Yamaha 8D User Manual

OWNER’S MANUAL
8D
U.S.A.Edition
LIT-18626-05-81
6M8-F8199-18
Read this owners manual carefully before operating your outboard motor.
ZMU01690

Important manual information

To the owner

Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains infor­mation needed for proper operation, mainte­nance and care. A thorough understanding of these simple instructions will help you ob­tain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important information is distinguished in the following ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
EWM00780
WARNING
Failure to follow WARNING instructions could result in severe injury or death the machine operator, a bystander, or a person inspecting or repairing the out­board motor.
ECM00700
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
to
al, please consult your Yamaha dealer.
NOTE:
The 8MH 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.
8D
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation, USA
1st Edition, January 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in France
P/N LIT-18626-05-81
NOTE:
A NOTE 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 there is any question concerning this manu-

Table of contents

General information .......................... 1
Identification numbers record.......... 1
Outboard motor serial number .......... 1
Emission control information ........... 1
North American models..................... 1
Safety information ........................... 2
Important labels............................... 3
Warning labels ..................................3
Basic boating rules (Rules of the
road) .............................................. 4
Steering and sailing rules and sound
signals............................................. 4
Rules when encountering vessels .... 4
Other special situations..................... 5
Fueling instructions ......................... 7
Gasoline............................................ 8
Engine oil ..........................................8
Propeller selection........................... 8
Start-in-gear protection ................... 9
Basic components ..........................10
Main components.......................... 10
Fuel tank .........................................10
Fuel joint ......................................... 11
Fuel gauge ...................................... 11
Fuel tank cap .................................. 11
Air vent screw ................................. 11
Tiller handle .................................... 11
Gear shift lever................................ 11
Throttle grip..................................... 11
Throttle indicator .............................12
Throttle friction adjuster................... 12
Engine stop lanyard switch .............12
Engine stop button .......................... 13
Choke knob for pull type .................13
Manual starter handle .....................13
Steering friction adjuster .................13
Trim rod (tilt pin).............................. 14
Shallow water lever......................... 14
Tilt support knob ............................. 14
Top cowling lock lever(s) (turn
type).............................................. 14
Operation .........................................16
Installation ..................................... 16
Mounting the outboard motor.......... 16
Clamping the outboard motor ......... 17
Breaking in engine ........................ 18
Gasoline and engine oil mixing
chart (25:1).................................... 18
Procedure for pre-mixed models..... 18
Preoperation checks ..................... 19
Fuel .................................................19
Oil.................................................... 19
Controls........................................... 19
Engine ............................................. 19
Filling fuel and engine oil .............. 19
Filling fuel for portable tank ............. 19
Gasoline and oil mixing (100:1)....... 20
Operating engine .......................... 20
Feeding fuel (portable tank) ............20
Starting engine ................................ 21
Warming up engine....................... 23
Choke start models .........................23
Shifting.......................................... 23
Forward (tiller handle and remote
control models) .............................23
Reverse (manual tilt and hydro tilt
models) ......................................... 24
Stopping engine............................ 24
Procedure........................................ 24
Trimming outboard motor.............. 25
Adjusting trim angle for manual tilt
models ..........................................26
Adjusting boat trim ..........................26
Tilting up and down....................... 27
Procedure for tilting up (manual tilt
models) ......................................... 28
Procedure for tilting down (manual
tilt models)..................................... 29
Cruising in shallow water .............. 29
Cruising in shallow water (manual
tilt models)..................................... 29
Cruising in other conditions........... 30
Maintenance .................................... 31
Specifications................................ 31
Transporting and storing
outboard motor ........................... 31
Clamp screw mounting models ....... 32
Storing outboard motor ...................32
Procedure........................................ 33
Lubrication (except oil injection
models) ......................................... 34
Cleaning and anticorrosion
measures ...................................... 34
Cleaning the outboard motor .......... 34
Checking painted surface of
motor............................................. 34
Periodic maintenance.................... 34
Replacement parts.......................... 35
Maintenance chart .......................... 36
Greasing ......................................... 37
Cleaning and adjusting spark plug.. 37
Checking fuel system...................... 38
Checking fuel filter .......................... 39
Inspecting idling speed ................... 39
Checking wiring and connectors ..... 40
Exhaust leakage ............................. 40
Water leakage................................. 40
Checking propeller .......................... 40
Removing the propeller................... 41
Installing the propeller..................... 41
Changing gear oil............................ 42
Cleaning fuel tank ...........................42
Inspecting and replacing anode(s).. 43
Checking top cowling ...................... 43
Coating the boat bottom.................. 44
Trouble Recovery............................ 45
Troubleshooting ............................ 45
Temporary action in emergency.... 48
Impact damage ...............................48
Starter will not operate .................... 48
Emergency starting engine .............49
Treatment of submerged motor..... 50
Procedure ....................................... 50
Consumer information.................... 52
Important warranty information for
U.S.A. and Canada ..................... 52
YAMAHA MOTOR
CORPORATION, U.S.A. OUTBOARD MOTOR TWO
YEAR LIMITED WARRANTY ...... 54
IMPORTANT WARRANTY
INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE
U.S.A. OR CANADA ...................57
Table of contents

General information

Identification numbers record

Outboard motor serial number
The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket or the upper part of the swivel bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto­len.
1
ZMU02836
1. Outboard motor serial number location
engine for details.
Approval label of emission control certif­icate
This label is attached to the bottom cowling. Existing Technology; N/A
1
ZMU02839
1. Approval label location

Emission control information

North American models
This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for ma­rine SI engines. See the label affixed to your
1
ZMU02896
Manufactured date label
This label is attached to the clamp bracket or the swivel bracket.
1
ZMU02838
1. Manufactured date label location
Manufactured:
ZMU04346

Safety information

Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation
Before operating the boat, read any own­ers or operators manuals supplied with it and all labels. Be sure you understand each item before operating.
Do not overpower the boat with this out­board motor. Overpowering the boat could result in loss of control. The rated power of the outboard should be equal to or less than the rated horsepower capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer.
General information
Do not modify the outboard. Modifications could make the motor unfit or unsafe to use.
Never operate after drinking alcohol or tak­ing drugs. About 50% of all boating fatali­ties involve intoxication.
Have an approved personal flotation de­vice (PFD) on board for every occupant. It is a good idea to wear a PFD whenever boating. At a minimum, children and non­swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating condi­tions. Gasoline is highly flammable, and its va-
pors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel be­fore starting the engine.
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. Check throttle, shift, and steering for prop-
er operation before starting the engine.
Attach the engine stop switch lanyard cord to a secure place on your clothing, or your arm or leg while operating. If you acciden­tally leave the helm, the cord will pull from the switch, stopping the engine.
Know the marine laws and regulations where you will be boatingand obey them. For basic boating rules, see “Rules of the road on page 4.
Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.
Tell someone where you are going: leave
2
General information
a Float Plan with a responsible person. Be sure to cancel the Float Plan when you re­turn.
Use common sense and good judgment when boating. Know your abilities, and be sure you understand how your boat han­dles under the different boating conditions you may encounter. Operate within your limits, and the limits of your boat. Always operate at safe speeds, and keep a careful watch for obstacles and other traffic. Always watch carefully for swimmers dur-
ing the engine operation.
Stay away from swimming areas. When a swimmer is in the water near you
shift into neutral and shut off the engine. Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the fol­lowing:
United States Coast Guard
Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Af­fairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647
National Marine Manufacturers Associa­tion (NMMA)
401 N. Michigan Ave. Chicago, Il 60611
Marine Retailers Association of America
155 N. Michigan Ave. Chicago, Il 60601

Important labels

Warning labels
ZMU02841
ZMU02842
Label
EWM01260
WARNING
Be sure shift control is in neutral before starting engine. (except 2HP)
Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away
from flywheel and other rotating parts while engine is running.
Label
EWM01300
WARNING
This engine is equipped with a neutral
3
General information
starting device.
The engine will not start unless the shift
control is in neutral position.
Basic boating rules (Rules of
the road)
Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast Guard and local agen­cies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water. Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the Road. The rules presented here in your Owner’s Manual are condensed, and have been pro­vided for your convenience only. Consult your local U.S. Coast Guard Auxiliary or De­partment of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat.
Steering and sailing rules and sound signals
Whenever two vessels on the water meet one another, one vessel has the right-of­way; it is called the “stand-on” vessel. The vessel which does not have the right-of-way is called the “give-way” or “burdened” vessel. These rules determine which vessel has the right-of-way, and what each vessel should do.
Stand-on vessel
The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision. When you maintain your direction and speed, the other
vessel will be able to determine how best to avoid you.
Give-way vessel
The vessel which does not have the right-of­way has the duty to take positive and timely action to stay out of the way of the Stand-On vessel. Normally, you should not cross in front of the vessel with the right-of-way. You should slow down or change directions brief­ly and pass behind the other vessel. You should always move in such a way that the operator of the other vessel can see what you are doing.
“The general prudential rule”
This rule is called Rule 2 in the International Rules and says, In obeying and construing these rules due regard shall be had to all dangers of naviga­tion and collision, and to any special circum­stances, which may render a departure from the above rules necessary in order to avoid immediate danger. In other words, follow the standard rules ex­cept when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become “Give-Way” ves­sels.
Rules when encountering vessels
There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed:
Meeting:
sel head-on)
Crossing:
er vessels path)
Overtaking:
passed by another vessel) In the following illustration, your boat is in the center. You should give the right-of-way to any vessels shown in white area (you are the
(you are approaching another ves-
(you are traveling across the oth-
(you are passing or being
4
General information
Give-Way vessel). Any vessels in the shad­ed area must yield to you (they are the Give­Way vessels). Both you and the meeting vessel must alter course to avoid each other.
Meeting
If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of­way! Both of you should alter course to avoid an accident. You should keep the other ves­sel on your port (left) side. This rule doesn’t apply if both of you will clear one another if you continue on your set course and speed.
Crossing
When two power driven vessels are crossing each others path close enough to run the risk of collision, the vessel which has the oth­er on the starboard (right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; you are the Give-Way vessel. If the other
vessel is on your port (left) side, remember that you should maintain course and direc­tion, provided the other vessel gives you the right-of-way as it should.
Overtaking
If you are passing another vessel, you are the Give-Way vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if an­other vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.
Other special situations
There are three other rules you should be aware of when driving your boat around oth­er vessels.
Narrow channels and bends
When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a power­driven vessel is preparing to go around a bend that may obstruct the view of other wa­ter vessels, the operator should sound a pro­longed blast on the whistle (4 to 6 seconds). If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still pro­ceed around the bend with caution. If you navigate such waters with your boat, you will
5
General information
need to carry a portable air horn, available from local marine supply stores.
Fishing vessel right-of-way
All vessels which are fishing with nets, lines or trawls are considered to be fishing ves­sels under the International Rules. Vessels with trolling lines are not considered fishing vessels. Fishing vessels have the right-of­way regardless of position. Fishing vessels cannot, however, impede the passage of other vessels in narrow channels.
Sailing vessel right-of-way
Sailing vessels should normally be given the right-of-way. The exceptions to this are:
1. When the sailing vessel is overtaking
the power-driven vessel, the power-driv­en vessel has the right-of-way.
2. Sailing vessels should keep clear of any
fishing vessel.
3. In a narrow channel, a sailing vessel
should not hamper the safe passage of a power-driven vessel which can navi­gate only in such a channel.
Reading buoys and other markers
The waters of the United states are marked for safe navigation by the lateral system of buoyage. Simply put, buoys and markers have an arrangement of shapes, colors, numbers and lights to show which side of the buoy a boater should pass on when navigat­ing in a particular direction. The markings on these buoys are oriented from the perspec­tive of being entered from seaward (the boat­er is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open wa­ter into port, and black buoys are to port (left) side. When navigating out of port, your posi­tion with respect to the buoys should be re­versed; red buoys should be to port and black buoys to starboard.
Many bodies of water used by boaters are entirely within the boundaries of a particular state. The Uniform State Waterway Marking System has been devised for these waters. This system uses buoys and signs with dis­tinctive shapes and colors to show regulato­ry or advisory information. These markers are white with black letters and orange boarders. They signify speed zones, restrict­ed areas, danger areas, and general infor­mation. Remember, markings may vary by geo­graphic location. Always consult local boat­ing authorities before driving your boat in unfamiliar waters.
6
General information

Fueling instructions

EWM00010
WARNING
GASOLINE AND ITS VAPORS ARE HIGH­LY FLAMMABLE AND EXPLOSIVE!
Do not smoke when refueling, and keep
7
ZMU01708
away from sparks, flames, or other sources of ignition.
Stop engine before refueling.
Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat.
Take care not to spill gasoline. If gaso­line spills, wipe it up immediately with
General information
dry rags.
Do not overfill the fuel tank.
Tighten the filler cap securely after re-
fueling.
If you should swallow some gasoline,
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.
If any gasoline spills onto your skin, im-
mediately wash with soap and water.
Change clothing if gasoline spills on it.
Touch the fuel nozzle to the filler open-
ing or funnel to help prevent electro-
static sparks.
ECM00010
CAUTION:
Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign mat­ter.
Gasoline
If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.
Recommended gasoline:
Regular unleaded gasoline with a min­imum octane rating of 86 (Pump Oc­tane Number) = (R+M)/2
Gasohol
There are two types of gasohol: gasohol con­taining ethanol and that containing metha­nol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Yamaha does not recommended gasohol containing methanol because it can cause fuel system damage or engine performance problems.
Engine oil
If the recommended engine oil is not avail­able, another 2-stroke engine oil with an NMMA-certified TC-W3 rating may be used.
Recommended engine oil:
YAMALUBE 2-stroke outboard motor oil

Propeller selection

The performance of your outboard motor will be critically affected by your choice of propel­ler, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine. Yamaha outboard motors are fitted with pro­pellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suit­able as it enables the correct engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable for a smaller oper­ating load. Yamaha dealers stock a range of propellers, and can advise you and install a propeller on your outboard that is best suited to your ap­plication.
8
General information
×
9 1
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
NOTE:
Select a propeller which will allow the engine to reach the middle or upper half of the oper­ating range at full throttle with the maximum boat load. If operating conditions such as light boat loads then allow the engine r/min to rise above the maximum recommended range, reduce the throttle setting to maintain the engine in the proper operating range.
7 2
N
3
ZMU02844
For instructions on propeller removal and in­stallation, see page 40.
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.
9

Basic components

Main components

NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all mod­els.
8D
15
14
13 12
11 10
9
8
7
1. Manual starter handle
2. Engine stop button/Engine stop lanyard switch
3. Choke knob
4. Throttle grip
5. Throttle friction adjuster
6. Clamp screw
7. Cooling water inlet
8. Anti-cavitation plate
9. Trim rod
10. Shallow water lever
11. Rope attachment
12. Tilt support knob
13. Cooling water pilot hole
14. Gear shift lever
1
3
4
5
2
6
16
ZMU04490
15. Top cowling
16. Fuel tank*

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 licensing or approval authority regula-
10
Basic components
tions.
1. Air vent screw
2. Fuel gauge
3. Fuel joint
4. Fuel tank cap
4
3
1
2
ZMU01992
Fuel joint
This joint is used to connect the fuel line.
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.
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.
Air vent screw
This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise.

Tiller handle

To change direction, move the tiller handle to the left or right as necessary.
ZMU02846

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.
R
N
F
123
ZMU02847
1. Neutral “”
2. Forward “”
3. Reverse “”
Throttle grip
The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.
11
ZMU02848
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
ZMU02849
1. Throttle indicator
Throttle friction adjuster
A friction device provides adjustable resis­tance to movement of the throttle grip or the remote control lever, and can be set accord­ing to operator preference. To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.
EWM00030
WARNING
Do not overtighten the friction adjuster. If
Basic components
there is too much resistance, it could be difficult to move throttle lever or grip, which could result in an accident.
ZMU02850
When constant speed is desired, tighten the adjuster to maintain the desired throttle set­ting.

Engine stop lanyard switch

The lock plate must be attached to the en­gine stop switch for the engine to run. The lanyard should be attached to a secure place on the operators clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away un­der power.
EWM00120
WARNING
Attach the engine stop switch lanyard
to a secure place on your clothing, or your arm or leg while operating. Do not attach the lanyard to clothing
that could tear loose. Do not route the lanyard where it could become entan­gled, preventing it from functioning.
Avoid accidentally pulling the lanyard during normal operation. Loss of en­gine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This
12
Basic components
could cause people and objects in the
boat to be thrown forward.
NOTE:
The engine cannot be started with the lock plate removed.
1
2
ZMU02851
1. Lock plate
2. Lanyard
Engine stop button
To open the ignition circuit and stop the en­gine, push this button.
ZMU02860
Manual starter handle
To start the engine, first gently pull the han­dle out until resistance is felt. From that posi­tion, then pull the handle straight out quickly to crank the engine.
ZMU02852
Choke knob for pull type
To supply the engine with the rich fuel mix­ture required to start, pull out this knob.
13
Steering friction adjuster
A friction device provides adjustable resis­tance to the steering mechanism, and can be set according to operator preference. An ad­justing screw or bolt is located on the swivel bracket.
Basic components
ZMU04508
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.
Trim rod (tilt pin)
The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.
ZMU02854
Tilt support knob
To keep the outboard motor in the tilted up position, push the tilt support knob under the swivel bracket.
ZMU02855
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.
ZMU02853
Shallow water lever
Pushing this lever down will tilt the motor up partially to provide more clearance when op­erating in shallow water.
14
Basic components
1
ZMU02862
1. Top cowling lock lever(s)
15
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