Yamaha 9.9F, 15F User Manual

Page 1
OWNER’S MANUAL
Read this manual carefully before operating this
outboard motor.
9.9F 15F
63V-28199-7E-E0
Page 2
Read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.
Page 3

Important manual information

WARNING
NOTICE
TIP:
TIP:
EMU25108
To the owner
Thank you for selecting a Yamaha outboard motor. This Owner’s Manual contains infor­mation needed for proper operation, mainte­nance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important information is distinguished in the following ways.
: This is the safety alert symbol. It is used to alert you to potential personal injury haz­ards. Obey all safety messages that follow this symbol to avoid possible injury or death.
EWM00782
A WARNING indicates a hazardous situa­tion which, if not avoided, could result in death or serious injury.
ECM00702
A NOTICE indicates special precautions that must be taken to avoid damage to the outboard motor or other property.
between your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer. To ensure long product life, Yamaha recom­mends that you use the product and perform the specified periodic inspections and main­tenance by correctly following the instruc­tions in the owner’s manual. Any damage resulting from neglect of these instructions is not covered by warranty. Some countries have laws or regulations re­stricting users from taking the product out of the country where it was purchased, and it may be impossible to register the product in the destination country. Additionally, the war­ranty may not apply in certain regions. When planning to take the product to another coun­try, consult the dealer where the product was purchased for further information. If the product was purchased used, please consult your closest dealer for customer re­registration, and to be eligible for the speci­fied services.
The 9.9FMH, 15FMH and the standard ac­cessories are used as a base for the explana­tions and illustrations in this manual. Therefore some items may not apply to every model.
EMU25122
A TIP provides key information to make pro­cedures easier or clearer.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current prod­uct information available at the time of print­ing, there may be minor discrepancies
9.9F, 15F
OWNER’S MANUAL
©2013 by Yamaha Motor Co., Ltd.
1st Edition, October 2013
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
Page 4

Table of contents

Safety information ............................. 1
Outboard motor safety .................... 1
Propeller............................................. 1
Rotating parts..................................... 1
Hot parts ............................................ 1
Electric shock..................................... 1
Engine shut-off cord (lanyard)............ 1
Gasoline ............................................. 1
Gasoline exposure and spills ............. 1
Carbon monoxide .............................. 2
Modifications...................................... 2
Boating safety ................................. 2
Alcohol and drugs.............................. 2
Personal flotation devices (PFDs) ...... 2
People in the water ............................ 2
Passengers......................................... 2
Overloading........................................ 2
Avoid collisions .................................. 2
Weather.............................................. 3
Passenger training ............................. 3
Boating safety publications................ 3
Laws and regulations......................... 3
General information .......................... 4
Identification numbers record ......... 4
Outboard motor serial number........... 4
EC Declaration of Conformity
(DoC) ........................................... 4
CE Marking .................................... 4
Read manuals and labels ................ 5
Warning labels ................................... 5
Specifications and requirements..... 8
Specifications.................................. 8
Installation requirements................. 9
Boat horsepower rating...................... 9
Mounting outboard motor.................. 9
Propeller selection .......................... 9
Start-in-gear protection ............... 10
Engine oil requirements ................ 10
Fuel requirements ......................... 10
Gasoline ........................................... 10
Anti-fouling paint .......................... 10
Outboard motor disposal
requirements.............................. 11
Emergency equipment.................. 11
Components .................................... 12
Components diagram ................... 12
Fuel tank........................................... 12
Fuel joint........................................... 13
Fuel gauge........................................ 13
Fuel tank cap.................................... 13
Air vent screw................................... 13
Tiller handle ..................................... 13
Gear shift lever ................................ 13
Throttle grip ..................................... 13
Throttle indicator ............................. 14
Throttle friction adjuster ................... 14
Engine shut-off cord (lanyard) and
clip ................................................ 14
Engine stop button .......................... 15
Choke knob ...................................... 15
Manual starter handle....................... 15
Steering friction adjuster .................. 15
Trim rod (tilt pin) ............................... 16
Tilt lock mechanism ......................... 16
Tilt support bar................................. 16
Cowling lock lever(s) (turn type) ....... 16
2-pin connector................................ 17
Battery charging information............ 17
Installation ....................................... 18
Installation..................................... 18
Mounting the outboard motor .......... 18
Clamping the outboard motor.......... 19
Operation ......................................... 21
First-time operation ...................... 21
Breaking in engine............................ 21
Getting to know your boat ............... 21
Checks before starting engine...... 21
Fuel level .......................................... 21
Remove the top cowling .................. 22
Fuel system ...................................... 22
Controls............................................ 22
Page 5
Table of contents
Engine shut-off cord (lanyard).......... 22
Oil ..................................................... 23
Engine .............................................. 23
Install top cowling ............................ 23
Filling fuel and engine oil............... 23
Filling fuel for portable tank.............. 23
Gasoline and oil mixing (100:1) ........ 24
Operating engine........................... 25
Sending fuel (portable tank) ............. 26
Starting engine................................. 26
Checks after starting engine ......... 28
Cooling water ................................... 28
Warming up engine ....................... 28
Choke start models.......................... 28
Checks after engine warm up ....... 28
Shifting ............................................. 28
Stop switches................................... 29
Shifting .......................................... 29
Stopping boat ............................... 30
Stopping engine ............................ 30
Procedure......................................... 30
Trimming outboard motor ............. 31
Adjusting trim angle for manual tilt
models .......................................... 31
Adjusting boat trim........................... 32
Tilting up and down ...................... 32
Procedure for tilting up (manual tilt
models) ......................................... 33
Procedure for tilting down (manual
tilt models) .................................... 34
Shallow water ............................... 34
Cruising in shallow water (manual
tilt models) .................................... 34
Cruising in other conditions .......... 35
Checking painted surface of
outboard motor............................. 38
Periodic maintenance ................... 38
Replacement parts........................... 39
Severe operating conditions ............ 39
Maintenance chart 1......................... 40
Maintenance chart 2......................... 41
Greasing ........................................... 42
Cleaning and adjusting spark plug... 43
Checking fuel filter............................ 43
Inspecting idle speed ....................... 43
Inspecting wiring and connectors .... 44
Checking propeller ........................... 44
Removing propeller.......................... 45
Installing propeller............................ 45
Changing gear oil ............................. 46
Cleaning fuel tank............................. 47
Inspecting and replacing anode(s) ... 48
Trouble Recovery............................ 49
Troubleshooting............................ 49
Temporary action in emergency... 52
Impact damage ................................ 52
Starter will not operate..................... 52
Emergency starting engine............... 53
Treatment of submerged motor.... 54
INDEX ............................................... 55
Maintenance .................................... 36
Transporting and storing outboard
motor.......................................... 36
Clamp screw mounting models ....... 36
Storing outboard motor.................... 37
Procedure......................................... 37
Lubrication ....................................... 38
Cleaning the outboard motor........... 38
Page 6

Safety information

EMU33623
Outboard motor safety
Observe these precautions at all times.
EMU36502
Propeller
People can be injured or killed if they come in contact with the propeller. The propeller can keep moving even when the motor is in neu­tral, and sharp edges of the propeller can cut even when stationary. Stop the engine when a person is in the
water near you.
Keep people out of reach of the propeller,
even when the engine is off.
EMU40272
Rotating parts
Hands, feet, hair, jewelry, clothing, personal flotation device (PFD) straps, etc., can be­come entangled with internal rotating parts of the engine, resulting in serious injury or death. Keep the top cowling in place whenever pos­sible. Do not remove or replace the top cowl­ing with the engine running. Only operate the engine with the top cowling removed according to the specific instruc­tions in the manual. Keep hands, feet, hair, jewelry, clothing, PFD straps, etc., away from any exposed moving parts.
EMU33641
Hot parts
During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the en­gine has cooled.
EMU33651
Electric shock
Do not touch any electrical parts while start­ing or operating the engine. They can cause shock or electrocution.
EMU33672
Engine shut-off cord (lanyard)
Attach the engine shut-off cord so that the engine stops if the operator falls overboard or leaves the helm. This prevents the boat from running away under power and leaving peo­ple stranded, or running over people or ob­jects. Always attach the engine shut-off cord to a secure place on your clothing or your arm or leg while operating. Do not remove it to leave the helm while the boat is moving. Do not at­tach the cord to clothing that could tear loose, or route the cord where it could be­come entangled, preventing it from function­ing. Do not route the cord where it is likely to be accidentally pulled out. If the cord is pulled during operation, the engine will shut off and you will lose most steering control. The boat could slow rapidly, throwing people and ob­jects forward.
EMU33811
Gasoline
Gasoline and its vapors are highly flamma­ble and explosive. Always, refuel according
to the procedure on page 25 to reduce the risk of fire and explosion.
EMU33821
Gasoline exposure and spills
Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Dispose of rags properly. If any gasoline spills onto your skin, immedi­ately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gaso­line vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth.
1
Page 7
Safety information
EMU33901
Carbon monoxide
This product emits exhaust gases which con­tain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.
EMU33781
Modifications
Do not attempt to modify this outboard mo­tor. Modifications to your outboard motor may reduce safety and reliability, and render the outboard unsafe or illegal to use.
EMU33741
Boating safety
This section includes a few of the many im­portant safety precautions that you should follow when boating.
EMU33711
Alcohol and drugs
Never operate after drinking alcohol or taking drugs. Intoxication is one of the most com­mon factors contributing to boating fatalities.
EMU40281
Personal flotation devices (PFDs)
Have an approved PFD on board for every occupant. Yamaha recommends that you must wear a PFD whenever boating. At a mi­nimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazard­ous boating conditions.
EMU33732
People in the water
Always watch carefully for people in the wa­ter, such as swimmers, skiers, or divers, whenever the engine is running. When some­one is in the water near the boat, shift into neutral and stop the engine. Stay away from swimming areas. Swimmers can be hard to see.
The propeller can keep moving even when the motor is in neutral. Stop the engine when a person is in the water near you.
EMU33752
Passengers
Consult your boat manufacturer’s instruc­tions for details about appropriate passenger locations in your boat and be sure all passen­gers are positioned properly before acceler­ating and when operating above an idle speed. Standing or sitting in non-designated locations may result in being thrown either overboard or within the boat due to waves, wakes, or sudden changes in speed or direc­tion. Even when people are positioned prop­erly, alert your passengers if you must make any unusual maneuver. Always avoid jump­ing waves or wakes.
EMU33762
Overloading
Do not overload the boat. Consult the boat capacity plate or boat manufacturer for maxi­mum weight and number of passengers. Be sure that weight is properly distributed ac­cording to the boat manufacturer’s instruc­tions. Overloading or incorrect weight distribution can compromise the boats han­dling and lead to an accident, capsizing or swamping.
EMU33773
Avoid collisions
Scan constantly for people, objects, and oth­er boats. Be alert for conditions that limit your visibility or block your vision of others.
2
Page 8
Safety information
ZMU06025
Operate defensively at safe speeds and keep a safe distance away from people, objects, and other boats. Do not follow directly behind other boats or
waterskiers.
Avoid sharp turns or other maneuvers that
make it hard for others to avoid you or un­derstand where you are going.
Avoid areas with submerged objects or
shallow water.
Ride within your limits and avoid aggres-
sive maneuvers to reduce the risk of loss of control, ejection, and collision.
Take early action to avoid collisions. Re-
member, boats do not have brakes, and stopping the engine or reducing throttle can reduce the ability to steer. If you are not sure that you can stop in time before hitting an obstacle, apply throttle and turn in an­other direction.
EMU33791
Weather
Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.
EMU33881
Passenger training
Make sure at least one other passenger is trained to operate the boat in the event of an emergency.
EMU33891
Boating safety publications
Be informed about boating safety. Additional publications and information can be obtained from many boating organizations.
EMU33601
Laws and regulations
Know the marine laws and regulations where you will be boating- and obey them. Several sets of rules prevail according to geographic location, but all are basically the same as the International Rules of the Road.
3
Page 9

General information

ZMU06040
EMU25172
Identification numbers record
EMU25185
Outboard motor serial number
The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto­len.
1. Outboard motor serial number location
Each conformed outboard motor accompa­nied with EC DoC.EC DoC contains the fol­lowing information;
Name of Engine ManufactureModel nameProduct code of model (Approved model
code)
Code of conformed directives
EMU25207
CE Marking
Outboard motors affixed with this “CE”mark­ing conform with the directives of; 2006/42/EC, 94/25/EC - 2003/44/EC and 2004/108/EC.
EMU37292
EC Declaration of Conformity
(DoC)
This outboard motor conforms to certain por­tions of the European Parliament directive re­lating to machinery.
1. CE marking location
4
Page 10
General information
ZMU06038
1
2
3
EMU33524
Read manuals and labels
Before operating or working on this outboard motor:
Read this manual.Read any manuals supplied with the boat.Read all labels on the outboard motor and the boat.
If you need any additional information, contact your Yamaha dealer.
EMU33833
Warning labels
If these labels are damaged or missing, contact your Yamaha dealer for replacements.
5
Page 11
General information
WARNING
WARNING
WARNING
1
2
3
ZMU05740
EMU33913
Contents of labels
The above warning labels mean as follows.
1
EWM01692
Emergency starting does not have start­in-gear protection. Ensure shift control is in neutral before starting engine.
2
EWM01682
Keep hands, hair, and clothing away
from rotating parts while the engine is running.
Do not touch or remove electrical parts
when starting or during operation.
3
EWM01672
Read Owner’s Manuals and labels.Wear an approved personal flotation de-
vice (PFD).
Attach engine shut-off cord (lanyard) to
your PFD, arm, or leg so the engine stops if you accidentally leave the helm, which could prevent a runaway boat.
6
Page 12
General information
ZMU05696
ZMU05664
ZMU05665
ZMU05666
EMU35133
Symbols
The following symbols mean as follows.
Notice/Warning
Read Owner’s Manual
Electrical hazard
Hazard caused by continuous rotation
7
Page 13

Specifications and requirements

TIP:
EMU34522
Specifications
“(AL)” stated in the specification data below represents the numerical value for the alumi­num propeller installed. Likewise, “(SUS)” represents the value for stainless steel propeller installed and “(PL)” for plastic propeller installed.
EMU2821U
Dimension and weight:
Overall length:
873 mm (34.4 in)
Overall width:
332 mm (13.1 in)
Overall height S:
1040 mm (40.9 in)
Overall height L:
1167 mm (45.9 in)
Motor transom height S:
440 mm (17.3 in)
Motor transom height L:
567 mm (22.3 in)
Dry weight (AL) S:
36 kg (79 lb)
Dry weight (AL) L:
38 kg (83 lb)
Performance:
Full throttle operating range:
4500–5500 r/min
Rated power:
9.9FMH 7.3 kW (9.9 HP)
Rated power:
15FMH 11.0 kW (15 HP)
Idle speed (in neutral):
700–800 r/min
Power unit:
Type:
2-stroke L2
Total displacement:
246 cm³ (15.0 c.i.)
Bore × stroke:
56.0 × 50.0 mm (2.20 × 1.97 in)
Ignition system:
CDI
Spark plug (NGK):
BR7HS-10
Spark plug gap:
0.9–1.0 mm (0.035–0.039 in)
Steering system:
Tiller handle
Starting system:
Manual starter
Starting carburetion system:
Choke valve
Alternator output:
80 W
Lower unit:
Gear shift positions:
Forward-neutral-reverse
Gear ratio:
2.08 (27/13)
Trim and tilt system:
Manual tilt
Propeller mark:
J
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Min. research octane number (RON):
90
Fuel tank capacity:
25 L (6.61 US gal, 5.50 Imp.gal)
Recommended engine oil:
YAMALUBE 2-stroke outboard motor oil
Recommended engine oil:
TC-W3
Gasoline:oil mixing ratio:
100 :1
Lubrication system:
Pre-mixed fuel and oil
8
Page 14
Specifications and requirements
WARNING
WARNING
Recommended gear oil:
YAMALUBE outboard gear oil or Hypoid gear oil
Recommended gear oil grade:
SAE 90 API GL-4
Gear oil quantity:
0.250 L (0.264 US qt, 0.220 Imp.qt)
Tightening torque:
Spark plug:
25 Nm (2.55 kgf-m, 18.4 ft-lb)
Propeller nut:
17 Nm (1.73 kgf-m, 12.5 ft-lb)
Noise and vibration level:
Operator sound pressure level (ICOMIA 39/94):
85.2 dB(A)
Sound power (ICOMIA 40/94):
92.1 dB(A)
Vibration on tiller handle (ICOMIA 38/94):
Vibration on tiller handle is under 2.5 m/s²
EMU33555
Installation requirements
EMU33565
Boat horsepower rating
EWM01561
Overpowering a boat can cause severe in­stability.
Before installing the outboard motor(s), con­firm that the total horsepower of your out­board motor(s) does not exceed the boats maximum horsepower rating. See the boat’s capacity plate or contact the manufacturer.
EMU40491
Mounting outboard motor
EWM02501
Improper mounting of the outboard mo-
tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards.
Because the outboard motor is very
heavy, special equipment and training is required to mount it safely.
Your dealer or other person experienced in proper rigging should mount the outboard motor using correct equipment and complete rigging instructions. For further information, see page 18.
EMU34196
Propeller selection
Next to selecting an outboard motor, select­ing the right propeller is one of the most im­portant purchasing decisions a boater can make. The type, size, and design of your pro­peller have a direct impact on acceleration, top speed, fuel economy, and even engine life. Yamaha designs and manufactures pro­pellers for every Yamaha outboard motor and every application. Your outboard motor came with a Yamaha propeller selected to perform well over a range of applications, but there may be uses where a different propeller would be more appropriate. Your Yamaha dealer can help you select the right propeller for your boating needs. Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat­load. Generally, select a larger pitch propeller for a smaller operating load and a smaller pitch propeller for a heavier load. If you carry loads that vary widely, select the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle setting to stay within the recommended engine speed range when carrying lighter loads. To check the propeller, see page 44.
9
Page 15
Specifications and requirements
NOTICE
ZMU04606
-
x
123
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
EMU39192
Start-in-gear protection
Yamaha outboard motors are equipped with start-in-gear protection device. This feature permits the engine to be started only when it is in neutral. Always select neutral before starting the engine.
EMU25652
Engine oil requirements
Recommended engine oil:
YAMALUBE 2-stroke outboard motor oil
If the recommended engine oil is not avail­able, another 2-stroke engine oil with an NMMA-certified TC-W3 rating may be used.
EMU36361
EMU40202
Gasoline
Use a good quality gasoline that meets the minimum octane rating. If knocking or ping­ing occurs, use a different brand of gasoline or premium unleaded fuel.
Fuel requirements
Recommended fuel:
Regular unleaded gasoline
Min. research octane number (RON):
90
ECM01982
Do not use leaded gasoline. Leaded
gasoline can seriously damage the en­gine.
Avoid getting water and contaminants in
the fuel tank. Contaminated fuel can cause poor performance or engine dam­age. Use only fresh gasoline that has been stored in clean containers.
Gasohol
There are two types of gasohol: gasohol con­taining ethanol (E10) and that containing methanol. Ethanol can be used if the ethanol content does not exceed 10% and the fuel meets the minimum octane ratings. E85 is a fuel containing 85% ethanol and must not be used in your outboard motor. All ethanol blends containing more than 10% ethanol can cause fuel system damage or cause en­gine starting and running problems. Yamaha does not recommend gasohol containing methanol because it can cause fuel system damage or engine performance problems. It is recommended that you install a water­separating marine fuel filter assembly (10 mi­cron minimum) between your boat’s fuel tank and outboard motor when using ethanol. Eth­anol is known to allow moisture to be ab­sorbed into boat fuel tanks and systems. Moisture in the fuel can cause corrosion of metallic fuel system components, starting and running complaints and require addition­al fuel system maintenance.
EMU36331
Anti-fouling paint
A clean hull improves boat performance. The boat bottom should be kept as clean of mari­ne growth as possible. If necessary, the boat
10
Page 16
Specifications and requirements
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.
EMU40302
Outboard motor disposal re-
quirements
Never illegally discard (dump) the outboard motor. Yamaha recommends consulting the dealer about discarding the outboard motor.
EMU36353
Emergency equipment
Keep the following items onboard in case there is trouble with the outboard motor. A tool kit with assorted screwdrivers, pliers,
wrenches (including metric sizes), and electrical tape.
Waterproof flashlight with extra batteries.An extra engine shut-off cord (lanyard) with
clip.
Spare parts, such as an extra set of spark
plugs.
Consult your Yamaha dealer for details.
11
Page 17

Components

TIP:
WARNING
EMU2579Z
Components diagram
* May not be exactly as shown; also may not be included as standard equipment on all models (order from dealer).
1. Top cowling
2. Cowling lock lever
3. Cooling water pilot hole
4. Tilt lock lever
5. Manual starter handle
6. Gear shift lever
7. Engine stop button/Engine shut-off switch
8. Tiller handle
9. Throttle friction adjuster
10.Clamp screw
11.2-pin connector*
12.Choke knob
13.Restraint cable attachment
14.Clamp bracket
15.Trim rod
16.Anti-cavitation plate
17.Cooling water inlet
18.Propeller
19.Fuel tank
EMU25804
Fuel tank
If your model was equipped with a portable fuel tank, its function is as follows.
EWM00021
The fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Com-
12
Page 18
Components
mercial users should conform to relevant licensing or approval authority regula­tions.
1. Fuel joint
2. Fuel gauge
3. Fuel tank cap
4. Air vent screw
EMU25831
Fuel joint
This joint is used to connect the fuel line.
EMU25842
Fuel gauge
This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the ap­proximate amount of fuel remaining in the tank.
EMU25851
Fuel tank cap
This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise.
EMU25861
Air vent screw
This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise.
EMU25914
Tiller handle
To change direction, move the tiller handle to the left or right as necessary.
EMU25925
Gear shift lever
Move the gear shift lever forward to engage the forward gear or rearward to engage the reverse gear.
1. Forward “ ”
2. Neutral “ ”
3. Reverse “ ”
EMU25943
Throttle grip
The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.
13
Page 19
Components
EMU25963
Throttle indicator
The fuel consumption curve on the throttle in­dicator shows the relative amount of fuel con­sumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation.
1. Throttle indicator
EMU25977
Throttle friction adjuster
A friction device provides adjustable resis­tance to movement of the throttle grip or the remote control lever, and can be set accord­ing to operator preference. To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. WARNING! Do
not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident.
[EWM00033]
When constant speed is desired, tighten the adjuster to maintain the desired throttle set­ting.
EMU25996
Engine shut-off cord (lanyard) and clip
The clip must be attached to the engine shut­off switch for the engine to run. The cord should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power. WARNING! At-
tach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not rou­te the cord where it could become entan­gled, preventing it from functioning. Avoid accidentally pulling the cord during nor­mal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause peo­ple and objects in the boat to be thrown forward.
[EWM00123]
14
Page 20
Components
1. Engine shut-off cord (lanyard)
2. Clip
3. Engine shut-off switch
EMU26004
Engine stop button
The engine stop button stops the engine when the button is pushed.
EMU26031
Choke knob
To supply the engine with the rich fuel mix­ture required to start, pull out this knob. The choke knob has the 4 operating positions shown in the following illustration.
1. Use to start a hot engine
2. Use to warm up a cold engine or restart a warm engine
3. Use to warm up a cold engine or restart a warm engine
4. Use to start a cold engine
EMU26075
Manual starter handle
The manual starter handle is used to crank and start the engine.
EMU26123
Steering friction adjuster
A friction device provides adjustable resis­tance to the steering mechanism, and can be set according to operator preference. An ad­justing screw or bolt is located on the swivel bracket.
15
Page 21
Components
WARNING
NOTICE
To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.
EWM00041
Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident.
EMU26263
Trim rod (tilt pin)
The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.
EMU30531
Tilt lock mechanism
The tilt lock mechanism is used to prevent the outboard motor from lifting out of the water when in reverse gear.
1. Tilt lock lever
To lock it, set the tilt lock lever in the lock po­sition. To release, push the tilt lock lever in the release position.
EMU26334
Tilt support bar
The tilt support bar keeps the outboard motor in the tilted up position.
ECM01661
Do not use the tilt support bar when traile­ring the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the nor­mal running position, use an additional support device to secure it in the tilt posi­tion.
EMU26374
Cowling lock lever(s) (turn type)
To remove the engine top cowling, turn the cowling lock lever(s) and lift off the cowling. When installing the cowling, check to be sure
16
Page 22
Components
NOTICE
TIP:
it fits properly in the rubber seal. Then lock the cowling again by returning the cowling lock lever(s) to the lock position.
1. Cowling lock lever(s)
EMU26411
2-pin connector
AC 12 V-40/60/80W power is delivered through this connector. When using it, keep in mind the following points:
ECM01001
Do not connect the 2-pin connector di­rectly to the battery terminals. Otherwise the electric system will be damaged.
EMU26421
Battery charging information
If you need to charge the battery, use a gen­uine charge cable to make the charging cir­cuit. For details on the cable connections, consult your Yamaha dealer.
Do not use the 2-pin connector while
charging. The battery will not be charged.
If you need to use lighting equipment while
charging the battery, connect it to the bat­tery, not to the 2-pin connector.
Use a genuine Yamaha connector.Use lighting equipment only.Connect lighting equipment directly to the
2-pin connector.
Capacity of the lighting equipment must be
more than 12 V-40/60/80W; otherwise the bulb could burn out.
When the connector is not in use, place the
cap on it.
17
Page 23
EMU26903
WARNING
WARNING
ZMU01760
1
ZMU02011
0–25mm (0–1in)

Installation

The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat and motor combination. Proper mounting depends in part on experience and the specific boat and motor combination.
EWM01591
Installation
Overpowering a boat could cause se-
vere instability. Do not install an out­board motor with more horsepower than the maximum rating on the capaci­ty plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.
Improper mounting of the outboard mo-
tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. For permanently mount­ed models, your dealer or other person experienced in proper rigging should mount the motor.
EMU26912
Mounting the outboard motor
EWM01721
Your dealer or other person experienced in proper outboard motor mounting should show you how to mount your out­board motor.
The outboard motor should be mounted so that the boat is well balanced. Otherwise, the boat could be hard to steer. For single-engine boats, mount the outboard motor on the cen­terline (keel line) of the boat.
1. Center line (keel line)
EMU26926
Mounting height
To run your boat at optimum efficiency, the water resistance (drag) of the boat and out­board motor must be made as little as possi­ble. The mounting height of the outboard motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the en­gine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in) below it.
18
Page 24
Installation
NOTICE
TIP:
ZMU02012
ZMU02013
ECM01635
Make sure that the idle hole is high
enough to prevent water from entering the engine even if the boat is stationary with the maximum load.
Incorrect engine height or obstructions
to the smooth flow of water (such as the design or condition of the boat, or ac­cessories, such as transom ladders or depth finder transducers) can create air­borne water spray while the boat is cruising. If the outboard motor is oper­ated continuously in the presence of air­borne water spray, enough water could enter the engine through the air intake opening in the top cowling to cause se­vere engine damage. Remove the cause of the airborne water spray.
The optimum mounting height of the out-
board motor is affected by the boat and motor combination and the desired use. Test runs at different heights can help de­termine the optimum mounting height. Consult your Yamaha dealer or boat man­ufacturer for further information on deter­mining the proper mounting height.
For instructions on setting the trim angle of
the outboard motor, see page 31.
EMU26974
Clamping the outboard motor
1. Place the outboard motor on the tran­som so that it is positioned as close to the center as possible. Tighten the tran­som clamp screws evenly and securely. Occasionally check the clamp screws for tightness during operation of the out­board motor because they could be­come loose due to engine vibration.
WARNING! Loose clamp screws could
allow the outboard motor to fall off or move on the transom. This could cau­se loss of control and serious injury. Make sure the clamp screws are tight­ened securely. Occasionally check the screws for tightness during operation.
[EWM00643]
2. If the restraint cable attachment is equipped on your engine, a restraint ca­ble or chain should be used. Attach one end to the restraint cable attachment and the other to a secure mounting point on the boat. Otherwise the engine could be completely lost if it accidentally falls off the transom.
3. Secure the clamp bracket to the transom using the bolts provided with the out­board (if packed). For details, consult your Yamaha dealer. WARNING! Avoid
using bolts, nuts or washers other than those contained in the engine
19
Page 25
packaging. If used, they must be of at least the same quality of material and strength and must be tightened se­curely. After tightening, test run the engine and check their tightness.
[EWM00652]
Installation
20
Page 26

Operation

NOTICE
WARNING
NOTICE
EMU36382
First-time operation
EMU30175
Breaking in engine
Your new engine requires a period of break­in to allow mating surfaces of moving parts to wear in evenly. Correct break-in will help en­sure proper performance and longer engine life. NOTICE: Failure to follow the break-in
procedure could result in reduced engine life or even severe engine damage.
EMU27061
Gasoline and engine oil mixing chart (50:1)
1. : Gasoline
2. : Engine oil
ECM00151
Be sure to mix gasoline and oil completely, otherwise the engine may be damaged.
EMU27075
Procedure for pre-mixed models
Run the engine under load (in gear with a pro­peller installed) for 10 hours as follows.
1. First 10 minutes: Run the engine at the lowest possible speed. A fast idle in neutral is best.
2. Next 50 minutes: Do not exceed half throttle (approxi­mately 3000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3000 r/min or less.
[ECM00802]
3. Next two hours: Accelerate at full throttle onto plane, then reduce engine speed to three-quarter throttle (approximately 4000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three-quarter throttle or less to let the engine cool.
4. Remaining seven hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.
5. After the first 10 hours: Operate the engine normally. Use the standard premix ratio of gasoline and oil. For details on mixing fuel and oil, see page 23.
EMU36402
Getting to know your boat
All boats have unique handling characteris­tics. Operate cautiously while you learn how your boat handles under different conditions and various trim angles (see page 31).
EMU36414
Checks before starting engine
EWM01922
If any item in “Checks before starting en­gine” is not working properly, have it in­spected and repaired before operating the outboard motor. Otherwise, an accident could occur.
ECM00121
Do not start the engine out of water. Over­heating and serious engine damage can occur.
EMU37142
Fuel level
Be sure you have plenty of fuel for your trip. A good rule is to use 1/3 of your fuel to get to the destination, 1/3 to return, and to keep 1/3
21
Page 27
Operation
WARNING
WARNING
ZMU06092
as an emergency reserve. With the boat level on a trailer or in the water, check the fuel lev­el. For fuel filling instructions, see page 23.
EMU36573
Remove the top cowling
For the following checks, remove the top cowling from the bottom cowling. To remove the top cowling, release the cowling lock le­ver and lift off the top cowling.
EMU36443
Fuel system
EWM00061
Gasoline and its vapors are highly flamma­ble and explosive. Keep away from sparks, cigarettes, flames, or other sources of ig­nition.
EWM00911
Leaking fuel can result in fire or explosion.
Check for fuel leakage regularly.If any fuel leakage is found, the fuel sys-
tem must be repaired by a qualified me­chanic. Improper repairs can make the outboard unsafe to operate.
EMU36452
Check for fuel leaks
Check for fuel leaks or gasoline fumes in
the boat.
Check for fuel leakage from the fuel sys-
tem.
Check the fuel tank and fuel lines for
cracks, swellings, or other damages.
EMU37323
Checking the fuel filter
Check that the fuel filter is clean and free of water. If any water is found in the fuel, or if a significant amount of debris is found, the fuel tank should be checked and cleaned by a Yamaha dealer.
EMU36892
Controls
Move the tiller handle fully to the left and
right to make sure operation is smooth.
Turn the throttle grip from the fully closed
to the fully open position. Make sure that it turns smoothly and that it completely re­turns to the fully closed position.
Look for loose or damaged connections of
the throttle and shift cables.
EMU36484
Engine shut-off cord (lanyard)
Inspect the engine shut-off cord and clip for damage, such as cuts, breaks, and wear.
22
Page 28
Operation
WARNING
ZMU06873
1
2
ZMU06117
1. Clip
2. Engine shut-off cord (lanyard)
EMU27121
Oil
Check to be sure you have plenty of oil for
your trip.
EMU27142
Engine
Check the engine and engine mounting.Look for loose or damaged fasteners.Check the propeller for damage.
EMU36956
Install top cowling
1. Be sure that the cowling lock lever is re­leased.
2. Be sure that the rubber seal is seated all the way around the top cowling.
3. Place the top cowling on the bottom cowling.
4. Check to be sure the rubber seal is seat­ed correctly between the top cowling and the bottom cowling.
5. Move the cowling lock lever to lock the top cowling as shown. NOTICE: If the
top cowling is not installed correctly, water spray under the top cowling can damage the engine, or the top cowling can blow off at high speeds.
[ECM01992]
After installing, check the fitting of the top cowling by pushing it with both hands. If the top cowling is loose, have it repaired by your Yamaha dealer.
EMU27235
Filling fuel and engine oil
EMU27249
Filling fuel for portable tank
EWM01831
Gasoline and its vapors are highly flam-
mable and explosive. Always refuel ac­cording to this procedure to reduce the risk of fire and explosion.
Gasoline is poisonous and can cause in-
jury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gas­oline in your eyes, see your doctor im­mediately. If gasoline spills on your skin,
23
Page 29
Operation
NOTICE
ZMU06621
ZMU02041
ZMU03012
wash with soap and water. If gasoline spills on your clothing, change your clothes.
1. Be sure the engine is stopped.
2. Disconnect the fuel line from the fuel tank and tighten the air vent screw on the fuel tank cap.
8. Fill the fuel tank, but do not overfill.
WARNING! Do not overfill. Otherwise fuel can expand and overflow if the temperature increases.
[EWM02611]
Fuel tank capacity:
25 L (6.61 US gal, 5.50 Imp.gal)
9. Tighten the filler cap securely.
10. Wipe up any spilled gasoline immediate­ly with dry rags. Dispose rags properly according to local laws or regulations.
EMU27407
Gasoline and oil mixing (100:1)
ECM00812
3. Remove the portable tank from the boat.
4. Be sure you are in a well-ventilated out­door area, either securely moored or trailered.
5. Do not smoke and keep away from sparks, flames, static electric discharge, or other sources of ignition.
6. If you use a portable container to store and dispense fuel, use only an approved GASOLINE container.
7. Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
Avoid using any oil other than the spec-
ified type.
Use a thoroughly blended fuel-oil mix-
ture.
If the mixture is not thoroughly mixed, or
if the mixing ratio is incorrect, the fol­lowing problems could occur.
Low oil ratio: Lack of oil could cause
major engine trouble, such as piston seizure.
High oil ratio: Too much oil could cause
fouled spark plugs, smoky exhaust, and heavy carbon deposits.
24
Page 30
Operation
TIP:
WARNING
100:1
1 L
(0.26 US gal,
0.22 Imp gal)
12 L
(3.2 US gal,
2.6 Imp gal)
14 L
(3.7 US gal,
3.1 Imp gal)
24 L
(6.3 US gal,
5.3 Imp gal)
0.01 L
(0.01 US qt,
0.01 Imp qt)
0.12 L
(0.13 US qt,
0.11 Imp qt)
0.14 L
(0.15 US qt,
0.12 Imp qt)
0.24 L
(0.25 US qt,
0.21 Imp qt)
ZMU04910
Gasoline to engine oil
ratio
Break-in period See page 21
After break-in 100:1
1. : Gasoline
2. : Engine oil
If equipped with a portable fuel tank
1. Pour oil into the portable fuel tank, and then add gasoline.
2. Replace the fuel tank cap and close tightly.
3. Shake the fuel tank to mix the fuel thor­oughly.
4. Make sure that the oil and gasoline are mixed.
If equipped with a built-in fuel tank
1. Pour oil into a clean fuel can, and then add gasoline.
2. Replace the fuel can cap and close tight­ly.
3. Shake the fuel can to mix the fuel thor­oughly.
4. Make sure that the oil and gasoline are mixed.
5. Pour the gasoline and oil mixture into the built-in fuel tank.
If using a permanently installed tank, pour the oil gradually as the gasoline is being added to the tank.
EMU27453
Operating engine
EWM00421
1. Engine oil
2. Gasoline
25
Before starting the engine, make sure
that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you.
When the air vent screw is loosened,
gasoline vapor will be released. Gaso­line is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw.
This product emits exhaust gases which
contain carbon monoxide, a colorless, odorless gas which could cause brain damage or death when inhaled. Symp-
Page 31
toms include nausea, dizziness, and
TIP:
WARNING
ZMU02022
ZMU02024
drowsiness. Keep cockpit and cabin ar­eas well ventilated. Avoid blocking ex­haust outlets.
EMU27469
Sending fuel (portable tank)
1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.
2. If there is a fuel joint on the motor, align the fuel joint on the fuel line with the fuel joint on the motor and firmly connect the fuel line to the joint while pinching the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank.
Operation
Wipe up any spilled gasoline immediately with dry rags. Dispose rags properly accord­ing to local laws or regulations.
3. Squeeze the primer pump, with the ar­row pointing up, until you feel it become firm. During engine operation place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank.
1. Arrow
EMU27495
Starting engine
EWM01601
Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you.
26
Page 32
Operation
WARNING
TIP:
TIP:
EMU27533
Manual start models
EWM01841
Failure to attached engine shut-off cord
could result in a runaway boat if opera­tor is ejected. Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, pre­venting it from functioning.
Avoid accidentally pulling the cord dur-
ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cau­se people and objects in the boat to be thrown forward.
1. Place the gear shift lever in neutral.
3. Place the throttle grip in the “ ” (start) position.
The start-in-gear protection device prevents the engine from starting except when in neu­tral.
2. Attach the engine shut-off cord to a se­cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.
27
4. Pull out / turn the choke knob fully. Place the choke knob back in to the second or third position to warm up the engine after starting. When the engine has fully warmed up, replace the choke knob back in to its home position.
It is not necessary to use the choke when
starting a warm engine.
Page 33
Operation
TIP:
NOTICE
ZMU02856
If the choke knob is left in the pulled out po-
sition while the engine is running, the en­gine will run poorly or stall.
5. Pull the manual starter handle slowly un­til you feel resistance. Then give a strong pull straight out to crank and start the en­gine. Repeat if necessary.
6. After the engine starts, slowly return the manual starter handle to its original posi­tion before releasing it.
7. Slowly return the throttle grip to the fully closed position.
When the engine is cold, it needs to be
warmed up. For further information, see page 28.
If the engine does not start on the first try,
repeat the procedure. If the engine fails to start after 4 or 5 tries, open the throttle a small amount (between 1/8 and 1/4) and try again. Also if the engine is warm and fails to start, open the throttle a same amount and try to start the engine again. If the engine still fails to start, see page 49.
EMU36511
Checks after starting engine
EMU36524
Cooling water
Check for a steady flow of water from the cooling water pilot hole. A continuous flow of water from the pilot hole indicates that the water pump is pumping water through the
cooling water passages. If the cooling water passages are frozen, it may take a while for water to start flowing out of the pilot hole.
ECM01811
If water is not flowing out of the pilot hole at all times while the engine is running, overheating and serious damage could occur. Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the prob­lem cannot be located and corrected.
EMU27671
Warming up engine
EMU27684
Choke start models
After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life. Gradually return the choke knob to its home position as the en­gine warms up.
EMU36532
Checks after engine warm up
EMU36542
Shifting
While the boat is tightly moored, and without applying throttle, confirm that the engine shifts smoothly into forward and reverse, and back to neutral.
28
Page 34
Operation
WARNING
NOTICE
ZMU02030
EMU36972
Stop switches
Perform the following procedure to check that the engine stop switch and engine shut­off switch operate properly. Start the engine, and then check that the
engine stops when the engine stop button is pushed.
Restart the engine, and then check that the
engine stops when the clip is pulled from the engine shut-off switch.
Check that the engine cannot be started
with the clip removed from the engine shut­off switch.
EMU34551
Shifting
EWM00181
Before shifting, make sure there are no swimmers or obstacles in the water near you.
ECM01611
Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral. If this occurs, stop the en­gine, shift to neutral, then restart the en­gine and allow it to warm up.
To shift from in gear (forward/reverse) to neu­tral
1. Close the throttle so that the engine slows to idle speed.
To shift out of neutral Move the gear shift lever firmly and crisply forward (for forward gear) or backward (for reverse gear). Be sure to check that the tilt lock lever is in the lock/down position (if equipped) before operating in reverse.
29
2. After the engine is at idle speed in gear move the gear shift lever firmly and crisp­ly into the neutral position.
Page 35
Operation
WARNING
TIP:
ZMU02041
EMU31743
Stopping boat
EWM01511
Do not use the reverse function to slow
down or stop the boat as it could cause you to lose control, be ejected, or im­pact the steering wheel or other parts of the boat. This could increase the risk of serious injury. It could also damage the shift mechanism.
Do not shift into reverse while traveling
at planing speeds. Loss of control, boat swamping, or damage to the boat could occur.
The boat is not equipped with a separate braking system. Water resistance stops it af­ter the throttle lever is moved back to idle. The stopping distance varies depending on gross weight, water surface conditions, and wind direction.
EMU27822
Stopping engine
Before stopping the engine, first let it cool off for a few minutes at idle or low speed. Stop­ping the engine immediately after operating at high speed is not recommended.
EMU27834
Procedure
1. Push and hold the engine stop button until the engine comes to a complete stop.
2. After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to the closed position, if equipped.
3. Disconnect the fuel line if you are using an external fuel tank.
If the outboard motor is equipped with an en­gine shut-off cord, the engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch.
30
Page 36
Operation
WARNING
WARNING
ZMU02043
1
EMU27863
Trimming outboard motor
EWM00741
Excessive trim for the operating condi­tions (either trim up or trim down) can cau­se boat instability and can make steering the boat more difficult. This increases the possibility of an accident. If the boat be­gins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.
The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help im­prove performance and fuel economy while reducing strain on the engine. Correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.
EMU27873
Adjusting trim angle for manual tilt models
There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim an­gle.
1. Stop the engine.
2. Tilt the outboard motor up, and then re­move the trim rod from the clamp brack­et.
1. Trim rod
3. Reposition the rod in the desired hole.
To raise the bow (“trim-out”), move the rod away from the transom. To lower the bow (“trim-in”), move the rod to­ward the transom. Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.
EWM00401
1. Trim operating angle
31
Stop the engine before adjusting the
trim angle.
Use care to avoid being pinched when
removing or installing the rod.
Use caution when trying a trim position
for the first time. Increase speed gradu­ally and watch for any signs of instability or control problems. Improper trim an­gle can cause loss of control.
Page 37
TIP:
The outboard motor trim angle can be
TIP:
changed approximately 4 degrees by shifting the trim rod one hole.
EMU27913
Adjusting boat trim
When the boat is on plane, a bow-up attitude results in less drag, greater stability and effi­ciency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden­cy to steer to one side or the other. Compen­sate for this as you steer. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.
Operation
Bow Down
Too much trim-in causes the boat to “plow” through the water, decreasing fuel economy and making it hard to increase speed. Oper­ating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making opera­tion difficult and dangerous.
Bow Up
Too much trim-out puts the bow of the boat too high in the water. Performance and econ­omy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces per­formance further, and the boat may “por­poise” (hop in the water), which could throw the operator and passengers overboard.
Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.
EMU27936
Tilting up and down
If the engine will be stopped for some time or if the boat is moored in shallows, the out­board motor should be tilted up to protect the propeller and lower casing from damage by collision with obstructions, and also to re­duce salt corrosion.
32
Page 38
Operation
WARNING
WARNING
NOTICE
EWM00223
Make sure that no one is near the out­board motor when tilting the outboard motor up or down. Otherwise, body parts could be crushed between the outboard motor and the clamp bracket.
EWM00251
Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, discon­nect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.
ECM00242
Before tilting the outboard motor, stop
the engine by following the procedure on page 30. Never tilt the outboard mo­tor while the engine is running. Severe damage from overheating can result.
Do not tilt up the engine by pushing the
tiller handle (if equipped) because this could break the handle.
EMU32663
Procedure for tilting up (manual tilt models)
1. Place the gear shift lever in neutral.
3. Place the tilt lock lever (if equipped) in the release/up position.
4. Pull up the shallow water lever (if equipped).
5. Hold the rear of the top cowling with one hand and tilt the engine up fully.
6. Push the tilt support knob into the clamp bracket. Or the tilt support bar will turn to the lock position automatically. NOTICE:
Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the mo­tor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position. For more detailed informa­tion, see page 36.
[ECM01642]
2. Disconnect the fuel line from the out­board motor.
33
Page 39
Operation
WARNING
NOTICE
ZMU02868
ting an underwater obstacle could cau­se the outboard motor to lift out of the water, resulting in loss of control.
Use extra care when operating in re-
verse. Too much reverse thrust can cau­se the outboard motor to lift out of the water, increasing the chance of acci­dent and personal injury.
ECM00261
EMU28023
Procedure for tilting down (manual tilt models)
1. Place the tilt lock lever in the re­lease/down position or return the shallow water lever to its original position.
2. Slightly tilt the engine up until the tilt sup­port bar is automatically released.
3. Slowly tilt the engine down.
EMU28063
Shallow water
EMU28074
Cruising in shallow water (manual tilt models)
EWM01782
Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set­ting up for and cruising in shallow water. Otherwise severe damage from overheat­ing can result.
EMU32742
Procedure
1. Place the gear shift lever in neutral.
Run the boat at the lowest possible
speed when using the shallow water cruising system. The tilt lock mecha­nism does not work while the shallow water cruising system is being used. Hit-
2. Place the tilt lock lever in the release/up position.
34
Page 40
Operation
ZMU08033
3. Slightly tilt the outboard motor up. The tilt support bar will lock automatically, sup­porting the outboard motor in a partially raised position. This outboard motor has 2 positions for shallow water cruising.
4. To return the outboard motor to the nor­mal running position, place the gear shift lever in neutral.
5. Place the tilt lock lever in the lock/down position, then slightly tilt the outboard motor up until the tilt support bar auto­matically returns to the free position.
6. Slowly lower the outboard motor to the normal position.
EMU35392
Cruising in other conditions
Cruising in salt water
After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh wa­ter.
Cruising in muddy, turbid, or acidic water
Water in some areas can be acidic or with a lot of sediment in it, such as muddy or turbid (cloudy) water. After operating in such water, flush the cooling passages with fresh water to prevent corrosion. Also rinse the outside of the outboard motor with fresh water.
35
Page 41

Maintenance

WARNING
NOTICE
EMU2822B
Transporting and storing out-
board motor
EWM02621
USE CARE when transporting fuel tank,
whether in a boat or car.
DO NOT fill fuel container to maximum
capacity. Gasoline will expand consider­ably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.
Leaking fuel is a fire hazard. When
transporting and storing the outboard motor, disconnect the fuel line from the outboard motor to prevent fuel from leaking.
Never get under the outboard motor
while it is tilted. Severe injury could oc­cur if the outboard motor accidentally falls.
Do not use the tilt support lever or knob
when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the outboard motor cannot be trailered in the normal run­ning position, use an additional support device to secure it in the tilt position.
ECM02441
Disconnect the fuel line from the outboard
motor.
Tighten the fuel tank cap and its air vent
screw.
When the outboard motor is tilted pro-
longed time for mooring or trailering the boat, disconnect the fuel line from the out­board motor. Tighten the fuel tank cap and
its air vent screw. The outboard motor should be transported and stored in the normal running position. If there is insufficient road clearance in this po­sition, then trailer the outboard motor in the tilt position using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details.
EMU28237
Clamp screw mounting models
When transporting or storing the outboard motor while removed from a boat, keep the outboard motor in the attitude shown.
When storing the outboard motor for pro­longed time, fuel must be drained from the fuel tank. The deteriorated fuel could clog the fuel line causing engine start difficulty or malfunction.
When storing or transporting the outboard motor, make sure to follow the procedure list­ed below.
36
Page 42
Maintenance
TIP:
NOTICE
NOTICE
ZMU02051
1
2
Place a towel or something similar under the outboard motor to protect it from damage.
EMU30273
Storing outboard motor
When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer pri­or to storage. However, you, the owner, with a minimum of tools, can perform the follow­ing procedures.
ECM01412
Do not place the outboard motor on its
side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trouble.
Store the outboard motor in a dry, well-
ventilated place, not in direct sunlight.
EMU28306
Procedure
EMU28336
Flushing in a test tank
ECM00302
Before starting the engine, make sure to supply water to the cooling water passag­es. Otherwise, the engine could overheat and be damaged.
1. Wash the outboard motor body using fresh water. NOTICE: Do not spray wa-
ter into the air intake.
information, see page 38.
2. Disconnect the fuel line from the motor or shut off the fuel cock, if equipped.
3. Remove the engine top cowling and si­lencer cover. Remove the propeller.
[ECM01841] For further
4. Install the outboard motor on the test tank. Fill the tank with fresh water to above the level of the anti-cavitation plate. NOTICE: If the fresh water level
is below the level of the anti-cavitation plate, or if the water supply is insuffi­cient, engine seizure may occur.
[ECM00292]
1. Water surface
2. Lowest water level
5. Cooling system flushing is essential to prevent the cooling system from clog­ging up with salt, sand, or dirt. In addi­tion, fogging/lubricating of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flushing and fogging at the same time.
WARNING! Do not touch or remove electrical parts when starting or dur­ing operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.
[EWM00092]
6. Run the engine at a fast idle for a few mi­nutes in neutral position.
7. Just prior to turning off the engine, quick­ly spray “Fogging Oil” alternately into each carburetor or the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke ex­cessively and almost stall.
37
Page 43
Maintenance
TIP:
TIP:
WARNING
1
ZMU07862
8. Remove the outboard motor from the test tank.
9. Install the silencer cover/cap of fogging hole and top cowling.
10. If the “Fogging Oil” is not available, run the engine at a fast idle until the fuel sys­tem becomes empty and the engine stops.
11. Drain the cooling water completely out of the motor. Clean the body thoroughly.
12. If the “Fogging Oil” is not available, re­move the spark plug(s). Pour a tea­spoonful of clean engine oil into each cylinder. Crank several times manually. Replace the spark plug(s).
13. Drain the fuel from the fuel tank.
Store the fuel tank in a dry, well-ventilated place, not in direct sunlight.
EMU28403
Lubrication
1. Install the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 43.
2. Change the gear oil. For instructions, see page 46. Inspect the oil for the presence of water that indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use.
3. Grease all grease fittings. For further de­tails, see page 42.
For long-term storage, fogging the engine with oil is recommended. Contact your Yamaha dealer for information about fogging oil and procedures for your engine.
EMU44341
Cleaning the outboard motor
When cleaning the outboard motor, the top cowling must be installed.
1. Wash the exterior of the outboard motor using fresh water. NOTICE: Do not
spray water into the air intake.
1. Air intake
[ECM01841]
2. Drain the cooling water completely out of the outboard motor. Clean the body thoroughly.
EMU28462
Checking painted surface of outboard motor
Check the outboard motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer.
EMU37075
Periodic maintenance
EWM01982
These procedures require mechanical skills, tools, and supplies. If you do not have the proper skills, tools, or supplies to perform a maintenance procedure, have a Yamaha dealer or other qualified mechan­ic do the work. The procedures involve disassembling the motor and exposing dangerous parts. To reduce the risk of injury from moving, hot, or electrical parts:
38
Page 44
Maintenance
Turn off the engine and keep engine
shut-off cord (lanyard) with you when you perform maintenance unless other­wise specified.
Allow the engine to cool before handling
hot parts or fluids.
Always completely reassemble the mo-
tor before operation.
EMU28512
Replacement parts
If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and pas­sengers. Yamaha genuine parts and acces­sories are available from your Yamaha dealer.
EMU34152
Severe operating conditions
Severe operating conditions involve one or more of the following types of operation on a regular basis: Operating continuously at or near maxi-
mum engine speed (rpm) for many hours
Operating continuously at a low engine
speed (rpm) for many hours
Operating without sufficient time for engine
to warm up and cool down
Frequent quick acceleration and decelera-
tion
Frequent shiftingFrequently starting and stopping the en-
gine(s)
Operation that fluctuates often between
light and heavy cargo loads Outboard motors operating under any of these above conditions require more fre­quent maintenance. Yamaha recommends that you do this service twice as often as specified in the maintenance chart. For ex­ample, if a particular service should be done
at 50 hours, do it instead at 25 hours. This will help prevent more rapid deterioration of en­gine components.
39
Page 45
Maintenance
TIP:
EMU34448
Maintenance chart 1
Refer to the sections in this chapter for explanations of each owner-specific action.The maintenance cycle on these charts assume usage of 100 hours per year and regular
flushing of the cooling water passages. Maintenance frequency should be adjusted when
operating the engine under adverse conditions such as extended trolling. Disassembly or repairs may be necessary depending on the outcome of maintenance
checks. Expendable or consumable parts and lubricants will lose their effectiveness over time and
through normal usage regardless of the warranty period. When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should
be flushed with clean water after each use. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer.
Initial Every
Item Actions
Anode(s) (external)
Anode(s) (cylinder head, thermostat cov­er)
Anodes (exhaust cov­er, cooling water pas­sage cover, Rectifier Regulator cover)
Cooling water leakage
Cowling lock lever Inspection
Engine starting condi­tion/noise
Engine idle speed/noise
Fuel filter (can be dis­assembled)
Fuel line Inspection
Fuel line
Fuel pump
Fuel/engine oil leakage Inspection
Gear oil Replacement
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Replacement
Inspection or replace­ment as necessary
Inspection
Inspection
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
20 hours
(3 months)
100 hours
(1 year)
300 hours
(3 years)
500 hours
(5 years)
40
Page 46
Maintenance
Item Actions
Greasing points Greasing
Impeller/water pump housing
Impeller/water pump housing
Propeller/propeller nut/cotter pin
Shift link/shift cable
Spark plug(s)
Spark plug caps/spark plug wires
Water from the cooling water pilot hole
Throttle link/throttle cable/throttle pick-up timing
Thermostat
Cooling water inlet Inspection
Main switch/stop switch/choke switch
Wire harness connec­tions/wire coupler con­nections
Fuel tank (Yamaha por­table tank)
EMU34452
Maintenance chart 2
Item Actions
Exhaust guide/ex­haust manifold
Inspection or replace­ment as necessary
Replacement
Inspection or replace­ment as necessary
Inspection, adjust­ment or replacement as necessary
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Inspection
Inspection, adjust­ment or replacement as necessary
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Inspection or replace­ment as necessary
Inspection and clean­ing as necessary
Inspection or replace­ment as necessary
Initial Every
20 hours
(3 months)
100 hours
(1 year)
Every
1000 hours
300 hours
(3 years)
500 hours
(5 years)
41
Page 47
EMU28944
Greasing
Yamaha grease A (water resistant grease) Yamaha grease D (corrosion resistant grease; for propeller shaft)
Maintenance
42
Page 48
Maintenance
TIP:
WARNING
EMU44491
Cleaning and adjusting spark plug
The spark plug is an important engine com­ponent and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For exam­ple, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically re­move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.
1. Remove the spark plug caps from the
spark plugs.
2. Remove the spark plug. If electrode ero-
sion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with an­other of the correct type. WARNING!
When removing or installing a spark plug, be careful not to damage the in­sulator. A damaged insulator could al­low external sparks, which could lead to explosion or fire.
Standard spark plug:
BR7HS-10
3. Be sure to use the specified spark plug,
otherwise the engine may not operate properly. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; replace it if out of spec­ification.
[EWM00562]
1. Spark plug gap
2. Spark plug part number
3. Spark plug I.D. mark (NGK)
Spark plug gap:
0.9–1.0 mm (0.035–0.039 in)
4. When fitting the plug, wipe off any dirt from the threads, and then screw it in to the correct torque.
Spark plug torque:
25 Nm (2.55 kgf-m, 18.4 ft-lb)
If a torque-wrench is not available when you are reinstalling a spark plug, a good estimate of the correct torque is 1/12 turn past finger­tight. When you are installing a new spark plug, a good estimate of the correct torque is 1/2 to 2/3 turn past finger-tight.
EMU37451
Checking fuel filter
Check the fuel filter periodically. If any water or foreign matter is found in the filter, clean or replace it. For cleaning or replacement of the fuel filter, consult your Yamaha dealer.
EMU29045
Inspecting idle speed
EWM00452
Do not touch or remove electrical parts
when starting or during operation.
43
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Maintenance
NOTICE
WARNING
ZMU02087
ZMU01897
Keep hands, hair, and clothes away
from the flywheel and other rotating parts while the engine is running.
ECM00491
This procedure must be performed while the outboard motor is in the water. A flush­ing attachment or test tank can be used.
If the boat is not equipped with a tachometer for the outboard motor, use a diagnostic ta­chometer for this procedure. Results may vary depending on whether testing is con­ducted with the flushing attachment, in a test tank, or with the outboard motor in the water.
1. Start the engine and allow it to warm up fully in neutral until it is running smoothly.
2. Once the engine has warmed up, verify whether the idle speed is set to specifi­cation. For idle speed specifications, see page 8. If you have difficulty verifying the idle speed, or the idle speed requires ad­justment, consult a Yamaha dealer or other qualified mechanic.
EMU29115
Inspecting wiring and connectors
Inspect that each connector is engaged se-
curely.
Inspect that each ground lead is properly
secured.
EMU32113
Checking propeller
EWM01882
You could be seriously injured if the en­gine accidentally starts when you are near the propeller. Before inspecting, remov­ing, or installing the propeller, place the shift control in neutral, turn the main switch to “ ” (off) and remove the key, and remove the clip from the engine shut­off switch. Turn off the battery cut-off switch if your boat has one.
Do not use your hand to hold the propeller when loosening or tightening the propeller nut. Put a wood block between the anti-cavi­tation plate and the propeller to prevent the propeller from turning.
Checkpoints Check each of the propeller blades for ero-
sion from cavitation or ventilation, or other damage.
Check the propeller shaft for damage.Check the splines for wear or damage.Check for fish line tangled around the pro-
peller shaft.
44
Page 50
Maintenance
NOTICE
ZMU02877
2
3
4
5
1
EMU30673
Installing propeller
EMU29235
Spline models
ECM00502
Make sure to use a new cotter pin and bend the ends over securely. Otherwise, the propeller could come off during oper­ation and be lost.
Check the propeller shaft oil seal for dam-
age.
EMU30663
Removing propeller
EMU29198
Spline models
1. Straighten the cotter pin and pull it out using a pair of pliers.
2. Remove the propeller nut, washer, and spacer (if equipped). WARNING! Do not
use your hand to hold the propeller when loosening the propeller nut.
[EWM01891]
1. Cotter pin
2. Propeller nut
3. Washer
4. Propeller
5. Thrust washer
3. Remove the propeller, washer (if equipped), and thrust washer.
1. Apply Yamaha marine grease or a corro­sion resistant grease to the propeller shaft.
2. Install the spacer (if equipped), thrust washer, washer (if equipped), and pro­peller on the propeller shaft. NOTICE:
Make sure to install the thrust washer before installing the propeller. Other­wise, the lower case and propeller boss could be damaged.
[ECM01882]
3. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque.
Propeller nut tightening torque:
17 Nm (1.73 kgf-m, 12.5 ft-lb)
4. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.
NOTICE: Do not reuse the cotter pin. Otherwise, the propeller can come off during operation.
[ECM01892]
45
Page 51
Maintenance
TIP:
WARNING
TIP:
TIP:
ZMU02064
2
1
ZMU02065
If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to align it with the hole.
EMU2928C
Changing gear oil
EWM00801
Be sure the outboard motor is securely
fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you.
Never get under the lower unit while it is
tilted, even when the tilt support lever or knob is locked. Severe injury could oc­cur if the outboard motor accidentally falls.
1. Tilt the outboard motor so that the gear oil drain screw is at the lowest point pos­sible.
2. Place a suitable container under the gear case.
3. Remove the gear oil drain screw and gasket. NOTICE: If there is an exces-
sive quantity of metal particles on the magnetic gear oil drain screw, this can indicate lower unit problem. Con­sult your Yamaha dealer.
[ECM01901]
If a magnetic gear oil drain screw is
equipped, remove all metal particles from the screw before installing it.
Always use new gaskets. Do not reuse the
removed gaskets.
4. Remove the oil level plug and gasket to allow the oil to drain completely.
NOTICE: Check the used gear oil after it has been drained. If the gear oil is milky or contains water or a large amount of metal particles, the gear case may be damaged. Have a Yamaha dealer check and repair the outboard motor.
[ECM00714]
For disposal of used oil, consult your Yamaha dealer.
5. Put the outboard motor in a vertical posi­tion. Using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole.
Recommended gear oil:
YAMALUBE outboard gear oil or Hyp­oid gear oil
Recommended gear oil grade:
SAE 90 API GL-4
Gear oil quantity:
0.250 L (0.264 US qt, 0.220 Imp.qt)
1. Gear oil drain screw
2. Oil level plug
46
Page 52
Maintenance
WARNING
ZMU03231
ZMU02066
6. Put a new gasket on the oil level plug. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.
Tightening torque:
9 Nm (0.92 kgf-m, 6.6 ft-lb)
7. Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw.
Tightening torque:
9 Nm (0.92 kgf-m, 6.6 ft-lb)
EMU29304
Cleaning fuel tank
EWM00921
Gasoline is highly flammable, and its va­pors are flammable and explosive. If you have any question about properly
doing this procedure, consult your Yamaha dealer.
Keep away from sparks, cigarettes,
flames, or other sources of ignition when cleaning the fuel tank.
Remove the fuel tank from the boat be-
fore cleaning it. Work only outdoors in an area with good ventilation.
Wipe up any spilled fuel immediately.Reassemble the fuel tank carefully. Im-
proper assembly can result in a fuel leak, which could result in a fire or ex­plosion hazard.
Dispose of old gasoline according to lo-
cal regulations.
1. Empty the fuel tank into an approved container.
2. Pour a small amount of suitable solvent into the tank. Install the cap and shake the tank. Drain the solvent completely.
3. Remove the screws holding the fuel joint assembly. Pull the assembly out of the tank.
4. Clean the filter (located on the end of the suction pipe) in a suitable cleaning sol­vent. Allow the filter to dry.
5. Replace the gasket with a new one. Re­install the fuel joint assembly and tighten the screws firmly.
47
Page 53
EMU29317
NOTICE
TIP:
ZMU02067
Inspecting and replacing anode(s)
Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.
ECM00721
Do not paint anodes, as this would render them ineffective.
Maintenance
Inspect ground leads attached to external an­odes on equipped models. Consult a Yamaha dealer for inspection and replace­ment of internal anodes attached to the pow­er unit.
48
Page 54

Trouble Recovery

EMU29428
Troubleshooting
A problem in the fuel, compression, or igni­tion systems can cause poor starting, loss of power, or other problems. This section de­scribes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble-alert indicator is flashing, consult your Yamaha dealer.
Starter will not operate.
Q. Is battery capacity weak or low? A. Check battery condition. Use battery of recommended capacity.
Q. Are battery connections loose or corrod­ed? A. Tighten battery cables and clean battery terminals.
Q. Is fuse for electric start relay or electric cir­cuit blown? A. Check for cause of electric overload and repair. Replace fuse with one of correct am­perage.
Q. Are starter components faulty? A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear? A. Shift to neutral.
Engine will not start (starter operates).
Q. Is fuel tank empty? A. Fill tank with clean, fresh fuel.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Is starting procedure incorrect? A. See page 26.
Q. Has fuel pump malfunctioned? A. Have serviced by a Yamaha dealer.
Q. Are spark plug(s) fouled or of incorrect ty­pe? A. Inspect spark plug(s). Clean or replace with recommended type.
Q. Are spark plug cap(s) fitted incorrectly? A. Check and re-fit cap(s).
Q. Is ignition wiring damaged or poorly con­nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.
Q. Are ignition parts faulty? A. Have serviced by a Yamaha dealer.
Q. Is engine shut-off cord (lanyard) not at­tached? A. Attach cord.
Q. Are engine inner parts damaged? A. Have serviced by a Yamaha dealer.
Engine idles irregularly or stalls.
Q. Are spark plug(s) fouled or of incorrect ty­pe? A. Inspect spark plug(s). Clean or replace with recommended type.
49
Page 55
Trouble Recovery
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.
Q. Has alert system activated? A. Find and correct cause of alert.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con­nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.
Q. Is specified engine oil not being used? A. Check and replace oil as specified.
A. Return to home position.
Q. Is motor angle too high? A. Return to normal operating position.
Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect? A. Connect correctly.
Q. Is throttle valve adjustment incorrect? A. Have serviced by a Yamaha dealer.
Q. Is battery cable disconnected? A. Connect securely.
Alert buzzer sounds or indicator lights.
Q. Is cooling system clogged? A. Check water intake for restriction.
Q. Is engine oil level low? A. Fill oil tank with specified engine oil.
Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec­ommended type.
Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.
Q. Are carburetor adjustments incorrect? A. Have serviced by a Yamaha dealer.
Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.
Q. Is air vent screw on fuel tank closed? A. Open air vent screw.
Q. Is choke knob pulled out?
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Is engine oil contaminated or deteriorat­ed? A. Replace oil with fresh, specified type.
Q. Is oil filter clogged? A. Have serviced by a Yamaha dealer.
Q. Has oil feed/injection pump malfunc­tioned?
50
Page 56
Trouble Recovery
A. Have serviced by a Yamaha dealer.
Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane.
Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer.
Q. Is there excess water in fuel filter cup? A. Drain filter cup.
Engine power loss.
Q. Is propeller damaged? A. Have propeller repaired or replaced.
Q. Is propeller pitch or diameter incorrect? A. Install correct propeller to operate out­board at its recommended speed (r/min) range.
Q. Is trim angle incorrect? A. Adjust trim angle to achieve most efficient operation.
Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height.
Q. Are weeds or other foreign matter tangled on gear housing? A. Remove foreign matter and clean lower unit.
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con­nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires.
Q. Have electrical parts failed? A. Have serviced by a Yamaha dealer.
Q. Is specified fuel not being used? A. Replace fuel with specified type.
Q. Has alert system activated? A. Find and correct cause of alert.
Q. Is boat bottom fouled with marine growth? A. Clean boat bottom.
Q. Are spark plug(s) fouled or of incorrect ty­pe? A. Inspect spark plug(s). Clean or replace with recommended type.
51
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.
Q. Is air vent screw closed? A. Open the air vent screw.
Q. Is fuel pump damaged?
Page 57
Trouble Recovery
WARNING
A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect? A. Connect correctly.
Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec­ommended type.
Q. Is high pressure fuel pump drive belt bro­ken? A. Have serviced by a Yamaha dealer.
Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer.
Engine vibrates excessively.
Q. Is propeller damaged? A. Have propeller repaired or replaced.
Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer.
Q. Are weeds or other foreign matter tangled on propeller? A. Remove and clean propeller.
Q. Is motor mounting bolt loose? A. Tighten bolt.
Q. Is steering pivot loose or damaged? A. Tighten or have serviced by a Yamaha dealer.
EMU29434
Temporary action in emergen-
cy
EMU29442
Impact damage
EWM00871
The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the out­board motor unsafe to operate.
If the outboard motor hits an object in the wa­ter, follow the procedure below.
1. Stop the engine immediately.
2. Check the control system and all compo­nents for damage. Also, check the boat for damage.
3. Whether damage is found or not, return to the nearest harbor slowly and careful­ly.
4. Have a Yamaha dealer check the out­board motor before operating it again.
EMU39792
Starter will not operate
If the starter mechanism does not operate (the engine cannot be cranked with the start­er), the engine can be started with an emer­gency starter rope.
52
Page 58
Trouble Recovery
WARNING
EWM02362
Use this procedure only for emergency
engine starting to return to the nearest port for repairs.
When the emergency starter rope is
used to start the engine, the start-in­gear protection device does not oper­ate. Make sure that the shift lever is in the neutral position. Otherwise, the boat could unexpectedly start to move, which could result in an accident.
Attach the engine shut-off cord to a se-
cure place on your clothing, or your arm or leg while operating the boat.
Do not attach the cord to clothing that
could tear loose. Do not route the cord where it could become entangled, pre­venting it from functioning.
Avoid accidentally pulling the cord dur-
ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cau­se people and objects in the boat to be thrown forward.
Make sure that no one is standing be-
hind you when pulling the starter rope. It could whip behind you and injure some­one.
An unguarded, rotating flywheel is very
dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the fly­wheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.
Do not touch the ignition coil, spark plug
wire, spark plug cap, or other electrical components when starting or operating the outboard motor. You could get an electrical shock.
EMU29563
Emergency starting engine
1. Remove the top cowling.
2. Remove the start-in-gear protection ca­ble from the starter, if equipped.
3. Remove the starter/flywheel cover after removing the bolt(s).
4. Prepare the engine for starting. For fur­ther information, see page 26. Be sure the engine is in neutral and that the clip is attached to the engine shut-off switch. The main switch must be “ ” (on), if equipped.
5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms up.
6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise.
7. Give a strong pull straight out to crank and start the engine. Repeat if neces­sary.
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EMU33502
Treatment of submerged motor
If the outboard motor is submerged, immedi­ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi­ately. NOTICE: Do not attempt to run the
outboard motor until it has been com­pletely inspected.
[ECM00402]
Trouble Recovery
54
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INDEX

2-pin connector .................................... 17
A
Alcohol and drugs................................... 2
Anode(s), inspecting and replacing ...... 48
Anti-fouling paint .................................. 10
Avoid collisions....................................... 2
B
Battery charging information ................ 17
Boat horsepower rating.......................... 9
Boating safety......................................... 2
Boating safety publications .................... 3
Breaking in engine................................ 21
C
Carbon monoxide................................... 2
CE Marking............................................. 4
Checks after engine warm up............... 28
Checks after starting engine................. 28
Checks before starting engine.............. 21
Choke knob .......................................... 15
Clamping the outboard motor .............. 19
Cleaning the outboard motor ............... 38
Components diagram........................... 12
Control functions, checking.................. 22
Cooling water ....................................... 28
Cowling lock lever ................................ 16
Cruising in salt water or other
conditions...........................................35
E
EC Declaration of Conformity (DoC)....... 4
Electric shock ......................................... 1
Emergency equipment ......................... 11
Emergency starting engine................... 53
Emergency, temporary action in........... 52
Engine, checking .................................. 23
Engine oil, checking.............................. 23
Engine oil requirements........................ 10
Engine shut-off cord (lanyard) .......... 1, 22
Engine shut-off cord (lanyard) and
clip...................................................... 14
Engine stop button ............................... 15
F
Filling fuel for portable tank ..................23
First-time operation ..............................21
Flushing in a test tank........................... 37
Fuel and engine oil, filling ..................... 23
Fuel filter, checking......................... 22, 43
Fuel leaks, checking for........................ 22
Fuel level...............................................21
Fuel requirements................................. 10
Fuel system........................................... 22
Fuel tank ............................................... 12
Fuel tank, cleaning................................47
G
Gasoline............................................1, 10
Gasoline and oil mixing ........................24
Gasoline exposure and spills.................. 1
Gear oil, changing................................. 46
Gear shift lever...................................... 13
Greasing ............................................... 42
H
Hot parts................................................. 1
I
Identification numbers record.................4
Idle speed, inspecting........................... 43
Impact damage.....................................52
Installation requirements ........................9
L
Laws and regulations.............................. 3
Lubrication............................................ 38
M
Maintenance chart 1............................. 40
Maintenance chart 2............................. 41
Manual starter handle...........................15
Modifications .......................................... 2
Mounting height....................................18
Mounting outboard motor ...................... 9
Mounting the outboard motor .............. 18
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INDEX
O
Operating engine .................................. 25
Outboard motor disposal
requirements ...................................... 11
Outboard motor (painted surface),
checking............................................. 38
Outboard motor safety ...........................1
Outboard motor serial number............... 4
Overloading ............................................ 2
P
Passenger training.................................. 3
Passengers.............................................2
People in the water................................. 2
Periodic maintenance........................... 38
Personal flotation devices (PFDs)........... 2
Propeller ................................................. 1
Propeller, checking............................... 44
Propeller, installing ............................... 45
Propeller, removing .............................. 45
Propeller selection.................................. 9
R
Read manuals and labels .......................5
Replacement parts ............................... 39
Rotating parts......................................... 1
Submerged outboard motor................. 54
T
Throttle friction adjuster........................14
Throttle grip .......................................... 13
Throttle indicator................................... 14
Tiller handle .......................................... 13
Tilt lock mechanism.............................. 16
Tilt support bar .....................................16
Tilting up and down.............................. 32
Top cowling, installing.......................... 23
Top cowling, removing .........................22
Transporting and storing outboard
motor ..................................................36
Trim rod (tilt pin).................................... 16
Trimming outboard motor.....................31
Troubleshooting....................................49
W
Warming up engine...............................28
Warning labels ........................................ 5
Weather .................................................. 3
Wiring and connectors, inspecting ....... 44
S
Sending fuel (portable tank).................. 26
Severe operating conditions................. 39
Shallow water ....................................... 34
Shifting.................................................. 29
Shifting (checks after engine warm
up) ...................................................... 28
Spark plug, cleaning and adjusting ...... 43
Specifications ......................................... 8
Starter will not operate ......................... 52
Starting engine ..................................... 26
Start-in-gear protection........................ 10
Steering friction adjuster ...................... 15
Stop switches....................................... 29
Stopping boat....................................... 30
Stopping engine ...................................30
Storing outboard motor........................ 37
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Printed in Japan December 2013–0.2 × 1 CR
Printed on recycled paper
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