Page 1
OWNER’S MANUAL
F9.9C
FT9.9D
F13.5A
F15A
66M-28199-79-E0
Page 2
EMU25050
Read this owner’s manual carefully before operating your outboard motor.
Page 3
Important manual information
EMU25100
To the owner
Thank you for choosing a Yamaha outboard
motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding
of these simple instructions will help you obtain maximum enjoyment from your new
Yamaha. If you have any question about the
operation or maintenance of your outboard
motor, please consult a Yamaha dealer.
In this Owner’s Manual particularly important
information is distinguished in the following
ways.
The Safety Alert Symbol means
ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
EWM00780
WARNING
Failure to follow WARNING instructions
could result in severe injury or death
the machine operator, a bystander, or a
person inspecting or repairing the outboard motor.
ECM00700
CAUTION:
A CAUTION indicates special precautions
that must be taken to avoid damage to the
outboard motor.
to
al, please consult your Yamaha dealer.
NOTE:
The F9.9CMH, F9.9CE, FT9.9DMH,
FT9.9DE, F13.5AMH, F13.5AEP, F15AMH,
F15AEH, F15AE, F15AEP 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.
EMU25120
F9.9C, FT9.9D, F13.5A, F15A
OWNER’S MANUAL
©2004 by Yamaha Motor Co., Ltd.
1st Edition, March 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
Yamaha continually seeks advancements in
product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing, there may be minor discrepancies
between your machine and this manual. If
there is any question concerning this manu-
Page 4
Table of contents
General information .......................... 1
Identification numbers record........... 1
Outboard motor serial number .......... 1
Key number....................................... 1
EC label............................................ 1
Emission control information ............ 2
SAV models ......................................2
Safety information ............................ 2
Important labels................................ 3
Warning labels ..................................3
Caution labels ...................................4
Fueling instructions .......................... 4
Gasoline............................................ 4
Engine oil ..........................................5
Battery requirement.......................... 5
Battery specifications ........................ 5
Without a rectifier or Rectifier
Regulator ........................................ 5
Propeller selection............................ 6
Start-in-gear protection ....................6
Basic components ............................7
Main components............................. 7
Fuel tank ...........................................8
Fuel joint ........................................... 9
Fuel gauge ........................................ 9
Fuel tank cap .................................... 9
Air vent screw ................................... 9
Remote control.................................. 9
Remote control lever......................... 9
Neutral interlock trigger................... 10
Neutral throttle lever........................ 10
Choke switch................................... 10
Tiller handle .................................... 10
Gear shift lever................................ 11
Throttle grip..................................... 11
Throttle indicator .............................11
Throttle friction adjuster................... 12
Engine stop lanyard switch .............12
Engine stop button .......................... 13
Choke knob for pull type .................13
Manual starter handle .....................13
Starter button ..................................14
Main switch .....................................14
Power tilt switch ..............................14
Steering friction adjuster .................14
Steering friction adjuster .................15
Trim tab with anode......................... 15
Trim rod (tilt pin) .............................. 16
Tilt lock mechanism......................... 16
Tilt support knob.............................. 16
Tilt support bar ................................16
Power tilt unit................................... 17
Top cowling lock lever(s)
(turn type)...................................... 17
Flushing device ...............................17
Warning indicator ............................17
Warning system ............................. 18
Overheat warning............................ 18
Low oil pressure warning ................18
Operation ......................................... 20
Installation...................................... 20
Mounting the outboard motor .......... 20
Clamping the outboard motor.......... 21
Breaking in engine ......................... 22
Procedure for 4-stroke models........ 22
Preoperation checks ...................... 22
Fuel .................................................22
Controls........................................... 22
Engine ............................................. 23
Checking the engine oil level ..........23
Filling fuel....................................... 23
Operating engine ........................... 23
Feeding fuel (portable tank) ............23
Starting engine ................................ 24
Warming up engine........................ 30
Manual start and electric start
models ..........................................30
Shifting........................................... 30
Forward (tiller handle and remote
control models) .............................30
Reverse (manual tilt and hydro tilt
models) ......................................... 31
Stopping engine............................. 32
Procedure........................................ 32
Trimming outboard motor............... 33
Adjusting trim angle for manual tilt
models ..........................................33
Adjusting trim angle
(power tilt models)......................... 34
Adjusting boat trim ..........................35
Page 5
Table of contents
Tilting up and down ........................ 35
Procedure for tilting up
(manual tilt models) ...................... 36
Procedure for tilting up.................... 37
Procedure for tilting down
(manual tilt models) ...................... 38
Procedure for tilting down ...............38
Cruising in shallow water ...............39
Cruising in shallow water
(manual tilt models) ...................... 39
Power trim and tilt models / power
tilt models...................................... 40
Cruising in other conditions............ 41
Maintenance..................................... 42
Specifications ................................. 42
Transporting and storing outboard
motor ............................................ 45
Clamp screw mounting models....... 45
Storing outboard motor ...................46
Procedure ....................................... 46
Lubrication
(except oil injection models) ......... 47
Battery care..................................... 47
Flushing power unit......................... 48
Cleaning the outboard motor .......... 49
Checking painted surface of
motor............................................. 49
Periodic maintenance..................... 49
Replacement parts.......................... 49
Maintenance chart .......................... 50
Maintenance chart (additional)........ 51
Greasing ......................................... 52
Cleaning and adjusting spark plug.. 54
Checking fuel system...................... 54
Inspecting fuel filter ......................... 55
Cleaning fuel filter ...........................55
Inspecting idling speed ................... 56
Changing engine oil ........................57
Checking wiring and connectors ..... 58
Exhaust leakage ............................. 58
Water leakage................................. 59
Engine oil leakage........................... 59
Checking power trim and tilt
system .......................................... 59
Checking propeller .......................... 59
Removing the propeller ................... 60
Removing the propeller ................... 60
Installing the propeller ..................... 61
Installing the propeller ..................... 61
Changing gear oil ............................ 62
Cleaning fuel tank ...........................63
Inspecting and replacing anode(s) .. 64
Checking battery
(for electric start models) ..............64
Connecting the battery .................... 65
Disconnecting the battery................ 66
Checking top cowling ......................66
Coating the boat bottom.................. 66
Trouble Recovery............................ 67
Troubleshooting ............................. 67
Temporary action in emergency .... 70
Impact damage ...............................70
Replacing fuse ................................70
Power trim and tilt will not operate ..71
Starter will not operate ....................71
Emergency starting engine .............72
Treatment of submerged motor ..... 73
Procedure........................................ 73
Page 6
General information
EMU25170
Identification numbers record
EMU25182
Outboard motor serial number
The outboard motor serial number is
stamped on the label attached to the port
side of the clamp bracket or the upper part of
the swivel bracket.
Record your outboard motor serial number in
the spaces provided to assist you in ordering
spare parts from your Yamaha dealer or for
reference in case your outboard motor is stolen.
1. Key number
EMU25202
EC label
Engines affixed with this label conform to
certain portions of the European Parliament
directive relating to machinery. Refer to the
label and the EC Declaration of Conformity
for more details.
1. Outboard motor serial number location
EMU25190
Key number
If a main key switch is equipped with the motor, the key identification number is stamped
on your key as shown in the illustration.
Record this number in the space provided for
reference in case you need a new key.
1
ZMU02342
Page 7
ZMU01696
EMU25220
Emission control information
EMU25351
SAV models
Engines affixed with the label pictured below
conform to SAV (the Swiss exhaust emission
regulations for Swiss inshore waters).
Approval label of emission control certificate
ZMU02343
YAMAHA MOTOR CO.,LTD.
Motorfamilie
AbgastypenprufNummer
ZMU04492
General information
Fuel requirement label
1
1. Fuel requirement label location
EMU25370
Safety information
Before mounting or operating the outboard
●
motor, read this entire manual. Reading it
should give you an understanding of the
motor and its operation.
Before operating the boat, read any own-
●
er’s or operator’s manuals supplied with it
and all labels. Be sure you understand
each item before operating.
●
Do not overpower the boat with this outboard motor. Overpowering the boat could
result in loss of control. The rated power of
the outboard should be equal to or less
than the rated horsepower capacity of the
boat. If the rated horsepower capacity of
the boat is unknown, consult the dealer or
boat manufacturer.
Do not modify the outboard. Modifications
●
could make the motor unfit or unsafe to
ZMU04875
ZMU04494
2
Page 8
General information
use.
●
Never operate after drinking alcohol or taking drugs. About 50% of all boating fatalities involve intoxication.
●
Have an approved personal flotation device (PFD) on board for every occupant. It
is a good idea to wear a PFD whenever
boating. At a minimum, children and nonswimmers should always wear PFDs, and
everyone should wear PFDs when there
are potentially hazardous boating conditions.
●
Gasoline is highly flammable, and its vapors are flammable and explosive. Handle
and store gasoline carefully. Make sure
there are no gas fumes or leaking fuel before starting the engine.
This product emits exhaust gases which
●
contain carbon monoxide, a colorless,
odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness.
Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.
●
Check throttle, shift, and steering for proper operation before starting the engine.
Attach the engine stop switch lanyard to a
●
secure place on your clothing, or your arm
or leg while operating. If you accidentally
leave the helm, the lanyard will pull from
the switch, stopping the engine.
●
Know the marine laws and regulations
where you will be boating - and obey them.
●
Stay informed about the weather. Check
weather forecasts before boating. Avoid
boating in hazardous weather.
●
Tell someone where you are going: leave
a Float Plan with a responsible person. Be
sure to cancel the Float Plan when you return.
●
Use common sense and good judgment
when boating. Know your abilities, and be
sure you understand how your boat handles under the different boating conditions
you may encounter. Operate within your
limits, and the limits of your boat. Always
operate at safe speeds, and keep a careful
watch for obstacles and other traffic.
●
Always watch carefully for swimmers during the engine operation.
●
Stay away from swimming areas.
●
When a swimmer is in the water near you
shift into neutral and shut off the engine.
EMU25380
Important labels
EMU25395
Warning labels
ZMU01989
EMU25401
Label
EWM01260
WARNING
●
Be sure shift control is in neutral before
starting engine. (except 2HP)
●
Do not touch or remove electrical parts
when starting or during operation.
●
Keep hands, hair, and clothes away
from flywheel and other rotating parts
while engine is running.
EMU25431
Label
EWM01300
WARNING
●
This engine is equipped with a neutral
3
Page 9
General information
starting device.
●
The engine will not start unless the shift
control is in neutral position.
EMU25464
Caution labels
ZMU01987
EMU25472
Label
ECM01190
CAUTION:
Transport and store the engine only as
shown. Otherwise, engine damage could
result from Leaking oil.
EMU25540
Fueling instructions
EWM00010
WARNING
GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE!
Do not smoke when refueling, and keep
●
away from sparks, flames, or other
sources of ignition.
Stop engine before refueling.
●
Refuel in a well-ventilated area. Refuel
●
portable fuel tanks off the boat.
Take care not to spill gasoline. If gaso-
●
line spills, wipe it up immediately with
dry rags.
Do not overfill the fuel tank.
●
Tighten the filler cap securely after re-
●
fueling.
If you should swallow some gasoline,
●
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.
●
If any gasoline spills onto your skin, immediately wash with soap and water.
Change clothing if gasoline spills on it.
●
Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
ECM00010
CAUTION:
Use only new clean gasoline which has
been stored in clean containers and is not
contaminated with water or foreign matter.
EMU25580
Gasoline
Recommended gasoline:
Regular unleaded gasoline with a minimum octane rating of 90 (Research
Octane Number).
If knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel.
4
Page 10
General information
EMU25680
Engine oil
Recommended engine oil:
4-stroke motor oil with a combination
of corresponding SAE and API as
shown in the chart
Engine oil quantity (excluding oil filter):
1.0 L (1.06 US qt) (0.88 Imp.qt)
ECM01050
CAUTION:
All 4-stroke engines are shipped from the
factory without engine oil.
electric system could perform poorly or
be overloaded, causing electric system
damage.
For electric start models, choose a battery
which meets the following specifications.
EMU25720
Battery specifications
Minimum cold cranking amps (CCA/EN):
F15AE 347.0 A
F15AEH 347.0 A
F15AEP 347.0 A
F9.9CE 347.0 A
FT9.9DE 347.0 A
Minimum rated capacity (20HR/IEC):
F15AE 40.0 Ah
F15AEH 40.0 Ah
F15AEP 40.0 Ah
F9.9CE 40.0 Ah
FT9.9DE 40.0 Ah
EMU25730
Without a rectifier or Rectifier
Regulator
ECM01090
CAUTION:
A battery cannot be connected to models
that do not have a rectifier or Rectifier
Regulator.
ZMU01710
EMU25690
Battery requirement
ECM01060
CAUTION:
Do not use a battery that does not meet
the specified capacity. If a battery which
does not meet specifications is used, the
5
If you wish to use a battery with the models
without a rectifier or Rectifier Regulator, install an optional Rectifier Regulator.
Using a maintenance-free battery with the
above models can shorten the life of the battery significantly.
Install an optional Rectifier Regulator or use
accessories rated to withstand 18 volts or
higher with the above models. Consult your
Yamaha dealer for details on installing an
optional Rectifier Regulator.
Page 11
General information
EMU25741
Propeller selection
The performance of your outboard motor will
be critically affected by your choice of propeller, as an incorrect choice could adversely
affect performance and could also seriously
damage the motor. Engine speed depends
on the propeller size and boat load. If engine
speed is too high or too low for good engine
performance, this will have an adverse effect
on the engine.
Yamaha outboard motors are fitted with propellers chosen to perform well over a range
of applications, but there may be uses where
a propeller with a different pitch would be
more appropriate. For a greater operating
load, a smaller-pitch propeller is more suitable as it enables the correct engine speed
to be maintained. Conversely, a larger-pitch
propeller is more suitable for a smaller operating load.
Yamaha dealers stock a range of propellers,
and can advise you and install a propeller on
your outboard that is best suited to your application.
to reach the middle or upper half of the operating range at full throttle with the maximum
boat load. If operating conditions such as
light boat loads then allow the engine r/min to
rise above the maximum recommended
range, reduce the throttle setting to maintain
the engine in the proper operating range.
For instructions on propeller removal and installation, see page 59.
EMU25760
Start-in-gear protection
Yamaha outboard motors affixed with the
pictured label or Yamaha-approved remote
control units are equipped with start-in-gear
protection device(s). This feature permits the
engine to be started only when it is in neutral.
Always select neutral before starting the engine.
1
x
-
123
ZMU04605
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
NOTE:
Select a propeller which will allow the engine
ZMU01713
1. Start-in-gear protection label
6
Page 12
Basic components
EMU25795
Main components
NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all models.
F9.9C, F13.5A, F15A
10
11
12
14
13
1
19
18
9
2
17
16
8
7
3
23
22
15
20
21
6
5
1. Top cowling
2. Top cowling lock lever(s)
3. Drain screw
4. Anti-cavitation plate
5. Propeller
6. Cooling water inlet
7. Trim rod*
8. Clamp bracket
9. Steering friction screw
10. Manual starter handle*
11. Choke knob
12. Warning indicator(s)
13. Gear shift lever*
14. Tiller handle*
7
4
15. Engine stop button/Engine stop lanyard
switch*
16. Transom clamp handle
17. Rope attachment
18. Tilt lock lever*
19. Flushing device*
20. Starter button*
21. Throttle friction adjuster*
22. Tilt support knob*
23. Remote control box (side mount type)*
24. Fuel tank
24
ZMU04892
Page 13
FT9.9D
Basic components
10
9
8
7
6
1. Top cowling
2. Top cowling lock lever(s)
3. Drain screw
4. Anti-cavitation plate
5. Propeller
6. Cooling water inlet
7. Trim rod*
8. Steering friction screw
9. Clamp bracket
10. Tiller handle*
11. Choke knob
12. Manual starter handle*
13. Warning indicator
14. Throttle friction adjuster*
15. Engine stop button/Engine stop lanyard
switch*
16. Transom clamp handle
17. Rope attachment
11
1
12
13
18
2
17
3
19
4
15 14
16
20
5
18. Tilt lock lever*
19. Remote control box (side mount type)*
20. Fuel tank
EMU25802
Fuel tank
If your model was equipped with a portable
fuel tank, its function is as follows.
EWM00020
WARNING
The fuel tank supplied with this engine is
its dedicated fuel reservoir and must not
be used as a fuel storage container. Commercial users should conform to relevant
licensing or approval authority regulations.
ZMU04891
8
Page 14
Basic components
1. Air vent screw
2. Fuel gauge
3. Fuel joint
4. Fuel tank cap
4
3
1
2
ZMU01992
the tank can be filled with fuel. To remove the
cap, turn it counterclockwise.
EMU25860
Air vent screw
This screw is on the fuel tank cap. To loosen
the screw, turn it counterclockwise.
EMU26180
Remote control
The remote control lever actuates both the
shifter and the throttle. The electrical switches are mounted on the remote control box.
13
1. Air vent screw
2. Fuel gauge
3. Fuel joint
4. Fuel tank cap
EMU25830
42
ZMU03157
Fuel joint
This joint is used to connect the fuel line.
EMU25841
Fuel gauge
This gauge is located on either the fuel tank
cap or on the fuel joint base. It shows the approximate amount of fuel remaining in the
tank.
EMU25850
Fuel tank cap
This cap seals the fuel tank. When removed,
1. Power trim and tilt switch
2. Remote control lever
3. Neutral interlock trigger
4. Neutral throttle lever
5. Main switch / choke switch
6. Engine stop lanyard switch
7. Throttle friction adjuster
EMU26190
Remote control lever
Moving the lever forward from the neutral position engages forward gear. Pulling the lever back from neutral engages reverse. The
engine will continue to run at idle until the lever is moved about 35° (a detent can be felt).
Moving the lever farther opens the throttle,
and the engine will begin to accelerate.
9
Page 15
1. Neutral “”
2. Forward “”
3. Reverse “”
4. Shift
5. Fully closed
6. Throttle
7. Fully open
EMU26201
Neutral interlock trigger
To shift out of neutral, first pull the neutral interlock trigger up.
Basic components
when the remote control lever is in neutral.
The remote control lever will operate only
when the neutral throttle lever is in the closed
position.
1. Fully open
2. Fully closed
EMU26221
Choke switch
To activate the choke system, press in the
main switch while the key is turned to the
“” (on) or “” (start) position. The
choke system will then supply the rich fuel
mixture required to start the engine. When
the key is released, the choke will switch off
automatically.
1. Neutral interlock trigger
EMU26211
Neutral throttle lever
To open the throttle without shifting into either forward or reverse, put the remote control lever in the neutral position and lift the
neutral throttle lever.
NOTE:
The neutral throttle lever will operate only
ZMU03160
EMU25911
Tiller handle
To change direction, move the tiller handle to
the left or right as necessary.
10
Page 16
Basic components
ZMU01997
ZMU04879
EMU25922
Gear shift lever
Pulling the gear shift lever towards you puts
the engine in forward gear so that the boat
moves ahead. Pushing the lever away from
you puts the engine in reverse gear so that
the boat moves astern.
R
3
N
2
F
1
ZMU04878
1. Forward “”
2. Neutral “”
3. Reverse “”
EMU25941
Throttle grip
The throttle grip is on the tiller handle. Turn
the grip counterclockwise to increase speed
and clockwise to decrease speed.
1. Forward “”
2. Neutral “”
3. Reverse “”
11
R
N
3
2
2
F
1
EMU25961
Throttle indicator
The fuel consumption curve on the throttle
ZMU01999
indicator shows the relative amount of fuel
consumed for each throttle position. Choose
the setting that offers the best performance
ZMU01998
and fuel economy for the desired operation.
Page 17
Basic components
1
ZMU02000
1. Throttle indicator
EMU25970
Throttle friction adjuster
A friction device provides adjustable resistance to movement of the throttle grip or the
remote control lever, and can be set according to operator preference.
To increase resistance, turn the adjuster
clockwise. To decrease resistance, turn the
adjuster counterclockwise.
EWM00030
WARNING
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to move throttle lever or grip,
which could result in an accident.
ZMU02001
When constant speed is desired, tighten the
adjuster to maintain the desired throttle setting.
EMU25990
Engine stop lanyard switch
The lock plate must be attached to the engine stop switch for the engine to run. The
lanyard should be attached to a secure place
on the operator’s clothing, or arm or leg.
Should the operator fall overboard or leave
the helm, the lanyard will pull out the lock
plate, stopping ignition to the engine. This
will prevent the boat from running away under power.
EWM00120
WARNING
Attach the engine stop switch lanyard
●
to a secure place on your clothing, or
your arm or leg while operating.
Do not attach the lanyard to clothing
●
that could tear loose. Do not route the
lanyard where it could become entangled, preventing it from functioning.
Avoid accidentally pulling the lanyard
●
during normal operation. Loss of engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly. This
could cause people and objects in the
boat to be thrown forward.
12
Page 18
Basic components
NOTE:
The engine cannot be started with the lock
plate removed.
2
1
ZMU02003
1. Lanyard
2. Lock plate
1. Lanyard
2. Lock plate
EMU26001
Engine stop button
To open the ignition circuit and stop the engine, push this button.
ZMU02083
EMU26011
Choke knob for pull type
To supply the engine with the rich fuel mixture required to start, pull out this knob.
ZMU02355
EMU26070
Manual starter handle
To start the engine, first gently pull the handle out until resistance is felt. From that position, then pull the handle straight out quickly
to crank the engine.
13
ZMU02005
Page 19
Basic components
EMU26080
Starter button
To start the engine with the electric starter,
push the starter button.
ZMU04880
EMU26090
Main switch
The main switch controls the ignition system;
its operation is described below.
●
“”
(off)
With the main switch in the “” (off) posi-
tion, the electrical circuits are off, and the key
can be removed.
●
“”
(on)
With the main switch in the “” (on) posi-
tion, the electrical circuits are on, and the key
cannot be removed.
●
“”
With the main switch in the “” (start) po-
sition, the starter motor turns to start the engine. When the key is released, it returns
automatically to the “” (on) position.
(start)
EMU26102
Power tilt switch
The power tilt system adjusts the outboard
motor angle in relation to the transom. Pushing the switch “” (up) tilts the outboard mo-
tor up. Pressing the switch “” (down) tilts
the outboard motor down. When the switch is
released, the outboard motor will stop in its
current position.
UP
DN
ZMU02811
NOTE:
For instructions on using the power tilt
switch, see pages 33 and 35.
EMU26110
Steering friction adjuster
A friction device provides adjustable resistance to the steering mechanism, and can be
set according to operator preference. An adjuster lever is located on the bottom of the
tiller handle bracket.
To increase resistance, turn the lever to the
left.
14
Page 20
Basic components
To decrease resistance, turn the lever to the
right.
EWM00040
WARNING
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to steer, which could result in an
accident.
ZMU02340
EMU26122
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.
counterclockwise.
EWM00040
WARNING
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to steer, which could result in an
accident.
EMU26240
Trim tab with anode
The trim tab should be adjusted so that the
steering control can be turned to either the
right or left by applying the same amount of
force.
EWM00840
WARNING
An improperly adjusted trim tab could
cause difficult steering. Always test run
after the trim tab has been installed or replaced to be sure steering is correct. Be
sure you have tightened the bolt after adjusting the trim tab.
If the boat tends to veer the left (port side),
turn the trim tab rear end to the port side “A”
in the figure. If the boat tends to veer the right
(starboard side), turn the trim tab end to the
starboard side “B” in the figure.
ECM00840
CAUTION:
The trim tab also serves as an anode to
protect the engine from electrochemical
corrosion. Never paint the trim tab as it
will become ineffective as an anode.
ZMU02080
To increase resistance, turn the adjuster
clockwise.
To decrease resistance, turn the adjuster
15
Page 21
Basic components
A
1
2
B
ZMU03097
1
ZMU02008
1. Trim tab
2. Bolt
EMU26261
Trim rod (tilt pin)
The position of the trim rod determines the
minimum trim angle of the outboard motor in
relation to the transom.
ZMU02007
EMU26312
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.
EMU26320
Tilt support knob
To keep the outboard motor in the tilted up
position, push the tilt support knob under the
swivel bracket.
ZMU04884
EMU26330
Tilt support bar
The tilt support bar keeps the outboard motor
in the tilted up position.
16
Page 22
Basic components
1
ZMU02078
EMU26360
Power tilt unit
This unit tilts the outboard motor up and
down and is controlled with the power tilt
switch.
ECM00630
CAUTION:
Do not step on or exert pressure on the
power tilt motor. The power tilt unit could
be damaged as a result.
1. Power tilt unit
2. Power tilt motor
EMU26372
Top cowling lock lever(s) (turn type)
To remove the engine top cowling, turn the
lock lever(s) and lift off the cowling. When installing the cowling, check to be sure it fits
properly in the rubber seal. Then lock the
cowling again by returning the lever(s) to the
lock position.
ZMU02009
1. Top cowling lock lever(s)
EMU26460
Flushing device
This device is used to clean the cooling water passages of the motor using a garden
hose and tap water.
NOTE:
For details on usage, see page 48.
1
ZMU04885
1. Flushing device
EMU26300
Warning indicator
If the engine develops a condition which is
cause for warning, the indicator lights up. For
details on how to read the warning indicator,
see page 18.
17
Page 23
ZMU02010
Basic components
EMU26801
Warning system
ECM00090
CAUTION:
Do not continue to operate the engine if a
warning device has activated. Consult
your Yamaha dealer if the problem cannot be located and corrected.
EMU26813
Overheat warning
This engine has an overheat warning device.
If the engine temperature rises too high, the
warning device will activate.
Activation of warning device
The engine speed will automatically de-
●
crease to about 2000 r/min.
●
The overheat warning indicator will light (if
equipped on the bottom cowling or the ta-
chometer).
●
The buzzer will sound (if equipped on the
tiller handle, remote control box, or main
switch panel).
If the warning system has activated, stop the
engine and check the cooling water inlet for
clogging.
ZMU03026
EMU30164
Low oil pressure warning
If the oil pressure drops too low, the warning
device will activate.
Activation of warning device
The engine speed will automatically de-
●
crease to about 2000 r/min.
The low oil pressure warning indicator will
●
light.
18
Page 24
Basic components
ZMU02081
The buzzer will sound (if equipped on the
●
tiller handle, remote control box, or main
switch panel).
ZMU02360
If the warning system has activated, stop the
engine as soon as it is safe to do so. Check
the oil level and add oil as needed. If the oil
level is correct and the warning device does
not switch off, consult your Yamaha dealer.
ECM00100
CAUTION:
Do not continue to run the engine if the
low oil pressure warning indicator is on.
Serious engine damage could occur.
19
Page 25
Operation
EMU26901
Installation
ECM00110
CAUTION:
Incorrect engine height or obstructions
to smooth water flow (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. Severe
engine damage may result if the motor is
operated continuously in the presence of
airborne water spray.
NOTE:
During water testing check the buoyancy of
the boat, at rest, with its maximum load.
Check that the static water level on the exhaust housing is low enough to prevent water entry into the powerhead, when water
rises due to waves when the outboard is not
running.
EMU26910
Mounting the outboard motor
EWM00820
WARNING
Overpowering a boat could cause se-
●
vere instability. Do not install an out-
board motor with more horsepower
than the maximum rating on the capac-
ity plate of the boat. If the boat does not
have a capacity plate, consult the boat
manufacturer.
●
The information presented in this sec-
tion is intended as reference only. It is
not possible to provide complete in-
structions for every possible boat and
motor combination. Proper mounting
depends in part on experience and the
specific boat and motor combination.
EWM00830
WARNING
Improper mounting of the outboard motor could result in hazardous conditions
such as poor handling, loss of control, or
fire hazards. Observe the following:
●
For permanently mounted models, your
dealer or other person experienced in
proper rigging should mount the motor.
If you are mounting the motor yourself,
you should be trained by an experienced person.
●
For portable models, your dealer or other person experienced in proper outboard motor mounting should show
you how to mount your motor.
Mount the outboard motor on the center line
(keel line) of the boat, and ensure that the
boat itself is well balanced. Otherwise the
boat will be hard to steer. For boats without
a keel or which are asymmetrical, consult
your dealer.
1
1. Center line (keel line)
EMU26920
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
ZMU01760
20
Page 26
Operation
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.
0–25mm
(0–1in.)
ZMU02011
NOTE:
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 de-
termine the optimum mounting height.
Consult your Yamaha dealer or boat man-
ufacturer for further information on deter-
mining the proper mounting height.
●
For instructions on setting the trim angle of
the outboard motor, see page 33.
EMU26970
Clamping the outboard motor
1. Place the outboard motor on the tran-
som 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 be-
come loose due to engine vibration.
EWM00640
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 transom screws are tightened securely. Occasionally check the screws for tightness
during operation.
ZMU02012
2. If the engine restraint cable attachment
is equipped on your engine, an engine
restraint cable or chain should be used.
Attach one end to the engine 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.
ZMU02013
3. Secure the clamp bracket to the transom
using the bolts provided with the out-
21
Page 27
Operation
board (if packed). For details, consult
your Yamaha dealer.
EWM00650
WARNING
Avoid using bolts, nuts or washers other
than those contained in the engine 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.
1
ZMU02631
1. Bolts
EMU30172
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.
ECM00800
CAUTION:
Failure to follow the break-in procedure
could result in reduced engine life or
even severe engine damage.
EMU27080
Procedure for 4-stroke models
Run the engine under load (in gear with a
propeller installed) as follows.
1. For the first hour of operation:
Run the engine at 2000 r/min or at approximately half throttle.
2. For the second hour of operation:
Run the engine at 3000 r/min or at approximately three-quarter throttle.
3. For the next eight hours of operation:
Avoid continuous operation at full throttle for more than five minutes at a time.
4. After the first 10 hours:
Operate the engine normally.
EMU27101
Preoperation checks
EWM00080
WARNING
If any item in the preoperation check is
not working properly, have it inspected
and repaired before operating the outboard motor. Otherwise an accident
could occur.
ECM00120
CAUTION:
Do not start the engine out of water. Overheating and serious engine damage can
occur.
EMU27110
Fuel
●
Check to be sure you have plenty of fuel
for your trip.
Make sure there are no fuel leaks or gaso-
●
line fumes.
Check fuel line connections to be sure they
●
are tight (if equipped Yamaha fuel tank or
boat tank).
Be sure the fuel tank is positioned on a se-
●
cure, flat surface, and that the fuel line is
not twisted or flattened, or likely to contact
sharp objects (if equipped Yamaha fuel
tank or boat tank).
EMU27130
Controls
●
Check throttle, shift, and steering for prop-
22
Page 28
Operation
er operation before starting the engine.
●
The controls should work smoothly, without binding or unusual free play.
●
Look for loose or damaged connections.
●
Check operation of the starter and stop
switches when the outboard motor is in the
water.
EMU27140
Engine
Check the engine and engine mounting.
●
●
Look for loose or damaged fasteners.
●
Check the propeller for damage.
EMU27163
Checking the engine oil level
1. Put the outboard motor in an upright position (not tilted).
2. Remove oil dipstick and wipe it clean.
3. Completely insert the dipstick and remove it again.
4. Check the oil level using the dipstick to
be sure the level falls between the upper
and lower marks. Fill with oil if it is below
the lower mark, or drain to the specified
level if it is above the upper mark.
1
3
2
ZMU02082
1. Lower level mark
2. Oil dipstick
3. Upper level mark
NOTE:
Be sure to completely insert the dipstick into
the dipstick guide.
EMU27441
Filling fuel
EWM00060
WARNING
Gasoline and its vapors are highly flammable and explosive. Keep away from
sparks, cigarettes, flames, or other
sources of ignition.
1. Remove the fuel tank cap.
2. Fill the fuel tank carefully.
3. Close the cap securely after refueling.
Wipe up any spilled fuel.
Fuel tank capacity:
12 L, 25 L
NOTE:
The smaller fuel filling hole on the fuel tank
has been designed to fit unleaded fuel fillers
only for emission control models (for Bodensee).
EMU27450
Operating engine
EMU27461
Feeding fuel (portable tank)
EWM00420
WARNING
Before starting the engine, make sure
●
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.
When the air vent screw is loosened,
●
gasoline vapor will be released. Gasoline is highly flammable, and its vapors
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 col-
23
Page 29
orless, odorless gas which could cause
brain damage or death when inhaled.
Symptoms include nausea, dizziness,
and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking
exhaust outlets.
1. If there is an air vent screw on the fuel
tank cap, loosen it 2 or 3 turns.
ZMU02022
2. If there is a fuel joint on the motor, firmly
connect the fuel line to the joint. Then
firmly connect the other end of the fuel
line to the joint on the fuel tank.
Operation
ZMU02023
3. If a steering friction adjuster is provided
on your outboard motor, securely attach
the fuel line to the fuel line clamp.
NOTE:
During engine operation place the tank horizontally, otherwise fuel cannot be drawn
from the fuel tank.
4. Squeeze the primer pump with the outlet
end up until you feel it become firm.
ZMU02024
ZMU02025
EMU27490
Starting engine
EMU27505
Manual start models (tiller control)
1. Place the gear shift lever in neutral.
24
Page 30
Operation
N
ZMU01988
N
ZMU04881
NOTE:
The start-in-gear protection device prevents
the engine from starting except when in neutral.
gine 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.
ZMU02026
3. Place the throttle grip in the “”
(start) position.
2. Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg. Then install the lock plate on
the other end of the lanyard into the engine stop switch.
EWM00120
WARNING
●
Attach the engine stop switch lanyard
to a secure place on your clothing, or
your arm or leg while operating.
●
Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entangled, preventing it from functioning.
●
Avoid accidentally pulling the lanyard
during normal operation. Loss of en-
25
ZMU02027
4. Pull out / turn the choke knob fully. After
the engine starts, replace / return the
knob to the home position.
ZMU02355
Page 31
Operation
NOTE:
●
It is not necessary to use the choke when
starting a warm engine.
●
If the choke knob is left in the “”
(start) position 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.
ZMU02029
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.
ZMU02030
NOTE:
When the engine is cold, it needs to be
●
warmed up. For further information, see
page 30.
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 67.
EMU27561
Electric start models
1. Place the gear shift lever in neutral.
N
ZMU01988
NOTE:
The start-in-gear protection device prevents
the engine from starting except when in neutral.
2. Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg. Then install the lock plate on
the other end of the lanyard into the engine stop switch.
EWM00120
WARNING
●
Attach the engine stop switch lanyard
to a secure place on your clothing, or
your arm or leg while operating.
●
Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entangled, preventing it from functioning.
●
Avoid accidentally pulling the lanyard
during normal operation. Loss of en-
26
Page 32
Operation
gine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly. This
could cause people and objects in the
boat to be thrown forward.
NOTE:
●
ZMU02026
3. Place the throttle grip in the “”
(start) position. After the engine starts,
return the throttle to the fully closed position.
●
5. Push the starter button to start the mo-
ZMU02355
It is not necessary to use the choke when
starting a warm engine.
If the choke knob is left in the “”
(start) position while the engine is running,
the engine will run poorly or stall.
tor. (Repeat if necessary.)
ZMU02027
4. Pull out / turn the choke knob fully. After
the engine starts, replace / return the
knob to the home position.
27
ZMU04880
6. Immediately after the engine starts, release the starter button to allow it to return to its original position.
7. Slowly return the throttle grip to the fully
closed position so that the engine does
not stall.
ECM00160
CAUTION:
Never push the starter button while the
●
engine is running.
●
Do not keep the starter motor turning
for more than 5 seconds. If the starter
Page 33
Operation
motor is turned continuously for more
than 5 seconds, the battery will be
quickly discharged, thus making it impossible to start the engine. The starter
can also be damaged. If the engine will
not start after 5 seconds of cranking,
release the starter button, wait 10 seconds, then crank the engine again.
NOTE:
●
When the engine is cold, it needs to be
warmed up. For further information, see
page 30.
●
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 67.
EMU27642
Electric start / remote control models
1. Place the remote control lever in neutral.
the other end of the lanyard into the engine stop switch.
EWM00120
WARNING
●
Attach the engine stop switch lanyard
to a secure place on your clothing, or
your arm or leg while operating.
●
Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entangled, preventing it from functioning.
●
Avoid accidentally pulling the lanyard
during normal operation. Loss of engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly. This
could cause people and objects in the
boat to be thrown forward.
NOTE:
The start-in-gear protection device prevents
the engine from starting except when in neutral.
2. Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg. Then install the lock plate on
3. Turn the main switch to “” (on).
ON
OFF
ZMU01880
4. Open the throttle slightly without shifting
28
Page 34
Operation
using the neutral throttle lever or free accelerator. You may need to change the
throttle opening slightly depending on
engine temperature. After the engine
starts, return the throttle to the original
position.
N
ZMU02314
NOTE:
●
On remote controls equipped with a neutral throttle lever, a good starting point is to
lift the lever just until you feel resistance,
then lift slightly more.
●
The neutral throttle lever or free accelerator can only be used when the remote control lever is in neutral.
5. Press in and hold the main switch to operate the remote choke system. The remote choke switch automatically returns
to its normal position when you release
your hand. Therefore keep the switch
pressed in.
ON
STARTOFF
NOTE:
●
It is not necessary to use the choke when
starting a warm engine.
●
Push in the main switch fully, or the remote
choke system will not operate.
6. Turn the main switch to “” (start),
and hold it for a maximum of 5 seconds.
7. Immediately after the engine starts, release the main switch and allow it to return to “” (on).
ECM00191
CAUTION:
Never turn the main switch to “”
●
(start) while the engine is running.
●
Do not keep the starter motor turning
for more than 5 seconds. If the starter
motor is turned continuously for more
than 5 seconds, the battery will be
quickly discharged, thus making it impossible to start the engine. The starter
can also be damaged. If the engine will
not start after 5 seconds of cranking,
return the main switch to “” (on), wait
10 seconds, then crank the engine
again.
29
ZMU02315
Page 35
EMU27670
Warming up engine
EMU27710
Manual start and electric start
models
1. After starting the engine, allow it to idle
for 3 minutes to warm up. Failure to do
so will shorten engine life.
2. Be sure the low oil pressure warning indicator goes off after starting the engine.
3. Check for a steady flow of water from the
cooling water pilot hole.
ECM00210
CAUTION:
●
If the low oil pressure warning indicator
does not go off after the engine starts,
stop the engine. Otherwise serious engine damage could occur. Check the oil
level and add oil if necessary. Consult
your Yamaha dealer if the cause for the
low oil pressure warning indicator cannot be found.
●
A continuous flow of water from the pilot hole shows that the water pump is
pumping water through the cooling
passages. If water is not flowing out of
the pilot hole at all times while the engine is running, overheating and serious damage could occur. Stop the
engine and check whether the cooling
water inlet on the lower case or the
cooling water pilot hole is blocked.
Consult your Yamaha dealer if the problem cannot be located and corrected.
Operation
ZMU02034
EMU27740
Shifting
EWM00180
WARNING
Before shifting, make sure there are no
swimmers or obstacles in the water near
you.
ECM00220
CAUTION:
To change the boat direction or shifting
position from forward to reverse or viceversa, first close the throttle so that the
engine idles (or runs at low speeds).
EMU27763
Forward (tiller handle and remote
control models)
Tiller control models
1. Place the throttle grip in the fully closed
position.
ZMU02030
2. Move the gear shift lever quickly and
30
Page 36
Operation
firmly from neutral to forward.
N
F
ZMU02036
N
F
ZMU04882
Remote control models
1. Pull up the neutral interlock trigger (if
equipped) and move the remote control
lever quickly and firmly from neutral to
forward.
EMU27795
Reverse (manual tilt and hydro tilt
models)
EWM00190
WARNING
When operating in reverse, go slowly. Do
not open the throttle more than half. Otherwise the boat could become unstable,
which could result in loss of control and
an accident.
Tiller control models
1. Place the throttle grip in the fully closed
position.
ZMU02030
2. On models equipped with a tilt lock lever, check that it is in the lock/down position.
31
ZMU02086
3. Move the gear shift lever quickly and
firmly from neutral to reverse.
Page 37
NR
ZMU02038
R
Remote control models
1. Check that the tilt lock lever is in the lock
position.
N
ZMU04883
Operation
EMU27820
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.
EMU27844
Procedure
1. Push and hold the engine stop button or
turn the main switch to “” (off).
ZMU02086
2. Pull up the neutral interlock trigger (if
equipped) and move the remote control
lever quickly and firmly from neutral to
reverse.
ZMU02083
2. After stopping the engine, disconnect
32
Page 38
Operation
the fuel line if there is a fuel joint on the
outboard motor.
ZMU02042
3. Tighten the air vent screw on the fuel
tank cap (if equipped).
ZMU02041
also affected by variables such as the load in
the boat, sea conditions, and running speed.
EWM00740
WARNING
Excessive trim for the operating conditions (either trim up or trim down) can
cause boat instability and can make
steering the boat more difficult. This increases the possibility of an accident. If
the boat begins to feel unstable or is hard
to steer, slow down and/or readjust the
trim angle.
4. Remove the key if the boat will be left
unattended.
NOTE:
The engine can also be stopped by pulling
the lanyard and removing the lock plate from
the engine stop switch, then turning the main
switch to “” (off).
EMU27861
Trimming outboard motor
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
33
1
ZMU02043
1. Trim operating angle
EMU27871
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.
Page 39
Operation
2. Remove the trim rod from the clamp
bracket while slightly tilting the outboard
motor up.
ZMU02007
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.
EWM00400
WARNING
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.
EMU27901
Adjusting trim angle (power tilt
models)
EWM00750
WARNING
●
Be sure all people are clear of the outboard motor when adjusting the tilt angle, also be careful not to pinch any
body parts between the drive unit and
clamp bracket.
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.
Use the power tilt switch located on the
●
bottom engine cowling (if equipped)
only when the boat is at a complete
stop with the engine off.
Tilt the engine to the desired angle using the
power tilt switch.
NOTE:
The outboard motor trim angle can be
changed approximately 4 degrees by shifting
the trim rod one hole.
UP
DN
ZMU02811
34
Page 40
Operation
NOTE:
Stay within the trim operating angle when
trimming the outboard motor using the power
tilt system.
To raise the bow (“trim-out”), tilt the engine
up.
To lower the bow (“trim-in”), tilt the engine
down.
Make test runs with the trim set to different
angles to find the position that works best for
your boat and operating conditions.
EMU27911
Adjusting boat trim
When the boat is on plane, a bow-up attitude
results in less drag, greater stability and efficiency. This is generally when the keel line of
the boat is up about 3 to 5 degrees. With the
bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can
also be adjusted to help offset this effect.
When the bow of the boat is down, it is easier
to accelerate from a standing start onto
plane.
formance further, and the boat may “por-
poise” (hop in the water), which could throw
the operator and passengers overboard.
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 per-
35
NOTE:
Depending on the type of boat, the outboard
motor trim angle may have little effect on the
trim of the boat when operating.
EMU27932
Tilting up and down
If the engine will be stopped for some time or
if the boat is moored in shallows, the out-
Page 41
Operation
board motor should be tilted up to protect the
propeller and casing from damage by collision with obstructions, and also to reduce
salt corrosion.
EWM00220
WARNING
Be sure all people are clear of the outboard motor when tilting up and down,
also be careful not to pinch any body
parts between the drive unit and engine
bracket.
EWM00250
WARNING
Leaking fuel is a fire hazard. If there is a
fuel joint on the outboard motor, disconnect the fuel line or close the fuel cock if
the engine will be tilted for more than a
few minutes. Otherwise fuel may leak.
ECM00241
CAUTION:
●
Before tilting the outboard motor, stop
the engine by following the procedure
on page 32. 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.
EMU27976
Procedure for tilting up (manual tilt
models)
1. Place the gear shift lever in neutral.
N
ZMU01988
N
ZMU04881
2. Disconnect the fuel line from the outboard motor.
ZMU02042
3. Place the tilt lock lever (if equipped) in
the release/up position.
36
Page 42
Operation
ZMU02044
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.
ZMU02078
EMU28005
Procedure for tilting up
Power trim and tilt models / power tilt models
1. Place the remote control lever / the gear
shift lever in neutral.
2. Disconnect the fuel line from the outboard motor or close the fuel cock.
ZMU02042
3. Press the power trim and tilt switch /
power tilt switch “” (up) until the out-
board motor has tilted up completely.
37
Page 43
UP
ZMU02823
4. Push the tilt support knob into the clamp
bracket or pull the tilt support lever toward you to support the engine.
ZMU04884
EWM00260
WARNING
After tilting the outboard motor, be sure
to support it with the tilt support knob or
tilt support lever. Otherwise the outboard
motor could fall back down suddenly if oil
in the power trim and tilt unit loses pressure.
Operation
from marine growth and corrosion which
could damage the power trim and tilt
mechanism.
EMU30190
Procedure for tilting down (manual
tilt models)
1. Place the tilt lock lever in the lock position.
ZMU02048
2. Slightly tilt the engine up until the tilt support bar is automatically released.
3. Slowly tilt the engine down.
EMU28052
Procedure for tilting down
Power trim and tilt models / power tilt models
1. Push the power tilt / power trim and tilt
switch “” (up) until the outboard motor
is supported by the tilt rod and the tilt
support lever / tilt support knob becomes
free.
2. Release the tilt support lever or pull out
the tilt support knob.
5. Models equipped with trim rods: Once
the outboard motor is supported with the
tilt support lever, press the power trim
and tilt switch “” (down) to retract the
trim rods.
ECM00250
CAUTION:
Be sure to retract the trim rods completely during mooring. This protects the rods
ZMU04886
38
Page 44
Operation
3. Push the power tilt / power trim and tilt
switch “” (down) to lower the outboard
motor to the desired position.
UP
DN
DN
ZMU01936
DN
ZMU02826
EMU28060
Cruising in shallow water
The outboard motor can be tilted up partially
to allow operation in shallow water.
EMU28071
Cruising in shallow water (manual tilt
models)
EWM00710
WARNING
●
Place the gear shift in neutral before using the shallow water cruising system.
●
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.
Hitting an underwater obstacle could
cause the outboard motor to lift out of
the water, resulting in loss of control.
●
Do not rotate the outboard motor 180°
and operate the boat in reverse. Place
the gear shift in reverse to operate the
boat in reverse.
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.
●
Return the outboard motor to its normal
position as soon as the boat is back in
deeper water.
ECM00260
CAUTION:
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.
ZMU02047
EMU28123
Procedure
1. Place the gear shift lever in neutral.
39
Page 45
Operation
ZMU02044
N
ZMU01988
N
ZMU04881
2. Place the tilt lock lever in the release/up
position.
3. Slightly tilt the outboard motor up. The
tilt support bar will lock automatically,
supporting the outboard motor in a partially raised position.
NOTE:
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, then place the tilt lock lever in the lock/down position.
ZMU02048
5. 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.
EMU28090
Power trim and tilt models / power tilt
models
The outboard motor can be tilted up partially
40
Page 46
Operation
to allow operation in shallow water.
EWM00660
WARNING
Place the gear shift in neutral before
●
setting up for shallow water cruising.
●
Return the outboard motor to its normal
position as soon as the boat is back in
deeper water.
ECM00260
CAUTION:
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.
EMU28184
Procedure for power trim and tilt / power
tilt models
1. Place the gear shift lever in neutral.
N
ZMU03525
2. Slightly tilt the outboard motor up to the
desired position using the power trim / tilt
switch.
UP
UP
DN
ZMU01935
UP
ZMU02823
3. To return the outboard motor to the normal running position, press the power
trim / tilt switch and slowly tilt the outboard motor down.
EMU28190
Cruising in other conditions
Cruising in salt water
After operating in salt water, wash out the
cooling water passages with fresh water to
prevent them from becoming clogged with
salt deposits.
NOTE:
For cooling system flushing instructions, see
page 45.
41
Cruising in turbid water
Yamaha strongly recommends that you use
the optional chromium-plated water pump kit
if you use the outboard motor in turbid (muddy) water conditions.
Page 47
Maintenance
EMU28216
Specifications
Dimension:
Overall length:
F13.5AMH 1001 mm (39.4 in)
F15AE 643 mm (25.3 in)
F15AEH 1001 mm (39.4 in)
F15AEP 643 mm (25.3 in)
F15AMH 1001 mm (39.4 in)
F9.9CE 643 mm (25.3 in)
F9.9CMH 1001 mm (39.4 in)
FT9.9DE 643 mm (25.3 in)
FT9.9DMH 1105 mm (43.5 in)
Overall width:
F13.5AMH 427 mm (16.8 in)
F15AE 369 mm (14.5 in)
F15AEH 427 mm (16.8 in)
F15AEP 369 mm (14.5 in)
F15AMH 427 mm (16.8 in)
F9.9CE 369 mm (14.5 in)
F9.9CMH 427 mm (16.8 in)
FT9.9DE 369 mm (14.5 in)
FT9.9DMH 501 mm (19.7 in)
Overall height S:
F13.5AMH 1080 mm (42.5 in)
F15AE 1080 mm (42.5 in)
F15AEH 1080 mm (42.5 in)
F15AEP 1080 mm (42.5 in)
F15AMH 1080 mm (42.5 in)
F9.9CE 1080 mm (42.5 in)
F9.9CMH 1080 mm (42.5 in)
Overall height L:
F13.5AMH 1207 mm (47.5 in)
F15AE 1207 mm (47.5 in)
F15AEH 1207 mm (47.5 in)
F15AEP 1207 mm (47.5 in)
F15AMH 1207 mm (47.5 in)
F9.9CE 1207 mm (47.5 in)
F9.9CMH 1207 mm (47.5 in)
FT9.9DE 1253 mm (49.3 in)
FT9.9DMH 1253 mm (49.3 in)
Overall height X:
FT9.9DE 1321 mm (52.0 in)
Transom height S:
F13.5AMH 440 mm (17.3 in)
F15AE 440 mm (17.3 in)
F15AEH 440 mm (17.3 in)
F15AEP 440 mm (17.3 in)
F15AMH 440 mm (17.3 in)
F9.9CE 440 mm (17.3 in)
F9.9CMH 440 mm (17.3 in)
Transom height L:
567 mm (22.3 in)
Transom height X:
FT9.9DE 635 mm (25.0 in)
Weight (AL) S:
F13.5AMH 45.0 kg (99 lb)
F15AE 47.0 kg (104 lb)
F15AEH 48.0 kg (106 lb)
F15AEP 52.0 kg (115 lb)
F15AMH 45.0 kg (99 lb)
F9.9CE 47.0 kg (104 lb)
F9.9CMH 45.0 kg (99 lb)
Weight (AL) L:
F13.5AMH 47.0 kg (104 lb)
F15AE 49.0 kg (108 lb)
F15AEH 50.0 kg (110 lb)
F15AEP 54.0 kg (119 lb)
F15AMH 47.0 kg (104 lb)
F9.9CE 49.0 kg (108 lb)
F9.9CMH 47.0 kg (104 lb)
FT9.9DE 50.0 kg (110 lb)
FT9.9DMH 49.0 kg (108 lb)
Weight (AL) X:
FT9.9DE 51.0 kg (112 lb)
Performance:
Full throttle operating range:
4500–5500 r/min
Maximum output:
F13.5AMH 9.9 kW@5000 r/min
(13 HP@5000 r/min)
F15AE 11.0 kW@5000 r/min
42
Page 48
Maintenance
(15 HP@5000 r/min)
F15AEH 11.0 kW@5000 r/min
(15 HP@5000 r/min)
F15AEP 11.0 kW@5000 r/min
(15 HP@5000 r/min)
F15AMH 11.0 kW@5000 r/min
(15 HP@5000 r/min)
F9.9CE 7.3 kW@5000 r/min
(10 HP@5000 r/min)
F9.9CMH 7.3 kW@5000 r/min
(10 HP@5000 r/min)
FT9.9DE 7.3 kW@5000 r/min
(10 HP@5000 r/min)
FT9.9DMH 7.3 kW@5000 r/min
(10 HP@5000 r/min)
Idling speed (in neutral):
F13.5AMH 950 ±50 r/min
F15AE 950 ±50 r/min
F15AEH 950 ±50 r/min
F15AEP 950 ±50 r/min
F15AMH 950 ±50 r/min
F9.9CE 950 ±50 r/min
F9.9CMH 950 ±50 r/min
FT9.9DE 1050 ±50 r/min
FT9.9DMH 1050 ±50 r/min
Engine:
Type:
4-stroke L
Displacement:
323.0 cm
Bore × stroke:
59.0 × 59.0 mm (2.32 × 2.32 in)
Ignition system:
CDI
Spark plug (NGK):
DPR6EA-9
Spark plug with resistor (NGK):
DPR6EA-9
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Control system:
3
(19.71 cu.in)
F13.5AMH Tiller
F15AE Remote control
F15AEH Tiller
F15AEP Remote control
F15AMH Tiller
F9.9CE Remote control
F9.9CMH Tiller
FT9.9DE Remote control
FT9.9DMH Tiller
Starting system:
F13.5AMH Manual
F15AE Electric
F15AEH Electric
F15AEP Electric
F15AMH Manual
F9.9CE Electric
F9.9CMH Manual
FT9.9DE Electric
FT9.9DMH Manual
Starting carburetion system:
Choke valve
Valve clearance (cold engine) IN:
0.15–0.25 mm (0.0059–0.0098 in)
Valve clearance (cold engine) EX:
0.20–0.30 mm (0.0079–0.0118 in)
Min. cold cranking amps (CCA/EN):
F15AE 347.0 A
F15AEH 347.0 A
F15AEP 347.0 A
F9.9CE 347.0 A
FT9.9DE 347.0 A
Min. rated capacity (20HR/IEC):
F15AE 40.0 Ah
F15AEH 40.0 Ah
F15AEP 40.0 Ah
F9.9CE 40.0 Ah
FT9.9DE 40.0 Ah
Alternator output:
F13.5AMH 80 W
F15AMH 80 W
F9.9CMH 80 W
43
Page 49
Maintenance
Alternator output for battery DC:
F15AE 10.0 A
F15AEH 10.0 A
F15AEP 10.0 A
F9.9CE 10.0 A
FT9.9DE 10.0 A
FT9.9DMH 10.0 A
Drive unit:
Gear positions:
Forward-neutral-reverse
Gear ratio:
F13.5AMH 2.08 (27/13)
F15AE 2.08 (27/13)
F15AEH 2.08 (27/13)
F15AEP 2.08 (27/13)
F15AMH 2.08 (27/13)
F9.9CE 2.08 (27/13)
F9.9CMH 2.08 (27/13)
FT9.9DE 2.92 (38/13)
FT9.9DMH 2.92 (38/13)
Trim and tilt system:
F13.5AMH Manual tilt
F15AE Manual tilt
F15AEH Manual tilt
F15AEP Power tilt
F15AMH Manual tilt
F9.9CE Manual tilt
F9.9CMH Manual tilt
FT9.9DE Manual tilt
FT9.9DMH Manual tilt
Propeller mark:
F13.5AMH J
F15AE J
F15AEH J
F15AEP J
F15AMH J
F9.9CE J
F9.9CMH J
FT9.9DE R
FT9.9DMH R
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Min. research octane:
F13.5AMH 90
F15AE 90
F15AEH 90
F15AEP 90
F15AMH 90 (CHE)(EUR)
F9.9CE 90
F9.9CMH 90
FT9.9DE 90
FT9.9DMH 90
Recommended engine oil:
4-stroke outboard motor oil
Engine oil grade API:
API SE, SF, SG, SH, SJ
Engine oil type SAE:
SAE10W30 or SAE10W40
Lubrication:
Wet sump
Engine oil quantity (excluding oil filter):
1.0 L (1.06 US qt) (0.88 Imp.qt)
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
F13.5AMH 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
F15AE 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
F15AEH 250.0 cm3 (8.45 US oz)
(8.82 Imp.oz)
F15AEP 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
F15AMH 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
F9.9CE 250.0 cm3 (8.45 US oz)
(8.82 Imp.oz)
F9.9CMH 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
FT9.9DE 370.0 cm
3
(12.51 US oz)
(13.05 Imp.oz)
44
Page 50
Maintenance
FT9.9DMH 370.0 cm3 (12.51 US oz)
(13.05 Imp.oz)
Tightening torque for engine:
Spark plug:
18.0 Nm (13.3 ft-lb) (1.84 kgf-m)
Propeller nut:
F13.5AMH 17.0 Nm (12.5 ft-lb)
(1.73 kgf-m)
F15AE 17.0 Nm (12.5 ft-lb)
(1.73 kgf-m)
F15AEH 17.0 Nm (12.5 ft-lb)
(1.73 kgf-m)
F15AEP 17.0 Nm (12.5 ft-lb)
(1.73 kgf-m)
F15AMH 17.0 Nm (12.5 ft-lb)
(1.73 kgf-m)
F9.9CE 17.0 Nm (12.5 ft-lb)
(1.73 kgf-m)
F9.9CMH 17.0 Nm (12.5 ft-lb)
(1.73 kgf-m)
FT9.9DE 21.0 Nm (15.5 ft-lb)
(2.14 kgf-m)
FT9.9DMH 21.0 Nm (15.5 ft-lb)
(2.14 kgf-m)
Engine oil drain bolt:
28.0 Nm (20.7 ft-lb) (2.86 kgf-m)
Engine oil filter:
18.0 Nm (13.3 ft-lb) (1.84 kgf-m)
EMU28222
Transporting and storing
outboard motor
EWM00690
WARNING
●
Leaking fuel is a fire hazard. When
transporting and storing the outboard
motor, close the air vent screw and fuel
cock to prevent fuel from leaking.
●
USE CARE when transporting fuel tank,
whether in a boat or car.
●
DO NOT fill fuel container to maximum
capacity. Gasoline will expand consid-
erably as it warms up and can build up
pressure in the fuel container. This can
cause fuel leakage and a potential fire
hazard.
EWM00700
WARNING
Never get under the lower unit while it is
tilted, even if a motor support bar is used.
Severe injury could occur if the outboard
motor accidentally falls.
ECM00660
CAUTION:
Do not use the tilt support lever or knob
when trailering the boat. The outboard
motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use
an additional support device to secure it
in the tilt position.
The outboard motor should be trailered and
stored in the normal running position. If there
is insufficient road clearance in this position,
then trailer the outboard motor in the tilt position using a motor support device such as
a transom saver bar. Consult your Yamaha
dealer for further details.
EMU28235
Clamp screw mounting models
When transporting or storing the outboard
motor while removed from a boat, keep the
outboard motor in the attitude shown.
45
Page 51
ZMU02049
ZMU02050
NOTE:
Place a towel or something similar under the
outboard motor to protect it from damage.
EMU28241
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.
ECM01080
CAUTION:
●
To prevent problems which can be
caused by oil entering the cylinder from
the sump, keep the outboard motor in
the attitude shown when transporting
Maintenance
and storing it. If storing or transporting
the outboard motor on its side (not upright), put it on a cushion after draining
the engine oil.
●
Do not place the outboard motor on its
side before the cooling water has
drained from it completely, otherwise
water may enter the cylinder through
the exhaust port and cause engine trouble.
●
Store the outboard motor in a dry, wellventilated place, not in direct sunlight.
EMU28301
Procedure
EMU28332
Flushing in a test tank
ECM00300
CAUTION:
Do not run the engine without supplying
it with cooling water. Either the engine
water pump will be damaged or the engine will be damaged from overheating.
Before starting the engine, be sure to
supply water to the cooling water passages.
1. Wash the outboard motor body using
fresh water. For further information, see
page 49.
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.
4. Install the outboard motor on the test
tank. Fill the tank with fresh water to
above the level of the anti-cavitation
plate.
46
Page 52
Maintenance
1
2
ZMU02051
1. Water surface
2. Lowest water level
ECM00290
CAUTION:
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.
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.
EWM00090
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.
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 ex-
cessively and almost stall.
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.
NOTE:
Store the fuel tank in a dry, well-ventilated
place, not in direct sunlight.
EMU28400
Lubrication (except oil injection
models)
1. Grease the spark plug threads and install the spark plug(s) and torque to
proper specification. For information on
spark plug installation, see page 54.
2. Change the gear oil. For instructions,
see page 62. 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 52.
EMU28430
Battery care
EWM00330
WARNING
Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is
47
Page 53
Maintenance
poisonous and highly caustic.
Always follow these preventive measures:
●
Avoid bodily contact with electrolytic
fluid as it can cause severe burns or
permanent eye injury.
●
Wear protective eye gear when handling or working near batteries.
Antidote (EXTERNAL):
●
SKIN - Flush with water.
●
EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
●
Drink large quantities of water or milk
followed by milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive hydrogen gas; therefore, you should always
follow these preventive measures:
Charge batteries in a well-ventilated ar-
●
ea.
●
Keep batteries away from fire, sparks,
or open flames (for example: welding
equipment, lighted cigarettes, and so
on.)
DO NOT SMOKE when charging or han-
●
dling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
tilled water.
3. Store the battery on a level surface in a
cool, dry, well-ventilated place out of direct sunlight.
4. Once a month, check the specific gravity
of the electrolyte and recharge as required to prolong battery life.
EMU28440
Flushing power unit
Perform this procedure right after operation
for the most thorough flushing.
1. After shutting off the engine, unscrew
the garden hose connector from the fitting on the bottom cowling.
1
2
3
Batteries vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery
manufacturer’s instructions.
Procedure
1. Disconnect and remove the battery from
the boat. Always disconnect the black
negative cable first to prevent the risk of
shorting.
2. Clean the battery casing and terminals.
Fill each cell to the upper level with dis-
ZMU04887
1. Fitting
2. Garden hose connector
3. Garden hose
2. Screw the garden hose connector onto a
garden hose which is connected to a
fresh water supply.
3. With the engine off, turn on the water tap
48
Page 54
Maintenance
and let the water flush through the cooling passages for about 15 minutes. Turn
off the water and disconnect the garden
hose.
4. When flushing is complete, reinstall the
garden hose connector on the fitting on
the bottom cowling. Tighten the connector securely.
ECM00540
CAUTION:
Do not leave the garden hose connector
loose on the bottom cowling fitting or let
the hose hang free during normal operation. Water will leak out of the connector
instead of cooling the engine, which can
cause serious overheating. Be sure the
connector is tightened securely on the fitting after flushing the engine.
NOTE:
●
When flushing the engine with the boat in
the water, tilting up the outboard motor until it is completely out of the water will
achieve better results.
For cooling system flushing instructions,
●
see page 45.
EMU28450
Cleaning the outboard motor
After use, wash the exterior of the outboard
motor with fresh water. Flush the cooling
system with fresh water.
NOTE:
For cooling system flushing instructions, see
page 45.
EMU28460
Checking painted surface of motor
Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are
more likely to corrode. If necessary, clean
and paint the areas. A touch-up paint is available from your Yamaha dealer.
EMU28474
Periodic maintenance
EWM01070
WARNING
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If you or the owner is not familiar with machine servicing, this work
should be done by your Yamaha dealer or
other qualified mechanic.
EMU28510
Replacement parts
If replacement parts are necessary, use only
genuine Yamaha parts or parts of the same
type and of equivalent strength and materials. Any part of inferior quality may malfunction, and the resulting loss of control could
endanger the operator and passengers.
Yamaha genuine parts and accessories are
available from your Yamaha dealer.
49
ZMU02052
Page 55
Maintenance
EMU28521
Maintenance chart
Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. Refer to the sections in this chapter for
explanations of each owner-specific action.
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) (internal)
Battery Inspection / charging
Cooling water passages
Cowling clamp Inspection
Fuel filter (can be disassembled)
Fuel system Inspection
Fuel tank (Yamaha portable tank)
Gear oil Change
Greasing points Greasing
Idling speed (carburetor models)
Power trim and tilt unit Inspection
Propeller and cotter pin
Shift link / shift cable Inspection / adjustment
Thermostat Inspection
Throttle link / throttle
cable / throttle pick-up
timing
Water pump Inspection
Engine oil Inspection / change
Oil filter (cartridge) Change
Inspection / replacement
Inspection / replacement
Cleaning
Inspection / cleaning
Inspection / cleaning
Inspection / adjustment
Inspection / replacement
Inspection / adjustment
10 hours
(1 month)
50 hours
(3
months)
100
hours (6
months)
200
hours (1
year)
50
Page 56
Maintenance
Initial Every
Item Actions
Spark plug(s)
Timing belt
Valve clearance (OHC,
OHV)
10 hours
(1 month)
Cleaning / adjustment /
replacement
Inspection / replacement
Inspection / adjustment
50 hours
(3
months)
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean
water after each use.
EMU28871
Maintenance chart (additional)
Item Actions
Timing belt Replacement
EMU28910
500 hours (2.5 years) 1000 hours (5 years)
NOTE:
When using lead or high-sulfur gasoline, inspecting valve clearance may be required more
frequently than every 500 hours.
Every
100
hours (6
months)
200
hours (1
year)
51
Page 57
EMU28940
Greasing
Yamaha grease A (water resistant grease)
Yamaha grease D (corrosion resistant grease; for propeller shaft)
F9.9CE, FT9.9DE, F13.5AEP, F15AE, F15AEP
Maintenance
ZMU02330
52
Page 58
Maintenance
F9.9CMH, FT9.9DMH, F13.5AMH, F15AMH, F15AEH
53
ZMU02331
Page 59
EMU28951
Cleaning and adjusting spark plug
EWM00560
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.
The spark plug is an important engine component and is easy to inspect. The condition
of the spark plug can indicate something
about the condition of the engine. For example, if the center electrode porcelain is very
white, this could indicate an intake air leak or
carburetion problem in that cylinder. Do not
attempt to diagnose any problems yourself.
Instead, take the outboard motor to a
Yamaha dealer. You should periodically remove and inspect the spark plug because
heat and deposits will cause the spark plug
to slowly break down and erode. If electrode
erosion becomes excessive, or if carbon and
other deposits are excessive, you should replace the spark plug with another of the correct type.
Standard spark plug:
DPR6EA-9
Before fitting the spark plug, measure the
electrode gap with a wire thickness gauge;
adjust the gap to specification if necessary.
Maintenance
1. Spark plug gap
2. Spark plug I.D. mark (NGK)
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off
any dirt from the threads and screw in the
spark plug to the correct torque.
Spark plug torque:
18.0 Nm (13.3 ft-lb) (1.84 kgf-m)
NOTE:
If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of
the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the
correct torque as soon as possible with a
torque-wrench.
EMU28962
Checking fuel system
EWM00060
WARNING
Gasoline and its vapors are highly flammable and explosive. Keep away from
sparks, cigarettes, flames, or other
54
Page 60
Maintenance
sources of ignition.
EWM00910
WARNING
Leaking fuel can result in fire or explosion.
Check for fuel leakage regularly.
●
●
If any fuel leakage is found, the fuel
system must be repaired by a qualified
mechanic. Improper repairs can make
the outboard unsafe to operate.
Check the fuel lines for leaks, crack, or malfunction. If a problem is found, your Yamaha
dealer or other qualified mechanic should repair it immediately.
EMU28980
Inspecting fuel filter
EWM00310
WARNING
Gasoline is highly flammable, and its vapors are flammable and explosive.
●
If you have any question about properly
doing this procedure, consult your
Yamaha dealer.
●
Do not perform this procedure on a hot
or running engine. Allow the engine to
cool.
●
There will be fuel in the fuel filter. Keep
away from sparks, cigarettes, flames or
other sources of ignition.
●
This procedure will allow some fuel to
spill. Catch fuel in a rag. Wipe up any
spilled fuel immediately.
●
The fuel filter must be reassembled
carefully with the O-ring, filter cup, and
hoses in place. Improper assembly or
replacement could result in a fuel leak,
which could result in a fire or explosion
hazard.
EMU29001
Cleaning fuel filter
1. Remove the nut holding the fuel filter assembly if equipped.
Checkpoints
Fuel system parts leakage
●
●
Fuel line joint leakage
●
Fuel line cracks or other damage
Fuel connector leakage
●
55
1
ZMU02054
ZMU02055
1. Nut
Page 61
Maintenance
2. Unscrew the filter cup, catching any
spilled fuel in a rag.
3. Remove the filter element, and wash it in
solvent. Allow it to dry. Inspect the filter
element and O-ring to make sure they
are in good condition. Replace them if
necessary. If any water is found in the
fuel, the Yamaha portable fuel tank or
other fuel tanks should be checked and
cleaned.
2
3
4
1
ZMU02079
1. Filter cup
2. Filter element
3. Filter housing
4. O-ring
4. Reinstall the filter element in the cup.
Make sure the O-ring is in position in the
cup. Firmly screw the cup onto the filter
housing.
5. Attach the filter assembly to the bracket
so that the fuel hoses are attached to the
filter assembly.
6. Run the engine and check the filter and
lines for leaks.
EMU29040
Inspecting idling speed
EWM00450
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.
2-hp models
●
: The propeller rotates
whenever the engine is running. Do not
move the throttle control lever from the
start position during warm-up. The boat
could unexpectedly start to move,
which could result in an accident.
ECM00490
CAUTION:
This procedure must be performed while
the outboard motor is in the water. A
flushing attachment or test tank can be
used.
A diagnostic tachometer should be used for
this procedure. Results may vary depending
on whether testing is conducted with the
flushing attachment, in a test tank, or with the
outboard motor in the water.
1. Start the engine and allow it to warm up
fully in neutral until it is running smoothly.
2-hp model: Warm the engine with the
throttle in the start position or less. If the
outboard is mounted on a boat, be sure
the boat is tightly moored.
NOTE:
Correct idling speed inspection is only possible if the engine is fully warmed up. If not
warmed up fully, the idle speed will measure
higher than normal. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer
or other qualified mechanic.
2. Verify whether the idle speed is set to
specification. For idle speed specifications, see page 42.
56
Page 62
Maintenance
EMU29073
Changing engine oil
EWM00760
WARNING
Avoid draining the engine oil immedi-
●
ately after stopping the engine. The oil
is hot and should be handled with care
to avoid burns.
●
Be sure the outboard motor is securely
fastened to the transom or a stable
stand.
ECM00970
CAUTION:
●
Do not overfill the oil, and be sure the
outboard motor is upright (not tilted)
when checking and changing the engine oil.
●
If the oil level is above the upper level
mark, drain until the level meets the
specified capacity. Overfilling the oil
could cause leakage or damage.
ECM01240
CAUTION:
Change the engine oil after the first 10
hours of operation, and every 100 hours
or at 6-month intervals thereafter. Otherwise the engine will wear quickly.
NOTE:
Change the engine oil when the oil is still
warm.
1. Put the outboard motor in an upright position (not tilted).
ZMU02049
2. Prepare a suitable container that holds a
larger amount than the engine oil capacity. Loosen and remove the drain screw
while holding the container under the
drain hole. Then remove the oil filler cap.
Let the oil drain completely. Wipe up any
spilled oil immediately.
1
ZMU02056
1. Drain screw
3. Put a new gasket on the oil drain screw.
Apply a light coat of oil to the gasket and
install the drain screw.
Drain screw tightening torque:
28.0 Nm (20.7 ft-lb) (2.86 kgf-m)
57
NOTE:
If a torque wrench is not available when you
are installing the drain screw, finger tighten
the screw just until the gasket comes into
contact with the surface of the drain hole.
Page 63
Maintenance
Then tighten 1/4 to 1/2 turn more. Tighten
the drain screw to the correct torque with a
torque wrench as soon as possible.
4. Add the correct amount of oil through the
filler hole. Install the filler cap.
Recommended engine oil:
4-stroke outboard motor oil
Engine oil quantity (excluding oil filter):
1.0 L (1.06 US qt) (0.88 Imp.qt)
ZMU02057
5. Start the engine and watch to make sure
the low oil pressure warning indicator (if
equipped) turns off. Make sure that
there are no oil leaks.
ECM00680
CAUTION:
If the low oil pressure warning indicator
does not turn off or if there are oil leaks,
stop the engine and find the cause. Continued operation with a problem could
cause severe engine damage. Consult
your Yamaha dealer if the problem cannot be located and corrected.
6. Turn off the engine and wait 3 minutes.
Recheck the oil level using the dipstick
to be sure the level falls between the upper and lower marks. Fill with oil if it is
below the lower mark, or drain to the
specified level if it is above the upper
mark.
ZMU02058
7. Dispose of used oil according to local
regulations.
NOTE:
●
For more information on the disposal of
used oil, consult your Yamaha dealer.
●
Change the oil more often when operating
the engine under adverse conditions such
as extended trolling.
EMU29111
Checking wiring and connectors
●
Check that each grounding wire is properly
secured.
●
Check that each connector is engaged securely.
ZMU02087
EMU29120
Exhaust leakage
Start the engine and check that no exhaust
leaks from the joints between the exhaust
cover, cylinder head, and body cylinder.
58
Page 64
Maintenance
EMU29130
Water leakage
Start the engine and check that no water
leaks from the joints between the exhaust
cover, cylinder head, and body cylinder.
EMU29140
Engine oil leakage
Check for oil leaks on the around the engine.
NOTE:
If any leaks are found, consult your Yamaha
dealer.
EMU29161
Checking power trim and tilt system
EWM00430
WARNING
●
Never get under the lower unit while it
is tilted, even when the tilt support lever
is locked. Severe injury could occur if
the outboard motor accidentally falls.
●
Make sure no one is under the outboard
motor before performing this test.
1. Check the power trim and tilt unit for any
sign of oil leaks.
that the trim and tilt rod is pushed out
completely.
4. Check that the trim and tilt rod is free of
corrosion or other flaws.
5. Tilt the outboard motor down. Check
that the trim and tilt rod operates
smoothly.
NOTE:
Consult your Yamaha dealer if any operation
is abnormal.
EMU29171
Checking propeller
EWM00321
WARNING
You could be seriously injured if the engine accidentally starts when you are
near the propeller.
●
Before inspecting, removing, or installing the propeller, remove the spark
plug caps from the spark plugs. Also,
place the shift control in neutral, turn
the main switch to “” (off) and re-
move the key, and remove the lanyard
from the engine stop 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.
1. Tilt rod
2. Operate each of the power trim and tilt
switches / the power tilt switches on the
remote control and engine bottom cowling (if equipped) to check that all switches work.
3. Tilt the outboard motor up and check
59
Page 65
ZMU02059
ZMU01897
Checkpoints
●
Check each of the propeller blades for
wear, erosion from cavitation or ventilation, or other damage.
●
Check the propeller shaft for damage.
●
Check the splines / shear pin for wear or
damage.
●
Check for fish line tangled around the propeller shaft.
Maintenance
NOTE:
If the shear pin equipped: it is designed to
break if the propeller hits a hard underwater
obstacle to help protect the propeller and
drive mechanism. The propeller will then
spin freely on the shaft. If this happens, the
shear pin must be replaced.
EMU29193
Removing the propeller
1. Straighten the cotter pin and pull it out
using a pair of pliers.
2. Remove the propeller nut, washer, and
spacer (if equipped).
1
2
3
4
5
ZMU02062
1. Cotter pin
2. Propeller nut
3. Washer
4. Propeller
5. Thrust washer
3. Remove the propeller and thrust washer.
EMU29211
Removing the propeller
1. Straighten the cotter pin and pull it out
using a pair of pliers.
●
Check the propeller shaft oil seal for damage.
60
Page 66
Maintenance
1
2
3
4
5
6
1. Cotter pin
2. Propeller nut
3. Washer
4. Deflector
5. Propeller
6. Thrust washer
2. Remove the propeller nut and washer.
3. Remove the deflector, propeller, and
thrust washer.
EMU29230
Installing the propeller
ECM00340
CAUTION:
Be sure to install the thrust washer be-
●
fore installing the propeller, otherwise
the lower case and propeller boss
could be damaged.
●
Be sure to use a new cotter pin and
bend the ends over securely. Otherwise
the propeller could come off during operation and be lost.
1. Apply Yamaha marine grease or a corrosion resistant grease to the propeller
shaft.
2. Install the spacer(if equipped), thrust
washer, and propeller on the propeller
shaft.
3. Install the spacer (if equipped) and the
washer. Tighten the propeller nut to the
specified torque.
ZMU02329
4. Align the propeller nut with the propeller
shaft hole. Insert a new cotter pin in the
hole and bend the cotter pin ends.
ZMU02063
NOTE:
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.
EMU29261
Installing the propeller
ECM00340
CAUTION:
●
Be sure to install the thrust washer before installing the propeller, otherwise
the lower case and propeller boss
could be damaged.
Be sure to use a new cotter pin and
●
bend the ends over securely. Otherwise
the propeller could come off during operation and be lost.
1. Apply Yamaha marine grease or a corrosion resistant grease to the propeller
shaft.
2. Install the thrust washer and propeller
on the propeller shaft. Install the deflector on the propeller.
3. Install the washer and tighten the propeller nut to the specified torque.
4. Align the propeller nut with the propeller
shaft hole. Insert a new cotter pin in the
61
Page 67
hole and bend the cotter pin ends.
ZMU02063
NOTE:
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.
EMU29280
Changing gear oil
EWM00800
WARNING
●
Be sure the outboard motor is securely
fastened to the transom or a stable
stand. You could be severely injured if
the outboard motor falls on you.
●
Never get under the lower unit while it
is tilted, even when the tilt support lever
or knob is locked. Severe injury could
occur if the outboard motor accidentally falls.
1. Tilt the outboard motor so that the gear
oil drain screw is at the lowest point possible.
2. Place a suitable container under the
gear case.
3. Remove the gear oil drain screw.
Maintenance
2
1
ZMU02064
1. Gear oil drain screw
2. Oil level plug
NOTE:
If the magnetic gear oil drain screw
equipped: remove all metal particles from
the screw before installing it.
4. Remove the oil level plug to allow the oil
to drain completely.
ECM00710
CAUTION:
Inspect the used oil after it has been
drained. If the oil is milky, water is getting
into the gear case which can cause gear
damage. Consult a Yamaha dealer for repair of the lower unit seals.
NOTE:
For disposal of used oil consult your Yamaha
dealer.
5. With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into
62
Page 68
Maintenance
the gear oil drain screw hole.
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
F13.5AMH 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
F15AE 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
F15AEH 250.0 cm3 (8.45 US oz)
(8.82 Imp.oz)
F15AEP 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
F15AMH 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
F9.9CE 250.0 cm3 (8.45 US oz)
(8.82 Imp.oz)
F9.9CMH 250.0 cm
3
(8.45 US oz)
(8.82 Imp.oz)
FT9.9DE 370.0 cm
3
(12.51 US oz)
(13.05 Imp.oz)
FT9.9DMH 370.0 cm3 (12.51 US oz)
(13.05 Imp.oz)
EMU29302
Cleaning fuel tank
EWM00920
WARNING
Gasoline is highly flammable, and its vapors are flammable and explosive.
●
If you have any question about properly
doing this procedure, consult your
Yamaha dealer.
●
Keep away from sparks, cigarettes,
flames, or other sources of ignition
when cleaning the fuel tank.
●
Remove the fuel tank from the boat before 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 local regulations.
1. Empty the fuel tank into an approved
container.
2. Pour a small amount of suitable solvent
into the tank. Install the cap and shake
the tank. Drain the solvent completely.
3. Remove the screws holding the fuel joint
assembly. Pull the assembly out of the
tank.
ZMU02065
6. When the oil begins to flow out of the oil
level plug hole, insert and tighten the oil
level plug.
7. Insert and tighten the gear oil drain
screw.
63
ZMU02066
Page 69
4. Clean the filter (located on the end of the
suction pipe) in a suitable cleaning solvent. Allow the filter to dry.
5. Replace the gasket with a new one. Reinstall the fuel joint assembly and tighten
the screws firmly.
EMU29312
Inspecting and replacing anode(s)
Yamaha outboard motors are protected from
corrosion by sacrificial anodes. Inspect the
external anodes periodically. Remove scales
from the surfaces of the anodes. Consult a
Yamaha dealer for replacement of external
anodes.
ECM00720
CAUTION:
Do not paint anodes, as this would render
them ineffective.
Maintenance
ZMU02067
ZMU02924
NOTE:
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.
EMU29320
Checking battery (for electric start
models)
EWM00330
WARNING
Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is
poisonous and highly caustic.
Always follow these preventive measures:
●
Avoid bodily contact with electrolytic
64
Page 70
Maintenance
fluid as it can cause severe burns or
permanent eye injury.
Wear protective eye gear when han-
●
dling or working near batteries.
Antidote (EXTERNAL):
SKIN - Flush with water.
●
●
EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
●
Drink large quantities of water or milk
followed by milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive hydrogen gas; therefore, you should always
follow these preventive measures:
●
Charge batteries in a well-ventilated ar-
ea.
●
Keep batteries away from fire, sparks,
or open flames (for example: welding
equipment, lighted cigarettes, and so
on.)
●
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
ECM00360
CAUTION:
●
A poorly maintained battery will quickly
deteriorate.
●
Ordinary tap water contains minerals
harmful to a battery, and should not be
used for topping up.
1. Check the electrolyte level at least once
a month. Fill to the manufacturer’s recommended level when necessary. Top
up only with distilled water (or pure deionized water suitable to use in batteries).
2. Always keep the battery in a good state
of charge. Installing a voltmeter will help
you monitor your battery. If you will not
use the boat for a month or more, remove the battery from the boat and store
it in a cool, dark place. Completely recharge the battery before using it.
3. If the battery will be stored for longer
than a month, check the specific gravity
of the fluid at least once a month and recharge the battery when it is low.
NOTE:
Consult a Yamaha dealer when charging or
re-charging batteries.
EMU29331
Connecting the battery
EWM00570
WARNING
Mount the battery holder securely in a
dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder.
ECM01121
CAUTION:
●
Make sure the main switch (on applicable models) is “” (off) before work-
ing on the battery.
●
Reversal of the battery cables will damage the electrical parts.
●
Connect the red battery cable first
65
Page 71
when installing the battery and disconnect the black battery cable first when
removing it. Otherwise, the electrical
parts can be damaged.
●
The electrical contacts of the battery
and cables must be clean and properly
connected, or the battery will not start
the engine.
Maintenance
Connect the red battery cable to the POSITIVE (+) terminal first. Then connect the
black battery cable to the NEGATIVE (-) terminal.
1. Red cable
2. Black cable
3. Battery
EMU29370
Disconnecting the battery
Disconnect the BLACK cable from the NEGATIVE (-) terminal first. Then disconnect the
RED cable from the POSITIVE (+) terminal.
EMU29390
Checking top cowling
Check the fitting of the top cowling by pushing it with both hands. If it is loose have it repaired by your Yamaha dealer.
ZMU02068
EMU29400
Coating the boat bottom
A clean hull improves boat performance. The
boat bottom should be kept as clean of marine growth as possible. If necessary, the
boat bottom can be coated with an anti-fouling paint approved for your area to inhibit
marine growth.
Do not use anti-fouling paint which includes
copper or graphite. These paints can cause
more rapid engine corrosion.
ZMU01943
66
Page 72
Trouble Recovery
EMU29422
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 warning 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 24.
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 stop switch lanyard not attached?
A. Attach lanyard.
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.
67
Page 73
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 warning system activated?
A. Find and correct cause of warning.
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.
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.
Warning 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 specified engine oil not being used?
A. Check and replace oil as specified.
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 heat range of spark plug incorrect?
A. Inspect spark plug and replace it with recommended type.
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?
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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 ignition parts failed?
A. Have serviced by a Yamaha dealer.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Has warning system activated?
A. Find and correct cause of warning.
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.
69
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?
A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect?
A. Connect correctly.
Page 75
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.
Trouble Recovery
board motor unsafe to operate.
If the outboard motor hits an object in the water, follow the procedure below.
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.
EMU29432
Temporary action in
emergency
EMU29440
Impact damage
EWM00870
WARNING
The outboard motor can be seriously
damaged by a collision while operating or
trailering. Damage could make the out-
1. Stop the engine immediately.
2. Inspect the control system and all components for damage. Also inspect the
boat for damage.
3. Whether damage is found or not, return
to the nearest harbor slowly and carefully.
4. Have a Yamaha dealer inspect the outboard motor before operating it again.
EMU29462
Replacing fuse
If the fuse has blown on an electric start
model, open the fuse holder and replace the
fuse with a new one of the proper amperage.
EWM00630
WARNING
Be sure to use the specified fuse. An incorrect fuse or a piece of wire could allow
excessive current flow. This could cause
electric system damage and a fire hazard.
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Trouble Recovery
3
2
1
ZMU02092
1. Fuse holder
2. Fuse (20 A)
3. Spare fuse (20 A)
NOTE:
Consult your Yamaha dealer if the new fuse
immediately blows again.
EMU29520
Power trim and tilt will not operate
If the engine cannot be tilted up or down with
the power trim and tilt/ the power tilt because
of a discharged battery or a failure with the
power trim and tilt unit/the power tilt, the engine can be tilted manually.
1. Loosen the manual valve screw by turning it counterclockwise until it stops.
1. Manual valve screw
2. Put the engine in the desired position,
then tighten the manual valve screw by
turning it clockwise.
EMU29531
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.
EWM01020
WARNING
●
Use this procedure only in an emergency and only to return to port for repairs.
When the emergency starter rope is
●
used to start the engine, the start-ingear protection device does not operate. Make sure the remote control lever
is in neutral. Otherwise the boat could
unexpectedly start to move, which
could result in an accident.
●
Attach the engine stop switch lanyard
to a secure place on your clothing, or
your arm or leg while operating.
●
Do not attach the lanyard to clothing
that could tear loose. Do not route the
cord where it could become entangled,
preventing it from functioning.
●
Avoid accidentally pulling the lanyard
during normal operation. Loss of engine power means the loss of most
steering control. Also, without engine
power, the boat could slow rapidly. This
could cause people and objects in the
boat to be thrown forward.
Be sure no one is standing behind you
●
when pulling the starter rope. It could
whip behind you and injure someone.
An unguarded, rotating flywheel is very
●
dangerous. Keep loose clothing and
other objects away when starting the
engine. Use the emergency starter rope
only as instructed. Do not touch the flywheel or other moving parts when the
engine is running. Do not install the
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starter mechanism or top cowling after
the engine is running.
Do not touch the ignition coil, spark
●
plug wire, spark plug cap, or other electrical components when starting or operating the motor. You could get an
electrical shock.
EMU29602
Emergency starting engine
1. Remove the top cowling.
2. Remove the cable by pulling out it from
the starter, if the cable is equipped.
1
ZMU02069
Trouble Recovery
ZMU02070
5. Prepare the engine for starting. For further information, see page 24. Be sure
the engine is in neutral and that the engine stop switch lanyard lock plate is attached to the engine stop switch.
1. Start-in-gear protection cable
3. Remove both ends of the choke link rod.
1
ZMU02332
1. Choke link rod
4. Remove the starter/flywheel cover after
removing the 3 bolts. Disconnect the
wire leads from the starter/flywheel cover.
ZMU02026
ZMU02334
6. Pull up the lever on the carburetor to operate the choke system when the engine
is cold. After the engine starts, return the
lever to the original position.
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Trouble Recovery
ZMU02333
7. Insert the knotted end of the emergency
starter rope into the notch in the flywheel
rotor and wind the rope around the flywheel several turns clockwise.
ZMU02074
8. Pull the rope slowly until resistance is
felt.
9. Give a strong pull straight out to crank
and start the engine. Repeat if necessary.
EMU29760
Treatment of submerged motor
If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise
some corrosion may begin almost immediately.
If you cannot immediately take the outboard
motor to a Yamaha dealer, follow the procedure below in order to minimize engine damage.
EMU29783
Procedure
1. Thoroughly wash away mud, salt, seaweed, and so on, with fresh water.
2. Remove the spark plug(s), then face the
spark plug holes downward to allow any
water, mud, or contaminants to drain.
3. Drain the fuel from the carburetor, fuel
filter, and fuel line. Drain the engine oil
completely.
4. Fill the sump with the fresh engine oil.
Engine oil capacity:
1.0 L (1.06 US qt) (0.88 Imp.qt)
5. Feed engine fogging oil or engine oil
through the carburetor(s) and spark plug
holes while cranking the engine with the
manual starter or emergency starter
rope.
6. Take the outboard motor to a Yamaha
dealer as soon as possible.
ECM00400
CAUTION:
Do not attempt to run the outboard motor
until it has been completely inspected.
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Page 80
YAMAHA MOTOR CO., LTD.
Printed in Japan
March 2004–0.9 × 1
!
Printed on recycled paper
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