Yamaha 9.9 Owner's Manual

F2.5

OWNER’S MANUAL

U.S.A.Edition

LIT-18626-07-04

69M-F8199-15

U69M15E0.book Page 1 Wednesday, April 5, 2006 4:48 PM

ZMU01690

Read this owner’s manual carefully before operating your outboard motor.


Important manual information

EMU31280

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.

your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.

NOTE:

The F2.5MH and the standard accessories are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model.

EMU25130

The Safety Alert Symbol means AT-

TENTION! BECOME ALERT! YOUR SAFE-

TY IS INVOLVED!

EWM00780

WARNING

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

ECM00700

CAUTION:

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

F2.5

OWNER’S MANUAL

©2006 by Yamaha Motor Corporation,

USA

1st Edition, January 2006

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-18626-07-04

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


Table of contents

General information .......................... 1

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

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

Emission control information ........... 1

North American models...................... 1

Star labels .......................................... 2

Safety information ........................... 3

Important labels............................... 4

Warning labels.................................... 4

Caution labels..................................... 5

Basic boating rules

(Rules of the road) ....................... 5

Steering and sailing rules and sound signals .................................. 5

Rules when encountering vessels...... 6

Other special situations ...................... 7

Fueling instructions ......................... 9

Gasoline ............................................. 9

Engine oil............................................ 9

Propeller selection......................... 10

Basic components .......................... 11

Main components.......................... 11

Fuel tank........................................... 11

Fuel tank cap.................................... 12

Air vent screw................................... 12

Fuel cock .......................................... 12

Tiller handle...................................... 12

Gear shift lever ................................. 13

Throttle grip ...................................... 13

Throttle indicator............................... 13

Throttle friction adjuster.................... 13

Engine stop lanyard switch............... 14

Engine stop button ........................... 14

Choke knob for pull type................... 14

Manual starter handle....................... 14

Steering friction adjuster................... 15

Trim rod (tilt pin) ............................... 15

Tilt support lever for manual tilt model ............................................ 15

Top cowling lock lever

(pull up type) ................................. 15

Carrying handle ................................ 16

Operation ......................................... 17

Installation..................................... 17

Mounting the outboard motor ........... 17

Clamping the outboard motor ........... 18

Breaking in engine ........................ 19

Procedure for 4-stroke models ......... 19

Preoperation checks ..................... 19

Fuel .................................................. 19

Controls ............................................ 19

Engine .............................................. 19

Checking the engine oil level............ 19

Filling fuel for built-in tank ............. 20

Ring Free Fuel Additive .................... 20

Operating engine .......................... 21

Feeding fuel...................................... 21

Starting engine ................................. 21

Warming up engine....................... 23

Manual start models ......................... 23

Shifting .......................................... 23

Forward (tiller handle and remote control models) ................. 23

Reverse ............................................ 24

Stopping engine ............................ 25

Procedure ......................................... 25

Trimming outboard motor.............. 25

Adjusting trim angle for manual tilt models .......................................... 26

Adjusting boat trim............................ 26

Tilting up and down....................... 27

Procedure for tilting up

(manual tilt models)....................... 28

Procedure for tilting down

(manual tilt models)....................... 29

Maintenance .................................... 30

Specifications................................ 30

Transporting and storing outboard motor .......................... 31

Clamp screw mounting models ........ 31

Storing outboard motor..................... 32

Procedure ......................................... 32

Lubrication

(except oil injection models).......... 33


Table of contents

Cleaning and anticorrosion measures ...................................... 33

Cleaning the outboard motor............ 33

Checking painted surface of motor... 34

Periodic maintenance.................... 34

Replacement parts ........................... 34

Maintenance chart............................ 35

Maintenance chart (additional) ......... 36

Greasing........................................... 36

Cleaning and adjusting spark plug ... 36

Checking fuel system ....................... 37

Inspecting idling speed..................... 38

Changing engine oil.......................... 38

Checking wiring and connectors ...... 40

Exhaust leakage............................... 40

Water leakage .................................. 40

Engine oil leakage ............................ 40

Checking propeller ........................... 40

Removing the propeller .................... 41

Installing the Propeller...................... 41

Changing gear oil ............................. 42

Inspecting and replacing anode(s) ... 43

Checking top cowling ....................... 43

Coating the boat bottom ................... 43

Consumer information ................... 52

Important warranty information for

U.S.A. and Canada .................... 52

YAMAHA MOTOR

CORPORATION, U.S.A.

FOUR-STROKE OUTBOARD

MOTOR THREE-YEAR

LIMITED WARRANTY ............... 54

IMPORTANT WARRANTY

INFORMATION IF YOU USE

YOUR YAMAHA OUTSIDE

THE USA OR CANADA ............. 56

Trouble Recovery ............................ 45

Troubleshooting ............................ 45

Temporary action in emergency.... 48

Impact damage................................. 48

Starter will not operate ..................... 48

Emergency Starting Engine.............. 49

Treatment of submerged motor..... 51

Procedure......................................... 51


General information

EMU25170

Identification numbers record

EMU25183

Outboard motor serial number

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

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

EMU25242

Approval label of emission control certificate

This label is attached to the bottom cowling.

New Technology; (4-stroke/HPDI) EM

1. Approval label location

EMU25262

Manufactured date label

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

EMU25221

Emission control information

EMU25230

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.

1. Manufactured date label location

1

1. Outboard motor serial number location



Manufactured:

ZMU04346

ZMU01702

EMU25272

Star labels

Your outboard motor is labeled with a California Air Resources Board (CARB) star label.

See below for a description of your particular label.

EMU25290

Two Stars—Very Low Emission

The two-star label identifies engines that meet the Air Resources Board’s 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than

One Star-Low-Emission engines.

ZMU01703

1. Star labels location

EMU25280

One Star—Low Emission

The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the

U.S. EPA’s 2006 standards for marine engines.

EMU25300

Three Stars—Ultra Low Emission

The three-star label identifies engines that meet the Air Resources Board’s 2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low-Emission engines.

2



EMU25362

ZMU01704

●

Safety information

Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the

● motor and its operation.

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

● Do not overpower the boat with this outboard motor. Overpowering the boat could result in loss of control. The rated power of the outboard should be equal to or less than the rated horsepower capacity of the boat.

If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer.

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

● Incorrect propeller selection and incorrect use may not only cause engine damage, but also adversely affect fuel consumption.

Consult your dealer for correct use.

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

● involve intoxication.

Have an approved personal flotation device

(PFD) on board for every occupant. It is a good idea to wear a PFD whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating conditions.

● Gasoline is highly flammable, and its vapors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel before starting the engine.

● This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness.

Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.

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

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

● Know the marine laws and regulations where you will be boating—and obey them.

For basic boating rules, see “Rules of the

road” on page 5.

● Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.

● Tell someone where you are going: leave a

Float Plan with a responsible person. Be sure to cancel the Float Plan when you return.

● Use common sense and good judgment when boating. Know your abilities, and be sure you understand how your boat handles under the different boating conditions you may encounter. Operate within your

3


General information limits, and the limits of your boat. Always operate at safe speeds, and keep a careful

● watch for obstacles and other traffic.

Always watch carefully for swimmers during the engine operation.

●

●

Stay away from swimming areas.

When a swimmer is in the water near you

● shift into neutral and shut off the engine.

Do not illegally discard empty containers used to replace or replenish oil. For the correct processing of empty containers, consult the dealer where you purchased the oil.

● When replacing oils used to lubricate the product (engine or gear oil), be sure to wipe away any spilt oil. Never pour oil without using a funnel or similar device. If necessary, verify the necessary replacement procedure with the dealer.

● Never illegally discard (dump) the product.

Yamaha recommends consulting the dealer on discarding the product.

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

EMU25382

Important labels

EMU25395

Warning labels

EMU25401

Label

EWM01260

WARNING

● Be sure shift control is in neutral before starting engine. (except 2HP)

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

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

EMU25441

Label

EWM01311

WARNING

LEAKING FUEL COULD CAUSE A FIRE.

Before tilting up the engine or laying it on its side:

4



● Turn the fuel cock to the “closed” position.

● Tighten the air-vent screw on the fuel tank cap.

EMU25465

Caution labels

EMU25482

Label

ECM01201

CAUTION:

Store the engine only as shown.

Otherwise, engine damage could result from leaking oil.

EMU25500

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.

EMU25510

Steering and sailing rules and sound signals

Whenever two vessels on the water meet one another, one vessel has the right-of-way; it is called the “stand-on” vessel. The vessel which does not have the right-of-way is called the “give-way” or “burdened” vessel. These rules determine which vessel has the right-ofway, and what each vessel should do.

Stand-on vessel

The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision. When you maintain your direction and speed, the other vessel will be able to determine how best to avoid you.

Give-way vessel

The vessel which does not have the right-ofway has the duty to take positive and timely action to stay out of the way of the Stand-On vessel. Normally, you should not cross in front of the vessel with the right-of-way. You should slow down or change directions briefly and pass behind the other vessel. You should always move in such a way that the operator of the other vessel can see what you are doing.

5



“The general prudential rule”

This rule is called Rule 2 in the International

Rules and says,

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

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

EMU25520

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 traveling across the other vessel’s path)

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

In the following illustration, your boat is in the center. You should give the right-of-way to 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.

Meeting

If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of-way!

Both of you should alter course to avoid an accident. You should keep the other vessel on your port (left) side. This rule doesn’t apply if both of you will clear one another if you continue on your set course and speed.

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.

6


7


Overtaking

If you are passing another vessel, you are the

“Give-Way” vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.

EMU25530

Other special situations

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

Narrow channels and bends

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

Fishing vessel right-of-way

All vessels which are fishing with nets, lines or trawls are considered to be “fishing vessels” under the International Rules. Vessels with trolling lines are not considered fishing vessels. Fishing vessels have the right-of-way regardless of position. Fishing vessels cannot, however, impede the passage of other vessels in narrow channels.

Sailing vessel right-of-way

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

1.

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

2.

Sailing vessels should keep clear of any fishing vessel.

3.

In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel 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.

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

ZMU01708

8



EMU31490

Fueling instructions

EWM01490

WARNING

GASOLINE AND ITS VAPORS ARE HIGH-

LY FLAMMABLE AND EXPLOSIVE!

● Do not smoke when refueling, and keep away from sparks, flames, or other

●

●

● sources of ignition.

Stop engine before refueling.

Refuel in a well-ventilated area.

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

●

●

Do not overfill the fuel tank.

Tighten the filler cap securely after refu-

● eling.

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

● If any gasoline spills onto your skin, immediately wash with soap and water.

●

Change clothing if gasoline spills on it.

Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.

ECM00010

CAUTION:

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

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. Yamaha does not recommended gasohol containing methanol because it can cause fuel system damage or engine performance problems.

EMU31440

Engine oil

Recommended engine oil:

YAMALUBE 4-M FC-W oil or 4-stroke motor oil with a combination of the following SAE and API oil classifications

Engine oil type SAE:

10W-30 or 10W-40

Engine oil grade API:

SE, SF, SG, SH, SJ, SL

Engine oil quantity (excluding oil filter):

0.35 L (0.37 US qt) (0.31 Imp.qt)

NOTE:

If the recommended engine oil grades are not available, select an alternative from the following chart according to the average temperatures in your area.

EMU25570

Gasoline

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

Recommended gasoline:

Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2

9


ECM01050

CAUTION:

All 4-stroke engines are shipped from the factory without engine oil.

General information x -

1 2 3

ZMU04604

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

ZMU01710

EMU25742

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:

Select a propeller which will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat load. If operating conditions such as light boat loads then allow the engine r/min to rise above the maximum recommended range, reduce the throttle setting to maintain the engine in the proper operating range.

For instructions on propeller removal and in-

stallation, see page 40.

10


Basic components

EMU25797

Main components

NOTE:

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

1. Top cowling

2. Top cowling lock lever

3. Carrying handle

4. Steering friction screw

5. Anti-cavitation plate

6. Propeller

7. Cooling water inlet

8. Trim rod

9. Clamp bracket

10.Tiller handle

11.Air vent screw

12.Fuel tank cap

13.Manual starter handle

14.Engine stop button/Engine stop lanyard switch

15.Clamp screw

16.Rope attachment

11

17.Gear shift lever

18.Choke knob

EMU25821

Fuel tank

If your model included a fuel tank, its parts and functions are as follows.



1. Fuel tank cap

2. Air vent screw

EMU25850

Fuel tank cap

This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise.

EMU25860

Air vent screw

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

EMU25872

Fuel cock

The fuel cock turns on and off the supply of fuel from the fuel tank to the engine.

1. Close position

EMU25891

Open

With the lever/knob in this position, fuel flows to the carburetor.

Normal running is done with the lever/knob in this position.

1. Open position

EMU25911

Tiller handle

To change direction, move the tiller handle to the left or right as necessary.

1. Fuel cock

EMU25881

Close

To stop fuel flow to the engine, turn the lever or knob to close position.

Always turn the lever or knob to close position when the engine is not running.

12



EMU25930

Gear shift lever

Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead.

1. Forward “ ”

2. Neutral “ ”

EMU25941

Throttle grip

The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.

1. Throttle indicator

EMU25971

Throttle friction adjuster

A friction device provides adjustable resistance to movement of the throttle grip or the remote control lever, and can be set according to operator preference.

To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.

EWM00031

WARNING

Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident.

EMU25961

Throttle indicator

The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation.

When constant speed is desired, tighten the adjuster to maintain the desired throttle setting.

13



EMU25990

Engine stop lanyard switch

The lock plate must be attached to the engine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away under power.

EWM00120

WARNING

● Attach the engine stop switch lanyard to a secure place on your clothing, or your

● arm or leg while operating.

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

● Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

EMU26001

Engine stop button

To open the ignition circuit and stop the engine, push this button.

EMU26011

Choke knob for pull type

To supply the engine with the rich fuel mixture required to start, pull out this knob.

NOTE:

The engine cannot be started with the lock plate removed.

EMU26070

Manual starter handle

To start the engine, first gently pull the handle out until resistance is felt. From that position, then pull the handle straight out quickly to crank the engine.

1. Lock plate

2. Lanyard

14



EMU26122

Steering friction adjuster

A friction device provides adjustable resistance to the steering mechanism, and can be set according to operator preference. An adjusting screw or bolt is located on the swivel bracket.

EMU30200

Tilt support lever for manual tilt model

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

To increase resistance, turn the adjuster clockwise.

To decrease resistance, turn the adjuster counterclockwise.

EWM00040

WARNING

Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident.

EMU26261

Trim rod (tilt pin)

The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.

EMU26382

Top cowling lock lever (pull up type)

To remove the engine top cowling, pull up the lock lever(s) and lift off the cowling. When installing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling by moving the lever(s) downward.

15



EMU26450

Carrying handle

A carrying handle is provided on the rear of the outboard motor. It enables you to carry the outboard motor easily with one hand.

16


Operation

EMU26901

Installation

ECM00110

CAUTION:

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

NOTE:

During water testing check the buoyancy of the boat, at rest, with its maximum load.

Check that the static water level on the exhaust housing is low enough to prevent water entry into the powerhead, when water rises due to waves when the outboard is not running.

EMU26910

Mounting the outboard motor

EWM00820

WARNING

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

● manufacturer.

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

EWM00830

WARNING

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

● For permanently mounted models, your dealer or other person experienced in proper rigging should mount the motor.

If you are mounting the motor yourself, you should be trained by an experienced person.

● For portable models, your dealer or other person experienced in proper outboard motor mounting should show you how to mount your motor.

Mount the outboard motor on the center line

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

1

ZMU01760

1. Center line (keel line)

EMU26920

Mounting height

To run your boat at optimum efficiency, the water resistance (drag) of the boat and outboard motor must be made as little as possible. The mounting height of the outboard motor greatly affects the water resistance. If the mounting height is too high, cavitation

17


Operation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in.) below it.

EWM00640

WARNING

Loose clamp screws could allow the outboard motor to fall off or move on the transom. This could cause loss of control and serious injury. Make sure the transom screws are tightened securely. Occasionally check the screws for tightness during operation.

ZMU02012

NOTE:

● The optimum mounting height of the outboard motor is affected by the boat and motor combination and the desired use. Test runs at different heights can help determine the optimum mounting height. Consult your

Yamaha dealer or boat manufacturer for further information on determining the proper mounting height.

● For instructions on setting the trim angle of

the outboard motor, see page 25.

EMU26970

Clamping the outboard motor

1.

Place the outboard motor on the transom so that it is positioned as close to the center as possible. Tighten the transom clamp screws evenly and securely. Occasionally check the clamp screws for tightness during operation of the outboard motor because they could become loose due to engine vibration.

2.

If the engine restraint cable attachment is equipped on your engine, an engine restraint cable or chain should be used. Attach one end to the engine restraint cable attachment and the other to a secure mounting point on the boat. Otherwise the engine could be completely lost if it accidentally falls off the transom.

3.

Secure the clamp bracket to the transom using the bolts provided with the outboard (if packed). For details, consult your Yamaha dealer.

18


Operation

EWM00650

WARNING

Avoid using bolts, nuts or washers other than those contained in the engine packaging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tightening, test run the engine and check their tightness.

EMU27102

Preoperation checks

EWM00080

WARNING

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

ECM00120

CAUTION:

Do not start the engine out of water. Overheating and serious engine damage can occur.

EMU30173

Breaking in engine

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

ECM00800

CAUTION:

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

EMU27081

Procedure for 4-stroke models

Run the engine under load (in gear with a propeller installed) for 10 hours as follows.

1.

First hour:

Run the engine at 2000 r/min or at approximately half throttle.

2.

Second hour:

Run the engine at 3000 r/min or at approximately three-quarter throttle.

3.

Remaining eight hours:

Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.

4.

After the first 10 hours:

Operate the engine normally.

EMU31500

Fuel

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

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

EMU27130

Controls

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

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

● Look for loose or damaged connections.

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

EMU27140

Engine

● Check the engine and engine mounting.

● Look for loose or damaged fasteners.

● Check the propeller for damage.

EMU30212

Checking the engine oil level

1.

Put the outboard motor in an upright position (not tilted).

2.

Check the oil level using the oil level check window to be sure the level falls between the upper and lower marks. Fill

19


Operation with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark.

3.

Fill the fuel tank carefully.

4.

Securely close the cap after refueling.

Wipe up any spilled fuel.

Fuel tank capacity:

0.9 L (0.24 US gal) (0.20 Imp.gal)

1. Oil level check window

1. Lower level mark

2. Upper level mark

EMU30850

Filling fuel for built-in tank

EWM00060

WARNING

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

1.

With the outboard motor tilted down (in the vertical running position), remove the fuel tank cap.

2.

Use a funnel if the nozzle on the fuel can or pump is not small enough or long enough to fit into the mouth of the fuel tank.

EMU27270

Ring Free Fuel Additive

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

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

While many additives available may reduce deposits, Yamaha recommends the use of

Ring Free Fuel Additive, available from your

Yamaha dealer. Ring Free Fuel Additive has repeatedly proven its ability to clean combustion deposits from inside the engine, notably the critical piston-ring-land area, and fuel system components. Follow product labeling for use instructions.

20


Operation

EMU27450

Operating engine

EMU31510

Feeding fuel

EWM00420

WARNING

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

Be sure there are no swimmers in the

● water near you.

When the air vent screw is loosened, gasoline vapor will be released. Gasoline is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening

● the air vent screw.

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

1.

Loosen the air vent screw on the fuel tank cap by one turn.

EMU27490

Starting engine

EMU27522

Manual start models

1.

Place the gear shift lever in neutral.

EWM00110

WARNING

Always start the engine in neutral to avoid accidentally moving the boat.

2.

Open the fuel cock.

2.

If the engine stop switch lanyard is equipped, attach it to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the engine stop switch.

EWM00120

WARNING

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

21


Operation

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

● Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

NOTE:

● When restarting a warm engine, place the choke knob in the “ ” (run) position.

● If the choke knob is left in the “ ” (start) position while the engine is running, the engine will run poorly or stall.

5.

Pull the manual starter handle slowly until you feel resistance. Then give a strong pull straight out to start the engine. Repeat if necessary.

3.

Place the throttle grip in the “

(start) position.

”

4.

Place the choke knob in the “ ”

(start) position. After the engine starts, return the knob to the “ ” (run) position.

6.

After the engine starts, slowly return the manual starter handle to the original position before releasing it.

7.

Slowly return the throttle grip to the fully closed position.

NOTE:

● When the engine is cold, it needs to be warmed up. For further information, see

page 23.

22


Operation

● If the engine does not start on the first try, repeat the procedure. If the engine fails to start after 4 or 5 tries, open the throttle a small amount (between 1/8 and 1/4) and try again. Also if the engine is warm and fails to start, open the throttle a same amount and try to start the engine again. If the engine

still fails to start, see page 45.

EMU27670

Warming up engine

EMU27732

Manual start models

1.

After starting the engine, return the choke knob to the halfway position. For approximately the first 5 minutes after starting, warm up the engine by operating at one fifth throttle or less. After the engine has warmed up, push the choke knob in fully.

Failure to do so will shorten engine life.

NOTE:

● If the choke knob is left pulled out after the engine starts, the engine will stall.

● In temperatures of -5°C or less, leave the choke knob pulled out fully for approximately 30 seconds after starting.

2.

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

ECM00511

CAUTION:

A continuous flow of water from the cooling water pilot hole shows that the water pump is pumping water through the cooling passages. If water is not flowing out of the hole at all times while the engine is running, overheating and serious damage could occur. Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and corrected.

EMU27740

EWM00180

WARNING

Shifting

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

ECM00220

CAUTION:

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

EMU27764

Forward (tiller handle and remote control models)

Tiller handle models

1.

Place the throttle grip in the fully closed position.

23


Operation

2.

Move the gear shift lever quickly and firmly from neutral to forward.

2.

Turn the outboard motor around 180°, and then move the tiller handle so that it is facing toward the bow.

NOTE:

The outboard motor can be turned a full 360° in its bracket (full-pivot system).

Remote control models

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

EMU27811

Reverse

EWM00190

WARNING

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

1.

Place the throttle grip in the fully closed position.

3.

Move the gear shift lever quickly and firmly from neutral to forward.

24


Operation

EMU27820

Stopping engine

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

EMU31520

Procedure

1.

Push and hold the engine stop button until the engine comes to a complete stop.

2.

After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock to the closed position.

EMU27861

Trimming outboard motor

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

EWM00740

WARNING

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

NOTE:

The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop switch.

1. Trim operating angle

25


Operation

EMU27872

Adjusting trim angle for manual tilt models

There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim angle.

1.

Stop the engine.

2.

Tilt the outboard motor up, and then remove the trim rod from the clamp bracket.

NOTE:

The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim rod one hole.

EMU27911

Adjusting boat trim

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

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

1. Trim rod

3.

Reposition the rod in the desired hole.

To raise the bow (“trim-out”), move the rod away from the transom.

To lower the bow (“trim-in”), move the rod toward the transom.

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

EWM00400

WARNING

● Stop the engine before adjusting the trim angle.

● Use care to avoid being pinched when removing or installing the rod.

● Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim angle can cause loss of control.

Bow Up

Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces performance further, and the boat may “porpoise”

(hop in the water), which could throw the operator and passengers overboard.

26


Operation

Bow Down

Too much trim-in causes the boat to “plow” through the water, decreasing fuel economy and making it hard to increase speed. Operating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making operation difficult and dangerous.

NOTE:

Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.

EMU27921

Tilting up and down

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

EWM00220

WARNING

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

EWM00230

WARNING

Leaking fuel is a fire hazard. Tighten the air vent screw and place the fuel cock in the closed position if the outboard motor will be tilted for more than a few minutes.

Otherwise fuel may leak.

ECM00231

CAUTION:

● Before tilting the outboard motor, follow the procedure under “Stopping engine” in this chapter. Never tilt the outboard motor while the engine is running. Severe damage from overheating can result.

● Do not tilt up the engine by pushing the tiller handle because this could break the handle.

● Keep the power unit higher than the propeller at all times. Otherwise water could run into the cylinder and cause damage.

● The outboard motor cannot be tilted when in reverse or when the outboard motor is turned 180° (facing the rear).

27


EMU27964

Procedure for tilting up (manual tilt models)

1.

Place the gear shift lever in neutral (if equipped) and face the outboard motor forward.

Operation

2.

On full-pivot system models, tighten the steering friction adjuster by turning it clockwise to prevent the motor from turning freely.

3.

Tighten the air vent screw. On models equipped with a fuel joint, disconnect the fuel line from the outboard motor.

5.

Tilt support bar equipped models: Hold the rear of the top cowling or the rear handle (if equipped) with one hand and tilt the outboard motor up fully until the tilt support bar automatically locks.

6.

Tilt support knob equipped models: Hold the rear of the top cowling with one hand, fully tilt the outboard motor up, and push the tilt support knob into the clamp bracket.

7.

Tilt support lever equipped models: Hold the rear handle and tilt the engine up fully until the tilt support lever automatically locks.

4.

Close the fuel cock.

NOTE:

Tilt support lever/bar equipped models: If the motor is not facing forward, the tilt support lever/bar cannot automatically turn to the

28


Operation locked position. If the tilt support lever/bar does not automatically lock, swing the motor a little to the left and right.

EMU28032

Procedure for tilting down (manual tilt models)

1.

Slightly tilt the outboard motor up.

2.

If equipped with the tilt support bar: Slowly tilt the outboard motor down while pulling the tilt support bar lever up.

3.

If equipped with the tilt support knob: Pull the knob out, and then slowly tilt the outboard motor down.

4.

If equipped with the tilt support lever:

Slowly tilt the outboard motor down while pulling the tilt support lever up.

5.

Loosen the steering friction adjuster by turning it counterclockwise, and adjust the steering friction according to operator preference.

EWM00720

WARNING

If there is too much resistance it could be difficult to steer, which could result in an accident.

29


Maintenance

EMU31480

Specifications

NOTE:

“(AL)” stated in the specification data below represents the numerical value for the aluminum propeller installed.

Likewise, “(SUS)” represents the value for stainless steel propeller installed and “(PL)” for plastic propeller installed.

EMU28218

Dimension:

Overall length:

623 mm (24.5 in)

Overall width:

345 mm (13.6 in)

Overall height S:

1021 mm (40.2 in)

Transom height S:

432 mm (17.0 in)

Weight (AL) S:

17.0 kg (37 lb)

Performance:

Full throttle operating range:

5250–5750 r/min

Maximum output:

1.8 kW@5500 r/min (2.5 HP@5500 r/min)

Idling speed (in neutral):

1900 ±100 r/min

Engine:

Type:

4-stroke S

Displacement:

72.0 cm³ (4.39 cu.in)

Bore

× stroke:

54.0

× 31.5 mm (2.13 × 1.24 in)

Ignition system:

TCI

Spark plug (NGK):

BR6HS

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Control system:

Tiller

Starting system:

Manual

Starting carburetion system:

Choke valve

Valve clearance (cold engine) IN:

0.08–0.12 mm (0.0032–0.0047 in)

Valve clearance (cold engine) EX:

0.08–0.12 mm (0.0032–0.0047 in)

Drive unit:

Gear positions:

Forward-neutral

Gear ratio:

2.08 (27/13)

Trim and tilt system:

Manual tilt

Propeller mark:

BS

Fuel and oil:

Recommended fuel:

Regular unleaded gasoline

Min. pump octane:

86

Fuel tank capacity (built in type):

0.9 L (0.24 US gal) (0.20 Imp.gal)


4-stroke outboard motor oil

Engine oil grade API:

API SE, SF, SG, SH, SJ, SL

Engine oil type SAE:

SAE10W30 or SAE10W40

Lubrication:

Wet sump


0.35 L (0.37 US qt) (0.31 Imp.qt)

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

75.0 cm³ (2.54 US oz) (2.65 Imp.oz)

Tightening torque for engine:

Spark plug:

25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Engine oil drain bolt:

18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

30


Maintenance

EMU28222

Transporting and storing outboard motor

EWM00690

WARNING

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

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

● DO NOT fill fuel container to maximum capacity. Gasoline will expand considerably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.

EWM00700

WARNING

Never get under the lower unit while it is tilted, even if a motor support bar is used.

Severe injury could occur if the outboard motor accidentally falls.

EMU28235

Clamp screw mounting models

When transporting or storing the outboard motor while removed from a boat, keep the outboard motor in the attitude shown.

ECM00660

CAUTION:

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

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

31


Maintenance

● Store the outboard motor in a dry, wellventilated place, not in direct sunlight.

NOTE:

Place a towel or something similar under the outboard motor to protect it from damage.

EMU28241

Storing outboard motor

When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage.

It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the following procedures.

ECM01080

CAUTION:

● To prevent problems which can be caused by oil entering the cylinder from the sump, keep the outboard motor in the attitude shown when transporting and storing it. If storing or transporting the outboard motor on its side (not upright), put it on a cushion after draining the engine oil.

● Do not place the outboard motor on its side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trouble.

EMU28302

Procedure

EMU28372

Flushing in a test tank

1.

Wash the outboard motor body using fresh water. For further information, see

page 33.

2.

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

00) to each gallon of fuel.

NOTE:

The use of “Yamaha Fuel Conditioner and

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

3.

Remove the engine top cowling and silencer cover.

4.

Install the outboard motor on the test tank.

1. Water surface

2. Lowest water level

5.

Fill the tank with fresh water to above the level of the anti-cavitation plate.

32


Maintenance

ECM00300

CAUTION:

Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the engine will be damaged from overheating. Before starting the engine, be sure to supply water to the cooling water passages.

ECM00290

CAUTION:

If the fresh water level is below the level of the anti-cavitation plate, or if the water supply is insufficient, engine seizure may occur.

6.

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

EWM00090

WARNING


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

7.

Run the engine at a fast idle for 10–15 minutes in neutral position.

8.

Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite Engine Fogging

Oil” (Part No. LUB-STRRT-12-00) alternately into each carburetor or the fogging hole of the silencer cover, if equipped.

When properly done, the engine will smoke excessively and almost stall.

9.

Remove the outboard motor from the test tank.

10. Drain the cooling water completely out of the motor. Clean the body thoroughly.

11. Install the silencer cover/cap and top cowling.

EMU28400

Lubrication (except oil injection models)

1.

Grease the spark plug threads and install the spark plug(s) and torque to proper specification. For information on spark

plug installation, see page 36.

2.

Change the gear oil. For instructions, see

page 42. Inspect the oil for the presence

of water that indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use.

3.

Grease all grease fittings. For further de-

tails, see page 36.

EMU28421

Cleaning and anticorrosion measures

1.

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

2.

Spray the outboard motor 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).

EMU28450

Cleaning the outboard motor

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

33


Maintenance

NOTE:

For cooling system flushing instructions, see

page 31.

EMU28460

Checking painted surface of motor

Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer.

EMU28486

Periodic maintenance

EWM01070

WARNING

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

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 your Yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform maintenance not covered by this owner’s manual.

EMU28510

Replacement parts

If replacement parts are necessary, use only genuine Yamaha parts or parts of the same type and of equivalent strength and materials.

Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from your Yamaha dealer.

34


Maintenance

EMU28522

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.

NOTE:

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

The “ ” symbol indicates the check-ups which you may carry out yourself.

The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

10 hours

(1 month)

50 hours

(3 months)

100 hours

(6 months)

200 hours

(1 year)

Anode(s) (external)

Anode(s) (internal)

Inspection / replacement


Cooling water passages

Cowling clamp

Fuel filter (inside builtin fuel tank)

Fuel system

Cleaning

Inspection

Inspection / cleaning

Inspection

Fuel tank (built-in tank) Inspection / cleaning

Gear oil

Greasing points

Idling speed (carburetor models)

Change

Greasing

Inspection

Propeller and cotter pin

Shift link / shift cable

Thermostat


Inspection / adjustment


Throttle link / throttle cable / throttle pick-up timing


Water pump

Engine oil

Spark plug(s)


Inspection / change

Cleaning / adjustment / replacement

Valve clearance (OHC,

OHV)


35


Maintenance

EMU28874

Maintenance chart (additional)

Item Actions

Exhaust guide, exhaust manifold


EMU28931

Greasing

Yamaha marine grease (Water resistant grease)

Every

500 hours (2.5 years) 1000 hours (5 years)

EMU28952

Cleaning and adjusting spark plug

EWM00560

WARNING

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

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

36


Maintenance 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:

BR6HS

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

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 fingertight. Have the spark plug adjusted to the correct torque as soon as possible with a torquewrench.

EMU28962

Checking fuel system

EWM00060

WARNING

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

1. Spark plug gap

2. Spark plug I.D. mark (NGK)

EWM00910

WARNING

Leaking fuel can result in fire or explosion.

● Check for fuel leakage regularly.

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

Check the fuel lines for leaks, crack, or malfunction. If a problem is found, your Yamaha dealer or other qualified mechanic should repair it immediately.

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque.

Spark plug torque:

25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Checkpoints

● Fuel system parts leakage

● Fuel line joint leakage

37


Maintenance

● Fuel line cracks or other damage

● Fuel connector leakage

EMU29041

Inspecting idling speed

EWM00451

WARNING


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

EMU30222

Changing engine oil

EWM00760

WARNING

● Avoid draining the engine oil immediately after stopping the engine. The oil is hot and should be handled with care to avoid burns.

● Be sure the outboard motor is securely fastened to the transom or a stable stand.

ECM00490

CAUTION:

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

A diagnostic tachometer should be used for this procedure. Results may vary depending on whether testing is conducted with the flushing attachment, in a test tank, or with the outboard motor in the water.

1.

Start the engine and allow it to warm up fully in neutral until it is running smoothly.

NOTE:

Correct idling speed inspection is only possible if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechanic.

2.

Verify whether the idle speed is set to specification. For idle speed specifica-

tions, see page 30.

ECM00970

CAUTION:

● Do not overfill the oil, and be sure the outboard motor is upright (not tilted) when checking and changing the engine oil.

● If the oil level is above the upper level mark, drain until the level meets the specified capacity. Overfilling the oil could cause leakage or damage.

ECM01240

CAUTION:

Change the engine oil after the first 10 hours of operation, and every 100 hours or at 6-month intervals thereafter. Otherwise the engine will wear quickly.

NOTE:

Change the engine oil when the oil is still warm.

1.

Put the outboard motor in an upright position (not tilted).

38


Maintenance

2.

Prepare a suitable container that holds a larger amount than the engine oil capacity. Loosen and remove the drain screw while holding the container under the drain hole. Then remove the oil filler cap.

Let the oil drain completely. Wipe up any spilled oil immediately.

tighten 1/4 to 1/2 turn more. Tighten the drain screw to the correct torque with a torque wrench as soon as possible.

4.

Add the correct amount of oil through the filler hole. Install the filler cap.


4-stroke outboard motor oil


0.35 L (0.37 US qt) (0.31 Imp.qt)

1. Drain screw

3.

Put a new gasket on the oil drain screw.

Apply a light coat of oil to the gasket and install the drain screw.

Drain screw tightening torque:

18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

NOTE:

If a torque wrench is not available when you are installing the drain screw, finger tighten the screw just until the gasket comes into contact with the surface of the drain hole. Then

1. Oil filler cap

5.

Start the engine and watch to make sure the low oil pressure warning indicator (if equipped) turns off. Make sure that there are no oil leaks.

ECM00680

CAUTION:

If the low oil pressure warning indicator does not turn off or if there are oil leaks, stop the engine and find the cause. Continued operation with a problem could cause severe engine damage. Consult your Yamaha dealer if the problem cannot be located and corrected.

6.

Turn off the engine and wait 3 minutes.

Recheck the oil level using the oil level check window to be sure the level falls between the upper and lower marks. Fill

39


Maintenance with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark.

NOTE:

If any leaks are found, consult your Yamaha dealer.

7.

Dispose of used oil according to local regulations.

NOTE:

● For more information on the disposal of used oil, consult your Yamaha dealer.

● Change the oil more often when operating the engine under adverse conditions such as extended trolling.

EMU29112

Checking wiring and connectors

● Check that each grounding wire is properly secured.

● Check that each connector is engaged securely.

EMU29120

Exhaust leakage

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

EMU29130

Water leakage

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

EMU29140

Engine oil leakage

Check for oil leaks on the around the engine.

EMU29171

Checking propeller

EWM00321

WARNING

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

● Before inspecting, removing, or installing the propeller, remove the spark plug caps from the spark plugs. Also, place the shift control in neutral, turn the main switch to “ ” (off) and remove the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one.

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

40


Maintenance

EMU30660

Removing the propeller

EMU29194

Spline models

1.

Straighten the cotter pin and pull it out using a pair of pliers.

2.

Remove the propeller nut, washer, and spacer (if equipped).

●

●

Checkpoints

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

Check the propeller shaft for damage.

Check the splines / shear pin for wear or damage.

● Check for fish line tangled around the propeller shaft.

● Check the propeller shaft oil seal for damage.

NOTE:

If the shear pin equipped: it is designed to break if the propeller hits a hard underwater obstacle to help protect the propeller and drive mechanism. The propeller will then spin freely on the shaft. If this happens, the shear pin must be replaced.

1. Cotter pin

2. Propeller nut

3. Washer

4. Propeller

5. Thrust washer

3.

Remove the propeller and thrust washer.

EMU30670

Installing the Propeller

EMU30371

Spline models

ECM00340

CAUTION:

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

● 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.

Apply Yamaha marine grease or a corrosion resistant grease to the propeller shaft.

41


Maintenance

2.

Install the spacer (if equipped), thrust washer, and propeller on the propeller shaft.

3.

Install the spacer (if equipped) and the washer. Tighten the propeller nut until there is no forward-and-backward movement.

4.

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

2.

Place a suitable container under the gear case.

3.

Remove the gear oil drain screw and gasket.

1. Gear oil drain screw

2. Oil level plug

NOTE:

If the propeller nut does not align with the propeller shaft hole after tightening it, loosen the nut until it aligns with the hole.

EMU29282

Changing gear oil

EWM00800

WARNING

● Be sure the outboard motor is securely fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you.

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

1.

Tilt the outboard motor so that the gear oil drain screw is at the lowest point possible.

NOTE:

● If a magnetic gear oil drain screw is equipped, remove all metal particles from the screw before installing it.

● Always use new gaskets. Do not reuse the removed gaskets.

4.

Remove the oil level plug and gasket to allow the oil to drain completely.

ECM00710

CAUTION:

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

NOTE:

For disposal of used oil, consult your Yamaha dealer.

5.

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

42


Maintenance

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

75.0 cm³ (2.54 US oz) (2.65 Imp.oz)

EMU29390

Checking top cowling

Check the fitting of the top cowling by pushing it with both hands. If it is loose have it repaired by your Yamaha dealer.

6.

Put a new gasket on the oil level plug.

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

7.

Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw.

EMU29312

Inspecting and replacing anode(s)

Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a

Yamaha dealer for replacement of external anodes.

ECM00720

CAUTION:

Do not paint anodes, as this would render them ineffective.

NOTE:

Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit.

EMU29400

Coating the boat bottom

A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth.

Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.

43


Maintenance

44


Trouble Recovery

EMU29424

Troubleshooting

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

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

If the engine trouble warning indicator is flashing, consult your Yamaha dealer.

Q. Is fuel filter clogged?

A. Clean or replace filter.

Q. Is starting procedure incorrect?

A. See page 21.

Q. Has fuel pump malfunctioned?

A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrect type?

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

Starter will not operate.

Q. Is battery capacity weak or low?

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

Q. Are spark plug cap(s) fitted incorrectly?

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

Q. Are battery connections loose or corroded?

A. Tighten battery cables and clean battery terminals.

Q. Is ignition wiring damaged or poorly connected?

A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.

Q. Is fuse for electric start relay or electric circuit blown?

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

Q. Are ignition parts faulty?


Q. Is engine stop switch lanyard not attached?

A. Attach lanyard.

Q. Are starter components faulty?


Q. Are engine inner parts damaged?


Q. Is shift lever in gear?

A. Shift to neutral.

Engine will not start (starter operates).

Q. Is fuel tank empty?

A. Fill tank with clean, fresh fuel.

Engine idles irregularly or stalls.



Q. Is fuel contaminated or stale?


Q. Is fuel system obstructed?

45



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

A. Return to home position.



Q. Is motor angle too high?

A. Return to normal operating position.



Q. Is carburetor clogged?


Q. Have ignition parts failed?


Q. Is fuel joint connection incorrect?

A. Connect correctly.

Q. Has warning system activated?

A. Find and correct cause of warning.

Q. Is throttle valve adjustment incorrect?


Q. Is spark plug gap incorrect?

A. Inspect and adjust as specified.

Q. Is battery cable disconnected?

A. Connect securely.



Warning buzzer sounds or indicator lights.

Q. Is cooling system clogged?

A. Check water intake for restriction.

Q. Is engine oil level low?

A. Fill oil tank with specified engine oil.

Q. Is specified engine oil not being used?

A. Check and replace oil as specified.

Q. Is thermostat faulty or clogged?


Q. Are carburetor adjustments incorrect?


Q. Is fuel pump damaged?


Q. Is air vent screw on fuel tank closed?

A. Open air vent screw.

Q. Is choke knob pulled out?

Q. Is heat range of spark plug incorrect?

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


A. Check and replace oil with specified type.

Q. Is engine oil contaminated or deteriorated?

A. Replace oil with fresh, specified type.

Q. Is oil filter clogged?


Q. Has oil feed/injection pump malfunctioned?


46



Q. Is load on boat improperly distributed?

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

A. Remove foreign matter and clean lower unit.

Q. Is water pump or thermostat faulty?


Q. Is fuel system obstructed?

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

Q. Is there excess water in fuel filter cup?

A. Drain filter cup.



Engine power loss.

Q. Is propeller damaged?

A. Have propeller repaired or replaced.



Q. Is propeller pitch or diameter incorrect?

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

Q. Is spark plug gap incorrect?

A. Inspect and adjust as specified.

Q. Is trim angle incorrect?

A. Adjust trim angle to achieve most efficient operation.



Q. Is motor mounted at incorrect height on transom?

A. Have motor adjusted to proper transom height.

Q. Have electrical parts failed?


Q. Is specified fuel not being used?

A. Replace fuel with specified type.

Q. Has warning system activated?

A. Find and correct cause of warning.


A. Check and replace oil with specified type.

Q. Is boat bottom fouled with marine growth?

A. Clean boat bottom.

Q. Is thermostat faulty or clogged?




Q. Is air vent screw closed?

A. Open the air vent screw.

Q. Are weeds or other foreign matter tangled on gear housing?

Q. Is fuel pump damaged?


Q. Is fuel joint connection incorrect?

47


A. Connect correctly.

Q. Is heat range of spark plug incorrect?

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


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

Q. Is high pressure fuel pump drive belt broken?


Q. Is engine not responding properly to shift lever position?


Engine vibrates excessively.

Q. Is propeller damaged?

A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged?


Q. Are weeds or other foreign matter tangled on propeller?

A. Remove and clean propeller.

Q. Is motor mounting bolt loose?

A. Tighten bolt.

Q. Is steering pivot loose or damaged?

A. Tighten or have serviced by a Yamaha dealer.

EMU29432

Temporary action in emergency

EMU29440

Impact damage

EWM00870

WARNING

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

1.

Stop the engine immediately.

2.

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

3.

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

4.

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

EMU31300

Starter will not operate

If the starter mechanism does not operate

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

EWM01450

WARNING

● Use this procedure only in an emergency to return to the nearest port for repairs.

● Make sure the remote control lever is in neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.

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

48



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

● Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to

● be thrown forward.

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

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

● the engine is running.

Do not touch the ignition coil, spark plug wire, spark plug cap, or other electrical components when starting or operating the motor. You could get an electrical shock.

3.

Remove the bolts from the starter case.

4.

While lifting the fuel tank up, remove the bolt from the starter case.

5.

Remove the collar.

EMU29631

Emergency Starting Engine

1.

Remove the top cowling.

2.

Remove the bolts from the fuel tank.

6.

While lifting the starter case up, disconnect the choke wire from the carburetor.

49



7.

Remove the starter case by pulling it towards you.

10. Prepare the engine for starting; see page

21. Be sure the engine is in neutral and

that the engine stop switch lanyard lock plate is attached to the engine stop switch.

11. Turn the lever on the carburetor to operate the choke system when the engine is cold. After the engine starts, return the lever to the original position.

8.

Install the fuel tank bracket by installing the bolts.

9.

Install 2 bolts into the rear section of the fuel tank.

12. While lifting the fuel tank, insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise.

NOTE:

If the rope is too long after winding it around the flywheel, shorten its length at the handle.

13. Pull the rope slowly until resistance is felt.

14. Give a strong pull straight out to crank and start the engine. Repeat if necessary.

50



EMU29760

Treatment of submerged motor

If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immediately.

If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure below in order to minimize engine damage.

EMU29783

Procedure

1.

Thoroughly wash away mud, salt, seaweed, and so on, with fresh water.

2.

Remove the spark plug(s), then face the spark plug holes downward to allow any water, mud, or contaminants to drain.

3.

Drain the fuel from the carburetor, fuel filter, and fuel line. Drain the engine oil completely.

4.

Fill the sump with the fresh engine oil.

Engine oil capacity:

0.35 L (0.37 US qt) (0.31 Imp.qt)

5.

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

6.

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

ECM00400

CAUTION:

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

51


Consumer information

EMU29811

Important warranty information for U.S.A. and Canada

52



53


EMU29830


YAMAHA MOTOR CORPORATION, U.S.A.

FOUR-STROKE OUTBOARD MOTOR

THREE-YEAR LIMITED WARRANTY

54



55



EMU29841

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR

YAMAHA OUTSIDE THE USA OR CANADA

56

A5-tate_Blank.fm Page 1 Friday, May 16, 2003 9:00 AM

A5-tate_Blank.fm Page 1 Friday, May 16, 2003 9:00 AM

YAMAHA MOTOR CORPORATION, USA

Printed in France

January 2006–0.3 × 1 CR

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