Yamaha 130B (2013) User guide

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Page 1

Read this manual carefully before operating this

outboard motor.

OWNER’S MANUAL

115C 130B

6N6-28199-78-E0

Page 2

EMU25052

Read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.

Page 3

Important manual information

EMU25107

To the owner

Thank you for selecting a Yamaha outboard motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important information is distinguished in the following ways.

: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

WARNING

EWM00781

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

ECM00701

A NOTICE indicates special precautions that must be taken to avoid damage to the outboard motor or other property.

TIP:

A TIP provides key information to make procedures easier or clearer.

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If

there is any question concerning this manual, please consult your Yamaha dealer. To ensure long product life, Yamaha recommends that you use the product and perform the specified periodic inspections and maintenance by correctly following the instructions in the owner’s manual. Any damage resulting from neglect of these instructions is not covered by warranty. Some countries have laws or regulations restricting users from taking the product out of the country where it was purchased, and it may be impossible to register the product in the destination country. Additionally, the warranty may not apply in certain regions. When planning to take the product to another country, consult the dealer where the product was purchased for further information. If the product was purchased used, please consult your closest dealer for customer reregistration, and to be eligible for the specified services.

TIP:

The 115CETO, 130BETO 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.

EMU25121

115C, 130B

OWNER’S MANUAL

1st Edition, September 2012

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd. is expressly prohibited.

Printed in Japan

Page 4

Table of contents

Safety information............................. 1

Outboard motor safety .....................1

Propeller............................................ 1

Rotating parts.................................... 1

Hot parts ........................................... 1

Electric shock.................................... 1

Power trim and tilt ............................. 1

Engine shut-off cord (lanyard)........... 1

Gasoline............................................ 1

Gasoline exposure and spills ............ 2

Carbon monoxide.............................. 2

Modifications ..................................... 2

Boating safety ..................................2

Alcohol and drugs ............................. 2

Personal flotation devices ................. 2

People in the water ........................... 2

Passengers ....................................... 2

Overloading....................................... 2

Avoid collisions ................................. 3

Weather ............................................ 3

Passenger training ............................ 3

Boating safety publications ............... 3

Laws and regulations ........................ 3

General information .......................... 4

Identification numbers record...........4

Outboard motor serial number .......... 4

Key number....................................... 4

EC Declaration of Conformity

(DoC) ............................................. 4

CE Marking .....................................5

Read manuals and labels................. 6

Warning labels ................................. 6

Specifications and

requirements...................................... 9

Specifications ................................... 9

Installation requirements ................ 10

Boat horsepower rating................... 10

Mounting motor ............................... 10

Remote control requirements.........10

Battery requirements......................11

Battery specifications ...................... 11

Mounting battery ............................. 11

Multiple batteries............................. 11

Propeller selection.......................... 11

Start-in-gear protection .................. 12

Engine oil requirements ................. 12

Fuel requirements.......................... 12

Gasoline .......................................... 12

Muddy or acidic water.................... 13

Anti-fouling paint ............................ 13

Motor disposal requirements.......... 13

Emergency equipment................... 13

Components .................................... 14

Components diagram..................... 14

Fuel tank ......................................... 14

Fuel joint.......................................... 15

Fuel gauge ...................................... 15

Fuel tank cap................................... 15

Air vent screw.................................. 15

Remote control box ......................... 15

Remote control lever ....................... 15

Neutral interlock trigger ................... 16

Neutral throttle lever........................16

Choke switch...................................16

Throttle friction adjuster................... 17

Engine shut-off cord

(lanyard) and clip ..........................17

Choke knob for pull type ................. 17

Main switch ..................................... 18

Power trim and tilt switch on

remote control ............................... 18

Power trim and tilt switch on

bottom cowling .............................. 18

Trim tab with anode......................... 19

Tilt support lever for power trim

and tilt model................................. 19

Top cowling release lever ............... 20

Flushing device ............................... 21

Instruments and indicators............ 22

Digital tachometer .......................... 22

Tachometer ..................................... 22

Trim meter.......................................22

Hour meter ...................................... 22

Oil level indicator (digital type) ........ 23

Overheat-alert indicator................... 23

Digital speedometer ....................... 23

Speedometer................................... 23

Fuel gauge ...................................... 24

Trip meter / Clock / Voltmeter ......... 24

Page 5

Table of contents

Fuel level-alert indicator.................. 25

Low battery voltage-alert

indicator ........................................ 25

Engine control system.................... 26

Alert system ...................................26

Overheat alert ................................. 26

Oil level alert and oil filter

clogging alert ................................ 26

Installation .......................................28

Installation ...................................... 28

Mounting the outboard motor.......... 28

Operation .........................................30

First-time operation ........................ 30

Breaking in engine .......................... 30

Getting to know your boat ............... 30

Checks before starting engine .......30

Fuel level......................................... 31

Remove the top cowling.................. 31

Fuel system..................................... 31

Controls........................................... 31

Engine shut-off cord (lanyard)......... 32

Oil.................................................... 32

Engine............................................. 32

Operation after long period of

storage.......................................... 32

Flushing device ............................... 32

Install cowling.................................. 33

Checking power trim and

tilt system...................................... 33

Battery............................................. 34

Filling fuel and engine oil................ 35

Filling fuel for portable tank............. 35

Filling fuel for models without a

fuel joint ........................................ 36

Filling oil .......................................... 36

Oil level indicator operation............. 38

Operating engine............................ 39

Sending fuel (portable tank)............ 40

Sending fuel .................................... 40

Starting engine................................ 40

Checks after starting engine ..........42

Cooling water .................................. 42

Warming up engine ........................ 43

Choke start models ......................... 43

Checks after engine warm up ........ 43

Shifting ............................................ 43

Stop switches .................................. 43

Shifting........................................... 43

Stopping boat................................. 44

Stopping engine............................. 44

Procedure........................................ 44

Trimming outboard motor............... 44

Adjusting trim angle

(Power trim and tilt)....................... 45

Adjusting boat trim .......................... 46

Tilting up and down........................ 47

Procedure for tilting up

(power trim and tilt models)........... 47

Procedure for tilting down

(power trim and tilt models)........... 48

Shallow water ................................ 49

Power trim and tilt models...............49

Cruising in other conditions............ 49

Maintenance .................................... 51

Transporting and storing

outboard motor ............................ 51

Storing outboard motor ................... 51

Procedure........................................ 52

Lubrication

(oil injection models) ..................... 53

Flushing power unit ......................... 53

Cleaning the outboard motor .......... 54

Checking painted surface of

outboard motor.............................. 54

Periodic maintenance .................... 54

Replacement parts .......................... 54

Severe operating conditions............ 55

Maintenance chart 1........................ 56

Maintenance chart 2........................ 58

Greasing.......................................... 59

Cleaning and adjusting

spark plug .....................................59

Checking fuel filter........................... 60

Inspecting idle speed ...................... 60

Checking water in engine

oil tank........................................... 61

Inspecting wiring and

connectors ....................................61

Checking propeller .......................... 61

Page 6

Table of contents

Removing propeller......................... 62

Installing propeller........................... 62

Changing gear oil............................ 63

Cleaning fuel tank ........................... 64

Inspecting and replacing

anode(s)........................................ 65

Checking battery

(for electric start models) .............. 65

Connecting the battery.................... 66

Disconnecting the battery ............... 66

Trouble Recovery............................ 67

Troubleshooting .............................67

Temporary action in

emergency ...................................70

Impact damage ............................... 70

Replacing fuse ................................ 70

Power trim and tilt will not

operate.......................................... 71

Starter will not operate .................... 71

Emergency starting engine ............. 72

Engine fails to operate ...................73

Low oil level alert activates ............. 73

Top cowling does not unlock..........74

Treatment of submerged motor...... 74

Page 7

Safety information

EMU33622

Outboard motor safety

Observe these precautions at all times.

EMU36501

Propeller

People can be injured or killed if they come in contact with the propeller. The propeller can keep moving even when the motor is in neutral, and sharp edges of the propeller can cut even when stationary.

 Stop the engine when a person is in the

water near you.

 Keep people out of reach of the propeller,

even when the engine is off.

EMU33630

Rotating parts

Hands, feet, hair, jewelry, clothing, PFD straps, etc. can become entangled with internal rotating parts of the engine, resulting in serious injury or death. Keep the top cowling in place whenever possible. Do not remove or replace the cowling with the engine running. Only operate the engine with the cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, PFD straps, etc. away from any exposed moving parts.

EMU33640

Hot parts

During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the engine has cooled.

EMU33650

Electric shock

Do not touch any electrical parts while starting or operating the engine. They can cause shock or electrocution.

EMU33660

Power trim and tilt

Body parts can be crushed between the mo-

tor and the clamp bracket when the motor is trimmed or tilted. Keep body parts out of this area at all times. Be sure no one is in this area before operating the power trim and tilt mechanism. The power trim and tilt switches operate even when the main switch is off. Keep people be away from the switches whenever working around the motor. Never get under the lower unit while it is tilted, even when the tilt support lever is locked. Severe injury could occur if the outboard motor accidentally falls.

EMU33671

Engine shut-off cord (lanyard)

Attach the engine shut-off cord so that the engine stops if the operator falls overboard or leaves the helm. This prevents the boat from running away under power and leaving people stranded, or running over people or objects. Always attach the engine shut-off cord to a secure place on your clothing or your arm or leg while operating. Do not remove it to leave the helm while the boat is moving. Do not attach the cord to clothing that could tear loose, or route the cord where it could become entangled, preventing it from functioning. Do not route the cord where it is likely to be accidentally pulled out. If the cord is pulled during operation, the engine will shut off and you will lose most steering control. The boat could slow rapidly, throwing people and objects forward.

EMU33810

Gasoline

Gasoline and its vapors are highly flammable and explosive. Always, refuel ac-

cording to the procedure on page 39 to reduce the risk of fire and explosion.

Page 8

Safety information

EMU33820

Gasoline exposure and spills

Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Dispose of rags properly. If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth.

EMU33900

Carbon monoxide

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

EMU33780

Modifications

Do not attempt to modify this outboard motor. Modifications to your outboard motor may reduce safety and reliability, and render the outboard unsafe or illegal to use.

EMU33740

Boating safety

This section includes a few of the many important safety precautions that you should follow when boating.

EMU33710

Alcohol and drugs

Never operate after drinking alcohol or taking drugs. Intoxication is one of the most common factors contributing to boating fatalities.

EMU33720

Personal flotation devices

Have an approved personal flotation device (PFD) on board for every occupant. Yamaha recommends that you must wear a PFD

whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating conditions.

EMU33731

People in the water

Always watch carefully for people in the water, such as swimmers, skiers, or divers, whenever the engine is running. When someone is in the water near the boat, shift into neutral and stop the engine. Stay away from swimming areas. Swimmers can be hard to see. The propeller can keep moving even when the motor is in neutral. Stop the engine when a person is in the water near you.

EMU33751

Passengers

Consult your boat manufacturer’s instructions for details about appropriate passenger locations in your boat and be sure all passengers are positioned properly before accelerating and when operating above an idle speed. Standing or sitting in non-designated locations may result in being thrown either overboard or within the boat due to waves, wakes, or sudden changes in speed or direction. Even when people are positioned properly, alert your passengers if you must make any unusual maneuver. Always avoid jumping waves or wakes.

EMU33760

Overloading

Do not overload the boat. Consult the boat capacity plate or boat manufacturer for maximum weight and number of passengers. Be sure that weight is properly distributed according to the boat manufacturers instructions. Overloading or incorrect weight distribution can compromise the boats handling and lead to an accident, capsizing or

Page 9

Safety information

swamping.

EMU33772

Avoid collisions

Scan constantly for people, objects, and other boats. Be alert for conditions that limit your visibility or block your vision of others.

Operate defensively at safe speeds and keep a safe distance away from people, objects, and other boats.

 Do not follow directly behind other boats or

waterskiers.

 Avoid sharp turns or other maneuvers that

make it hard for others to avoid you or understand where you are going.

 Avoid areas with submerged objects or

shallow water.

 Ride within your limits and avoid aggres-

sive maneuvers to reduce the risk of loss of control, ejection, and collision.

 Take early action to avoid collisions. Re-

member, boats do not have brakes, and stopping the engine or reducing throttle can reduce the ability to steer. If you are not sure that you can stop in time before hitting an obstacle, apply throttle and turn in another direction.

EMU33790

Weather

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

EMU33880

Passenger training

Make sure at least one other passenger is trained to operate the boat in the event of an emergency.

EMU33890

Boating safety publications

Be informed about boating safety. Additional publications and information can be obtained from many boating organizations.

EMU33600

Laws and regulations

Know the marine laws and regulations where you will be boating- and obey them. Several sets of rules prevail according to geographic location, but all are basically the same as the International Rules of the Road.

ZMU06025

Page 10

General information

EMU25171

Identification numbers record

EMU25184

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.

EMU25191

Key number

If a main key switch is equipped with the motor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key.

EMU37291

EC Declaration of Conformity

(DoC)

This outboard motor conforms to certain portions of the European Parliament directive relating to machinery. Each conformed outboard motor accompanied with EC DoC.EC DoC contains the following information;

 Name of Engine Manufacture  Model name  Product code of model (Approved model

code)

 Code of conformed directives

1. Outboard motor serial number location

1. Key number

Page 11

General information

EMU25205

CE Marking

Outboard motors affixed with this “CE”marking conform with the directives of; 98/37/EC, 94/25/EC - 2003/44/EC and 2004/108/EC.

1. CE marking location

ZMU03473

ZMU06040

Page 12

General information

EMU33523

Read manuals and labels

Before operating or working on this outboard motor:

 Read this manual.  Read any manuals supplied with the boat.  Read all labels on the outboard motor and the boat.

If you need any additional information, contact your Yamaha dealer.

EMU33832

Warning labels

If these labels are damaged or missing, contact your Yamaha dealer for replacements.

115C, 130B

ZMU06695

Page 13

General information

EMU33912

Contents of labels

The above warning labels mean as follows.

WARNING

EWM01691

Emergency starting does not have startin-gear protection. Ensure shift control is in neutral before starting engine.

WARNING

EWM01681

 Keep hands, hair, and clothing away

from rotating parts while the engine is running.

 Do not touch or remove electrical parts

when starting or during operation.

WARNING

EWM01671

 Read Owner’s Manuals and labels.  Wear an approved personal flotation

device (PFD).

 Attach engine shut-off cord (lanyard) to

your PFD, arm, or leg so the engine stops if you accidentally leave the helm, which could prevent a runaway boat.

ZMU05706

Page 14

General information

EMU33843

Symbols

The following symbols mean as follows.

Notice/Warning

Read Owner’s Manual

Hazard caused by continuous rotation

Electrical hazard

Remote control lever/gear shift lever operating direction, dual direction

Engine start/ Engine cranking

ZMU05696

ZMU05664

ZMU05665

ZMU05666

ZMU05667

ZMU05668

Page 15

Specifications and requirements

EMU31480

Specifications

TIP:

“(AL)” stated in the specification data below represents the numerical value for the aluminum propeller installed. Likewise, “(SUS)” represents the value for stainless steel propeller installed and “(PL)” for plastic propeller installed.

EMU2821K

Dimension:

Overall length:

808 mm (31.8 in)

Overall width:

582 mm (22.9 in)

Overall height L:

1472 mm (58.0 in)

Overall height X:

1599 mm (63.0 in)

Transom height L:

516 mm (20.3 in)

Transom height X:

642 mm (25.3 in)

Weight (AL) L:

165.0 kg (364 lb)

Weight (AL) X:

169.0 kg (373 lb)

Weight (SUS) L:

167.0 kg (368 lb)

Weight (SUS) X:

171.0 kg (377 lb)

Performance:

Full throttle operating range:

115CETO 4500–5500 r/min

130BETO 5000–6000 r/min

Maximum output:

115CETO 84.6 kW@5000 r/min

(115 HP@5000 r/min)

130BETO 95.6 kW@5500 r/min

(130 HP@5500 r/min)

Idle speed (in neutral):

750 50 r/min

Engine:

Type:

2-stroke V

Displacement:

1730.0 cm

Bore  stroke:

90.0  68.0 mm (3.54  2.68 in)

Ignition system:

CDI

Spark plug with resistor (NGK):

115CETO BR8HS-10 130BETO BR9HS-10

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

Control system:

Remote control

Starting system:

Electric starter

Starting carburetion system:

Choke valve

Min. cold cranking amps (CCA/EN):

430.0 A

Min. rated capacity (20HR/IEC):

70 Ah

Maximum generator output:

20 A

Drive unit:

Gear positions:

Forward-neutral-reverse

Gear ratio:

2.00 (26/13)

Trim and tilt system:

Power trim and tilt

Propeller mark:

Fuel and oil:

Recommended fuel:

Regular unleaded gasoline

Min. research octane:

Page 16

Specifications and requirements

115CETO 90

Fuel tank capacity:

24 L (6.34 US gal, 5.28 Imp.gal)

Recommended engine oil:

YAMALUBE 2-stroke outboard motor

oil

Recommended engine oil:

TC-W3

Lubrication:

Oil injection

Engine oil tank capacity:

0.9 L (0.95 US qt, 0.79 Imp.qt)

Remote oil tank capacity:

115CETO 10.5 L

(11.10 US qt, 9.24 Imp.qt)

115CETO 18.0 L

(19.03 US qt, 15.84 Imp.qt)

130BETO 18.0 L

(19.03 US qt, 15.84 Imp.qt)

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

0.760 L (0.803 US qt, 0.669 Imp.qt)

Tightening torque for engine:

Spark plug:

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

Propeller nut:

55.0 Nm (5.61 kgf-m, 40.6 ft-lb)

Noise and vibration level:

Operator sound pressure level (ICOMIA 39/94 and 40/94):

115CETO 82.9 dB(A)

EMU33554

Installation requirements

EMU33564

Boat horsepower rating

WARNING

EWM01560

Overpowering a boat can cause severe instability.

Before installing the outboard motor(s), con-

firm that the total horsepower of your outboard motor(s) does not exceed the boats maximum horsepower rating. See the boat’s capacity plate or contact the manufacturer.

EMU33571

Mounting motor

WARNING

EWM01570

 Improper mounting of the outboard mo-

tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards.

 Because the motor is very heavy, spe-

cial equipment and training is required to mount it safely.

Your dealer or other person experienced in proper rigging should mount the motor using correct equipment and complete rigging instructions. For further information, see page

28.

EMU33581

Remote control requirements

WARNING

EWM01580

 If the engine starts in gear, the boat can

move suddenly and unexpectedly, possibly causing a collision or throwing passengers overboard.

 If the engine ever starts in gear, the

start-in-gear protection device is not working correctly and you should discontinue using the outboard. Contact your Yamaha dealer.

The remote control unit must be equipped with a start-in-gear protection device(s). This device prevents the engine from starting unless it is in neutral.

Page 17

Specifications and requirements

EMU25694

Battery requirements

EMU25721

Battery specifications

The engine cannot be started if battery voltage is too low.

EMU36290

Mounting battery

Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. WARNING! Do not put flammable

items, or loose heavy or metal objects in the same compartment as the battery. Fire, explosion or sparks could result.

[EWM01820]

EMU36300

Multiple batteries

To connect multiple batteries, such as for multiple engine configurations or for an accessory battery, consult your Yamaha dealer about battery selection and correct wiring.

EMU34195

Propeller selection

Next to selecting an outboard motor, selecting the right propeller is one of the most important purchasing decisions a boater can make. The type, size, and design of your propeller have a direct impact on acceleration, top speed, fuel economy, and even engine life. Yamaha designs and manufactures propellers for every Yamaha outboard motor and every application. Your outboard motor came with a Yamaha propeller selected to perform well over a range of applications, but there may be uses where a different propeller would be more appropriate.

Your Yamaha dealer can help you select the right propeller for your boating needs. Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boatload. Generally, select a larger pitch propeller for a smaller operating load and a smaller pitch propeller for a heavier load. If you carry loads that vary widely, select the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle setting to stay within the recommended engine speed range when carrying lighter loads. To check the propeller, see page 61.

Minimum cold cranking amps (CCA/EN):

430.0 A

Minimum rated capacity (20HR/IEC):

70 Ah

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

ZMU04605

123

Page 18

Specifications and requirements

EMU25770

Start-in-gear protection

Yamaha outboard motors or Yamaha-approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is in neutral. Always select neutral before starting the engine.

EMU25651

Engine oil requirements

If the recommended engine oil is not available, another 2-stroke engine oil with an NMMA-certified TC-W3 rating may be used.

EMU36360

Fuel requirements

EMU36803

Gasoline

Use a good quality gasoline that meets the minimum octane rating. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.

NOTICE

ECM01981

 Do not use leaded gasoline. Leaded

gasoline can seriously damage the engine.

 Avoid getting water and contaminants

in the fuel tank. Contaminated fuel can cause poor performance or engine damage. Use only fresh gasoline that has been stored in clean containers.

Gasohol

There are two types of gasohol: gasohol containing ethanol (E10) and that containing methanol. Ethanol can be used if the ethanol content does not exceed 10% and the fuel meets the minimum octane ratings. E85 is a fuel containing 85% ethanol and must not be used in your outboard motor. All ethanol

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

ZMU04606

123

ZMU04608

123

Recommended engine oil:

YAMALUBE 2-stroke outboard motor oil

Recommended gasoline:

Regular unleaded gasoline with a minimum octane rating of 90 (Research Octane Number).

Page 19

Specifications and requirements

blends containing more than 10% ethanol can cause fuel system damage or cause engine starting and running problems. Yamaha does not recommend gasohol containing methanol because it can cause fuel system damage or engine performance problems. It is recommended that you install a waterseparating marine fuel filter assembly (10 micron minimum) between your boat’s fuel tank and outboard motor when using ethanol. Ethanol is known to allow moisture to be absorbed into boat fuel tanks and systems. Moisture in the fuel can cause corrosion of metallic fuel system components, starting and running complaints and require additional fuel system maintenance.

EMU36880

Muddy or acidic water

Yamaha strongly recommends that you have your dealer install the optional chromiumplated water pump kit if you use the outboard motor in muddy or acidic water conditions. However, depending on the model it might not be required.

EMU36330

Anti-fouling paint

A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.

EMU36341

Motor disposal requirements

Never illegally discard (dump) the motor. Yamaha recommends consulting the dealer about discarding the motor.

EMU36352

Emergency equipment

Keep the following items onboard in case there is trouble with the outboard motor.

 A tool kit with assorted screwdrivers, pli-

ers, wrenches (including metric sizes), and electrical tape.

 Waterproof flashlight with extra batteries.  An extra engine shut-off cord (lanyard)

with clip.

 Spare parts, such as an extra set of spark

plugs.

Consult your Yamaha dealer for details.

Page 20

Components

EMU2579Y

Components diagram

TIP:

* May not be exactly as shown; also may not be included as standard equipment on all models (order from dealer).

115C, 130B

EMU25802

Fuel tank

If your model was equipped with a portable fuel tank, its function is as follows.

WARNING

EWM00020

The fuel tank supplied with this engine is its dedicated fuel reservoir and must not

15 16 17

18 19

ZMU07565

1. Top cowling

2. Power trim and tilt switch

3. Flushing device*

4. Tilt support lever

5. Anti-cavitation plate

6. Trim tab (anode)

7. Propeller*

8. Cooling water inlet

9. Anode

10. Clamp bracket

11. Top cowling release lever

12. Choke knob

13. Cooling water pilot hole

14. Remote control box (side mount type)*

15. Digital tachometer

16. Digital speedometer

17. Fuel tank*

18. Remote oil tank [10.5 L (11.10 US qt, 9.24 Imp.qt)]*

19. Remote oil tank [18.0 L (19.03 US qt, 15.84 Imp.qt)]*

Page 21

Components

be used as a fuel storage container. Commercial users should conform to relevant licensing or approval authority regulations.

EMU25830

Fuel joint

This joint is used to connect the fuel line.

EMU25841

Fuel gauge

This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the approximate amount of fuel remaining in the tank.

EMU25850

Fuel tank cap

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

EMU25860

Air vent screw

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

EMU26181

Remote control box

The remote control lever actuates both the shifter and the throttle. The electrical switches are mounted on the remote control box.

EMU26190

Remote control lever

Moving the lever forward from the neutral position engages forward gear. Pulling the lever back from neutral engages reverse. The engine will continue to run at idle until the lever is moved about 35 (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.

1. Fuel joint

2. Fuel gauge

3. Fuel tank cap

4. Air vent screw

ZMU02284

1. Power trim and tilt switch

2. Remote control lever

3. Neutral interlock trigger

4. Neutral throttle lever

5. Main switch / choke switch

6. Engine shut-off switch

7. Throttle friction adjuster

Page 22

Components

EMU26201

Neutral interlock trigger

To shift out of neutral, first pull the neutral interlock trigger up.

EMU26212

Neutral throttle lever

To open the throttle without shifting into either forward or reverse, put the remote control lever in the neutral position and lift the neutral throttle lever.

TIP:

The neutral throttle lever will operate only when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position.

EMU26221

Choke switch

To activate the choke system, press in the main switch while the key is turned to the “ ” (on) or “ ” (start) position. The choke system will then supply the rich fuel mixture required to start the engine. When the key is released, the choke will switch off automatically.

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”

4. Shift

5. Fully closed

6. Throttle

7. Fully open

1. Neutral interlock trigger

1. Fully open

2. Fully closed

ZMU03160

Page 23

Components

EMU25976

Throttle friction adjuster

A friction device provides adjustable resistance to movement of the throttle grip or the remote control lever, and can be set according to operator preference. To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. WARNING! Do

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

[EWM00032]

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

EMU25995

Engine shut-off cord (lanyard) and clip

The clip must be attached to the engine shutoff switch for the engine to run. The cord should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power. WARNING! At-

tach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to

clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. Avoid accidentally pulling the cord during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

[EWM00122]

EMU26013

Choke knob for pull type

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

1. Cord

2. Clip

3. Engine shut-off switch

ZMU03903

Page 24

Components

EMU26091

Main switch

The main switch controls the ignition system; its operation is described below.

 “” (off)

With the main switch in the “ ” (off) position, the electrical circuits are off, and the key can be removed.

 “” (on)

With the main switch in the “ ” (on) position, the electrical circuits are on, and the key cannot be removed.

 “” (start)

With the main switch in the “ ” (start) position, the starter motor turns to start the engine. When the key is released, it returns automatically to the “ ” (on) position.

EMU32053

Power trim and tilt switch on remote control

The power trim and tilt system adjusts the outboard motor angle in relation to the transom. Pushing the switch “ ” (up) trims the outboard motor up, and then tilts it up. Pushing the switch “ ” (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current position. For instructions on using the power trim and tilt switch, see pages 44 and 47.

EMU26155

Power trim and tilt switch on bottom cowling

The power trim and tilt switch is located on the side of the bottom cowling. Pushing the switch “ ” (up) trims the outboard motor up, and then tilts it up. Pushing the switch “ ” (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current position. For instructions on using the power trim and tilt switch, see page 47.

WARNING

EWM01031

Use the power trim and tilt switch located on the bottom cowling only when the boat is at a complete stop with the engine off. Attempting to use this switch while the boat is moving could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obstacle.

Page 25

Components

EMU26244

Trim tab with anode

WARNING

EWM00840

An improperly adjusted trim tab could cause difficult steering. Always test run after the trim tab has been installed or replaced to be sure steering is correct. Be sure you have tightened the bolt after adjusting the trim tab.

The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force. If the boat tends to veer to the left (port side), turn the trim tab rear end to the port side “A” in the figure. If the boat tends to veer to the right (starboard side), turn the trim tab end to the starboard side “B” in the figure.

NOTICE

ECM00840

The trim tab also serves as an anode to protect the engine from electrochemical corrosion. Never paint the trim tab as it will become ineffective as an anode.

EMU26341

Tilt support lever for power trim and tilt model

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

ZMU03517

1. Trim tab

2. Bolt

3. Cap

Bolt tightening torque:

43.0 Nm (4.3 kgf-m, 32 ft-lb)

ZMU02525

ZMU01863

Page 26

Components

NOTICE

ECM00660

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.

EMU26401

Top cowling release lever

The top cowling can be removed by operating the cowling release lever. Pulling the front lever unlocks the top cowling for removal.

When installing the top cowling:

1. Set the top cowling straight down onto the engine, being careful to avoid catching spark plug wires or other wires.

2. Align the three cowling hooks with the locks on the bottom cowling.

3. Press down on the top of the cowling at the front and both sides of the back until the three locks click.

4. To make sure the cowling is locked properly push the cowling from each side. If it lifts, repeat step 3.

NOTICE

ECM00070

 Make sure the cowling lock connection

cable is operating correctly before reinstalling the top cowling.

 When the release lever is operated,

both the front and rear cowling hooks should be released at the same time. If not, adjust the rear clamp cable adjusters.

 Make sure the cable operates smoothly

and is free of corrosion.

 Check that the cable is properly se-

cured in the holder.

 When reinstalling the cowling, ensure

that both the front and rear locks have operated properly. If the cowling has not been locked properly, some parts may be damaged by the top cowling shaking during operation.

1. Tilt support lever

ZMU03979

ZMU03518

ZMU03519

Page 27

Components

EMU26463

Flushing device

This device is used to clean the cooling water passages of the motor using a garden hose and tap water.

TIP:

For details on usage, see page 53.

1. Flushing device

ZMU04139

Page 28

Instruments and indicators

EMU26493

Digital tachometer

The tachometer shows the engine speed and has the following functions. All segments of the display will light momentarily after the main switch is turned on and will return to normal thereafter.

TIP:

The water separator and engine trouble-alert indicators only operate when the engine is equipped with the appropriate functions.

EMU36050

Tachometer

The tachometer displays engine speed in hundreds of revolutions per minute (r/min). For example, if the tachometer display reads “22” then the engine speed is 2200 r/min.

EMU26621

Trim meter

This meter shows the trim angle of your outboard motor.

 Memorize the trim angles that work best

for your boat under different conditions. Adjust the trim angle to the desired using

the power trim and tilt switch.

 If the trim angle of your motor exceeds the

trim operating range, the top segment on the trim meter display will blink.

EMU26651

Hour meter

This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off.

To change the display format, press the “ ” (mode) button. The display can show total hours or trip hours, or turn off. To reset the trip hours, simultaneously press the “ ” (set) and “ ” (mode) buttons for more than 1 second while the trip hours are displayed. This resets the trip counter to 0 (zero). The total number of hours the engine has been run cannot be reset.

1. Tachometer

2. Trim meter

3. Hour meter

4. Oil level indicator

5. Overheat-alert indicator

6. Set button

7. Mode button

ZMU01891

ZMU01869

ZMU01870

Page 29

Instruments and indicators

EMU26551

Oil level indicator (digital type)

This indicator shows the engine oil level. If the oil level falls below the lower limit, the alert indicator will start to blink. For further information, see page 26.

NOTICE

ECM00030

Do not operate the engine without oil. Serious engine damage will occur.

EMU26583

Overheat-alert indicator

If the engine temperature rises too high, the alert indicator will start to blink. For further information on reading the indicator, see page

26.

NOTICE

ECM00052

Do not continue to run the engine if the overheat-alert indicator is on. Serious engine damage will occur.

EMU26602

Digital speedometer

This gauge shows the boat speed and other information.

All segments of the display will light momentarily after the main switch is turned on and will return to normal thereafter.

EMU36061

Speedometer

The speedometer displays km/h, mph, or knots, according to operator preference. Select the desired units of measurement by setting the selector switch on the back of the gauge. See the illustration for settings.

1. Oil level indicator

ZMU01867

1. Overheat-alert indicator

1. Speedometer

2. Fuel gauge

3. Trip meter/clock/voltmeter

4. Alert indicator(s)

ZMU01868

Page 30

Instruments and indicators

EMU26713

Fuel gauge

Eight segments indicate the fuel level. When all segments are showing, the fuel tank is full.

The fuel level reading can be inaccurate due to the position of the sensor in the fuel tank and the attitude of the boat in the water. Operation with bow-up trim or continuous turning can give false readings. Do not adjust the selector switch for fuel sensor. Incorrectly setting the selector switch on the gauge will give false readings. Consult your Yamaha dealer on how to correctly set the selector switch. NOTICE: Running out

of fuel can damage the engine.

[ECM01770]

EMU36071

Trip meter / Clock / Voltmeter

The display shows either the trip meter, the clock, or the voltmeter. To change the display, press the “ ” (mode) button repeatedly until the indicator on the face of the gauge points to “ ” (trip meter), “ ” (clock), or “ ” (voltmeter).

EMU26691

Trip meter

This gauge displays the distance the boat has traveled since the gauge was last reset. The trip distance is shown in kilometers or miles depending upon the unit of measurement selected for the speedometer. To reset the trip meter to zero, press the “ ” (set) and “ ” (mode) buttons at the same time. The trip distance is kept in memory by battery power. The stored data will be lost if the battery is disconnected.

EMU26701

Clock

To set the clock:

1. Be sure the gauge is in the “ ” (time) mode.

2. Press the “ ” (set) button; the hour display will begin blinking.

3. Press the “ ” (mode) button until the desired hour is displayed.

4. Press the “ ” (set) button again, the minute display will begin blinking.

1. Cap

2. Selector switch (for speed unit)

3. Selector switch (for fuel sensor)

ZMU01745

Page 31

Instruments and indicators

5. Press the “ ” (mode) button until the desired minute is displayed.

6. Press the “ ” (set) button again to start the clock.

The clock operates on battery power. Disconnecting the battery will stop the clock. Reset the clock after connecting the battery.

EMU36080

Voltmeter

The voltmeter displays the charge of the battery in volts(V).

EMU26721

Fuel level-alert indicator

If the fuel level decreases to one segment, the fuel level alert segment will blink. Do not continue to operate the engine with full throttle if an alert device has activated. Get back to the port within trolling engine speed. NOTICE: Running out of fuel can

damage the engine.

[ECM01770]

EMU26732

Low battery voltage-alert indicator

If battery voltage drops, the display will automatically turn on and blink. Get back to the port soon if an alert device has activated. For charging the battery, consult your Yamaha dealer.

1. Fuel level-alert segment

1. Low battery indicator

Page 32

Engine control system

EMU26803

Alert system

NOTICE

ECM00091

Do not continue to operate the engine if a alert device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected.

EMU2681C

Overheat alert

This engine has an overheat-alert device. If the engine temperature rises too high, the alert device will activate.

 The engine speed will automatically de-

crease to about 2000 r/min.

 The overheat-alert indicator will light or

blink.

 The buzzer will sound (if equipped on the

tiller handle, remote control box, or main switch panel).

If the alert system has activated, stop the en-

gine and check the cooling water inlets:

 Check trim angle to be sure that the cool-

ing water inlet is submerged.

 Check the cooling water inlet for clogging.

EMU26849

Oil level alert and oil filter clogging alert

Oil injection models

This engine has an oil level alert system. If the oil level falls below the lower limit, the alert system will activate.

Activation of alert device

 Engine speed will automatically decrease

to about 2000 r/min.

 The oil level-alert indicator will light or

blink.

 The buzzer will sound (if equipped on the

tiller handle, remote control box, or main switch panel).

ZMU01757

ZMU02630

ZMU03942

Page 33

Engine control system

If the alert system has been activated, stop the engine and check for the cause.

TIP:

The alert for oil filter clogging is similar to the alerts for low oil level and overheating. To make troubleshooting easier, check for engine overheating first, then oil level, and finally oil filter clogging.

Remote oil tank [10.5 L (11.10 US qt, 9.24 Imp.qt)]

Remote oil tank [18.0 L (19.03 US qt, 15.84 Imp.qt)]

1. Oil filter

ZMU03025

ZMU03906

1. Oil filter

ZMU01952

ZMU07406

Page 34

Installation

EMU26902

Installation

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

WARNING

EWM01590

 Overpowering a boat could cause se-

vere instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.

 Improper mounting of the outboard mo-

tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. For permanently mounted models, your dealer or other person experienced in proper rigging should mount the motor.

EMU33470

Mounting the outboard motor

The outboard motor should be mounted so that the boat is well balanced. Otherwise, the boat could be hard to steer. For single-engine boats, mount the outboard motor on the centerline (keel line) of the boat.

EMU26933

Mounting height (boat bottom)

The mounting height of your outboard motor affects its efficiency and reliability. If it is mounted too high, propeller ventilation may occur, which will reduce propulsion due to excessive propeller slip, and the water intakes for the cooling system may not get adequate water supply, which can cause engine overheating. If the engine is mounted too low, water resistance (drag) will increase, thereby reducing engine efficiency and performance. Most commonly, outboard motor should be mounted so that the anti-cavitation plate is in alignment with the bottom of the boat. 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. Consult your Yamaha dealer or boat manufacturer for further information on determining the proper mounting height.

1. Center line (keel line)

ZMU01873

Page 35

Installation

NOTICE

ECM01634

 Make sure that the idle hole is high

enough to prevent water from entering the engine even if the boat is stationary with the maximum load.

 Incorrect engine height or obstructions

to the smooth flow of water (such as the design or condition of the boat, or accessories, such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. If the outboard motor is operated continuously in the presence of airborne water spray, enough water could enter the engine through the air intake opening in the top cowling to cause severe engine damage. Remove the cause of the airborne water spray.

ZMU01762

Page 36

Operation

EMU36381

First-time operation

EMU27020

Breaking in engine

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

NOTICE

ECM00140

 Failure to follow the break-in procedure

could result in reduced engine life or even severe engine damage.

 Premix fuel must be used during break-

in in addition to oil in the oil injection system.

EMU27060

Gasoline and engine oil mixing chart (50:1)

NOTICE

ECM00150

Be sure to mix gasoline and oil completely, otherwise the engine may be damaged.

EMU30311

Procedure for oil injection models

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

1. First 10 minutes: Run the engine at the lowest possible

speed. A fast idle in neutral is best.

2. Next 50 minutes: Do not exceed half throttle (approximately 3000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3000 r/min or less.

3. Next two hours: Accelerate at full throttle onto plane, then reduce engine speed to three-quarter throttle (approximately 4000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at threequarter throttle or less to let the engine cool.

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

5. After the first 10 hours: Operate the engine normally. Use only straight gasoline in the fuel tank. The Yamaha oil injection system provides proper lubrication for normal operation.

EMU36400

Getting to know your boat

Different boats handle differently. Operate cautiously while you learn how your boat handles under different conditions and with different trim angles (see page 44).

EMU36413

Checks before starting engine

WARNING

EWM01921

If any item in “Checks before starting engine” is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur.

1. : Gasoline

2. : Engine oil

Page 37

Operation

NOTICE

ECM00120

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

EMU37151

Fuel level

Be sure you have plenty of fuel for your trip. A good rule is to use 1/3 of your fuel to get to the destination, 1/3 to return, and to keep 1/3 as an emergency reserve. With the boat level on a trailer or in the water, turn the key to “ ” (on) and check the fuel level. For fuel filling instructions, see page 35.

EMU36572

Remove the top cowling

For the following checks, remove the top cowling from the bottom cowling. To remove the top cowling, release the cowling lock lever and lift off the top cowling.

EMU36442

Fuel system

WARNING

EWM00060

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

WARNING

EWM00910

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.

EMU36451

Check for fuel leaks

 Check for fuel leaks or gasoline fumes in

the boat.

 Check for fuel leakage from the fuel sys-

tem.

 Check the fuel tank and fuel lines for

cracks, swellings, or other damages.

EMU37322

Checking the fuel filter

Check that the fuel filter is clean and free of water. If any water is found in the fuel, or if a significant amount of debris is found, the fuel tank should be checked and cleaned by a Yamaha dealer.

EMU36462

Controls

 Turn the steering wheel full-right and full-

left. Make sure operation is smooth and unrestricted throughout the whole range with no binding or excessive free play.

 Operate the throttle levers several times to

ZMU06101

ZMU04151

Page 38

Operation

make sure there is no hesitation in their travel. Operation should be smooth over the complete range of motion, and each lever should return completely to the idle position.

 Look for loose or damaged connections of

the throttle and shift cables.

EMU36483

Engine shut-off cord (lanyard)

Inspect the engine shut-off cord and clip for damage, such as cuts, breaks, and wear.

EMU27120

Oil

 Check to be sure you have plenty of oil for

your trip.

EMU27153

Engine

 Check the engine and engine mounting.  Look for loose or damaged fasteners.  Check the propeller for damage.  Check for engine oil leaks.

EMU27181

Operation after long period of storage

Oil injection models

When operating the engine after a long period (12 months) of storage, proceed as follows:

1. Use a 50:1 gasoline to oil mixture to start the engine.

2. Start the engine. Leave it idling.

WARNING! Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.

[EWM01331]

3. Watch for oil flowing through the oil feed pipes. After any air in the oil lines has been expelled, the oil injection system should supply oil normally. If no oil is flowing after 10 minutes of idling, consult your Yamaha dealer.

NOTICE

ECM01260

Be sure to take the above steps when operating the engine after a long period of storage. Otherwise engine seizure could occur.

EMU36493

Flushing device

Check that the flushing device’s garden hose connector is securely screwed on to the fitting on the bottom cowling. NOTICE: If the

garden hose connector is not properly connected, cooling water can leak out and the engine can overheat during operation.

[ECM01801]

1. Cord

2. Clip

3. Engine shut-off switch

ZMU04141

Page 39

Operation

EMU37521

Install cowling

1. Be sure that a cowling lock lever is released.

2. Be sure that the rubber seal is seated all the way around the engine.

3. Set the top cowling straight down onto the engine, being careful to avoid catching spark plug wires or other wires.

4. Align the three cowling hooks with the locks on the bottom cowling.

5. Press down on the top of the cowling at the front and both sides of the back until the three locks click.

6. Check to be sure it fits properly in the rubber seal.

7. Move the lever to lock the cowling as shown. NOTICE: If the top cowling is

not installed correctly, water spray under the top cowling can damage the engine, or the top cowling can blow off at high speeds.

[ECM01991]

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

EMU29158

Checking power trim and tilt system

WARNING

EWM01930

 Never get under the lower unit while it

is tilted, even when the tilt support lever is locked. Severe injury could occur if the outboard motor accidentally falls.

 Body parts can be crushed between the

motor and the clamp bracket when the motor is trimmed or tilted.

 Be sure no one is near the outboard

1. Fitting

2. Flushing device

ZMU06052

ZMU03519

ZMU06126

ZMU04679

Page 40

Operation

motor before performing this check.

1. Check the power trim and tilt unit for any sign of oil leaks.

2. Operate each of the power trim and tilt switches on the remote control and engine bottom cowling to check that all switches work.

3. Tilt the outboard motor up and check that the tilt rod and trim rods are extended completely.

4. Use the tilt support lever to lock the motor in the up position. Operate the tilt down switch briefly so the motor is supported by the tilt support lever.

5. Check that the tilt rod and trim rods are free of corrosion or other flaws.

6. Activate the tilt-down switch until the trim rods have retracted completely into the cylinders.

7. Activate the trim-up switch until the tilt rod is fully extended. Unlock the tilt support lever.

8. Tilt the outboard motor down. Check that the tilt rod and trim rods operate smoothly.

EMU36582

Battery

Check that the battery is in good condition, and fully charged. Check that the battery connections are clean, secure and covered by insulating covers. The electrical contacts of the battery and cables must be clean and properly connected or the battery will not start the engine. Refer to the battery manufacturer’s instructions for checks for your particular battery.

1. Tilt rod

2. Trim rods

1. Tilt support lever

ZMU03458

ZMU03459

ZMU04156

ZMU02635

Page 41

Operation

EMU27234

Filling fuel and engine oil

EMU27248

Filling fuel for portable tank

WARNING

EWM01830

 Gasoline and its vapors are highly flam-

mable and explosive. Always refuel according to this procedure to reduce the risk of fire and explosion.

 Gasoline is poisonous and can cause

injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

1. Be sure the engine is stopped.

2. Disconnect the fuel line from the fuel tank and tighten the air vent screw on the fuel tank cap.

3. Remove the portable tank from the boat.

4. Be sure you are in a well-ventilated outdoor area, either securely moored or trailered.

5. Do not smoke and keep away from sparks, flames, static electric discharge, or other sources of ignition.

6. If you use a portable container to store and dispense fuel, use only an approved GASOLINE container.

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

8. Fill the fuel tank, but do not overfill.

WARNING! Do not overfill. Otherwise fuel can expand and overflow if the temperature increases.

[EWM02610]

ZMU06621

Fuel tank capacity:

24 L (6.34 US gal, 5.28 Imp.gal)

ZMU02301

ZMU02834

Page 42

Operation

9. Tighten the filler cap securely.

10. Wipe up any spilled gasoline immediately with dry rags. Dispose rags properly according to local laws or regulations.

EMU30322

Filling fuel for models without a fuel joint

WARNING

EWM01830

 Gasoline and its vapors are highly flam-

mable and explosive. Always refuel according to this procedure to reduce the risk of fire and explosion.

 Gasoline is poisonous and can cause

1. Stop the engine.

2. Be sure you are in a well-ventilated outdoor area, either securely moored or trailered.

3. Make sure no one is in the boat.

4. Do not smoke and keep away from sparks, flames, static electric discharge, or other sources of ignition.

5. If you use a portable container to store and dispense fuel, only use a locally approved GASOLINE container.

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

7. Fill the fuel tank, but do not overfill.

WARNING! Do not overfill. Otherwise fuel can expand and overflow if the temperature increases.

[EWM02610]

8. Tighten the filler cap securely.

9. Wipe up any spilled gasoline immediately with dry rags. Dispose rags properly. According to local laws or regulations.

EMU43360

Filling oil

This engine uses the Yamaha oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operating conditions. No fuel premixing is needed. Simply pour gasoline into the fuel tank and oil into the oil tank. Convenient indicator segments indicate the status of the oil supply. For details on reading the indicator segments, see page 38.

WARNING

EWM00530

Do not add gasoline into the oil tank. Fire or explosion could result.

To fill the engine oil tank, proceed as follows:

1. Pour engine oil into the remote oil tank.

TIP:

The oil level lines on the remote oil tank indicate the amount of additional oil that can be added to the tank. The top oil level line indicates approximately 1.9 L (2.01 US qt, 1.67 Imp qt) can be added, and the bottom oil lev-

Engine oil tank capacity:

0.9 L (0.95 US qt, 0.79 Imp.qt)

ZMU04142

Page 43

Operation

el line indicates approximately 3.8 L (4.02 US qt, 3.34 Imp qt) can be added.

2. Turn on the main switch. The Yamaha oil injection system will automatically feed oil from the remote oil tank to the engine oil tank.

3. After the engine oil tank has filled, turn off the main switch to cancel the oil level alert.

4. Operate the engine normally.

NOTICE

ECM02540

 Remote oil tank [10.5 L (11.10 US qt,

9.24 Imp.qt)]: When the engine is operated for the first time or stored for a period of time, a minimum of 5 L (5.3 US qt, 4.4 Imp qt) of oil should be kept in the remote oil tank. Otherwise the oilfeed pump chamber will not be filled with oil, and no oil will be supplied.

 Remote oil tank [18.0 L (19.03 US qt,

15.84 Imp.qt)]: When the engine is operated for the first time or stored for a period of time , a minimum of 8 L (8.5 US qt, 7 Imp qt) of oil should be kept in the remote oil tank. Otherwise the oilfeed pump chamber will not be filled with oil, and no oil will be supplied.

ON STARTOFF

ZMU04143

ON STARTOFF

ZMU04144

Page 44

Operation

EMU27321

Oil level indicator operation

The various functions of the oil level system are as follows:

EMU43400

Oil level indicator

Electric start models using remote oil tank [10.5 L (11.10 US qt, 9.24 Imp.qt)]

Oil level-alert

indicator

(digital

tachometer)

Oil level-alert

indicator (analog

tachometer)

Engine oil

tank

Remote oil

tank

Remarks

Green

more than

0.3 L

(0.32 US qt,

0.26 Imp qt)

more than

1.5 L

(1.6 US qt,

1.31 Imp qt)

 No refilling necessary.

Yellow

more than

0.3 L

(0.32 US qt,

0.26 Imp qt)

1.5 L

(1.6 US qt,

1.31 Imp qt) or less

 Add oil; see page 36.

Red–Yellow–

Green

0.3 L

(0.32 US qt,

0.26 Imp qt) or less

more than

1.5 L

(1.6 US qt,

1.31 Imp qt)

 Check oil filter for clog-

ging.

 Check battery cable

connection. Buzzer will sound.

 Engine speed is auto-

matically reduced to about 2000 r/min.

Red

0.3 L

(0.32 US qt,

0.26 Imp qt) or less

1.5 L

(1.6 US qt,

1.31 Imp qt) or less

 Oil has not been added.  Buzzer will sound.  Engine speed is auto-

matically reduced to about 2000 r/min.

 Buzzer sounds in

remote control box and engine speed is limited to about 2000 r/min to help conserve oil.

Page 45

Operation

Electric start models using remote oil tank [18.0 L (19.03 US qt, 15.84 Imp.qt)]

EMU27452

Operating engine

WARNING

EWM00420

 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.

Oil level-alert

indicator

(digital

tachometer)

Oil level-alert

indicator (analog

tachometer)

Engine oil

tank

Remote oil

tank

Remarks

Green

more than

0.3 L

(0.32 US qt,

0.26 Imp qt)

more than

2.8 L

(3.0 US qt,

2.5 Imp qt)

 No refilling necessary.

Yellow

more than

0.3 L

(0.32 US qt,

0.26 Imp qt)

2.8 L

(3.0 US qt,

2.5 Imp qt) or less

 Add oil; see page 36.

Red–Yellow–

Green

0.3 L

(0.32 US qt,

0.26 Imp qt) or less

more than

2.8 L

(3.0 US qt,

2.5 Imp qt)

 Check oil filter for clog-

ging.

 Check battery cable

connection. Buzzer will sound.

 Engine speed is auto-

matically reduced to about 2000 r/min.

Red

0.3 L

(0.32 US qt,

0.26 Imp qt) or less

2.8 L

(3.0 US qt,

2.5 Imp qt) or less

 Oil has not been added.  Buzzer will sound.  Engine speed is auto-

matically reduced to about 2000 r/min.

 Buzzer sounds in

remote control box and engine speed is limited to about 2000 r/min to help conserve oil.

Page 46

Operation

 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.

EMU27468

Sending fuel (portable tank)

1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.

2. If there is a fuel joint on the motor, align the fuel joint on the fuel line with the fuel joint on the motor and firmly connect the fuel line to the joint while pinching the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank.

TIP:

Wipe up any spilled gasoline immediately with dry rags. Dispose rags properly according to local laws or regulations.

3. Squeeze the primer pump, with the arrow pointing up, until you feel it become firm. During engine operation place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank.

EMU27484

Sending fuel

1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.

2. If there is a fuel joint or a fuel cock on the boat, firmly connect the fuel line to the joint or open the fuel cock.

3. Squeeze the primer pump, with the arrow pointing up, until you feel it become firm.

EMU27494

Starting engine

WARNING

EWM01600

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 wa-

ZMU02295

1. Arrow

Page 47

Operation

ter near you.

EMU27645

Electric start / remote control models

WARNING

EWM01840

 Failure to attached engine shut-off cord

could result in a runaway boat if operator is ejected. Attach the engine shutoff cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning.

 Avoid accidentally pulling the cord dur-

ing 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.

1. Place the remote control lever in neutral.

TIP:

The start-in-gear protection device prevents the engine from starting except when in neutral.

2. Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off

switch.

3. Turn the main switch to “ ” (on).

4. Open the throttle slightly without shifting using the neutral throttle lever or free accelerator. You may need to change the throttle opening slightly depending on engine temperature. After the engine starts, return the throttle to the original position.

TIP:

 On remote controls equipped with a neu-

OFF

ZMU01880

ZMU03200

Page 48

Operation

tral throttle lever, a good starting point is to lift the lever just until you feel resistance, then lift slightly more.

 The neutral throttle lever or free accelera-

tor can only be used when the remote control lever is in neutral.

5. Press in and hold the main switch to operate the remote choke system. The remote choke switch automatically returns to its normal position when you release your hand. Therefore keep the switch pressed in.

TIP:

 It is not necessary to use the choke when

starting a warm engine.

 Push in the main switch fully, or the remote

choke system will not operate.

6. Turn the main switch to “ ” (start), and hold it for a maximum of 5 seconds.

7. Immediately after the engine starts, release the main switch and allow it to return to “ ” (on). NOTICE: Never turn

the main switch to “ ” (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged. If the

engine will not start after 5 seconds of cranking, return the main switch to “ ” (on), wait 10 seconds, then crank the engine again.

[ECM00192]

EMU36510

Checks after starting engine

EMU36523

Cooling water

Check for a steady flow of water from the cooling water pilot hole. A continuous flow of water from the pilot hole indicates that the water pump is pumping water through the cooling water passages. If the cooling water passages are frozen, it may take a while for water to start flowing out of the pilot hole.

NOTICE

ECM01810

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

ZMU07440

STARTOFF

ZMU03908

Page 49

Operation

EMU27670

Warming up engine

EMU27683

Choke start models

After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life. Gradually return the choke knob to its home position as the engine warms up.

EMU36531

Checks after engine warm up

EMU36541

Shifting

While the boat is tightly moored, and without applying throttle, confirm that the engine shifts smoothly into forward and reverse, and back to neutral.

EMU31721

Stop switches

 Confirm that turning the main switch to the

“ ” (off) position stops the engine.

 Confirm that removing the clip from the en-

gine shut-off switch stops the engine.

 Confirm that the engine cannot be started

with the clip removed from the engine shut-off switch.

EMU31733

Shifting

WARNING

EWM00180

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

NOTICE

ECM01610

Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral. If this occurs, stop the engine, shift to neutral, then restart the

engine and allow it to warm up.

To shift out of neutral

1. Pull the neutral interlock trigger up (if equipped).

2. Move the remote control lever firmly and crisply forward (for forward gear) or rearward (for reverse gear) about 35 (a detent can be felt).

To shift from in gear (forward/reverse) to neutral

1. Close the throttle so that the engine slows to idle speed.

1. Neutral interlock trigger

Page 50

Operation

2. After the engine is at idle speed in gear, move the remote control lever firmly and crisply to the neutral position.

EMU31742

Stopping boat

WARNING

EWM01510

 Do not use the reverse function to slow

down or stop the boat as it could cause you to lose control, be ejected, or impact the steering wheel or other parts of the boat. This could increase the risk of serious injury. It could also damage the shift mechanism.

 Do not shift into reverse while traveling

at planing speeds. Loss of control, boat swamping, or damage to the boat could occur.

The boat is not equipped with a separate braking system. Water resistance stops it after the throttle lever is moved back to idle.

The stopping distance varies depending on gross weight, water surface conditions, and wind direction.

EMU27821

Stopping engine

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

EMU27854

Procedure

1. Turn the main switch to “ ” (off).

2. After stopping the engine, disconnect the fuel line or close the fuel cock if there is a fuel joint or a fuel cock on the boat.

3. Tighten the air vent screw on the fuel tank cap (if equipped).

4. Remove the key if the boat will be left unattended.

TIP:

The engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch, then turning the main switch to “ ” (off).

EMU27862

Trimming outboard motor

WARNING

EWM00740

Excessive trim for the operating conditions (either trim up or trim down) can cause boat instability and can make

Page 51

Operation

steering the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.

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

EMU27888

Adjusting trim angle (Power trim and tilt)

WARNING

EWM00753

 Be sure all people are clear of the out-

board motor when adjusting the trim angle. Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted.

 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.

 If equipped with a power trim and tilt

switch located on the bottom cowling, use the switch only when the boat is at a complete stop with the engine off. Do not adjust the trim angle with this switch while the boat is moving.

Adjust the outboard motor trim angle using the power trim and tilt switch.

1. Trim operating angle

ZMU04145

1. Power trim and tilt switch

Page 52

Operation

To raise the bow (trim-out), press the switch “ ” (up). To lower the bow (trim-in), press the switch “ ” (down). Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.

EMU27912

Adjusting boat trim

When the boat is on plane, a bow-up attitude results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.

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

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.

TIP:

Depending on the type of boat, the outboard

1. Power trim and tilt switch

ZMU03522

Page 53

Operation

motor trim angle may have little effect on the trim of the boat when operating.

EMU27935

Tilting up and down

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

WARNING

EWM00222

Make sure that no one is near the outboard motor when tilting the outboard motor up or down. Otherwise, body parts could be crushed between the outboard motor and the clamp bracket.

WARNING

EWM00250

Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, disconnect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.

NOTICE

ECM00241

 Before tilting the outboard motor, stop

the engine by following the procedure on page 44. 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 (if equipped) because this could break the handle.

EMU32724

Procedure for tilting up (power trim and tilt models)

1. Place the remote control lever in neutral.

2. Press the power trim and tilt switch “ ” (up) until the outboard motor has tilted up completely.

3. Pull the tilt support lever toward you to support the engine. WARNING! After

tilting the outboard motor, be sure to support it with the tilt support knob or

ZMU03196

ZMU04146

Page 54

Operation

tilt support lever. Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit or in the power tilt unit loses pressure.

[EWM00262] NOTICE: Do not use

the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position. For more detailed information, see page 51.

[ECM01641]

4. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim and tilt switch “ ” (down) to retract the trim rods. NOTICE: Make sure that the

trim rods retracts completely during mooring. This protects the rods from marine growth and corrosion, which could damage the power trim and tilt mechanism.

[ECM00252]

EMU33121

Procedure for tilting down (power trim and tilt models)

1. Push the power trim and tilt switch “ ” (up) until the outboard motor is supported by the tilt rod and the tilt support lever becomes free.

2. Release the tilt support lever.

3. Push the power trim and tilt switch “ ” (down) to lower the outboard motor to the desired position.

ZMU03432

ZMU03452

ZMU03453

ZMU01936

Page 55

Operation

EMU28062

Shallow water

EMU32851

Power trim and tilt models

The outboard motor can be tilted up partially to allow operation in shallow water.

NOTICE

ECM00260

Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when setting up for and cruising in shallow water. Otherwise severe damage from overheating can result.

EMU32922

Procedure for power trim and tilt models

1. Place the remote control lever in neutral.

2. Slightly tilt the outboard motor up to the desired position using the power trim and tilt switch. WARNING! Using the

power trim and tilt switch on the bot-

tom cowling while the boat is moving or engine is on could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obstacle.

[EWM01850]

3. To return the outboard motor to the normal running position, press the power trim and tilt switch and slowly tilt the outboard motor down.

EMU28195

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh water.

Cruising in muddy, turbid, or acidic water

Yamaha strongly recommends that you use the optional chromium-plated water pump kit

ZMU04147

ZMU01935

ZMU04146

Page 56

Operation

(see page 13) if you use the outboard motor in acidic water or water with a lot of sediment in it, such as muddy or turbid (cloudy) water. After operating in such water, flush the cooling passages with fresh water to prevent corrosion. Also rinse the outside of the outboard motor with fresh water.

Page 57

Maintenance

EMU2822A

Transporting and storing

outboard motor

WARNING

EWM02620

 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.

 Leaking fuel is a fire hazard. When

transporting and storing the outboard motor, disconnect the fuel line from the outboard motor to prevent fuel from leaking.

 Never get under the outboard motor

while it is tilted. Severe injury could occur if the outboard motor accidentally falls.

 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 outboard motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position.

NOTICE

ECM02440

When storing the outboard motor for prolonged time, fuel must be drained from the fuel tank. The deteriorated fuel could clog the fuel line causing engine start difficulty or malfunction.

When storing or transporting the outboard motor, make sure to follow the procedure listed below.

 Disconnect the fuel line from the outboard

motor.

 Tighten the fuel tank cap and its air vent

screw.

 When the outboard motor is tilted pro-

longed time for mooring or trailering the boat, disconnect the fuel line from the outboard motor. Tighten the fuel tank cap and

its air vent screw. The outboard motor should be transported 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.

EMU30272

Storing outboard motor

When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the following procedures.

NOTICE

ECM01411

 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 trou-

ble.

 Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

Page 58

Maintenance

EMU28305

Procedure

EMU28323

Flushing with the flushing attachment

1. Wash the outboard motor body using fresh water. NOTICE: Do not spray wa-

ter into the air intake. [ECM01840] For fur-

ther information, see page 54.

2. Disconnect the fuel line from the motor or shut off the fuel cock, if equipped.

3. Remove the engine top cowling and silencer cover. Remove the propeller.

4. Install the flushing attachment over the cooling water inlet. NOTICE: Do not run

the engine without supplying it with cooling water. Either the engine water pump will be damaged or the engine will be damaged from overheating. Before starting the engine, be sure to supply water to the cooling water passages. Avoid running the outboard motor at high speed while on the flushing attachment, otherwise overheating could occur.

[ECM02000]

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

WARNING! Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.

[EWM00091]

6. Run the engine at a fast idle for a few minutes in neutral position.

7. Just prior to turning off the engine, quickly spray “Fogging Oil” alternately into each carburetor or the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke excessively and almost stall.

8. Remove the flushing attachment.

9. Install the silencer cover/cap of fogging hole and top cowling.

10. If the “Fogging Oil” is not available, run the engine at a fast idle until the fuel system becomes empty and the engine stops.

11. Drain the cooling water completely out of

ZMU04154

1. Flushing attachment

Page 59

Maintenance

the motor. Clean the body thoroughly.

12. If the “Fogging Oil” is not available, remove the spark plug(s). Pour a teaspoonful of clean engine oil into each cylinder. Crank several times manually. Replace the spark plug(s).

TIP:

A flushing attachment is available from your Yamaha dealer.

EMU28411

Lubrication (oil injection models)

1. Install the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 59.

2. Fill the oil tanks. This prevents the formation of condensation. For models with a remote oil tank, it may be necessary to manually override the control unit to completely fill the engine oil tank.

3. Change the gear oil. For instructions, see page 63. Inspect the oil for the presence of water which indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use.

4. Grease all grease fittings. For further details, see page 59.

TIP:

For long-term storage, fogging the engine with oil is recommended. Contact your Yamaha dealer for information about fogging oil and procedures for your engine.

EMU28445

Flushing power unit

Perform this procedure right after operation for the most thorough flushing.

NOTICE

ECM01530

Do not perform this procedure while the engine is running. The water pump may be damaged and severe damage from

overheating can result.

1. After shutting off the engine, unscrew the garden hose connector from the fitting on the bottom cowling.

2. Screw the garden hose adapter onto a garden hose, which is connected to a fresh water supply, and then connect it to the garden hose connector.

3. With the engine off, turn on the water tap and let the water flush through the cooling passages for about 15 minutes. Turn off the water and disconnect the garden hose adapter from the garden hose connector.

4. Reinstall the garden hose connector onto the fitting on the bottom cowling. Tighten the connector securely.

1. Fitting

2. Garden hose connector

3. Garden hose adapter

ZMU04148

Page 60

Maintenance

NOTICE: Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal operation. Water will leak out of the connector instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fitting after flushing the engine.

[ECM00541]

TIP:

 When flushing the engine with the boat in

the water, tilting up the outboard motor until it is completely out of the water will achieve better results.

 For cooling system flushing instructions,

see page 51.

EMU28452

Cleaning the outboard motor

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

EMU28461

Checking painted surface of outboard motor

Check the outboard 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.

EMU2847C

Periodic maintenance

WARNING

EWM01871

These procedures require mechanical skills, tools, and supplies. If you do not have the proper skills, tools, or supplies to perform a maintenance procedure, have a Yamaha dealer or other qualified mechanic do the work. The procedures involve disassembling the motor and exposing dangerous parts. To reduce the risk of injury from moving, hot, or electrical parts:

 Turn off the engine and keep the key(s)

and engine shut-off cord (lanyard) with you when you perform maintenance unless otherwise specified.

 The power trim and tilt switches oper-

ate even when the ignition key is off. Keep people away from the switches whenever working around the motor. When the motor is tilted, keep away from the area under it or between it and the clamp bracket. Be sure no one is in this area before operating the power trim and tilt mechanism.

 Allow the engine to cool before han-

dling hot parts or fluids.

 Always completely reassemble the mo-

tor before operation.

EMU28511

Replacement parts

If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from your Yamaha dealer.

ZMU02550

Page 61

Maintenance

EMU34151

Severe operating conditions

Severe operating conditions involve one or more of the following types of operation on a regular basis:

 Operating continuously at or near maxi-

mum engine speed (rpm) for many hours

 Operating continuously at a low engine

speed (rpm) for many hours

 Operating without sufficient time for engine

to warm up and cool down

 Frequent quick acceleration and decelera-

tion

 Frequent shifting  Frequently starting and stopping the en-

gine(s)

 Operation that fluctuates often between

light and heavy cargo loads Outboard motors operating under any of these above conditions require more frequent maintenance. Yamaha recommends that you do this service twice as often as specified in the maintenance chart. For example, if a particular service should be done at 50 hours, do it instead at 25 hours. This will help prevent more rapid deterioration of engine components.

Page 62

Maintenance

EMU34446

Maintenance chart 1

TIP:

 Refer to the sections in this chapter for explanations of each owner-specific action.  The maintenance cycle on these charts assume usage of 100 hours per year and regular

flushing of the cooling water passages. Maintenance frequency should be adjusted when

operating the engine under adverse conditions such as extended trolling.

 Disassembly or repairs may be necessary depending on the outcome of maintenance

checks.

 Expendable or consumable parts and lubricants will lose their effectiveness over time and

through normal usage regardless of the warranty period.

 When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should

be flushed with clean water after each use. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

20 hours

months)

100

hours

(1 year)

300

hours

(3 years)

500

hours

(5 years)

Anode(s) (external)

Inspection or replacement as necessary

Anode(s) (cylinder head, thermostat cover)

Inspection or replacement as necessary

Anodes (exhaust cover, cooling water passage cover, Rectifier Regulator cover)

Replacement

Battery (electrolyte level, terminal)

Inspection

Battery (electrolyte level, terminal)

Fill, charging or replacing as necessary

Cooling water leakage

Inspection or replacement as necessary

Cowling lock lever Inspection

Engine starting condition/noise

Inspection

Engine idle speed/noise

Inspection

Fuel filter (can be disassembled)

Inspection or replacement as necessary

Fuel line Inspection

Page 63

Maintenance

Fuel line

Inspection or replacement as necessary

Fuel pump

Inspection or replacement as necessary

Fuel/engine oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Impeller/water pump housing

Inspection or replacement as necessary

Impeller/water pump housing

Replacement

Oil tank water drain Inspection or cleaning

Oil injection pump/oil feed pump

Inspection or Adjustment

Power trim and tilt unit/Operation, noise and oil leakage

Inspection

Propeller/propeller nut/cotter pin

Inspection or replacement as necessary

PCV (Pressure Control Valve)

Inspection or replacement as necessary

Shift link/shift cable

Inspection, adjustment or replacement as necessary

Spark plug(s)

Inspection or replacement as necessary

Spark plug caps/spark plug wires

Inspection or replacement as necessary

Water from the cooling water pilot hole

Inspection

Throttle link/throttle cable/throttle pick-up timing

Inspection, adjustment or replacement as necessary

Thermostat

Inspection or replacement as necessary

Cooling water inlet Inspection

Main switch/stop switch/choke switch

Inspection or replacement as necessary

Item Actions

Initial Every

20 hours

months)

100

hours

(1 year)

300

hours

(3 years)

500

hours

(5 years)

Page 64

Maintenance

EMU34451

Maintenance chart 2

Wire harness connections/wire coupler connections

Inspection or replacement as necessary

(Yamaha) Meter/gauge Inspection

Fuel tank (Yamaha portable tank)

Inspection and cleaning as necessary

Item Actions

Every

1000 hours

Exhaust guide/exhaust manifold

Inspection or replacement as necessary

Item Actions

Initial Every

20 hours

months)

100

hours

(1 year)

300

hours

(3 years)

500

hours

(5 years)

Page 65

Maintenance

EMU28943

Greasing

Yamaha grease A (water resistant grease) Yamaha grease D (corrosion resistant grease; for propeller shaft)

115C, 130B

EMU28957

Cleaning and adjusting spark plug

The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For exam-

ple, 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 re-

ZMU04149

Page 66

Maintenance

move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.

1. Remove the spark plug caps from the

spark plugs.

2. Remove the spark plug. If electrode ero-

sion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type. WARNING!

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

[EWM00561]

3. Be sure to use the specified spark plug,

otherwise the engine may not operate properly. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; replace it if out of specification.

4. When fitting the plug, wipe off any dirt from the threads, and then screw it in to the correct torque.

TIP:

If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.

EMU37450

Checking fuel filter

Check the fuel filter periodically. If any water or foreign matter is found in the filter, clean or replace it. For cleaning or replacement of the fuel filter, consult your Yamaha dealer.

EMU29044

Inspecting idle speed

WARNING

EWM00451

 Do not touch or remove electrical parts

when starting or during operation.

 Keep hands, hair, and clothes away

from the flywheel and other rotating

Standard spark plug:

115CETO BR8HS-10 130BETO BR9HS-10

1. Spark plug gap

2. Spark plug part number

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

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

Spark plug torque:

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

ZMU04151

Page 67

Maintenance

parts while the engine is running.

NOTICE

ECM00490

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

If the boat is not equipped with a tachometer for the outboard motor, use a diagnostic tachometer for this procedure. Results may vary depending on whether testing is conducted with the flushing attachment, in a test tank, or with the outboard motor in the water.

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

2. Once the engine has warmed up, verify whether the idle speed is set to specification. For idle speed specifications, see page 9. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechanic.

EMU29050

Checking water in engine oil tank

Oil injection models

There is a water trap at the bottom of the engine oil tank. If water or foreign matter is visible in this trap, consult your Yamaha dealer.

EMU29114

Inspecting wiring and connectors

 Inspect that each connector is engaged

securely.

 Inspect that each ground lead is properly

secured.

EMU32112

Checking propeller

WARNING

EWM01881

You could be seriously injured if the engine accidentally starts when you are near the propeller. Before inspecting, removing, or installing the propeller, place the shift control in neutral, turn the main switch to “ ” (off) and remove the key, and remove the clip from the engine shutoff switch. Turn off the battery cut-off

1. Water trap

2. Engine oil tank

ZMU01895

ZMU03915

Page 68

Maintenance

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.

Checkpoints

 Check each of the propeller blades for ero-

sion from cavitation or ventilation, or other damage.

 Check the propeller shaft for damage.  Check the splines for wear or damage.  Check for fish line tangled around the pro-

peller shaft.

 Check the propeller shaft oil seal for dam-

age.

EMU30662

Removing propeller

EMU29197

Spline models

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

2. Remove the propeller nut, washer, and spacer (if equipped). WARNING! Do

not use your hand to hold the propeller when loosening the propeller nut.

[EWM01890]

3. Remove the propeller, washer (if equipped), and thrust washer.

EMU30672

Installing propeller

EMU29234

Spline models

NOTICE

ECM00501

Make 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

ZMU01897

1. Cotter pin

2. Propeller nut

3. Washer

4. Spacer

5. Propeller

6. Thrust washer

Page 69

Maintenance

shaft.

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

Make sure to install the thrust washer before installing the propeller. Otherwise, the lower case and propeller boss could be damaged.

[ECM01881]

3. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque.

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

NOTICE: Do not reuse the cotter pin. Otherwise, the propeller can come off during operation.

[ECM01891]

TIP:

If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to align it with the hole.

EMU29289

Changing gear oil

WARNING

EWM00800

 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.

2. Place a suitable container under the gear case.

3. Remove the gear oil drain screw and gasket. NOTICE: If there is an exces-

sive quantity of metal particles on the magnetic gear oil drain screw, this can indicate lower unit problem. Consult your Yamaha dealer.

[ECM01900]

TIP:

 If a magnetic gear oil drain screw is

equipped, remove all metal particles from the screw before installing it.

 Always use new gaskets. Do not reuse the

removed gaskets.

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

NOTICE: Check the used gear oil after it has been drained. If the gear oil is

Propeller nut tightening torque:

55.0 Nm (5.61 kgf-m, 40.6 ft-lb)

ZMU03545

1. Gear oil drain screw

2. Oil level plug

ZMU03273

Page 70

Maintenance

milky or contains water or a large amount of metal particles, the gear case may be damaged. Have a Yamaha dealer check and repair the outboard motor.

[ECM00713]

TIP:

For disposal of used oil, consult your Yamaha dealer.

5. Put the outboard motor in a vertical position. Using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole.

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.

EMU29302

Cleaning fuel tank

WARNING

EWM00920

Gasoline is highly flammable, and its vapors are flammable and explosive.

 If you have any question about properly

doing this procedure, consult your Yamaha dealer.

 Keep away from sparks, cigarettes,

flames, or other sources of ignition when cleaning the fuel tank.

 Remove the fuel tank from the boat be-

fore cleaning it. Work only outdoors in an area with good ventilation.

 Wipe up any spilled fuel immediately.  Reassemble the fuel tank carefully. Im-

proper assembly can result in a fuel leak, which could result in a fire or explosion hazard.

 Dispose of old gasoline according to lo-

cal regulations.

1. Empty the fuel tank into an approved container.

2. Pour a small amount of suitable solvent into the tank. Install the cap and shake the tank. Drain the solvent completely.

3. Remove the screws holding the fuel joint assembly. Pull the assembly out of the tank.

4. Clean the filter (located on the end of the

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

0.760 L (0.803 US qt, 0.669 Imp.qt)

Tightening torque:

9 Nm (0.9 kgf-m, 6.6 ft-lb)

Tightening torque:

9 Nm (0.9 kgf-m, 6.6 ft-lb)

ZMU03274

ZMU02324

Page 71

Maintenance

suction pipe) in a suitable cleaning solvent. Allow the filter to dry.

5. Replace the gasket with a new one. Reinstall the fuel joint assembly and tighten the screws firmly.

EMU29314

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.

NOTICE

ECM00720

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

TIP:

Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replace-

ment of internal anodes attached to the power unit.

EMU29323

Checking battery (for electric start models)

WARNING

EWM01902

Battery electrolyte is poisonous and caustic, and batteries generate explosive hydrogen gas. When working near the battery:

 Wear protective eye gear and rubber

gloves.

 Do not smoke or bring any other source

of ignition near the battery.

The procedure for checking the battery varies for different batteries. This procedure contains typical checks that apply to many batteries, but you should always refer to the battery manufacturer’s instructions.

NOTICE

ECM01920

A poorly maintained battery will quickly deteriorate.

1. Check the electrolyte level.

2. Check the battery’s charge. If your boat is equipped with the digital speedometer, the voltmeter and low battery alert functions will help you monitor the battery’s charge. If the battery needs charg-

ZMU01901

ZMU03461

Page 72

Maintenance

ing, consult your Yamaha dealer.

3. Check the battery connections. They should be clean, secure, and covered by an insulating cover. WARNING! Bad

connections can produce shorting or arcing and cause an explosion.

[EWM01912]

EMU29334

Connecting the battery

WARNING

EWM00572

Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder.

NOTICE

ECM01124

Do not reverse the battery cables. Otherwise, the electrical parts could be damaged.

1. Make sure the main switch (on applicable models) is “ ” (off) before working on the battery.

2. Connect the red battery cable to the POSITIVE (+) terminal first. Then connect the black battery cable to the NEGATIVE (-) terminal.

3. The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine.

EMU29371

Disconnecting the battery

1. Turn off the battery cut-off switch (if equipped) and main switch. NOTICE: If

they are left on, the electrical system can be damaged.

[ECM01930]

2. Disconnect the negative cable(s) from the negative (-) terminal. NOTICE: Al-

ways disconnect all negative (-) cables first to avoid a short circuit and damage to the electrical system.

[ECM01940]

3. Disconnect the positive cable(s) and remove the battery from the boat.

4. Clean, maintain, and store the battery according to the manufacturer’s instructions.

1. Red cable

2. Black cable

3. Battery

ZMU01811

Page 73

Trouble Recovery

EMU29427

Troubleshooting

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. This section describes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble-alert indicator is flashing, consult your Yamaha dealer.

Starter will not operate.

Q. Is battery capacity weak or low? A. Check battery condition. Use battery of recommended capacity.

Q. Are battery connections loose or corroded? A. Tighten battery cables and clean battery terminals.

Q. Is fuse for electric start relay or electric circuit blown? A. Check for cause of electric overload and repair. Replace fuse with one of correct amperage.

Q. Are starter components faulty? A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear? A. Shift to neutral.

Engine will not start (starter operates).

Q. Is fuel tank empty? A. Fill tank with clean, fresh fuel.

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged? A. Clean or replace filter.

Q. Is starting procedure incorrect? A. See page 40.

Q. Has fuel pump malfunctioned? A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Q. Are spark plug cap(s) fitted incorrectly? A. Check and re-fit cap(s).

Q. Is ignition wiring damaged or poorly connected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.

Q. Are ignition parts faulty? A. Have serviced by a Yamaha dealer.

Q. Is engine shut-off cord (lanyard) not attached? A. Attach cord.

Q. Are engine inner parts damaged? A. Have serviced by a Yamaha dealer.

Engine idles irregularly or stalls.

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Page 74

Trouble Recovery

Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.

Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged? A. Clean or replace filter.

Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.

Q. Has alert system activated? A. Find and correct cause of alert.

Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.

Q. Is ignition wiring damaged or poorly connected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.

Q. Is specified engine oil not being used? A. Check and replace oil as specified.

Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.

Q. Are carburetor adjustments incorrect? A. Have serviced by a Yamaha dealer.

Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.

Q. Is air vent screw on fuel tank closed? A. Open air vent screw.

Q. Is choke knob pulled out?

A. Return to home position.

Q. Is motor angle too high? A. Return to normal operating position.

Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect? A. Connect correctly.

Q. Is throttle valve adjustment incorrect? A. Have serviced by a Yamaha dealer.

Q. Is battery cable disconnected? A. Connect securely.

Alert buzzer sounds or indicator lights.

Q. Is cooling system clogged? A. Check water intake for restriction.

Q. Is engine oil level low? A. Fill oil tank with specified engine oil.

Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type.

Q. Is specified engine oil not being used? A. Check and replace oil with specified type.

Q. Is engine oil contaminated or deteriorated? A. Replace oil with fresh, specified type.

Q. Is oil filter clogged? A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunctioned? A. Have serviced by a Yamaha dealer.

Page 75

Trouble Recovery

Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane.

Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer.

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 trim angle incorrect? A. Adjust trim angle to achieve most efficient operation.

Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height.

Q. Has alert system activated? A. Find and correct cause of alert.

Q. Is boat bottom fouled with marine growth? A. Clean boat bottom.

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

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

A. Remove foreign matter and clean lower unit.

Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.

Q. Is fuel filter clogged? A. Clean or replace filter.

Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.

Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.

Q. Is ignition wiring damaged or poorly connected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.

Q. Have electrical parts failed? A. Have serviced by a Yamaha dealer.

Q. Is specified fuel not being used? A. Replace fuel with specified type.

Q. Is specified engine oil not being used? A. Check and replace oil with specified type.

Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.

Q. Is air vent screw closed? A. Open the air vent screw.

Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect?

Page 76

Trouble Recovery

A. Connect correctly.

Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type.

Q. Is high pressure fuel pump drive belt broken? A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer.

Engine vibrates excessively.

Q. Is propeller damaged? A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangled on propeller? A. Remove and clean propeller.

Q. Is motor mounting bolt loose? A. Tighten bolt.

Q. Is steering pivot loose or damaged? A. Tighten or have serviced by a Yamaha dealer.

EMU29433

Temporary action in

emergency

EMU29441

Impact damage

WARNING

EWM00870

The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the out-

board motor unsafe to operate.

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

1. Stop the engine immediately.

2. Check the control system and all components for damage. Also, check the boat for damage.

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

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

EMU29463

Replacing fuse

If the fuse has blown on an electric start model, open the fuse holder and replace the fuse with a new one of the proper amperage.

WARNING

EWM00631

Substituting an incorrect fuse or a piece of wire could allow excessive current flow. This could cause electric system damage and a fire hazard.

Page 77

Trouble Recovery

Consult your Yamaha dealer if the new fuse immediately blows again.

EMU29525

Power trim and tilt will not operate

If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit, the engine can be tilted manually.

1. Loosen the manual valve screw by turning it counterclockwise until it stops.

2. Put the engine in the desired position, then tighten the manual valve screw by turning it clockwise.

EMU29533

Starter will not operate

If the starter mechanism does not operate (the engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.

WARNING

EWM01022

 Use this procedure only in an emergen-

cy to return to the nearest port for repairs.

 When the emergency starter rope is

used to start the engine, the start-ingear protection device does not operate. Make sure the remote control lever is in neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.

 Attach the engine shut-off cord to a se-

cure place on your clothing, or your arm or leg while operating the boat.

 Do not attach the cord to clothing that

could tear loose. Do not route the cord where it could become entangled, preventing it from functioning.

 Avoid accidentally pulling the cord dur-

 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 fly-

1. Fuse holder

2. Fuse (20 A, 30 A)

3. Spare fuse (20 A, 30 A)

1. Manual valve screw

ZMU05052

ZMU03464

Page 78

Trouble Recovery

wheel 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.

EMU29562

Emergency starting engine

1. Remove the top cowling.

2. Remove the start-in-gear protection cable from the starter, if equipped.

3. Remove the starter/flywheel cover after removing the bolt(s).

4. Prepare the engine for starting. For further information, see page 40. Be sure the engine is in neutral and that the clip is attached to the engine shut-off switch. The main switch must be “ ” (on), if equipped.

5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms up.

6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise.

7. Give a strong pull straight out to crank and start the engine. Repeat if neces-

ZMU03920

ZMU02334

ON STARTOFF

ZMU01906

ZMU03921

Page 79

Trouble Recovery

sary.

EMU29671

Engine fails to operate

EMU43420

Low oil level alert activates

If the oil level is allowed to drop too low, the red segment will appear on the oil level indicator, the buzzer will sound, and engine speed will be limited to about 2000 r/min. If this happens, a reserve amount of oil can be pumped from the remote oil tank to the engine oil tank using the emergency switch.

WARNING

EWM01050

Be sure to stop the engine before performing this procedure.

NOTICE

ECM00901

 If the emergency switch is held up too

long, too much oil will be pumped into the engine oil tank, overflowing it. Release the switch when oil reaches the upper level line on the engine oil tank.

 Do not use this emergency procedure

unless the oil level-alert indicators are working.

1. Remove the top cowling.

2. Turn on the main switch.

3. Lift the emergency switch to pump reserve oil into the engine oil tank from the remote oil tank.

4. After using the emergency switch, turn off the main switch, then turn it back on. This resets the alert system to normal

ZMU03466

1. Emergency switch

1. Engine oil tank

2. Remote oil tank

ON STARTOFF

ZMU01906

ZMU04153

ZMU01908

Page 80

Trouble Recovery

operation. The yellow segment will continue to be displayed on the oil level indicator.

5. Start the engine and return to the nearest port for more oil.

TIP:

 Remote oil tank [10.5 L (11.10 US qt, 9.24

Imp.qt)]: The maximum reserve oil capacity is 1.5 L (1.6 US qt, 1.31 Imp qt).

 Remote oil tank [18.0 L (19.03 US qt,

15.84 Imp.qt)]: The maximum reserve oil capacity is 2.8 L (3.0 US qt, 2.5 Imp qt).

 The oil-feed pump will not operate if the

engine is tilted up more than 35. Put the engine in the upright position (not tilted) before using the emergency switch.

EMU29751

Top cowling does not unlock

If the top cowling stays locked when the release lever is operated, the cable may be damaged or incorrectly adjusted.

1. Pull the cowling release lever to unlock the front lock.

2. Pull the emergency cowling release wire coming out of the hole on the side of the pilot hole in the bottom cowling to release the port side rear lock.

3. Lift the port side of the top cowling to pull out the emergency cowling release wire from the port side of the bottom cowling.

4. Pull the emergency cowling release wire to release the starboard side rear lock.

NOTICE: Be sure the problem with the cowling lock is repaired before reinstalling the cowling.

[ECM00391]

EMU33501

Treatment of submerged motor

If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immediately. NOTICE: Do not attempt to run the

outboard motor until it has been completely inspected.

[ECM00401]

1. Cowling release lever

2. Starboard-side cowling release wire

3. Port-side cowling release wire

ZMU03544

Page 81

Page 82

Printed on recycled paper

Printed in Japan October 2012–0.1  1 !