Yamaha 5C (2015) User guide

OWNER’S MANUAL

Read this manual carefully before operating this

outboard motor.

5C

6A1-28199-7W-E0

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

WARNING

NOTICE

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.

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

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

EMU25122

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

OWNER’S MANUAL

5C

©2014 by Yamaha Motor Co., Ltd.

1st Edition, October 2014

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

Table of contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

EC Declaration of Conformity

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

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

Read manuals and labels ................ 5

Warning labels ................................... 5

Specifications and requirements..... 8

Specifications.................................. 8

Installation requirements................. 9

Boat horsepower rating...................... 9

Mounting outboard motor.................. 9

Battery requirements....................... 9

Without a rectifier or Rectifier

Regulator ........................................ 9

Propeller selection .......................... 9

Start-in-gear protection ............... 10

Engine oil requirements ................ 10

Fuel requirements ......................... 10

Gasoline ........................................... 10

Muddy or acidic water .................. 11

Anti-fouling paint .......................... 11

Outboard motor disposal

requirements.............................. 11

Emergency equipment.................. 11

Components .................................... 12

Components diagram ................... 12

Fuel tank........................................... 12

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

Fuel joint........................................... 13

Fuel gauge........................................ 13

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

Air vent screw................................... 13

Fuel cock.......................................... 13

Open................................................. 14

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

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

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

Throttle indicator ............................. 14

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

Engine shut-off cord (lanyard) and

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

Engine stop button .......................... 15

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

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

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

Trim rod (tilt pin) ............................... 16

Tilt support bar................................. 17

Cowling lock lever(s) (turn type) ....... 17

Installation ....................................... 18

Installation..................................... 18

Mounting the outboard motor .......... 18

Clamping the outboard motor.......... 19

Table of contents

Operation ......................................... 21

First-time operation....................... 21

Breaking in engine............................ 21

Getting to know your boat ............... 21

Checks before starting engine ...... 21

Fuel level .......................................... 21

Remove the top cowling .................. 22

Fuel system...................................... 22

Controls............................................ 22

Engine shut-off cord (lanyard).......... 22

Oil ..................................................... 22

Engine .............................................. 22

Install top cowling ............................ 22

Filling fuel and engine oil............... 23

Filling fuel for portable tank.............. 23

Filling fuel for built-in tank................ 24

Gasoline and oil mixing (100:1) ........ 25

Operating engine........................... 26

Sending fuel (portable tank) ............. 26

Sending fuel ..................................... 27

Starting engine................................. 28

Checks after starting engine ......... 30

Cooling water ................................... 30

Warming up engine ....................... 30

Choke start models.......................... 30

Checks after engine warm up ....... 30

Shifting ............................................. 30

Stop switches................................... 30

Shifting .......................................... 30

Stopping boat ............................... 31

Stopping engine ............................ 31

Procedure......................................... 31

Trimming outboard motor ............. 32

Adjusting trim angle for manual tilt

models .......................................... 33

Adjusting boat trim........................... 33

Tilting up and down ...................... 34

Procedure for tilting up

(manual tilt models)....................... 34

Procedure for tilting down

(manual tilt models)....................... 35

Shallow water ............................... 36

Cruising in shallow water

(manual tilt models)....................... 36

Cruising in other conditions.......... 37

Maintenance.................................... 38

Transporting and storing outboard

motor ......................................... 38

Clamp screw mounting models ....... 38

Storing outboard motor.................... 39

Procedure......................................... 39

Lubrication ....................................... 40

Cleaning the outboard motor........... 40

Checking painted surface of

outboard motor............................. 40

Periodic maintenance ................... 40

Replacement parts........................... 41

Severe operating conditions ............ 41

Maintenance chart 1......................... 42

Maintenance chart 2......................... 43

Greasing ........................................... 44

Cleaning and adjusting spark plug... 45

Checking fuel filter............................ 45

Inspecting idle speed ....................... 46

Inspecting wiring and connectors .... 46

Checking propeller ........................... 46

Removing propeller.......................... 47

Installing propeller............................ 47

Changing gear oil ............................. 48

Inspecting and replacing anode(s) ... 49

Trouble Recovery............................ 50

Troubleshooting............................ 50

Temporary action in emergency ... 53

Impact damage ................................ 53

Starter will not operate..................... 53

Emergency starting engine............... 54

Treatment of submerged motor.... 55

INDEX ............................................... 56

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.

EMU33641

Hot parts

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

EMU33651

Electric shock

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

EMU33672

Engine shut-off cord (lanyard)

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

EMU33811

Gasoline

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

to the procedure on page 26 to reduce the
risk of fire and explosion.

EMU33821

Gasoline exposure and spills

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

1

Safety information

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.

EMU33741

Boating safety

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

EMU33711

Alcohol and drugs

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

EMU40281

Personal flotation devices (PFDs)

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

EMU33732

People in the water

Always watch carefully for people in the wa­ter, such as swimmers, skiers, or divers,
whenever the engine is running. When some­one is in the water near the boat, shift into
neutral and stop the engine.
Stay away from swimming areas. Swimmers
can be hard to see.

The propeller can keep moving even when
the motor is in neutral. Stop the engine when
a person is in the water near you.

EMU33752

Passengers

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

EMU33762

Overloading

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

EMU33773

Avoid collisions

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

2

Safety information

ZMU06025

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.

EMU33791

Weather

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

EMU33881

Passenger training

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

EMU33891

Boating safety publications

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

EMU33601

Laws and regulations

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

3

General information

3412

ZMU01692

ZMU06040

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

EMU37292

EC Declaration of Conformity

(DoC)

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

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

code)

 Code of conformed directives

EMU25207

CE Marking

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

1. Serial number

2. Model name

3. Motor transom height

4. Approved model code

1. CE marking location

4

General information

ZMU06034

4

1

3

2

3

EMU33524

Read manuals and labels

Before operating or working on this outboard motor:

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

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

EMU33834

Warning labels

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

5

General information

WARNING

WARNING

WARNING

ZMU05920

1

2

3

4

EMU35282

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 de-

vice (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.

6

General information

WARNING

ZMU05696

ZMU05664

ZMU05665

ZMU05666

4

EWM01702

Gasoline is highly flammable and explo­sive. Shut off engine before refueling.
Tighten tank cap and air vent screw when
not in use.

EMU35133

Symbols

The following symbols mean as follows.

Notice/Warning

Read Owner’s Manual

Hazard caused by continuous rotation

Electrical hazard

7

Specifications and requirements

TIP:

EMU38092

Specifications

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

EMU2821U

Dimension and weight:

Overall length:

677 mm (26.7 in)

Overall width:

322 mm (12.7 in)

Overall height S:

1011 mm (39.8 in)

Overall height L:

1138 mm (44.8 in)

Motor transom height S:

444 mm (17.5 in)

Motor transom height L:

571 mm (22.5 in)

Dry weight (AL) S:

21 kg (46 lb)

Dry weight (AL) L:

22 kg (47 lb)

Performance:

Full throttle operating range:

4500–5500 r/min

Rated power:

3.7 kW (5 HP)

Idle speed (in neutral):

1100–1200 r/min

Power unit:

Type:

2-stroke S1

Total displacement:

103 cm³ (6.3 c.i.)

Bore × stroke:

54.0 × 45.0 mm (2.13 × 1.77 in)

Ignition system:

CDI

Spark plug (NGK):

BR7HS

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Steering system:

Tiller handle

Starting system:

Manual starter

Starting carburetion system:

Choke valve

Alternator output:

40/60 W

Lower unit:

Gear shift positions:

Forward-neutral-reverse

Gear ratio:

2.08 (27/13)

Trim and tilt system:

Manual tilt

Propeller mark:

BA

Fuel and oil:

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

90

Fuel tank capacity:

12 L (3.17 US gal, 2.64 Imp.gal)

Fuel tank capacity (built in type):

2.8 L (0.74 US gal, 0.62 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

8

Specifications and requirements

WARNING

WARNING

NOTICE

Recommended gear oil grade:

SAE 90 API GL-4

Gear oil quantity:

0.100 L (0.106 US qt, 0.088 Imp.qt)

Tightening torque:

Spark plug:

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

Noise and vibration level:

Operator sound pressure level (ICOMIA
39/94):

81.4 dB(A)

Vibration on tiller handle (ICOMIA 38/94):

6.0 m/s²

EMU33555

Installation requirements

EMU33565

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 boats
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 18.

EMU25695

Battery requirements

EMU25732

Without a rectifier or Rectifier Regula­tor

ECM01091

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

If you wish to use a battery with the models
without a rectifier or Rectifier Regulator, in­stall an optional Rectifier Regulator.
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
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

9

Specifications and requirements

NOTICE

ZMU04604

-

x

123

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 46.

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

EMU39192

Start-in-gear protection

Yamaha outboard motors are equipped with
start-in-gear protection device. This feature
permits the engine to be started only when it
is in neutral. Always select neutral before
starting the engine.

EMU25652

Engine oil requirements

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.

EMU36361

Fuel requirements

EMU40202

Gasoline

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

Recommended fuel:

Regular unleaded gasoline

Min. research octane number (RON):

90

ECM01982

 Do not use leaded gasoline. Leaded

gasoline can seriously damage the en­gine.

 Avoid getting water and contaminants in

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

Gasohol

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

10

Specifications and requirements

sorbed 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.

EMU36353

Emergency equipment

Keep the following items onboard in case
there is trouble with the outboard motor.
 A tool kit with assorted screwdrivers, pliers,

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.

EMU40302

Outboard motor disposal re-

quirements

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

11

Components

TIP:

WARNING

EMU2579Z

Components diagram

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

1. Air vent screw

2. Fuel tank cap

3. Top cowling

4. Cowling lock lever

5. Steering friction adjuster

6. Anti-cavitation plate

7. Propeller*

8. Cooling water inlet

9. Trim rod

10.Clamp bracket

11.Clamp screw

12.Tiller handle

13.Throttle friction adjuster

14.Manual starter handle

15.Choke knob

16.Engine stop button/Engine shut-off switch

17.Restraint cable attachment

18.Tilt support bar

19.Gear shift lever

20.Fuel cock

21.Fuel tank

EMU25804

Fuel tank

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

EWM00021

The fuel tank supplied with this engine is
its dedicated fuel reservoir and must not
be used as a fuel storage container. Com-

12

Components

ZMU01992

3

2

4

1

mercial users should conform to relevant
licensing or approval authority regula­tions.

1. Air vent screw

2. Fuel gauge

3. Fuel joint

4. Fuel tank cap

EMU25822

Fuel tank

If your model included a fuel tank, its parts
and functions are as follows.

EMU25851

Fuel tank cap

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

EMU25861

Air vent screw

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

EMU25873

Fuel cock

The fuel cock turns on and off the supply of
fuel from the fuel tank to the engine.

1. Fuel cock

EMU25882

Close

To stop fuel flow to the engine, turn the lever
or knob to close position.
Always turn the lever or knob to close posi­tion when the engine is not running.

1. Air vent screw

2. Fuel tank cap

EMU25831

Fuel joint

This joint is used to connect the fuel line.

EMU25842

Fuel gauge

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

13

1. Close position

EMU25902

Open

The fuel cock has two open positions, one for
selecting fuel flow from the built-in fuel tank,
and one for an external tank.
Fuel flows to the carburetor with the lever or
knob in either open position. These are the
normal running positions.

1. “OPEN” position for the built-in tank

2. “OPEN” position for the portable tank

EMU25914

Tiller handle

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

Components

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

EMU25943

Throttle grip

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

EMU25925

Gear shift lever

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

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.

14

Components

1. Throttle indicator

EMU25977

Throttle friction adjuster

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

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

[EWM00033]

EMU25996

Engine shut-off cord (lanyard) and clip

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

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

[EWM00123]

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

15

1. Engine shut-off cord (lanyard)

2. Clip

3. Engine shut-off switch

EMU26004

Engine stop button

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

EMU26021

WARNING

Choke knob

To supply the engine with the rich fuel mix­ture required to start, turn this knob to the
right.

Components

EMU26123

Steering friction adjuster

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

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

EWM00041

EMU26075

Manual starter handle

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

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

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.

16

Components

NOTICE

EMU26334

Tilt support bar

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

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.

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. Cowling lock lever(s)

17

EMU26903

WARNING

WARNING

ZMU01760

1

ZMU02011

0–25mm
(0–1in)

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

Installation

 Overpowering a boat could cause se-

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

 Improper mounting of the outboard mo-

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

EMU26912

Mounting the outboard motor

EWM01721

Your dealer or other person experienced
in proper outboard motor mounting
should show you how to mount your 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.

18

Installation

NOTICE

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

 The optimum mounting height of the out-

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

 For instructions on setting the trim angle of

the outboard motor, see page 32.

EMU26974

Clamping the outboard motor

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

WARNING! Loose clamp screws could

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

[EWM00643]

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

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

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

19

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]

Installation

20

Operation

NOTICE

WARNING

NOTICE

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-planing
boat, accelerate at full throttle onto
plane, then immediately reduce the
throttle to 3000 r/min or less.

[ECM00802]

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 three-quarter
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 23.

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 32).

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. Over­heating and serious engine damage can
occur.

EMU37142

Fuel level

Be sure you have ple nty 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

21

Operation

WARNING

WARNING

ZMU06089

ZMU06873

1

2

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 23.

EMU36573

Remove the top cowling

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

EMU36443

Fuel system

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 explosion.

 Check for fuel leakage regularly.
 If any fuel leakage is found, the fuel sys-

tem must be repaired by a qualified me­chanic. Improper repairs can make the
outboard unsafe to operate.

EMU36452

Check for fuel leaks

 Check for fuel leaks or gasoline fumes in

the boat.

 Check for fuel leakage from the fuel sys-

tem.

 Check the fuel tank and fuel lines for

cracks, swellings, or other damages.

EMU36892

Controls

 Move the tiller handle fully to the left and

right to make sure operation is smooth.

 Turn the throttle grip from the fully closed

to the fully open position. Make sure that it
turns smoothly and that it completely re­turns to the fully closed position.

 Look for loose or damaged connections of

the throttle and shift cables.

EMU36484

Engine shut-off cord (lanyard)

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

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.

EMU36956

Install top cowling

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

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

22

Operation

WARNING

ZMU06114

ZMU06621

3. Place the top cowling on the bottom
cowling.

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

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

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

[ECM01992]

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

EMU27235

Filling fuel and engine oil

EMU27249

Filling fuel for portable tank

EWM01831

 Gasoline and its vapors are highly flam-

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

 Gasoline is poisonous and can cause in-

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

1. Be sure the engine is stopped.

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

23

3. Remove the portable tank from the boat.

WARNING

WARNING

ZMU04484

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

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

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

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

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

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

[EWM02611]

Fuel tank capacity:

12 L (3.17 US gal, 2.64 Imp.gal)

Operation

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

EMU27257

Filling fuel for built-in tank

EWM01951

Be sure the outboard motor is securely
fastened to the transom or a stable stand.

EWM01831

 Gasoline and its vapors are highly flam-

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

 Gasoline is poisonous and can cause in-

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

1. Be sure the engine is stopped.

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

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

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

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

9. Tighten the filler cap securely.

24

Operation

NOTICE

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

6. Fill fuel to the upper fuel level mark on the
fuel tank. Do not overfill. WARNING! Do

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

[EWM02611]

Fuel tank capacity:

2.8 L (0.74 US gal, 0.62 Imp.gal)

7. Tighten the filler cap securely.

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

EMU27407

Gasoline and oil mixing (100:1)

ECM00812

Gasoline to engine oil

ratio

Break-in period See page 21

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.

 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.

25

1. Engine oil

2. Gasoline

2. Replace the fuel tank cap and close

TIP:

WARNING

tightly.

3. Shake the fuel tank to mix the fuel thor­oughly.

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.

1. Engine oil

2. Gasoline

2. Replace the fuel can cap and close tight­ly.

3. Shake the fuel can to mix the fuel thor­oughly.

4. Make sure that the oil and gasoline are
mixed.

5. Pour the gasoline and oil mixture into the
built-in fuel tank.

Operation

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.

EMU27469

Sending fuel (portable tank)

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

26

Operation

TIP:

ZMU02024

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.

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

1. Arrow

EMU27477

Sending fuel

1. For the built in tank, loosen the air vent
screw on the fuel tank cap by one turn.
For the external fuel tank, loosen it on the
fuel tank cap by 2 or 3 turns.

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

27

2. Select the fuel tank using the fuel cock or
open the fuel cock.

3. If you are using an external fuel tank,

WARNING

WARNING

TIP:

align the fuel joint on the fuel line with the
fuel joint on the motor and connect the
fuel joints securely while pinching the
joint. Then squeeze the primer pump,
with the arrow pointing up, until you feel
it become firm (if equipped the fuel joint).

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.

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

28

Operation

TIP:

TIP:

ZMU02030

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

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

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

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

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

 It is not necessary to use the choke when

starting a warm engine.

 If the choke knob is left in the “ ” (start)

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

29

 When the engine is cold, it needs to be

warmed up. For further information, see
page 30.

 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 50.

Operation

NOTICE

WARNING

NOTICE

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.

EMU36532

Checks after engine warm up

EMU36542

Shifting

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

EMU36972

Stop switches

Perform the following procedure to check
that the engine stop switch and engine shut­off switch operate properly.
 Start the engine, and then check that the

engine stops when the engine stop button
is pushed.

 Restart the engine, and then check that the

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

 Check that the engine cannot be started

with the clip removed from the engine shut­off switch.

EMU34611

Shifting

EWM00181

EMU27671

Warming up engine

EMU27684

Choke start models

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

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.

To shift out of neutral
Move the gear shift lever firmly and crisply
forward (for forward gear) or backward (for
reverse gear).

30

Operation

TIP:

WARNING

The outboard motor can turn 360° in its
bracket (full-pivot system). The boat can also
be backed up by simply turning the outboard
motor around 180° with the steering handle
facing toward you.

EMU31743

Stopping boat

EWM01511

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

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

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

 Do not use the reverse function to slow

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

 Do not shift into reverse while traveling

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

The boat is not equipped with a separate
braking system. Water resistance stops it af­ter the throttle lever is moved back to idle.
The stopping distance varies depending on
gross weight, water surface conditions, and
wind direction.

EMU27822

Stopping engine

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

EMU27834

Procedure

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

31

2. After stopping the engine, tighten the air

TIP:

WARNING

ZMU02043

1

vent screw on the fuel tank cap and set
the fuel cock lever or knob to the closed
position, if equipped.

Operation

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.

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.

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

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

1. Trim operating angle

32

Operation

WARNING

TIP:

EMU27873

Adjusting trim angle for manual tilt
models

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

1. Stop the engine.

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

1. Trim 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

 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
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.

33

Operation

TIP:

WARNING

WARNING

NOTICE

EWM00223

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

EWM00231

Bow Down

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

Depending on the type of boat, the outboard
motor trim angle may have little effect on the
trim of the boat when operating.

EMU27924

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.

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

ECM00232

 Before tilting the outboard motor, follow

the procedure under “Stopping engine”
in this chapter. 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 because this could break
the handle.

 Keep the power unit higher than the pro-

peller at all times. Otherwise water
could run into the cylinder and cause
damage.

 The outboard motor cannot be tilted

when in reverse or when the outboard
motor is turned 180° (facing the rear).

EMU34621

Procedure for tilting up (manual tilt
models)

1. Place the gear shift lever in neutral and
face the outboard motor forward.

34

Operation

NOTICE

TIP:

2. Tighten the steering friction adjuster by
turning it clockwise to prevent the motor
from turning freely.

3. Tighten the air vent screw.

4. Close the fuel cock.

ECM01671

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. For more detailed information, see
page 38.

If the motor is not facing forward, the tilt sup­port bar cannot automatically turn to the
locked position. If the tilt support bar does
not automatically lock, swing the motor a little
to the left and right.

EMU28034

Procedure for tilting down (manual tilt
models)

1. Slightly tilt the outboard motor up.

2. If equipped with the tilt support bar:
Slowly tilt the outboard motor down
while pulling the tilt support bar lever up.

5. Hold the rear of the top cowling or the
rear handle (if equipped) with one hand
and tilt the outboard motor up fully until
the tilt support bar automatically locks.

35

3. If equipped with the tilt support knob:

WARNING

NOTICE

Pull the knob out, and then slowly tilt the
outboard motor down.

4. If equipped with the tilt support lever:
Slowly tilt the outboard motor down
while pulling the tilt support lever up.

5. Loosen the steering friction adjuster by
turning it counterclockwise, and adjust
the steering friction according to opera­tor preference. WARNING! If there is

too much resistance it could be diffi­cult to steer, which could result in an
accident.

EMU28063

[EWM00722]

Shallow water

EMU35692

Cruising in shallow water (manual tilt
models)

EWM00712

Operation

 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

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

EMU28103

Procedure

1. Place the gear shift lever in neutral and
face the outboard motor forward.

 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.

 Do not rotate the outboard motor 180°

and operate the boat in reverse. Place
the gear shift in reverse to operate the
boat in reverse.

36

Operation

2. Slightly tilt the outboard motor up until
the tilt support bar automatically turns to
the lock position to support the engine.
The outboard motor is equipped with 2
or 3 positions for shallow water cruising.

3. To lower the outboard motor to the nor­mal running position, first slightly tilt the
outboard motor up. Then pull up the tilt
support bar lever and slowly tilt the en­gine down.

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.

EMU28196

Cruising in other conditions

Cruising in salt water

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

Cruising in muddy, turbid, or acidic water

Yamaha strongly recommends that you use
the optional chromium-plated water pump kit
(see page 11) if you use the outboard motor

37

Maintenance

WARNING

NOTICE

EMU2822B

Transporting and storing out-

board 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.

38

Maintenance

TIP:

NOTICE

ZMU02704

2

1

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

 Do not place the outboard motor on its

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

 Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

EMU28306

Procedure

EMU28316

Flushing in a water tank

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

ter into the air intake.

information, see page 40.

2. Place the fuel cock in the closed position
and disconnect the fuel line if equipped.
Tighten the air vent screw, if equipped.

3. Remove the engine top cowling and si­lencer cover.

4. Install the outboard motor on the test
tank.

[ECM01841] For further

1. Lowest water level

2. Water surface

5. 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]

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

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

[EWM00092]

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

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

39

Maintenance

TIP:

TIP:

WARNING

1

ZMU07862

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

10. Remove the outboard motor from the
test tank.

11. Install the silencer cover or fogging hole
cap, and the top cowling.

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

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

14. Drain the fuel from both the built-in and
portable fuel tanks, on equipped models.

Portable fuel tank equipped models: Store
the portable fuel tank in a dry, well-ventilated
place, not in direct sunlight.

EMU41072

Lubrication

1. Change the gear oil. For instructions, see
page 48. 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 44.

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.

EMU44341

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]

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

EMU28462

Checking painted surface of outboard
motor

Check the outboard motor for scratches,
nicks, or flaking paint. Areas with damaged
paint are more likely to corrode. If necessary,
clean and paint the areas. A touch-up paint is
available from your Yamaha dealer.

EMU37075

Periodic maintenance

EWM01982

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

40

Maintenance

 Turn off the engine and keep engine

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

 Allow the engine to cool before handling

hot parts or fluids.

 Always completely reassemble the mo-

tor before operation.

EMU28512

Replacement parts

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

EMU34152

Severe operating conditions

Severe operating conditions involve one or
more of the following types of operation on a
regular basis:
 Operating continuously at or near maxi-

mum engine speed (rpm) for many hours

 Operating continuously at a low engine

speed (rpm) for many hours

 Operating without sufficient time for engine

to warm up and cool down

 Frequent quick acceleration and decelera-

tion

 Frequent shifting
 Frequently starting and stopping the en-

gine(s)

 Operation that fluctuates often between

light and heavy cargo loads
Outboard motors operating under any of
these above conditions require more fre­quent maintenance. Yamaha recommends
that you do this service twice as often as
specified in the maintenance chart. For 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.

41

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)

Cooling water leakage

Cowling lock lever Inspection

Engine starting condi­tion/noise

Engine idle
speed/noise

Fuel filter (disposal
type)

Fuel filter (inside built­in fuel tank)

Fuel line Inspection

Fuel line

Fuel pump

Fuel/engine oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Impeller/water pump
housing

Impeller/water pump
housing

Inspection or replace­ment as necessary

Inspection or replace­ment as necessary

Inspection

Inspection

Replacement

Inspection and clean­ing as necessary

Inspection or replace­ment as necessary

Inspection or replace­ment as necessary

Inspection or replace­ment as necessary

Replacement

20 hours

(3 months)

100 hours

(1 year)

300 hours

(3 years)

500 hours

(5 years)

42

Maintenance

Item Actions

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

Fuel tank (Yamaha por­table tank)

Fuel tank (built-in tank)

EMU34452

Maintenance chart 2

Item Actions

Exhaust guide/ex­haust manifold

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

Inspection and clean­ing as necessary

Inspection or replace­ment as necessary

Initial Every

20 hours

(3 months)

100 hours

(1 year)

Every

1000 hours

300 hours

(3 years)

500 hours

(5 years)

43

EMU28945

Greasing

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

Maintenance

44

Maintenance

TIP:

EMU44491

Cleaning and adjusting spark plug

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

1. Remove the spark plug caps from the

spark plugs.

2. Remove the spark plug. If electrode 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.

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.

[EWM00562]

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
the correct torque.

Spark plug torque:

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

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.

EMU28992

Checking fuel filter

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 your
Yamaha dealer.

45

EMU29045

WARNING

NOTICE

WARNING

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

Maintenance

EMU29116

Inspecting wiring and connectors

 Inspect that each connector is engaged se-

curely.

 Inspect that each ground lead is properly

secured.

EMU39302

Checking propeller

EWM02281

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
gear shift lever in neutral, and remove the
clip from the engine shut-off switch.

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.

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 8. If you have difficulty verifying the
idle speed, or the idle speed requires ad­justment, consult a Yamaha dealer or
other qualified mechanic.

Checkpoints
 Check each of the propeller blades for ero-

sion from cavitation or ventilation, or other
damage.

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

peller shaft.

 Check the propeller shaft oil seal for dam-

age.

46

Maintenance

NOTICE

EMU30673

Installing propeller

EMU30374

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.

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]

1. Cotter pin

2. Propeller nut

3. Washer

4. Propeller

5. Thrust washer

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

1. Apply Yamaha marine grease or a corro­sion resistant grease to the propeller
shaft.

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

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

[ECM01882]

3. Install the spacer (if equipped) and the
washer. Tighten the propeller nut until
there is no forward-and-backward
movement.

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

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

[ECM01892]

47

Maintenance

TIP:

WARNING

TIP:

TIP:

If the propeller nut does not align with the
propeller shaft hole after tightening it, loosen
the nut until it aligns with the hole.

EMU2928C

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 accidentally
falls.

1. Tilt the outboard motor so that the gear
oil drain screw is at the lowest point pos­sible.

2. Place a suitable container under the gear
case.

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

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

[ECM01901]

 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]

For disposal of used oil, consult your Yamaha
dealer.

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

Recommended gear oil:

YAMALUBE outboard gear oil or Hyp­oid gear oil

Recommended gear oil grade:

SAE 90 API GL-4

Gear oil quantity:

0.100 L (0.106 US qt, 0.088 Imp.qt)

1. Gear oil drain screw

2. Oil level plug

48

Maintenance

NOTICE

TIP:

6. Put a new gasket on the oil level plug.
When the oil begins to flow out of the oil
level plug hole, insert and tighten the oil
level plug.

Tightening torque:

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

7. Put a new gasket on the gear oil drain
screw. Insert and tighten the gear oil
drain screw.

Tightening torque:

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

EMU29317

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

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.

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

49

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 28.

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.

50

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?

51

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?

Trouble Recovery

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.

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. Are weeds or other foreign matter tangled
on gear housing?
A. Remove foreign matter and clean lower
unit.

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

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

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

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

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

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

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

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

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

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

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

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

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

Q. Is fuel pump damaged?

52

Trouble Recovery

WARNING

A. Have serviced by a Yamaha dealer.

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

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

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

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

Engine vibrates excessively.

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

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

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

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

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

EMU29434

Temporary action in emergen-

cy

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 the wa­ter, follow the procedure below.

1. Stop the engine immediately.

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

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

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

EMU39792

Starter will not operate

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

53

Trouble Recovery

WARNING

EWM02362

 Use this procedure only for emergency

engine starting to return to the nearest
port for repairs.

 When the emergency starter rope is

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

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

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

 Do not attach the cord to clothing that

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

 Avoid accidentally pulling the cord dur-

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

 Make sure that no one is standing be-

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

 An unguarded, rotating flywheel is very

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

 Do not touch the ignition coil, spark plug

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

EMU29563

Emergency starting engine

1. Remove the top cowling.

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

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

4. Prepare the engine for starting. For fur­ther information, see page 28. Be sure
the engine is in neutral and that the clip is
attached to the engine shut-off switch.
The main switch must be “ ” (on), if
equipped.

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

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

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

54

Trouble Recovery

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]

55

INDEX

A

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

Anode(s), inspecting and replacing ...... 49

Anti-fouling paint .................................. 11

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

B

Battery requirements.............................. 9

Boat horsepower rating.......................... 9

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

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

Breaking in engine................................ 21

C

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

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

Checks after engine warm up............... 30

Checks after starting engine................. 30

Checks before starting engine.............. 21

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

Clamping the outboard motor .............. 19

Cleaning the outboard motor ............... 40

Components diagram........................... 12

Control functions, checking.................. 22

Cooling water ....................................... 30

Cowling lock lever ................................ 17

Cruising in salt water or other

conditions...........................................37

E

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

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

Emergency equipment ......................... 11

Emergency starting engine................... 54

Emergency, temporary action in........... 53

Engine, checking .................................. 22

Engine oil, checking.............................. 22

Engine oil requirements........................ 10

Engine shut-off cord (lanyard) .......... 1, 22

Engine shut-off cord (lanyard) and

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

Engine stop button ............................... 15

F

Filling fuel for built-in tank .................... 24

Filling fuel for portable tank ..................23

First-time operation .............................. 21

Flushing in a water tank........................ 39

Fuel and engine oil, filling ..................... 23

Fuel cock .............................................. 13

Fuel filter, checking............................... 45

Fuel leaks, checking for........................ 22

Fuel level...............................................21

Fuel requirements................................. 10

Fuel system...........................................22

Fuel tank ......................................... 12, 13

G

Gasoline............................................1, 10

Gasoline and oil mixing ........................25

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

Gear oil, changing................................. 48

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

Greasing ...............................................44

H

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

I

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

Idle speed, inspecting........................... 46

Impact damage.....................................53

Installation requirements ........................9

L

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

Lubrication............................................ 40

M

Maintenance chart 1............................. 42

Maintenance chart 2............................. 43

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

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

Mounting height....................................18

Mounting outboard motor ...................... 9

Mounting the outboard motor .............. 18

Muddy or acidic water.......................... 11

56

INDEX

O

Operating engine .................................. 26

Outboard motor disposal

requirements ...................................... 11

Outboard motor (painted surface),

checking............................................. 40

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

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

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

P

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

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

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

Periodic maintenance........................... 40

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

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

Propeller, checking............................... 46

Propeller, installing ............................... 47

Propeller, removing .............................. 47

Propeller selection.................................. 9

R

Read manuals and labels ....................... 5

Rectifier Regulator (optional) .................. 9

Replacement parts ............................... 41

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

Stopping engine ...................................31

Storing outboard motor ........................ 39

Submerged outboard motor................. 55

T

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

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

Throttle indicator................................... 14

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

Tilt support bar ..................................... 17

Tilting up and down.............................. 34

Top cowling, installing.......................... 22

Top cowling, removing .........................22

Transporting and storing outboard

motor ..................................................38

Trim rod (tilt pin).................................... 16

Trimming outboard motor.....................32

Troubleshooting....................................50

W

Warming up engine...............................30

Warning labels ........................................ 5

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

Wiring and connectors, inspecting ....... 46

S

Sending fuel..........................................27

Sending fuel (portable tank).................. 26

Severe operating conditions................. 41

Shallow water ....................................... 36

Shifting.................................................. 30

Shifting (checks after engine warm

up) ...................................................... 30

Spark plug, cleaning and adjusting ...... 45

Specifications ......................................... 8

Starter will not operate ......................... 53

Starting engine .....................................28

Start-in-gear protection........................ 10

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

Stop switches....................................... 30

Stopping boat....................................... 31

57

Printed in Japan
December 2014–0.1 × 1 CR

Printed on recycled paper