damaged.
2. Propeller shaft damaged.
E. Engine vibrates
excessively.
3. Weeds or other foreign matter
tangled on propeller.
4. Motor mounting bolt loose.
5. Steering pivot loose or damaged.
5-4
Remedy
1. Have propeller repaired or
replaced.
2. Have serviced by a Yamaha
dealer.
3. Remove and clean propeller.
4. Tighten bolt.
5. Tighten or have serviced by a
Yamaha dealer.
E
EMN20010
TEMPORARY ACTION IN
EMERGENCY
EMH80010
IMPACT DAMAGE
w
The outboard motor can be seriously
damaged by a collision while operating
or trailering. Damage could make the outboard motor unsafe to operate.
607011
If the outboard motor hits any object in
the water, follow the procedure below;
1) Stop the engine immediately.
2) Inspect control system and all components for damage. Also, inspect the
boat damage.
3) However damage is found or not
found, go back to a nearest harbor
slowly and carefully.
4) Have a Yamaha dealer inspection of
the outboard motor, before operating
it again.
5-5
E
EMN30110
STARTER WILL NOT OPERATE
If the starter mechanism does not operate
(engine cannot be cranked with the
starter), the engine can be started with an
emergency starter rope.
w
8 Use this procedure only in an emergency and only to return to port for
repairs.
8 When the emergency starter rope is
used to start the engine, the start-ingear protection device does not operate. Make sure the transmission is in
neutral. Otherwise, the boat could
unexpectedly start to move, which
could result in an accident.
8 Be sure no one is standing behind you
when pulling the starter rope. It could
whip behind you and injure someone.
8 An unguarded rotating flywheel is very
dangerous. Keep loose clothing and
other objects away when starting the
engine. Use the emergency starter rope
only as instructed. Do not touch the flywheel or other moving parts when the
engine is running. Do not install the
starter mechanism or top cowling after
the engine is running.
8 Do not touch the ignition coil, high
voltage wire, spark plug cap or other
electrical components when starting of
operating the motor. You could be
shocked.
5-6
E
Procedure
1) Remove the top cowling.
2) Remove the starter/flywheel cover by
removing the bolts.
208012
NOTE:
On a model equipped with the start-ingear protection device (cable), disconnect
the cable from the starter.
3)
Prepare the engine for starting. See
"STARTING ENGINE" for procedures.
Be sure the engine is in Neutral and
that the lanyard is attached to the
engine stop switch.
On the electric start model the main
switch must be on if the main switch
is equipped.
EMR00001
4)
208014
5-7
To start the engine with emergency
starter rope, insert the knotted end of
the rope into the notch in the flywheel
rotor and wind the rope several turns
clockwise. Then, give a strong pull
straight out to crank the engine.
Repeat if necessary.
E
EMN50011
TREATMENT OF SUBMERGED
MOTOR
107012
If the outboard motor is submerged,
immediately take it a Yamaha dealer.
Otherwise, some corrosion may begin
almost immediately. If you cannot immediately take the outboard motor to a
Yamaha dealer, follow the procedure bellow for taking care to minimize engine
damage.
1)
2)
107013
3)
4)
5)
Thoroughly wash away mud, salt,
seaweed, etc. with fresh water.
Remove the spark plugs and face the
spark plug holes downward to allow
any water, mud or contaminants to
drain.
Drain the fuel from the carburetor.
Feed fogging oil or engine oil through
the carburetors and spark plug holes
while cranking with the manual
starter or emergency starter rope.
Take the outboard motor to a Yamaha
dealer as soon as possible.
cC
Do not attempt to run the motor until it
has been completely inspected.
107014
5-8
E
-MEMO-
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EMP00010
Chapter 6
INDEX
INDEX........................................................6-1
1
2
3
4
5
6
E
EMP10010
INDEX
A
Adjusting trim angle..............................3-17
Air vent screw...........................................2-2
B
Basic Boating rules
(Rules of the road) ...................................1-6
Break in (running in) engine ...................3-8
C
Changing gear oil...................................4-18
Checking bolts and nuts........................4-21
Checking fuel system ............................4-10
Checking painted surface of motor......4-21
Checking propeller.................................4-15
Checking top cowling ............................4-13
Checking wiring and connectors..........4-13
Choke knob ...............................................2-4
Clamping the outboard motor................3-4
Cleaning and adjusting spark plug ........4-8
Cleaning fuel tank ..................................4-19
Cleaning the outboard motor ...............4-21
Coating the boat bottom .......................4-21
Crusing in other conditions ..................3-23
Cruising in salt water.............................3-23
Crusing in shallow water ......................3-19
Cruising in turbid water ........................3-23
E
Emission control information.................1-2
Engine oil ................................................1-11
Engine stop button ..................................2-2
Engine stop lanyard switch.....................2-3
Exhaust leakage .....................................4-13
F
Filling fuel .................................................3-5
Filling fuel and engine oil........................3-5
Flushing cooling system and fogging
engine........................................................4-4
Forward...................................................3-14
Fuel hose joint ..........................................2-2
Fuel meter.................................................2-2
Fuel tank cap.............................................2-2
Fuel tank....................................................2-2
Fueling instructions ...............................1-10
G
Gasoline (petrol) ....................................1-11
Gasoline (petrol) and oil mixing.............3-6
Gear shift lever .........................................2-2
Greasing..................................................4-14
I
Identification numbers record ................1-1
Impact damage ........................................5-5
Important labels .......................................1-5
Inspecting and replacing anode ...........4-20
Inspecting and replacing fuel filter ......4-11
Inspecting idling speed .........................4-12
Installation ................................................3-1
M
Main components....................................2-1
Maintenance chart ...................................4-7
Motor exterior ........................................4-21
Mounting height ......................................3-3
Mounting the outboard motor ...............3-2
O
Operations of controls and other
functions ...................................................2-2
Outboard motor serial number ..............1-1
P
Periodic maintenance..............................4-6
Pre-operation checks ...............................3-7
Procedure for tilting down ....................3-22
Procedure for tilting up .........................3-22
Propeller selection .................................1-12
R
Recoil starter handle................................2-4
Replacement parts ...................................4-6
Reverse ...................................................3-14
S
Safety information ...................................1-3
Shallow water lever .................................2-7
Shifting....................................................3-14
Specifications ...........................................4-1
6-1
E
Start-in-gear protection.........................1-13
Starter will not operate............................5-6
Starting engine.......................................3-10
Steering friction adjustment ...................2-6
Stopping engine.....................................3-15
Storing outboard motor ..........................4-3
T
Temporary action in emergency............5-5
Throttle control grip.................................2-4
Throttle friction adjustment ....................2-5
Throttle indicator .....................................2-4
Tiller handle..............................................2-5
Tilt support knob......................................2-7
Tilting up/down ......................................3-21
Top cowling lock lever ............................2-7
Trailering outboard motor ......................4-2
Transporting and storing outboard
motor.........................................................4-2
Treatment of submerged motor ............5-8
Trim angle adjusting rod.........................2-6
Trim angle settings and boat
handling ..................................................3-18
Trimming outboard motor....................3-16
Troubleshooting.......................................5-1
W
Warning labels .........................................1-5
Warming up engine...............................3-13
Water leakage.........................................4-13
Warranty information .................Next page
6-2
EMU01599
IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND
CANADA
Welcome to the Yamaha Family!
Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be
a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha.
Yamaha is ready to stand behind your purchase with strong warranty coverage. To be sure
you receive all the benefits of warranty, please take the following steps:
1. Be sure your new Yamaha is registered for warranty. Your boat dealer should do this at
the time of sale. Make sure your dealer gives you a copy of the completed Yamaha registration card for your records. If you are unsure whether or not your Yamaha is registered,
complete the Warranty Registration card found inside the cover of the Owner's Manual.
Mail it to the distributor for the country in which you live (see step 6 for the correct
address). If your Yamaha is not properly registered, a warranty repair could be unnecessarily delayed while registration records are checked.
2. Read the Limited Warranty statement which follows these instructions. This warranty
applies to Yamaha outboard motors sold in the United States, whether purchased separately or when supplied as original equipment by a boat builder. The terms also apply to
original equipment packages sold in Canada, with coverage provided by Yamaha Motor
Canada (see ``Warranty Guide'' for Canadian models). This warranty explains the conditions of the warranty, including the obligations that your dealer and you as the owner
have under the warranty. For example, your Yamaha outboard must receive a proper
pre-delivery inspection (PDI) by the selling dealer. Failure to take this important step
could jeopardize warranty coverage!
3. If you need warranty repairs, you must take your Yamaha outboard to an authorized
Yamaha outboard dealer. Be aware that not all selling boat dealers are authorized
Yamaha dealers. Only authorized dealers have the factory training, special tools, and
Yamaha support needed to perform warranty repairs.
4. If you are away from home, or your selling dealer is not an authorized Yamaha dealer,
use the following toll-free numbers to find the nearest Yamaha dealer.
United States Dealer Locations: 1-800-692-6242
Canada Dealer Locations:
1-800-267-8577
5. Your warranty applies specifically to repairs made in the country of purchase. If your
U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian purchased Yamaha needs service while in the United States, Yamaha will assist the local
dealer whenever possible. However, some products available in one country may not be
sold or serviced in the other.
6. If you need any additional information about your Yamaha or warranty coverage which
your dealer cannot provide, please contact us directly.
Yamaha Motor Corporation, U.S.A.
P.O. Box 6555
Cypress, CA 90630
Attention: Customer Relations Department
Telephone No.
Fax No.
(714) 761-7439
(714) 761-7559
Yamaha Motor Canada Ltd.
480 Gordon Baker Road
Toronto, Ontario
M2H 3B4
Attention: Customer Relations Department
Telephone No.
Fax No.
(416) 498-1911
(416) 491-3122
EMU00912*
YAMAHA MOTOR CORPORATION, U.S.A.
OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY
Yamaha Motor Corporation, U.S.A. is proud of its heritage and reputation for producing products with high standards of quality and
workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Outboard
Limited Warranty is your assurance of this commitment.
This warranty provides you with protection against the expense of repairs for your outboard motor that are required as a result of
defects in materials or workmanship. When maintained and utilized in the prescribed manner, you can count on your Yamaha outboard
to provide reliable service.
This warranty provides you with specific coverage and notes your responsibilities in maintaining and operating your outboard. Please
take the time to read and become familiar with this warranty.
PERIOD OF WARRANTY. Any new Yamaha outboard motor purchased and registered with Yamaha Motor Corporation, U.S.A. for pleasure use in the United States, will be warranted against defects in material or workmanship for a period of two (2) years from date of
purchase, subject to exclusions noted herein. Any Yamaha outboard motor purchased and utilized for commercial applications will be
warranted for a period of one (1) year from the date of purchase, subject to exclusions noted herein. Yamaha peripheral equipment
included with the motor, such as gauges, fuel tanks and hoses, remote control boxes, propellers, and wiring external from the motor
unit, will be warranted for one (1) year from the date of purchase for either pleasure or commercial use. Replacement parts used in warranty repairs will be warranted for the balance of the applicable warranty period.
The second year of warranty (if applicable) shall be limited to covering the cost of parts and labor for major components only. The major
components covered are:
Power Unit Section
8 Power Head
8 Intake Manifold and Reed Valve Assembly
8 Carburetor Assembly and its Related Components
8 Fuel and Oil Pump Assemblies
8 Ignition System (Standard and Microcomputer)
8 Precision Blend ® System
Bracket Section
8 Bracket System
8 Power Trim and Tilt Assembly
Lower Unit Section
8 Exhaust System
8 Upper Casing
8 Lower Unit Assembly
The warranty described here applies to outboard motor purchased and registered for use in the United States only excluding its territories. For warranty provisions outside the United States, contact the particular country’s local Yamaha distributor.
WARRANTY REGISTRATION. To be eligible for warranty coverage, the outboard motor must first be registered with Yamaha Motor
Corporation, U.S.A. A warranty registration form is provided in the Owner`s Manual with each outboard. This form must be completed
and mailed to Yamaha by either the selling dealer or the purchaser. Warranty registration can also be accomplished by any authorized
Yamaha outboard dealer. Upon receipt of the registration, an Owner`s Warranty Card will be sent by Yamaha to the registered purchaser.
OBTAINING REPAIRS UNDER WARRANTY. To receive repairs under this warranty, a valid Owner`s Warranty Card must be presented to
an authorized Yamaha outboard dealer.
During the period of warranty, any authorized Yamaha outboard dealer will, free of charge, repair or replace, at Yamaha`s option, any
parts adjudged defective by Yamaha due to faulty workmanship or material from the factory. All replaced parts will become the property
of Yamaha Motor Corporation, U.S.A.
CUSTOMER`S RESPONSIBILITY. Under the terms of this warranty, the customer will be responsible for ensuring that the outboard
motor is properly operated, maintained and stored as specified in the applicable Owner’s Manual.
The owner of the outboard motor shall give notice to an authorized Yamaha marine dealer of any and all apparent defects within ten
(10) days of discovery and make the motor available at that time for inspection and repairs at the dealer’s place of business.
GENERAL EXCLUSIONS FROM WARRANTY. This warranty will not cover the repair of damage if the damage is a result of abuse or
neglect of the product. Examples of abuse and neglect include, but are not limited to:
1.
Racing or competition use, modification of original parts, abnormal strain.
2.
Lack of proper maintenance and off-season storage as described in the Owner`s Manual, improper mounting of the motor, installation of parts or accessories that are not equivalent in design and quality to genuine Yamaha parts.
3.
Operation of the motor at an rpm other than specified, improper propeller selection, use of lubricants, oils, and fuel/oil mixtures
that are not suitable for outboard motor use.
4.
Damage as a result of accidents, collisions, contact with foreign materials, or submersion.
5.
Growth of marine organisms on motor surfaces.
6.
Normal deterioration.
SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs,
shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes,
are not covered by warranty.
Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yamaha Outboard Motor Dealer are
excluded from warranty coverage.
Specific parts excluded from the second and third year of warranty (if applicable) are:
8 Top and Bottom Cowling
8 Electric Components (other than ignition system)
8 Rubber Components (such as hoses, tubes, rubber seals,
fittings, and clamps)
TRANSFER OF WARRANTY. Transfer of the warranty from the original purchaser to any subsequent purchaser is possible by having the
motor inspected by an authorized Yamaha Outboard Motor Dealer and requesting the dealer to submit a change of registration to
Yamaha Motor Corporation, U.S.A. within ten (10) days of the transfer.
YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND
TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND
EXCLUDED FROM THIS WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS
MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE
TO STATE.
YAMAHA MOTOR CORPORATION, U.S.A.
Post Office Box 6555
Cypress, California 90630
WARRANTY QUESTIONS AND ANSWERS
Q.
A.
What costs are my responsibility during the warranty period?
The customer`s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damages.
Q.
A.
What are some examples of ``abnormal’’ strain, neglect, or abuse?
These terms are general and overlap each other in areas. Specific examples include:
Running the machine out of oil, operating the machine with a broken or damaged part which causes another part to fail, damage or
failure due to improper or careless transportation, and/or tie down. If you have any specific questions on operation or maintenance, please contact your Yamaha outboard dealer for advice.
Q.
A.
Does the warranty cover incidental costs such as towing or transportation due to a failure?
No. The warranty is limited to repair of the machine itself.
Q.
A.
May I perform any or all of the recommended maintenance shown in the Owner’s Manual instead of having the dealer do them?
Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s and Service Manuals. We do recommend,
however, that items requiring special tools or equipment be done by a Yamaha outboard dealer.
Q.
A.
Will the warranty be void or canceled if I do not operate or maintain my new outboard exactly as specified in the Owner’s Manual?
No. The warranty on a new outboard cannot be ’’voided`` or ’’canceled``. However, if a particular failure is caused by operation or
maintenance other than as shown in the Owner’s Manual, that failure may not be covered under warranty.
Q.
A.
What responsibility does a Yamaha outboard dealer have under this warranty?
Each Yamaha outboard dealer is expected to:
1. Completely set up each outboard he sells prior to delivery.
2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request
at any later date.
In addition, each Yamaha outboard dealer is held responsible for his setup, service and warranty repair work.
Q.
A.
Is the warranty transferable to second owners?
Yes. The remainder of any existing warranty can be transferred upon request. The unit has to be inspected and re-registered by an
authorized Yamaha outboard dealer for the policy to remain effective.
CUSTOMER SERVICE
If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United
States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or
problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level,
this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:
YAMAHA MOTOR CORPORATION U.S.A.
CUSTOMER RELATIONS DEPARTMENT
P.O.Box 6555
Cypress, California 90630
When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include any important information such as names, addresses,
model, engine serial number, dates, and receipts.
CHANGE OF ADDRESS
The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers
against the possibility of a safety-related defect and recall. This list is complied from the purchase registrations sent to Yamaha Motor
Corporation, U.S.A. by the selling dealer at the time of your purchase.
If you should move after you have purchased your new outboard, please advise us of your new address by sending a postcard listing
your outboard model name, engine serial number, dealer number (or dealer’s name) as it is shown on your warranty identification, your
name and new mailing address. Mail to:
YAMAHA MOTOR CORPORATION, U.S.A.
WARRANTY DEPARTMENT
P.O.Box 6555
Cypress, California 90630
This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.
EMU01178
IMPORTANT WARRANTY INFORMATION
IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA
Welcome to the Yamaha Family!
Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience
to be a satisfying one. Please read the following warranty information to help ensure
satisfaction with your Yamaha.
This model was manufactured as a U.S.A. specification model, and the warranty statement shown in this manual is for market. To receive the benefits of the warranty that
applies to the country in which you use your Yamaha, please note the following information.
1.
The warranty on this model is the same as equivalent models sold in the country
where you will receive service. If you need more information about your warranty
coverage or your Yamaha outside the U.S.A. or Canada, please contact an authorized Yamaha dealer in your country.
2.
Keep a copy of your sales contract or invoice for the purchase of your Yamaha and
present it if you need warranty repairs. This document should show the date of
purchase, which is important evidence the repairing dealer will need to be sure
your Yamaha is covered by warranty.
3.
If your Yamaha needs warranty repairs, contact an authorized Yamaha dealer in
the country where you are. He will explain how to get warranty service in that
country.
4.
This Yamaha model may not be sold in some countries. Therefore, in some cases
your local dealer may not have all the parts or service information he may need,
which may unavoidably delay repairs. If this happens, we thank you for your
understanding and assure you we will attempt to resolve the situation as quickly as
possible.
Printed in France
January 2003-0.5 × 1 !
6M8-F8199-17
(8CMH)
(E)
Printed on recycled paper
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