Yamaha 30D (2015) User guide

Read this manual carefully before operating this

outboard motor.

OWNER’S MANUAL

30D

6J8-28199-78-E0

EMU25053

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

Important manual information

EMU25108

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

EWM00782

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

NOTICE

ECM00702

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 30DMHO 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.

EMU25122

30D

OWNER’S MANUAL

©2014 by Yamaha Motor Co., Ltd.

1st Edition, November 2014

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in Japan

Table of contents

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

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

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

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

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

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

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

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

Gasoline exposure and spills .............. 1

Carbon monoxide ................................ 1

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

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

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

Personal flotation devices (PFDs) ....... 2

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

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

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

Avoid collisions.................................... 2

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

EC Declaration of Conformity

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

CE Marking .....................................4

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

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

Specifications and requirements..... 9

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

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

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

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

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

Start-in-gear protection ..................11

Engine oil requirements .................11

Fuel requirements .......................... 11

Gasoline ............................................ 11

Muddy or acidic water .................... 12

Anti-fouling paint ............................ 12

Motor disposal requirements.......... 12

Emergency equipment................... 12

Components .................................... 13

Components diagram..................... 13

Fuel tank............................................ 13

Fuel joint............................................ 14

Fuel gauge ........................................ 14

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

Air vent screw.................................... 14

Tiller handle ...................................... 14

Gear shift lever ................................. 14

Throttle grip ......................................14

Throttle indicator ............................... 15

Throttle friction adjuster..................... 15

Engine shut-off cord (lanyard) and

clip.................................................. 15

Engine stop button ........................... 16

Choke knob for pull type.................... 16

Manual starter handle........................ 16

Steering friction adjuster.................... 16

Trim tab with anode........................... 17

Trim rod (tilt pin) ................................17

Shallow water lever ...........................17

Tilt lock mechanism........................... 18

Tilt support lever for manual tilt

model .............................................18

Cowling lock lever(s) (turn type)........ 18

2-pin connector.................................. 19

Alert indicator ................................... 19

Instruments and indicators............ 20

Indicators ...................................... 20

Overheat-alert indicator..................... 20

Oil level-alert indicator....................... 20

Engine control system ................... 21

Alert system ................................... 21

Overheat alert.................................... 21

Oil level alert and oil filter clogging

alert ................................................ 21

Table of contents

Installation .......................................23

Installation ...................................... 23

Mounting the outboard motor ............ 23

Clamping the outboard motor............ 24

Operation .........................................26

First-time operation ........................ 26

Breaking in engine............................. 26

Getting to know your boat ................. 26

Checks before starting engine .......26

Fuel level ........................................... 27

Remove the top cowling .................... 27

Fuel system ....................................... 27

Controls ............................................. 27

Engine shut-off cord (lanyard) ........... 28

Oil ...................................................... 28

Engine ............................................... 28

Operation after long period of

storage ........................................... 28

Install top cowling .............................. 28

Filling fuel and engine oil................ 29

Filling fuel for portable tank ............... 29

Filling oil for manual starter model .... 30

Oil level indicator operation ............... 31

Operating engine............................ 31

Sending fuel (portable tank) .............. 31

Starting engine .................................. 32

Checks after starting engine ..........34

Cooling water .................................... 34

Warming up engine ........................ 34

Choke start models ........................... 34

Checks after engine warm up ........34

Shifting .............................................. 34

Stop switches .................................... 34

Shifting ........................................... 35

Stopping boat ................................. 36

Stopping engine ............................. 36

Procedure.......................................... 36

Trimming outboard motor...............37

Adjusting trim angle for manual tilt

models ........................................... 37

Adjusting boat trim............................. 38

Tilting up and down ........................ 39

Procedure for tilting up (manual tilt

models) ..........................................39

Procedure for tilting down (manual

tilt models)...................................... 40

Shallow water ................................ 40

Cruising in shallow water (manual

tilt models)...................................... 40

Cruising in other conditions............ 41

Maintenance .................................... 43

Transporting and storing outboard

motor........................................... 43

Clamp screw mounting models .........43

Storing outboard motor...................... 44

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

Lubrication (oil injection models) ....... 46

Cleaning the outboard motor............. 46

Checking painted surface of

outboard motor............................... 46

Periodic maintenance .................... 46

Replacement parts ............................47

Severe operating conditions.............. 47

Maintenance chart 1.......................... 48

Maintenance chart 2.......................... 49

Greasing............................................ 50

Cleaning and adjusting spark plug ....50

Checking fuel filter............................. 51

Inspecting idle speed......................... 51

Checking water in engine oil tank...... 52

Inspecting wiring and connectors ...... 52

Checking propeller ............................ 52

Removing propeller ...........................53

Installing propeller .............................53

Changing gear oil ..............................54

Cleaning fuel tank.............................. 55

Inspecting and replacing anode(s) ....55

Trouble Recovery............................ 57

Troubleshooting ............................. 57

Temporary action in emergency .... 60

Impact damage.................................. 60

Starter will not operate ...................... 60

Emergency starting engine................ 61

Treatment of submerged motor ..... 62

Table of contents

INDEX ...............................................63

1

Safety information

EMU33623

Outboard motor safety

Observe these precautions at all times.

EMU36502

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.

EMU33631

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.

EMU33641

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.

EMU33651

Electric shock

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

EMU33672

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.

EMU33811

Gasoline

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

cording to the procedure on page 31 to
reduce the risk of fire and explosion.

EMU33821

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.

EMU33901

Carbon monoxide

This product emits exhaust gases which con­tain carbon monoxide, a colorless, odorless
gas which may cause brain damage or death

Safety information

2

when inhaled. Symptoms include nausea,
dizziness, and drowsiness. Keep cockpit and
cabin areas well ventilated. Avoid blocking
exhaust outlets.

EMU33781

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.

EMU33741

Boating safety

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

EMU33711

Alcohol and drugs

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

EMU40281

Personal flotation devices (PFDs)

Have an approved 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.

EMU33732

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.

EMU33752

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.

EMU33762

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 manufacturer’s instruc­tions. Overloading or incorrect weight
distribution can compromise the boats han­dling and lead to an accident, capsizing or
swamping.

EMU33773

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

ZMU06025

Safety information

3

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.

EMU33791

Weather

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

EMU33881

Passenger training

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

EMU33891

Boating safety publications

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

EMU33601

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.

4

General information

EMU25172

Identification numbers record

EMU25186

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.

EMU37292

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

EMU25207

CE Marking

Outboard motors affixed with this “CE”mark­ing conform with the directives of;
2006/42/EC, 94/25/EC - 2003/44/EC and
2004/108/EC.

1. Outboard motor serial number location

1. Serial number

2. Model name

3. Motor transom height

4. Approved model code

3412

ZMU01692

1. CE marking location

ZMU06200

1

General information

5

ZMU06040

General information

6

EMU33524

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.

EMU33834

Warning labels

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

ZMU08306

3

1

2

General information

7

EMU33913

Contents of labels

The above warning labels mean as follows.

1

WARNING

EWM01692

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

2

WARNING

EWM01682

 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.

3

WARNING

EWM01672

 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.

6EE-42794-40

6EE-81994-40

6EE-81995-40

1

2

3

6EE-42794-50

6EE-81994-50

6EE-81995-50

ZMU05740

General information

8

EMU35133

Symbols

The following symbols mean as follows.

Notice/Warning

Read Owner’s Manual

Hazard caused by continuous rotation

Electrical hazard

ZMU05696

ZMU05664

ZMU05665

ZMU05666

9

Specifications and requirements

EMU34522

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.

EMU2821V

Dimension and weight:

Overall length:

993 mm (39.1 in)

Overall width:

360 mm (14.2 in)

Overall height L:

1279 mm (50.4 in)

Motor transom height L:

545 mm (21.5 in)

Dry weight (AL) L:

62 kg (137 lb)

Performance:

Full throttle operating range:

4500–5500 r/min

Rated power:

22.1 kW (30 HP)

Idle speed (in neutral):

700–800 r/min

Power unit:

Type:

2-stroke L3

Total displacement:

496 cm

3

(30.3 c.i.)

Bore  stroke:

59.5  59.5 mm (2.34  2.34 in)

Ignition system:

CDI

Spark plug with resistor (NGK):

BR7HS-10

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

Steering system:

Tiller handle

Starting system:

Manual starter

Starting carburetion system:

Choke valve

Alternator output:

80 W

Lower unit:

Gear shift positions:

Forward-neutral-reverse

Gear ratio:

1.85 (24/13)

Trim and tilt system:

Manual tilt

Propeller mark:

F

Fuel and oil:

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

90

Fuel tank capacity:

25 L (6.60 US gal, 5.50 Imp.gal)

Recommended engine oil:

YAMALUBE 2-stroke outboard motor
oil

Recommended engine oil:

TC-W3

Lubrication system:

Oil injection

Engine oil tank capacity:

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

Recommended gear oil:

YAMALUBE outboard gear oil or Hy­poid gear oil

Recommended gear oil grade:

SAE 90 API GL-4

Specifications and requirements

10

Gear oil quantity:

0.200 L (0.211 US qt, 0.176 Imp.qt)

Tightening torque:

Spark plug:

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

Propeller nut:

34 Nm (3.47 kgf-m, 25.1 ft-lb)

Noise and vibration level:

Operator sound pressure level (ICOMIA
39/94):

91.7 dB(A)

Vibration on tiller handle (ICOMIA 38/94):

Vibration on tiller handle is under 2.5
m/s

2

EMU33555

Installation requirements

EMU33565

Boat horsepower rating

WARNING

EWM01561

Overpowering a boat can cause severe
instability.

Before installing the outboard motor(s), con­firm 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.

EMU33572

Mounting motor

WARNING

EWM01571

 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 in-

structions. For further information, see page

23.

EMU34196

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 52.

Specifications and requirements

11

EMU25771

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.

EMU25652

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.

EMU36361

Fuel requirements

EMU40202

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

ECM01982

 Do not use leaded gasoline. Leaded

gasoline can seriously damage the en­gine.

 Avoid getting water and contaminants

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

Gasohol

There are two types of gasohol: gasohol con­taining ethanol (E10) and that containing
methanol. Ethanol can be used if the ethanol
content does not exceed 10% and the fuel
meets the minimum octane ratings. E85 is a
fuel containing 85% ethanol and must not be
used in your outboard motor. All ethanol
blends containing more than 10% ethanol
can cause fuel system damage or cause en­gine starting and running problems. Yamaha
does not recommend gasohol containing
methanol because it can cause fuel system
damage or engine performance problems.
It is recommended that you install a water­separating marine fuel filter assembly (10 mi­cron minimum) between your boat’s fuel tank
and outboard motor when using ethanol.
Ethanol is known to allow moisture to be ab­sorbed into boat fuel tanks and systems.
Moisture in the fuel can cause corrosion of
metallic fuel system components, starting
and running complaints and require addition­al fuel system maintenance.

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

Recommended engine oil:

YAMALUBE 2-stroke outboard motor
oil

ZMU04605

-

x

123

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

90

Specifications and requirements

12

EMU36881

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.

EMU36331

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.

EMU36342

Motor disposal requirements

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

EMU36353

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.

13

Components

EMU2579Z

Components diagram

TIP:

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

EMU25804

Fuel tank

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

WARNING

EWM00021

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

1

3

6

7

4

5

2

12

13

10
11

15

16

21

17

14

9

8

19

20

18

ZMU08222

1. Top cowling

2. Cowling lock lever(s)

3. Anti-cavitation plate

4. Trim tab (anode)

5. Propeller

6. Cooling water inlet

7. Tilt rod

8. Manual starter handle

9. Engine stop button/Engine shut-off switch

10. Alert indicator

11. 2-pin connector

12. Gear shift lever

13. Throttle grip

14. Tilt lock lever

15. Clamp screw

16. Shallow water lever

17. Restraint cable attachment

18. Tilt support lever

19. Choke knob

20. Clip

21. Fuel tank

Components

14

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

EMU25831

Fuel joint

This joint is used to connect the fuel line.

EMU25842

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.

EMU25851

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.

EMU25861

Air vent screw

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

EMU25914

Tiller handle

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

EMU25925

Gear shift lever

Move the gear shift lever forward to engage
the forward gear or rearward to engage the
reverse gear.

EMU25943

Throttle grip

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

1. Fuel joint

2. Fuel gauge

3. Fuel tank cap

4. Air vent screw

ZMU03157

13

42

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

ZMU02846

2

1

3

R

N

F

ZMU03687

Components

15

EMU25963

Throttle indicator

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

EMU25977

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.

[EWM00033]

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

EMU25996

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.

[EWM00123]

1. Throttle indicator

ZMU02848

ZMU02849

1

ZMU03688

Components

16

EMU26004

Engine stop button

The engine stop button stops the engine
when the button is pushed.

EMU26014

Choke knob for pull type

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

EMU26075

Manual starter handle

The manual starter handle is used to crank
and start the engine.

EMU26123

Steering friction adjuster

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

1. Clip

2. Cord

3. Engine shut-off switch

1

2

3

ZMU03759

ZMU03760

ZMU03761

Components

17

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

WARNING

EWM00041

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

EMU26246

Trim tab with anode

WARNING

EWM00841

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

ECM00841

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.

EMU26263

Trim rod (tilt pin)

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

EMU26281

Shallow water lever

Pushing this lever down will tilt the motor up
partially to provide more clearance when op-

ZMU02908

1. Trim tab

2. Bolt

Bolt tightening torque:

18 Nm (1.84 kgf-m, 13.3 ft-lb)

A

B

ZMU03097

1

2

ZMU03762

Components

18

erating in shallow water.

EMU30531

Tilt lock mechanism

The tilt lock mechanism is used to prevent
the outboard motor from lifting out of the wa­ter when in reverse gear.

To lock it, set the tilt lock lever in the lock po­sition. To release, push the tilt lock lever in
the release position.

EMU26352

Tilt support lever for manual tilt
model

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

NOTICE

ECM00661

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.

EMU26374

Cowling lock lever(s) (turn type)

To remove the engine top cowling, turn the
cowling lock lever(s) and lift off the cowling.
When installing the cowling, check to be sure
it fits properly in the rubber seal. Then lock
the cowling again by returning the cowling
lock lever(s) to the lock position.

1. Tilt lock lever

ZMU06789

1

ZMU06790

1. Cowling lock lever(s)

ZMU03766

ZMU03701

1

Components

19

EMU26411

2-pin connector

AC 12 V-40/60/80W power is delivered
through this connector. When using it, keep
in mind the following points:

 Use a genuine Yamaha connector.
 Use lighting equipment only.
 Connect lighting equipment directly to the

2-pin connector.

 Capacity of the lighting equipment must be

more than 12 V-40/60/80W; otherwise the
bulb could burn out.

 When the connector is not in use, place

the cap on it.

NOTICE

ECM01001

Do not connect the 2-pin connector di­rectly to the battery terminals. Otherwise
the electric system will be damaged.

EMU26305

Alert indicator

If the engine develops a condition which is
cause for alert, the indicator lights up. For
details on how to read the alert indicator, see
page 21.

ZMU03767

1. Alert indicator

ZMU06794

1

20

Instruments and indicators

EMU36016

Indicators

EMU36034

Overheat-alert indicator

If the engine temperature rises too high, this
indicator will light up. For further information
on reading the indicator, see page 21.

NOTICE

ECM00053

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

EMU37561

Oil level-alert indicator

If the oil level falls below the lower limit, this
indicator will light up. For further information,
see page 21.

NOTICE

ECM00031

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

1. Overheat-alert indicator

ZMU06794

1

1. Oil level-alert indicator

ZMU06794

1

21

Engine control system

EMU26804

Alert system

NOTICE

ECM00092

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.

EMU2681D

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 en­gine 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.

EMU2684A

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).
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 en-

ZMU03769

ZMU03026

ZMU03769

Engine control system

22

gine overheating first, then oil level, and fi­nally oil filter clogging.

1. Oil filter

1

ZMU03707

23

Installation

EMU26903

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

EWM01591

 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.

EMU33471

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.

EMU26926

Mounting height

To run your boat at optimum efficiency, the
water resistance (drag) of the boat and out­board motor must be made as little as possi­ble. The mounting height of the outboard
motor greatly affects the water resistance. If
the mounting height is too high, cavitation
tends to occur, thus reducing the propulsion;
and if the propeller tips cut the air, the engine
speed will rise abnormally and cause the en­gine to overheat. If the mounting height is too
low, the water resistance will increase and
thereby reduce engine efficiency. Mount the
outboard motor so that the anti-cavitation
plate is between the bottom of the boat and
a level 25 mm (1 in) below it.

1. Center line (keel line)

ZMU01760

1

ZMU02011

0–25mm
(0–1in)

Installation

24

NOTICE

ECM01635

 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.

TIP:

 The optimum mounting height of the out-

board motor is affected by the boat and
motor combination and the desired use.
Test runs at different heights can help de­termine the optimum mounting height.
Consult your Yamaha dealer or boat man­ufacturer for further information on deter­mining the proper mounting height.

 For instructions on setting the trim angle of

the outboard motor, see page 37.

EMU26974

Clamping the outboard motor

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

WARNING! Loose clamp screws

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

[EWM00643]

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

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

using bolts, nuts or washers other
than those contained in the engine

ZMU02012

ZMU02013

Installation

25

packaging. If used, they must be of at
least the same quality of material and
strength and must be tightened se­curely. After tightening, test run the
engine and check their tightness.

[EWM00652]

1. Bolts

1

ZMU03806

26

Operation

EMU36382

First-time operation

EMU27022

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

ECM00142

 Failure to follow the break-in procedure

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

 Premixed fuel must be used during

break-in.

EMU27061

Gasoline and engine oil mixing chart
(50:1)

NOTICE

ECM00151

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

EMU30312

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.

EMU36402

Getting to know your boat

All boats have unique handling characteris­tics. Operate cautiously while you learn how
your boat handles under different conditions
and various trim angles (see page 37).

EMU36414

Checks before starting engine

WARNING

EWM01922

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

Operation

27

NOTICE

ECM00121

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

EMU37142

Fuel level

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

29.

EMU36573

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.

EMU36443

Fuel system

WARNING

EWM00061

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

WARNING

EWM00911

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.

EMU36452

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.

EMU37323

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.

EMU36892

Controls

 Move the tiller handle fully to the left and

right to make sure operation is smooth.

 Turn the throttle grip from the fully closed

to the fully open position. Make sure that it
turns smoothly and that it completely re-

ZMU06092

ZMU06201

Operation

28

turns to the fully closed position.

 Look for loose or damaged connections of

the throttle and shift cables.

EMU36484

Engine shut-off cord (lanyard)

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

EMU27121

Oil

 Check to be sure you have plenty of oil for

your trip.

EMU27154

Engine

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

EMU27182

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.

[EWM01332]

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

ECM01261

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

EMU36956

Install top cowling

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

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

3. Place the top cowling on the bottom
cowling.

4. Check to be sure the rubber seal is seat­ed correctly between the top cowling
and the bottom cowling.

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

top cowling is not installed correctly,

1. Clip

2. Cord

3. Engine shut-off switch

1

2

3

ZMU03759

ZMU03770

Operation

29

water spray under the top cowling
can damage the engine, or the top
cowling can blow off at high speeds.

[ECM01992]

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.

EMU27235

Filling fuel and engine oil

EMU27249

Filling fuel for portable tank

WARNING

EWM01831

 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

ZMU06117

ZMU04678

ZMU06621

ZMU02041

Operation

30

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.

[EWM02611]

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.

EMU27302

Filling oil for manual starter model

WARNING

EWM00531

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

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 31.

To fill the engine oil tank, proceed as follows:

1. Remove the top cowling.

2. Open the oil tank filler cap by pulling the
tab.

3. Slowly fill the engine oil into the engine
oil tank.

4. After filling, replace the cap securely.

Fuel tank capacity:

25 L (6.60 US gal, 5.50 Imp.gal)

ZMU03012

Engine oil tank capacity:

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

1. Engine oil tank

2. Oil tank filler cap

1

2

ZMU03711

Operation

31

EMU27322

Oil level indicator operation

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

EMU27337

EMU27453

Operating engine

WARNING

EWM00421

 Before starting the engine, make sure

that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.

 When the air vent screw is loosened,

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

 This product emits exhaust gases

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

exhaust outlets.

EMU27469

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.

Oil level-alert indicator Engine oil tank Remarks

OFF

more than

0.2 L
(0.21 US qt,

0.181 Imp qt)

No refilling necessary.

ON

Red

0.2 L
(0.21 US qt,

0.181 Imp qt)
or less

 Buzzer sounds in

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

 Check oil filter for

clogging.

 Add oil; see page

30.

ZMU02022

Operation

32

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.

EMU27495

Starting engine

WARNING

EWM01601

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.

EMU2750A

Manual start models (tiller control)

WARNING

EWM01842

 Failure to attach the engine shut-off

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

 Avoid accidentally pulling the cord 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 gear shift lever in neutral.

1. Arrow

ZMU03772

ZMU02024

N

ZMU03714

Operation

33

TIP:

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

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

3. Place the throttle grip in the “ ”
(start) position.

4. Pull out / turn the choke knob fully. After
the engine starts, replace / return the
knob to the home position.

TIP:

 It is not necessary to use the choke when

starting a warm engine.

 If the choke knob is left in the “ ”

(start) position while the engine is running,
the engine will run poorly or stall.

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

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

7. Slowly return the throttle grip to the fully
closed position.

ZMU03803

ZMU02954

ZMU03774

Operation

34

TIP:

 When the engine is cold, it needs to be

warmed up. For further information, see
page 34.

 If the engine does not start on the first try,

repeat the procedure. If the engine fails to
start after 4 or 5 tries, open the throttle a
small amount (between 1/8 and 1/4) and
try again. Also if the engine is warm and
fails to start, open the throttle a same
amount and try to start the engine again. If
the engine still fails to start, see page 57.

EMU36511

Checks after starting engine

EMU36524

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

ECM01811

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.

EMU27671

Warming up engine

EMU27684

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.

EMU36532

Checks after engine warm up

EMU36542

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.

EMU36972

Stop switches

Perform the following procedure to check
that the engine stop switch and engine shut­off switch operate properly.

 Start the engine, and then check that the

engine stops when the engine stop button
is pushed.

 Restart the engine, and then check that

the engine stops when the clip is pulled
from the engine shut-off switch.

ZMU02030

ZMU02856

Operation

35

 Check that the engine cannot be started

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

EMU34551

Shifting

WARNING

EWM00181

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

NOTICE

ECM01611

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. Move the gear shift lever firmly and
crisply forward (for forward gear) or
backward (for reverse gear). Be sure to
check that the tilt lock lever is in the
lock/down position (if equipped) before
operating in reverse.

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

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

2. After the engine is at idle speed in gear
move the gear shift lever firmly and
crisply into the neutral position.

ZMU03788

R

N

F

ZMU05678

ZMU02030

N

ZMU03724

Operation

36

EMU31743

Stopping boat

WARNING

EWM01511

 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.

EMU27822

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.

EMU27834

Procedure

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

2. After stopping the engine, tighten the air
vent screw on the fuel tank cap and set
the fuel cock lever or knob to the closed
position, if equipped.

3. Disconnect the fuel line if you are using
an external fuel tank.

TIP:

If the outboard motor is equipped with an en­gine shut-off cord, the engine can also be
stopped by pulling the cord and removing the
clip from the engine shut-off switch.

ZMU03778

ZMU02041

ZMU03779

Operation

37

EMU27865

Trimming outboard motor

WARNING

EWM00741

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

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

EMU27873

Adjusting trim angle for manual tilt
models

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

1. Stop the engine.

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

1. Trim operating angle

ZMU02858

1

Operation

38

3. Reposition the rod in the desired hole.
To raise the bow (“trim-out”), move the rod
away from the transom.
To lower the bow (“trim-in”), move the rod to­ward the transom.
Make test runs with the trim set to different
angles to find the position that works best for
your boat and operating conditions.

WARNING

EWM00401

 Stop the engine before adjusting the

trim angle.

 Use care to avoid being pinched when

removing or installing the rod.

 Use caution when trying a trim position

for the first time. Increase speed gradu­ally and watch for any signs of instabil­ity or control problems. Improper trim
angle can cause loss of control.

TIP:

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

EMU27913

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

1. Trim rod

ZMU03780

1

Operation

39

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

EMU27936

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

EWM00223

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

EWM00251

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

ECM00242

 Before tilting the outboard motor, stop

the engine by following the procedure
on page 36. 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.

EMU32642

Procedure for tilting up (manual tilt
models)

1. Place the gear shift lever in neutral.

2. Place the tilt lock lever in the release po­sition.

3. Hold the rear of the top cowling with one
hand, tilt the engine up, and turn the tilt
support lever to the lock position and
support the engine. NOTICE: Do not

use the tilt support lever or knob

N

ZMU03724

ZMU06791

Operation

40

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 43.

[ECM01642]

EMU30412

Procedure for tilting down (manual
tilt models)

1. Slightly tilt the engine up.

2. On models equipped with a tilt support
lever, return it to the release position.

3. Slowly tilt the engine down.

EMU28063

Shallow water

EMU28074

Cruising in shallow water (manual tilt
models)

WARNING

EWM01782

 Run the boat at the lowest possible

speed when using the shallow water
cruising system. The tilt lock mecha­nism does not work while the shallow
water cruising system is being used.
Hitting an underwater obstacle could
cause the outboard motor to lift out of
the water, resulting in loss of control.

 Use extra care when operating in re-

verse. Too much reverse thrust can
cause the outboard motor to lift out of
the water, increasing the chance of ac­cident and personal injury.

NOTICE

ECM00261

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.

ZMU03783

ZMU03787

ZMU02868

Operation

41

EMU46580

Procedure

1. Place the gear shift lever in neutral.

2. Push the tilt lock lever down to the re­lease position.

3. Push the shallow water lever down to
the set position.

4. To set the outboard motor in a partially
tilted position, slightly tilt the outboard
motor up until the plate turns completely.

5. To return the outboard motor to the nor­mal running position, place the gear shift
lever in neutral, then slightly tilt the out­board motor up. Set the tilt lock lever
and shallow water lever to the lock posi­tion and slowly tilt the outboard motor
down.

EMU28196

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.

N

ZMU03790

ZMU06791

ZMU06789

ZMU08308

Operation

42

Cruising in muddy, turbid, or acidic water

Yamaha strongly recommends that you use
the optional chromium-plated water pump kit
(see page 12) 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.

43

Maintenance

EMU2822B

Transporting and storing

outboard motor

WARNING

EWM02621

 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

ECM02441

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.

EMU28237

Clamp screw mounting models

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

ZMU02870

ZMU02869

Maintenance

44

TIP:

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

EMU30273

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

ECM01412

 Do not place the outboard motor on its

side before the cooling water has
drained from it completely, otherwise
water may enter the cylinder through
the exhaust port and cause engine trou­ble.

 Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

EMU28306

Procedure

EMU28336

Flushing in a test tank

NOTICE

ECM00302

Before starting the engine, make sure to
supply water to the cooling water passag­es. Otherwise, the engine could overheat
and be damaged.

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

ter into the air intake. [ECM01841] For fur-

ther information, see page 46.

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

3. Remove the engine top cowling and si-

lencer cover. Remove the propeller.

4. Install the outboard motor on the test
tank. Fill the tank with fresh water to
above the level of the anti-cavitation
plate. NOTICE: If the fresh water level

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

[ECM00292]

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.

[EWM00092]

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

1. Water surface

2. Lowest water level

ZMU02051

1

2

Maintenance

45

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

8. Remove the outboard motor from the
test tank.

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
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).

13. Drain the fuel from the fuel tank.

TIP:

Store the fuel tank in a dry, well-ventilated
place, not in direct sunlight.

EMU28347

Flushing with the water flush plug

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

ter into the air intake.

[ECM01841] For fur-

ther information, see page 46.

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. Remove the screw located beside the
“ ” (wash) mark on the lower case.
Install the water flush plug and connect
it to a fresh water tap. Cover the cooling
water inlet with tape.

NOTICE

ECM00302

Before starting the engine, make sure to
supply water to the cooling water passag­es. Otherwise, the engine could overheat

and be damaged.

NOTICE

ECM00311

Avoid running the outboard motor at high
speed while on the flushing attachment,
otherwise overheating could occur.

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.

[EWM00092]

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 water flush plug and the

1. Water flush plug

1

1

ZMU03757

Maintenance

46

tape.

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
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).

13. Drain the fuel from the fuel tank.

TIP:

Store the fuel tank in a dry, well-ventilated
place, not in direct sunlight.

EMU46270

Lubrication (oil injection models)

1. 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.

2. Change the gear oil. For instructions,
see page 54. 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.

3. Grease all grease fittings. For further de­tails, see page 50.

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.

EMU44342

Cleaning the outboard motor

When cleaning the outboard motor, the top

cowling must be installed.

1. Wash the exterior of the outboard motor
using fresh water. NOTICE: Do not

spray water into the air intake.

[ECM01841]

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

EMU28462

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.

EMU37075

Periodic maintenance

WARNING

EWM01982

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:

1. Air intake

1

ZMU07873

Maintenance

47

 Turn off the engine and keep engine

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

 Allow the engine to cool before han-

dling hot parts or fluids.

 Always completely reassemble the mo-

tor before operation.

EMU28512

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.

EMU34152

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 ex-

ample, 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.

Maintenance

48

EMU34449

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

(3 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

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

Fuel line

Inspection or replace­ment as necessary

Fuel pump

Inspection or replace­ment as necessary

Fuel/engine oil leakage Inspection

Maintenance

49

EMU34452

Maintenance chart 2

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

Propeller/propeller
nut/cotter pin

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

Wire harness connec­tions/wire coupler con­nections

Inspection or replace­ment as necessary

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

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

Maintenance

50

EMU28945

Greasing

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

EMU44491

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-

ZMU03793

Maintenance

51

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.

[EWM00562]

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 reinstalling a spark plug, a good estimate
of the correct torque is 1/12 turn past finger­tight. When you are installing a new spark
plug, a good estimate of the correct torque is
1/2 to 2/3 turn past finger-tight.

EMU37451

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.

EMU29045

Inspecting idle speed

WARNING

EWM00452

 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.

NOTICE

ECM00491

This procedure must be performed while

Standard spark plug:

BR7HS-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 Nm (2.55 kgf-m, 18.4 ft-lb)

ZMU06201

Maintenance

52

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.

EMU29062

Checking water in engine oil tank

A translucent water drain hose is connected
from the bottom of the oil tank to the filler
neck. If water or foreign matter collects in this
hose, consult a Yamaha dealer.

EMU29116

Inspecting wiring and connectors

 Inspect that each connector is engaged

securely.

 Inspect that each ground lead is properly

secured.

EMU32113

Checking propeller

WARNING

EWM01882

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
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.

1. Drain hose

2. Filler neck side

1

2

ZMU03748

ZMU03737

Maintenance

53

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.

EMU30663

Removing propeller

EMU29198

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.

[EWM01891]

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

EMU30673

Installing propeller

EMU46120

Spline models

NOTICE

ECM00502

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 Yamalube Marine Grease or a
corrosion resistant grease to the propel­ler 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.

[ECM01882]

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

ZMU01897

ZMU03227

1. Cotter pin

2. Propeller nut

3. Washer

4. Spacer

5. Propeller

6. Thrust washer

ZMU02829

6

5

4

3

2

1

Maintenance

54

4. Align the propeller nut slot 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. [ECM01892]

TIP:

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

EMU2928C

Changing gear oil

WARNING

EWM00801

 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.

[ECM01901]

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
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.

[ECM00714]

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

Propeller nut tightening torque:

34 Nm (3.47 kgf-m, 25.1 ft-lb)

ZMU02063

1. Gear oil drain screw

2. Oil level plug

ZMU03738

2

1

Maintenance

55

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.

EMU29304

Cleaning fuel tank

WARNING

EWM00921

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
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.

EMU29318

Inspecting and replacing anode(s)

Yamaha outboard motors are protected from
corrosion by sacrificial anodes. Inspect the

Recommended gear oil:

YAMALUBE outboard gear oil or Hyp­oid gear oil

Recommended gear oil grade:

SAE 90 API GL-4

Gear oil quantity:

0.200 L (0.211 US qt, 0.176 Imp.qt)

Tightening torque:

9 Nm (0.92 kgf-m, 6.6 ft-lb)

Tightening torque:

9 Nm (0.92 kgf-m, 6.6 ft-lb)

ZMU03739

ZMU02066

Maintenance

56

external anodes periodically. Remove scales
from the surfaces of the anodes. Consult a
Yamaha dealer for replacement of external
anodes.

NOTICE

ECM00721

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 replace­ment of internal anodes attached to the pow­er unit.

ZMU02924

57

Trouble Recovery

EMU29428

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 32.

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

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

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

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

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

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

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

Engine idles irregularly or stalls.

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

Trouble Recovery

58

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.

Trouble Recovery

59

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.

Trouble Recovery

60

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

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

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.

EMU29434

Temporary action in

emergency

EMU29442

Impact damage

WARNING

EWM00871

The outboard motor can be seriously
damaged by a collision while operating or

trailering. Damage could make the out­board 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.

EMU39792

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

EWM02362

 Use this procedure only for emergency

engine starting 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 that the shift lever is in
the neutral position. Otherwise, the
boat could unexpectedly start to move,
which could result in an accident.

Trouble Recovery

61

 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-

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.

 Make sure that no one is standing be-

hind you when pulling the starter rope.
It could whip behind you and injure
someone.

 An unguarded, rotating flywheel is very

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

 Do not touch the ignition coil, spark

plug wire, spark plug cap, or other elec­trical components when starting or op­erating the outboard motor. You could
get an electrical shock.

EMU29563

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 32. 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

ZMU03801

ZMU03802

ZMU03803

Trouble Recovery

62

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 neces­sary.

EMU33502

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.

[ECM00402]

ZMU03804

ZMU02928

63

INDEX

2

2-pin connector ..................................... 19

A

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

Alert indicator........................................ 19

Alert system .......................................... 21

Anode(s), inspecting and replacing ...... 55

Anti-fouling paint ................................... 12

Avoid collisions ....................................... 2

B

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

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

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

Breaking in engine ................................ 26

C

Carbon monoxide ................................... 1

CE Marking ............................................. 4

Checks after engine warm up ............... 34

Checks after starting engine ................. 34

Checks before starting engine .............. 26

Choke knob........................................... 16

Clamping the outboard motor ............... 24

Cleaning the outboard motor ................ 46

Components diagram ........................... 13

Control functions, checking................... 27

Cooling water........................................ 34

Cowling lock lever................................. 18

Cruising in salt water or other

conditions ........................................... 41

E

EC Declaration of Conformity (DoC)....... 4

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

Emergency equipment.......................... 12

Emergency starting engine ................... 61

Emergency, temporary action in ........... 60

Engine, checking .................................. 28

Engine oil, checking.............................. 28

Engine oil requirements ........................ 11

Engine oil tank, checking water in ........ 52

Engine shut-off cord (lanyard) .......... 1, 28

Engine shut-off cord (lanyard) and

clip ......................................................15

Engine stop button................................ 16

F

Filling fuel for portable tank................... 29

Filling oil for manual starter model........ 30

First-time operation............................... 26

Flushing in a test tank........................... 44

Flushing with the water flush plug......... 45

Fuel and engine oil, filling .....................29

Fuel filter, checking......................... 27, 51

Fuel leaks, checking for ........................ 27

Fuel level .............................................. 27

Fuel requirements................................. 11

Fuel system .......................................... 27

Fuel tank ............................................... 13

Fuel tank, cleaning................................ 55

G

Gasoline............................................ 1, 11

Gasoline exposure and spills.................. 1

Gear oil, changing................................. 54

Gear shift lever ..................................... 14

Greasing ...............................................50

H

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

I

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

Idle speed, inspecting ........................... 51

Impact damage ..................................... 60

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

Instruments and indicators.................... 20

L

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

Lubrication ............................................46

M

Maintenance chart 1 .............................48

Maintenance chart 2 .............................49

Manual starter handle ........................... 16

INDEX

64

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

Motor disposal requirements ................ 12

Mounting height .................................... 23

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

Mounting the outboard motor................ 23

Muddy or acidic water........................... 12

O

Oil level alert and oil filter clogging

alert .................................................... 21

Oil level-alert indicator .......................... 20

Oil level indicator operation .................. 31

Operating engine .................................. 31

Operation after long period of

storage ............................................... 28

Outboard motor (painted surface),

checking ............................................. 46

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

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

Overheat alert ....................................... 21

Overheat-alert indicator ........................ 20

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

P

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

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

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

Periodic maintenance ........................... 46

Personal flotation devices (PFDs) .......... 2

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

Propeller, checking ............................... 52

Propeller, installing ............................... 53

Propeller, removing............................... 53

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

R

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

Replacement parts................................ 47

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

S

Sending fuel (portable tank).................. 31

Severe operating conditions ................. 47

Shallow water ....................................... 40

Shallow water lever............................... 17

Shifting.................................................. 35

Shifting (checks after engine warm

up) ...................................................... 34

Spark plug, cleaning and adjusting....... 50

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

Starter will not operate.......................... 60

Start-in-gear protection ......................... 11

Starting engine...................................... 32

Steering friction adjuster ....................... 16

Stopping boat........................................ 36

Stopping engine.................................... 36

Stop switches........................................ 34

Storing outboard motor ......................... 44

Submerged outboard motor.................. 62

T

Throttle friction adjuster ........................15

Throttle grip........................................... 14

Throttle indicator ................................... 15

Tiller handle ..........................................14

Tilting up and down............................... 39

Tilt lock mechanism ..............................18

Tilt support lever ...................................18

Top cowling, installing........................... 28

Top cowling, removing.......................... 27

Transporting and storing outboard

motor .................................................. 43

Trimming outboard motor ..................... 37

Trim rod (tilt pin).................................... 17

Trim tab with anode ..............................17

Troubleshooting .................................... 57

W

Warming up engine............................... 34

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

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

Wiring and connectors, inspecting........ 52

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