Page 1
OWNER’S MANUAL
60A
70A
90A
U.S.A.Edition
LIT-18626-04-56
Page 2
Page 3
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!
Q
YOUR SAFETY IS INVOLVED!
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cC
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.
5
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
1-2
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EMU00917
SAFETY
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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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Page 11
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
1
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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
1-7
Page 15
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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.
1-8
Page 16
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.
1-11
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EMU01430¯
BATTERY REQUIREMENT
cC
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.
1-14
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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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!4
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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.
Page 27
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N
q
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
2-5
Page 29
UP
DN
E
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
w
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.
2-6
Page 30
E
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.
w
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.
2-7
Page 31
E
q
w
e
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.
w
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”
cC
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.
2-8
Page 32
q
t
w
u
y
e
r
001078
001082
E
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
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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
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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
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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
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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
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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
Page 61
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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
Page 62
EMK10011*
E
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 —
E
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
E
000940
EMU01369
TRANSPORTING AND
STORING OUTBOARD MOTOR
w
Leaking fuel is a fire hazard. When transporting and storing the outboard motor,
close the air vent screw and fuel cock to
prevent fuel from leaking.
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.
w
8 Never get under the lower unit while it
is tilted, even if a motor support bar is
used. Severe injury could occur if the
outboard accidentally falls.
8 USE CARE when transporting fuel tank,
whether in a boat or car.
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
Page 65
E
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
Page 66
E
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.
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) 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
Page 67
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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
Page 68
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EMK29010
Battery Care
w
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
Page 69
E
EMK32110
PERIODIC MAINTENANCE
w
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If the owner is not familiar with
machine servicing, this work should be
done by a Yamaha dealer or other qualified mechanic.
A service manual is available for purchase
through a Yamaha dealer for owners who
have the mechanical skills, tools, and
other equipment necessary to perform
maintenance not covered by this owner’s
manual.
EMK33011
REPLACEMENT PARTS
If replacement parts are necessary, use
only genuine Yamaha parts or equivalents of the same type and of equivalent
strength and materials. Any part of inferior quality may malfunction, and the
resulting loss of control could endanger
the operator and passengers.
Yamaha genuine parts and accessories
are available from a Yamaha dealer.
4-8
Page 70
E
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
Page 71
E
EMU01202
CLEANING AND ADJUSTING SPARK
PLUG
w
When removing or installing a spark plug,
be careful not to damage the insulator. A
damaged insulator could allow external
sparks, which could lead to explosion or
fire.
The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
something about the condition of the
engine. For example, if the center electrode porcelain is very white, this could
indicate an intake air leak or carburetion
problem in that cylinder. Do not attempt
to diagnose any problems yourself.
Instead, take the outboard motor to a
Yamaha dealer. You should periodically
remove and inspect the spark plug
because heat and deposits will cause the
spark plug to slowly break down and
erode. If electrode erosion becomes
excessive, or if carbon and other deposits
are excessive, you should replace the
spark plug with another of the correct
type.
Standard spark plug:
Refer to “SPECIFICATIONS”, page 4-1.
Before fitting the spark plug, measure the
electrode gap with a wire thickness
gauge; adjust the gap to specification if
necessary.
Spark plug gap:
Refer to “SPECIFICATIONS”, page 4-1.
4-10
Page 72
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903022
q
w
When fitting the plug, always clean the
gasket surface and use a new gasket.
Wipe off any dirt from the threads and
screw in the spark plug to the correct
torque.
Spark plug torque:
Refer to “SPECIFICATIONS”, page 4-1.
NOTE:
If a torque-wrench is not available when
you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a
turn past finger-tight. Have the spark plug
adjusted to the correct torque as soon as
possible with a torque-wrench.
Initial of spark Plug wrench size
plug I.D. mark
B 21 mm (13/16 in.)
C/BK 16 mm (5/8 in.)
D 18.3 mm (23/32 in.)
1 Spark plug gap
2 Spark plug I.D. mark (NGK)
4-11
Page 73
106071
E
EMK38010
CHECKING FUEL SYSTEM
w
Gasoline (petrol) and its vapors are highly
flammable and explosive. Keep away
from sparks, cigarettes, flames or other
sources of ignition.
Check the fuel line for leaks, cracks, or
malfunctions. If any problem is found, it
should be repaired immediately by
Yamaha dealer or other qualified mechanic.
Checking points
8 Fuel system parts leakage.
8 Fuel hose joint leakage.
8 Fuel hose cracks or other damage.
8 Fuel connector leakage.
w
Leaking fuel can result in fire or explosion.
8 Check for fuel leakage regularly.
8 If any fuel leakage is found, the fuel
system must be repaired by a qualified
mechanic. Improper repairs can make
the outboard unsafe to operate.
4-12
Page 74
E
207016
EMK50011
CLEANING FUEL FILTER
w
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.
4-13
Page 75
E
207013
q
w
e
r
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
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.
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
Page 76
204015
q
60/70
w
q
E
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
w
q
213013
213014
1 Hose
2 Filler neck side
4-15
Page 77
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205016
q
w
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.
w
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)
E
4-17
103031*
Page 79
411015
411016
E
EML02011
CHECKING POWER TRIM AND TILT
SYSTEM
w
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
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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.
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602053
EMU00397
Installing the Propeller
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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.
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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).
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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
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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.
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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.
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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).
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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
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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.
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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
1
2
3
4
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.
5-1
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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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Page 92
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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Page 93
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
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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
5-5
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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.
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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
Page 96
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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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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.
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When the connection is disconnected, the
idling and low speeds are slightly higher
90
than normal. Use care when starting off
or stopping.
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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.
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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.
5-8
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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”.
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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”.
5-10
Page 100
107012
107013
E
EMN50011
TREATMENT OF SUBMERGED
MOTOR
If the outboard motor is submerged,
immediately take it a Yamaha dealer.
Otherwise, some corrosion may begin
almost immediately. If you cannot immediately take the outboard motor to a
Yamaha dealer, follow the procedure bellow for taking care to minimize engine
damage.
1) Thoroughly wash away mud, salt,
seaweed, etc. with fresh water.
2) Remove the spark plugs and face the
spark plug holes downward to allow
any water, mud or contaminants to
drain.
3) Drain the fuel from the carburetor.
4) Feed fogging oil or engine oil through
the carburetors and spark plug holes
while cranking with the manual
starter or emergency starter rope.
5) Take the outboard motor to a Yamaha
dealer as soon as possible.
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Do not attempt to run the motor until it
has been completely inspected.
107014
5-11
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