Yamaha 40V, 50H User Manual

Page 1
OWNER’S MANUAL
Read this manual carefully before operating this
outboard motor.
40V 50H
63B-28199-7F-E0
Page 2
EMU25052
Page 3
Important manual information
WARNING
NOTICE
TIP:
TIP:
EMU25107
To the owner
Thank you for selecting a Yamaha outboard motor. This Owner’s Manual contains infor­mation needed for proper operation, mainte­nance and care. A thorough understanding of these simple instructions will help you ob­tain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important information is distinguished in the following ways.
: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that fol­low this symbol to avoid possible injury or death.
EWM00781
A WARNING indicates a hazardous situa­tion which, if not avoided, could result in death or serious injury.
ECM00701
A NOTICE indicates special precautions that must be taken to avoid damage to the outboard motor or other property.
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.
The 40VEO, 40VMHO, 50HETO, 50HMHO and the standard accessories are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model.
EMU25121
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
40V, 50H
OWNER’S MANUAL
©2010 by Yamaha Motor Co., Ltd.
1st Edition, April 2010
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd. is expressly prohibited.
Printed in Japan
Page 4
Table of contents
Safety information............................. 1
Outboard motor safety .....................1
Propeller............................................ 1
Rotating parts.................................... 1
Hot parts ........................................... 1
Electric shock.................................... 1
Power trim and tilt ............................. 1
Engine shut-off cord (lanyard)........... 1
Gasoline............................................ 1
Gasoline exposure and spills ............ 2
Carbon monoxide.............................. 2
Modifications ..................................... 2
Boating safety ..................................2
Alcohol and drugs ............................. 2
Personal flotation devices ................. 2
People in the water ........................... 2
Passengers ....................................... 2
Overloading....................................... 2
Avoid collisions ................................. 3
Weather ............................................ 3
Passenger training ............................ 3
Boating safety publications ............... 3
Laws and regulations ........................ 3
General information .......................... 4
Identification numbers record...........4
Outboard motor serial number .......... 4
Key number....................................... 4
EC Declaration of Conformity
(DoC).............................................. 4
CE Marking ......................................4
Read manuals and labels................. 6
Warning labels ................................. 6
Specifications and requirements..... 9
Specifications ................................... 9
Installation requirements ................ 10
Boat horsepower rating................... 10
Mounting motor ............................... 11
Remote control requirements.........11
Battery requirements......................11
Battery specifications ...................... 11
Mounting battery ............................. 11
Multiple batteries............................. 11
Propeller selection.......................... 11
Start-in-gear protection ..................12
Engine oil requirements .................12
Fuel requirements.......................... 12
Gasoline .......................................... 12
Muddy or acidic water.................... 13
Anti-fouling paint ............................ 13
Motor disposal requirements.......... 13
Emergency equipment................... 13
Components .................................... 14
Components diagram..................... 14
Fuel tank ......................................... 16
Fuel joint.......................................... 17
Fuel gauge ...................................... 17
Fuel tank cap................................... 17
Air vent screw.................................. 17
Remote control box ......................... 17
Remote control lever ....................... 17
Neutral interlock trigger ................... 18
Neutral throttle lever........................18
Tiller handle..................................... 18
Gear shift lever................................18
Throttle grip ..................................... 19
Throttle indicator ............................. 19
Throttle friction adjuster................... 19
Engine shut-off cord (lanyard)
and clip.......................................... 20
Engine stop button .......................... 20
Choke knob for pull type ................. 21
Manual starter handle ..................... 21
Main switch ..................................... 21
Steering friction adjuster ................. 21
Steering friction adjuster ................. 22
Power trim and tilt switch on
remote control or tiller handle .......22
Power trim and tilt switch on
bottom cowling .............................. 22
Trim tab with anode......................... 23
Trim rod (tilt pin) .............................. 23
Tilt lock mechanism......................... 24
Tilt support lever for power trim
and tilt model................................. 24
Tilt support lever for manual tilt
model ............................................ 24
Cowling lock lever(s) (turn type)...... 25
Alert indicator .................................. 25
Instruments and indicators............ 26
Indicators ....................................... 26
Page 5
Table of contents
Alert indicator for three indicators ... 26
Overheat-alert indicator .................. 26
Oil level-alert indicator .................... 26
Digital tachometer .......................... 26
Tachometer..................................... 27
Trim meter....................................... 27
Hour meter ...................................... 27
Oil level indicator (digital type) ........ 27
Overheat-alert indicator .................. 28
Analog tachometer ......................... 28
Oil level indicators
(three indicators)........................... 28
Overheat-alert indicator .................. 28
Analog trim meter...........................29
Engine control system.................... 30
Alert system ...................................30
Overheat alert ................................. 30
Oil level alert and oil filter clogging
alert............................................... 31
Installation .......................................33
Installation ...................................... 33
Mounting the outboard motor.......... 33
Clamping the outboard motor ......... 34
Operation .........................................36
First-time operation ........................ 36
Breaking in engine .......................... 36
Getting to know your boat ............... 36
Checks before starting engine .......36
Fuel level......................................... 37
Remove the top cowling.................. 37
Fuel system..................................... 37
Controls........................................... 37
Engine shut-off cord (lanyard)......... 38
Oil.................................................... 38
Engine............................................. 38
Operation after long period of
storage.......................................... 38
Install top cowling............................ 39
Power trim and tilt system............... 39
Battery............................................. 40
Filling fuel and engine oil................ 40
Filling fuel for portable tank............. 40
Filling oil for manual starter
model ............................................ 41
Filling oil for electric start models.... 41
Oil level indicator operation.............43
Operating engine ........................... 44
Sending fuel (portable tank) ............ 44
Starting engine ................................ 45
Checks after starting engine .......... 49
Cooling water .................................. 49
Warming up engine........................ 49
Choke start models ......................... 49
Electric start and prime start
models ..........................................49
Checks after engine warm up ........ 50
Shifting ............................................ 50
Stop switches .................................. 50
Shifting........................................... 50
Stopping boat................................. 51
Stopping engine............................. 52
Procedure........................................ 52
Trimming outboard motor............... 52
Adjusting trim angle for manual tilt
models ..........................................53
Adjusting trim angle (Power trim
and tilt) .......................................... 54
Adjusting boat trim .......................... 54
Tilting up and down........................ 55
Procedure for tilting up (manual tilt
models) ......................................... 56
Procedure for tilting up (power trim
and tilt models).............................. 56
Procedure for tilting down
(manual tilt models)....................... 58
Procedure for tilting down
(power trim and tilt models)........... 58
Shallow water................................. 59
Power trim and tilt models...............59
Cruising in other conditions............ 60
Maintenance .................................... 61
Transporting and storing outboard
motor............................................ 61
Clamp screw mounting models ....... 61
Storing outboard motor ................... 61
Procedure........................................ 62
Lubrication (oil injection models).....63
Cleaning the outboard motor........... 63
Checking painted surface of
outboard motor.............................. 63
Page 6
Table of contents
Periodic maintenance..................... 63
Replacement parts.......................... 64
Severe operating conditions ........... 64
Maintenance chart 1 ....................... 65
Maintenance chart 2 ....................... 67
Greasing ......................................... 68
Cleaning and adjusting spark
plug ............................................... 69
Checking fuel filter .......................... 70
Inspecting idle speed ...................... 70
Checking water in engine oil tank ... 71
Inspecting wiring and connectors.... 71
Checking propeller .......................... 71
Removing propeller......................... 72
Installing propeller........................... 72
Changing gear oil............................ 73
Cleaning fuel tank ........................... 74
Inspecting and replacing
anode(s)........................................ 75
Checking battery (for electric start
models) ......................................... 75
Connecting the battery.................... 76
Disconnecting the battery ............... 76
Trouble Recovery............................ 77
Troubleshooting .............................77
Temporary action in emergency..... 80
Impact damage ............................... 80
Replacing fuse ................................ 80
Power trim and tilt will not
operate.......................................... 81
Starter will not operate .................... 81
Emergency starting engine ............. 82
Engine fails to operate ...................83
Cold engine fails to start ................. 83
Treatment of submerged motor...... 84
Page 7

Safety information

EMU33622
Outboard motor safety
Observe these precautions at all times.
EMU36501
Propeller
People can be injured or killed if they come in contact with the propeller. The propeller can keep moving even when the motor is in neutral, and sharp edges of the propeller can cut even when stationary.
Stop the engine when a person is in the
water near you.
Keep people out of reach of the propeller,
even when the engine is off.
EMU33630
Rotating parts
Hands, feet, hair, jewelry, clothing, PFD straps, etc. can become entangled with inter­nal rotating parts of the engine, resulting in serious injury or death. Keep the top cowling in place whenever pos­sible. Do not remove or replace the cowling with the engine running. Only operate the engine with the cowling re­moved according to the specific instructions in the manual. Keep hands, feet, hair, jewel­ry, clothing, PFD straps, etc. away from any exposed moving parts.
EMU33640
Hot parts
During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the en­gine has cooled.
EMU33650
Electric shock
Do not touch any electrical parts while start­ing or operating the engine. They can cause shock or electrocution.
EMU33660
Power trim and tilt
Body parts can be crushed between the mo-
tor and the clamp bracket when the motor is trimmed or tilted. Keep body parts out of this area at all times. Be sure no one is in this area before operating the power trim and tilt mechanism. The power trim and tilt switches operate even when the main switch is off. Keep peo­ple be away from the switches whenever working around the motor. Never get under the lower unit while it is tilt­ed, even when the tilt support lever is locked. Severe injury could occur if the outboard mo­tor accidentally falls.
EMU33671
Engine shut-off cord (lanyard)
Attach the engine shut-off cord so that the engine stops if the operator falls overboard or leaves the helm. This prevents the boat from running away under power and leaving people stranded, or running over people or objects. Always attach the engine shut-off cord to a secure place on your clothing or your arm or leg while operating. Do not remove it to leave the helm while the boat is moving. Do not at­tach the cord to clothing that could tear loose, or route the cord where it could be­come entangled, preventing it from function­ing. Do not route the cord where it is likely to be accidentally pulled out. If the cord is pulled during operation, the engine will shut off and you will lose most steering control. The boat could slow rapidly, throwing people and ob­jects forward.
EMU33810
Gasoline
Gasoline and its vapors are highly flam­mable and explosive. Always, refuel ac-
cording to the procedure on page 44 to reduce the risk of fire and explosion.
1
Page 8
Safety information
EMU33820
Gasoline exposure and spills
Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Dispose of rags properly. If any gasoline spills onto your skin, immedi­ately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gaso­line vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth.
EMU33900
Carbon monoxide
This product emits exhaust gases which con­tain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.
EMU33780
Modifications
Do not attempt to modify this outboard mo­tor. Modifications to your outboard motor may reduce safety and reliability, and render the outboard unsafe or illegal to use.
EMU33740
Boating safety
This section includes a few of the many im­portant safety precautions that you should follow when boating.
EMU33710
Alcohol and drugs
Never operate after drinking alcohol or taking drugs. Intoxication is one of the most com­mon factors contributing to boating fatalities.
EMU33720
Personal flotation devices
Have an approved personal flotation device (PFD) on board for every occupant. Yamaha recommends that you must wear a PFD
whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boat­ing conditions.
EMU33731
People in the water
Always watch carefully for people in the wa­ter, such as swimmers, skiers, or divers, whenever the engine is running. When someone is in the water near the boat, shift into neutral and stop the engine. Stay away from swimming areas. Swimmers can be hard to see. The propeller can keep moving even when the motor is in neutral. Stop the engine when a person is in the water near you.
EMU33751
Passengers
Consult your boat manufacturer’s instruc­tions for details about appropriate passenger locations in your boat and be sure all pas­sengers are positioned properly before ac­celerating and when operating above an idle speed. Standing or sitting in non-designated locations may result in being thrown either overboard or within the boat due to waves, wakes, or sudden changes in speed or direc­tion. Even when people are positioned prop­erly, alert your passengers if you must make any unusual maneuver. Always avoid jump­ing waves or wakes.
EMU33760
Overloading
Do not overload the boat. Consult the boat capacity plate or boat manufacturer for max­imum weight and number of passengers. Be sure that weight is properly distributed ac­cording to the boat manufacturers instruc­tions. Overloading or incorrect weight distribution can compromise the boats han­dling and lead to an accident, capsizing or
2
Page 9
Safety information
ZMU06025
swamping.
EMU33772
Avoid collisions
Scan constantly for people, objects, and oth­er boats. Be alert for conditions that limit your visibility or block your vision of others.
Operate defensively at safe speeds and keep a safe distance away from people, ob­jects, and other boats.
Do not follow directly behind other boats or
waterskiers.
Avoid sharp turns or other maneuvers that
make it hard for others to avoid you or un­derstand where you are going.
Avoid areas with submerged objects or
shallow water.
Ride within your limits and avoid aggres-
sive maneuvers to reduce the risk of loss of control, ejection, and collision.
Take early action to avoid collisions. Re-
member, boats do not have brakes, and stopping the engine or reducing throttle can reduce the ability to steer. If you are not sure that you can stop in time before hitting an obstacle, apply throttle and turn in another direction.
EMU33790
Weather
Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.
EMU33880
Passenger training
Make sure at least one other passenger is trained to operate the boat in the event of an emergency.
EMU33890
Boating safety publications
Be informed about boating safety. Additional publications and information can be obtained from many boating organizations.
EMU33600
Laws and regulations
Know the marine laws and regulations where you will be boating- and obey them. Several sets of rules prevail according to geographic location, but all are basically the same as the International Rules of the Road.
3
Page 10

General information

1
ZMU02931
EMU25171
Identification numbers record
EMU25183
Outboard motor serial number
The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto­len.
1. Outboard motor serial number location
EMU25191
Key number
If a main key switch is equipped with the mo­tor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key.
1. Key number
EMU37290
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
EMU25203
CE Marking
Outboard motors affixed with this “CE”mark­ing conform with the directives of; 98/37/EC, 94/25/EC - 2003/44/EC and 2004/108/EC.
4
Page 11
1. CE marking location
1
ZMU04889
ZMU06040
General information
5
Page 12
General information
ZMU07315
3
2
1
EMU33522
Read manuals and labels
Before operating or working on this outboard motor:
Read this manual.
Read any manuals supplied with the boat.
Read all labels on the outboard motor and the boat.
If you need any additional information, contact your Yamaha dealer.
EMU33832
Warning labels
If these labels are damaged or missing, contact your Yamaha dealer for replacements.
40V, 50H
6
Page 13
General information
WARNING
WARNING
WARNING
ZMU05706
1
2
3
EMU33912
Contents of labels
The above warning labels mean as follows.
1
EWM01691
Emergency starting does not have start­in-gear protection. Ensure shift control is in neutral before starting engine.
2
EWM01681
Keep hands, hair, and clothing away
from rotating parts while the engine is running.
Do not touch or remove electrical parts
when starting or during operation.
3
EWM01671
Read Owner’s Manuals and labels.
Wear an approved personal flotation
device (PFD).
Attach engine shut-off cord (lanyard) to
your PFD, arm, or leg so the engine stops if you accidentally leave the helm, which could prevent a runaway boat.
7
Page 14
General information
ZMU05696
ZMU05664
ZMU05665
ZMU05666
ZMU05667
ZMU05668
EMU33843
Symbols
The following symbols mean as follows.
Notice/Warning
Read Owner’s Manual
Electrical hazard
Remote control lever/gear shift lever operat­ing direction, dual direction
Engine start/ Engine cranking
Hazard caused by continuous rotation
8
Page 15

Specifications and requirements

TIP:
EMU31480
Specifications
“(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.
EMU2821J
Dimension:
Overall length:
40VEO 670 mm (26.4 in)
40VMHO 1281 mm (50.4 in)
50HETO 670 mm (26.4 in)
50HMHO 1281 mm (50.4 in)
Overall width:
40VEO 349 mm (13.7 in)
40VMHO 349 mm (13.7 in)
50HETO 360 mm (14.2 in)
50HMHO 349 mm (13.7 in)
Overall height S:
40VEO 1192 mm (46.9 in)
40VMHO 1223 mm (48.1 in)
50HMHO 1223 mm (48.1 in)
Overall height L:
40VEO 1319 mm (51.9 in)
40VMHO 1350 mm (53.1 in)
50HETO 1319 mm (51.9 in)
Transom height S:
406 mm (16.0 in)
Transom height L:
533 mm (21.0 in)
Weight (AL) S:
40VEO 74.5 kg (164 lb)
40VMHO 75.8 kg (167 lb)
50HMHO 75.0 kg (165 lb)
Weight (AL) L:
40VEO 77.3 kg (170 lb)
40VMHO 77.5 kg (171 lb)
50HETO 88.0 kg (194 lb)
Performance:
Full throttle operating range:
4500–5500 r/min
Maximum output:
40VEO 29.4 kW@5000 r/min (40 HP@5000 r/min) 40VMHO 29.4 kW@5000 r/min (40 HP@5000 r/min) 50HETO 36.8 kW@5000 r/min (50 HP@5000 r/min) 50HMHO 36.8 kW@5000 r/min (50 HP@5000 r/min)
Idle speed (in neutral):
800 50 r/min
Engine:
Type:
2-stroke L
Displacement:
698.0 cm
Bore stroke:
67.0 66.0 mm (2.64 2.60 in)
Ignition system:
CDI
Spark plug with resistor (NGK):
40VEO BR7HS-10 40VMHO BR7HS-10 50HETO BR8HS-10 50HMHO BR8HS-10
Spark plug gap:
0.9–1.0 mm (0.035–0.039 in)
Control system:
40VEO Remote control 40VMHO Tiller handle 50HETO Remote control 50HMHO Tiller handle
Starting system:
40VEO Electric starter 40VMHO Manual starter 50HETO Electric starter 50HMHO Manual starter
3
9
Page 16
Specifications and requirements
WARNING
Starting carburetion system:
40VEO Prime start
40VMHO Choke valve
50HETO Prime start
50HMHO Choke valve
Min. cold cranking amps (CCA/EN):
40VEO 347.0 A
50HETO 347.0 A
Min. rated capacity (20HR/IEC):
40VEO 40.0 Ah
50HETO 40.0 Ah
Alternator output:
40VMHO 80 W
50HMHO 80 W
Maximum generator output:
40VEO 6 A
50HETO 6 A
Drive unit:
Gear positions:
Forward-neutral-reverse
Gear ratio:
1.85 (24/13)
Trim and tilt system:
40VEO Manual tilt
40VMHO Manual tilt
50HETO Power trim and tilt
50HMHO Manual tilt
Propeller mark:
G
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Min. research octane:
40VEO 90
40VMHO 90
Fuel tank capacity:
24 L (6.34 US gal, 5.28 Imp.gal),
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:
Oil injection
Engine oil tank capacity:
1.5 L (1.59 US qt, 1.32 Imp.qt)
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
0.430 L (0.455 US qt, 0.378 Imp.qt)
Tightening torque for engine:
Spark plug:
25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
Propeller nut:
39.0 Nm (3.98 kgf-m, 28.8 ft-lb)
Noise and vibration level:
Operator sound pressure level (ICOMIA 39/94 and 40/94):
40VEO 89.5 dB(A)
40VMHO 89.5 dB(A) Sound power level (ICOMIA 39/94 and 40/94):
40VEO 97.4 dB(A)
40VMHO 97.4 dB(A) Vibration on tiller handle (ICOMIA 38/94):
40VEO Vibration on tiller handle is
under 2.5 m/s
2
40VMHO Vibration on tiller handle is
under 2.5 m/s
EMU33554
2
Installation requirements
EMU33564
Boat horsepower rating
EWM01560
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
10
Page 17
Specifications and requirements
WARNING
WARNING
capacity plate or contact the manufacturer.
EMU33571
Mounting motor
EWM01570
Improper mounting of the outboard mo-
tor could result in hazardous condi­tions such as poor handling, loss of control, or fire hazards.
Because the motor is very heavy, spe-
cial equipment and training is required to mount it safely.
Your dealer or other person experienced in proper rigging should mount the motor using correct equipment and complete rigging in­structions. For further information, see page
33.
EMU33581
Remote control requirements
EWM01580
If the engine starts in gear, the boat can
move suddenly and unexpectedly, pos­sibly causing a collision or throwing passengers overboard.
If the engine ever starts in gear, the
start-in-gear protection device is not working correctly and you should dis­continue using the outboard. Contact your Yamaha dealer.
The remote control unit must be equipped with a start-in-gear protection device(s). This device prevents the engine from starting un­less it is in neutral.
EMU25694
Battery requirements
EMU25721
Battery specifications
Minimum cold cranking amps (CCA/EN):
40VEO 347.0 A 50HETO 347.0 A
Minimum rated capacity (20HR/IEC):
40VEO 40.0 Ah 50HETO 40.0 Ah
The engine cannot be started if battery volt­age is too low.
EMU36290
Mounting battery
Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. WARNING! Do not put flammable
items, or loose heavy or metal objects in the same compartment as the battery. Fire, explosion or sparks could result.
[EWM01820]
EMU36300
Multiple batteries
To connect multiple batteries, such as for multiple engine configurations or for an ac­cessory battery, consult your Yamaha dealer about battery selection and correct wiring.
EMU34194
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
11
Page 18
Specifications and requirements
ZMU04606
-
x
123
ZMU04607
-
x
123
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 71.
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
EMU25770
Start-in-gear protection
Yamaha outboard motors or Yamaha-ap­proved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is in neutral. Always select neutral before starting the engine.
EMU25651
Engine oil requirements
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
12
Recommended engine oil:
YAMALUBE 2-stroke outboard motor oil
If the recommended engine oil is not avail­able, another 2-stroke engine oil with an NMMA-certified TC-W3 rating may be used.
EMU36360
Fuel requirements
EMU36802
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.
Page 19
Specifications and requirements
NOTICE
Recommended gasoline:
Regular unleaded gasoline with a min­imum octane rating of 90 (Research Octane Number).
ECM01981
Do not use leaded gasoline. Leaded
gasoline can seriously damage the en­gine.
Avoid getting water and contaminants
in the fuel tank. Contaminated fuel can cause poor performance or engine damage. Use only fresh gasoline that has been stored in clean containers.
EMU36880
Muddy or acidic water
Yamaha strongly recommends that you have your dealer install the optional chromium­plated water pump kit if you use the outboard motor in muddy or acidic water conditions. However, depending on the model it might not be required.
EMU36330
Anti-fouling paint
A clean hull improves boat performance. The boat bottom should be kept as clean of ma­rine growth as possible. If necessary, the boat bottom can be coated with an anti-foul­ing paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
EMU36341
Motor disposal requirements
Never illegally discard (dump) the motor. Yamaha recommends consulting the dealer about discarding the motor.
EMU36352
Emergency equipment
Keep the following items onboard in case there is trouble with the outboard motor.
A tool kit with assorted screwdrivers, pli-
ers, wrenches (including metric sizes), and electrical tape.
Waterproof flashlight with extra batteries.
An extra engine shut-off cord (lanyard)
with clip.
Spare parts, such as an extra set of spark
plugs.
Consult your Yamaha dealer for details.
13
Page 20

Components

TIP:
17
2 3
4
5 6 7
16
8
9
10
11
12
13
14
15
ZMU03344
2
1
EMU2579V
Components diagram
* May not be exactly as shown; also may not be included as standard equipment on all mod­els (order from dealer).
40VMHO, 50HMHO
1. Manual starter handle
2. Tiller handle*
3. Choke knob
4. Alert indicator
5. Tilt lock lever
6. Clamp screw
7. Trim rod
8. Cooling water inlet
9. Propeller
10. Trim tab (anode)
11. Anti-cavitation plate
12. Anode
13. Tilt support lever
14. Clamp bracket
15. Top cowling
14
16. Fuel tank*
17. Engine shut-off switch
Page 21
40VEO
7
8
9
10
11
12
13
14
1
15
16
2
3
4
5
6
ZMU06642
1. Oil tank filler cap
2. Alert indicator(s)
3. Tilt lock lever
4. Clamp screw
5. Trim rod
6. Battery cable
7. Propeller
8. Cooling water inlet
9. Trim tab (anode)
10. Anti-cavitation plate
11. Anode
12. Tilt support lever
13. Clamp bracket
14. Top cowling
15. Remote control box (side mount type)*
16. Fuel tank*
Components
15
Page 22
Components
WARNING
113
14 15 16
17
2
3
4
6 5
7
8
4
9
10
11
12
ZMU06643
50HETO
1. Oil tank filler cap
2. Alert indicator(s)
3. Battery cable
4. Anode(s)
5. Propeller
6. Cooling water inlet
7. Trim tab (anode)
8. Anti-cavitation plate
9. Trim rod
10. Clamp bracket
11. Tilt support lever
12. Top cowling
13. Remote control box (side mount type)*
14. Trim meter*
15. Tachometer*
16. Digital tachometer*
17. Fuel tank*
EMU25802
Fuel tank
If your model was equipped with a portable
16
fuel tank, its function is as follows.
EWM00020
The fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Com­mercial users should conform to relevant licensing or approval authority regula­tions.
Page 23
1. Fuel joint
ZMU02284
3
1
4
2
ZMU03157
13
42
2. Fuel gauge
3. Fuel tank cap
4. Air vent screw
1. Fuel joint
2. Fuel gauge
3. Fuel tank cap
4. Air vent screw
EMU25830
Fuel joint
This joint is used to connect the fuel line.
EMU25841
Fuel gauge
This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the ap­proximate amount of fuel remaining in the tank.
EMU25850
Fuel tank cap
This cap seals the fuel tank. When removed,
Components
the tank can be filled with fuel. To remove the cap, turn it counterclockwise.
EMU25860
Air vent screw
This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise.
EMU26181
Remote control box
The remote control lever actuates both the shifter and the throttle. The electrical switch­es are mounted on the remote control box.
1. Power trim and tilt switch
2. Remote control lever
3. Neutral interlock trigger
4. Neutral throttle lever
5. Main switch
6. Engine shut-off switch
7. Throttle friction adjuster
EMU26190
Remote control lever
Moving the lever forward from the neutral po­sition engages forward gear. Pulling the le­ver back from neutral engages reverse. The engine will continue to run at idle until the le­ver is moved about 35 (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.
17
Page 24
Components
TIP:
1. Neutral “ ”
2. Forward “ ”
3. Reverse “ ”
4. Shift
5. Fully closed
6. Throttle
7. Fully open
EMU26201
Neutral interlock trigger
To shift out of neutral, first pull the neutral in­terlock trigger up.
1. Neutral interlock trigger
EMU26212
Neutral throttle lever
To open the throttle without shifting into ei­ther forward or reverse, put the remote con­trol lever in the neutral position and lift the neutral throttle lever.
1. Fully open
2. Fully closed
The neutral throttle lever will operate only when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position.
EMU25912
Tiller handle
To change direction, move the tiller handle to the left or right as necessary.
EMU25923
Gear shift lever
Move the gear shift lever forward to engage the forward gear or rearward to engage the reverse gear.
18
Page 25
Components
ZMU03095
1. Forward “ ”
2. Neutral “ ”
3. Reverse “ ”
EMU25941
Throttle grip
The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.
EMU25961
Throttle indicator
The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation.
1. Throttle indicator
EMU25976
Throttle friction adjuster
A friction device provides adjustable resis­tance to movement of the throttle grip or the remote control lever, and can be set accord­ing to operator preference. To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. WARNING! Do
not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident.
[EWM00032]
19
Page 26
Components
When constant speed is desired, tighten the adjuster to maintain the desired throttle set­ting.
EMU25994
Engine shut-off cord (lanyard) and clip
The clip must be attached to the engine shut­off switch for the engine to run. The cord should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power. WARNING! At-
tach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become en­tangled, preventing it from functioning. Avoid accidentally pulling the cord dur­ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
[EWM00122]
1. Cord
2. Clip
3. Engine shut-off switch
1. Cord
2. Clip
3. Engine shut-off switch
EMU26002
Engine stop button
The engine stop button stops the engine when the button is pushed.
20
Page 27
Components
WARNING
ZMU03355
ZMU02942
EMU26012
Choke knob for pull type
To supply the engine with the rich fuel mix­ture required to start, pull out this knob.
EMU26073
Manual starter handle
The manual starter handle is used to crank and start the engine.
EMU26091
Main switch
The main switch controls the ignition system; its operation is described below.
“” (off)
With the main switch in the “ ” (off) posi­tion, the electrical circuits are off, and the key can be removed.
“” (on)
With the main switch in the “ ” (on) posi­tion, the electrical circuits are on, and the key cannot be removed.
“” (start)
With the main switch in the “ ” (start) po-
sition, the starter motor turns to start the en­gine. When the key is released, it returns automatically to the “ ” (on) position.
EMU26111
Steering friction adjuster
A friction device provides adjustable resis­tance to the steering mechanism, and can be set according to operator preference. An ad­juster lever is located on the bottom of the tiller handle bracket. To increase resistance, turn the lever to the port side “A”. To decrease resistance, turn the lever to the starboard side “B”.
EWM00040
Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident.
21
Page 28
Components
TIP:
WARNING
ZMU02908
Check the tiller handle for smooth move-
ment when the lever is turned to the star­board side “B”.
Do not apply lubricants such as grease to
the friction areas of the steering friction ad­juster.
EMU26122
Steering friction adjuster
A friction device provides adjustable resis­tance to the steering mechanism, and can be set according to operator preference. An ad­justing screw or bolt is located on the swivel bracket.
there is too much resistance, it could be difficult to steer, which could result in an accident.
EMU26143
Power trim and tilt switch on remote control or tiller handle
The power trim and tilt system adjusts the outboard motor angle in relation to the tran­som. Pressing the switch “ ” (up) trims the outboard motor up, and then tilts it up. Press­ing the switch “ ” (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current position. For instructions on using the power trim and tilt switch, see pages 52 and 55.
To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.
EWM00040
Do not overtighten the friction adjuster. If
22
EMU26154
Power trim and tilt switch on bottom cowling
The power trim and tilt switch is located on the side of the bottom cowling. Pushing the
Page 29
Components
WARNING
WARNING
NOTICE
DOWN
UP
ZMU03096
A
B
ZMU03097
1
2
switch “ ” (up) trims the outboard motor up, and then tilts it up. Pushing the switch “ ” (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current po­sition. For instructions on using the power trim and tilt switch, see page 55.
EWM01031
Use the power trim and tilt switch located on the bottom cowling only when the boat is at a complete stop with the engine off. Attempting to use this switch while the boat is moving could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obstacle.
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.
ECM00840
The trim tab also serves as an anode to protect the engine from electrochemical corrosion. Never paint the trim tab as it will become ineffective as an anode.
1. Trim tab
2. Bolt
EMU26244
Trim tab with anode
EWM00840
An improperly adjusted trim tab could cause difficult steering. Always test run after the trim tab has been installed or re­placed to be sure steering is correct. Be sure you have tightened the bolt after ad­justing the trim tab.
The trim tab should be adjusted so that the steering control can be turned to either the
Bolt tightening torque:
18.0 Nm (1.8 kgf-m, 13 ft-lb)
EMU26262
Trim rod (tilt pin)
The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.
23
Page 30
Components
NOTICE
NOTICE
ZMU03098
1
ZMU06790
ZMU03194
ZMU03358
EMU30530
Tilt lock mechanism
The tilt lock mechanism is used to prevent the outboard motor from lifting out of the wa­ter when in reverse gear.
1. Tilt lock lever
To lock it, set the tilt lock lever in the lock po­sition. To release, push the tilt lock lever in the release position.
EMU26341
Tilt support lever for power trim and tilt model
To keep the outboard motor in the tilted up position, lock the tilt support lever to the clamp bracket.
ECM00660
Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt sup­port and fall. If the motor cannot be trail­ered in the normal running position, use an additional support device to secure it in the tilt position.
EMU30201
Tilt support lever for manual tilt model
To keep the outboard motor in the tilted up position, lock the tilt support lever to the clamp bracket.
ECM00660
24
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 trail-
Page 31
ered in the normal running position, use
ZMU02862
1
ZMU03361
1
1
ZMU03360
an additional support device to secure it in the tilt position.
EMU26373
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. Cowling lock lever(s)
Components
1. Alert indicator(s)
EMU26303
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 30.
1. Alert indicator
25
Page 32

Instruments and indicators

NOTICE
NOTICE
1
ZMU03360
ZMU03361
1
ZMU03361
1
EMU36014
Indicators
EMU26291
Alert indicator for three indicators
If the engine develops a condition which is cause for alert, the indicator on the front of the bottom cowling lights up. The three indi­cators mounted on the bottom cowling also indicate the engine oil level. For details on how to read the alert indicators, see page 30.
1. Overheat-alert indicator
EMU37560
Oil level-alert indicator
If the oil level falls below the lower limit, this indicator will light up. For further information, see page 30.
ECM00030
Do not operate the engine without oil. Se-
1. Alert indicator(s)
EMU36033
Overheat-alert indicator
If the engine temperature rises too high, this indicator will light up. For further information on reading the indicator, see page 30.
ECM00052
rious engine damage will occur.
Do not continue to run the engine if the overheat-alert indicator is on. Serious en­gine damage will occur.
26
1. Oil level-alert indicator
EMU26493
Digital tachometer
The tachometer shows the engine speed and has the following functions. All segments of the display will light momen­tarily after the main switch is turned on and will return to normal thereafter.
Page 33
Instruments and indicators
TIP:
1
3
5
6
7
4
2
ZMU01891
ZMU01869
ZMU01870
1. Tachometer
2. Trim meter
3. Hour meter
4. Oil level indicator
5. Overheat-alert indicator
6. Set button
7. Mode button
The water separator and engine trouble-alert indicators only operate when the engine is equipped with the appropriate functions.
EMU36050
Tachometer
The tachometer displays engine speed in hundreds of revolutions per minute (r/min). For example, if the tachometer display reads “22” then the engine speed is 2200 r/min.
EMU26621
Trim meter
This meter shows the trim angle of your out­board motor.
Memorize the trim angles that work best
for your boat under different conditions. Adjust the trim angle to the desired using the power trim and tilt switch.
If the trim angle of your motor exceeds the
trim operating range, the top segment on the trim meter display will blink.
EMU26651
Hour meter
This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off.
To change the display format, press the “ ” (mode) button. The display can show total hours or trip hours, or turn off. To reset the trip hours, simultaneously press the “ ” (set) and “ ” (mode) buttons for more than 1 second while the trip hours are displayed. This resets the trip counter to 0 (zero). The total number of hours the engine has been run cannot be reset.
EMU26551
Oil level indicator (digital type)
This indicator shows the engine oil level. If the oil level falls below the lower limit, the
27
Page 34
Instruments and indicators
NOTICE
NOTICE
NOTICE
1
ZMU01867
1
ZMU01868
ZMU04577
1
2
ZMU04580
1
alert indicator will start to blink. For further in­formation, see page 31.
ECM00030
Do not operate the engine without oil. Se­rious engine damage will occur.
1. Oil level indicator
EMU26583
Overheat-alert indicator
If the engine temperature rises too high, the alert indicator will start to blink. For further in­formation on reading the indicator, see page
30.
ECM00052
EMU26471
Analog tachometer
This gauge shows the engine speed and has the following functions.
1. Tachometer
2. Oil level indicator
EMU26541
Oil level indicators (three indicators)
The indicators on the gauge show the status of the oil level. For details on how to read the indicators, see page 43.
ECM00030
Do not operate the engine without oil. Se­rious engine damage will occur.
Do not continue to run the engine if the overheat-alert indicator is on. Serious en­gine damage will occur.
1. Overheat-alert indicator
28
1. Oil level indicators
EMU26574
Overheat-alert indicator
If the engine temperature rises too high, this
Page 35
Instruments and indicators
NOTICE
ZMU03361
1
ZMU04581
indicator will flash. For further information on reading the indicator, see page 30.
ECM00052
Do not continue to run the engine if the overheat-alert indicator is on. Serious en­gine damage will occur.
1. Overheat-alert indicator
EMU26611
Analog trim meter
This gauge shows the trim angle of your out­board motor.
Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired setting with the power trim and tilt switch.
29
Page 36

Engine control system

NOTICE
ZMU04766
ZMU03364 ZMU01757
ZMU03025
ZMU03026
EMU26803
Alert system
ECM00091
Do not continue to operate the engine if a alert device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected.
EMU2681C
Overheat alert
This engine has an overheat-alert device. If the engine temperature rises too high, the alert device will activate.
The engine speed will automatically de-
crease to about 2000 r/min.
The buzzer will sound (if equipped on the
tiller handle, remote control box, or main switch panel).
The overheat-alert indicator will light or
blink.
30
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.
Page 37
EMU26848
TIP:
ZMU04586
ZMU03364
ZMU03363
ZMU03942
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.
Engine control system
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.
The alert for oil filter clogging is similar to the alerts for low oil level and overheating. To make troubleshooting easier, check for en­gine overheating first, then oil level, and fi­nally oil filter clogging.
31
Page 38
Engine control system
1
ZMU06661
1
ZMU06662
1. Oil filter
1. Oil filter
32
Page 39
EMU26902
WARNING
ZMU01760
1

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.
EWM01590
Installation
Overpowering a boat could cause se-
vere instability. Do not install an out­board motor with more horsepower than the maximum rating on the capac­ity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.
Improper mounting of the outboard mo-
tor could result in hazardous condi­tions such as poor handling, loss of control, or fire hazards. For permanent­ly mounted models, your dealer or oth­er person experienced in proper rigging should mount the motor.
EMU33470
Mounting the outboard motor
The outboard motor should be mounted so that the boat is well balanced. Otherwise, the boat could be hard to steer. For single-en­gine boats, mount the outboard motor on the centerline (keel line) of the boat.
1. Center line (keel line)
EMU26933
Mounting height (boat bottom)
The mounting height of your outboard motor affects its efficiency and reliability. If it is mounted too high, propeller ventilation may occur, which will reduce propulsion due to excessive propeller slip, and the water in­takes for the cooling system may not get ad­equate water supply, which can cause engine overheating. If the engine is mounted too low, water resistance (drag) will increase, thereby reducing engine efficiency and per­formance. Most commonly, outboard motor should be mounted so that the anti-cavitation plate is in alignment with the bottom of the boat. The optimum mounting height of the outboard motor is affected by the boat/motor combina­tion and the desired use. Test runs at differ­ent heights can help determine the optimum mounting height. Consult your Yamaha deal­er or boat manufacturer for further informa­tion on determining the proper mounting height.
33
Page 40
Installation
NOTICE
ZMU01762
ZMU02012
ZMU02013
ECM01634
Make sure that the idle hole is high
enough to prevent water from entering the engine even if the boat is stationary with the maximum load.
Incorrect engine height or obstructions
to the smooth flow of water (such as the design or condition of the boat, or ac­cessories, such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. If the outboard motor is oper­ated continuously in the presence of airborne water spray, enough water could enter the engine through the air intake opening in the top cowling to cause severe engine damage. Remove the cause of the airborne water spray.
EMU26973
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.
[EWM00642]
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 packaging. If used, they must be of at
34
Page 41
least the same quality of material and
ZMU03185
1
1
strength and must be tightened se­curely. After tightening, test run the engine and check their tightness.
[EWM00651]
1. Bolts
Installation
35
Page 42

Operation

NOTICE
NOTICE
WARNING
EMU36381
First-time operation
EMU27020
Breaking in engine
Your new engine requires a period of break­in to allow mating surfaces of moving parts to wear in evenly. Correct break-in will help en­sure proper performance and longer engine life.
ECM00140
Failure to follow the break-in procedure
could result in reduced engine life or even severe engine damage.
Premix fuel must be used during break-
in in addition to oil in the oil injection system.
EMU27060
Gasoline and engine oil mixing chart (50:1)
1. : Gasoline
2. : Engine oil
ECM00150
Be sure to mix gasoline and oil complete­ly, otherwise the engine may be dam­aged.
EMU30311
Procedure for oil injection models
Run the engine under load (in gear with a propeller installed) for 10 hours as follows.
1. First 10 minutes: Run the engine at the lowest possible
speed. A fast idle in neutral is best.
2. Next 50 minutes: Do not exceed half throttle (approxi­mately 3000 r/min). Vary engine speed occasionally. If you have an easy-plan­ing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3000 r/min or less.
3. Next two hours: Accelerate at full throttle onto plane, then reduce engine speed to three-quar­ter throttle (approximately 4000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three­quarter throttle or less to let the engine cool.
4. Remaining seven hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.
5. After the first 10 hours: Operate the engine normally. Use only straight gasoline in the fuel tank. The Yamaha oil injection system provides proper lubrication for normal operation.
EMU36400
Getting to know your boat
Different boats handle differently. Operate cautiously while you learn how your boat handles under different conditions and with different trim angles (see page 52).
EMU36413
Checks before starting engine
EWM01921
If any item in “Checks before starting en­gine” is not working properly, have it in­spected and repaired before operating the outboard motor. Otherwise, an acci­dent could occur.
36
Page 43
Operation
NOTICE
WARNING
WARNING
ZMU06084
ZMU06150
ECM00120
Do not start the engine out of water. Over­heating and serious engine damage can occur.
EMU37141
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
40.
EMU36571
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.
sion.
Check for fuel leakage regularly.
If any fuel leakage is found, the fuel
system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate.
EMU36451
Check for fuel leaks
Check for fuel leaks or gasoline fumes in
the boat.
Check for fuel leakage from the fuel sys-
tem.
Check the fuel tank and fuel lines for
cracks, swellings, or other damages.
EMU37321
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.
EMU36442
Fuel system
EWM00060
Gasoline and its vapors are highly flam­mable and explosive. Keep away from sparks, cigarettes, flames, or other sourc­es of ignition.
EWM00910
Leaking fuel can result in fire or explo-
EMU36902
Controls
Tiller handle models:
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 re­turns to the fully closed position.
Look for loose or damaged connections of
the throttle and shift cables.
37
Page 44
Operation
Remote control models:
Turn the steering wheel full-right and full-
left. Make sure operation is smooth and unrestricted throughout the whole range with no binding or excessive free play.
Operate the throttle levers several times to
make sure there is no hesitation in their travel. Operation should be smooth over the complete range of motion, and each le­ver should return completely to the idle po­sition.
Look for loose or damaged connections of
the throttle and shift cables.
EMU36483
Engine shut-off cord (lanyard)
Inspect the engine shut-off cord and clip for damage, such as cuts, breaks, and wear.
1. Cord
2. Clip
3. Engine shut-off switch
1. Cord
2. Clip
3. Engine shut-off switch
EMU27120
Oil
Check to be sure you have plenty of oil for
your trip.
EMU27153
Engine
Check the engine and engine mounting.
Look for loose or damaged fasteners.
Check the propeller for damage.
Check for engine oil leaks.
EMU27181
Operation after long period of storage
Oil injection models
When operating the engine after a long peri­od (12 months) of storage, proceed as fol­lows:
1. Use a 50:1 gasoline to oil mixture to start the engine.
2. Start the engine. Leave it idling. WARN-
ING! 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.
3. Watch for oil flowing through the oil feed pipes. After any air in the oil lines has
[EWM01331]
38
Page 45
been expelled, the oil injection system
NOTICE
WARNING
ZMU03367
ZMU06109
ZMU04678
should supply oil normally. If no oil is flowing after 10 minutes of idling, consult your Yamaha dealer.
ECM01260
Be sure to take the above steps when op­erating the engine after a long period of storage. Otherwise engine seizure could occur.
EMU36954
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 lever to lock the cowling as shown. NOTICE: If the top cowling is
not installed correctly, water spray under the top cowling can damage the engine, or the top cowling can blow off at high speeds.
[ECM01991]
Operation
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.
EMU34581
Power trim and tilt system
EWM01930
Never get under the lower unit while it
is tilted, even when the tilt support lever is locked. Severe injury could occur if the outboard motor accidentally falls.
Body parts can be crushed between the
motor and the clamp bracket when the motor is trimmed or tilted.
Be sure no one is near the outboard
motor before performing this check.
1. Check the power trim and tilt unit for any sign of oil leaks.
39
Page 46
Operation
WARNING
1
ZMU07311
ZMU06621
ZMU02301
1. Trim and tilt rod
2. Operate each of the power trim and tilt switches to check that all switches work.
3. Tilt the outboard motor up and check that the trim and tilt rod is pushed out completely.
4. Check that the trim and tilt rod is free of corrosion or other flaws.
5. Tilt the outboard motor down. Check that the trim and tilt rod operates smoothly.
EMU36582
Battery
Check that the battery is in good condition, and fully charged. Check that the battery connections are clean, secure and covered by insulating covers. The electrical contacts of the battery and cables must be clean and properly connected or the battery will not start the engine. Refer to the battery manufacturer’s instruc­tions for checks for your particular battery.
EMU27234
Filling fuel and engine oil
EMU27248
Filling fuel for portable tank
EWM01830
Gasoline and its vapors are highly flam-
mable and explosive. Always refuel ac­cording to this procedure to reduce the risk of fire and explosion.
Gasoline is poisonous and can cause
injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and wa­ter. If gasoline spills on your clothing, change your clothes.
1. Be sure the engine is stopped.
2. Disconnect the fuel line from the fuel tank and tighten the air vent screw on the fuel tank cap.
3. Remove the portable tank from the boat.
4. Be sure you are in a well-ventilated out­door area, either securely moored or trailered.
5. Do not smoke and keep away from sparks, flames, static electric discharge,
40
Page 47
Operation
WARNING
WARNING
ZMU02834
1
2
ZMU03368
or other sources of ignition.
6. If you use a portable container to store and dispense fuel, use only an approved GASOLINE container.
7. Touch the fuel nozzle to the filler open­ing or funnel to help prevent electrostatic sparks.
8. Fill the fuel tank, but do not overfill.
WARNING! Do not overfill. Otherwise fuel can expand and overflow if the temperature increases.
[EWM02610]
Fuel tank capacity:
24 L (6.34 US gal, 5.28 Imp.gal), 25 L (6.60 US gal, 5.50 Imp.gal)
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.
EMU27301
Filling oil for manual starter model
EWM00530
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 43. To fill the engine oil tank, proceed as follows:
Engine oil tank capacity:
1.5 L (1.59 US qt, 1.32 Imp.qt)
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.
1. Engine oil tank
2. Oil tank filler cap
4. After filling, replace the cap securely.
EMU27311
Filling oil for electric start models
EWM00530
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.
41
Page 48
Operation
ZMU03369
ZMU03370
ZMU03371
2
1
For details on reading the indicator seg­ments, see page 43. To fill the engine oil tank, proceed as follows:
Engine oil tank capacity:
1.5 L (1.59 US qt, 1.32 Imp.qt)
1. Turn the oil filler access cap on the top cowling counterclockwise and open it.
2. Open the oil tank filler cap by pulling the tab on the cap.
1. Oil filler access cap
2. Oil tank filler cap
4. After filling, replace the all caps secure­ly.
3. Slowly pour the engine oil into the en­gine oil tank.
42
Page 49
EMU27321
Oil level indicator operation
The various functions of the oil level system are as follows:
EMU27342
Manual start models
Oil level-alert indicator Engine oil tank Remarks
more than
3
OFF
Red
ON
Electric start models
Oil level-alert
indicator
(digital
tachometer)
Oil level-alert
tachometer/b
indicator
(analog
ottom
cowling)
Green
Engine oil tank Remarks
200 cm (0.21 US qt,
0.181 Imp qt)
3
200 cm (0.21 US qt,
0.181 Imp qt) or less
more than 450
3
(0.48 US qt,
cm
0.40 Imp qt)
Operation
No refilling necessary.
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
41.
No refilling necessary.
Yellow
from 450 cm
3
(0.48 US qt, 0.40 Imp qt) down to
3
200 cm (0.21 US qt, 0.18 Imp qt)
Add oil; see page 41.
43
Page 50
Operation
WARNING
ZMU02295
ZMU03100
Oil level-alert
indicator
(digital
tachometer)
EMU27452
Oil level-alert
indicator
(analog
tachometer/b
ottom
cowling)
Red
Engine oil tank Remarks
Operating engine
EWM00420
Before starting the engine, make sure
that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you.
When the air vent screw is loosened,
gasoline vapor will be released. Gaso­line is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosen­ing the air vent screw.
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.
EMU35704
Sending fuel (portable tank)
1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.
Buzzer sounds in
remote control box
3
200 cm (0.21 US qt, 0.18 Imp qt) or less
and engine speed is limited to about 2000 r/min to help con­serve oil.
Check oil filter for
clogging.
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.
44
Page 51
TIP:
Wipe up any spilled gasoline immediately
WARNING
WARNING
TIP:
ZMU02024
with dry rags. Dispose rags properly accord­ing to local laws or regulations.
3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp.
4. 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.
Operation
Be sure there are no swimmers in the wa­ter near you.
EMU27508
Manual start models (tiller control)
EWM01840
Failure to attached engine shut-off cord
could result in a runaway boat if opera­tor is ejected. Attach the engine shut­off cord to a secure place on your cloth­ing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre­venting it from functioning.
Avoid accidentally pulling the cord dur-
ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
1. Place the gear shift lever in neutral.
1. Arrow
EMU27494
Starting engine
EWM01600
Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions.
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
45
Page 52
Operation
TIP:
TIP:
ZMU07239
ZMU03389
ZMU03279
end of the cord into the engine shut-off switch.
3. Place the throttle grip in the “ ” (start) position.
(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.
4. Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position.
It is not necessary to use the choke when
starting a warm engine.
If the choke knob is left in the “
46
When the engine is cold, it needs to be
warmed up. For further information, see page 49.
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
Page 53
Operation
WARNING
TIP:
amount and try to start the engine again. If the engine still fails to start, see page 77.
EMU27595
Electric start / prime start models
EWM01840
Failure to attached engine shut-off cord
could result in a runaway boat if opera­tor is ejected. Attach the engine shut­off cord to a secure place on your cloth­ing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre­venting it from functioning.
Avoid accidentally pulling the cord dur-
ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
1. Place the gear shift lever in neutral.
switch.
3. Place the throttle grip in the “ ” (start) position. After the engine starts, return the throttle to the fully closed po­sition.
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
4. Turn the main switch to “ ” (start), and hold it for a maximum of 5 seconds.
5. Immediately after the engine starts, re­lease the main switch and allow it to re­turn to “ ” (on). NOTICE: Never turn
the main switch to “ ” (start)
47
Page 54
Operation
TIP:
WARNING
TIP:
while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, return the main switch to “ ” (on), wait 10 seconds, then crank the engine again.
When the engine is cold, it needs to be
warmed up. For further information, see page 49.
If the engine is warm and fails to start,
open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 77.
EMU27664
Electric start and remote control models
EWM01840
[ECM00192]
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.
Failure to attached engine shut-off cord
could result in a runaway boat if opera­tor is ejected. Attach the engine shut­off cord to a secure place on your cloth­ing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre­venting it from functioning.
Avoid accidentally pulling the cord dur-
ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
1. Place the remote control lever in neutral.
48
3. Turn the main switch to “ ” (on).
4. Turn the main switch to “ ” (start), and hold it for a maximum of 5 seconds.
Page 55
5. Immediately after the engine starts, re-
TIP:
NOTICE
ZMU03391
lease the main switch and allow it to re­turn to “ ” (on). NOTICE: Never turn
the main switch to “ ” (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, return the main switch to “ ” (on), wait 10 seconds, then crank the engine again.
When the engine is cold, it needs to be
[ECM00192]
warmed up. For further information, see page 49.
If the engine is warm and fails to start,
open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 77.
EMU36510
Checks after starting engine
EMU36522
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
Operation
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.
ECM01810
If water is not flowing out of the pilot hole at all times while the engine is running, overheating and serious damage could occur. Stop the engine and check wheth­er the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and cor­rected.
EMU27670
Warming up engine
EMU27683
Choke start models
After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life. Gradually return the choke knob to its home position as the en­gine warms up.
EMU27704
Electric start and prime start models
After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life.
49
Page 56
Operation
WARNING
NOTICE
ZMU03399
EMU36531
Checks after engine warm up
EMU36541
Shifting
While the boat is tightly moored, and without applying throttle, confirm that the engine shifts smoothly into forward and reverse, and back to neutral.
EMU31721
Stop switches
Confirm that turning the main switch to the
” (off) position stops the engine.
Confirm that removing the clip from the en-
gine shut-off switch stops the engine.
Confirm that the engine cannot be started
with the clip removed from the engine shut-off switch.
EMU34530
Shifting
EWM00180
Before shifting, make sure there are no swimmers or obstacles in the water near you.
ECM01610
1. Neutral interlock trigger
2. Move the remote control lever / gear shift lever firmly and crisply forward (for forward gear) or backward (for reverse gear) [about 35 (a detent can felt) for re­mote control models]. Be sure to check that the tilt lock lever is in the lock/down position (if equipped) before operating in reverse.
Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral. If this occurs, stop the engine, shift to neutral, then restart the engine and allow it to warm up.
To shift out of neutral
1. Pull the neutral interlock trigger up (if equipped).
50
Page 57
To shift from in gear (forward/reverse) to
WARNING
neutral
1. Close the throttle so that the engine slows to idle speed.
Operation
EMU31742
Stopping boat
EWM01510
2. After the engine is at idle speed in gear move the remote control lever / gear shift lever firmly and crisply into the neu­tral position.
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.
51
Page 58
Operation
TIP:
WARNING
ZMU03108
ZMU02301
EMU27821
Stopping engine
Before stopping the engine, first let it cool off for a few minutes at idle or low speed. Stop­ping the engine immediately after operating at high speed is not recommended.
EMU27847
Procedure
1. Push and hold the engine stop button or turn the main switch to “ ” (off).
the fuel line if there is a fuel joint on the outboard motor.
3. Tighten the air vent screw on the fuel tank cap (if equipped).
2. After stopping the engine, disconnect
52
4. Remove the key if the boat will be left un­attended.
The engine can also be stopped by pulling the cord and removing the clip from the en­gine shut-off switch, then turning the main switch to “ ” (off).
EMU27862
Trimming outboard motor
EWM00740
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
Page 59
Operation
WARNING
TIP:
ZMU03109
1
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.
1. Trim operating angle
EMU27872
Adjusting trim angle for manual tilt models
There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim an­gle.
1. Stop the engine.
2. Tilt the outboard motor up, and then re-
move the trim rod from the clamp brack­et.
1. Trim rod
3. Reposition the rod in the desired hole.
To raise the bow (“trim-out”), move the rod away from the transom. To lower the bow (“trim-in”), move the rod to­ward the transom. Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.
EWM00400
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.
The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim rod one hole.
53
Page 60
Operation
WARNING
DOWN
UP
ZMU05675
1
EMU27886
Adjusting trim angle (Power trim and tilt)
EWM00753
Be sure all people are clear of the out-
board motor when adjusting the trim angle. Body parts can be crushed be­tween the motor and the clamp bracket when the motor is trimmed or tilted.
Use caution when trying a trim position
for the first time. Increase speed gradu­ally and watch for any signs of instabil­ity or control problems. Improper trim angle can cause loss of control.
If equipped with a power trim and tilt
switch located on the bottom cowling, use the switch only when the boat is at a complete stop with the engine off. Do not adjust the trim angle with this switch while the boat is moving.
Adjust the outboard motor trim angle using the power trim and tilt switch.
1. Power trim and tilt switch
1. Power trim and tilt switch
1. Power trim and tilt switch
54
To raise the bow (trim-out), press the switch “” (up). To lower the bow (trim-in), press the switch “ ” (down). Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.
EMU27912
Adjusting boat trim
When the boat is on plane, a bow-up attitude results in less drag, greater stability and effi­ciency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden­cy to steer to one side or the other. Compen­sate for this as you steer. When the bow of the boat is down, it is easier to accelerate
Page 61
from a standing start onto plane.
TIP:
WARNING
WARNING
NOTICE
Operation
Bow Up
Too much trim-out puts the bow of the boat too high in the water. Performance and econ­omy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces per­formance further, and the boat may “por­poise” (hop in the water), which could throw the operator and passengers overboard.
Bow Down
Too much trim-in causes the boat to “plow” through the water, decreasing fuel economy and making it hard to increase speed. Oper­ating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making opera­tion difficult and dangerous.
Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.
EMU27935
Tilting up and down
If the engine will be stopped for some time or if the boat is moored in shallows, the out­board motor should be tilted up to protect the propeller and lower casing from damage by collision with obstructions, and also to re­duce salt corrosion.
EWM00222
Make sure that no one is near the out­board motor when tilting the outboard motor up or down. Otherwise, body parts could be crushed between the outboard motor and the clamp bracket.
EWM00250
Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, discon­nect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.
ECM00241
Before tilting the outboard motor, stop
the engine by following the procedure
55
Page 62
Operation
ZMU03405
ZMU03358
on page 52. 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.
EMU27955
Procedure for tilting up (manual tilt models)
1. Place the remote control lever / gear shift lever in neutral.
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 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 61.
[ECM01641]
2. Place the tilt lock lever in the release po­sition.
56
EMU32724
Procedure for tilting up (power trim and tilt models)
1. Place the remote control lever / gear shift lever in neutral.
Page 63
Operation
UP
ZMU01935
UP DN
UP
ZMU04993
2. Press the power trim and tilt switch “ ” (up) until the outboard motor has tilted up completely.
3. Pull the tilt support lever toward you to support the engine. WARNING! After
tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever. Otherwise the out­board motor could fall back down suddenly if oil in the power trim and tilt unit or in the power tilt unit loses pressure.
[EWM00262] NOTICE: Do not use
the tilt support lever or knob when trailering the boat. The outboard mo­tor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running po­sition, use an additional support de­vice to secure it in the tilt position. For more detailed information, see page 61.
[ECM01641]
57
Page 64
Operation
ZMU03115
ZMU06644
ZMU02569
DN
ZMU01936
UP DN
DOWN
ZMU03410
4. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim and tilt switch “ ” (down) to retract the trim rods. NOTICE: Make sure that the
trim rods retracts completely during mooring. This protects the rods from marine growth and corrosion, which could damage the power trim and tilt mechanism.
EMU30411
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.
[ECM00252]
(up) until the outboard motor is support­ed by the tilt rod and the tilt support lever becomes free.
2. Release the tilt support lever.
3. Push the power trim and tilt switch “ ” (down) to lower the outboard motor to the desired position.
3. Slowly tilt the engine down.
EMU33121
Procedure for tilting down (power trim and tilt models)
1. Push the power trim and tilt switch “
58
Page 65
Operation
NOTICE
UP
ZMU01935
UP DN
UP
ZMU03412
EMU28061
Shallow water
EMU32851
Power trim and tilt models
The outboard motor can be tilted up partially to allow operation in shallow water.
ECM00260
Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set­ting up for and cruising in shallow water. Otherwise severe damage from overheat­ing can result.
EMU32913
Procedure for power trim and tilt models
1. Place the remote control lever / gear shift lever in neutral.
2. Slightly tilt the outboard motor up to the desired position using the power trim and tilt switch. WARNING! Using the
power trim and tilt switch on the bot­tom cowling while the boat is moving or engine is on could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obstacle.
[EWM01850]
59
Page 66
Operation
3. To return the outboard motor to the nor­mal running position, press the power trim and tilt switch and slowly tilt the out­board motor down.
EMU28195
Cruising in other conditions
Cruising in salt water
After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh wa­ter.
Cruising in muddy, turbid, or acidic water
Yamaha strongly recommends that you use the optional chromium-plated water pump kit (see page 13) if you use the outboard motor in acidic water or water with a lot of sediment in it, such as muddy or turbid (cloudy) water. After operating in such water, flush the cool­ing passages with fresh water to prevent cor­rosion. Also rinse the outside of the outboard motor with fresh water.
60
Page 67

Maintenance

WARNING
NOTICE
TIP:
ZMU03122
EMU2822A
Transporting and storing
outboard motor
EWM02620
USE CARE when transporting fuel tank,
whether in a boat or car.
DO NOT fill fuel container to maximum
capacity. Gasoline will expand consid­erably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.
Leaking fuel is a fire hazard. When
transporting and storing the outboard motor, disconnect the fuel line from the outboard motor to prevent fuel from leaking.
Never get under the outboard motor
while it is tilted. Severe injury could oc­cur if the outboard motor accidentally falls.
Do not use the tilt support lever or knob
when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the outboard motor cannot be trailered in the normal run­ning position, use an additional sup­port device to secure it in the tilt position.
ECM02440
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.
EMU28236
Clamp screw mounting models
When transporting or storing the outboard motor while removed from a boat, keep the outboard motor in the attitude shown.
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.
Place a towel or something similar under the outboard motor to protect it from damage.
EMU30272
Storing outboard motor
When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard motor
61
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Maintenance
NOTICE
NOTICE
ZMU02051
1
2
serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the fol­lowing procedures.
ECM01411
Do not place the outboard motor on its
side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trou­ble.
Store the outboard motor in a dry, well-
ventilated place, not in direct sunlight.
EMU28305
Procedure
EMU28335
Flushing in a test tank
ECM00301
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.
ther information, see page 63.
2. Disconnect the fuel line from the motor or shut off the fuel cock, if equipped.
3. Remove the engine top cowling and si­lencer cover. Remove the propeller.
4. Install the 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.
[ECM00291]
[ECM01840] For fur-
1. Water surface
2. Lowest water level
5. Cooling system flushing is essential to prevent the cooling system from clog­ging up with salt, sand, or dirt. In addi­tion, fogging/lubricating of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flush­ing and fogging at the same time.
WARNING! Do not touch or remove electrical parts when starting or dur­ing operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.
[EWM00091]
6. Run the engine at a fast idle for a few minutes in neutral position.
7. Just prior to turning off the engine, quick­ly spray “Fogging Oil” alternately into each carburetor or the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke ex­cessively and almost stall.
8. Remove the 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
62
Page 69
stops.
TIP:
TIP:
WARNING
ZMU03223
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.
Maintenance
Store the fuel tank in a dry, well-ventilated place, not in direct sunlight.
EMU28411
Lubrication (oil injection models)
1. Install the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 69.
2. Fill the oil tanks. This prevents the for­mation of condensation. For models with a remote oil tank, it may be necessary to manually override the control unit to completely fill the engine oil tank.
3. Change the gear oil. For instructions, see page 73. Inspect the oil for the pres­ence of water which indicates a leaky seal. Seal replacement should be per­formed by an authorized Yamaha dealer prior to use.
4. Grease all grease fittings. For further de­tails, see page 68.
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.
EMU28451
Cleaning the outboard motor
After use, wash the exterior of the outboard motor with fresh water. Flush the cooling system with fresh water.
EMU28461
Checking painted surface of outboard motor
Check the outboard motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer.
EMU2847C
Periodic maintenance
EWM01871
These procedures require mechanical skills, tools, and supplies. If you do not have the proper skills, tools, or supplies to perform a maintenance procedure, have a Yamaha dealer or other qualified mechanic do the work. The procedures involve disassembling the motor and exposing dangerous parts. To reduce the risk of injury from moving, hot, or electrical parts:
Turn off the engine and keep the key(s)
and engine shut-off cord (lanyard) with you when you perform maintenance un­less otherwise specified.
The power trim and tilt switches oper-
ate even when the ignition key is off. Keep people away from the switches whenever working around the motor. When the motor is tilted, keep away
63
Page 70
Maintenance
from the area under it or between it and the clamp bracket. Be sure no one is in this area before operating the power trim and tilt mechanism.
Allow the engine to cool before han-
dling hot parts or fluids.
Always completely reassemble the mo-
tor before operation.
EMU28511
Replacement parts
If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and ac­cessories are available from your Yamaha dealer.
EMU34151
Severe operating conditions
Severe operating conditions involve one or more of the following types of operation on a regular basis:
Operating continuously at or near maxi-
mum engine speed (rpm) for many hours
Operating continuously at a low engine
speed (rpm) for many hours
Operating without sufficient time for engine
to warm up and cool down
Frequent quick acceleration and decelera-
tion
Frequent shifting
Frequently starting and stopping the en-
gine(s)
Operation that fluctuates often between
light and heavy cargo loads Outboard motors operating under any of these above conditions require more fre­quent maintenance. Yamaha recommends that you do this service twice as often as specified in the maintenance chart. For 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.
64
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Maintenance
TIP:
EMU34446
Maintenance chart 1
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.
Initial Every
Item Actions
Anode(s) (external)
Anode(s) (cylinder head, thermostat cover)
Anodes (exhaust cover, cooling water passage cover, Rectifier Regula­tor cover)
Battery (electrolyte level, terminal)
Battery (electrolyte level, terminal)
Cooling water leakage
Cowling lock lever Inspection
Engine starting condi­tion/noise
Engine idle speed/noise
Fuel filter (can be dis­assembled)
Fuel line (High pres­sure)
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Replacement
Inspection
Fill, charging or replac­ing as necessary
Inspection or replace­ment as necessary
Inspection
Inspection
Inspection or replace­ment as necessary
Inspection
20 hours
(3
months)
100
hours (1
year)
300
hours (3
years)
500
hours (5
years)
65
Page 72
Maintenance
Item Actions
Fuel line (High pres­sure)
Fuel line (Low pres­sure)
Fuel line (Low pres­sure)
Fuel pump
Fuel/engine oil leakage Inspection
Gear oil Replacement
Greasing points Greasing
Impeller/water pump housing
Impeller/water pump housing
Oil tank water drain Inspection or cleaning
Oil injection pump/oil feed pump
Power trim and tilt unit/Operation, noise and oil leakage
Propeller/propeller nut/cotter pin
Shift link/shift cable
Spark plug(s)
Spark plug caps/spark plug wires
Water from the cooling water pilot hole
Throttle link/throttle cable/throttle pick-up timing
Thermostat
Cooling water inlet Inspection
Inspection or replace­ment as necessary
Inspection
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Replacement
Inspection or Adjust­ment
Inspection
Inspection or replace­ment as necessary
Inspection, adjustment or replacement as nec­essary
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Inspection
Inspection, adjustment or replacement as nec­essary
Inspection or replace­ment as necessary
Initial Every
20 hours
(3
months)
100
hours (1
year)
hours (3
years)
300
500
hours (5
years)
66
Page 73
Item Actions
Main switch/stop switch/choke switch
Wire harness connec­tions/wire coupler con­nections
(Yamaha) Meter/gauge Inspection
Fuel tank (Yamaha por­table tank)
EMU34451
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Inspection and clean­ing as necessary
Maintenance chart 2
Maintenance
Initial Every
20 hours
(3
months)
100
hours (1
year)
hours (3
years)
300
500
hours (5
years)
Item Actions
Exhaust guide/exhaust manifold
Every
1000 hours
Inspection or replace­ment as necessary
67
Page 74
Maintenance
ZMU03415
EMU28943
Greasing
Yamaha grease A (water resistant grease) Yamaha grease D (corrosion resistant grease; for propeller shaft)
40VMHO, 50HMHO
68
Page 75
40VEO, 50HETO
ZMU03414
Maintenance
EMU28957
Cleaning and adjusting spark plug
The spark plug is an important engine com­ponent and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For exam­ple, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically re­move and inspect the spark plug because
heat and deposits will cause the spark plug to slowly break down and erode.
1. Remove the spark plug caps from the spark plugs.
2. Remove the spark plug. If electrode ero­sion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with an­other of the correct type. WARNING!
When removing or installing a spark plug, be careful not to damage the in­sulator. A damaged insulator could
69
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Maintenance
TIP:
WARNING
NOTICE
ZMU06150
allow external sparks, which could lead to explosion or fire.
[EWM00561]
Standard spark plug:
40VEO B7HS-10 40VMHO B7HS-10 50HETO B8HS-10 50HMHO B8HS-10
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.
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)
4. When fitting the plug, wipe off any dirt from the threads, and then screw it in to the correct torque.
Spark plug torque:
25.0 Nm (2.55 kgf-m, 18.4 ft-lb)
If a torque-wrench is not available when you are fitting a spark plug, a good estimate of
the correct torque is 1/4 to 1/2 a turn past fin­ger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.
EMU37450
Checking fuel filter
Check the fuel filter periodically. If any water or foreign matter is found in the filter, clean or replace it. For cleaning or replacement of the fuel filter, consult your Yamaha dealer.
EMU29044
Inspecting idle speed
EWM00451
Do not touch or remove electrical parts
when starting or during operation.
Keep hands, hair, and clothes away
from the flywheel and other rotating parts while the engine is running.
ECM00490
This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used.
If the boat is not equipped with a tachometer for the outboard motor, use a diagnostic ta­chometer for this procedure. Results may vary depending on whether testing is con­ducted with the flushing attachment, in a test tank, or with the outboard motor in the water.
70
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Maintenance
WARNING
1
2
ZMU03416
1
2
ZMU04989
ZMU03240
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.
EMU29061
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.
1. Drain hose
2. Filler neck side
EMU29114
Inspecting wiring and connectors
Inspect that each connector is engaged
securely.
Inspect that each ground lead is properly
secured.
EMU32112
Checking propeller
EWM01881
You could be seriously injured if the en­gine accidentally starts when you are near the propeller. Before inspecting, re­moving, or installing the propeller, place the shift control in neutral, turn the main switch to “ ” (off) and remove the key, and remove the clip from the engine shut­off switch. Turn off the battery cut-off switch if your boat has one.
1. Drain hose
2. Filler neck side
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.
71
Page 78
Maintenance
NOTICE
ZMU01897
ZMU03131
1
2
3
5
6
4
Checkpoints
Check each of the propeller blades for ero-
sion from cavitation or ventilation, or other damage.
Check the propeller shaft for damage.
Check the splines for wear or damage.
Check for fish line tangled around the pro-
peller shaft.
Check the propeller shaft oil seal for dam-
age.
EMU30662
Removing propeller
EMU29197
Spline models
1. Straighten the cotter pin and pull it out using a pair of pliers.
2. Remove the propeller nut, washer, and spacer (if equipped). WARNING! Do
not use your hand to hold the propel­ler when loosening the propeller nut.
[EWM01890]
1. Cotter pin
2. Propeller nut
3. Washer
4. Spacer
5. Propeller
6. Thrust washer
3. Remove the propeller, washer (if equipped), and thrust washer.
EMU30672
Installing propeller
EMU29234
Spline models
ECM00501
Make sure to use a new cotter pin and bend the ends over securely. Otherwise, the propeller could come off during oper­ation and be lost.
1. Apply Yamaha marine grease or a corro­sion resistant grease to the propeller 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.
3. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque.
[ECM01881]
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Page 79
Maintenance
TIP:
WARNING
TIP:
TIP:
ZMU03133
2
1
Propeller nut tightening torque:
39.0 Nm (3.98 kgf-m, 28.8 ft-lb)
4. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends. NO-
TICE: Do not reuse the cotter pin. Otherwise, the propeller can come off during operation.
[ECM01891]
If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to align it with the hole.
EMU29289
Changing gear oil
EWM00800
Be sure the outboard motor is securely
fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you.
Never get under the lower unit while it
is tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor accidental­ly falls.
1. Tilt the outboard motor so that the gear oil drain screw is at the lowest point pos­sible.
2. Place a suitable container under the
gear case.
3. Remove the gear oil drain screw and gasket. NOTICE: If there is an exces-
sive quantity of metal particles on the magnetic gear oil drain screw, this can indicate lower unit problem. Con­sult your Yamaha dealer.
1. Gear oil drain screw
2. Oil level plug
If a magnetic gear oil drain screw is
[ECM01900]
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. NO-
TICE: 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.
[ECM00713]
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
73
Page 80
Maintenance
WARNING
ZMU03132
ZMU02324
ZMU03232
gear oil drain screw hole.
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
0.430 L (0.455 US qt, 0.378 Imp.qt)
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.
Tightening torque:
9 Nm (0.9 kgf-m, 6.6 ft-lb)
7. Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw.
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.
Tightening torque:
9 Nm (0.9 kgf-m, 6.6 ft-lb)
EMU29302
Cleaning fuel tank
EWM00920
Gasoline is highly flammable, and its va­pors are flammable and explosive.
If you have any question about properly
doing this procedure, consult your Yamaha dealer.
Keep away from sparks, cigarettes,
flames, or other sources of ignition
74
4. Clean the filter (located on the end of the
Page 81
suction pipe) in a suitable cleaning sol-
NOTICE
TIP:
WARNING
NOTICE
ZMU03134
ZMU03135
ZMU03418
vent. Allow the filter to dry.
5. Replace the gasket with a new one. Re­install the fuel joint assembly and tighten the screws firmly.
EMU29313
Inspecting and replacing anode(s)
Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.
ECM00720
Do not paint anodes, as this would render them ineffective.
Maintenance
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.
EMU29323
Checking battery (for electric start models)
EWM01902
Battery electrolyte is poisonous and caustic, and batteries generate explosive hydrogen gas. When working near the battery:
Wear protective eye gear and rubber
gloves.
Do not smoke or bring any other source
of ignition near the battery.
The procedure for checking the battery var­ies for different batteries. This procedure contains typical checks that apply to many batteries, but you should always refer to the battery manufacturer’s instructions.
ECM01920
A poorly maintained battery will quickly deteriorate.
1. Check the electrolyte level.
75
Page 82
Maintenance
WARNING
NOTICE
ZMU01811
1
2
3
2. Check the battery’s charge. If your boat is equipped with the digital speedome­ter, the voltmeter and low battery alert functions will help you monitor the bat­tery’s charge. If the battery needs charg­ing, consult your Yamaha dealer.
3. Check the battery connections. They should be clean, secure, and covered by an insulating cover. WARNING! Bad
connections can produce shorting or arcing and cause an explosion.
[EWM01912]
EMU29334
Connecting the battery
EWM00572
Mount the battery holder securely in a dry, well-ventilated, vibration-free loca­tion in the boat. Install a fully charged bat­tery in the holder.
ECM01124
Do not reverse the battery cables. Other­wise, the electrical parts could be dam­aged.
1. Make sure the main switch (on applica­ble models) is “ ” (off) before working on the battery.
2. Connect the red battery cable to the POSITIVE (+) terminal first. Then con-
nect the black battery cable to the NEG­ATIVE (-) terminal.
1. Red cable
2. Black cable
3. Battery
3. The electrical contacts of the battery and cables must be clean and properly con­nected, or the battery will not start the engine.
EMU29371
Disconnecting the battery
1. Turn off the battery cut-off switch (if equipped) and main switch. NOTICE: If
they are left on, the electrical system can be damaged.
2. Disconnect the negative cable(s) from the negative (-) terminal. NOTICE: Al-
ways disconnect all negative (-) ca­bles first to avoid a short circuit and damage to the electrical system.
[ECM01940]
3. Disconnect the positive cable(s) and re­move the battery from the boat.
4. Clean, maintain, and store the battery according to the manufacturer’s instruc­tions.
[ECM01930]
76
Page 83

Trouble Recovery

EMU29427
Troubleshooting
A problem in the fuel, compression, or igni­tion systems can cause poor starting, loss of power, or other problems. This section de­scribes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble-alert indicator is flash­ing, consult your Yamaha dealer.
Starter will not operate.
Q. Is battery capacity weak or low? A. Check battery condition. Use battery of recommended capacity.
Q. Are battery connections loose or corrod­ed? A. Tighten battery cables and clean battery terminals.
Q. Is fuse for electric start relay or electric cir­cuit blown? A. Check for cause of electric overload and repair. Replace fuse with one of correct am­perage.
Q. Are starter components faulty? A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear? A. Shift to neutral.
Engine will not start (starter operates).
Q. Is fuel tank empty? A. Fill tank with clean, fresh fuel.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Is starting procedure incorrect? A. See page 45.
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.
77
Page 84
Trouble Recovery
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.
Q. Has alert system activated? A. Find and correct cause of alert.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con­nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro­ken wires.
Q. Is specified engine oil not being used? A. Check and replace oil as specified.
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 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?
78
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Is engine oil contaminated or deteriorat­ed? A. Replace oil with fresh, specified type.
Q. Is oil filter clogged? A. Have serviced by a Yamaha dealer.
Q. Has oil feed/injection pump malfunc­tioned? A. Have serviced by a Yamaha dealer.
Page 85
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.
Trouble Recovery
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 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. 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. 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
Q. Is air vent screw closed? A. Open the air vent screw.
Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.
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Trouble Recovery
WARNING
WARNING
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.
EMU29433
Temporary action in
emergency
EMU29441
Impact damage
EWM00870
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.
EMU29463
Replacing fuse
If the fuse has blown on an electric start mod­el, open the fuse holder and replace the fuse with a new one of the proper amperage.
EWM00631
Substituting an incorrect fuse or a piece of wire could allow excessive current flow. This could cause electric system damage and a fire hazard.
The outboard motor can be seriously damaged by a collision while operating or
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Page 87
WARNING
1. Fuse holder
1
2
3
ZMU03421
1
ZMU03422
2. Fuse (20 A)
3. Spare fuse (20 A)
Consult your Yamaha dealer if the new fuse immediately blows again.
EMU29524
Power trim and tilt will not operate
If the engine cannot be tilted up or down with the power trim and tilt because of a dis­charged battery or a failure with the power trim and tilt unit, the engine can be tilted manually.
1. Loosen the manual valve screw by turn­ing it counterclockwise until it stops.
1. Manual valve screw
2. Put the engine in the desired position, then tighten the manual valve screw by turning it clockwise.
Trouble Recovery
EMU29533
Starter will not operate
If the starter mechanism does not operate (the engine cannot be cranked with the start­er), the engine can be started with an emer­gency starter rope.
EWM01022
Use this procedure only in an emergen-
cy to return to the nearest port for re­pairs.
When the emergency starter rope is
used to start the engine, the start-in­gear protection device does not oper­ate. Make sure the remote control lever is in neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.
Attach the engine shut-off cord to a se-
cure place on your clothing, or your arm or leg while operating the boat.
Do not attach the cord to clothing that
could tear loose. Do not route the cord where it could become entangled, pre­venting it from functioning.
Avoid accidentally pulling the cord dur-
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 no one is standing behind
you when pulling the starter rope. It could whip behind you and injure someone.
An unguarded, rotating flywheel is very
dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the fly-
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Trouble Recovery
ZMU03425
ZMU03139
ZMU03140
ON STARTOFF
ZMU01906
wheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.
Do not touch the ignition coil, spark
plug wire, spark plug cap, or other elec­trical components when starting or op­erating the motor. You could get an electrical shock.
EMU29562
Emergency starting engine
1. Remove the top cowling.
2. Remove the start-in-gear protection ca­ble from the starter, if equipped.
equipped.
3. Remove the starter/flywheel cover after removing the bolt(s).
4. Prepare the engine for starting. For fur­ther information, see page 45. 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
82
5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms up.
Page 89
6. Insert the knotted end of the emergency
WARNING
ZMU03355
ZMU03429
ZMU03141
OPEN
CLOSE
ZMU03142
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.
Trouble Recovery
flywheel or other moving parts when the engine is running.
1. Adjust the trim angle so that the drive shaft is at right angles to the water sur­face or is trimmed in.
2. On models equipped with an emergency starter valve, open it. The valve is locat­ed behind the silencer cover on the front of the engine.
3. Squeeze the primer pump two or three times to feed fuel.
EMU29671
Engine fails to operate
EMU29706
Cold engine fails to start
If the engine fails to start when it is cold, use the following procedure.
EWM00410
When starting or operating the engine, do not touch the ignition coil, spark plug wire, spark plug cap, or other electrical parts carrying high voltage. Keep loose clothing and other objects away from the engine when starting it. Do not touch the
4. Open the throttle slightly without shifting using the throttle grip, neutral throttle le­ver or free accelerator. It is necessary to change the throttle opening slightly de­pending on the engine temperature. Af­ter the engine starts, return the throttle to its original position.
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Trouble Recovery
TIP:
N
ZMU03143
ON STARTOFF
ZMU03144
ZMU03335
ON
START
OFF
ZMU03145
OPEN
CLOSE
5. Turn the main switch to “ ” (on).
6. Turn the main switch to “ ” (start).
NOTICE: Never turn the main switch to “ ” (start) while the engine is running. Do not keep the starter mo­tor turning for more than 5 seconds. If the starter motor is turned continu­ously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be dam­aged. If the engine will not start after 5 seconds of cranking, return the main switch to “ ” (on), wait 10 sec­onds, then crank the engine again.
[ECM00192]
7. After the engine starts, close the emer­gency starter valve (if used), then return the throttle to its original position.
When the starter mechanism malfunctions, see page 81.
EMU33501
Treatment of submerged motor
If the outboard motor is submerged, immedi­ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi­ately. NOTICE: Do not attempt to run the
outboard motor until it has been com­pletely inspected.
[ECM00401]
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YAMAHA MOTOR CO., LTD.
Printed in Japan April 2010–0.2 1 !
Printed on recycled paper
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