Yamaha 40X (2020) User guide

OWNER’S MANUAL

Read this manual carefully before operating this

outboard motor.

40X

66T-28199-7H-E0

EMU25053

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

Important manual information

TIP:

TIP:

EMU25108

To the owner

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

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

EWM00782

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

ECM00702

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 40XMH 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.

EMU25123

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

40X

OWNER’S MANUAL

©2020 by Yamaha Motor Co., Ltd.

1st Edition, November 2019

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in Japan

Table of contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Collisions with floating or submerged

objects.............................................. 3

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

Passenger training .............................. 4

Boating safety publications.................. 4

Laws and regulations .......................... 4

General information .......................... 5

Identification numbers record...........5

Outboard motor serial number ............ 5

EC Declaration of Conformity

(DoC)............................................. 5

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

Read manuals and labels................. 7

Warning labels .................................... 7

Engine oil requirements ................. 13

Why Yamalube .................................. 13

Fuel requirements.......................... 13

Gasoline ............................................13

Muddy or acidic water.................... 14

Anti-fouling paint ............................ 14

Outboard motor disposal

requirements............................... 14

Emergency equipment................... 14

Components .................................... 15

Components diagram..................... 15

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

Fuel joint............................................ 16

Fuel gauge ........................................ 16

Fuel tank cap..................................... 16

Air vent screw.................................... 16

Tiller handle ...................................... 16

Gear shift lever ................................. 16

Throttle grip ......................................16

Throttle indicator ............................... 17

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

Engine shut-off cord (lanyard) and

clip.................................................. 17

Engine stop button ........................... 18

Pull-type choke knob ......................... 18

Manual starter handle........................ 18

Steering friction adjuster.................... 18

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

Trim rod (tilt pin) ................................19

Tilt lock mechanism........................... 19

Tilt support bar .................................. 20

Cowling lock lever(s) (turn type)........ 20

Specifications and requirements... 10

Specifications ................................. 10

Installation requirements ................ 11

Boat horsepower rating ..................... 11

Mounting outboard motor .................. 11

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

To use the battery ............................. 11

Propeller selection.......................... 12

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

Instruments and indicators............ 21

Analog tachometer......................... 21

Analog speedometer...................... 21

Hour meter..................................... 21

Engine control system ................... 22

Alert system ................................... 22

Overheat alert.................................... 22

Table of contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Gasoline and oil mixing (100:1)......... 30

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

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

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

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

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

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

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

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

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

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

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

Stopping boat ................................. 35

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

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

Trimming outboard motor...............36

Adjusting trim angle for manual tilt

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

Adjusting boat trim............................. 37

Tilting up and down ........................ 38

Procedure for tilting up (manual tilt

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

Procedure for tilting down (manual

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

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

Cruising in shallow water (manual

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

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

Maintenance .................................... 42

Transporting and storing outboard

motor........................................... 42

Clamp screw mounting models .........42

Storing outboard motor...................... 43

Procedure.......................................... 43

Lubrication......................................... 44

Cleaning the outboard motor............. 44

Checking painted surface of

outboard motor............................... 45

Periodic maintenance .................... 45

Replacement parts ............................45

Severe operating conditions.............. 45

Maintenance chart 1.......................... 46

Maintenance chart 2.......................... 48

Greasing............................................ 49

Cleaning and adjusting spark plug ....49

Checking fuel filter............................. 50

Inspecting idle speed......................... 50

Inspecting wiring and connectors ...... 51

Checking propeller ............................ 51

Removing propeller ...........................52

Installing propeller .............................52

Changing gear oil ..............................53

Inspecting and replacing anode(s) ....54

Connecting the battery ......................54

Disconnecting the battery.................. 55

Trouble Recovery............................ 56

Troubleshooting ............................. 56

Temporary action in emergency .... 59

Impact damage.................................. 59

Starter will not operate ...................... 59

Emergency starting engine................ 60

Treatment of submerged motor ..... 61

INDEX ............................................... 62

Safety information

EMU33623

Outboard motor safety

Observe these precautions at all times.

EMU36502

Propeller

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

 Stop the engine when a person is in the

water near you.

 Keep people out of reach of the propeller,

even when the engine is off.

EMU40272

Rotating parts

Hands, feet, hair, jewelry, clothing, personal
flotation device (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 top cowl­ing with the engine running.
Only operate the engine with the top 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.

shock or electrocution.

EMU33672

Engine shut-off cord (lanyard)

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

EMU33811

Gasoline

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

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

EMU33641

Hot parts

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

EMU33651

Electric shock

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

1

EMU33821

Gasoline exposure and spills

Take care not to spill gasoline. If gasoline
spills, wipe it up immediately with dry rags.
Dispose of rags properly.
If any gasoline spills onto your skin, immedi­ately wash with soap and water. Change
clothing if gasoline spills on it.
If you swallow gasoline, inhale a lot of gaso­line vapor, or get gasoline in your eyes, get

Safety information

immediate medical attention. Never siphon
fuel by mouth.

EMU33901

Carbon monoxide

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

EMU33781

Modifications

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

EMU33742

Boating safety

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

EMU33711

Alcohol and drugs

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

EMU40281

Personal flotation devices (PFDs)

Have an approved PFD on board for every
occupant. Yamaha recommends that you
must wear a PFD whenever boating. At a
minimum, children and non-swimmers
should always wear PFDs, and everyone
should wear PFDs when there are potentially
hazardous boating conditions.

EMU33732

People in the water

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

EMU33752

Passengers

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

EMU33763

Overloading

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

2

Safety information

ZMU06025

EMU33773

Avoid collisions

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

Operate defensively at safe speeds and
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.

following could occur:

 The passengers and any loose equipment

or luggage could be thrown forward due to
the sudden deceleration.

 Parts of the outboard motor could come

loose as a result of the impact and could
be thrown into the boat.

 The boat or outboard motor could be dam-

aged as a result of the impact.
When you operate the boat in an area where
there might be floating objects or obstacles
in the water, be sure to adjust the trim angle
of the outboard motor, slow down, and oper­ate carefully. For further information, see
page 40.
If the outboard motor hits a floating object or
an obstacle in the water, make sure that
there are no abnormalities with the boat and
the outboard motor. If anything abnormal is
found, return to the nearest harbor at low
speed and have a Yamaha dealer inspect
the outboard motor.

EMU48100

Collisions with floating or
submerged objects

If the outboard motor hits a floating object or
an obstacle in the water while cruising, the

3

EMU33791

Weather

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

boating in hazardous weather.

EMU33881

Passenger training

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

EMU33891

Boating safety publications

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

EMU33602

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.

Safety information

4

General information

ZMU05336

1

3412

ZMU01692

1

ZMU06081

EMU25172

Identification numbers record

EMU25186

Outboard motor serial number

The outboard motor serial number is
stamped on the label attached to the port
side of the clamp bracket.
Record your outboard motor serial number in
the spaces provided to assist you in ordering
spare parts from your Yamaha dealer or for
reference in case your outboard motor is sto­len.

1. Outboard motor serial number location

EMU38983

EC Declaration of Conformity

(DoC)

This declaration is included with outboard
motors that conform to European regula­tions.
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 manufacturer
 Model name
 Product code of model (Approved model

code)

 Code of conformed directives

EMU38995

CE Marking

This label is affixed to outboard motors that
conform to European regulations.
Outboard motors affixed with this “CE” mark­ing conform with the directives of;
2006/42/EC, 94/25/EC - 2003/44/EC,
2014/30/EU, and 2004/108/EC, 2013/53/EU.

1. Serial number

2. Model name

3. Motor transom height

4. Approved model code

5

1. CE marking location

General information

ZMU08148

2500 SHINGAI, IWATA,

SHIZUOKA, JAPAN

YAMAHA MOTOR CO., LTD.

YAMAHA

6

General information

1

2

3

ZMU08828

EMU33524

Read manuals and labels

Before operating or working on this outboard motor:

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

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

EMU33836

Warning labels

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

7

General information

6EE-G2794-40

6EE-H1994-40

6EE-H1995-40

1

2

3

6EE-G2794-50

6EE-H1994-50

6EE-H1995-50

ZMU05740

EMU33913

Contents of labels

The above warning labels mean as follows.

1

EWM01692

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

2

EWM01682

 Keep hands, hair, and clothing away

from rotating parts while the engine is
running.

 Do not touch or remove electrical parts

when starting or during operation.

3

EWM01672

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

device (PFD).

 Attach engine shut-off cord (lanyard) to

your PFD, arm, or leg so the engine

stops if you accidentally leave the

helm, which could prevent a runaway

boat.

8

General information

ZMU05664

ZMU05666

EMU35133

Symbols

The following symbols mean as follows.

Notice/Warning

ZMU05696

Read Owner’s Manual

Electrical hazard

Hazard caused by continuous rotation

ZMU05665

9

Specifications and requirements

TIP:

EMU38092

Specifications

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

EMU48360

Dimension and weight:

Overall length:

1073 mm (42.2 in)

Overall width:

402 mm (15.8 in)

Overall height L:

1364 mm (53.7 in)

Motor transom height L:

550 mm (21.7 in)

Dry weight (AL) L:

74 kg (162 lb)

Performance:

Full throttle operating range:

4500–5500 r/min

Rated power:

29.4 kW (40 HP)

Idle speed (in neutral):

950–1050 r/min

Power unit:

Type:

2-stroke L2

Total displacement:

Bore  stroke:

Ignition system:

Spark plug with resistor (NGK):

Spark plug gap:

3

703 cm

80.0  70.0 mm (3.15  2.76 in)

CDI

BR7HS

0.6–0.7 mm (0.024–0.028 in)

(42.9 c.i.)

Steering system:

Tiller handle

Starting system:

Manual starter

Starting carburetion system:

Choke valve

Alternator output:

80 W

Lower unit:

Gear shift positions:

Forward-neutral-reverse

Gear ratio:

2.00 (26/13)

Trim and tilt system:

Manual tilt

Propeller mark:

G

Fuel and oil:

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

90

Fuel tank capacity:

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

Recommended engine oil:

YAMALUBE 2-stroke outboard motor
oil

Recommended engine oil:

TC-W3

Gasoline:oil mixing ratio:

100 : 1

Lubrication system:

Pre-mixed fuel and oil

Recommended gear oil:

YAMALUBE outboard gear oil or Hy­poid gear oil

10

Specifications and requirements

Recommended gear oil grade:

SAE 90 API GL-4

Gear oil quantity:

0.430 L (0.455 US qt, 0.378 Imp.qt)

Noise and vibration level:

Operator sound pressure level (ICOMIA
39/94):

92.2 dB(A)

Vibration on tiller handle (ICOMIA 38/94):

Vibration on tiller handle is under 2.5

2

m/s

EMU33556

Installation requirements

EMU33566

Boat horsepower rating

EWM01561

Overpowering a boat can cause severe
instability.

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

EMU40491

Mounting outboard motor

EWM02501

 Improper mounting of the outboard mo-

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

 Because the outboard motor is very

heavy, special equipment and training
is required to mount it safely.

Your dealer or other person experienced in
proper rigging should mount the outboard
motor using correct equipment and complete

rigging instructions. For further information,
see page 23.

EMU25695

Battery requirements

EMU36293

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.

[EWM01821]

Battery cable

The battery cable size and length are critical.
Consult your Yamaha dealer about the bat­tery cable size and length.

EMU25733

To use the battery

ECM01091

A battery cannot be connected to models
that do not have a rectifier or Rectifier
Regulator.

If you wish to use a battery, your outboard
motor must be equipped with the following
parts.

 Rectifier or Rectifier Regulator
 Lighting coil

If you do not know if your outboard motor is
equipped with these parts, consult your
Yamaha dealer.
Using maintenance-free sealed batteries or
gel cell batteries is not recommended be­cause they may not be compatible with
Yamaha’s charging system for this outboard
motor.
Install an optional Rectifier Regulator or use

11

Specifications and requirements

-

x

123

ZMU07508

ZMU04606

-

x

123

accessories rated to withstand 18 volts or
higher with the above models. Consult your
Yamaha dealer for details on installing an
optional Rectifier Regulator.

EMU34196

Propeller selection

Next to selecting an outboard motor, select­ing the right propeller is one of the most im­portant purchasing decisions a boater can
make. The type, size, and design of your pro­peller have a direct impact on acceleration,
top speed, fuel economy, and even engine
life. Yamaha designs and manufactures pro­pellers for every Yamaha outboard motor
and every application.
Your outboard motor came with a Yamaha
propeller selected to perform well over a
range of applications, but there may be uses
where a different propeller would be more
appropriate.
Your Yamaha dealer can help you select the
right propeller for your boating needs. Select
a propeller that will allow the engine to reach
the middle or upper half of the operating
range at full throttle with the maximum boat­load. Generally, select a larger pitch propel­ler for a smaller operating load and a smaller
pitch propeller for a heavier load. If you carry
loads that vary widely, select the propeller
that lets the engine run in the proper range
for your maximum load but remember that
you may need to reduce your throttle setting
to stay within the recommended engine
speed range when carrying lighter loads.
To check the propeller, see page 51.

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

EMU25771

Start-in-gear protection

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

12

Specifications and requirements

TIP:

E5 E10

EMU25653

Engine oil requirements

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.

EMU48120

Why Yamalube

YAMALUBE oil is a Genuine YAMAHA Part
born of the engineers’ passion and belief that
engine oil is an important liquid engine com­ponent. We form teams of specialists in the
fields of mechanical engineering, chemistry,
electronics and track testing, and have them
develop the engine together with the oil it will
use. Yamalube oils take full advantage of the
base oil’s qualities and blend in the ideal bal­ance of additives to make sure the final oil
clears our performance standards. Thus, Ya­malube mineral, semisynthetic and synthetic
oils have their own distinct characters and
value. Yamaha’s experience gained over
many years of research and development
into oil since the 1960’s helps make Yama­lube the best choice for your Yamaha en­gine.

EMU36361

Fuel requirements

EMU40203

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.

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

90

ECM01982

 Do not use leaded gasoline. Leaded

gasoline can seriously damage the en-

gine.

 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.

13

 This mark identifies the recommended fuel

for this outboard motor as specified by Eu-

ropean regulation (EN228).

 Check that gasoline nozzle has the same

identifier when fueling.

Specifications and requirements

Gasohol

There are two types of gasohol: gasohol con­taining ethanol (E5 and E10) and that con­taining methanol. Ethanol can be used if the
ethanol content does not exceed 10% and
the fuel meets the minimum octane ratings.
E85 is a fuel containing 85% ethanol and
must not be used in your outboard motor. All
ethanol blends containing more than 10%
ethanol can cause fuel system damage or
cause engine starting and running problems.
Yamaha does not recommend gasohol con­taining methanol because it can cause fuel
system damage or engine performance
problems.
It is recommended that you install a water­separating marine fuel filter assembly (10 mi­cron minimum) between your boat’s fuel tank
and outboard motor when using ethanol.
Ethanol is known to allow moisture to be ab­sorbed into boat fuel tanks and systems.
Moisture in the fuel can cause corrosion of
metallic fuel system components, starting
and running complaints and require addition­al fuel system maintenance.

EMU36881

Muddy or acidic water

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

EMU36331

Anti-fouling paint

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

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

EMU40302

Outboard motor disposal

requirements

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

EMU36353

Emergency equipment

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

 A tool kit with assorted screwdrivers, pli-

ers, wrenches (including metric sizes), and

electrical tape.

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

with clip.

 Spare parts, such as an extra set of spark

plugs.
Consult your Yamaha dealer for details.

14

Components

TIP:

21 22

23 24

19

20

18

11

12

13

14

15

16

1

2

9

10

8

17

3
4
5

6

7

EMU46722

Components diagram

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

1. Top cowling

2. Cowling lock lever

3. Anode

4. Anti-cavitation plate

5. Trim tab (anode)

6. Propeller

7. Cooling water inlet

8. Trim rod

9. Clamp bracket

10. Steering friction adjuster

11. Manual starter handle

12. Choke knob

13. Gear shift lever

14. Tiller handle

15. Throttle friction adjuster

15

16. Engine stop button/Engine shut-off switch

17. Clip

18. Clamp screw

19. Tilt lock lever

20. Cooling water pilot hole

21. Fuel tank*

22. Tachometer*

23. Speedometer*

24. Hour meter*

EMU25804

Fuel tank

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

Components

ZMU02284

3

1

4

2

ZMU03032

ZMU03033

3

2

1

R

N

F

EWM00021

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.

1. Fuel joint

2. Fuel gauge

3. Fuel tank cap

4. Air vent screw

EMU25831

Fuel joint

This joint is used to connect the fuel line.

EMU25861

Air vent screw

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

EMU25914

Tiller handle

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

EMU25925

Gear shift lever

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

EMU25842

Fuel gauge

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

EMU25851

Fuel tank cap

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

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

EMU25943

Throttle grip

The throttle grip is on the tiller handle. Turn

16

Components

ZMU03034

ZMU02849

1

ZMU02001

the grip counterclockwise to increase speed
and clockwise to decrease speed.

EMU25963

Throttle indicator

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

1. Throttle indicator

EMU25978

Throttle friction adjuster

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

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

[EWM00033]

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

EMU25996

Engine shut-off cord (lanyard) and
clip

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

tach the engine shut-off cord to a secure
place on your clothing, or your arm or leg
while operating. Do not attach the cord to
clothing that could tear loose. Do not
route the cord where it could become en­tangled, preventing it from functioning.
Avoid accidentally pulling the cord dur­ing normal operation. Loss of engine
power means the loss of most steering
control. Also, without engine power, the
boat could slow rapidly. This could cause

17

people and objects in the boat to be

2

1

3

ZMU02003

ZMU02083

ZMU03036

ZMU03037

thrown forward.

1. Engine shut-off cord (lanyard)

2. Clip

3. Engine shut-off switch

EMU26004

[EWM00123]

Engine stop button

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

Components

EMU26075

Manual starter handle

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

EMU26015

Pull-type choke knob

Pull the choke knob to supply a rich fuel mix­ture to the engine.

EMU26124

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.

18

Components

ZMU03039

ZMU03040

ECM00841

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

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

EWM00041

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

EMU26246

Trim tab with anode

EWM00841

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

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

1

A

B

2

ZMU02822

1. Trim tab

2. Bolt

Bolt tightening torque:

18 N·m (1.8 kgf·m, 13 lb·ft)

EMU26263

Trim rod (tilt pin)

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

EMU30531

Tilt lock mechanism

The tilt lock mechanism is used to prevent

19

Components

ZMU03041

1

ZMU03043

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.

EMU26334

Tilt support bar

The tilt support bar keeps the outboard motor
in the tilted up position.

EMU26374

Cowling lock lever(s) (turn type)

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

1

ZMU02009

1. Cowling lock lever(s)

ECM01661

Do not use the tilt support bar 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.

20

Instruments and indicators

TIP:

ZMU04579

ZMU04650

ZMU04855

EMU26482

Analog tachometer

The gauge shows the engine speed.

This gauge can be set to count the amount of

EMU26592

Analog speedometer

This gauge shows the boat speed in km/h
and mph.

time elapsed either when the main switch is
on or only when the engine is running. For in­structions on how to select the counting
mode, consult your Yamaha dealer.

EMU26632

Hour meter

This gauge shows the number of hours the
engine has been run.

21

EMU26806

ZMU04585

Alert system

ECM00093

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

EMU43754

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 2000–3500 r/min.

Engine control system

 The overheat-alert indicator will light or

blink (if equipped).

 The buzzer will sound (if equipped on the

tiller handle, remote control box, or main

switch panel).
If the alert system has activated, stop the en­gine and check the cooling water inlets:

 Check trim angle to be sure that the cool-

ing water inlet is submerged.

 Check the cooling water inlet for clogging.

22

Installation

ZMU01760

1

ZMU02011

0–25mm
(0–1in)

EMU26903

Installation

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

EWM01591

 Overpowering a boat could cause se-

vere instability. Do not install an out-

board motor with more horsepower

than the maximum rating on the capac-

ity 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 condi-

tions such as poor handling, loss of

control, or fire hazards. For permanent-

ly mounted models, your dealer or oth-

er person experienced in proper rigging

should mount the motor.

EMU33471

Mounting the outboard motor

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

1. Center line (keel line)

EMU26926

Mounting height

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

23

Installation

TIP:

ZMU02012

ZMU02013

ECM01635

 Make sure that the idle hole is high

enough to prevent water from entering

the engine even if the boat is stationary

with the maximum load.

 Incorrect engine height or obstructions

to the smooth flow of water (such as the

design or condition of the boat, or ac-

cessories, such as transom ladders or

depth finder transducers) can create

airborne water spray while the boat is

cruising. If the outboard motor is oper-

ated 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.

 The optimum mounting height of the out-

board motor is affected by the boat and

motor combination and the desired use.

Test runs at different heights can help de-

termine the optimum mounting height.

Consult your Yamaha dealer or boat man-

ufacturer for further information on deter-

mining the proper mounting height.

 For instructions on setting the trim angle of

the outboard motor, see page 36.

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

[EWM00643]

(2) If the restraint cable attachment is

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

EMU26974

Clamping the outboard motor

(1) Place the outboard motor on the tran-

som 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.

(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

24

Installation

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

[EWM00652]

1

1. Bolts

ZMU02637

25

Operation

EMU36382

First-time operation

EMU30175

Breaking in engine

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

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

EMU27061

Gasoline and engine oil mixing chart
(50:1)

1. : Gasoline

2. : Engine oil

ECM00151

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

EMU27075

Procedure for pre-mixed 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-plan-

[ECM00802]

ing 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 the
standard premix ratio of gasoline and oil.
For details on mixing fuel and oil, see
page 29.

EMU36402

Getting to know your boat

All boats have unique handling characteris­tics. Operate cautiously while you learn how
your boat handles under different conditions
and various trim angles (see page 36).

EMU36414

Checks before starting engine

EWM01922

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

ECM00121

Do not start the engine out of water. Over-

26

Operation

ZMU06090

ZMU06082

heating and serious engine damage can
occur.

EMU37142

Fuel level

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

29.

EMU36573

Remove the top cowling

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

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.

EMU36453

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 damage.

EMU37323

Checking the fuel filter

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

EMU36443

Fuel system

EWM00061

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

EWM00911

Leaking fuel can result in fire or explo-

27

EMU36903

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

Operation

ZMU06873

1

2

ZMU06115

the throttle and shift cables.
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 le-

ver should return completely to the idle po-

sition.

 Look for loose or damaged connections of

the throttle and shift cables.

EMU36484

Engine shut-off cord (lanyard)

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

EMU36956

Install top cowling

(1) Be sure that the cowling lock lever is re-

leased.

(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 seat-

ed correctly between the top cowling
and the bottom cowling.

(5) Move the cowling lock lever to lock the

top cowling as shown. NOTICE: If the

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

[ECM01992]

1. Clip

2. Engine shut-off cord (lanyard)

EMU27121

Oil

 Check to be sure you have plenty of oil for

your trip.

EMU27142

Engine

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

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.

28

Operation

ZMU04678

ZMU06621

ZMU02301

EMU27235

Filling fuel and engine oil

EMU2724A

Filling fuel for portable tank

EWM01831

 Gasoline and its vapors are highly flam-

mable and explosive. Always refuel ac-

cording 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 wa-

ter. 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 out-

door area, either securely moored or
trailered.

(5) Do not smoke and keep away from

sparks, flames, static electric discharge,
or other sources of ignition.

(6) If you use a portable container to store

and dispense fuel, use only an approved
GASOLINE container.

(7) Touch the fuel nozzle to the filler open-

ing or funnel to help prevent electrostatic
sparks.

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

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

[EWM02611]

29

Fuel tank capacity:

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

Operation

ZMU02834

100:1

1 L

(0.26 US gal,

0.22 Imp gal)

12 L

(3.2 US gal,

2.6 Imp gal)

14 L

(3.7 US gal,

3.1 Imp gal)

24 L

(6.3 US gal,

5.3 Imp gal)

0.01 L

(0.01 US qt,

0.01 Imp qt)

0.12 L

(0.13 US qt,

0.11 Imp qt)

0.14 L

(0.15 US qt,

0.12 Imp qt)

0.24 L

(0.25 US qt,

0.21 Imp qt)

ZMU04910

2

(9) Tighten the filler cap securely.
(10)Wipe up any spilled gasoline immediate-

ly with dry rags. Dispose of rags properly
according to local laws or regulations.

EMU27407

Gasoline and oil mixing (100:1)

ECM00812

 Avoid using any oil other than the spec-

ified type.

 Use a thoroughly blended fuel-oil mix-

ture.

 If the mixture is not thoroughly mixed,

or if the mixing ratio is incorrect, the

following problems could occur.

 Low oil ratio: Lack of oil could cause

major engine trouble, such as piston

seizure.

 High oil ratio: Too much oil could cause

fouled spark plugs, smoky exhaust,

and heavy carbon deposits.

Gasoline to engine

oil ratio

Break-in period See page 26

After break-in 100:1

1. : Gasoline

2. : Engine oil

If equipped with a portable fuel tank
(1) Pour oil into the portable fuel tank, and

then add gasoline.

111

2

1. Engine oil

2. Gasoline

(2) Replace the fuel tank cap and close

tightly.

30

Operation

TIP:

ZMU02295

ZMU03044

(3) Shake the fuel tank to mix the fuel thor-

oughly.

(4) Make sure that the oil and gasoline are

mixed.
If equipped with a built-in fuel tank
(1) Pour oil into a clean fuel can, and then

add gasoline.
(2) Replace the fuel can cap and close tight-

ly.
(3) Shake the fuel can to mix the fuel thor-

oughly.
(4) Make sure that the oil and gasoline are

mixed.
(5) Pour the gasoline and oil mixture into the

built-in fuel tank.

If using a permanently installed tank, pour
the oil gradually as the gasoline is being add­ed to the tank.

EMU27453

Operating engine

EWM00421

 Before starting the engine, make sure

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

 When the air vent screw is loosened,

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

 This product emits exhaust gases

which contain carbon monoxide, a col­orless, odorless gas which could cause
brain damage or death when inhaled.
Symptoms include nausea, dizziness,

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

EMU2746B

Sending fuel (portable tank)

(1) If there is an air vent screw on the fuel

tank cap, loosen it 2 or 3 turns.

(2) If there is a fuel joint on the motor, align

the fuel joint on the fuel line with the fuel
joint on the motor and firmly connect the
fuel line to the joint while pinching the
joint. Then firmly connect the other end
of the fuel line to the joint on the fuel
tank.

31

TIP:

Wipe up any spilled gasoline immediately

TIP:

ZMU02024

1

ZMU03045

N

with dry rags. Dispose of rags properly ac­cording to local laws or regulations.
(3) Squeeze the primer pump, with the ar-

row pointing up, until you feel it become

firm. During engine operation, place the

tank horizontally, otherwise fuel cannot

be drawn from the fuel tank.

1

Operation

EMU2750A

Manual start models (tiller control)

EWM01842

 Failure to attach the engine shut-off

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

 Avoid accidentally pulling the cord dur-

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

(1) Place the gear shift lever in neutral.

1. Arrow

EMU27495

Starting engine

EWM01601

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

The start-in-gear protection device prevents
the engine from starting except when in neu­tral.
(2) Attach the engine shut-off cord to a se-

cure 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.

32

Operation

TIP:

TIP:

ZMU02026

ZMU02954

ZMU03047

ZMU02030

(3) Place the throttle grip in the “ ”

(start) position.

(4) Pull out / turn the choke knob fully. After

the engine starts, replace / return the

knob to the home position.

(5) Pull the manual starter handle slowly un-

til 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.

 It is not necessary to use the choke when

starting a warm engine.

 If the choke knob is left in the “ ”

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

33

 When the engine is cold, it needs to be

warmed up. For further information, see
page 34.

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

repeat the procedure. If the engine fails to
start after 4 or 5 tries, open the throttle a
small amount (between 1/8 and 1/4) and
try again. Also if the engine is warm and
fails to start, open the throttle a same
amount and try to start the engine again. If
the engine still fails to start, see page 56.

Operation

ZMU03054

EMU36511

Checks after starting engine

EMU36524

Cooling water

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

ECM01811

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

so will shorten engine life.

[ECM04550] Gradual-

ly return the choke knob to its home position
as the engine warms up.

EMU36532

Checks after engine warm up

EMU36542

Shifting

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

EMU36981

Stop switches

 Turn the main switch to “ ”, or press the

engine stop button and make sure the en­gine stops.

 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.

EMU34531

Shifting

EWM00181

EMU27671

Warming up engine

EMU27685

Choke start models

After starting the engine, allow it to idle for 3
minutes to warm up. NOTICE: Failure to do

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

ECM01611

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

34

Operation

ZMU03060

ZMU05737

R

N

F

ZMU02030

ZMU03064

N

To shift out of neutral
(1) Pull the neutral interlock trigger up (if

equipped).
(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 re-

mote control models]. Be sure to check

that the tilt lock lever is in the lock/down

position (if equipped) before operating in

reverse.

(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.

To shift from in gear (forward/reverse) to
neutral
(1) Close the throttle so that the engine

slows to idle speed.

35

EMU31743

Stopping boat

EWM01511

 Do not use the reverse function to slow

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

 Do not shift into reverse while traveling

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

The boat is not equipped with a separate

Operation

TIP:

ZMU02083

ZMU03061

ZMU02301

braking system. Water resistance stops it af­ter the throttle lever is moved back to idle.
The stopping distance varies depending on
gross weight, water surface conditions, and
wind direction.

EMU27822

Stopping engine

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

EMU2784A

Procedure

(1) Push and hold the engine stop button or

turn the main switch to “ ” (off).

(2) After stopping the engine, disconnect

the fuel line if there is a fuel joint on the

outboard motor.

tank cap (if equipped).

(4) Remove the key if the boat will be left un-

attended.

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).

EMU27865

Trimming outboard motor

EWM00741

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

(3) Tighten the air vent screw on the fuel

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.

36

Operation

TIP:

1

ZMU03062

ZMU03063

1

1. Trim operating angle

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.

EWM00401

EMU27873

Adjusting trim angle for manual tilt
models

There are 4 or 5 holes provided in the clamp
bracket to adjust the outboard motor trim an­gle.
(1) Stop the engine.
(2) Tilt the outboard motor up, and then re-

move the trim rod from the clamp brack-

et.

37

 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.

EMU27913

Adjusting boat trim

When the boat is on plane, a bow-up attitude
results in less drag, greater stability and effi­ciency. This is generally when the keel line of

Operation

TIP:

the boat is up about 3 to 5 degrees. With the
bow up, the boat may have a greater tenden­cy to steer to one side or the other. Compen­sate for this as you steer. When the bow of
the boat is down, it is easier to accelerate
from a standing start onto plane.

Bow Up

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

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.

EMU27936

Tilting up and down

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

EWM00223

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

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.

EWM00251

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

38

Operation

ZMU03064

N

ZMU03065

ZMU03066

ZMU04851

few minutes. Otherwise fuel may leak.

ECM00242

 Before tilting the outboard motor, stop

the engine by following the procedure
on page 36. Never tilt the outboard mo­tor while the engine is running. Severe
damage from overheating can result.

 Do not tilt up the engine by pushing the

tiller handle (if equipped) because this
could break the handle.

EMU2797C

Procedure for tilting up (manual tilt
models)

(1) Place the remote control lever / gear

shift lever in neutral.

the release/up position.

(4) Pull up the shallow water lever (if

equipped).

(5) Hold the rear of the top cowling with one

hand and tilt the engine up fully.

(6) Push the tilt support knob into the clamp

bracket. Or the tilt support bar will turn to
the lock position automatically.

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 42.

[ECM01642]

(2) Disconnect the fuel line from the out-

board motor.

(3) Place the tilt lock lever (if equipped) in

39

EMU30632

Procedure for tilting down (manual
tilt models)

(1) Slightly tilt the outboard motor up.

Operation

ZMU04851

ZMU03069

ZMU03070

N

ZMU03071

(2) If equipped with a tilt support bar: Slight-

ly tilt up the engine until the tilt support

bar is automatically released.

(3) If equipped with a tilt support knob: Pull

it out, then slowly tilt the engine down.

EMU28063

Shallow water

EMU28074

Cruising in shallow water (manual tilt
models)

EWM01782

 Run the boat at the lowest possible

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

 Use extra care when operating in re-

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

ECM00261

above the surface of the water when set­ting up for and cruising in shallow water.
Otherwise severe damage from overheat­ing can result.

EMU28126

Procedure

(1) Place the remote control lever / gear

shift lever in neutral.

(2) Place the tilt lock lever in the release/up

position.

Do not tilt the outboard motor up so that
the cooling water inlet on the lower unit is

(3) Slightly tilt the outboard motor up. The

40

Operation

ZMU04851

ZMU03072

tilt support bar will lock automatically,

supporting the outboard motor in a par-

tially raised position. This outboard mo-

tor has 2 positions for shallow water

cruising.

(4) To return the outboard motor to the nor-

mal running position, place the remote

control lever / gear shift lever in neutral.
(5) Place the tilt lock lever in the lock/down

position, then slightly tilt the outboard

motor up until the tilt support bar auto-

matically returns to the free position.

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 14) 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.

(6) Slowly lower the outboard motor to the

normal position.

EMU28196

Cruising in other conditions

Cruising in salt water

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

41

Maintenance

ZMU03089

EMU2822B

Transporting and storing

outboard motor

EWM02621

 USE CARE when transporting fuel tank,

whether in a boat or car.

 DO NOT fill fuel container to maximum

capacity. Gasoline will expand consid­erably as it warms up and can build up
pressure in the fuel container. This can
cause fuel leakage and a potential fire
hazard.

 Leaking fuel is a fire hazard. When

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

 Never get under the outboard motor

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

 Do not use the tilt support lever or knob

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

ECM02441

 Disconnect the fuel line from the outboard

motor.

 Tighten the fuel tank cap and its air vent

screw.

 When the outboard motor is tilted pro-

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

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

EMU28237

Clamp screw mounting models

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

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.

42

Maintenance

TIP:

ZMU02050

ZMU02051

1

2

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

EMU30273

Storing outboard motor

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

ECM01412

EMU28306

Procedure

EMU28336

Flushing in a test tank

ECM00302

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

(1) Wash the outboard motor body using

fresh water. NOTICE: Do not spray wa-

ter into the air intake.

ther information, see page 44.

(2) Disconnect the fuel line from the motor

or shut off the fuel cock, if equipped.

(3) Remove the engine top cowling and si-

lencer cover. Remove the propeller.

(4) Install the outboard motor on the test

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

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

[ECM00292]

[ECM01841] For fur-

 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.

43

1. Water surface

2. Lowest water level

(5) Cooling system flushing is essential to

prevent the cooling system from clog-

Maintenance

TIP:

TIP:

1

ZMU07861

ging up with salt, sand, or dirt. In addi­tion, fogging/lubricating of the engine is
mandatory to prevent excessive engine
damage due to rust. Perform the flush­ing and fogging at the same time.

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

[EWM00092]

(6) Run the engine at a fast idle for a few

minutes in neutral position.

(7) Just prior to turning off the engine, quick-

ly 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
stops.

(11)Drain the cooling water completely out of

the motor. Clean the body thoroughly.

(12)If the “Fogging Oil” is not available, re-

move 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.

EMU41072

Lubrication

(1) Change the gear oil. For instructions,

see page 53. Check the gear oil for the
presence of water that indicates a leaky
seal. Seal replacement should be per­formed by an authorized Yamaha dealer
prior to use.

(2) Lubricate all grease fittings. For further

details, see page 49.

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

EMU44342

Cleaning the outboard motor

When cleaning the outboard motor, the top
cowling must be installed.
(1) Wash the exterior of the outboard motor

using fresh water. NOTICE: Do not

spray water into the air intake.

1. Air intake

[ECM01841]

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

(2) Drain the cooling water completely out of

the outboard motor. Clean the body thor­oughly.

44

Maintenance

EMU28463

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. Touch-up paint is
available from your Yamaha dealer.

EMU37125

Periodic maintenance

EWM02011

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.

 Allow the engine to cool before han-

dling hot parts or fluids.

 Always completely reassemble the mo-

tor before operation.

dealer.

EMU34152

Severe operating conditions

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

 Operating continuously at or near maxi-

mum engine speed (rpm) for many hours

 Operating continuously at a low engine

speed (rpm) for many hours

 Operating without sufficient time for engine

to warm up and cool down

 Frequent quick acceleration and decelera-

tion

 Frequent shifting
 Frequently starting and stopping the en-

gine(s)

 Operation that fluctuates often between

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

EMU28512

Replacement parts

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

45

Maintenance

TIP:

EMU34449

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 Inspection

Fuel line

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 or replace­ment as necessary

20 hours

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

46

Maintenance

Item Actions

Fuel pump

Fuel/engine oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Impeller/water pump
housing

Impeller/water pump
housing

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

Main switch/stop
switch/choke switch

Wire harness connec­tions/wire coupler con­nections

(Yamaha) Meter/gauge Inspection

Fuel tank (Yamaha por­table tank)

Inspection or replace­ment as necessary

Inspection or replace­ment as necessary

Replacement

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

Inspection or replace­ment as necessary

Inspection or replace­ment as necessary

Inspection and clean­ing as necessary

Initial Every

20 hours

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

47

EMU34452

Maintenance chart 2

Maintenance

Item Actions

Exhaust guide/exhaust
manifold

Every

1000 hours

Inspection or replace­ment as necessary

48

Maintenance

ZMU04865

EMU28945

Greasing

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

EMU44493

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

49

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

Maintenance

TIP:

11

22

33

ZMU06082

to slowly break down and erode.
(1) Remove the spark plug caps from the

spark plugs.

(2) Remove the spark plug. If electrode ero-

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

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

[EWM00562]

Standard spark plug:

BR7HS

(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.

the correct torque.

Spark plug torque:

25 N·m (2.5 kgf·m, 18 lb·ft)

If a torque-wrench is not available when you
are reinstalling a spark plug, a good estimate
of the correct torque is 1/12 turn past finger­tight. When you are installing a new spark
plug, a good estimate of the correct torque is
1/2 to 2/3 turn past finger-tight.

EMU37451

Checking fuel filter

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

1. Spark plug gap

2. Spark plug part number

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

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

(4) When fitting the plug, wipe off any dirt

from the threads, and then screw it in to

EMU29045

Inspecting idle speed

EWM00452

 Do not touch or remove electrical parts

when starting or during operation.

 Keep hands, hair, and clothes away

from the flywheel and other rotating
parts while the engine is running.

ECM00491

This procedure must be performed while

50

Maintenance

ZMU03078

ZMU01897

the outboard motor is in the water. A
flushing attachment or test tank can be
used.

If the boat is not equipped with a tachometer
for the outboard motor, use a diagnostic ta­chometer for this procedure. Results may
vary depending on whether testing is con­ducted with the flushing attachment, in a test
tank, or with the outboard motor in the water.
(1) Start the engine and allow it to warm up

fully in neutral until it is running smooth­ly.

(2) Once the engine has warmed up, verify

whether the idle speed is set to specifi­cation. For idle speed specifications, see
page 10. If you have difficulty verifying
the idle speed, or the idle speed requires
adjustment, consult a Yamaha dealer or
other qualified mechanic.

EMU29116

Inspecting wiring and connectors

 Inspect that each connector is engaged

securely.

 Inspect that each ground lead is properly

secured.

EMU32113

Checking propeller

EWM01882

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

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

51

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-

111

22

33

44

55

66

age.

EMU30663

Removing propeller

EMU29198

Spline models

(1) Straighten the cotter pin and pull it out

using a pair of pliers.

(2) Remove the propeller nut, washer, and

spacer (if equipped). WARNING! Do

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

[EWM01891]

Maintenance

equipped), and thrust washer.

EMU30673

Installing propeller

EMU46121

Spline models

ECM00502

Make sure to use a new cotter pin and
bend the ends over securely. Otherwise,
the propeller could come off during oper­ation and be lost.

(1) Apply Yamalube Marine Grease or a

corrosion resistant grease to the propel­ler shaft.

(2) Install the spacer (if equipped), thrust

washer, washer (if equipped), and pro­peller on the propeller shaft. NOTICE:

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

(3) Install the spacer (if equipped) and the

washer. Tighten the propeller nut to the
specified torque.

[ECM01882]

1. Cotter pin

2. Propeller nut

3. Washer

4. Spacer

5. Propeller

6. Thrust washer

(3) Remove the propeller, washer (if

1. Cotter pin

2. Propeller nut

1

2

3

4

6

5

ZMU08159

52

Maintenance

TIP:

TIP:

ZMU02063

3. Washer

4. Spacer

5. Propeller

6. Thrust washer

Propeller nut tightening torque:

39 N·m (3.9 kgf·m, 29 lb·ft)

(4) Align the propeller nut slot with the pro-

peller shaft hole. Insert a new cotter pin
in the hole and bend the cotter pin ends.

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

[ECM01892]

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

EMU47070

Changing gear oil

EWM00801

 Be sure the outboard motor is securely

fastened to the transom or a stable

stand. You could be severely injured if

the outboard motor falls on you.

 Never get under the lower unit while it

is tilted, even when the tilt support lever

or knob is locked. Severe injury could

occur if the outboard motor accidental-

ly falls.

(1) Tilt the outboard motor so that the gear

oil drain screw is at the lowest point pos­sible.

(2) Place a suitable container under the

gear case.

(3) Remove the gear oil drain screw and

gasket. NOTICE: If there is an exces-

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

[ECM01901]

2

1

ZMU03079

1. Gear oil drain screw

2. Oil level plug

 If a magnetic gear oil drain screw is

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

 Always use new gaskets. Do not reuse the

removed gaskets.

(4) Remove the oil level plug and gasket to

allow the oil to drain completely.

NOTICE: Check the used gear oil after
it has been drained. If the gear oil is
milky or contains water or a large
amount of metal particles, the gear
case may be damaged. Have a
Yamaha dealer check and repair the
outboard motor.

[ECM00714]

53

TIP:

For disposal of used oil, consult your

TIP:

TIP:

TIP:

ZMU03090

ZMU02820

Yamaha dealer.
(5) Put the outboard motor in a vertical posi-

tion. Using a flexible or pressurized fill­ing device, inject the gear oil into the
gear oil drain screw hole.

Recommended gear oil:

YAMALUBE outboard gear oil or Hyp­oid gear oil

Recommended gear oil grade:

SAE 90 API GL-4

Gear oil quantity:

0.430 L (0.455 US qt, 0.378 Imp.qt)

Maintenance

lation.

Tightening torque:

7 N·m (0.7 kgf·m, 5.2 lb·ft)

EMU29318

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.

ECM00721

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

(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.

Apply a light coat of gear oil to the oil level
plug thread and gasket before installation.

Tightening torque:

7 N·m (0.7 kgf·m, 5.2 lb·ft)

(7) Put a new gasket on the gear oil drain

screw. Insert and tighten the gear oil
drain screw.

Apply a light coat of gear oil to the gear oil
drain screw thread and gasket before instal-

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.

EMU29335

Connecting the battery

EWM00573

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

54

Maintenance

ZMU01811

1

2

3

tery in the holder.

ECM01125

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

(1) Make sure the main switch (on applica-

ble models) is “ ” (off) before working
on the battery.

(2) Connect the red battery cable to the

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

1. Red cable

2. Black cable

3. Battery

bles first to avoid a short circuit and
damage to the electrical system.

[ECM01941]

(3) Disconnect the positive cable(s) and re-

move the battery from the boat.

(4) Clean, maintain, and store the battery

according to the manufacturer’s instruc­tions.

(3) The electrical contacts of the battery and

cables must be clean and properly con­nected, or the battery will not start the
engine.

EMU29372

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 (-) ca-

55

[ECM01931]

Trouble Recovery

EMU29428

Troubleshooting

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

Starter will not operate.

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

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

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

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

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

Engine will not start (starter operates).

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

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

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

Q. Is starting procedure incorrect?
A. See page 32.

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

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

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

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

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

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

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

Engine idles irregularly or stalls.

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

56

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?

57

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.

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.

58

Trouble Recovery

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.

EMU29435

Temporary action in

emergency

EMU29442

Impact damage

EWM00871

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

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

(1) Stop the engine immediately.
(2) Check the control system and all compo-

nents 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 out-

board motor before operating it again.

59

EMU29534

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.

Trouble Recovery

ZMU03082

1

ZMU03083

EWM01023

 Use this procedure only in an emergen-

cy to return to the nearest port for re-

pairs.

 When the emergency starter rope is

used to start the engine, the start-in-

gear protection device does not oper-

ate. 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, pre-

venting 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-

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 elec-

trical components when starting or op­erating the motor. You could get an
electrical shock.

EMU29563

Emergency starting engine

(1) Remove the top cowling.
(2) Remove the start-in-gear protection ca-

ble from the starter, if equipped.

1. Start-in-gear protection cable

(3) Remove the starter/flywheel cover after

removing the bolt(s).

(4) Prepare the engine for starting. For fur-

ther information, see page 32. Be sure
the engine is in neutral and that the clip
is attached to the engine shut-off switch.
The main switch must be “ ” (on), if
equipped.

60

Trouble Recovery

ZMU02026

ZMU03084

ZMU03085

(5) If equipped the choke knob, pull out it

when the engine is cold. After the engine
starts, gradually return the choke knob
to its home position as the engine warms
up.

(6) Insert the knotted end of the emergency

starter rope into the notch in the flywheel
rotor and wind the rope several turns
around the flywheel clockwise.

(7) Give a strong pull straight out to crank

and start the engine. Repeat if neces­sary.

EMU33502

Treatment of submerged motor

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

outboard motor until it has been com­pletely inspected.

[ECM00402]

61

INDEX

A

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

Alert system .......................................... 22

Analog speedometer............................. 21

Analog tachometer................................ 21

Anode(s), inspecting and replacing ...... 54

Anti-fouling paint ................................... 14

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

B

Battery, connecting ............................... 54

Battery, disconnecting .......................... 55

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

Boat horsepower rating......................... 11

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

Boating safety publications ..................... 4

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

C

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

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

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

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

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

Choke knob........................................... 18

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

Cleaning the outboard motor ................ 44

Collisions with floating or submerged

objects .................................................. 3

Components diagram ........................... 15

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

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

Cowling lock lever................................. 20

Cruising in salt water or other

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

Engine oil requirements ........................ 13

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

Engine shut-off cord (lanyard) and

clip ......................................................17

Engine stop button................................ 18

F

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

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

Flushing in a test tank........................... 43

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

Fuel filter, checking......................... 27, 50

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

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

Fuel requirements................................. 13

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

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

G

Gasoline............................................ 1, 13

Gasoline and oil mixing......................... 30

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

Gear oil, changing................................. 53

Gear shift lever ..................................... 16

Greasing ...............................................49

H

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

Hour meter............................................ 21

I

Identification numbers record ................. 5

Idle speed, inspecting ........................... 50

Impact damage ..................................... 59

Installation requirements....................... 11

E

EC Declaration of Conformity (DoC)....... 5

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

Emergency equipment.......................... 14

Emergency starting engine ................... 60

Emergency, temporary action in ........... 59

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

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

L

Laws and regulations.............................. 4

Lubrication ............................................44

M

Maintenance chart 1 .............................46

Maintenance chart 2 .............................48

Manual starter handle ........................... 18

62

INDEX

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

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

Mounting outboard motor...................... 11

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

Muddy or acidic water........................... 14

O

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

Outboard motor disposal

requirements ...................................... 14

Outboard motor (painted surface),

checking ............................................. 45

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

Outboard motor serial number................ 5

Overheat alert ....................................... 22

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

P

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

Passenger training.................................. 4

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

Periodic maintenance ........................... 45

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

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

Propeller, checking ............................... 51

Propeller, installing ............................... 52

Propeller, removing............................... 52

Propeller selection ................................ 12

R

Read manuals and labels ....................... 7

Replacement parts................................ 45

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

S

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

Severe operating conditions ................. 45

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

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

Shifting (checks after engine warm

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

Spark plug, cleaning and adjusting....... 49

Specifications........................................ 10

Starter will not operate.......................... 59

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

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

Steering friction adjuster ....................... 18

Stopping boat........................................ 35

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

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

Storing outboard motor ......................... 43

Submerged outboard motor.................. 61

T

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

Throttle grip........................................... 16

Throttle indicator ................................... 17

Tiller handle ..........................................16

Tilting up and down............................... 38

Tilt lock mechanism ..............................19

Tilt support bar...................................... 20

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

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

To use the battery................................. 11

Transporting and storing outboard

motor .................................................. 42

Trimming outboard motor ..................... 36

Trim rod (tilt pin).................................... 19

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

Troubleshooting .................................... 56

W

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

Warning labels ........................................ 7

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

Wiring and connectors, inspecting........ 51

Y

Yamalube.............................................. 13

63

Printed in Japan
December 2019–0.1  1 !