Yamaha 5A, 3A, 2A User Manual

OWNER’S MANUAL

2A
3A
5A

U.S.A.Edition

LIT-18626-04-51

EMU01449

TO THE OWNER

Thank you for choosing a Yamaha out­board motor. This Owner’s manual con­tains information needed for proper oper­ation, maintenance and care. A thorough
understanding of these simple instruc­tions will help you obtain maximum
enjoyment from your new Yamaha. If you
have any question about the operation or
maintenance of your outboard motor,
please consult a Yamaha dealer.

In this Owner’s Manual particularly
important information is distinguished in
the following ways.

The Safety Alert Symbol means
ATTENTION! BECOME ALERT!

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YOUR SAFETY IS INVOLVED!

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

NOTE:

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

* Yamaha continually seeks advance-

ments in product design and quality.
Therefore, while this manual contains
the most current product information
available at the time of printing, there
may be minor discrepancies between
your machine and this manual. If there
is any question concerning this manual,
please consult your Yamaha dealer.

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

EMU01446

2A/3A/5A

OWNER'S MANUAL

©2001 by Yamaha Motor Corporation, USA

1st Edition, March 2001

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in Japan

P/N LIT-18626-04-51

NOTE:

The 2MH, 3MH, 5MH and their standard
accessories are used as a base for the
explanations and illustrations in this man­ual. Therefore, some items may not apply
to every model.

EMA20010

CONTENTS

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GENERAL INFORMATION

BASIC COMPONENTS

OPERATION

MAINTENANCE

1

2

3

4

TROUBLE RECOVERY

INDEX

READ THIS OWNER’S MANUAL CAREFULLY

BEFORE OPERATING YOUR OUTBOARD MOTOR.

5

6

EMB00010

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Chapter 1

GENERAL

INFORMATION

IDENTIFICATION NUMBERS

RECORD..................................................1-1

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

EMISSION CONTROL INFORMATION .1-2

SAFETY INFORMATION ........................1-3

IMPORTANT LABELS ............................1-5

BASIC BOATING RULES .......................1-6

FUELING INSTRUCTIONS...................1-10

Gasoline ............................................1-11

Engine oil ..........................................1-11

PROPELLER SELECTION .....................1-12

1

2

3

4

START-IN-GEAR PROTECTION...........1-13

5

6

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401011

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EMB10010

IDENTIFICATION NUMBERS

RECORD

OUTBOARD MOTOR SERIAL NUMBER

YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D’ORIGINE JAPON

The outboard motor serial number is
stamped on the label attached to the port
side of the clamp-bracket. (2-hp model:
attached the upper part of the swivel
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
2 (2-hp model: outboard motor serial number)

1-1

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EMISSION CONTROL INFORMATION

ENGINE FAMILY :

THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.
FELs :
SPARK PLUG :

IDLE SPEED :

rpm IN NEUTRAL

SPARK PLUG GAP (mm) :

g/kw-hr

Manufactured:

2

EMU01385

EMISSION CONTROL

INFORMATION

EMU01386

NORTH AMERICAN MODELS

This engine conforms to U.S. Environ­mental Protection Agency (EPA) regula­tions for marine SI engines. See the label
affixed to your engine for details.

3

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Approval label of Emission control
certificate

This label is attached to the bottom cowl­ing.

1 Emission control information label

Existing Technology ; N/A

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Manufactured date label

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

2 Manufactured date label

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EMU00917

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8 Before mounting or operating the out-

board motor, read this entire manual.
Reading it should give you an under­standing of the motor and its operation.

8 Before operating the boat, read any

owner’s or operator’s manuals supplied
with it and all labels. Be sure you under­stand each item before operating.

8 Do not overpower the boat with this

outboard motor. Overpowering the
boat could result in loss of control. The
rated power of the outboard should be
equal to or less than the rated horse­power capacity of the boat. If the rated
horsepower capacity of the boat is
unknown, consult the dealer or boat
manufacturer.

8 Do not modify the outboard. Modifica-

tions could make the motor unfit or
unsafe to use.

8 Never operate after drinking alcohol or

taking drugs. About 50% of all boating
fatalities involve intoxication.

8 Have an approved personal flotation

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

8 Gasoline is highly flammable, and its

vapors are flammable and explosive.
Handle and store gasoline carefully.
Make sure there are no gas fumes or
leaking fuel before starting the engine.

SAFETY

INFORMATION

8 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.

8 Check throttle, shift, and steering for

proper operation before starting the
engine.

8 Attach the engine stop switch lanyard

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

8 Know the marine laws and regulations

where you will be boating - and obey
them. Refer to “RULES OF THE ROAD”
section for basic boating rules.

8 Stay informed about the weather.

Check weather forecasts before boat­ing. Avoid boating in hazardous weath­er.

8 Tell someone where you are going:

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

8 Use common sense and good judg-

ment when boating. Know your abili­ties, and be sure you understand how
your boat handles under the different
boating conditions you may encounter.
Operate within your limits, and the lim­its of your boat. Always operate at safe
speeds, and keep a careful watch for
obstacles and other traffic.

8 Always watch carefully for swimmers

during the engine operation.

8 Stay away from swimming areas.

1-3

8 When a swimmer is in the water near

you shift into neutral and shut off the
engine.

8 Be informed about boating safety.

Additional publications and informa­tion can be obtained from many orga­nizations, including the following:

United States Coast Guard

Consumer Affairs Staff (G-BC)
Office of Boating, Public, and Consumer
Affairs
U.S. Coast Guard Headquarters
Washington, D.C. 20593-0001
Boating Safety Hotline: [phone]

National Marine Manufacturers
Association (NMMA)

401 N. Michigan Ave.
Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave.
Chicago, Il 60601

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202063*

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WARNING

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

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

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

6A1-83 625-4 1

WARNING

LEAKING FUEL COULD CAUSE A FIRE.
Before tilting up the engine or laying it on its side:

●Turn the fuel cock to the "closed" position.

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

6A1-24 15A-41

WARNING

This engine is equipped with a neutral starting device.
The engine will not start unless the shift control is
in neutral position.

6E0-83 627-4 1

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EMB30010

IMPORTANT LABELS

WARNING LABELS

1

202055*

2

202056*

3

1-5

EMB40010

BASIC BOATING RULES

(Rules of the road)

Just as there are rules which apply
when you are driving on streets and
high ways, there are waterway rules
which apply when you are driving your
boat. These rules are used international­ly, and are also enforced by the United
States Coast Guard and local agencies.
You should be aware of these rules, and
follow them whenever you encounter
another vessel on the water.

Several sets of rules prevail according to
geographic location, but are all basically
the same as the International Rules of
the Road. The rules presented here in
your Owner’s Manual are condensed,
and have been provided for your conve­nience only. Consult your local U.S.
Coast Guard Auxiliary or Department of
Motor Vehicles for a complete set of
rules governing the waters in which you
will be using your boat.

STEERING AND SAILING RULES
AND SOUND SIGNALS

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

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Stand-on Vessel

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

Give-way Vessel

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

“The general prudential rule”

This rule is called Rule 2 in the Inter­national Rules and says,

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

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

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102045

102046

RULES WHEN ENCOUNTERING
VESSELS

There are three main situations which
you may encounter with other vessels
which could lead to a collision unless
the Steering Rules are followed:

Meeting

(you are approaching another vessel
head-on)

Crossing

(you are travelling across the other
vessel’s path)

Overtaking

(you are passing or being passed by
another vessel)

In the following illustration, your boat is
in the center. You should give the right­of-way to any vessels shown in white
area (you are the Give-Way vessel). Any
vessels in the shaded area must yield to
you (they are the Give-Way vessels).
Both you and the meeting vessel must
alter course to avoid each other.

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

102044

Crossing

When two power driven vessels are
crossing each other’s path close enough
to run the risk of collision, the vessel
which has the other on the starboard
(right) side must keep out of the way of
the other. If the other vessel is on your
right, you must keep out of its way; you
are the Give-Way vessel. If the other
vessel is on your port (left) side, remem­ber that you should maintain course and
direction, provided the other vessel
gives you the right-of-way as it should.

Meeting

If you are meeting another power vessel
head on, and are close enough to run
the risk of collision, neither of you has
the right-of-way! Both of you should
alter course to avoid an accident. You

Overtaking

If you are passing another vessel, you
are the “Give-Way” vessel. This means
that the other vessel is expected to

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maintain its course and speed. You must
stay out of its way until you are clear of
it. Likewise, if another vessel is passing
you, you should maintain your speed
and direction so that the other vessel
can steer itself around you.

OTHER SPECIAL SITUATIONS

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

Narrow Channels and Bends

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

Fishing Vessel Right-of-way

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

Sailing Vessel Right-of-way

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

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

2. Sailing vessels should keep clear of
any fishing vessel.

3. In a narrow channel, a sailing vessel
should not hamper the safe passage
of a power-driven vessel which can
navigate only in such a channel.

Reading Buoys and Other Markers

The waters of the United states are
marked for safe navigation by the lateral
system of buoyage. Simply put, buoys
and markers have an arrangement of
shapes, colors, numbers and lights to
show which side of the buoy a boater
should pass on when navigating in a
particular direction. The markings on
these buoys are oriented from the per­spective of being entered from seaward
(the boater is going towards the port).
This means that red buoys are passed
on the starboard (right) side when pro­ceeding from open water into port, and
black buoys are to port (left) side. When
navigating out of port, your position
with respect to the buoys should be
reversed; red buoys should be to port
and black buoys to starboard.

Many bodies of water used by boaters
are entirely within the boundaries of a
particular state. The Uniform State
Waterway Marking System has been
devised for these waters. This system
uses buoys and signs with distinctive
shapes and colors to show regulatory or
advisory information. These markers are
white with black letters and orange
boarders. They signify speed zones,
restricted areas, danger areas, and gen­eral information.

1-8

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11

A

1

11

Proceeding toward head

of navigation from seaward

CAN BUOY

Odd number. Leave to port.

OR

SECONDARY CHANNEL BUOYS

STARTS NEW NUMBERING SYSTEM

old new

C " 1

"

NUN BUOY

Even number. Leave to starboard

N

"

2

"

No change

BUOY

COLOR CODE

BLACK

RED

GREEN

"

A

"

"

2

"

"

1

"

"

3

"

"

4

"

"

5

"

"

7

"

N

"

2

"

"

6

"

C

"

1

"

RB

"

L

"

RG

"

L

"

or

SECONDARY CHANNEL

MAIN CHANNEL

old

new

22

22

22

AA

LL

LL

Odd number. increasing toward head of naviga-

MAIN CHANNEL BUOYS

"

1

" "

3

" "

5

" "

7

"

tion.Leave to port (left) proceeding upstream.

LIGHTED BUOY (Port Hand)`

White Light

Green Light

old

new

old

new

old

new

LIGHTED BUOY (Starboard Hand)`

"

2

" "

4

" "

6

"

Even number,increasing toward head of naviga­tion. Leave to starboard (right) proceeding up­stream.

White Light Red Light

"

A

"

LIGHTED SAFE WATER BUOY

No number. Marks midchannel, pass on either
side. Letter has no lateral significance, used for

No nu mbe r . Topm ost band red

-

prefe rred

Top Mark
White Light

White Light

OR

OR

LIGHTED PREFERRED CHANNEL TO

RB

"

L

"

RG

"

L

"

PORT BUOY

identification and location purposes.

channel is to le ft of buoy . Let ter has no latera l
significance, used for identification and location
purposes.

Red Light

Red or
White Light

OR

102052

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

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EMU00016

FUELING INSTRUCTIONS

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GASOLINE AND ITS VAPORS ARE HIGH­LY FLAMMABLE AND EXPLOSIVE!
8 Do not smoke when refueling, and

keep away from sparks, flames, or
other sources of ignition.

8 Stop engine before refueling.
8 Refuel in a well-ventilated area. Refuel

portable fuel tanks off the boat.

8 Take care not to spill gasoline. If gaso-

line spills, wipe it up immediately with
dry rags.

8 Do not overfill the fuel tank.
8 Tighten the filler cap securely after

refueling.

8 If you should swallow some gasoline

inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.

8 If any gasoline spills onto your skin,

immediately wash with soap and
water. Change clothing if gasoline
spills on it.

8 Touch the fuel nozzle to the filler open-

ing or funnel to help prevent electro­static sparks.

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

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EMU00018

GASOLINE (PETROL)

Recommended gasoline:

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

If knocking or pinging occurs, use a dif­ferent brand of gasoline or premium
unleaded fuel. If unleaded gasoline is not
available, then leaded regular gasoline
can be used.

EMU00027

Gasohol

There are two types of gasohol: gasohol
containing ethanol and that containing
methanol. Gasohol containing ethanol
can be used if ethanol content does not
exceed 10% and the fuel meets minimum
octane ratings. Gasohol containing
methanol is not recommended by Yama­ha because it can cause fuel system dam­age or engine performance problems.

EMU00858

ENGINE OIL

Recommended engine oil:

YAMALUBE 2 STROKE OUTBOARD
OIL

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

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EMU01395

PROPELLER SELECTION

The performance of your outboard motor
will be critically affected by your choice
of propeller, as an incorrect choice could
adversely affect performance and could
also seriously damage the motor. Engine
speed depends on the propeller size and
boat load. If engine speed is too high or
too low for good engine performance,
this will have an adverse effect on the
engine.

Yamaha outboard motors are fitted with
propellers chosen to perform well over a
range of applications, but there may be
uses where a propeller with a different
pitch would be more appropriate. For a
greater operating load, a smaller-pitch
propeller is more suitable as it enables
the correct engine speed to be main­tained. Conversely, a larger-pitch pro­peller is more suitable for a smaller oper­ating load.

Yamaha dealers stock a range of pro­pellers, and can advise you and install a
propeller on your outboard that is best
suited to your application.

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602024

7-1/4 x4 -A

1

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2

3/5

7-1/4 x7-1/4-BA

2 3

1

602025

NOTE:

At full throttle and under a maximum
boat load, the engine’s rpm should be
within the upper half of the full throttle
operating range, as listed in “SPECIFICA­TIONS” on page 4-1. Select a propeller
which fulfills this requirement.
If operating under conditions which allow
the engine’s rpm to rise above the maxi­mum recommended range (such as light
boat loads), reduce the throttle setting to
maintain the rpm in the proper operating
range.

1 Propeller diameter (in inches)
2 Propeller pitch (in inches)
3 Type of propeller (propeller mark)

Refer to the section “CHECKING PRO­PELLER” for instructions on propeller
removal and installation.

EMU01209

START-IN-GEAR PROTECTION

5

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 Neutral.
Always select Neutral before starting the
engine.

1-13

EMC00010

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Chapter 2

BASIC COMPONENTS

MAIN COMPONENTS............................2-1

OPERATIONS OF CONTROLS AND

OTHER FUNCTIONS ..............................2-4

Fuel tank..............................................2-4

Gear shift lever ...................................2-5

Engine stop button.............................2-6

Throttle control...................................2-6

Choke knob .........................................2-7

Recoil starter handle ..........................2-7

Tiller handle ........................................2-8

Fuel cock .............................................2-8

Throttle friction adjustment...............2-9

Steering friction adjustment............2-10

Trim angle adjusting rod .................2-10

Tilt support knob ..............................2-11

Tilt support bar .................................2-11

Top cowling lock lever .....................2-12

1

2

3

4

5

6

EMU01206

101221

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!2
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!4

101222

2

MAIN COMPONENTS

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1 Air-vent screw
2 Fuel tank cap
3 Top cowling
4 Anti-cavitation plate
5 Propeller
6 Cooling water inlet
7 Clamp bracket
8 Transom clamp handle
9 Tiller handle

0 Fuel cock
q Recoil starter handle
w Engine stop button
e Choke knob
r Trim angle adjusting-rod
t Rope attachment
y Tilt support knob
u Throttle control lever

* May not be exactly as shown; also may not

be included as standard equipment on all
models.

2-1

EMU01206

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!2

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!6

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MAIN COMPONENTS

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1 Air vent screw
2 Fuel tank cap
3 Recoil starter handle
4 Top cowling
5 Cowling lock lever
6 Tiller handle
7 Throttle control grip
8 Throttle friction knob
9 Engine stop button
0 Gear shift lever
q Fuel cock

w Choke knob
e Rope attachment
r Carrying-handle
t Transom clamp handle
y Tilt support bar (lever)
u Clamp bracket
i Trim angle adjusting-rod
o Anti-cavitation plate
p Cooling water inlet
a Propeller

* May not be exactly as shown; also may not

be included as standard equipment on all
models.

2-2

EMU01206

!2
!1
!0

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101213

101212

!5

!6

!7

@1

@2

@0
!9

!8

5

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MAIN COMPONENTS

1 Air vent screw
2 Fuel tank cap
3 Top cowling
4 Cowling lock lever
5 Steering friction adjusting lever
6 Anti cavitation plate
7 Propeller
8 Cooling water inlet
9 Trim angle adjusting-rod
0 Clamp bracket
q Transom clamp handle
w Tiller handle

e Throttle control grip
r Throttle friction adjusting knob
t Recoil starter handle
y Choke knob
u Engine stop button
i Rope attachment
o Tilt support bar (lever)
p Fuel hose connector
a Gear shift lever
s Fuel cock

* May not be exactly as shown; also may not

be included as standard equipment on all
models.

2-3

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EMC20010

OPERATIONS OF CONTROLS

AND

OTHER FUNCTIONS

EMC21012

FUEL TANK

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

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902065

1 Fuel hose joint
2 Fuel meter(If equipped)
3 Fuel tank cap
4 Air vent screw(If equipped)

Fuel hose joint

This connector is provided for connecting
or disconnecting fuel hose.

Fuel meter

This meter is on the fuel tank cap. It
shows current fuel quantity in the fuel
tank approximately.

Fuel tank cap

This cap is for filling fuel. To remove it,
turn it counterclockwise.

Air Vent screw

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

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310021

N

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EMC25110

GEAR SHIFT LEVER
(for Tiller control model)

3

Turning the gear-shift lever towards you
engages the clutch with the forward
gear so that the boat moves ahead.

1 Neutral
2 Forward

EMC25010

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GEAR SHIFT LEVER
(for Tiller control model)

5

Turning the gear-shift lever towards you
engages the clutch with the forward
gear so that the boat moves ahead.
Turning the lever away from you
engages the reverse gear so that the
boat moves astern.

1 Neutral
2 Forward
3 Reverse

2-5

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2

3

EMC27011

ENGINE STOP BUTTON
(for Tiller control model)

Pushing this button opens the ignition
circuit and stops the engine.

5

308044

2

EMC40110

THROTTLE CONTROL
(for Tiller control model)

2

Pushing the knob upward increases
speed.

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217011

3/5

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

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

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209012

2

EMC42110

CHOKE KNOB

2/5

Turning this knob to right (setting it to
ON) supplies a rich mixture required to
start the engine.

305036

5

308044*

3

EMC42210

CHOKE KNOB

3

Pulling out this knob (setting it to ON)
supplies a rich mixture required to start
the engine.

305041

EMC44010

RECOIL STARTER HANDLE

Pull the handle gently until resistance is
felt. Then vigorously pull the handle
straight out to crank the engine to start
it.

2-7

E

315021*

q

e

w

503015

EMC60010

TILLER HANDLE

Moving the tiller handle sideways to
adjust the steering direction.

EMC22110

2

q

CLOSE

OPEN

3

OPEN

5

q

CLOSE

FUEL COCK

A fuel cock is provided on top / bottom
cowling to open or close the fuel flow
from the fuel tank. There are two posi­tions (2-hp/3-hp) or three positions (4­hp/5-hp) on this fuel cock.

1 Fuel cock

CLOSE

With the lever / knob in this position, fuel
does not flow. Always turn the knob to
this position when the engine is not run­ning.

OPEN
2/3

With the lever / knob in this position, fuel
flows to the carburetor. Normal running
is done with the lever / knob in this posi­tion.

5

There are two “OPEN” positions on the
fuel cock for selecting the fuel flow from
the built-in tank or the separate tank.

2 “OPEN” position for the built-in tank
3 “OPEN” position for the separate tank

With the knob in both positions, fuel
flows to the carburetor. Normal running
is done with the knob in these positions.

2-8

E

502014

2

EMC64110

THROTTLE FRICTION
ADJUSTMENT
(for Tiller control model)

2

A friction device provides resistance to
movement of the throttle lever. This is
adjustable for operator preference. An

204033

3

5

adjusting screw is located within the
aprons.

3/5

A friction device in the tiller handle pro­vides resistance to movement of the
throttle grip. This is adjustable for oper­ator preference. An adjusting
screw/knob is located within the steering
handle.

To increase the resistance:
Turn the adjusting screw/knob clock­wise.

To decrease the resistance:
Turn the adjusting screw/knob counter­clockwise.

502015

When constant speed is desired, tighten
the adjusting screw/knob to maintain the
desired throttle setting.

w

Do not overtighten the friction adjusting
screw/knob. If there is too much resis­tance, it may be difficult to move throt­tle lever/grip, which could result in an
accident.

2-9

E

2 3

5

2 3

408022

EMD00010

STEERING FRICTION ADJUSTMENT
(for Tiller control model)

A friction device provides resistance to
steering movement. This is adjustable
for operator preference.
An adjusting screw/bolt is located on the
swivel bracket.

To increase the resistance:
Turn the adjusting screw/bolt clockwise.

To decrease the resistance:
Turn the adjusting screw/bolt counter­clockwise.

w

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

EMU01297

TRIM ANGLE ADJUSTING ROD

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

5

404025*

2-10

E

2

EMD47010

TILT SUPPORT KNOB

2

To keep the outboard motor in the tilted­up position, push the tilt support knob
under the swivel bracket.

403022

3

EMD48010

TILT SUPPORT BAR

3/5

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

403041

5

403016

2-11

E

3

EMD63010

TOP COWLING LOCK LEVER

3

To remove the engine top cowling, pull
up the front and rear lock levers. Then
lift off the cowling. When replacing the
cowling, check to be sure it fits properly
in the rubber seal. Then lock the cowling

301035

again by moving the levers downward.

5

5

To remove the engine top cowling, push
the lock lever downward. Then lift off
the cowling. When replacing the cowl­ing, check to be sure it fits properly in
the rubber seal. Then lock the cowling
again by moving the lever upward.

301036

2-12

-MEMO-

E

EMF00010

E

Chapter 3

OPERATION

INSTALLATION ......................................3-1

Mounting the outboard motor ..........3-2

Clamping the outboard motor ..........3-4

FILLING FUEL AND ENGINE OIL ..........3-5

Filling fuel ...........................................3-5

Gasoline and oil mixing.....................3-6

PRE-OPERATION CHECKS ....................3-8

BREAKING IN (RUNNING IN)

ENGINE...................................................3-9

STARTING ENGINE .............................3-11

WARMING UP ENGINE .......................3-15

SHIFTING..............................................3-16

Forward .............................................3-16

Reverse..............................................3-17

STOPPING ENGINE .............................3-18

1

2

3

4

TRIMMING OUTBOARD MOTOR .......3-19

Adjusting trim angle ........................3-20

CRUISING IN SHALLOW WATER .......3-22

TILTING UP/DOWN .............................3-24

CRUISING IN OTHER CONDITIONS ...3-27

Cruising in salt water .......................3-27

Cruising in turbid water ...................3-27

5

6

E

EMF10010

INSTALLATION

cC

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

NOTE:

During water testing check the buoyancy
of the boat, at rest, with its maximum
load. Check that the static water level on
the exhaust housing is low enough to
prevent water entry into the powerhead,
when water rises due to waves when the
outboard is not running.

3-1

E

104011

q

EMU00176

MOUNTING THE OUTBOARD
MOTOR

w

Improper mounting of the outboard
motor could result in hazardous condi­tions such as poor handling, loss of con­trol, or fire hazards. Observe the follow­ing:
8 The information presented in this sec-

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

8 Your dealer or other person experi-

enced in proper rigging should mount
the motor. If you are mounting the
motor yourself, you should be trained
by an experienced person. [permanent
mounted type]

8 Your dealer or other person experi-

enced in proper outboard motor
mounting should show you how to
mount your motor. [portable type]

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

1 Center line (keel line)

3-2

0~25mm
(0~1in.)

104013

E

w

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

EMU01298

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 engine so that the anti-cavita­tion plate is between the bottom of the
boat and a level 25 mm (1 in.) below it.

NOTE:

8 The optimum mounting height of the

outboard motor is affected by the
boat/motor combination and the
desired use. Test runs at different
heights can help determine the opti­mum mounting height.

8 Refer to the section “TRIMMING OUT-

BOARD MOTOR” for instructions on
setting the trim angle of the outboard.

3-3

409011

410012

E

EMF14010

CLAMPING THE OUTBOARD
MOTOR

1) Place the outboard on the transom
so that it is positioned as close to the
center as possible. Tighten the tran­som clamp screws evenly and
securely. Check the clamp-screws for
tightness occasionally during opera­tion of the motor as they can work
loose due to engine vibration.

w

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

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

3-4

222013

E

FILLING FUEL

AND ENGINE OIL

EMF30110

FILLING FUEL

1) Put the outboard in the tilt-down
position. Remove the fuel tank cap.

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

3) Fill the fuel tank carefully.

4) Close the cap securely after refuel­ing. Wipe up any spilled fuel.

Fuel tank capacity:

Refer to SPECIFICATIONS, Page 4-1.

Ring Free Fuel Additive

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

As gasoline has changed, the amount of
additives such as aromatics and oxy­genates has increased. These additives
are important for the engines in passen­ger cars, but they can have detrimental
effects in marine engines, particularly 2­cycle outboards because of increased
deposits in the combustion chamber.
When enough deposits collect, piston
rings begin sticking. Performance drops
and engine wear increases dramatically.

3-5

E

902034*

q

w

While many additives available may
reduce deposits, Yamaha recommends
the use of Ring Free Fuel Additive, avail­able from your Yamaha dealer. Ring
Free has repeatedly proven its ability to
clean combustion deposits from inside
the engine, notably the critical piston­ring-land area, and fuel system compo­nents. Follow product labeling for use
instructions.

EMF35010

GASOLINE (PETROL) AND OIL
MIXING

Pre-mix model

Oil : Gasoline (Petrol)

Break-in period 1 : 25

After break-in 1 : 100

1) Pour oil and gasoline into the fuel
tank, in that order.

1 Oil 2 Gasoline (Petrol)

2) Then mix the fuel thoroughly by
shaking.

3) Make sure the oil is mixed with gaso­line.

cC

8 Avoid using any oil other than the des-

ignated type.

8 Use a thoroughly blended fuel-oil mix-

ture.

8 If the mixture is not thoroughly blend-

ed, 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 exgaust, and
heavy carbon deposits.

3-6

Mixing

ratio

E

25 : 1

Gasoline
(Petrol)

Engine oil

Mixing

ratio

Gasoline
(Petrol)

Engine oil

1 L

(0.26 US gal,

0.22 Imp gal)

0.04 L

(0.04 US qt,

0.04 Imp ql)

1 L

(0.26 US gal,

0.22 Imp gal)

0.01 L

(0.01 US qt,

0.01 Imp ql)

12 L

(3.2 US gal,

2.6 Imp gal)

0.48 L

(0.51 US qt,

0.42 Imp qt)

100 : 1

12 L

(3.2 US gal,

2.6 Imp gal)

0.12 L

(0.13 US qt,

0.11 Imp qt)

14 L

(3.7 US gal,

3.1 Imp gal)

0.56 L

(0.59 US qt,

0.49 Imp qt)

14 L

(3.7 US gal,

3.1 Imp gal)

0.14 L

(0.15 US qt,

0.12 Imp qt)

24 L

(6.3 US gal,

5.3 Imp gal)

0.96 L

(1.01 US qt,

0.84 Imp qt)

24 L

(6.3 US gal,

5.3 Imp gal)

024 L

(0.25 US qt,

0.21 Imp qt)

NOTE:

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

3-7

E

EMF40012

PRE-OPERATION CHECKS

w

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

EMF41110

Fuel

8 Check to be sure you have plenty of

fuel for your trip.

8 Make sure there are no fuel leaks or

gasoline fumes.

8 Check fuel line connections to be sure

they are tight.

8 Be sure the fuel tank is positioned on a

secure, flat surface, and that the fuel
hose is not twisted or flattened, or like­ly to contact sharp objects.

EMF42110

Oil

8 Check to be sure you have plenty of oil

for your trip.

EMF43010

Controls

8 Check throttle, shift, and steering for

proper operation before starting the
engine.

8 The controls should work smoothly,

without binding or unusual free play.

8 Look for loose or damaged connec-

tions.

8 Check operation of the starter and stop

switches when the outboard motor is
in the water.

3-8

E

EMF43510

Engine

8 Check the engine and engine mount-

ing.

8 Look for loose or damaged fasteners.
8 Check the propeller for damage.

cC

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

EMF50012

BREAKING IN (RUNNING IN)

ENGINE

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

cC

Failure to follow the break-in (running-in)
procedure may result in reduced engine
life or even severe engine damage.

Break-in (running-in) time: 10 hours

Break-in (running-in) premix ratio:

Refer to “Gasoline/Petrol and Oil
Mixing”.

3-9

E

EMU00226

Run the engine under load (in gear with a
propeller installed) 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 3,000 r/min). Vary engine
speed occasionally. If you have an
easy-planing boat, accelerate at full
throttle onto plane, then immediately
reduce the throttle to 3,000 r/min or
less.

3) Second hour:

Accelerate at full throttle onto plane,
then reduce engine speed to three­quarter throttle (approximately 4,000
r/min). Vary engine speed occasional­ly. Run at full throttle for one minute,
then allow about 10 minutes of oper­ation at three-quarter throttle or less
to let the engine cool.

4) Third through tenth hours:

Avoid operating at full throttle for
more than 5 minutes at a time. Let
the engine cool between full-throttle
runs. Vary engine speed occasional­ly.

5) After the first 10 hours:

Operate the engine normally. Use the
standard premix ratio of gasoline :
Oil. (Refer to “Gasoline/Petrol and Oil
Mixing”.)

3-10

E

EMU00958

STARTING ENGINE

w

8 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.

8 When the air-vent screw is loosened,

gasoline(petrol) vapor will be released.
Gasoline(petrol) 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.

8 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.

1) Loosen the air vent screw attached to

the fuel tank cap by 2 or 3 turns.

3-11

E

OPEN

OPEN

902061*

2 3

5

5

2) Set the fuel cock in the “OPEN” posi­tion

315021*

5

5

3) If you select the separate fuel tank,
connect the fuel joints securely and
squeeze the primer bulb with the out­let end up until you feel it become
firm.

902025

3-12

E

N

EMU00987

PROCEDURE FOR TILLER CONTROL
MODEL

4) Place the gear shift lever in Neutral
position (except for 2-hp).

NOTE:

5

The start-in-gear protection device per­mits the engine to be started only when it
is in Neutral.

2

3/5

5) Place the throttle control lever/grip in
the “START” position.
After the engine starts, return the
throttle to the fully closed position.

3-13

E

START

2 3

5

308044*

EMU00988

Manual Start Model

w

2-hp model: The propeller rotates when­ever the engine is running. Do not move
the throttle control lever from the start
position during warm-up. The boat could
unexpectedly start to move, which could
result in an accident.

6) Place the choke knob in the “START”

position.
After the engine starts, return the
knob to the “RUN” position.

NOTE:

8 If the engine is warm, place the choke

knob in the “RUN” position.

8 If the choke knob is left in the “START”

position during running, the engine will
run poorly or stall.

7) Pull the starter handle slowly until

you feel resistance. Then, give a
strong pull straight out to start the
engine. Repeat it, if necessary.

2 3/5

209012

8) After the engine starts, return the

starter handle slowly to the original
position before releasing it.

3-14

E

309021*

EMG00110

WARMING UP ENGINE

w

2-hp model: The propeller rotates when­ever the engine is running. Do not move
the throttle control lever from the start
position during warm-up. The boat
could unexpectedly start to move,
which could result in an accident.

2

3/5

309023*

1) Before beginning operation, allow
the engine to warm up at idling
speed for 3 minutes. (Failure to do
this will shorten engine life.)

2

2) Check a flow of water with exhaust
gas from the hole on exhaust cover.

3/5

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

cC

A continuous flow of water from the
pilot hole shows that the water pump is
pumping water through the cooling
passages. If water is not flowing out of
the pilot hole at all times while the
engine is running, do not continue to
run the engine. Overheating and serious
damage could occur. Stop the engine
and check to see if the water inlet on
the lower casing is blocked. If the prob­lem cannot be found and corrected, con­sult your Yamaha dealer.

3-15

3/5

3

E

EMG20010

SHIFTING

w

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

cC

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

FORWARD

2

When the engine is started, the propeller

503012

N

F

turns and the boat begins to move for­ward.

3/5

1) Place the throttle control grip in the
fully closed position.

2) Turn the gear shift lever quickly and
firmly from Neutral to Forward.

310021*

5

N

F

310013

3-16

E

310023

2/3

5

REVERSE

2/3

The outboard motor will make a full 360°
turn in its bracket (full-pivot system).
Simply turn the engine around 180° turn
with the steering handle facing to the
rear to back up the boat.

5

1) Place the throttle control grip in the
fully closed position.

503012

2) Turn the gear shift lever quickly and

N

R

310014

firmly from Neutral to Reverse.

w

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

3-17

E

2 3

5

EMG38010

STOPPING ENGINE

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

EMG40711

PROCEDURE

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

308044

2

CLOSE

2) After stopping the engine, tighten the
air vent screw and set the fuel cock
lever / knob to the closed position.

5

3) Disconnect the fuel joints after using
the separate fuel tank.

3

5

315021*

3-18

E

EMU01412

TRIMMING OUTBOARD

MOTOR

The trim angle of the outboard motor
helps determine the position of the bow
of the boat in the water. The correct trim
angle will help improve performance and
fuel economy while reducing strain on
the engine. The 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.

q

105024*

w

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

NOTE:

Refer to the section “ADJUSTING TRIM
ANGLE” for instructions on usage.

1 Trim operating angle

3-19

E

q

q

2

3

ADJUSTING TRIM ANGLE

EMU00951

Manual tilt model

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

1) Stop the engine.

2) Remove the trim angle adjusting rod

1 from the clamp bracket while tilt­ing the motor up slightly.

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.

w

5

q

8 Stop the engine before adjusting the

trim angle.

8 Use care to avoid being pinched when

removing or installing the rod.

8 Use caution when trying a trim posi-

tion 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.

NOTE:

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

3-20

105011

q

w

E

EMU00282

Bow Up

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

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-up can cause the propeller
to ventilate, which reduces performance
further. When trimmed-out too much, a
boat may “porpoise” (hop in the water),
which could throw the operator and pas­sengers overboard.

EMU00283

Bow Down

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

e

105013

105015

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

1 Bow up
2 Bow down
3 Optimum angle

3-21

E

105023

EMG70011

CRUISING IN SHALLOW

WATER

3/5

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

w

8 Place the gear shift in the Neutral posi-

tion before using the shallow water
cruising system.

8 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 engine to lift out of the
water, resulting in loss of control.

8 Use extra care when operating in

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

8 Return the engine to its normal posi-

tion as soon as the boat is back in
deeper water.

cC

Place the gear-shift in the Neutral posi­tion before using the shallow water
cruising system.

3-22

E

N

EMU00963

PROCEDURE

3/5

1) Place the gear shift lever in Neutral

and face the motor forward.

2) Slightly tilt up the engine until the

tilt-support bar is turned to the locked

position automatically to support the

engine.

403015

3) When bringing the engine to the

home position, slightly tilt up the

engine and slowly tilt the engine

down pulling up the lever of the tilt

support bar.

NOTE:

The outboard motor is provided 2 or 3
positions for shallow water cruising.

403031

3-23

E

EMU00284

TILTING UP/DOWN

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

cC

8 Before tilting the motor, follow the

procedures under “STOPPING
ENGINE”. Never tilt the motor while
the engine is running. Severe damage
from overheating can result.

8 Do not tilt up the engine by pushing

the steering handle as this could break
the handle.

8 Keep the power unit higher than the

propeller at all times. Otherwise, water
can run into the cylinder, causing dam­age.

8 The outboard cannot be tilted when in

Reverse, or when the outboard is
turned 180° (facing to the rear).

w

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

w

Leaking fuel is a fire hazard. Tighten the
air-vent screw and place the fuel cock in
the closed position if the engine will be
tilted for more than a few minutes. Oth­erwise, fuel may leak.

3-24

N

EMU00962

222012

3

CLOSE

315016

PROCEDURE FOR TILTING UP

1) Tighten the air vent screw.

If the fuel connector is provided on

the motor, remove the fuel line con-

nection from the motor.

E

2 3

5

2) Put the fuel cock lever in the closed

position.

CLOSE

315021*

3) Place the gear shift lever in Neutral
and face the motor forward.

3-25

E

403022

2

3/5

4) Hold the rear of the top cowling with
one hand and fully tilt the engine up.

2

5) Push the tilt support knob into the
clamp bracket.

3/5

5) The tilt support bar turns to the
locked position automatically.

403016

EMU00298

PROCEDURE FOR TILTING DOWN

1) Slightly tilt up the engine.

2

2) Pull out the tilt support knob, then tilt
down the engine.

403022*

3/5

2) Tilt down the engine pulling up the
lever of the tilt support bar.

403031

3-26

E

EMH60010

CRUISING IN OTHER

CONDITIONS

CRUISING IN SALT WATER

After operating in salt water, wash out
the cooling-water passages with fresh
water to prevent them from becoming
clogged-up with salt deposits.

NOTE:

Refer to cooling system flushing instruc­tions in “TRANSPORTING AND STORING
OUTBOARD MOTOR”.

CRUISING IN TURBID WATER

It is strongly recommended that the
optional chromium-plated water-pump
kit be installed if the outboard is to be
used in turbid (muddy) water conditions.

3-27

EMK00010

E

Chapter 4

MAINTENANCE

SPECIFICATION DATA...........................4-1

TRANSPORTING AND STORING

OUTBOARD MOTOR .............................4-3

Trailering outboard motor.................4-3

Storing outboard motor.....................4-4

PERIODIC MAINTENANCE ....................4-8

Replacement parts .............................4-8

Maintenance chart..............................4-9

Cleaning and adjusting spark

plug....................................................4-10

Checking fuel system .......................4-12

Inspecting and replacing fuel

filter ...................................................4-13

Adjusting idling speed .....................4-14

Checking wiring and connectors.....4-15

Exhaust leakage................................4-15

Water leakage ...................................4-15

Greasing............................................4-16

Checking propeller; shear pin and

cotter pin ...........................................4-19

Changing gear oil .............................4-22

Cleaning fuel tank.............................4-23

Inspecting and replacing anode......4-24

Checking bolts and nuts ..................4-25

Motor exterior...................................4-25

Coating boat bottom ........................4-25

1

2

3

4

5

6

EMR50302*

E

SPECIFICATION DATA

Model

Item

DIMENSIONS

Unit 2MHA

9Overall Length mm (in.)
9Overall Height S/L mm (in.)
9Overall Width mm (in.)
9Transom height S/L mm (in.)
9Weight S/L kg (lb.)

PERFORMANCE

9Full throttle operating range r/min
9Maximum output kW (HP)
9Idling speed (in neutral) r/min

ENGINE

9Engine type

Displacement cm

× stroke mm (in.)

Bore

3

(cu.in.)

9Ignition system
9Spark plug NGK

Spark plug gap mm (in.)

9Control system
9Starting system
9Battery minimum capacity V-AH
9Alternator output V-A (W)
9Starting carburetion system

DRIVE UNIT

9Gear positions

Gear ratio

9Trim/tilt system
9Propeller mark

FUEL AND OIL

9Fuel

Fuel tank capacity L (US gal, Imp gal)

9Recommended engine oil

Fuel/oil ratio

9Recommended gear oil

Gear oil quantity cm

TIGHTENING TORQUE

3

(US oz, Imp oz)

9Spark plug N•m (kgf•m, lb•ft)
9Propeller nut N•m (kgf•m, lb•ft)

607 (23.9)
916 (36.1)/—
214 (8.4)
417 (16.4)/—

10 (22.0)/—

4,000 ~ 5,000

1.5 (2) at 4,500 r/min.
1,100~1,200

2-stroke, L1
43 (2.62)
39 × 36 (1.54 × 1.42)
C.D.I
B5HS

0.6~0.7 (0.024~0.028)
Tiller control
Manual start
—
—
Choke valve start system

Forward

2.08 (27/13)
Manual
A

Regular unleaded gasoline
(P.O.N.: minimum 86)

1.2 (0.32, 0.26)
YAMALUBE 2 STOROKE OUTBOARD
OIL or an equivalent TC-W3 certified
outboard oil
100 : 1
Hypoid gear oil (SAE90)
45 (1.52, 1.58)

25 (2.5, 18)
—

4-1

3MHA 5MHA

E

628 (24.7)
997 (39.3)/—
289 (11.4)
441 (17.4)/—

16.5 (36.3)/—

4,500~5,500

2.2 (3) at 5,000 r/min.
1,150~1,250

2-stroke, L1
70 (4.27)
46 × 42 (1.82 × 1.65)
C.D.I
B6HS-10

0.9~1.0 (0.035~0.039)
Tiller control
Manual start
—
—
Choke valve start system

Forward-Neutral

2.08 (27/13)
Manual
BS

Regular unleaded gasoline
(P.O.N.: minimum 86)

1.4 (0..37, 0.32)
YAMALUBE 2 STOROKE OUTBOARD
OIL or an equivqlent TC-W3 certified
outboard oil
100 : 1
Hypoid gear oil (SAE 90)
75 (2.53, 2.64)

677 (26.7)
1,011 (39.8)/1,138 (44.8)
322 (12.7)
444 (17.5)/571 (22.5)
21 (46.2)/21.5 (47.3)

4,500~5,500

3.7 (5) at 5,000 r/min.
1,100~1,200

2-stroke, L1
103 (6.3)
54 × 45 (2.13 × 1.77)
C.D.I
B7HS

0.6~0.7 (0.024~0.028)
Tiller control
Manual start
—
—
Choke valve start system

Forward-Neutral-Reverse

2.08 (27/13)
Manual
BA

Regular unleaded gasoline
(P.O.N.: minimum 86)

2.8 (0.74, 0.62)/25 (6.6, 5.5)
YAMALUBE 2 STOROKE OUTBOARD
OIL or an equivqlent TC-W3 certified
outboard oil
100 : 1
Hypoid gear oil (SAE 90)
100 (3.4, 3.5)

25 (2.5, 18)
17 (1.7, 12)

25 (2.5, 18)
17 (1.7, 12)

4-2

E

EMU01369

TRANSPORTING AND
STORING OUTBOARD

MOTOR

w

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

TRAILERING OUTBOARD MOTOR

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

cC

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

w

8 Never get under the lower unit while

it is tilted, even if a motor support bar
is used. Severe injury could occur if
the outboard accidentally falls.

8 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.

4-3

E

102015

1

2

102013

1 Vertical position
2 Horizontal position

When transporting or storing the out­board motor while removed from a boat,
fold the tiller handle and lean the motor
on the tiller handle to keep in a horizon­tal position.

NOTE:

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

cC

Keep the power unit higher than the
propeller at all times.
Otherwise, cooling water can run into
the cylinder, which could result in dam­age.

EMU00328

STORING OUTBOARD MOTOR

When storing your Yamaha outboard for
prolonged periods of time, (2 months or
longer), several important procedures
must be performed to prevent expensive
damage. This is especially important for
your Precision Blend equipped outboard
due to the lean oil ratios used at idle prior
to shutting the engine off for the season.
It is advisable to have your outboard ser­viced by an authorized Yamaha dealer
prior to storage. However, the following
procedures can be performed by you, the
owner, with a minimum of tools.

4-4

E

EMU00335

Filling Fuel Tank

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

00) to each gallon of fuel.

NOTE:

The use of “Yamaha Fuel Conditioner and
Stabilizer” eliminates the need to drain
the fuel system. Consult your Yamaha
dealer or other qualified mechanic if the
fuel system is to be drained instead.

EMU00338

Flushing Cooling System and Fogging
Engine

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

w

8 Do not touch or remove electrical parts

when starting or during operation.

8 Keep hands, hair and clothes away

from flywheel and other rotating parts
while engine is running.

4-5

E

605016*

q

w

EMU00339

8 Flushing in a Water Tank

cC

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.

1) Remove the engine top cowling and
silencer cover.

2) Install the outboard motor on the
water tank.

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

4) Run the engine at a fast idle for 10~15
minutes.

5) Just prior to turning off the engine,
quickly spray “Yamaha Stor-Rite
Engine Fogging Oil” (Part No. LUB­STRRT-12-00) alternately into each
carburetor. When properly done, the
engine will smoke excessively and
almost stall.

6) Remove the motor from the water
tank.

7) Install the silencer cover and top
cowling.

1 Water surface
2 Lowest water level

4-6

E

EMK26010

Lubrication

1) Remove the spark plugs, and spray a

10 second spray of Yamaha Stor-Rite
Engine Fogging Oil into each cylin­der. Grease the spark plug threads
and reinstall the spark plugs and
torque to proper specification.
(Refer to the Periodic Maintenance
section, “Cleanning and adjusting
spark plug.”).

2) Turn the engine over with the stop

lanyard disconnected to work the fog­ging oil into the piston rings.

3) Change the lower unit oil. (Refer to

the Periodic Maintenance section,
“Changing gear oil.”). Inspect the oil
for the presence of water which indi­cates a leaky seal. Seal replacement
should be performed by an autho­rized Yamaha dealership prior to use.

4) Grease all grease fittings. (Refer to

the Periodic Maintenance section,
“Greasing.”)

EMK27010

Cleaning and Anti-corrosion Measure

1) Wash down the exterior of the out-

board with fresh water and dry off
completely.

2) Spray the engine’s exterior with

Yamaha Silicone Protectant (Part No.
LUB-SILCNE-13-00).

3) Wax the cowling with a non-abrasive

wax such as Yamaha Silicone Wax
(Part No. ACC-11000-15-02).

4-7

E

EMK32110

PERIODIC MAINTENANCE

w

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

A service manual is available for purchase
through a Yamaha dealer for owners who
have the mechanical skills, tools, and
other equipment necessary to perform
maintenance not covered by this owner’s
manual.

EMK33011

REPLACEMENT PARTS

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

4-8

E

MAINTENANCE CHART

Frequency of maintenance operations may be adjusted according to the operating con­ditions, but the following table gives general guidelines.

The mark (●) indicates the check-ups which you may carry out yourself.

The mark (1) indicates work to be carried out by your Yamaha dealer.

Interval

Item

Spark plug(s)

Cleaning/Adjustment/

Replacement

Greasing points Greasing ● 4-16
Gear oil Change ● ● 4-22
Fuel system Inspection ● 4-12

Fuel filter(s)

Inspection/
Replacement

Fuel tank*1 Cleaning ● 4-23

Idling speed

Anode(s)

Outboard motor
exterior

Cooling water
passages *2

Inspection/
Adjustment

Inspection/
Replacement

Inspection ● ● 4-25

Flushing ● ● 4-6

Propeller/Cotter pin/ Inspection/
Shear pin Replacement

Carburetor setting

Ignition timing

Inspection/
Adjustment

Inspection/
Adjustment

Bolts/Nuts Retightening 1 1 4-25

*1 .......If a portable fuel tank is equipped

*2 .......When operating in salt water, turbid or muddy water, the engine should be flushed with

clean water after each use.

Initial Every

10 hours

(1 month)

50 hours

(3 months)

100 hours

(6 months)

200 hours

(1 year)

● ● ● 4-10

● ● ● 4-13

● 4-14

1 1 4-24

● ● 4-19

1 1 —

1 1 —

Refer

page

4-9

E

EMU01202

CLEANING AND ADJUSTING SPARK
PLUG

w

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

The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
something about the condition of the
engine. For example, if the center elec­trode porcelain is very white, this could
indicate an intake air leak or carburetion
problem in that cylinder. Do not attempt
to diagnose any problems yourself.
Instead, take the outboard motor to a
Yamaha dealer. You should periodically
remove and inspect the spark plug
because heat and deposits will cause the
spark plug to slowly break down and
erode. If electrode erosion becomes
excessive, or if carbon and other deposits
are excessive, you should replace the
spark plug with another of the correct
type.

Standard spark plug:
Refer to “SPECIFICATIONS”, page 4-1.

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

Spark plug gap:
Refer to “SPECIFICATIONS”, page 4-1.

4-10

E

903022

q

w

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

Spark plug torque:
Refer to “SPECIFICATIONS”, page 4-1.

NOTE:

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

Initial of spark Plug wrench size
plug I.D. mark

B 21 mm (13/16 in.)

C/BK 16 mm (5/8 in.)

D 18.3 mm (23/32 in.)

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

4-11

E

2

EMK38010

CHECKING FUEL SYSTEM

w

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

Check the fuel line for leaks, cracks, or
malfunctions. If any problem is found, it

3

106042

5

should be repaired immediately by
Yamaha dealer or other qualified
mechanic.

Checking points

8 Fuel system parts leakage.
8 Fuel hose joint leakage.
8 Fuel hose cracks or other damage.
8 Fuel connector leakage.

w

Leaking fuel can result in fire or explo­sion.

8 Check for fuel leakage regularly.
8 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.

4-12

E

EMM52010

INSPECTING AND REPLACING FUEL
FILTER

5

w

Gasoline (petrol) is highly flammable,
and its vapors are flammable and explo­sive.
8 If you have any question about prop-

erly doing the procedure, consult your
Yamaha dealer.

8 Do not perform the procedure on a

hot or running engine. Allow the
engine to cool.

8 There will be fuel in the fuel filter.

Keep away from sparks, cigarettes,
flames or other sources of ignition.

8 The procedure will allow some fuel to

spill.
Catch fuel in a rag. Wipe up any
spilled fuel immediately.

5

8 Improper replacement can result in a

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

207034

Check the fuel filter periodically.
The fuel filter is a one-piece, disposable
type. If foreign matter is found in the fil­ter, replace it. For replacement of the
fuel filter, consult a Yamaha dealer.

4-13

E

204033*

q

EMU01002

ADJUSTING IDLING SPEED

w

8 Do not touch or remove electrical parts

when starting or during operation.

8 Keep hands, hair and clothes away

from flywheel and other rotating parts
while engine is running.

8 2-hp model: Do not move the throttle

control lever from the start position

2

during warm-up. The propeller rotates
whenever the engine is running. The
boat could unexpectedly start to move
which could result in an accident.

cC

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

3

q

204035*

5

q

204036*

A diagnostic tachometer should be used
for this procedure.

1) Start the engine and allow it to warm
up fully in Neutral until it is running
smoothly.
2-hp model: Warm the engine with
the throttle in the Start position or
less. If the outboard is mounted on a
boat, be sure the boat is tightly
moored.

2) Adjust the throttle stop-screw 1 to
set the idling speed to specification
(refer to “SPECIFICATIONS”, page 4-

1) by turning the stop-screw clock­wise to increase the idling speed, and
turning it counterclockwise to
decrease the idling speed.

4-14

E

NOTE:

Correct idling-speed adjustment is only
possible if the engine is fully warmed-up.
If not warmed up fully, the speed setting
will tend to be too high. If you have diffi­culty obtaining the specified idle, consult
a Yamaha dealer or other qualified
mechanic.

EMK78010

CHECKING WIRING AND
CONNECTORS

1) Check that each grounding wire is
properly secured.

2) Check that each connector is engaged
securely.

EXHAUST LEAKAGE

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

WATER LEAKAGE

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

4-15

EMU00366

103081

GREASING

Yamaha marine grease
(Water resistant grease)

2

E

4-16

EMU00366

103082

GREASING

Yamaha marine grease
(Water resistant grease)

3

E

4-17

EMU00366

103091

GREASING

Yamaha marine grease
(Water resistant grease)

5

E

4-18

E

210012

EML06011*

CHECKING PROPELLER; SHEAR PIN
AND COTTER PIN

w

You could be seriously injured if the
engine accidentally starts while you are
near the propeller.
8 Before inspecting, removing or

installing the propeller, remove the
spark plug caps from the spark plugs.
Also, put the shift control in Neutral,
put the main switch in the “OFF”
position and remove the key, and
remove the lanyard from the engine
stop switch. Turn off the battery cut­off switch if your boat has one.

8 Do not use your hand to hold the pro-

peller when loosening or tightening

602051

2

the propeller nut. Put a wood block
between the cavitation plate and the
propeller to prevent the propeller
from turning.

602062

2

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

2) Check the shear pin for wear or dam­age. The shear pin is designed to
break if the propeller hits a hard
underwater obstacle to help protect
the propeller and drive mechanism.
The propeller will then spin freely on
the shaft. If this happens, the shear
pin must be replaced.

3) Check for fish line winding around
the propeller shaft. Check the pro­peller shaft oil seal for damage.

4-19

E

602061

602054

2

w

e

q

602046

Removal

1) Using the pliers provided, straighten

the cotter-pin and pull it out.

2) Remove the propeller.

3) Remove the shear-pin.

1 Shear pin
2 Propeller
3 Cotter pin

Installation

1) Apply Yamaha marine grease (water-

resistant grease) to the propeller­shaft.

2) Insert the shear-pin into the hole in

the propeller-shaft.

3) Align the shear-pin with the groove

in the propeller-boss, and slide the
propeller over the propeller-shaft.

4) Align the hole in the propeller with

the recess in the propeller-shaft.
Insert a new cotter pin in the hole
and bend the cotter pin ends.

cC

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

3/5

NOTE:

There is a holder on the steering handle
for spare shear and cotter pins. Be sure to
replace a pin in the holder if one is used.

3/5

1) Check each of propeller blades for

wear, erosion from cavitation or ven­tilation, or other damage.

2) Check the splines for wear and dam-

age.

3) Check for fish line winding around

the propeller shaft. Check the pro­peller shaft oil seal for damage.

4-20

602056

q

w

e

t

r

602044

E

Removal

1) Using the pliers provided, straighten
the cotter-pin and pull it out.

2) Remove the propeller nut.

3) Remove the propeller.

1 Thrust washer 4 Propeller nut
2 Propeller 5 Cotter pin
3 Washer

Installation

1) Apply Marine grease (water-resistant
grease) to the propeller-shaft.

2) Slide the propeller over the pro­peller-shaft.

cC

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

3) Tighten the propeller nut to the spec­ified torque.

Tightening torque:

Refer to SPECIFICATIONS, Page 4-1.

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

NOTE:

When the propeller nut does not align
with the propeller shaft hole after tight­ening to the specified torque, then tight­en it more to align the hole.

cC

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

602053

4-21

E

601034

1

2

EML20010

CHANGING GEAR OIL

w

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

1) Put the outboard in a vertical posi-

tion (not tilted).

2

w

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

2) Place a suitable container under the

gearcase.

3) Remove the oil drain plug.

3

q

NOTE:

The oil drain plug is magnetic. Remove
all metal particles from the plug before
reinstalling it.

w

5

1

2

601036

4) Remove the oil level plug to allow

the oil to drain completely.

1 Oil-level plug
2 Oil drain-plug

cC

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

4-22

601035

E

NOTE:

For disposal of used oil consult your
Yamaha dealer.

5) With the outboard motor in an verti­cal position, using a flexible or pres­surized filling device, inject outboard
motor hypoid gear oil (SAE 90) into
the oil drain plug hole.

Gear oil capacity:

Refer to SPECIFICATIONS, Page 4-1.

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

7) Insert and tighten in the oil drain
plug.

EML22011

CLEANING FUEL TANK

w

Gasoline (petrol) is highly flammable,
and its vapors are flammable and explo­sive.
8 If you have any question about prop-

erly doing this procedure, consult
your Yamaha dealer.

8 Keep away from sparks, cigarettes,

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

8 Remove the fuel tank from the boat

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

8 Wipe up any spilled fuel immediately.
8 Reassemble the fuel tank carefully.

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

8 Dispose of old gasoline (petrol)accord-

ing to local regulations.

4-23

E

902066

To clean the fuel tank

1) Empty the fuel tank into an approved

gasoline (petrol) container.

2) Pour a small amount of suitable sol-

vent in the tank. Reinstall the cap and
shake the tank. Drain the solvent
completely.

To clean the fuel filter

1) Remove the screws holding the fuel

hose joint assembly. Pull the assem­bly out of the tank.

2) Clean the filter (located on the end of

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

3) Replace the gasket with a new one.

Reinstall the fuel hose joint assembly
and tighten the screws firmly.

EML24010

2

3

INSPECTING AND REPLACING
ANODE

Yamaha outboard motor is protected
from corrosion by sacrificial anode.

Check the anode periodically. Remove
the scales from surfaces of the anode.
For the replacement of the anode, con­sult a Yamaha dealer.

5

cC

Do not paint the anode, for this would
render it ineffective.

604023

4-24

E

EML40010

CHECKING BOLTS AND NUTS

1) Check that bolts securing the cylinder
head and engine and the nut secur­ing the flywheel are tightened with
their specified tightening torques.

2) Check the tightening torques of other
bolts and nuts.

EML42010

MOTOR EXTERIOR

Cleaning the Outboard Motor

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

To clean cooling-water passages

NOTE:

Refer to cooling system flushing instruc­tions in TRANSPORTING AND STORING
OUTBOARD MOTOR.

102025

Checking Painted Surface of Motor

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

EMP60000

COATING THE BOAT BOTTOM

A clean hull improves boat performance.
The boat bottom should be kept as clean
of marine growths 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.

4-25

EMN00010

E

Chapter 5

TROUBLE RECOVERY

TROUBLESHOOTING ....................5-1

TEMPORARY ACTION IN

EMERGENCY..................................5-5

Impact damage...........................5-5

Starter will not operate..............5-6

Treatment of submerged

motor...........................................5-9

1

2

3

4

5

6

E

EMU01204¯

TROUBLESHOOTING

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of
power, or other problems. The troubleshooting chart describes basic checks and possi­ble remedies. (This chart covers all Yamaha outboard motors. Therefore, some items
may not apply to your model.)
If your outboard motor requires repair, bring it to a Yamaha dealer.

Trouble Possible Cause Remedy

A. Engine will not

start (Starter
operates).

1. Fuel tank empty.

2. Fuel contaminated or stale.

3. Fuel filter clogged.

4. Starting procedure incorrect.

5. Fuel pump malfunctions.

6. Spark plug(s) fouled or incorrect
type.

7. Spark plug cap(s) fitted incorrectly.

8. Poor connections or damaged
ignition wiring.

9. Ignition parts faulty.

10. Engine stop switch lanyard not
attached.

11. Shift lever in gear.

12. Engine inner parts damaged.

1. Fill tank with clean, fresh fuel.

2. Fill tank with clean, fresh fuel.

3. Clean or replace filter.

4. Read "STARTING ENGINE"
section.

5. Have serviced by a Yamaha
dealer.

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

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

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

9. Have serviced by a Yamaha
dealer.

10. Attach lanyard.

11. Shift to neutral.

12. Have serviced by a Yamaha
dealer.

5-1

Trouble Possible Cause Remedy

E

B. Engine idles

irregularly or stalls.

1. Spark plug(s) fouled or incorrect
type.

2. Fuel system obstructed.

3. Fuel contaminated or stale.

4. Fuel filter clogged.

5. Failed ignition parts.

6. Spark plug gap incorrect.

7. Poor connections or damaged
ignition wiring.

8. Specified engine oil not used.

9. Thermostat faulty or clogged.

10. Carburetor adjustments incorrect.

11. Fuel pump damaged.

12. Air vent screw on the fuel tank
closed.

13. Choke knob pulled out.

14. Motor angle too high.

15. Carburetor clogged.

16. Fuel joint connection incorrect.

17. Throttle valve adjustment incorrect.

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

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

3. Fill tank with clean, fresh fuel.

4. Clean or replace filter.

5. Have serviced by a Yamaha
dealer.

6. Inspect and adjust as specified.

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

8. Check and replace oil as specified.

9. Have serviced by a Yamaha
dealer.

10. Have serviced by a Yamaha
dealer.

11. Have serviced by a Yamaha
dealer.

12. Open the air vent screw.

13. Return to home position.

14. Return to normal operating
position.

15. Have serviced by a Yamaha
dealer.

16. Connect correctly.

17. Have serviced by a Yamaha
dealer.

5-2

Trouble Possible Cause Remedy

E

C. Engine power loss.

1. Propeller damaged.

2. Propeller pitch or diameter incorrect.

3. Trim angle incorrect.

4. Motor mounted at incorrect height
on transom.

5. Boat bottom fouled with marine
growth.

6. Spark plug(s) fouled or incorrect
type.

7. Weeds or other foreign matter
tangled on gear housing.

8. Fuel system obstructed.

9. Fuel filter clogged.

10. Fuel contaminated or stale.

11. Spark plug gap incorrect.

12. Poor connections or damaged
ignition wiring.

13. Failed ignition parts.

14. Specified engine oil not used.

15. Thermostat faulty or clogged.

16. Air vent screw closed.

17. Fuel pump damaged.

18. Fuel joint connection incorrect.

19. Heat range of spark plug incorrect.

20. Engine not responding properly to
shift lever position.

1. Have propeller repaired or
replaced.

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

3. Adjust trim angle to achieve most
efficient operation.

4. Have motor adjusted to proper
transom height.

5. Clean boat bottom.

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

7. Remove foreign matter and clean
lower unit.

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

9. Clean or replace filter.

10. Fill tank with clean, fresh fuel.

11. Inspect and adjust as specified.

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

13. Have serviced by a Yamaha
dealer.

14. Check and replace oil with
specified type.

15. Have serviced by a Yamaha
dealer.

16. Open the air vent screw.

17. Have serviced by a Yamaha
dealer.

18. Connect correctly.

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

20. Have serviced by a Yamaha
dealer.

5-3

Trouble Possible Cause Remedy

D. Engine vibrates

excessively.

1. Propeller damaged.

2. Propeller shaft damaged.

3. Weeds or other foreign matter
tangled on propeller.

4. Motor mounting bolt loose.

5. Steering pivot loose or damaged.

1. Have propeller repaired or
replaced.

2. Have serviced by a Yamaha
dealer.

3. Remove and clean propeller.

4. Tighten bolt.

5. Tighten or have serviced by a
Yamaha dealer.

E

5-4

E

607011

EMN20010

TEMPORARY ACTION IN

EMERGENCY

EMH80010

IMPACT DAMAGE

w

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 any object in
the water, (follow the procedure below;)

1) Stop the engine immediately .

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

3) However damage is found or not
found, go back to a nearest harbor
slowly and carefully.

4) Have a Yamaha dealer inspection of
the outboard motor, before operating
it again.

5-5

E

EMN30010

STARTER WILL NOT OPERATE

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

w

8 Use this procedure only in an emer-

gency and only to return to port for
repairs.

8 When the emergency starter rope is

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

8 2-hp model: The propeller rotates

whenever the engine is running. Do
not move the throttle control lever
from the start position during warm­up. Otherwise, the boat could unex­pectedly start to move, which could
result in an accident.

8 Be sure no one is standing behind you

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

8 An unguarded rotating flywheel is

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

8 Do not touch the ignition coil, high

voltage wire, spark plug cap or other
electrical components when starting
or operating the motor. You could be
shocked.

5-6

E

2

2

Procedure

1) Remove the spark plug cap cover by
removing two screws.

2) Remove the aprons by removing
eight screws.

3) Remove the starter mechanism by
removing three bolts.

4) Prepare the engine for starting. See
STARTING ENGINE for procedures.

5) To start the engine with the emer­gency starter rope, insert the knotted
end of the rope into the notch in the
flywheel rotor and wind the rope one
or two turns clockwise. Then, give a
strong pull straight out to crank the
engine. Repeat if necessary.

5-7

E

208021

3 5

5

3/5

Procedure

1) Remove the top cowling.

2) Remove the starter by removing the

bolts.

5

3) Disconnect the start-in-gear protec-

tion cable from the starter.

4) Prepare the engine for starting. See

STARTING ENGINE for procedures.
Be sure the engine is in Neutral.

5) To start the engine with emergency

starter rope, insert the knotted end of
the rope into the notch in the fly­wheel rotor and wind the rope sever­al turns clockwise. Then, give a
strong pull straight out to crank the
engine. Repeat if necessary.

208023

5-8

107012

107013

E

EMN50011

TREATMENT OF SUBMERGED
MOTOR

If the outboard motor is submerged,
immediately take it a Yamaha dealer.
Otherwise, some corrosion may begin
almost immediately. If you cannot
immediately take the outboard motor to
a Yamaha dealer, follow the procedure
bellow for taking care to minimize
engine damage.

1) Thoroughly wash away mud, salt,
seaweed, etc. with fresh water.

2) Remove the spark plugs and face the
spark plug holes downward to allow
any water, mud or contaminants to
drain.

3) Drain the fuel from the carburetor.

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

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

107014

cC

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

5-9

EMP00010

E

Chapter 6

INDEX

INDEX .............................................6-1

1

2

3

4

5

6

E

EMP10010

INDEX

A

Adjusting idling speed ........................4-14

Adjusting trim angle............................3-20

Air vent screw ........................................2-4

B

Basic Boating rules ................................1-6

Breaking in (running in) engine............3-9

C

Changing gear oil ................................4-22

Checking bolts and nuts......................4-25

Checking fuel system ..........................4-12

Checking painted surface of motor ....4-25

Checking propeller; shear pin and

cotter pin ..............................................4-19

Checking wiring and connectors ........4-15

Choke knob.............................................2-7

Clamping the outboard motor..............3-4

Cleaning and adjusting spark plug.....4-10

Cleaning fuel tank ................................4-23

Cleaning the outboard motor .............4-25

Coating the boat bottom .....................4-25

Cruising in other conditions ...............3-27

Cruising in salt water...........................3-27

Cruising in shallow water ...................3-22

Cruising in turbid water ......................3-27

E

Emission control information ...............1-2

Engine oil..............................................1-11

Engine stop button ................................2-6

Exhaust leakage ...................................4-14

F

Filling fuel...............................................3-5

Filling fuel and engine oil......................3-5

Forward ................................................3-16

Fuel cock.................................................2-8

Fuel hose joint........................................2-4

Fuel meter ..............................................2-4

Fuel tank .................................................2-4

Fuel tank cap ..........................................2-4

Fueling instructions .............................1-10

G

Gasoline (petrol) and oil mixing...........3-6

Gasoline (petrol) ..................................1-11

Gear shift lever.......................................2-5

Greasing ...............................................4-16

I

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

Impact damage ......................................5-5

Important labels.....................................1-5

Index .......................................................6-1

Inspecting and replacing anode .........4-24

Inspecting and replacing fuel filter.....4-13

Installation..............................................3-1

M

Main components..................................2-1

Maintenance chart .................................4-9

Motor exterior ......................................4-25

Mounting the outboard motor..............3-2

Mounting height ....................................3-3

O

Operations of controls and

other functions.......................................2-4

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

P

Periodic maintenance............................4-8

Pre-operation checks .............................3-8

peller selection.....................................1-12

R

Recoil starter handle..............................2-7

Replacement parts.................................4-8

Reverse .................................................3-17

S

Safety information.................................1-3

Shifting .................................................3-16

Specification data ..................................4-1

Start-in-gear protection.......................1-13

Starter will not operate .........................5-6

Starting engine ....................................3-11

Steering friction adjustment ...............2-10

Stopping engine ..................................3-18

Storing outboard motor ........................4-4

6-1