Yamaha 75C, 90A User Manual

OWNER’S MANUAL

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Read this manual carefully before operating this

outboard motor.

75C
90A

67P-28199-74-E0

EMU25052

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

T

T

EMU25105

To the owner

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

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

EWM00781

WARNING

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

ECM00701

NOTICE

A NOTICE indicates special precautions
that must be taken to avoid damage to the
outboard motor or other property.

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

IP:

The 75CETO, 90AETO and the standard ac­cessories are used as a base for the expla­nations and illustrations in this manual.
Therefore some items may not apply to ev­ery model.

EMU25121

IP:

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

Yamaha continually seeks advancements in
product design and quality. Therefore, while
this manual contains the most current prod­uct information available at the time of print­ing, there may be minor discrepancies
between your machine and this manual. If

75C, 90A

OWNER’S MANUAL

©2008 by Yamaha Motor Co., Ltd.

1st Edition, April 2008

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

Power trim and tilt .............................1

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

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

Gasoline exposure and spills ............ 2

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

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

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

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

Personal flotation devices ................. 2

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

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

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

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

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

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

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

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

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

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

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

Key number....................................... 4

EC Declaration of Conformity

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

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

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

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

Specifications and requirements..... 9

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

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

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

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

Remote control requirements........ 10

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

Battery specifications ...................... 11

Mounting battery .............................11

Multiple batteries............................. 11

Propeller selection......................... 11

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

Engine oil requirements ................ 12

Fuel requirements......................... 12

Gasoline .......................................... 12

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

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

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

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

Components .................................... 14

Components diagram.................... 14

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

Fuel joint.......................................... 15

Fuel gauge ......................................15

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

Air vent screw.................................. 15

Remote control box ......................... 15

Remote control lever ....................... 15

Neutral interlock trigger ................... 16

Neutral throttle lever........................ 16

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

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

Throttle grip ..................................... 17

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

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

Engine shut-off cord (lanyard) and

clip................................................. 18

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

Main switch .....................................19

Steering friction adjuster .................19

Power trim and tilt switch on

remote control or tiller handle .......19

Power trim and tilt switch on

bottom engine cowling ..................20

Trim tab with anode......................... 20

Trim rod (tilt pin) .............................. 21

Tilt support lever for power trim

and tilt model................................. 21

Top cowling lock lever(s)

(turn type)...................................... 21

Flushing device ...............................22

Instruments and indicators............ 23

Digital tachometer......................... 23

Tachometer ..................................... 23

Trim meter....................................... 23

Hour meter ......................................23

Oil level indicator (digital type) ........24

Overheat-alert indicator................... 24

Table of contents

Digital speedometer ...................... 24

Speedometer .................................. 24

Fuel gauge ...................................... 25

Trip meter / Clock / Voltmeter .........25

Fuel level-alert indicator.................. 26

Low battery voltage-alert

indicator ........................................ 26

Analog tachometer ........................ 26

Oil level indicators (three

indicators 2) .................................. 26

Analog trim meter.......................... 27

Engine control system.................... 28

Alert system .................................. 28

Overheat alert .................................28

Oil level alert and oil filter clogging

alert............................................... 28

Installation .......................................30

Installation ..................................... 30

Mounting the outboard motor.......... 30

Operation .........................................32

First-time operation ....................... 32

Breaking in engine ..........................32

Getting to know your boat ............... 32

Checks before starting engine ...... 32

Fuel level......................................... 33

Remove cowling.............................. 33

Fuel system..................................... 33

Controls........................................... 33

Engine shut-off cord (lanyard)......... 34

Oil.................................................... 34

Engine............................................. 34

Operation after long period of

storage.......................................... 34

Flushing device ............................... 35

Install cowling.................................. 35

Checking power trim and tilt

system .......................................... 36

Battery............................................. 36

Filling fuel and engine oil............... 36

Filling fuel for portable tank............. 36

Filling oil for electric start models.... 37

Oil level indicator operation............. 39

Operating engine........................... 39

Feeding fuel (portable tank) ............ 39

Starting engine................................ 40

Checks after starting engine ......... 43

Cooling water ..................................43

Warming up engine....................... 43

Electric start and prime start

models ..........................................43

Checks after engine warm-up....... 43

Shifting ............................................43

Stop switches .................................. 43

Shifting.......................................... 44

Stopping boat................................ 45

Stopping engine............................ 45

Procedure........................................ 45

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

Adjusting trim angle (Power trim

and tilt) ..........................................47

Adjusting boat trim ..........................48

Tilting up and down....................... 48

Procedure for tilting up (power

trim and tilt models)....................... 49

Procedure for tilting down (power

trim and tilt models)....................... 50

Shallow water................................ 51

Power trim and tilt models............... 51

Cruising in other conditions........... 52

Maintenance .................................... 53

Transporting and storing

outboard motor ........................... 53

Storing outboard motor ...................53

Procedure........................................ 53

Lubrication (oil injection models)..... 54

Flushing power unit ......................... 55

Cleaning the outboard motor........... 55

Checking painted surface of

motor.............................................56

Periodic maintenance ................... 56

Replacement parts .......................... 56

Severe operating conditions............ 56

Maintenance chart 1........................ 58

Maintenance chart 2........................ 60

Greasing.......................................... 61

Cleaning and adjusting spark

plug ...............................................61

Checking fuel filter........................... 62

Inspecting idling speed.................... 62

Checking water in engine oil tank ...63

Table of contents

Checking wiring and connectors ..... 63

Checking propeller .......................... 63

Removing propeller......................... 64

Installing propeller........................... 64

Changing gear oil............................ 65

Cleaning fuel tank ...........................66

Inspecting and replacing

anode(s)........................................ 67

Checking battery (for electric start

models) ......................................... 67

Connecting the battery.................... 68

Disconnecting the battery ............... 68

Trouble Recovery............................ 70

Troubleshooting ............................ 70

Temporary action in emergency.... 73

Impact damage ...............................73

Replacing fuse ................................73

Power trim and tilt will not

operate.......................................... 74

Starter will not operate .................... 74

Emergency starting engine .............75

Engine fails to operate .................. 76

Ignition system malfunction............. 76

Cold engine fails to start ................. 76

Treatment of submerged motor..... 78

Safety information

EMU33622

Outboard motor safety

Observe these precautions at all times.

EMU36500

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.

●

Shut off the engine when a person is in the
water near you.

●

Keep people out of reach of the propeller,
even when the engine is off.

EMU33630

Rotating parts

Hands, feet, hair, jewelry, clothing, PFD
straps, etc. can become entangled with inter­nal rotating parts of the engine, resulting in
serious injury or death.
Keep the top cowling in place whenever pos­sible. Do not remove or replace the cowling
with the engine running.
Only operate the engine with the cowling re­moved according to the specific instructions
in the manual. Keep hands, feet, hair, jewel­ry, clothing, PFD straps, etc. away from any
exposed moving parts.

EMU33640

Hot parts

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

EMU33650

Electric shock

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

EMU33660

Power trim and tilt

Body parts can be crushed between the mo-

tor and the clamp bracket when the motor is
trimmed or tilted. Keep body parts out of this
area at all times. Be sure no one is in this
area before operating the power trim and tilt
mechanism.
The power trim and tilt switches operate
even when the main switch is off. Keep peo­ple be away from the switches whenever
working around the motor.
Never get under the lower unit while it is tilt­ed, even when the tilt support lever is locked.
Severe injury could occur if the outboard mo­tor accidentally falls.

EMU33671

Engine shut-off cord (lanyard)

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

EMU33810

Gasoline

Gasoline and its vapors are highly flam­mable and explosive.

cording to the procedure on page 39 to
reduce the risk of fire and explosion.

Always, refuel ac-

1

Safety information

EMU33820

Gasoline exposure and spills

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

EMU33900

Carbon monoxide

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

EMU33780

Modifications

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

EMU33740

Boating safety

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

EMU33710

Alcohol and drugs

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

EMU33720

Personal flotation devices

Have an approved personal flotation device
(PFD) on board for every occupant. Yamaha

recommends that you must wear a PFD
whenever boating. At a minimum, children
and non-swimmers should always wear
PFDs, and everyone should wear PFDs
when there are potentially hazardous boat­ing conditions.

EMU33730

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 shut off the motor.
Stay away from swimming areas. Swimmers
can be hard to see.
The propeller can keep moving even when
the motor is in neutral. Shut off the engine
when a person is in the water near you.

EMU33750

Passengers

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

EMU33760

Overloading

Do not overload the boat. Consult the boat
capacity plate or boat manufacturer for max­imum weight and number of passengers. Be
sure that weight is properly distributed ac­cording to the boat manufacturers instruc­tions. Overloading or incorrect weight
distribution can compromise the boats han-

2

Safety information

dling and lead to an accident, capsizing or
swamping.

EMU33771

Avoid collisions

Scan constantly

other boats. Be alert for conditions that limit
your visibility or block your vision of others.

Operate defensively

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 aggres­sive maneuvers to reduce the risk of loss
of control, ejection, and collision.

●

Take early action

member,
stopping the engine or reducing throttle
can reduce the ability to steer. If you are
not sure that you can stop in time before
hitting an obstacle, apply throttle and turn
in another direction.

EMU33790

for people, objects, and

ZMU06025

at safe speeds and

to avoid collisions. Re-

boats do not have brakes

, and

Weather

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

boating in hazardous weather.

EMU33880

Passenger training

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

EMU33890

Boating safety publications

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

EMU33600

Laws and regulations

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

3

General information

EMU25171

Identification numbers record

EMU25183

Outboard motor serial number

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

1

ZMU02931

1. Outboard motor serial number location

EMU25190

Key number

If a main key switch is equipped with the mo­tor, the key identification number is stamped
on your key as shown in the illustration.
Record this number in the space provided for
reference in case you need a new key.

1. Key number

EMU37290

EC Declaration of Conformity

(DoC)

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

Name of Engine Manufacture

●

●

Model name
Product code of model (Approved model

●

code)

●

Code of conformed directives

4

EMU25203

CE Marking

Outboard motors affixed with this “CE”mark­ing conform with the directives of; 98/37/EC,
94/25/EC - 2003/44/EC and 2004/108/EC.

1

ZMU04693

1. CE marking location

General information

ZMU06040

5

General information

EMU33520

Read manuals and labels

Before operating or working on this 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.

EMU33831

Warning labels

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

1

2

3

ZMU06213

6

General information

1

EMU33912

Contents of labels

The above warning labels mean as follows.

1

EWM01691

WARNING

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

2

EWM01681

WARNING

●

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.

2

3

ZMU05706

3

EWM01671

WARNING

●

Read Owner’s Manuals and labels.

●

Wear an approved personal flotation
device (PFD).

●

Attach engine shut-off cord (lanyard) to
your PFD, arm, or leg so the engine
stops if you accidentally leave the
helm, which could prevent a runaway
boat.

7

General information

EMU33843

Symbols

The following symbols mean as follows.

Notice/Warning

ZMU05696

Read Owner’s Manual

ZMU05664

Electrical hazard

ZMU05666

Remote control lever/gear shift lever operat­ing direction, dual direction

ZMU05667

Engine start/ Engine cranking

Hazard caused by continuous rotation

ZMU05665

8

ZMU05668

Specifications and requirements

T

EMU31480

Specifications

IP:

“(AL)” stated in the specification data below
represents the numerical value for the alumi­num propeller installed.
Likewise, “(SUS)” represents the value for
stainless steel propeller installed and “(PL)”
for plastic propeller installed.

EMU2821C

Dimension:

Overall length:

726 mm (28.6 in)

Overall width:

374 mm (14.7 in)

Overall height L:

1413 mm (55.6 in)

Overall height X:

90AETO 1540 mm (60.6 in)

Transom height L:

520 mm (20.5 in)

Transom height X:

90AETO 647 mm (25.5 in)

Weight (AL) L:

120.5 kg (266 lb)

Weight (AL) X:

90AETO 123.5 kg (272 lb)

Weight (SUS) L:

122.5 kg (270 lb)

Weight (SUS) X:

90AETO 125.5 kg (277 lb)

Performance:

Full throttle operating range:

4500–5500 r/min

Maximum output:

75CETO 55.2 kW@5000 r/min

(75 HP@5000 r/min)

90AETO 66.2 kW@5000 r/min

(90 HP@5000 r/min)

Idling speed (in neutral):

800 ±50 r/min

Engine:

Type:

2-stroke L

Displacement:

1140.0 cm

Bore × stroke:

82.0 × 72.0 mm (3.23 × 2.83 in)

Ignition system:

CDI (micro computer)

Spark plug with resistor (NGK):

BR8HS-10

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

Control system:

Remote control

Starting system:

Electric

Starting carburetion system:

Prime start

Min. cold cranking amps (CCA/EN):

430.0 A

Min. rated capacity (20HR/IEC):

70.0 Ah

Maximum generator output:

10.0 A

Drive unit:

Gear positions:

Forward-neutral-reverse

Gear ratio:

2.00 (26/13)

Trim and tilt system:

Power trim and tilt

Propeller mark:

K

Fuel and oil:

Recommended fuel:

Regular unleaded gasoline

Min. research octane:

75CETO 90
90AETO 90

3

9

Specifications and requirements

Fuel tank capacity:

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

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

Recommended engine oil:

YAMALUBE 2-stroke outboard motor

oil

Lubrication:

Oil injection

Engine oil tank capacity:

3.3 L (3.49 US qt, 2.90 Imp.qt)

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

0.610 L (0.645 US qt, 0.537 Imp.qt)

Tightening torque for engine:

Spark plug:

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

Propeller nut:

35.0 Nm (3.57 kgf-m, 25.8 ft-lb)

Noise and vibration level:

Operator sound pressure level
(ICOMIA 39/94 and 40/94):

75CETO 91.1 dB(A)

90AETO 91.1 dB(A)

Sound power level
(ICOMIA 39/94 and 40/94):

75CETO 98.9 dB(A)

90AETO 98.9 dB(A)

Vibration on tiller handle (ICOMIA 38/94):

75CETO 2.8 m/s

90AETO 2.8 m/s

EMU33553

2

2

Installation requirements

EMU33563

Boat horsepower rating

EWM01560

WARNING

Overpowering a boat can cause severe
instability.

tor(s) does not exceed the boats maximum
horsepower rating. See the boat’s capacity
plate or contact the manufacturer.

EMU33571

Mounting motor

EWM01570

WARNING

Improper mounting of the outboard mo-

●

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

●

Because the motor is very heavy, spe­cial equipment and training is required
to mount it safely.

Your dealer or other person experienced in
proper rigging should mount the motor using
correct equipment and complete rigging in­structions. For further information, see page

30.

EMU33581

Remote control requirements

EWM01580

WARNING

●

If the engine starts in gear, the boat can
move suddenly and unexpectedly, pos­sibly causing a collision or throwing
passengers overboard.

●

If the engine ever starts in gear, the
start-in-gear protection device is not
working correctly and you should dis­continue using the outboard. Contact
your Yamaha dealer.

The remote control unit must be equipped
with a start-in-gear protection device(s). This
device prevents the engine from starting un­less it is in neutral.

Before installing the outboard motor(s), con­firm that the total horsepower of your mo-

10

Specifications and requirements

EMU25694

Battery requirements

EMU25721

Battery specifications

Minimum cold cranking amps (CCA/EN):

430.0 A

Minimum rated capacity (20HR/IEC):

70.0 Ah

The engine cannot be started if battery volt­age is too low.

EMU36290

Mounting battery

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

WARNING! Do not put flammable
items, or loose heavy or metal objects in
the same compartment as the battery.
Fire, explosion or sparks could result.

[EWM01820]

EMU36300

Multiple batteries

To connect multiple batteries, such as for
multiple engine configurations or for an ac­cessory battery, consult your Yamaha dealer
about battery selection and correct wiring.

EMU34191

Propeller selection

Next to selecting an outboard, choosing 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 chosen to perform well over a
range of applications, but there may be uses
where a different propeller would be more
appropriate.

Your Yamaha dealer can help you select the
right propeller for your boating needs. Select
a propeller that will allow the engine to reach
the middle or upper half of the operating
range at full throttle with the maximum boat­load. Generally, chose 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, chose 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.
For instructions on propeller removal and in­stallation, see page 63.

x

-

123

ZMU04606

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

x

-

123

ZMU04607

1. Propeller diameter in inches

11

Specifications and requirements

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

EMU25770

Start-in-gear protection

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

EMU25651

Engine oil requirements

Recommended engine oil:

YAMALUBE 2-stroke outboard motor
oil

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

EMU36360

Fuel requirements

EMU36801

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.

damage. Use only fresh gasoline that
has been stored in clean containers.

EMU36880

Muddy or acidic water

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

EMU36330

Anti-fouling paint

A clean hull improves boat performance. The
boat bottom should be kept as clean of ma­rine growth as possible. If necessary, the
boat bottom can be coated with an anti-foul­ing paint approved for your area to inhibit
marine growth.
Do not use anti-fouling paint which includes
copper or graphite. These paints can cause
more rapid engine corrosion.

Recommended gasoline:

Regular unleaded gasoline with a min­imum octane rating of 90 (Research
Octane Number).

ECM01980

NOTICE

●

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

12

EMU36341

Motor disposal requirements

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

EMU36351

Emergency equipment

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

A tool kit with assorted screwdrivers, pli-

●

Specifications and requirements

ers, wrenches (including metric sizes), and
electrical tape.
Waterproof flashlight with extra batteries.

●

●

An extra engine shut-off cord (lanyard)
with clip.
Spare parts, such as an extra set of spark

●

plugs.

Consult your Yamaha dealer for details.

13

Components

T

EMU2579J

Components diagram

IP:

* May not be exactly as shown; also may not be included as standard equipment on all mod­els.

75C, 90A

12
11
10

9

8

7

6

1. Top cowling

2. Top cowling lock lever

3. Anti-cavitation plate

4. Trim tab (anode)

5. Propeller

6. Cooling water inlet

7. Anode

8. Tilt rod

9. Clamp bracket

10. Tilt support lever

11. Power trim and tilt switch

12. Flushing device*

13. Remote control box (side mount type)

14. Digital speedometer*

15. Digital tachometer

13

1

14

SPEED

TRIP TIME BATT

YAMAHA

set

2

15 16 17

18

3
4

5

16. Tachometer*

17. Trim meter*

18. Fuel tank*

EMU25802

Fuel tank

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

EWM00020

WARNING

The fuel tank supplied with this engine is
its dedicated fuel reservoir and must not
be used as a fuel storage container. Com­mercial users should conform to relevant

Km/h
knot
mph

km

mile

mode

ZMU05246

14

Components

licensing or approval authority regula­tions.

2

1

4

3

ZMU02284

1. Fuel joint

2. Fuel gauge

3. Fuel tank cap

4. Air vent screw

13

1. Fuel joint

2. Fuel gauge

3. Fuel tank cap

4. Air vent screw

EMU25830

Fuel joint

This joint is used to connect the fuel line.

EMU25841

Fuel gauge

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

42

ZMU03157

EMU25850

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.

EMU25860

Air vent screw

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

EMU26181

Remote control box

The remote control lever actuates both the
shifter and the throttle. The electrical switch­es are mounted on the remote control box.

1. Power trim and tilt switch

2. Remote control lever

3. Neutral interlock trigger

4. Neutral throttle lever

5. Main switch

6. Engine shut-off switch

7. Throttle friction adjuster

EMU26190

Remote control lever

Moving the lever forward from the neutral po­sition engages forward gear. Pulling the le­ver back from neutral engages reverse. The
engine will continue to run at idle until the le­ver is moved about 35° (a detent can be felt).
Moving the lever farther opens the throttle,
and the engine will begin to accelerate.

15

Components

T

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”

4. Shift

5. Fully closed

6. Throttle

7. Fully open

EMU26201

Neutral interlock trigger

To shift out of neutral, first pull the neutral in­terlock trigger up.

when the remote control lever is in neutral.
The remote control lever will operate only
when the neutral throttle lever is in the closed
position.

1. Fully open

2. Fully closed

EMU25911

Tiller handle

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

1. Neutral interlock trigger

EMU26211

Neutral throttle lever

To open the throttle without shifting into ei­ther forward or reverse, put the remote con­trol lever in the neutral position and lift the
neutral throttle lever.

IP:

The neutral throttle lever will operate only

16

EMU25922

Gear shift lever

Pulling the gear shift lever towards you puts
the engine in forward gear so that the boat
moves ahead. Pushing the lever away from
you puts the engine in reverse gear so that
the boat moves astern.

Components

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

EMU25941

Throttle grip

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

EMU25961

Throttle indicator

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

1. Throttle indicator

EMU25973

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.

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.

To decrease resistance, turn the adjuster
counterclockwise.

WARNING! Do not overtighten

[EWM00032]

17

Components

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

EMU25993

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.

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

[EWM00122]

WARNING! At-

1. Cord

2. Clip

3. Engine shut-off switch

1. Cord

2. Clip

3. Engine shut-off switch

EMU26001

Engine stop button

To open the ignition circuit and stop the en­gine, push this button.

18

Components

EMU26090

Main switch

The main switch controls the ignition system;
its operation is described below.

●

“”

(off)

With the main switch in the “ ” (off) posi­tion, the electrical circuits are off, and the key
can be removed.

●

“”

(on)

With the main switch in the “ ” (on) posi­tion, the electrical circuits are on, and the key
cannot be removed.

“”

●

With the main switch in the “ ” (start) po­sition, the starter motor turns to start the en­gine. When the key is released, it returns
automatically to the “ ” (on) position.

(start)

set according to operator preference. An ad­justing screw or bolt is located on the clamp
bracket, on the right (starboard) side of the
through tube end.
To increase resistance, turn the adjuster
clockwise.
To decrease resistance, turn the adjuster
counterclockwise.

EWM00040

WARNING

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

ZMU03245

EMU26130

Steering friction adjuster

A friction device provides adjustable resis­tance to the steering mechanism, and can be

EMU26143

Power trim and tilt switch on remote
control or tiller handle

The power trim and tilt system adjusts the
outboard motor angle in relation to the tran­som. Pressing the switch “ ” (up) trims the
outboard motor up, and then tilts it up. Press­ing the switch “ ” (down) tilts the outboard
motor down and trims it down. When the
switch is released, the outboard motor will
stop in its current position.
For instructions on using the power trim and
tilt switch, see pages 46 and 48.

19

Components

EMU26153

Power trim and tilt switch on bottom
engine cowling

The power trim and tilt switch is located on
the side of the bottom engine cowling. Press­ing the switch “ ” (up) trims the outboard
motor up, and then tilts it up. Pressing the
switch “ ” (down) tilts the outboard motor
down and trims it down. When the switch is
released, the outboard motor will stop in its
current position.
For instructions on using the power trim and
tilt switch, see page 48.

EWM01030

WARNING

Use the power trim and tilt switch located
on the bottom engine cowling only when
the boat is at a complete stop with the en­gine off. Attempting to use this switch
while the boat is moving could increase
the risk of falling overboard and could

distract the operator, increasing the risk
of collision with another boat or an obsta­cle.

ZMU03851

EMU26244

Trim tab with anode

EWM00840

WARNING

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

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

ECM00840

NOTICE

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

20

1. Trim tab

2. Bolt

3. Cap

Bolt tightening torque:

36.0 Nm (3.6 kgf-m, 26 ft-lb)

EMU26261

Trim rod (tilt pin)

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

Components

EMU26341

Tilt support lever for power trim and
tilt model

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

ZMU03853

ECM00660

NOTICE

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

EMU26372

Top cowling lock lever(s) (turn type)

To remove the engine top cowling, turn the
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 lever(s) to the
lock position.

ZMU03852

21

Components

T

1

ZMU03854

EMU26460

Flushing device

This device is used to clean the cooling wa­ter passages of the motor using a garden
hose and tap water.

IP:

For details on usage, see page 55.

1. Top cowling lock lever(s)

1. Top cowling lock lever(s)

1

ZMU03857

1. Flushing device

1

ZMU03855

22

Instruments and indicators

T

EMU31414

Digital tachometer

The tachometer shows the engine speed
and has the following functions.
All segments of the display will light momen­tarily after the main switch is turned on and
will return to normal thereafter.

1

3

5

6

1. Tachometer

2. Trim meter

3. Hour meter

4. Oil level indicator

5. Overheat-alert indicator

6. Set button

7. Mode button

4

7

2

ZMU01891

the power trim and tilt switch.

●

If the trim angle of your motor exceeds the
trim operating range, the top segment on
the trim meter display will blink.

ZMU01869

EMU26651

Hour meter

This meter shows the number of hours the
engine has been run. It can be set to show
the total number of hours or the number of
hours for the current trip. The display can
also be turned on and off.

IP:

The water separator-alert indicator and en­gine trouble-alert indicator on the digital ta­chometer do not operate for this engine.

EMU36050

Tachometer

The tachometer displays engine speed in
hundreds of revolutions per minute (r/min).
For example, if the tachometer display reads
“22” then the engine speed is 2200 r/min.

EMU26621

Trim meter

This meter shows the trim angle of your out­board motor.

●

Memorize the trim angles that work best
for your boat under different conditions.
Adjust the trim angle to the desired using

ZMU01870

To change the display format, press the
“” (mode) button. The display can show
total hours or trip hours, or turn off.
To reset the trip hours, simultaneously press
the “ ” (set) and “ ” (mode) buttons for
more than 1 second while the trip hours are
displayed. This resets the trip counter to 0
(zero).
The total number of hours the engine has
been run cannot be reset.

23

Instruments and indicators

EMU26551

Oil level indicator (digital type)

This indicator shows the engine oil level. If
the oil level falls below the lower limit, the
alert indicator will start to blink. For further in­formation, see page 28.

ECM00030

NOTICE

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

1. Overheat-alert indicator

EMU26602

This gauge shows the boat speed and other
information.

1

ZMU01867

1. Oil level indicator

EMU26583

Overheat-alert indicator

If the engine temperature rises too high, the
alert indicator will start to blink. For further in­formation on reading the indicator, see page

28.

ECM00052

NOTICE

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

1. Speedometer

2. Fuel gauge

3. Trip meter/clock/voltmeter

4. Alert indicator(s)

All segments of the display will light momen­tarily after the main switch is turned on and
will return to normal thereafter.

EMU36061

Speedometer

The speedometer displays km/h, mph, or
knots, according to operator preference. Se­lect the desired units of measurement by set­ting the selector switch on the back of the
gauge. See the illustration for settings.

1

ZMU01868

Digital speedometer

24

Instruments and indicators

1. Cap

2. Selector switch (for speed unit)

3. Selector switch (for fuel sensor)

EMU26712

Fuel gauge

Eight segments indicate the fuel level. When
all segments are showing, the fuel tank is
full.

EMU36071

Trip meter / Clock / Voltmeter

The display shows either the trip meter, the
clock, or the voltmeter.
To change the display, press the “ ”
(mode) button repeatedly until the indicator
on the face of the gauge points to “ ” (trip
meter), “ ” (clock), or “ ” (voltmeter).

EMU26691

Trip meter

This gauge displays the distance the boat
has traveled since the gauge was last reset.
The trip distance is shown in kilometers or
miles depending upon the unit of measure­ment selected for the speedometer.
To reset the trip meter to zero, press the “ ”
(set) and “ ” (mode) buttons at the same
time.
The trip distance is kept in memory by bat­tery power. The stored data will be lost if the
battery is disconnected.

ZMU01745

The fuel level reading can be inaccurate due
to by the position of the sensor in the fuel
tank and the attitude of the boat in the water.
Operation with bow-up trim or continuous
turning can give false readings.
Do not adjust the selector switch for fuel sen­sor. Incorrectly setting the selector switch on
the gauge will give false readings. Consult
your Yamaha dealer on how to correctly set
the selector switch.

of fuel can damage the engine.

NOTICE:

Running out

[ECM01770]

EMU26701

Clock

To set the clock:

1. Be sure the gauge is in the “ ” (time)
mode.

2. Press the “ ” (set) button; the hour dis­play will begin blinking.

3. Press the “ ” (mode) button until the
desired hour is displayed.

4. Press the “ ” (set) button again, the
minute display will begin blinking.

25

Instruments and indicators

5. Press the “ ” (mode) button until the
desired minute is displayed.

6. Press the “ ” (set) button again to start
the clock.

The clock operates on battery power. Dis­connecting the battery will stop the clock.
Reset the clock after connecting the battery.

EMU36080

Voltmeter

The voltmeter displays the charge of the bat­tery in volts(V).

EMU26721

Fuel level-alert indicator

If the fuel level decreases to one segment,
the fuel level alert segment will blink.
Do not continue to operate the engine with
full throttle if an alert device has activated.
Get back to the port within trolling engine
speed.

damage the engine.

NOTICE:

Running out of fuel can

[ECM01770]

EMU26732

Low battery voltage-alert indicator

If battery voltage drops, the display will auto­matically turn on and blink.
Get back to the port soon if an alert device
has activated. For charging the battery, con­sult your Yamaha dealer.

1. Low battery indicator

EMU26471

Analog tachometer

This gauge shows the engine speed and has
the following functions.

1

2

1. Fuel level-alert segment

26

ZMU04577

1. Tachometer

2. Oil level indicator

EMU26541

Oil level indicators (three indicators

2)

The indicators on the gauge show the status
of the oil level. For details on how to read the

Instruments and indicators

indicators, see page 39.

ECM00030

NOTICE

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

1

ZMU04580

1. Oil level indicators

EMU26611

Analog trim meter

This gauge shows the trim angle of your out­board motor.

ZMU04581

Memorize the trim angles that work best for
your boat under different conditions. Adjust
the trim angle to the desired setting with the
power trim and tilt switch.

27

Engine control system

EMU26803

Alert system

ECM00091

NOTICE

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

EMU2681A

Overheat alert

This engine has an overheat-alert device. If
the engine temperature rises too high, the
alert device will activate.

The engine speed will automatically de-

●

crease to about 2000 r/min.
The overheat-alert indicator will light or

●

blink.

If the alert system has activated, stop the en­gine and check the cooling water inlets:

Check trim angle to be sure that the cool-

●

ing water inlet is submerged.

●

Check the cooling water inlet for clogging.

ZMU01757

ZMU04766

●

The buzzer will sound (if equipped on the
tiller handle, remote control box, or main
switch panel).

28

ZMU03858

EMU26848

Oil level alert and oil filter clogging
alert

Oil injection models

This engine has an oil level alert system. If
the oil level falls below the lower limit, the
alert system will activate.

Activation of alert device

●

Engine speed will automatically decrease
to about 2000 r/min.

●

The oil level-alert indicator will light or
blink.

T

ZMU03942

ZMU04586

●

The buzzer will sound (if equipped on the
tiller handle, remote control box, or main
switch panel).

Engine control system

nally oil filter clogging.

1

ZMU03828

1. Oil filter

If the alert system has been activated, stop
the engine and check for the cause.

IP:

The alert for oil filter clogging is similar to the
alerts for low oil level and overheating. To
make troubleshooting easier, check for en­gine overheating first, then oil level, and fi-

ZMU03025

29

Installation

EMU26902

Installation

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

EWM01590

WARNING

●

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

●

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

EMU33470

Mounting the outboard motor

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

1

1. Center line (keel line)

EMU26931

ZMU01760

Mounting height (boat bottom)

The mounting height of your outboard motor
affects its efficiency and reliability. If it is
mounted too high, propeller ventilation may
occur, which will reduce propulsion due to
excessive propeller slip, and the water in­takes for the cooling system may not get ad­equate water supply, which can cause
engine overheating. If the engine is mounted
too low, water resistance (drag) will in­crease, thereby reducing engine efficiency
and performance.
Most commonly, outboard motor should be
mounted so that the anti-cavitation plate is in
alignment with the bottom of the boat. The
optimum mounting height of the outboard
motor is affected by the boat/motor combina­tion and the desired use. Test runs at differ­ent heights can help determine the optimum
mounting height. Consult your Yamaha deal­er or boat manufacturer for further informa­tion on determining the proper mounting
height.

30

ZMU01762

ECM01630

NOTICE

During water testing, check the buoy-

●

ancy of the boat, at rest, with its maxi­mum load. Check that the static water
level on the exhaust housing is low
enough to prevent water entry into the
power head when water rises due to
waves when the outboard is not run­ning.
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 motor is operated con­tinuously in the presence of airborne
water spray, enough water could enter
the engine through the intake opening
on the cowling to cause severe engine
damage. Eliminate the cause of the air­borne water spray.

Installation

31

Operation

EMU36380

First-time operation

EMU27020

Breaking in engine

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

ECM00140

NOTICE

Failure to follow the break-in procedure

●

could result in reduced engine life or
even severe engine damage.
Premix fuel must be used during break-

●

in in addition to oil in the oil injection
system.

EMU27060

Gasoline and engine oil mixing chart
(50:1)

1. : Gasoline

2. : Engine oil

ECM00150

NOTICE

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

EMU30311

Procedure for oil injection models

Run the engine under load (in gear with a
propeller installed) for 10 hours as follows.

1. First 10 minutes:

Run the engine at the lowest possible
speed. A fast idle in neutral is best.

2. Next 50 minutes:
Do not exceed half throttle (approxi­mately 3000 r/min). Vary engine speed
occasionally. If you have an easy-plan­ing boat, accelerate at full throttle onto
plane, then immediately reduce the
throttle to 3000 r/min or less.

3. Next two hours:
Accelerate at full throttle onto plane,
then reduce engine speed to three-quar­ter throttle (approximately 4000 r/min).
Vary engine speed occasionally. Run at
full throttle for one minute, then allow
about 10 minutes of operation at three­quarter throttle or less to let the engine
cool.

4. Remaining seven hours:
Run the engine at any speed. However,
avoid operating at full throttle for more
than 5 minutes at a time.

5. After the first 10 hours:
Operate the engine normally. Use only
straight gasoline in the fuel tank. The
Yamaha oil injection system provides
proper lubrication for normal operation.

EMU36400

Getting to know your boat

Different boats handle differently. Operate
cautiously while you learn how your boat
handles under different conditions and with
different trim angles (see page 46).

EMU36412

Checks before starting engine

EWM01920

WARNING

If any item in the checks before starting
engine is not working properly, have it in­spected and repaired before operating
the outboard motor. Otherwise an acci-

32

Operation

dent could occur.

ECM00120

NOTICE

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

EMU37150

Fuel level

Be sure you have plenty of fuel for your trip.
A good rule is to use 1/3 of your fuel to get to
the destination, 1/3 to return, and to keep 1/
3 as an emergency reserve. With the boat
level on a trailer or in the water, turn the key
to “ ”(on) and check the fuel level. For fuel
filling instructions, see page 36.

EMU36431

Remove cowling

For the following checks, remove the top
cowling from the engine. To remove the en­gine cowling, release all the lock levers and
lift off the cowling.

sources of ignition.

EWM00910

WARNING

Leaking fuel can result in fire or explo­sion.

Check for fuel leakage regularly.

●

●

If any fuel leakage is found, the fuel
system must be repaired by a qualified
mechanic. Improper repairs can make
the outboard unsafe to operate.

EMU36450

Check for fuel leaks

Check under top cowling and in the boat

●

for fuel leaks or gasoline fumes.
Check fuel line connections to be sure they

●

are tight.

●

Check fuel lines for cracks, swelling, or
other damage.

EMU37320

Check the fuel filter

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

ZMU06093

EMU36441

Fuel system

EWM00060

WARNING

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

ZMU06184

EMU36900

Controls

Tiller handle models:

Turn the tiller handle fully to the left and

●

right to make sure operation is smooth.
Turn the throttle grip from the fully closed

●

33

Operation

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 under the en­gine cowling.

Remote control models:

●

Turn the steering wheel full-right and full­left. Make sure operation is smooth and
unrestricted throughout the whole range
with no binding or excessive free play.
Operate the throttle levers several times to

●

make sure there is no hesitation in their
travel. Operation should be smooth over
the complete range of motion, and each le­ver should return completely to the idle po­sition.
Look for loose or damaged connections of

●

the throttle and shift cables under the en­gine cowling.

EMU36481

Engine shut-off cord (lanyard)

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

1. Cord

2. Clip

3. Engine shut-off switch

1. Cord

2. Clip

3. Engine shut-off switch

EMU27120

Oil

●

Check to be sure you have plenty of oil for
your trip.

EMU27151

Engine

●

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

●

Check the propeller for damage.

●

●

Check for oil leaks.

EMU27181

Operation after long period of
storage

Oil injection models

When operating the engine after a long peri­od (12 months) of storage, proceed as fol­lows:

1. Use a 50:1 gasoline to oil mixture to start
the engine.

2. Start the engine. Leave it idling.

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.

3. Watch for oil flowing through the oil feed
pipes. After any air in the oil lines has

[EWM01331]

34

Operation

been expelled, the oil injection system
should supply oil normally. If no oil is
flowing after 10 minutes of idling, consult
your Yamaha dealer.

ZMU03367

ECM01260

NOTICE

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

EMU36490

Flushing device

Check that flushing device’s garden hose
connector is securely screwed on to the fit­ting on the bottom cowling.

flushing device is not properly connect­ed, cooling water can leak out and the en­gine can overheat during operation.

[ECM01800]

NOTICE:

If the

EMU36961

Install cowling

1. Be sure that all cowling lock levers are
released.

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

3. Place the cowling on top of the seal.

4. Check to be sure the rubber seal fits cor­rectly all the way around the engine.

5. Move the levers to lock the cowling as
shown.

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

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.

NOTICE:

[ECM01990]

If the cowling is not

ZMU06118

1

1. Flushing device

ZMU03857

ZMU04678

35

Operation

EMU29158

Checking power trim and tilt system

EWM01930

WARNING

Never get under the lower unit while it

●

is tilted, even when the tilt support lever
is locked. Severe injury could occur if
the outboard motor accidentally falls.

●

Body parts can be crushed between the
motor and the clamp bracket when the
motor is trimmed or tilted.

●

Be sure no one is near the outboard
motor before performing this check.

1. Check the power trim and tilt unit for any
sign of oil leaks.

2. Operate each of the power trim and tilt
switches on the remote control and en­gine bottom cowling to check that all
switches work.

3. Tilt the outboard motor up and check
that the tilt rod and trim rods are extend­ed completely.

ZMU03883

4. Use the tilt support lever to lock the mo­tor in the up position. Operate the tilt
down switch briefly so the motor is sup­ported by the tilt support lever.

5. Check that the tilt rod and trim rods are
free of corrosion or other flaws.

6. Activate the tilt-down switch until the trim
rods have retracted completely into the
cylinders.

ZMU03884

7. Activate the trim-up switch until the tilt
rod is fully extended. Unlock the tilt sup­port lever.

8. Tilt the outboard motor down. Check
that the tilt rod and trim rods operate
smoothly.

EMU36581

Battery

Check that the battery is in good condition,
and fully charged. Check that the battery
connections are clean, secure and covered
by insulating covers. The electrical contacts
of the battery and cables must be clean and
properly connected or the battery will not
start the engine.
Refer to the battery manufacturer’s instruc­tions for checks for your particular battery.

EMU27234

Filling fuel and engine oil

EMU27246

Filling fuel for portable tank

EWM01830

WARNING

●

Gasoline and its vapors are highly flam­mable and explosive. Always refuel ac­cording to this procedure to reduce the
risk of fire and explosion.
Gasoline is poisonous and can cause

●

injury or death. Handle gasoline with
care. Never siphon gasoline by mouth.
If you should swallow some gasoline or

36

Operation

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. Stop the engine.

2. Remove the portable tank from the boat.

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

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

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

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

7. Fill the fuel tank, but do not overfill. Fuel
can expand and overflow if the tempera­ture increases.

Fuel tank capacity:

24 L (6.34 US gal, 5.28 Imp.gal),
25 L (6.60 US gal, 5.50 Imp.gal)

ing conditions. No fuel premixing is needed.
Simply pour gasoline into the fuel tank and
oil into the oil tank. Convenient indicator seg­ments indicate the status of the oil supply.
For details on reading the indicator seg­ments, see page 39.
To fill the engine oil tank, proceed as follows:

Engine oil tank capacity:

3.3 L (3.49 US qt, 2.90 Imp.qt)

1. Turn the oil filler access cap on the top
cowling counterclockwise and open it.

ZMU03369

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

8. Tighten the filler cap securely.

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

EMU27311

Filling oil for electric start models

EWM00530

WARNING

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

This engine uses the Yamaha oil injection
system, which provides superior lubrication
by ensuring the proper oil ratio for all operat-

ZMU03370

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

37

Operation

2

1

1. Oil filler access cap

2. Oil tank filler cap

4. After filling, replace the all caps secure­ly.

ZMU03371

38

EMU27321

Oil level indicator operation

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

EMU27372

Electric start models

Oil level-alert

Oil level-alert

indicator

(digital

tachometer)

EMU27451

Operating engine

EMU27464

Feeding fuel (portable tank)

EWM00420

WARNING

●

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

indicator

(analog

tachometer/

bottom

cowling)

Green

Yellow

Red

Engine oil tank Remarks

more than

1130 cm
(1.19 US qt,

0.99 Imp qt)

from 1130 cm3
(1.19 US qt,

0.99 Imp qt) down

to 310 cm
(0.33 US qt,

0.27 Imp qt)

3

310 cm
(0.33 US qt,

0.27 Imp qt) or
less

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.

1. If there is an air vent screw on the fuel

Operation

3

3

No refilling necessary.

Add oil; see page 37.

●

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

●

Check oil filter for
clogging.

39

Operation

tank cap, loosen it 2 or 3 turns.

ZMU02295

2. If there is a fuel joint on the motor, firmly
connect the fuel line to the joint. Then
firmly connect the other end of the fuel
line to the joint on the fuel tank.

ZMU03869

ZMU02024

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.

ZMU02025

EMU27492

Starting engine

EWM01600

WARNING

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.

EMU27595

Electric start / prime start models

EWM01840

WARNING

●

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

●

Avoid accidentally pulling the cord 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.

1. Place the gear shift lever in neutral.

40

Operation

T

T

IP:

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

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

3. Place the throttle grip in the “ ”
(start) position. After the engine starts,
return the throttle to the fully closed po­sition.

4. Turn the main switch to “ ” (start),
and hold it for a maximum of 5 seconds.

5. Immediately after the engine starts, re­lease the main switch and allow it to re­turn to “ ” (on).

the main switch to “ ” (start)
while the engine is running. Do not
keep the starter motor turning for
more than 5 seconds. If the starter
motor is turned continuously for
more than 5 seconds, the battery will
be quickly discharged, thus making it
impossible to start the engine. The
starter can also be damaged. If the
engine will not start after 5 seconds
of cranking, return the main switch to
“” (on), wait 10 seconds, then
crank the engine again.

NOTICE:

[ECM00192]

Never turn

IP:

●

When the engine is cold, it needs to be
warmed up. For further information, see

41

Operation

T

page 43.

●

If the engine is warm and fails to start,
open the throttle slightly and try to start the
engine again. If the engine still fails to
start, see page 70.

EMU27664

Electric start and remote control models

EWM01840

WARNING

●

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

●

Avoid accidentally pulling the cord 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.

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

3. Turn the main switch to “ ” (on).

4. Turn the main switch to “ ” (start),
and hold it for a maximum of 5 seconds.

1. Place the remote control lever in neutral.

IP:

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

2. Attach the engine shut-off cord to a se-

42

5. Immediately after the engine starts, re­lease the main switch and allow it to re­turn to “ ” (on).

NOTICE:

Never turn
the main switch to “ ” (start)
while the engine is running. Do not
keep the starter motor turning for
more than 5 seconds. If the starter
motor is turned continuously for
more than 5 seconds, the battery will
be quickly discharged, thus making it
impossible to start the engine. The
starter can also be damaged. If the
engine will not start after 5 seconds
of cranking, return the main switch to

“” (on), wait 10 seconds, then

T

crank the engine again.

[ECM00192]

IP:

●

When the engine is cold, it needs to be
warmed up. For further information, see
page 43.

●

If the engine is warm and fails to start,
open the throttle slightly and try to start the
engine again. If the engine still fails to
start, see page 70.

EMU36510

Checks after starting engine

EMU36520

Cooling water

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

ECM01810

NOTICE

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.

Operation

ZMU03391

Check that no water leaks from the joints be­tween the exhaust cover, cylinder head, and
body cylinder.

EMU27670

Warming up engine

EMU27704

Electric start and prime start models

After starting the engine, allow it to idle for 3
minutes to warm up. Failure to do so will
shorten engine life.

EMU36530

Checks after engine warm-up

EMU36540

Shifting

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

EMU36980

Stop switches

●

Turn the main switch to “ ”, or press the
engine stop button and make sure the en­gine stops.

●

Confirm that removing the clip from the en­gine shut-off switch stops the engine.
Confirm that the engine cannot be started

●

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

43

Operation

EMU33492

Shifting

EWM00180

WARNING

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

ECM01610

NOTICE

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

To shift out of neutral

1. Pull the neutral interlock trigger up (if
equipped).

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

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

1. Neutral interlock trigger

2. Move the remote control lever / gear
shift lever firmly and crisply forward (for
forward gear) or backward (for reverse
gear) [about 35° (a detent can felt) for re­mote control models].

44

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

Operation

pact 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.

EMU27821

Stopping engine

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

EMU27845

Procedure

1. Push and hold the engine stop button or
turn the main switch to “ ” (off).

EMU31742

Stopping boat

EWM01510

WARNING

●

Do not use the reverse function to slow
down or stop the boat as it could cause
you to lose control, be ejected, or im-

45

Operation

T

2. After stopping the engine, disconnect
the fuel line if there is a fuel joint on the
outboard motor.

ZMU02301

4. Remove the key if the boat will be left
unattended.

IP:

The engine can also be stopped by pulling
the cord and removing the clip from the en­gine shut-off switch, then turning the main
switch to “ ” (off).

EMU27862

Trimming outboard motor

EWM00740

WARNING

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

3. Tighten the air vent screw on the fuel
tank cap (if equipped).

46

ZMU03870

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.

Operation

switch while the boat is moving.

Adjust the outboard motor trim angle using
the power trim and tilt switch.

UP
DN

1

ZMU03110

1. Power trim and tilt switch

1

ZMU03109

1. Trim operating angle

EMU27885

Adjusting trim angle (Power trim and
tilt)

EWM00753

WARNING

Be sure all people are clear of the out-

●

board motor when adjusting the trim
angle. Body parts can be crushed be­tween the motor and the clamp bracket
when the motor is trimmed or tilted.
Use caution when trying a trim position

●

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

●

If equipped with a power trim and tilt
switch located on the bottom cowling,
use the switch only when the boat is at
a complete stop with the engine off. Do
not adjust the trim angle with this

UP
DN

1

ZMU05793

1. Power trim and tilt switch

1. Power trim and tilt switch

To raise the bow (trim-out), press the switch

47

Operation

T

“” (up).
To lower the bow (trim-in), press the switch
“” (down).
Make test runs with the trim set to different
angles to find the position that works best for
your boat and operating conditions.

EMU27911

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. The trim tab can
also be adjusted to help offset this effect.
When the bow of the boat is down, it is easier
to accelerate from a standing start onto
plane.

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.

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.

48

IP:

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

EMU27934

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 re-

duce salt corrosion.

EWM00221

WARNING

Be sure all people are clear of the out­board motor when tilting up and down,
Body parts can be crushed between the
motor and the clamp bracket when the
motor is trimmed or tilted.

EWM00250

WARNING

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

ECM00241

NOTICE

●

Before tilting the outboard motor, stop
the engine by following the procedure
on page 45. Never tilt the outboard mo­tor while the engine is running. Severe
damage from overheating can result.

●

Do not tilt up the engine by pushing the
tiller handle (if equipped) because this
could break the handle.

EMU32723

Procedure for tilting up (power trim
and tilt models)

1. Place the remote control lever / gear
shift lever in neutral.

Operation

2. Press the power trim and tilt switch “ ”
(up) until the outboard motor has tilted
up completely.

UP

N

ZMU03196

ZMU03872

49

Operation

3. Pull the tilt support lever toward you to
support the engine.

tilting the outboard motor, be sure to
support it with the tilt support knob or
tilt support lever. Otherwise the out­board motor could fall back down
suddenly if oil in the power trim and
tilt unit or in the power tilt unit loses
pressure.

[EWM00262]

the tilt support lever or knob when
trailering the boat. The outboard mo­tor could shake loose from the tilt
support and fall. If the motor cannot
be trailered in the normal running po­sition, use an additional support de­vice to secure it in the tilt position.
For more detailed information, see
page 53.

[ECM01641]

WARNING! After

NOTICE:

Do not use

and tilt switch “ ” (down) to retract the
trim rods.

NOTICE:

Be sure to retract
the trim rods completely during
mooring. This protects the rods from
marine growth and corrosion which
could damage the power trim and tilt
mechanism.

EMU33120

[ECM00251]

ZMU03874

Procedure for tilting down (power
trim and tilt models)

1. Push the power trim and tilt switch “ ”
(up) until the outboard motor is support­ed by the tilt rod and the tilt support lever
becomes free.

2. Release the tilt support lever.

ZMU03115

4. Models equipped with trim rods: Once
the outboard motor is supported with the
tilt support lever, press the power trim

50

ZMU03875

3. Push the power trim and tilt switch “ ”
(down) to lower the outboard motor to
the desired position.

DN

Operation

ting up for and cruising in shallow water.
Otherwise severe damage from overheat-

UP

DN

ing can result.

EMU32912

Procedure for power trim and tilt models

1. Place the remote control lever / gear
shift lever in neutral.

ZMU01936

DN

ZMU03876

EMU28061

Shallow water

EMU32851

Power trim and tilt models

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

ECM00260

NOTICE

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 set-

N

ZMU03525

2. Slightly tilt the outboard motor up to the
desired position using the power trim
and tilt switch.

power trim and tilt switch on the bot­tom cowling while the boat is moving
or engine is on could increase the
risk of falling overboard and could
distract the operator, increasing the
risk of collision with another boat or
an obstacle.

WARNING! Using the

[EWM01850]

51

Operation

UP

ter and, if possible, rinse the power head un­der the cowling.

UP

DN

Cruising in muddy, turbid, or acidic water

Yamaha strongly recommends that you use
the optional chromium-plated water pump kit
(see page 12) if you use the outboard motor
in acidic water or water with a lot of sediment
in it, such as muddy or turbid (cloudy) water.

ZMU01935

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.

UP

ZMU03877

3. To return the outboard motor to the nor­mal running position, press the power
trim and tilt switch and slowly tilt the out­board motor down.

EMU28194

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 wa-

52

EMU28226

Transporting and storing

outboard motor

EWM00692

WARNING

●

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.

EWM01860

WARNING

Leaking fuel is a fire hazard. When trans­porting and storing the outboard motor,
close the fuel cock to prevent fuel from
leaking. Never get under the engine while
it is tilted. Severe injury could occur if the
outboard motor accidentally falls.

ECM00660

NOTICE

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

The outboard motor should be trailered 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.

Maintenance

ZMU03659

EMU30272

Storing outboard motor

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

ECM01411

NOTICE

●

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, well­ventilated place, not in direct sunlight.

EMU28303

Procedure

EMU28323

Flushing with the flushing attachment

Flushing with the flushing attachment

1. Wash the outboard motor body using
fresh water.

ter into the air intake.

ther information, see page 55.

2. Disconnect the fuel line from the motor

NOTICE:

Do not spray wa-

For fur-

[ECM01840]

53

Maintenance

T

or shut off the fuel cock, if equipped.

3. Remove the engine top cowling and si­lencer cover. Remove the propeller.

4. Install the flushing attachment over the
cooling water inlet.

NOTICE:

Do not run
the engine without supplying it with
cooling water. Either the engine wa­ter pump will be damaged or the en­gine will be damaged from
overheating. Before starting the en­gine, be sure to supply water to the
cooling water passages. Avoid run­ning the outboard motor at high
speed while on the flushing attach­ment, otherwise overheating could
occur.

[ECM02000]

1. Flushing attachment

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

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

[EWM00091]

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

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

8. Remove the flushing attachment.

9. Install the silencer cover/cap of fogging
hole and top cowling.

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

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

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

IP:

A flushing attachment is available from your
Yamaha dealer.

EMU28411

Lubrication (oil injection models)

1. Install the spark plug(s) and torque to
proper specification. For information on
spark plug installation, see page 61.

2. Fill the oil tanks. This prevents the for­mation of condensation. For models with
a remote oil tank, it may be necessary to
manually override the control unit to
completely fill the engine oil tank.

3. Change the gear oil. For instructions,
see page 65. Inspect the oil for the pres­ence of water which indicates a leaky
seal. Seal replacement should be per­formed by an authorized Yamaha dealer
prior to use.

54

Maintenance

T

T

4. Grease all grease fittings. For further de­tails, see page 61.

IP:

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

EMU28443

Flushing power unit

Perform this procedure right after operation
for the most thorough flushing.

ECM01530

NOTICE

Do not perform this procedure while the
engine is running. The water pump may
be damaged and severe damage from
overheating can result.

1. After shutting off the engine, unscrew
the garden hose connector from the fit­ting on the bottom cowling.

1

3

2

2. Garden hose connector

3. Garden hose adapter

2. Screw the garden hose adapter onto a
garden hose, which is connected to a
fresh water supply, and then connect it
to the garden hose connector.

3. With the engine off, turn on the water tap
and let the water flush through the cool­ing passages for about 15 minutes. Turn
off the water and disconnect the garden
hose adapter from the garden hose con­nector.

4. Reinstall the garden hose connector
onto the fitting on the bottom cowling.
Tighten the connector securely.

TICE:

Do not leave the garden hose

NO-

connector loose on the bottom cowl­ing fitting or let the hose hang free
during normal operation. Water will
leak out of the connector instead of
cooling the engine, which can cause
serious overheating. Be sure the con­nector is tightened securely on the
fitting after flushing the engine.

[ECM00541]

IP:

When flushing the engine with the boat in

●

the water, tilting up the outboard motor un­til it is completely out of the water will
achieve better results.

●

For cooling system flushing instructions,
see page 53.

EMU28450

Cleaning the outboard motor

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

ZMU04697

1. Fitting

55

Maintenance

T

ZMU02988

IP:

For cooling system flushing instructions, see
page 53.

EMU28460

Checking painted surface of motor

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

EMU2847B

Periodic maintenance

EWM01871

WARNING

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

Turn off the engine and keep the key(s)

●

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

●

The power trim and tilt switches oper­ate even when the ignition key is off.
Keep people away from the switches

whenever working around the motor.
When the motor is tilted, keep away
from the area under it or between it and
the clamp bracket. Be sure no one is in
this area before operating the power
trim and tilt mechanism.

●

Allow the engine to cool before han­dling hot parts or fluids.
Always completely reassemble the mo-

●

tor before operation.

EMU28511

Replacement parts

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

EMU34150

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 maxi­mum engine speed (rpm) for many hours
Operating continuously at a low engine

●

speed (rpm) for many hours

●

Brief periods of rapid acceleration and de­celeration followed by engine shut off be­fore the engine has reached proper
operating temperature
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

56

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.

Maintenance

57

Maintenance

T

EMU34445

Maintenance chart 1

IP:

●

Refer to the sections in this chapter for explanations of each owner-specific action.

●

The maintenance cycle on these charts assume usage of 100 hours per year and regular
flushing of the cooling water passages. Maintenance frequency should be adjusted when
operating the engine under adverse conditions such as extended trolling.

●

Disassembly or repairs may be necessary depending on the outcome of maintenance
checks.

●

Expendable or consumable parts and lubricants will lose their effectiveness over time and
through normal usage regardless of the warranty period.

●

When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should

be flushed with clean water after each use.
The “ ” symbol indicates the check-ups which you may carry out yourself.
The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Initial Every

Item Actions

Anode(s) (external)

Anode(s) (cylinder
head, thermostat
cover)

Anodes (exhaust cover,
cooling water passage
cover, Rectifier Regula­tor cover)

Battery (electrolyte
level, terminal)

Battery (electrolyte
level, terminal)

Cooling water leakage

Cowling clamp Inspection

Engine starting condi­tion/Noise

Engine idling speed/
Noise

Fuel filter (can be dis­assembled)

Fuel line(High pres­sure)

Inspection or replace­ment as necessary

Inspection or replace­ment as necessary

Replacement

Inspection

Fill, charging or replac­ing as necessary

Inspection or replace­ment as necessary

Inspection

Inspection

Inspection or replace­ment as necessary

Inspection

20 hours

(3

months)

100

hours (1

year)

300

hours (3

years)

500

hours (5

years)

58

Item Actions

Fuel line(High pres­sure)

Fuel line(Low pres­sure)

Fuel line(Low pres­sure)

Fuel pump

Fuel/oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Impeller/water pump
housing

Impeller/water pump
housing

Oil tank water drain Inspection or cleaning

Oil injection pump/oil
feed pump

Power trim & tilt unit/
Operation,noise and oil
leakage

Propeller/Propeller nut/
Cotter pin

PCV (Pressure Con­trol Valve)

Shift link/shift cable

Spark plug(s)

Spark plug caps/high
tension cords

Water from the cooling
water pilot hole

Throttle link/Throttle
cable/Throttle pick-up
timing

Thermostat

Inspection or replace­ment as necessary

Inspection

Inspection or replace­ment as necessary

Inspection or replace­ment as necessary

Inspection or replace­ment as necessary

Replacement

Inspection or Adjust­ment

Inspection

Inspection or replace­ment as necessary

Inspection 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

Maintenance

Initial Every

20 hours

(3

months)

100

hours (1

year)

hours (3

years)

300

500

hours (5

years)

59

Maintenance

Item Actions

Water inlet Inspection

Main switch/stop
switch/choke switch

Wire harness connec­tions/Wire coupler con­nections

(Yamaha) Meter/gauge Inspection

(Yamaha) Fuel tank

EMU34451

Maintenance chart 2

Item Actions

Guide exhaust/exhaust
manifold

Inspection or replace­ment as necessary

Inspection or replace­ment as necessary

Inspection and clean­ing as necessary

Inspection or replace­ment as necessary

Initial Every

20 hours

(3

months)

100

hours (1

year)

1000 hours

hours (3

years)

Every

300

500

hours (5

years)

60

EMU28941

Greasing

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

75C, 90A

Maintenance

EMU28955

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. If electrode

ZMU03879

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

1. Remove the spark plug caps from the
spark plugs.

2. Remove the spark plug. If electrode ero­sion becomes excessive, or if carbon
and other deposits are excessive, you
should replace the spark plug with an­other of the correct type.

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

61

Maintenance

T

lead to explosion or fire.

[EWM00561]

Standard spark plug:

BR8HS-10

3. Be sure to use the specified spark plug,
otherwise the engine may not operate
properly. Before fitting the spark plug,
measure the electrode gap with a wire
thickness gauge; adjust the gap to spec­ification if necessary.

1. Spark plug gap

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

3. Spark plug part number

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

4. When fitting the plug, wipe off any dirt
from the threads, and then screw it in to
the correct torque.

Spark plug torque:

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

IP:

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

EMU37450

Checking fuel filter

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

ZMU06184

EMU29041

Inspecting idling speed

EWM00451

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.

ECM00490

NOTICE

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

A diagnostic tachometer should be used 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.

62

T

IP:

Correct idling speed inspection is only possi­ble if the engine is fully warmed up. If not
warmed up fully, the idle speed will measure
higher than normal. If you have difficulty ver­ifying the idle speed, or the idle speed re­quires adjustment, consult a Yamaha dealer
or other qualified mechanic.

2. Verify whether the idle speed is set to
specification. For idle speed specifica­tions, see page 9.

EMU29061

Checking water in engine oil tank

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

2

1

Maintenance

ZMU03882

EMU32111

Checking propeller

EWM01880

WARNING

You could be seriously injured if the en­gine accidentally starts when you are
near the propeller.

●

Before inspecting, removing, or install­ing the propeller, place the shift control
in neutral, turn the main switch to “ ”
(off) and remove the key, and remove
the clip from the engine shut-off switch.
Turn off the battery cut-off switch if
your boat has one.

1. Drain hose

2. Filler neck side

EMU29112

Checking wiring and connectors

●

Check that each grounding wire is properly
secured.

●

Check that each connector is engaged se­curely.

ZMU03881

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.

ZMU01897

Checkpoints

63

Maintenance

●

Check each of the propeller blades for
wear, erosion 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 dam­age.

EMU30661

Removing propeller

EMU29197

Spline models

1. Straighten the cotter pin and pull it out
using a pair of pliers.

2. Remove the propeller nut, washer, and
spacer (if equipped).

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

[EWM01890]

WARNING! Do

2. Propeller nut

3. Washer

4. Spacer

5. Propeller

6. Thrust washer

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

EMU30671

Installing propeller

EMU29233

Spline models

ECM00500

NOTICE

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

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

2. Install the spacer (if equipped), thrust
washer, washer (if equipped), and pro­peller on the propeller shaft.

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

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

NOTICE:

[ECM01880]

1. Cotter pin

64

1

Propeller nut tightening torque:

35.0 Nm (3.57 kgf-m, 25.8 ft-lb)

4. Align the propeller nut with the propeller

2

3

4

5

6

ZMU01898

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

TICE:

Do not reuse the cotter pin in-

NO-

stalled. Otherwise the propeller can
come off during operation.

[ECM01890]

T

T

T

ZMU02063

Maintenance

2

1

ZMU03133

IP:

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

EMU29287

Changing gear oil

EWM00800

WARNING

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.

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

NOTICE:

If there is an exces-

[ECM01900]

1. Gear oil drain screw

2. Oil level plug

IP:

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.

TICE:

Inspect the used oil after it has

NO-

been drained. If the oil is milky, water
is getting into the gear case which
can cause gear damage. Consult a
Yamaha dealer for repair of the lower
unit seals.

[ECM00711]

IP:

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:

Hypoid gear oil SAE#90

Gear oil quantity:

0.610 L (0.645 US qt, 0.537 Imp.qt)

65

Maintenance

ZMU03887

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

Tightening torque:

9 Nm (0.9 kgf-m, 6.6 ft-lb)

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

Tightening torque:

9 Nm (0.9 kgf-m, 6.6 ft-lb)

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

●

Dispose of old gasoline according to lo­cal regulations.

1. Empty the fuel tank into an approved
container.

2. Pour a small amount of suitable solvent
into the tank. Install the cap and shake
the tank. Drain the solvent completely.

EMU29302

Cleaning fuel tank

EWM00920

WARNING

Gasoline is highly flammable, and its va­pors are flammable and explosive.

If you have any question about properly

●

doing this procedure, consult your
Yamaha dealer.
Keep away from sparks, cigarettes,

●

flames, or other sources of ignition
when cleaning the fuel tank.
Remove the fuel tank from the boat be-

●

fore cleaning it. Work only outdoors in
an area with good ventilation.
Wipe up any spilled fuel immediately.

●

●

Reassemble the fuel tank carefully. Im-

66

ZMU03231

3. Remove the screws holding the fuel joint
assembly. Pull the assembly out of the
tank.

T

ZMU02324

ZMU03232

4. Clean the filter (located on the end of the
suction pipe) in a suitable cleaning sol­vent. Allow the filter to dry.

5. Replace the gasket with a new one. Re­install the fuel joint assembly and tighten
the screws firmly.

EMU29312

Inspecting and replacing anode(s)

Yamaha outboard motors are protected from
corrosion by sacrificial anodes. Inspect the
external anodes periodically. Remove scales
from the surfaces of the anodes. Consult a
Yamaha dealer for replacement of external
anodes.

ECM00720

NOTICE

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

IP:

Inspect ground leads attached to external
anodes on equipped models. Consult a

Maintenance

Yamaha dealer for inspection and replace­ment of internal anodes attached to the pow­er unit.

ZMU01901

ZMU03888

EMU29322

Checking battery (for electric start
models)

EWM01900

WARNING

Battery electrolytic fluid is poisonous
and caustic, and batteries generate ex­plosive hydrogen gas. When working
near the battery:

●

Wear protective eye gear and rubber
gloves.

●

Do not smoke or bring any other source

of ignition near the battery.
Refer to page 11 for detailed safety infor­mation about batteries.

The procedure for checking the battery var­ies for different batteries. This procedure

67

Maintenance

contains typical checks that apply to many
batteries, but you should always refer to the
battery manufacturer’s instructions.

ECM01920

NOTICE

A poorly maintained battery will quickly
deteriorate.

1. Check the electrolyte level.

2. Check the battery’s charge. If your boat
is equipped with the digital speedome­ter, the voltmeter and low battery alert
functions will help you monitor the bat­tery’s charge. If the battery needs charg­ing, consult your Yamaha dealer.

3. Check the battery connections. They
should be clean, secure, and covered by
an insulating cover.

WARNING! Bad
connections can produce shorting or
arcing and cause an explosion.

[EWM01910]

EMU29333

Connecting the battery

EWM00570

WARNING

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

ECM01123

NOTICE

Reversal of the battery cables will dam-

age the electrical parts.

1. Make sure the main switch (on applica­ble models) is “ ” (off) before working
on the battery.

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

1. Red cable

2. Black cable

3. Battery

3. The electrical contacts of the battery and
cables must be clean and properly con­nected, or the battery will not start the
engine.

EMU29371

Disconnecting the battery

1. Turn off the battery cut-off switch (if
equipped) and main switch.

they are left on, the electrical system
can be damaged.

[ECM01930]

2. Disconnect the negative cable(s) from
the negative (-) terminal.

ways disconnect all negative (-) ca­bles first to avoid a short circuit and
damage to the electrical system.

[ECM01940]

3. Disconnect the positive cable(s) and re­move the battery from the boat.

4. Clean, maintain, and store the battery

NOTICE:

NOTICE:

If

Al-

68

according to the manufacturer’s instruc­tions.

Maintenance

69

Trouble Recovery

EMU29427

Troubleshooting

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

Starter will not operate.

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

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

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

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

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

Engine will not start (starter operates).

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

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

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

Q. Is starting procedure incorrect?
A. See page 40.

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.

70

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?

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

Q. Is engine oil contaminated or deteriorat­ed?
A. Replace oil with fresh, specified type.

Q. Is oil filter clogged?
A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunc­tioned?
A. Have serviced by a Yamaha dealer.

71

Trouble Recovery

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.

on gear housing?
A. Remove foreign matter and clean lower
unit.

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

Q. Is there excess water in fuel filter cup?
A. Drain filter cup.

Engine power loss.

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

Q. Is propeller pitch or diameter incorrect?
A. Install correct propeller to operate out­board at its recommended speed (r/min)
range.

Q. Is trim angle incorrect?
A. Adjust trim angle to achieve most efficient
operation.

Q. Is motor mounted at incorrect height on
transom?
A. Have motor adjusted to proper transom
height.

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

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

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

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

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

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

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

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

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

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

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

Q. Are weeds or other foreign matter tangled

72

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

Q. Is fuel pump damaged?
A. Have serviced by a Yamaha dealer.

Trouble Recovery

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

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

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

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

Engine vibrates excessively.

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

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

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

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

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

EMU29433

Temporary action in

emergency

EMU29440

Impact damage

EWM00870

WARNING

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

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

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

EMU29463

Replacing fuse

If the fuse has blown on an electric start
model, open the fuse holder and replace the
fuse with a new one of the proper amperage.

EWM00631

WARNING

Substituting an incorrect fuse or a piece
of wire could allow excessive current
flow. This could cause electric system
damage and a fire hazard.

73

Trouble Recovery

1

2

ZMU03889

1. Fuse holder

2. Fuse (20 A)

Consult your Yamaha dealer if the new fuse
immediately blows again.

EMU29512

Power trim and tilt will not operate

If the engine cannot be tilted up or down with
the power trim and tilt because of a dis­charged battery or a failure with the power
trim and tilt unit , the engine can be tilted
manually.

1. Loosen the manual valve screw by turn­ing it clockwise until it stops.

1

ZMU03890

1. Manual valve screw

2. Put the engine in the desired position,
then tighten the manual valve screw by
turning it counterclockwise.

EMU29533

Starter will not operate

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

EWM01022

WARNING

●

Use this procedure only in an emergen­cy to return to the nearest port for re­pairs.

●

When the emergency starter rope is
used to start the engine, the start-in­gear protection device does not oper­ate. Make sure the remote control lever
is in neutral. Otherwise the boat could
unexpectedly start to move, which
could result in an accident.

●

Attach the engine shut-off cord to a se­cure place on your clothing, or your
arm or leg while operating the boat.

●

Do not attach the cord to clothing that
could tear loose. Do not route the cord
where it could become entangled, pre­venting it from functioning.
Avoid accidentally pulling the cord dur-

●

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

●

Make sure no one is standing behind
you when pulling the starter rope. It
could whip behind you and injure
someone.

●

An unguarded, rotating flywheel is very
dangerous. Keep loose clothing and
other objects away when starting the
engine. Use the emergency starter rope
only as instructed. Do not touch the fly-

74

wheel or other moving parts when the
engine is running. Do not install the
starter mechanism or top cowling after
the engine is running.

●

Do not touch the ignition coil, spark
plug wire, spark plug cap, or other elec­trical components when starting or op­erating the motor. You could get an
electrical shock.

EMU29574

Emergency starting engine

1. Remove the top cowling.

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

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

Trouble Recovery

ZMU02334

ZMU03891

4. Prepare the engine for starting. For fur­ther information, see page 40. 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.

ON STARTOFF

ZMU01906

5. 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.

6. Pull the rope slowly until resistance is
felt.

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

75

Trouble Recovery

T

1

ZMU03892

IP:

When the engine does not start with this pro­cedure, see page 76.

EMU29671

Engine fails to operate

EMU29691

Ignition system malfunction

If the battery voltage is low or in the unlikely
event of an ignition system malfunction, the
engine speed may become erratic or the en­gine may stop. In such a situation, follow the
procedure below.

1. Remove the CDI unit cover or electrical
cover, if equipped.

2. Disconnect the yellow cord (emergency
circuit) of the CDI unit to return to port.

EWM00350

WARNING

When the yellow cord is disconnected,
the idle and low speeds are slightly high­er than normal. Use care when starting off
or stopping.

ECM00380

NOTICE

Follow this procedure only in an emer­gency and just long enough to return to
port for repairs.

2

1. CDI unit

2. Yellow cord

EMU29706

ZMU03893

Cold engine fails to start

If the engine fails to start when it is cold, use
the following procedure.

EWM00410

WARNING

When starting or operating the engine, do
not touch the ignition coil, spark plug
wire, spark plug cap, or other electrical
parts carrying high voltage. Keep loose
clothing and other objects away from the
engine when starting it. Do not touch the
flywheel or other moving parts when the
engine is running.

1. Adjust the trim angle so that the drive
shaft is at right angles to the water sur­face or is trimmed in.

2. On models equipped with an emergency
starter valve, open it. The valve is locat­ed behind the silencer cover on the front
of the engine.

76

CLOSE

Trouble Recovery

ON STARTOFF

OPEN

ZMU03894

3. Squeeze the primer pump two or three
times to feed fuel.

ZMU03142

4. Open the throttle slightly without shifting
using the throttle grip, neutral throttle le­ver or free accelerator. It is necessary to
change the throttle opening slightly de­pending on the engine temperature. Af­ter the engine starts, return the throttle to
its original position.

N

ZMU03144

6. Turn the main switch to “ ” (start).

NOTICE:

Never turn the main switch
to “ ” (start) while the engine is
running. Do not keep the starter mo­tor turning for more than 5 seconds. If
the starter motor is turned continu­ously for more than 5 seconds, the
battery will be quickly discharged,
thus making it impossible to start the
engine. The starter can also be dam­aged. If the engine will not start after
5 seconds of cranking, return the
main switch to “ ” (on), wait 10 sec­onds, then crank the engine again.

[ECM00192]

ON

OFF

START

ZMU03845

5. Turn the main switch to “ ” (on).

ZMU03335

7. After the engine starts, close the emer­gency starter valve (if used), then return
the throttle to its original position.

77

Trouble Recovery

T

OPEN

CLOSE

ZMU03895

IP:

When the starter mechanism malfunctions,
see page 74.

EMU33501

Treatment of submerged motor

If the outboard motor is submerged, immedi­ately take it to a Yamaha dealer. Otherwise
some corrosion may begin almost immedi­ately.

NOTICE:

outboard motor until it has been com­pletely inspected.

Do not attempt to run the

[ECM00401]

78

YAMAHA MOTOR CO., LTD.

Printed in Japan
April 2008–0.1 × 1

!

Printed on recycled paper