Yamaha 90A, 70A, 60A User Manual

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OWNER’S MANUAL
60A 70A 90A
U.S.A.Edition
LIT-18626-04-56
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EMU01449
TO THE OWNER
Thank you for choosing a Yamaha out­board motor. This Owner’s manual con­tains information needed for proper oper­ation, maintenance and care. A thorough understanding of these simple instruc­tions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.
In this Owner’s Manual particularly important information is distinguished in the following ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT!
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YOUR SAFETY IS INVOLVED!
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A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
* Yamaha continually seeks advance-
ments in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.
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Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the out­board motor.
EMU01446
60A/70A/90A
OWNER'S MANUAL
©2001 by Yamaha Motor Corporation, USA
1st Edition, April 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in Japan
P/N LIT-18626-04-56
NOTE:
The 70TR, 90TR and their standard acces­sories are used as a base for the explana­tions and illustrations in this manual. Therefore, some items may not apply to every model.
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EMA20010

CONTENTS

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GENERAL INFORMATION
BASIC COMPONENTS
OPERATION
MAINTENANCE
1
2
3
4
TROUBLE RECOVERY
INDEX
READ THIS OWNER’S MANUAL CAREFULLY
BEFORE OPERATING YOUR OUTBOARD MOTOR.
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6
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EMB00010
Chapter 1
GENERAL
INFORMATION
IDENTIFICATION NUMBERS
RECORD ....................................................1-1
Outboard motor serial number...........1-1
Key number...........................................1-1
EMISSION CONTROL INFORMATION...1-2
SAFETY INFORMATION..........................1-3
1
2
IMPORTANT LABELS ..............................1-5
BASIC BOATING RULES .........................1-6
FUELING INSTRUCTIONS.....................1-10
Gasoline ..............................................1-11
Engine oil ............................................1-11
BATTERY REQUIREMENT ....................1-12
PROPELLER SELECTION .......................1-13
START-IN-GEAR PROTECTION ............1-14
3
4
5
6
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1
904011*
123
YAMAHA
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401012
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EMU00005
IDENTIFICATION NUMBERS
RECORD
EMU00007
OUTBOARD MOTOR SERIAL NUMBER
YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D’ORIGINE JAPON
The outboard motor serial number is stamped on the label attached to the port side of the clamp-bracket. Record your outboard motor serial num­ber in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your out­board motor is stolen.
1 Outboard motor serial number
EMU00008
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
1-1
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EMISSION CONTROL INFORMATION
ENGINE FAMILY :
THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES. FELs : SPARK PLUG :
IDLE SPEED :
rpm IN NEUTRAL
SPARK PLUG GAP (mm) :
g/kw-hr
Manufactured:
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EMU01385
EMISSION CONTROL
INFORMATION
EMU01386
NORTH AMERICAN MODELS
This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details.
Approval label of Emission control certificate
This label is attached to the bottom cowl­ing.
1 Emission control information label
Existing Technology ; N/A
Manufactured date label
This label is attached to the clamp bracket or the swivel bracket.
2 Manufactured date label
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EMU00917
SAFETY
Q
INFORMATION
8 Before mounting or operating the out-
board motor, read this entire manual. Reading it should give you an under­standing of the motor and its operation.
8 Before operating the boat, read any
owner’s or operator’s manuals supplied with it and all labels. Be sure you under­stand each item before operating.
8 Do not overpower the boat with this
outboard motor. Overpowering the boat could result in loss of control. The rated power of the outboard should be equal to or less than the rated horse­power capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer.
8 Do not modify the outboard.
Modifications could make the motor unfit or unsafe to use.
8 Never operate after drinking alcohol or
taking drugs. About 50% of all boating fatalities involve intoxication.
8 Have an approved personal flotation
device (PFD) on board for every occu­pant. It is a good idea to wear a PFD whenever boating. At a minimum, chil­dren and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially haz­ardous boating conditions.
8 Gasoline is highly flammable, and its
vapors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel before starting the engine.
8 This product emits exhaust gases which
contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.
8 Check throttle, shift, and steering for
proper operation before starting the engine.
8 Attach the engine stop switch lanyard
to a secure place on your clothing, or your arm or leg while operating. If you accidentally leave the helm, the lanyard will pull from the switch, stopping the engine.
8 Know the marine laws and regulations
where you will be boating - and obey them. Refer to the “RULES OF THE ROAD” section for basic boating rules.
8 Stay informed about the weather.
Check weather forecasts before boating. Avoid boating in hazardous weather.
8 Tell someone where you are going:
leave a Float Plan with a responsible person. Be sure to cancel the Float Plan when you return.
8 Use common sense and good 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.
8 Always watch carefully for swimmers
during the engine operation.
8 Stay away from swimming areas.
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8 When a swimmer is in the water near
you shift into neutral and shut off the engine.
8 Be informed about boating safety.
Additional publications and information can be obtained from many organiza­tions, including the following:
United States Coast Guard
Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 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
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202021
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WARNING
Be sure shift control is in neutral before starting engine. (except 2HP) Do not touch or remove electrical parts when starting or during operation. Keep hands,hair,and clothes away from flywheel and other rotating parts while engine is running.
6A1-83625- 41
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EMB30010
IMPORTANT LABELS
WARNING LABELS
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EMB40010
BASIC BOATING RULES
(Rules of the road)
Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast Guard and local agencies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water.
Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the Road. The rules presented here in your Owner’s Manual are condensed, and have been provided for your convenience only. Consult your local U.S. Coast Guard Auxiliary or Department of Motor Vehicles for a complete set of rules gov­erning the waters in which you will be using your boat.
STEERING AND SAILING RULES AND SOUND SIGNALS
Whenever two vessels on the water meet one another, one vessel has the right-of­way; it is called the “stand-on” vessel. The vessel which does not have the right­of-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 right­of-way has the duty to take positive and timely action to stay out of the way of the Stand-On vessel. Normally, you should not cross in front of the vessel with the right-of-way. You should slow down or change directions briefly and pass behind the other vessel. You should always move in such a way that the operator of the other vessel can see what you are doing.
“The general prudential rule”
This rule is called Rule 2 in the Inter­national Rules and says,
‘In obeying and construing these rules due regard shall be had to all dangers of navigation and collision, and to any special circumstances, which may ren­der a departure from the above rules necessary in order to avoid immediate danger.’
In other words, follow the standard rules except when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become “Give-Way” vessels.
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102045
RULES WHEN ENCOUNTERING VESSELS
There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed:
Meeting
(you are approaching another vessel head-on)
Crossing
(you are travelling across the other ves­sel’s path)
Overtaking
(you are passing or being passed by another vessel)
In the following illustration, your boat is in the center. You should give the right-of­way to any vessels shown in white area (you are the Give-Way vessel). Any ves­sels in the shaded area must yield to you (they are the Give-Way vessels). Both you and the meeting vessel must alter course to avoid each other.
keep the other vessel on your port (left) side. This rule doesn’t apply if both of you will clear one another if you continue on your set course and speed.
102044
Crossing
When two power driven vessels are crossing each other’s path close enough to run the risk of collision, the vessel which has the other on the starboard (right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; you are the Give-Way vessel. If the other ves­sel is on your port (left) side, remember that you should maintain course and direction, provided the other vessel gives you the right-of-way as it should.
Meeting
If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of-way! Both of you should alter course to avoid an accident. You should
102046
Overtaking
If you are passing another vessel, you are the “Give-Way” vessel. This means that the other vessel is expected to maintain
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its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.
OTHER SPECIAL SITUATIONS
There are three other rules you should be aware of when driving your boat around other vessels.
Narrow Channels and Bends
When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a power-driven vessel is preparing to go around a bend that may obstruct the view of other water vessels, the operator should sound a prolonged blast on the whistle (4 to 6 seconds). If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still proceed around the bend with caution. If you navi­gate such waters with your boat, you will need to carry a portable air horn, avail­able from local marine supply stores.
Fishing Vessel Right-of-way
All vessels which are fishing with nets, lines or trawls are considered to be“fish­ing vessels” under the International Rules. Vessels with trolling lines are not considered fishing vessels. Fishing ves­sels have the right-of-way regardless of position. Fishing vessels cannot, howev­er, impede the passage of other vessels in narrow channels.
Sailing Vessel Right-of-way
Sailing vessels should normally be given the right-of-way. The exceptions to this are:
1. When the sailing vessel is overtaking the power-driven vessel, the power­driven vessel has the right-of-way.
2. Sailing vessels should keep clear of any fishing vessel.
3. In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel which can navigate only in such a channel.
Reading Buoys and Other Markers
The waters of the United states are marked for safe navigation by the lateral system of buoyage. Simply put, buoys and markers have an arrangement of shapes, colors, numbers and lights to show which side of the buoy a boater should pass on when navigating in a par­ticular direction. The markings on these buoys are oriented from the perspective of being entered from seaward (the boater is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open water into port, and black buoys are to port (left) side. When navi­gating out of port, your position with respect to the buoys should be reversed; red buoys should be to port and black buoys to starboard. Many bodies of water used by boaters are entirely within the boundaries of a partic­ular state. The Uniform State Waterway Marking System has been devised for these waters. This system uses buoys and signs with distinctive shapes and colors to show regulatory or advisory informa­tion. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information.
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Remember, markings may vary by geo-
1
11
A
1
11
Proceeding toward head
of navigation from seaward
CAN BUOY
Odd number. Leave to port.
OR
SECONDARY CHANNEL BUOYS
STARTS NEW NUMBERING SYSTEM
old new
C " 1
"
NUN BUOY
Even number. Leave to starboard
N
"
2
"
No change
BUOY
COLOR CODE
BLACK
RED
GREEN
"
A
"
"
2
"
"
1
"
"
3
"
"
4
"
"
5
"
"
7
"
N
"
2
"
"
6
"
C
"
1
"
RB
"
L
"
RG
"
L
"
or
SECONDARY CHANNEL
MAIN CHANNEL
old
new
22
22
22
AA
LL
LL
Odd number. increasing toward head of naviga-
MAIN CHANNEL BUOYS
"
1
" "
3
" "
5
" "
7
"
tion.Leave to port (left) proceeding upstream.
LIGHTED BUOY (Port Hand)`
White Light
Green Light
old
new
old
new
old
new
LIGHTED BUOY (Starboard Hand)`
"
2
" "
4
" "
6
"
Even number,increasing toward head of naviga­tion. Leave to starboard (right) proceeding up­stream.
White Light Red Light
"
A
"
LIGHTED SAFE WATER BUOY
No number. Marks midchannel, pass on either side. Letter has no lateral significance, used for
No nu mber . To pmos t b and re d
-
pre ferr ed
Top Mark White Light
White Light
OR
OR
LIGHTED PREFERRED CHANNEL TO
RB
"
L
"
RG
"
L
"
PORT BUOY
identification and location purposes.
channe l is to left of bu oy. Letter has no l ateral significance, used for identification and location purposes.
Red Light
Red or White Light
OR
graphic location. Always consult local boating authorities before driving your boat in unfamiliar waters.
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EMU00016
FUELING INSTRUCTIONS
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GASOLINE AND ITS VAPORS ARE HIGH­LY FLAMMABLE AND EXPLOSIVE! 8 Do not smoke when refueling, and
keep away from sparks, flames, or other sources of ignition.
8 Stop engine before refueling. 8 Refuel in a well-ventilated area. Refuel
portable fuel tanks off the boat.
8 Take care not to spill gasoline. If gaso-
line spills, wipe it up immediately with dry rags.
8 Do not overfill the fuel tank. 8 Tighten the filler cap securely after
refueling.
8 If you should swallow some gasoline
inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention.
8 If any gasoline spills onto your skin,
immediately wash with soap and water. Change clothing if gasoline spills on it.
8 Touch the fuel nozzle to the filler open-
ing or funnel to help prevent electrosta­tic sparks.
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Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign mat­ter.
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EMU00018
GASOLINE (PETROL)
Recommended gasoline:
Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2
If knocking or pinging occurs, use a differ­ent brand of gasoline or premium unlead­ed fuel. If unleaded gasoline is not avail­able, then leaded regular gasoline can be
EMU00027
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or engine performance prob­lems.
EMU00858
ENGINE OIL
Recommended engine oil: YAMALUBE 2 STROKE OUTBOARD OIL
If the recommended engine oil is not available, another 2-stroke engine oil with a NMMA-certified TC-W3 rating may be used.
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EMU01430¯
BATTERY REQUIREMENT
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Do not use a battery that does not meet the specified capacity. If a battery which differs from the specification is used, the electrical system may perform poorly or be overloaded, causing electrical system damage.
cC
Models with only a rectifier installed:
60TR, 70TR
8 Using a maintenance-free battery with
the above models can shorten the life of the battery significantly.
8 Use caution when connecting acces-
sories such as fish finders, as they may be damaged by high voltage. Install an optional rectifier regulator or use acces­sories rated to withstand 18 volts or higher with the above models. Consult your Yamaha dealer for details on installing an optional rectifier regulator.
Choose a battery for electric start models which meets the following specifications.
Minimum cold crank performance 380 Amps at -17.8°C (0°F) Minimum reserve capacity 124 minutes at 26.7°C (80°F)
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EMU01395
PROPELLER SELECTION
The performance of your outboard motor will be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine.
Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct engine speed to be main­tained. Conversely, a larger-pitch pro­peller is more suitable for a smaller oper­ating load.
Yamaha dealers stock a range of pro­pellers, and can advise you and install a propeller on your outboard that is best suited to your application.
NOTE:
At full throttle and under a maximum boat load, the engine’s rpm should be within the upper half of the full throttle operating range, as listed in “SPECIFICA­TIONS” on page 4-1. Select a propeller which fulfills this requirement. If operating under conditions which allow the engine’s rpm to rise above the maxi­mum recommended range (such as light boat loads), reduce the throttle setting to maintain the rpm in the proper operating range.
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13 x 17 - K
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000933
1 Propeller diameter (in inches) 2 Propeller pitch (in inches) 3 Type of propeller (propeller mark)
Refer to the section “CHECKING PRO­PELLER” for instructions on propeller removal and installation.
EMU01209
START-IN-GEAR PROTECTION
Yamaha outboard motors or Yamaha approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is Neutral. Always select Neutral before starting the engine.
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—MEMO—
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EMC00010
Chapter 2

BASIC COMPONENTS

MAIN COMPONENTS..............................2-1
OPERATIONS OF CONTROLS AND
OTHER FUNCTIONS ................................2-2
Fuel tank.................................................2-2
Remote control......................................2-3
Power trim/tilt switch............................2-7
Trim tab..................................................2-8
Digital tachometer ................................2-9
Tilt support lever.................................2-12
Top cowling lock levers......................2-12
Flushing device ...................................2-12
WARNING SYSTEM ..............................2-13
Overheat warning ...............................2-13
Oil level warning/oil filter clogging
warning ................................................2-14
2
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EMU01206
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!3
!4
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!2 !1
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MAIN COMPONENTS
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 Trim angle adjusting rod 9 Clamp bracket
0 Tilt support lever q Power trim and tilt switch
* w Flushing device * e Remote control box * r Digital tachometer
* May not be exactly as shown; also may not
be included as standard equipment on all models.
2-1
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902051
EMC20010
OPERATIONS OF CONTROLS
AND
OTHER FUNCTIONS
EMC21012
FUEL TANK
If your model was equipped with a portable fuel tank, its function is as fol­lows.
1 Fuel hose joint 2 Fuel meter(If equipped) 3 Fuel tank cap 4 Air vent screw(If equipped)
Fuel hose joint
This connector is provided for connecting or disconnecting fuel hose.
Fuel meter
This meter is on the fuel tank cap. It shows current fuel quantity in the fuel tank approximately.
Fuel tank cap
This cap is for filling fuel. To remove it, turn it counterclockwise.
Air Vent screw
This screw is on the fuel tank cap. To loosen it, turn it counterclockwise.
2-2E2-3
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701011*
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701031
EMC80612
REMOTE CONTROL
Both the shifter and the throttle are actu­ated by the remote control lever. In addi­tion, this control also has the electrical switches.
1 Remote control lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Main switch 5 Engine stop lanyard switch 6 Power trim and tilt switch 7 Throttle friction adjusting screw
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.
1 Neutral 2 Forward 3 Reverse 4 Shift 5 Fully closed 6 Throttle 7 Fully open
Neutral interlock trigger
To shift out of Neutral, the neutral inter-
UP DN
000323
lock trigger of the remote control lever must first be pulled up.
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N
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Neutral throttle lever
To open the throttle without shifting into either Forward or Reverse, place the remote control lever in the Neutral posi-
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tion and lift the neutral throttle lever.
NOTE:
The neutral throttle lever will operate only when the remote control lever is in
701033*
Neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position.
1 Fully open 2 Fully closed
Main switch
The main switch controls the ignition sys-
ON
STARTOFF
tem; its operation is described below.
701045
8 OFF
Electrical circuits switched off. (The key can be removed.)
8 ON
Electrical circuits switched on. (The key cannot be removed.)
8 START
Starter-motor will turn and start engine. (When the key is released, it returns auto­matically to “ON”.)
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000569
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EMC28210
Engine stop lanyard switch
The lock-plate on the end of the lanyard must be attached to the engine stop switch for the engine to run. The lanyard 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 lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away under power.
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8 Attach the engine stop switch lanyard
to a secure place on your clothing, your arm or leg while operating.
8 Do not attach the lanyard to clothing
that could tear loose. Do not route the lanyard in such a way that it could become entangled, preventing it from functioning.
8 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 could cause people and objects in the boat to be thrown forward.
NOTE:
The engine cannot be started with the lock-plate removed.
1 Lock-plate 2 Lanyard
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UP DN
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EMU01331
Power Trim/Tilt Switch
UP DN
701034*
The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the remote control lever grip. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.
NOTE:
Refer to the sections “ADJUSTING TRIM ANGLE” and “TILTING UP/DOWN” in Chapter 3 for instructions on usage.
EMU01155
Throttle Friction Adjusting Screw
A friction device in the remote control box provides adjustable resistance to move­ment of the remote control lever, and can be set according to operator preference. An adjusting screw is located on the front of the remote control box.
701035
Resistance Screw
Increase Turn clockwise
Decrease Turn counterclockwise
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Do not overtighten the friction adjusting screw. If there is too much resistance, it may be difficult to move the lever, which could result in an accident.
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302021
DN
UP
EMU01125
POWER TRIM/TILT SWITCH
The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the side of the bottom engine cowling. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.
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Use the power trim/tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the engine off. Attempting to use the cowl­ing-mounted power trim/tilt 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.
NOTE:
Refer to the section “Adjusting Trim Angle” and “Tilting Up/Down” for instruc­tions on usage.
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603014
EMD04011
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.
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An improperly adjusted trim tab may 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.
A
B
603012
1 Trim tab 2 Bolt 3 Cap
Boat tends to veer The rear end of
trim tab
To the left “Turn the left (port side) (port side), “”A””
in the figure”
To the right (starboard side)
“Turn the right (starboard side), “”B”” in the figure”
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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.
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001078
001082
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EMU01614
DIGITAL TACHOMETER
This gauge contains the tachometer, trim meter, hour meter, oil level indicator, and the overheat warning indicator.
1 Tachometer 2 Trim meter 3 Hour meter 4 Oil level indicator 5 Overheat warning indicator 6 Set button 7 Mode button
NOTE:
All segments of the display will light momentarily after the main switch is turned on and will return to normal there­after.
EMU00136
Tachometer
This meter shows the engine speed.
001049
2-9
Page 33
E
001087
001050
EMU01109
Trim Meter
This meter shows the trim angle of your outboard motor.
NOTE:
8 Memorize the trim angles that work
best for your boat under different condi­tions. Adjust the trim angle to the desired setting by operating the power trim and tilt switch.
8 If the trim angle of your motor exceeds
the trim operating range, the top seg­ment on the trim meter display will start to blink.
EMU01620
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. 8 Changing the display format
Pressing the MODE button changes the display format in the following circular pattern: Total hours - Trip hours - Display off
8 Resetting the trip hours
Simultaneously pressing the SET and MODE buttons for more than 1 second while the trip hours are displayed resets the trip counter to 0 (zero).
NOTE:
The total number of hours the engine has been run cannot be reset.
2-10
Page 34
E
001052
q
001051
q
EMU00138
Oil-Level Indicator
This indicator shows the engine oil level. If the oil level falls below the lower limit, the warning indicator will start to blink. Refer to the sections “FILLING OIL” and “OIL LEVEL WARNING” for details.
1 Oil-level indicator
cC
Do not operate the engine without oil. Serious engine damage will occur.
EMU01553
Overheat Warning Indicator
If the engine temperature rises too high, the warning indicator will start to blink. Refer to “OVERHEAT WARNING” for details.
1 Overheat warning indicator
cC
Do not continue to operate the engine if a warning device has activated. If neces­sary, refer to the “TROUBLESHOOTING” section in this manual. Consult your deal­er if the problem cannot be located and corrected.
2-11
Page 35
E
403011*
q
301042*
EMD60010
TILT SUPPORT LEVER
To keep the outboard motor in the tilted­up position, lock the tilt support lever to the clamp bracket.
EMD63111
TOP COWLING LOCK LEVERS
To remove the engine top cowling, turn the front lock lever and rear lock lever(s). Then lift off the cowling. When replacing the cowling, check to be sure it fits prop­erly in the rubber seal. Then lock the cowling again by returning the levers to the locked position.
1 Top cowling lock lever
q
q
301041*
000945
EMU01146
FLUSHING DEVICE
This device 1 is used to clean the cooling water passages of the motor using a gar­den hose and tap water.
NOTE:
Refer to “Cleaning Cooling-water Passages” in Chapter 4 for instructions on usage.
2-12
Page 36
701054
001053
605015
E
EMD80010
WARNING SYSTEM
cC
Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem can­not be located and corrected.
EMD82012
OVERHEAT WARNING
This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate.
(1); Included (—); N/A
Warning device Tiller Remote activation control control
model model
The engine speed will automatically decrease to about 2,000 r/min.
The overheat warning indicator 1 will come on.
The buzzer will sound.
If the warning system has been activated, stop the engine and check the water inlet for clogging.
1
1
2-13
Page 37
001054
701054
E
EMD84012
OIL LEVEL WARNING / OIL FILTER CLOGGING WARNING
This engine has an oil level warning sys­tem. If oil level falls below lower limit, the warning device will activate.
(1); Included (—); N/A
Warning device Tiller Remote activation control control
model model
The engine speed will automatically decrease to about 2,000 r/min.
The oil level warning indicator 1 will come on.
The buzzer will sound.
If the warning system has been activated, stop the engine and check for the cause.
1
1
q
213025
NOTE:
The warning for oil filter clogging is simi­lar to the warnings for low oil level and overheating. For easy troubleshooting, it is advisable to check for engine overheating first, then oil level and finally oil filter clogging.
1 Oil filter
2-14
Page 38
Oil level warning system
The various oil-level warning system functions are as follows:
60/70
E
Oil level warning
indicator (Digital
tachometer)
90
Oil level warning
indicator (Digital
tachometer)
Oil level warning
lamp (Analog
tachometer)
Green
Yellow
Red
Oil level warning
lamp (Analog
tachometer)
Green
Yellow
Red
Engine oil tank
3
(0.81 US qt, 0.68 Imp qt)
from 770 cm (0.81 US qt, 0.68 Imp qt) down to 280 cm (0.30 US qt, 0.25 Imp qt)
3
3
280 cm3(0.30 US qt,
0.25 Imp qt) or less
Engine oil tank
3
(1.19 US qt, 0.99 Imp qt)
from 1,130 cm (1.19 US qt, 0.99 Imp qt) down to 310 cm (0.33 US qt, 0.27 Imp qt)
3
3
310 cm3(0.33 US qt,
0.27 Imp qt) or less
Remarks
No refilling necessary.more than 770 cm
Add oil, refer to oil filling.
Buzzer sounds in remote control box and engine speed is limited to about 2,000 r/min to help conserve oil. Check oil filter for clogging.
Remarks
No refilling necessary.more than 1,130 cm
Add oil, refer to oil filling.
Buzzer sounds in remote control box and engine speed is limited to about 2,000 r/min to help conserve oil. Check oil filter for clogging.
2-15
Page 39
E
EMF00010
Chapter 3

OPERATION

INSTALLATION ........................................3-1
Mounting the outboard motor ............3-2
FILLING FUEL AND ENGINE OIL ............3-4
Filling fuel ..............................................3-4
Filling oil.................................................3-5
PRE-OPERATION CHECKS......................3-6
Operation after a long period of
storage ...................................................3-7
BREAKING IN (RUNNING IN)
ENGINE .....................................................3-8
STARTING ENGINE ...............................3-10
1
2
3
WARMING UP ENGINE .........................3-13
SHIFTING ................................................3-14
Forward................................................3-14
Reverse ................................................3-14
STOPPING ENGINE ...............................3-15
TRIMMING OUTBOARD MOTOR.........3-16
Adjusting trim angle ...........................3-17
TILTING UP/DOWN ...............................3-19
CRUISING IN OTHER CONDITIONS.....3-21
Cruising in salt water..........................3-21
Cruising in turbid water .....................3-21
4
5
6
Page 40
E
EMF10010
INSTALLATION
cC
Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat or accessories such as transom ladders/depth finder trans­ducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operat­ed continuously in the presence of air­borne water spray.
NOTE:
During water testing check the buoyancy of the boat, at rest, with its maximum load. Check that the static water level on the exhaust housing is low enough to pre­vent water entry into the powerhead, when water rises due to waves when the outboard is not running.
3-1
Page 41
E
104011
q
EMU00176
MOUNTING THE OUTBOARD MOTOR
w
Improper mounting of the outboard motor could result in hazardous condi­tions such as poor handling, loss of con­trol, or fire hazards. Observe the follow­ing: 8 The information presented in this sec-
tion is intended as reference only. It is not possible to provide complete instructions for every possible boat/motor combination. Proper mounting depends in part on experi­ence and the specific boat/motor com­bination.
8 Your dealer or other person experi-
enced in proper rigging should mount the motor. If you are mounting the motor yourself, you should be trained by an experienced person. [permanent mounted type]
8 Your dealer or other person experi-
enced in proper outboard motor mounting should show you how to mount your motor. [portable type]
Mount the outboard motor on the center line (keel line) of the boat, and ensure that the boat itself is well balanced. Otherwise, the boat will be hard to steer. For boats without a keel or which are asymmetrical, consult your dealer.
1 Center line (keel line)
3-2
Page 42
E
104014
w
Overpowering a boat may cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufac­turer.
EMU01299
Mounting Height
To run your boat at optimum efficiency, the water-resistance (drag) of the boat and outboard motor must be made as lit­tle as possible. The mounting-height of the outboard motor greatly affects the water-resistance. If the mounting-height is too high, cavitation tends to occur, thus reducing the propulsion; and if the pro­peller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting-height is too low, the water-resistance will increase and thereby reduce engine efficiency. Mount the engine so that the anti-cavita­tion plate is in alignment with the bottom of the boat .
NOTE:
8 The optimum mounting height of the
outboard motor is affected by the boat/motor combination. Test runs at different heights can help determine the optimum mounting height.
8 Refer to the section “TRIMMING OUT-
BOARD MOTOR” for instructions on setting the trim angle of the outboard.
3-3
Page 43
902055
E
EMU00186
FILLING FUEL AND
ENGINE OIL
EMU00188
FILLING FUEL
1) Put the outboard in the tilt-down posi­tion. Remove the fuel tank cap.
2) Use a funnel if the nozzle on the fuel can or pump is not small enough or long enough to fit into the mouth of the fuel tank.
3) Fill the fuel tank carefully.
4) Close the cap securely after refueling. Wipe up any spilled fuel.
Fuel tank capacity: Refer to SPECIFICATIONS, page 4-1.
EMU01031
FILLING FUEL
1) Remove the fuel tank cap.
2) Fill the fuel tank carefully.
3) Close the cap securely after refueling. Wipe up any spilled fuel.
Ring Free Fuel Additive
Gasoline is a precise blend of many differ­ent substances, each chosen to give cer­tain characteristics. Gasoline blends have been changing in recent years in response to concerns about pollution and resulting emissions regulations. One of the most obvious changes has been the elimination of lead from most fuels. As gasoline has changed, the amount of additives such as aromatics and oxy­genates has increased. These additives are important for the engines in passen­ger cars, but they can have detrimental effects in marine engines, particularly 2­cycle outboards because of increased deposits in the combustion chamber. When enough deposits collect, piston rings begin sticking. Performance drops and engine wear increases dramatically.
3-4
Page 44
203014
E
While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, avail­able from your Yamaha dealer. Ring Free has repeatedly proven its ability to clean combustion deposits from inside the engine, notably the critical piston-ring­land area, and fuel system components. Follow product labeling for use instruc­tions.
EMF32310
FILLING OIL (for Precision blend system model)
This engine uses the YAMAHA PRECI­SION BLEND SYSTEM, which provides superior lubrication by ensuring the prop­er oil ratio for all operating conditions. No fuel premixing is needed (except during break-in/running-in). Simply pour gaso­line into the fuel tank and oil into the oil tank. Convenient indicator segments indicate condition of the oil supply. Refer to oil warning system. To fill the engine oil into the engine oil tank, proceed as follows:
w
Do not add gasoline (Petrol) into the oil tank. Fire or explosion could result.
203015
Engine oil tank capacity:
Refer to “SPECIFICATION”, Page 4-1.
1) Turn the oil filler access cap on top of the top cowling counterclockwise and open it.
2) Open the oil tank filler cap by pulling a tab on the cap.
3-5
Page 45
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203016
q
w
3) Slowly fill the engine oil into the engine oil tank.
4) After filling, replace the all caps securely.
1 Oil filler access cap 2 Oil tank filler cap
EMF40110
PRE-OPERATION CHECKS
w
If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the out­board motor. Otherwise, an accident could occur.
Fuel
Check to be sure you have plenty of fuel for your trip. Make sure there are no fuel leaks or gasoline fumes. Be sure the fuel hose is not being flat­tened or kinked by objects in the boat, and that there are no sharp objects near it.
Oil
Check to be sure you have plenty of oil for your trip.
Controls
Check throttle, shift, and steering for proper operation before starting the engine. The controls should work smoothly, with­out binding or unusual free play. Look for loose or damaged connections. Check operation of the starter and stop switches when the outboard moter is in the water.
3-6
Page 46
E
212011*
Engine
Check the engine and engine mounting. Look for loose or damaged fasteners. Check the propeller for damage.
cC
Do not start the engine out of water. Overheating and serious engine damage can occur.
EMF44010
OPERATION AFTER A LONG PERIOD OF STORAGE (for Precision blend system model)
When operating the engine after a long period (12 months) of storage, proceed as follows:
1) Use a 50 : 1 gasoline-oil mixture to start the engine.
2) Start the engine. Leave it idling.
w
8 Do not touch or remove electrical parts
when starting or during operation.
8 Keep hands, hair, and clothes away
from flywheel and other rotating parts while engine is running.
3) Watch for oil flowing through the oil feed pipes. After any air in the oil lines has been expelled, YAMAHA PRECISION BLEND SYSTEM should supply oil normally. If no oil has begun flowing after 10 minutes of idling, consult your Yamaha dealer.
cC
When operating the engine after a long period of storage, be sure to take the above steps; otherwise, engine seizure may occur.
3-7E3-8
Page 47
EMF50112
BREAKING IN (RUNNING IN)
ENGINE
Your new engine requires a period of break-in (running-in) to allow mating sur­faces of moving parts to wear-in evenly. Correct break-in (running-in) will help ensure proper performance and longer engine life.
cC
8 Failure to follow the break-in (running-
in) procedure may result in reduced engine life or even severe engine dam­age.
8 Premix fuel must be used during break-
in (running-in) in addition to oil in the Precision Blend System.
Break-in (running-in) time:10 hours
Break-in (running-in) premix ratio
Gasoline (petrol) : Engine oil =50 : 1
EMF52010
Gasoline (Petrol)/ Engine oil mixing chart
Mixing
ratio
Gasoline (Petrol)
Engine oil
1 L
(0.26 US gal,
0.22 Imp gal)
0.02 L
(0.02 US qt,
0.02 Imp ql)
12 L
(3.2 US gal,
2.6 Imp gal)
0.24 L
(0.25 US qt,
0.21 Imp qt)
50 : 1
14 L
(3.7 US gal,
3.1 Imp gal)
0.28 L
(0.30 US qt,
0.25 Imp qt)
24 L
(6.3 US gal,
5.3 Imp gal)
0.48 L
(0.51 US qt,
0.42 Imp qt)
cC
Make sure to mix gasoline (petrol) and oil completely, otherwise your outboard motor may be damaged.
Page 48
E
EMU00227
Run the engine under load (in gear with a propeller installed) as follows.
1) First 10 minutes: Run the engine at the lowest possi­ble-speed. A fast idle in neutral is best.
2) Next 50 minutes: Do not exceed half throttle (approxi­mately 3,000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 r/min or less.
3) Second hour: Accelerate at full throttle onto plane, then reduce engine speed to three­quarter throttle (approximately 4,000 r/min). Vary engine speed occasional­ly. Run at full throttle for one minute, then allow about 10 minutes of opera­tion at three-quarter throttle or less to let the engine cool.
4) Third through tenth hours: Avoid operating at full throttle for more than 5 minutes at a time. Let the engine cool between full-throttle runs. Vary engine speed occasionally.
5) After the first 10 hours: Operate the engine normally. Use straight gasoline (petrol) in the fuel tank; YAMAHA PRECISION BLEND SYSTEM provides proper lubrication for normal operation.
3-9E3-10
Page 49
304034*
902053
EMU01147
STARTING ENGINE
w
8 Before starting the engine, make sure
that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you.
8 When the air vent screw is loosened,
gasoline (petrol) vapor will be released. Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw.
8 This product emits exhaust gases
which contain carbon monoxide, a col­orless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.
902061
902025
1) If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.
2) If there is a fuel joint on the motor, 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.
NOTE:
During engine operation place the tank horizontally, or fuel cannot be drawn into the engine.
3) Squeeze the primer bulb with the out­let end up until you feel it become firm.
Page 50
000293
N
701015
E
EMF65010
PROCEDURE FOR REMOTE CONTROL MODEL
4) Place the remote control lever in the Neutral position.
NOTE:
8 The start-in-gear protection device pre-
vents the engine from starting except when in Neutral.
8 It is not necessary to open the free
accelerator lever or Neutral throttle lever while starting.
5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock plate on the other end of the lanyard in the engine stop switch.
w
8 Attach the engine stop switch lanyard
to a secure place on your clothing, your arm or leg while operating.
8 Do not attach the lanyard to clothing
that could tear loose. Do not route the lanyard where it could become entan­gled, preventing from functioning.
8 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 could cause people and objects in the boat to be thrown forward.
6) Turn the main switch to “ON”.
3-11
Page 51
E
ON
START
OFF
701022
EMU00949
Electric Start Model
7) Turn the main switch to “START”, and hold it for a maximum of 5 sec­onds.
8) Immediately after the engine starts, release the main switch to return it to “ON”.
cC
8 Do not turn the main switch to
“START” when the engine is running.
8 Do not keep the starter-motor turning
for more than 5 seconds. The battery will rapidly become exhausted and it will be impossible for it to start the engine. If the engine does not start within 5 seconds, return the main switch to “ON”, wait 10 seconds, and then crank the engine again.
3-12
Page 52
E
309014
EMG00210
WARMING UP ENGINE
1) Before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (Failure to do this will shorten engine life.)
2) Check for a steady flow of water from the cooling-water pilot hole.
cC
A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling pas­sages. If water is not flowing out of the pilot hole at all times while the engine is running, do not continue to run the engine. Overheating and serious damage could occur. Stop the engine and check to see if the water inlet on the lower cas­ing is blocked. If the problem cannot be found and corrected, consult your Yamaha dealer.
NOTE:
After the engine starts, warm-up opera­tion is automatically controlled by the Prime Start system. Automatic control is cancelled if the throttle is opened more than halfway.
3-13
Page 53
E
701043
N
F
N
R
701044
EMU00261
SHIFTING
w
Before shifting, make sure there are no swimmers or obstacles in the water near you.
cC
To change the shifting position from for­ward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speeds).
EMU00264
FORWARD
Pull up the neutral interlock trigger (If equipped) and move the remote control lever quickly and firmly from Neutral to Forward.
EMU00269
REVERSE
w
When operating in Reverse, go slowly. Do not open the throttle more than half. Otherwise, the boat may become unsta­ble, which could result in loss of control and an accident.
Pull up the neutral interlock trigger (If equipped) and move the remote control lever quickly and firmly from Neutral to Reverse.
3-14
Page 54
OFF
ON
START
E
EMG38010
STOPPING ENGINE
Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended.
EMG41211
PROCEDURE
1) Turn the main switch to “OFF”.
NOTE:
The engine can also be stopped by pulling the lanyard from the engine stop switch (then turning the main switch to “OFF”).
701023
2) If the fuel joints are provided, discon­nect the fuel line from the motor after stopping the engine.
304034*
902052
3) Tighten the air vent screw on the fuel tank cap after stopping the engine, if it is equipped.
4) Remove the key if the boat will be left unattended.
3-15
Page 55
q
000862
E
EMU01412
TRIMMING OUTBOARD
MOTOR
The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.
w
Excessive trim for the operating condi­tions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.
NOTE:
Refer to the section “ADJUSTING TRIM ANGLE” for instructions on usage.
1 Trim operating angle
3-16
Page 56
E
UP DN
701034
UP DN
q
ADJUSTING TRIM ANGLE
EMU01401
Power Trim/Tilt Model
w
8 Be sure all people are clear of the out-
board motor when adjusting the trim/tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket.
8 Use caution when trying a trim position
for the first time. Increase speed gradu­ally and watch for any signs of instabili­ty or control problems.
8 Use the power trim/tilt switch located
on the bottom engine cowling (if equipped) only when the boat is at a complete stop with the engine off.
The outboard motor trim angle can be adjusted operating the power trim/tilt switch 1.
To raise the bow (“trim-out”), push the switch UP.
To lower the bow (“trim-in”), push the switch DN.
Make test runs with the trim set to differ­ent angles to find the position that works best for your boat and operating condi­tions.
NOTE:
To adjust the trim angle while the boat is moving, use the power trim and tilt switch located on the remote control device or tiller handle, if so equipped.
3-17
Page 57
105011
q
w
E
Bow up
When the boat is on plane, a bow-up atti­tude result in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. When trimmed out, the boat may have more tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adjust­ed to help offset this effect.
Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-up can cause the propeller to ventilate, which reduces performance further. When trimmed-out too much, a boat may “porpoise” (hop in the water), which could throw the operator and pas­sengers overboard.
Bow down
When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.
e
105013
105015
Too much trim-in causes the boat to “plow” through the water, decreasing fuel economy and making in hard to increase speed. Operating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making operation dif­ficult and dangerous.
1 Bow up 2 Bow down 3 Optimum angle
3-18
Page 58
000817
E
EMU01200
TILTING UP/DOWN
If the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion.
cC
Before tilting the motor, follow the proce­dures under “STOPPING ENGINE”. Never tilt the motor while the engine is running. Severe damage from overheating can result.
w
Be sure all people are clear of the out­board motor when adjusting the tilt angle, also be careful not to pinch any body parts between the drive unit and engine bracket.
w
Leaking fuel is a fire hazard. 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. (If the fuel connector is provided on the motor.)
3-19
Page 59
UP DN
701034*
UP DN
UP
DN
302021*
403011*
E
EMU00295
PROCEDURE FOR TILTING UP
Power tilt / Power trim/tilt model
1) Remove the fuel-line connection from the motor. (If the connector is provid­ed on the motor.)
2) Push the power tilt / power trim/tilt switch “UP” until the outboard has tilted up completely.
3) Turn the tilt-support lever toward you and support the engine.
w
After tilting the engine, be sure to sup­port it with the tilt-support lever. Otherwise, the engine could fall back down suddenly if oil in the power tilt / power trim/tilt unit should lose pressure.
Power trim/tilt model
4) Once the engine is supported with the tilt-support lever, push the power trim/tilt switch DOWN to retract the trim rods.
411014
3-20
Page 60
E
411021
cC
Be sure to retract the trim rods complete­ly during mooring. This protects the rods from marine growths and corrosion which could damage the power trim/tilt mechanism.
EMU00304
PROCEDURE FOR TILTING DOWN
Power tilt / Power trim/tilt model
1) Push the power tilt / power trim/tilt switch “UP” until the engine is sup­ported by the tilt rod.
2) Release the tilt-support lever.
3) Push the power tilt / power trim/tilt switch “DN”(Down) to lower the engine to the desired position.
EMH60010
CRUISING IN OTHER
CONDITIONS
CRUISING IN SALT WATER
After operating in salt water, wash out the cooling-water passages with fresh water to prevent them from becoming clogged­up with salt deposits.
NOTE:
Refer to cooling system flushing instruc­tions in “TRANSPORTING AND STORING OUTBOARD MOTOR”.
CRUISING IN TURBID WATER
It is strongly recommended that the optional chromium-plated water-pump kit be installed if the outboard is to be used in turbid (muddy) water conditions.
3-21
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EMK00010
Chapter 4

MAINTENANCE

SPECIFICATION DATA.............................4-1
TRANSPORTING AND STORING
OUTBOARD MOTOR ...............................4-3
Trailering outboard motor ...................4-3
Storing outboard motor .......................4-4
PERIODIC MAINTENANCE......................4-8
Replacement parts ................................4-8
Maintenance chart ................................4-9
Cleaning and adjusting spark plug ...4-10
Checking fuel system .........................4-12
Cleaning fuel filter...............................4-13
Adjusting idling speed .......................4-14
Checking water drain under engine
oil tank..................................................4-15
Replacing fuse.....................................4-16
Checking wiring and connectors.......4-16
Exhaust leakage ..................................4-16
Water leakage......................................4-16
Greasing...............................................4-17
Checking power trim and tilt
system..................................................4-18
Checking propeller..............................4-19
Changing gear oil................................4-21
Inspecting and replacing anode ........4-22
Checking battery .................................4-23
Checking bolts and nuts.....................4-26
Motor exterior .....................................4-26
Cleaning cooling-water passages .....4-26
Coating the boat bottom ....................4-27
1
2
3
4
5
6
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EMK10011*
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SPECIFICATION DATA
Item
DIMENSIONS
8Overall Length mm (in.) 8Overall Width mm (in.) 8Overall Height L/X mm (in.) 8Transom height L/X mm (in.) 8Weight kg (lb.)
PERFORMANCE
8Full throttle operating range r/min 8Maximum output kW (HP) 8Idling speed r/min
ENGINE
8Type
Number of cylinders Displacement cm
× stroke mm (in.)
Bore
8Ignition system 8Spark plug NGK
Spark plug gap mm (in.)
8Control system 8Starting system 8Battery capacity V-AH
Minimum cold crank performance Amps at —17.8°C (0°F) Minimum reserve capacity minutes at 26.7°F (80°F)
8Alternator output V-Amp (W) 8Starting carburetion system
DRIVE UNIT
8Gear positions
Gear ratio
8Trim/tilt system 8Propeller mark
FUEL AND OIL
8Fuel
Fuel tank capacity L (US gal, Imp gal)
8Recommended engine oil
Oil tank capacity L (US qt, Imp qt)
8Fuel/oil ratio 8Recommended gearcase oil
Gear oil capacity cm
TIGHTENING TORQUE
8Spark plug N•m (kgf•m, lb•ft) 8Propeller nut N•m (kgf•m, lb•ft)
Model
Unit 60TRA
3
(cu.in.)
3
(US oz, Imp oz)
4-1
713 (28.1) 364 (14.3) 1,252 (49.3)/1,374 (54.1)/1,501(59.1) 400(15.7)/521 (20.5)/648 (25.5) 106(234)/108(238)/111(245)
4,500~5,500
44.1 at 5,000 r/min 700~800
2-stroke, L 3 849 (51.8)
72.0 × 69.5 (2.8 × 2.7) C.D.I system B8HS-10
0.9~1.0 (0.035~0.039) Remote control Electric start 12-70~100 380 124 12-6 Prime start system
Forward-Neutral-Reverse
2.33 (28/12) Power trim/tilt K
Regular-unleaded gasoline (P.O.N.: minimum 86) — YAMALUBE 2 STROKE OUTBOARD OIL, or an equivalent TC-W3 certified outboard oil Remote: — Engine: 2.8 (3.0, 2.5) — Hypoid gear oil (SAE 90) 610 (20.6, 21.5)
25 (2.5, 18) 35 (3.5, 25)
Page 63
70TRA 90TRA
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713 (28.1) 364 (14.3) 1,374 (54.1)/1,501 (59.1) 521 (20.5)/648 (25.5)
107.5 (237)/110.5 (244)
5,000~6,000
51.5 (70) at 5,500 r/min 750~850
2-stroke, L 3 849 (51.8)
72.0 × 69.5 (2.8 × 2.7) C.D.I system B8HS-10
0.9~1.0 (0.035~0.039) Remote control Electric start 12-70~100 380 124 12-6 Prime start system
Forward-Neutral-Reverse
2.33 (28/12) Power trim/tilt K
726 (28.6) 374 (14.7) 1,413 (55.6)/1,540 (60.6) 520 (20.5)/647 (25.5)
122.5 (270)/125.5 (277)
4,500~5,500
66.2 (90) at 5,000 r/min 750~850
2-stroke, L 3 1,140 (69.6)
82.0 × 72.0 (3.2 × 2.8) C.D.I system B8HS-10
0.9~1.0 (0.035~0.039) Remote control Electric start 12-70~100 380 124 12-10 Prime start system
Forward-Neutral-Reverse
2.00 (26/13) Power trim/tilt K
Regular-unleaded gasoline (P.O.N.: minimum 86) — YAMALUBE 2 STROKE OUTBOARD OIL, or an equivalent TC-W3 certified outboard oil Remote: — Engine: 2.8 (3.0, 2.5) — Hypoid gear oil (SAE 90) 610 (20.6, 21.5)
25 (2.5, 18) 35 (3.5, 25)
Regular-unleaded gasoline (P.O.N.: minimum 86) — YAMALUBE 2 STROKE OUTBOARD OIL, or an equivalent TC-W3 certified outboard oil Remote: — Engine: 3.3 (3.5, 2.9) — Hypoid gear oil (SAE 90) 610 (20.6, 21.5)
25 (2.5, 18) 35 (3.5, 25)
4-2
Page 64
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000940
EMU01369
TRANSPORTING AND
STORING OUTBOARD MOTOR
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Leaking fuel is a fire hazard. When trans­porting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking.
EMU00326
TRAILERING OUTBOARD MOTOR
The motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the motor in the tilt position using a motor support device such as a transom saver bar. For further details, consult your Yamaha dealer.
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8 Never get under the lower unit while it
is tilted, even if a motor support bar is used. Severe injury could occur if the outboard accidentally falls.
8 USE CARE when transporting fuel tank,
whether in a boat or car.
8 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.
cC
Do not use the tilt support lever/knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor can not be trailered in the down position, use an additional support device to secure it in the up position.
4-3
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EMK16010
STORING OUTBOARD MOTOR
When storing your Yamaha outboard for prolonged periods of time, (2 months or longer), several important procedures must be performed to prevent expensive damage. This is especially important for your Precision Blend equipped outboard due to the lean oil ratios used at idle prior to shutting the engine off for the season. It is advisable to have your outboard ser­viced by an authorized Yamaha dealer prior to storage. However, the following procedures can be performed by you, the owner, with a minimum of tools.
EMK21010
Filling Fuel Tank
Fill the fuel tank with fresh fuel and add one ounce of “Yamaha Fuel Conditioner and Stabilizer” (Part No. LUB-FUELC-12-
00) to each gallon of fuel.
NOTE:
The use of “Yamaha Fuel Conditioner and Stabilizer” eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead.
4-4
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605014
EMK22111
Flushing Cooling System and Fogging Engine
Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fog­ging of the engine is mandatory to pre­vent expensive engine damage due to rust. Perform the flushing and fogging at the same time.
1) Remove the top cowling and silencer cover. Remove the propeller.
2) Install a flushing attachment to the lower unit. (Flushing attachment available from your Yamaha dealer).
cC
Avoid running the outboard at high speed while on the flushing attachment, or overheating could occur.
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8 Do not touch or remove electrical parts
when starting or during operation.
8 Keep hands, hair and clothes away
from flywheel and other rotating parts while engine is running.
3) Run the engine at a fast idle for 10~15 minutes.
4) Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite Engine Fogging Oil” (Part No. LUB­STRRT-12-00) alternately into each carburetor. When properly done, the engine will smoke excessively and almost stall.
5) Remove the flushing attachment and wipe off any excess water.
6) Install the silencer cover and top cowling. Install the propeller.
4-5
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EMK26111
Lubrication
1) Remove the spark plugs, and spray a 10 second spray of “Yamaha Stor­Rite Engine Fogging Oil” into each cylinder. Grease the spark plug threads and reinstall the spark plugs and torque to proper specification. (Refer to “CLEANING AND ADJUST­ING SPARK PLUG”.)
2) Turn the engine over with the stop lanyard disconnected to work the fog­ging oil into the piston rings.
3) Fill the oil tanks. This prevents the for­mation of condensation. For models with a remote tank, it may be neces­sary to manually override the control unit to completely fill the engine main tank. (Refer to “TEMPORARY ACTION IN EMERGENCY”).
4) Change the lower unit oil. (Refer to “CHANGING GEAR OIL”). Inspect the oil for the presence of water which indicates a leaky seal. Seal replace­ment should be performed by an authorized Yamaha dealership prior to use.
5) Grease all grease fittings. (Refer to “GREASING”)
EMK27011
Cleaning and Anti-corrosion Measure
1) Wash down the exterior of the out­board with fresh water and dry off completely.
2) Spray the engine’s exterior with “Yamaha Silicone Protectant” (Part No. LUB-SILCNE-13-00).
3) Wax the cowling with a non-abrasive wax such as “Yamaha Silicone Wax” (Part No. ACC-11000-15-02).
4-6
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EMK29010
Battery Care
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Battery electrolyte is poisonous and dan­gerous, causing severe burns, etc. It con­tains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL; Flush with water. INTERNAL; Drink large quantities of water or milk. Follow with milk of mag­nesia, beaten egg, or vegetable oil. Call physician immediately. EYES; Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases: Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in a closed space. Always wear eye protection when working near batteries. KEEP OUT OF REACH OF CHILDREN.
NOTE:
Batteries vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery manufacturer’s instructions.
1) Disconnect and remove the battery from the boat. Always disconnect the black negative lead first to prevent the risk of shorting.
2) Clean the battery casing and termi­nals. Fill each cell to the upper level with distilled water.
3) Store the battery on a level surface in a cool, dry, well-ventilated place out of direct sunlight.
4) Once a month, check the specific gravity of the electrolyte and recharge as required to prolong battery life.
4-7
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EMK32110
PERIODIC MAINTENANCE
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Be sure to turn off the engine when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other quali­fied mechanic.
A service manual is available for purchase through a Yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform maintenance not covered by this owner’s manual.
EMK33011
REPLACEMENT PARTS
If replacement parts are necessary, use only genuine Yamaha parts or equiva­lents of the same type and of equivalent strength and materials. Any part of inferi­or quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from a Yamaha dealer.
4-8
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MAINTENANCE CHART
Frequency of maintenance operations may be adjusted according to the operating con­ditions, but the following table gives general guidelines.
The mark (7) indicates the check-ups which you may carry out yourself. The mark (2) indicates work to be carried out by your Yamaha dealer.
Initial Every
1
1
50 hours
(3 months)
1
(every month)
10 hours
100 hours
(6 months)
1
200 hours
(1 year)
1 1
Refer Page
4-5 4-13 4-12
— 4-14 4-10 4-15
— 4-18 4-16 4-16 4-16 4-17 4-21 4-26
— 4-22 4-19 4-26 4-23
Item
Carburetor Cooling water passages Fuel filter Fuel system Throttle link Idling speed Spark plug Oil tank water drain Oil pump Power trim and tilt system Wiring & Connectors Exhaust leakage Water leakage Grease points Gear oil Bolts & Nuts Cowling clamp Anode Propeller Motor exterior Battery
Interval
Cleaning
Cleaning
Cleaning
Inspection Inspection/Adjustment Inspection/Adjustment
Cleaning/Adjustment/Replacement
Cleaning Inspection/Adjustment Inspection Inspection/Reconnect Inspection Inspection Greasing Change Retightening Inspection Inspection Inspection Inspection Inspection
NOTE:
Cooling water passages; When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.
4-9
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EMU01202
CLEANING AND ADJUSTING SPARK PLUG
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When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire.
The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center elec­trode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type.
Standard spark plug: Refer to “SPECIFICATIONS”, page 4-1.
Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification if necessary.
Spark plug gap: Refer to “SPECIFICATIONS”, page 4-1.
4-10
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903022
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When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque.
Spark plug torque: Refer to “SPECIFICATIONS”, page 4-1.
NOTE:
If a torque-wrench is not available when you are fitting a spark plug, a good esti­mate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.
Initial of spark Plug wrench size plug I.D. mark
B 21 mm (13/16 in.)
C/BK 16 mm (5/8 in.)
D 18.3 mm (23/32 in.)
1 Spark plug gap 2 Spark plug I.D. mark (NGK)
4-11
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106071
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EMK38010
CHECKING FUEL SYSTEM
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Gasoline (petrol) and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition.
Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by Yamaha dealer or other qualified mechan­ic.
Checking points
8 Fuel system parts leakage. 8 Fuel hose joint leakage. 8 Fuel hose cracks or other damage. 8 Fuel connector leakage.
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Leaking fuel can result in fire or explo­sion.
8 Check for fuel leakage regularly. 8 If any fuel leakage is found, the fuel
system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate.
4-12
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207016
EMK50011
CLEANING FUEL FILTER
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Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly
doing this procedure, consult your Yamaha dealer.
8 Do not perform this procedure on a hot
or running engine. Allow the engine to cool.
8 There will be fuel in the fuel filter. Keep
away from sparks, cigarettes, flames or other sources of ignition.
8 This procedure will allow some fuel to
spill. Catch fuel in a rag. Wipe up any spilled fuel immediately.
8 The fuel filter must be reassembled
carefully with O-ring, filter cup, and hoses in place. Improper assembly can result in a fuel leak, which could result in a fire or explosion hazard.
To clean the fuel filter:
1) Remove the nut holding the fuel filter assembly if equipped.
2) Unscrew the filter cup, catching any spilled fuel in a rag.
3) Remove the filter element, and wash it in solvent. Allow it to dry. Inspect the filter ele­ment and O-ring to make sure they are in good condition. Replace them if necessary.
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207013
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4) Reinstall the filter element in the cup. Make sure the O-ring in position in the cup. Firmly screw the cup onto the filter housing.
5) Attach the filter assembly to the bracket with that the fuel hoses are attached to the filter assembly.
6) Run the engine and check the filter and lines for leaks.
1 Filter element 2 O-ring 3 Filter cap 4 Filter housing
EMK54110
ADJUSTING IDLING SPEED
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8 Do not touch or remove electrical parts
when starting or during operation.
8 Keep hands, hair and clothes away
from flywheel and other rotating parts while engine is running.
cC
This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used.
Procedure NOTE:
A diagnostic tachometer should be used for this procedure.
1) Start the engine and allow it to warm up fully in Neutral until it is running smoothly. If the outboard is mounted on a boat, be sure the boat is tightly moored.
4-14
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204015
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60/70
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2) Adjust the throttle stop-screw to set the idling speed to specification (see “SPECIFICATIONS”) by turning the stop-screw clockwise to increase the idling speed, and turning it counter­clockwise to decrease the idling speed.
NOTE:
Correct idling-speed adjustment is only possible if the engine is fully warmed-up. If not warmed up fully, the speed setting will tend to be too high. If you have diffi­culty obtaining the specified idle, consult a Yamaha dealer or other qualified mechanic.
1 Throttle stop-screw
EMK58010
CHECKING WATER DRAIN UNDER 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, immediately remove the hose at the filler neck and drain the contaminants.
90
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213013
213014
1 Hose 2 Filler neck side
4-15
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205016
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EMU01329
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 proper amper­age.
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Be sure to use the specified fuse. An incorrect fuse or a piece of wire may allow excessive current flow. This could cause electrical system damage and a fire hazard.
NOTE:
If the new fuse blows again immediately, consult a Yamaha dealer.
1 Fuse holder 2 Fuse (20A)
EMK78010
CHECKING WIRING AND CONNECTORS
1) Check that each grounding wire is properly secured.
2) Check that each connector is engaged securely.
413011
EXHAUST LEAKAGE
Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head and crank case.
WATER LEAKAGE
Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head and crank case.
4-16
Page 78
EMU00366
GREASING
Yamaha marine grease (Water resistant grease)
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4-17
103031*
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411015
411016
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EML02011
CHECKING POWER TRIM AND TILT SYSTEM
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8 Never get under the lower unit while it
is tilted, even when the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls.
8 Make sure no one is under the out-
board before performing this test.
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 remote control and engine bottom cowling (If equipped) to check that all switches work.
3) Tilt up the motor and check that the tilt rod and trim rods are pushed out completely.
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 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 gone completely into the cylinders.
7) Activate the trim-up switch until the tilt rod is fully extended. Unlock the tilt-support lever.
8) Operate the motor to tilt down. Check that the tilt rod and trim rods operate smoothly.
NOTE:
If any operation is abnormal, consult a Yamaha dealer.
Recommended fluid;
Yamaha power trim & tilt fluid or ATF (DEXRON-
4-18
II).
Page 80
210012
602051
000357
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EML08011*
CHECKING PROPELLER
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You could be seriously injured if the engine accidentally starts while you are near the propeller. 8 Before inspecting, removing or
installing the propeller, remove the spark plug caps from the spark plugs. Also, put the shift control in Neutral, put the main switch in the “OFF” posi­tion and remove the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one.
8 Do not use your hand to hold the pro-
peller when loosening or tightening the propeller nut. Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning.
602054
1) Check each of the propeller blades for wear, erosion from cavitation or ven­tilation, or other damage.
2) Check the splines for wear and dam­age.
3) Check for fish line winding around the propeller shaft. Check the propeller shaft oil seal for damage.
EMU00976
Removing the Propeller
1) Straighten the cotter-pin 1 and pull it out using a pair of pliers.
2) Remove the propeller nut 2, washer 3 and spacer 4.
3) Remove the propeller 5 and thrust washer 6.
4-19
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602053
EMU00397
Installing the Propeller
cC
8 Be sure to install the thrust washer
before installing propeller, otherwise, lower case and propeller boss may be damaged.
8 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 Corrosion resistant grease to the pro­peller-shaft.
2) Install the thrust washer and propeller on the propeller-shaft.
3) Install the spacer and washer. Tighten the propeller nut to the specified torque.
Tightening torque: Refer to “SPECIFICATIONS” page 4-1.
4) Align the propeller nut with the pro­peller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.
NOTE:
If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, then tighten the nut fur­ther to align it with the hole.
4-20
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601016
EML20010
CHANGING GEAR OIL
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Never get under the lower unit while it is tilted, even when the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls.
1) Put the outboard in a vertical position (not tilted).
w
Be sure the outboard is securely fastened to the transom or a stable stand. You could be severely injured if the outboard falls on you.
2) Place a suitable container under the gearcase.
3) Remove the oil drain plug.
NOTE:
The oil drain plug is magnetic. Remove all metal particles from the plug before rein­stalling it.
4) Remove the oil level plug to allow the oil to drain completely.
1 Oil-level plug 2 Oil drain-plug
cC
Inspect the used oil after it has been drained. If the oil is milky, water is get­ting into the gearcase which can cause gear damage. Consult a Yamaha dealer for repair of the lower unit seals.
NOTE:
For disposal of used oil consult your Yamaha dealer.
4-21
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601015
5) With the outboard motor in an verti­cal position, using a flexible or pres­surized filling device, inject outboard motor hypoid gear oil (SAE 90) into the oil drain plug hole.
Gear oil capacity:
Refer to SPECIFICATIONS, Page 4-1.
6) When oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.
7) Insert and tighten the oil drain plug.
EML24010
INSPECTING AND REPLACING ANODE
Yamaha outboard motor is protected from corrosion by a sacrificial anode(s).
603024
405012
Check the anode periodically. Remove the scales from surfaces of the anode. For the replacement of the anode, consult a Yamaha dealer.
cC
Do not paint the anode, for this would render it ineffective.
4-22
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EML26010
CHECKING BATTERY (for Electric start model)
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Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poi­sonous and highly caustic. Always follow these preventive mea­sures: 8 Avoid bodily contact with electrolytic
fluid as it can cause severe burns or permanent eye injury.
8 Wear protective eye gear when han-
dling or working near batteries.
Antidote (EXTERNAL):
8 SKIN–Flush with water. 8 EYES–Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL): 8 Drink large quantities of water or milk
followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries also generate explosive hydrogen gas; therefore, you should always follow these preventive mea­sures:
8 Charge batteries in a well-ventilated
area.
8 Keep batteries away from fire, sparks,
or open flames (e.g., welding equip­ment, lighted cigarettes, etc.).
8 DO NOT SMOKE when charging or han-
dling batteries.
8 KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
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A poorly maintained battery will quickly deteriorate.
4-23
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1) Check the electrolyte level at least once a month. Fill to the manufactur­er’s recommended level when neces­sary. Top up only with distilled water (or pure de-ionized water suitable to use in batteries).
cC
Ordinary tap-water contains minerals harmhul to a battery, and should not be used for topping-up.
2) Keep the battery always in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month or more, remove the battery from the boat and store it in a cool, dark place. Completely recharge the battery before using it.
3) If the battery will be stored for longer than a month, check the specific grav­ity of the fluid at least once a month and recharge the battery when it is low.
EMU01279
Connecting the Battery
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Mount the battery holder securely in a dry, well-ventilated, vibration-free loca­tion in the boat. Install a fully charged battery in the holder.
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UPPER LEVEL
LOWER LEVEL
901012
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8 Make sure the main switch (on applica-
ble models) is “OFF” before working on the battery.
8 Reversal of the battery leads will dam-
age the rectifier.
8 Connect the RED lead first when
installing the battery and disconnect the RED lead last when removing it. Otherwise, the electrical system can be damaged.
8 The electrical contacts of the battery
and cables must be clean and properly connected, or the battery will not start the engine.
Connect the RED lead to the POSITIVE (+) terminal first. Then connect the BLACK lead to the NEG­ATIVE (-) terminal.
1 Red lead 2 Black lead 3 Battery
EMU01280
Disconnecting the Battery
Disconnect the BLACK lead from the NEG­ATIVE (-) terminal first. Then disconnect the RED lead from the POSITIVE (+) termi­nal.
4-25
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000841
102024
EML40010
CHECKING BOLTS AND NUTS
1) Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torques.
2) Check the tightening torques of other bolts and nuts.
EMU00409
MOTOR EXTERIOR
EMU00410
Cleaning the Outboard Motor
After use, wash the exterior of the out­board with fresh water. Flush the cooling system with fresh water.
NOTE:
Refer to Flushing Cooling System instruc­tions in “TRANSPORTING AND STORING OUTBOARD MOTOR”.
90
EMU01172
CLEANING COOLING-WATER PASSAGES
Flushing device equipped model
Perform this procedure right after opera­tion for the most thorough flushing.
1) After shutting off the engine, unscrew the garden-hose connector 2 from the fitting 1 on the bottom cowling.
2) Screw the garden-hose connector 2 onto a garden hose 3 which is con­nected to a fresh-water supply.
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 3.
4) When flushing is complete, reinstall the garden-hose connector 2 on the fitting 1 on the bottom cowling. Tighten the connector securely.
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102025
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Do not leave the garden-hose 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.
NOTE:
8 When flushing the engine with the boat
in the water, tilting up the engine until it is completely out of the water will achieve better results.
8 Refer to cooling system flushing
instructions in “TRANSPORTING AND STORING OUTBOARD MOTOR”.
EMU00412
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 a Yamaha dealer.
EML44010
COATING THE BOAT BOTTOM
A clean hull improves boat performance. The boat bottom should be kept as clean of marine growths as possible. If neces­sary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
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EMN00010
Chapter 5

TROUBLE RECOVERY

TROUBLESHOOTING ..............................5-1
TEMPORARY ACTION IN
EMERGENCY ............................................5-5
Impact damage .....................................5-5
Power trim/tilt will not operate............5-5
Starter will not operate.........................5-6
Engine fails to operate..........................5-8
Cold engine fails to start ......................5-8
Treatment of submerged motor .......5-11
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3
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5
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EMU01204¯
TROUBLESHOOTING
A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possi­ble remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.) If your outboard motor requires repair, bring it to a Yamaha dealer.
Trouble Possible Cause Remedy
A. Starter will not
operate.
B. Engine will not
start (Starter operates).
1. Battery capacity weak or low.
2. Battery connections loose or corroded.
3. Fuse for electric start circuit blown.
4. Starter components faulty.
5. Engine stop switch lanyard not attached.
6. Shift lever in gear.
1. Fuel tank empty.
2. Fuel contaminated or stale.
3. Fuel filter clogged.
4. Starting procedure incorrect.
5. Fuel pump malfunctions.
6. Spark plug(s) fouled or incorrect type.
7. Spark plug cap(s) fitted incorrectly.
8. Poor connections or damaged ignition wiring.
9. Ignition parts faulty.
10. Engine stop switch lanyard not attached.
11. Shift lever in gear.
12. Engine inner parts damaged.
1. Check battery condition. Use battery of recommended capacity.
2. Tighten battery cables and clean battery terminals.
3. Check for cause of electric overload and repair. Replace fuse with one of correct amperage.
4. Have serviced by a Yamaha dealer.
5. Attach lanyard.
6. Shift to neutral.
1. Fill tank with clean, fresh fuel.
2. Fill tank with clean, fresh fuel.
3. Clean or replace filter.
4. Read "STARTING ENGINE" section.
5. Have serviced by a Yamaha dealer.
6. Inspect spark plug(s). Clean or replace with recommended type.
7. Check and re-fit cap(s).
8. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.
9. Have serviced by a Yamaha dealer.
10. Attach lanyard.
11. Shift to neutral.
12. Have serviced by a Yamaha dealer.
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Trouble Possible Cause Remedy
C. Engine idles
irregularly or stalls.
1. Spark plug(s) fouled or incorrect type.
2. Fuel system obstructed.
3. Fuel contaminated or stale.
4. Fuel filter clogged.
5. Failed ignition parts.
6. Warning system activated.
7. Spark plug gap incorrect.
8. Poor connections or damaged ignition wiring.
9. Specified engine oil not used.
10. Thermostat faulty or clogged.
11. Carburetor adjustments incorrect.
12. Fuel pump damaged.
13. Air vent screw on the fuel tank closed.
14. Motor angle too high.
15. Carburetor clogged.
16. Fuel joint connection incorrect.
17. Throttle valve adjustment incorrect.
18. Battery lead disconnected.
1. Inspect spark plug(s). Clean or replace with recommended type.
2. Check for pinched or kinked fuel line or other obstructions in fuel system.
3. Fill tank with clean, fresh fuel.
4. Clean or replace filter.
5. Have serviced by a Yamaha dealer.
6. Find and correct cause of warning.
7. Inspect and adjust as specified.
8. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.
9. Check and replace oil as specified.
10. Have serviced by a Yamaha dealer.
11. Have serviced by a Yamaha dealer.
12. Have serviced by a Yamaha dealer.
13. Open the air vent screw.
14. Return to normal operating position.
15. Have serviced by a Yamaha dealer.
16. Connect correctly.
17. Have serviced by a Yamaha dealer.
18. Connect securely.
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Trouble Possible Cause Remedy
D. Warning buzzer
sounds or indicator lamp lights.
E. Engine power loss.
1. Cooling system clogged.
2. Engine oil level low.
3. Heat range of spark plug incorrect.
4. Specified engine oil not used.
5. Engine oil contaminated or deteriorated.
6. Oil filter clogged.
7. Oil feed/injection pump malfunctions.
8. Load on boat improperly distributed.
9. Water pump/thermostat faulty.
1. Propeller damaged.
2. Propeller pitch or diameter incorrect.
3. Trim angle incorrect.
4. Motor mounted at incorrect height on transom.
5. Warning system activated.
6. Boat bottom fouled with marine growth.
7. Spark plug(s) fouled or incorrect type.
8. Weeds or other foreign matter tangled on gear housing.
9. Fuel system obstructed.
10. Fuel filter clogged.
11. Fuel contaminated or stale.
12. Spark plug gap incorrect.
1. Check water intake for restriction.
2. Fill oil tank with specified engine oil.
3. Inspect spark plug and replace it with recommended type.
4. Check and replace oil with specified type.
5. Replace oil with fresh, specified type.
6. Have serviced by a Yamaha dealer.
7. Have serviced by a Yamaha dealer.
8. Distribute load to place boat on an even plane.
9. Have serviced by a Yamaha dealer.
1. Have propeller repaired or replaced.
2. Install correct propeller to operate outboard at its recommended speed (r/min) range.
3. Adjust trim angle to achieve most efficient operation.
4. Have motor adjusted to proper transom height.
5. Find and correct cause of warning.
6. Clean boat bottom.
7. Inspect spark plug(s). Clean or replace with recommended type.
8. Remove foreign matter and clean lower unit.
9. Check for pinched or kinked fuel line or other obstructions in fuel system.
10. Clean or replace filter.
11. Fill tank with clean, fresh fuel.
12. Inspect and adjust as specified.
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5-3
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Trouble Possible Cause Remedy
E. Engine power loss.
F. Engine vibrates
excessively.
13. Poor connections or damaged ignition wiring.
14. Failed ignition parts.
15. Specified engine oil not used.
16. Thermostat faulty or clogged.
17. Air vent screw closed.
18. Fuel pump damaged.
19. Fuel joint connection incorrect.
20. Heat range of spark plug incorrect.
21. Engine not responding properly to shift lever position.
1. Propeller damaged.
2. Propeller shaft damaged.
3. Weeds or other foreign matter tangled on propeller.
4. Motor mounting bolt loose.
5. Steering pivot loose or damaged.
13. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.
14. Have serviced by a Yamaha dealer.
15. Check and replace oil with specified type.
16. Have serviced by a Yamaha dealer.
17. Open the air vent screw.
18. Have serviced by a Yamaha dealer.
19. Connect correctly.
20. Inspect spark plug and replace it with recommended type.
21. Have serviced by a Yamaha dealer.
1. Have propeller repaired or replaced.
2. Have serviced by a Yamaha dealer.
3. Remove and clean propeller.
4. Tighten bolt.
5. Tighten or have serviced by a Yamaha dealer.
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EMN20010
TEMPORARY ACTION IN
EMERGENCY
EMH80010
IMPACT DAMAGE
w
The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the out­board motor unsafe to operate.
If the outboard motor hits any object in the water, follow the procedure below;
1) Stop the engine immediately.
2) Inspect control system and all compo­nents for damage. Also, inspect the boat damage.
3) However damage is found or not found, go back to a nearest harbor slowly and carefully.
4) Have a Yamaha dealer inspection of the outboard motor, before operating it again.
EMG65010
POWER TRIM / 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. Loosen the manual valve screw clockwise until it stops. Put the engine in the desired position, then tight­en the manual valve screw counterclock­wise.
1 Manual valve screw
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EMN30410
STARTER WILL NOT OPERATE
If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.
w
8 Use this procedure only in an emer-
gency and only to return to port for repairs.
8 When the emergency starter rope is
used to start the engine, the start-in­gear protection device does not oper­ate. Make sure the transmission is in neutral. Otherwise, the boat could unexpectedly start to move, which could result in an accident.
8 Be sure no one is standing behind you
when pulling the starter rope. It could whip behind you and injure someone.
8 An unguarded rotating flywheel is very
dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the fly­wheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.
8 Do not touch the ignition coil, high
voltage wire, spark plug cap or other electrical components when starting of operating the motor. You could be shocked.
5-6
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208022
ON
STARTOFF
701026
Procedure
1) Remove the top cowling.
2) Remove the flywheel cover by remov­ing the bolts.
3) Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch. The main switch must be on if the main switch is equipped on the elec­tric start model.
NOTE:
Prime start model
If the engine will not start with this proce­dure, refer to “ENGINE FAILS TO OPER­ATE”.
4) To start the engine with emergency starter rope, insert the knotted end of the rope into the notch in the flywheel rotor and wind the rope several turns
208016
clockwise. Then, give a strong pull straight out to crank the engine. Repeat if necessary.
5-7
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2
216011
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q
60/70
EMN32311
ENGINE FAILS TO OPERATE
If 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 case, dis­connect the connection on the yellow cord (emergency circuit) to return to port.
w
When the connection is disconnected, the idling and low speeds are slightly higher
90
than normal. Use care when starting off or stopping.
cC
Follow this procedure only in an emer­gency and just long enough to return to port for repairs.
1 CDI unit 2 Yellow cord
EMU00955*
COLD ENGINE FAILS TO START
If a cold engine fails to start for prime start model, use the following procedure.
w
When starting or operating the engine, do not touch the ignition coil, high volt­age wire, spark plug cap or other electri­cal parts carrying high voltage. Keep loose clothing and other objects away from the engine when starting it with an emergency starter rope. An unguarded rotating flywheel is very dangerous. Do not attempt to replace the top cowling when the engine is running. Proceed at once to the nearest port to get the engine repaired. Take care to prevent water splashing onto the flywheel.
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902025
214013
OPEN
CLOSE
ON
START
OFF
701022
1) Adjust the trim angle so that the drive shaft is at right angles to the water surface or is trimmed in.
2) Open the emergency starter valve located behind the silencer cover on the front side.
3) Squeeze the priming pump two or three times to feed fuel.
N
701014
4) Open the throttle slightly without shifting using the throttle control 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 the original position.
5) Set the MAIN SWITCH to “ON”.
6) Set the MAIN SWITCH to “START”.
cC
8 Do not turn the main switch to
“START” when the engine is running.
8 Do not keep the starter-motor turning
for more than 5 seconds. The battery will rapidly become exhausted and it will be impossible for the starter-motor to start the engine. If the engine does not start within 5 seconds, return the main switch to “ON”, wait 10 seconds, and then crank the engine again.
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OPEN
CLOSE
214014
7) After the engine starts, return the emergency starter valve (if used) to “CLOSE”.
NOTE:
When the starter mechanism malfunc­tions, refer to “STARTER WILL NOT OPERATE”.
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EMN50011
TREATMENT OF SUBMERGED MOTOR
If the outboard motor is submerged, immediately take it a Yamaha dealer. Otherwise, some corrosion may begin almost immediately. If you cannot imme­diately take the outboard motor to a Yamaha dealer, follow the procedure bel­low for taking care to minimize engine damage.
1) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.
2) Remove the spark plugs and face the spark plug holes downward to allow any water, mud or contaminants to drain.
3) Drain the fuel from the carburetor.
4) Feed fogging oil or engine oil through the carburetors and spark plug holes while cranking with the manual starter or emergency starter rope.
5) Take the outboard motor to a Yamaha dealer as soon as possible.
cC
Do not attempt to run the motor until it has been completely inspected.
107014
5-11
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