Yamaha F4D Owner's Manual

F4D

OWNER’S MANUAL

68D-F8199-14

U.S.A.Edition

LIT-18626-05-97

EMU25060

ZMU01690

Read this owner’s manual carefully before operating your outboard motor.

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!

WARNING

EWM00780

Failure to follow WARNING instructions
could result in severe injury or death

to
the machine operator, a bystander, or a
person inspecting or repairing the out­board motor.

CAUTION:

ECM00700

A CAUTION indicates special precautions
that must be taken to avoid damage to the
outboard motor.

NOTE:

A NOTE provides key information to make
procedures easier or clearer.

Yamaha continually seeks 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-

al, please consult your Yamaha dealer.

NOTE:

The F4MH 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.

EMU25130

F4D

OWNER’S MANUAL

©2004 by Yamaha Motor Corporation, USA

1st Edition, January 2004

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in France

P/N LIT-18626-05-97

Table of contents

General information .......................... 1

Identification numbers record.......... 1

Outboard motor serial number .......... 1

Emission control information ........... 1

North American models..................... 1

Star labels ......................................... 2

Safety information .......................... 3

Important labels............................... 4

Warning labels .................................. 4

Caution labels ................................... 4

Basic boating rules (Rules of the

road) .............................................. 5

Steering and sailing rules and sound

signals............................................. 5

Rules when encountering vessels .... 5

Other special situations..................... 6

Fueling instructions ......................... 8

Gasoline............................................ 9

Engine oil .......................................... 9

Propeller selection........................... 9

Start-in-gear protection ................. 10

Basic components .......................... 11

Main components.......................... 11

Fuel tank ......................................... 11

Fuel tank ......................................... 12

Fuel joint ......................................... 12

Fuel gauge ...................................... 12

Fuel tank cap .................................. 12

Air vent screw ................................. 12

Fuel cock......................................... 12

Open ............................................... 13

Tiller handle .................................... 13

Gear shift lever................................ 13

Throttle grip..................................... 14

Throttle indicator ............................. 14

Throttle friction adjuster................... 14

Engine stop lanyard switch ............. 15

Engine stop button .......................... 15

Choke knob for pull type ................. 15

Manual starter handle ..................... 16

Steering friction adjuster ................. 16

Trim rod (tilt pin).............................. 16

Tilt lock mechanism......................... 16

Tilt support bar ................................ 16

Top cowling lock lever (pull up

type) .............................................. 17

Carrying handle............................... 17

Operation ......................................... 18

Installation..................................... 18

Mounting the outboard motor .......... 18

Clamping the outboard motor.......... 19

Breaking in engine ........................ 20

Procedure for 4-stroke models........ 20

Preoperation checks ..................... 20

Fuel ................................................. 20

Controls........................................... 20

Engine ............................................. 21

Checking the engine oil level ..........21

Filling fuel...................................... 21

Operating engine .......................... 22

Feeding fuel ....................................22

Starting engine ................................ 23

Warming up engine....................... 25

Manual start models........................ 25

Shifting.......................................... 25

Forward (tiller handle and remote

control models) .............................26

Reverse........................................... 26

Stopping engine............................ 26

Procedure........................................ 26

Trimming outboard motor.............. 27

Adjusting trim angle for manual tilt

models ..........................................28

Adjusting boat trim ..........................28

Tilting up and down....................... 29

Procedure for tilting up (manual tilt

models) ......................................... 30

Procedure for tilting down (manual

tilt models)..................................... 31

Cruising in shallow water .............. 32

Cruising in shallow water (manual

tilt models)..................................... 32

Cruising in other conditions........... 33

Maintenance .................................... 34

Specifications................................ 34

Transporting and storing

outboard motor ........................... 35

Clamp screw mounting models .......35

Storing outboard motor ...................36

Procedure........................................ 36

Table of contents

Lubrication (except oil injection

models) ......................................... 37

Cleaning and anticorrosion

measures ...................................... 37

Cleaning the outboard motor .......... 38

Checking painted surface of

motor............................................. 38

Periodic maintenance.................... 38

Replacement parts.......................... 38

Maintenance chart .......................... 39

Greasing ......................................... 40

Cleaning and adjusting spark plug.. 40

Checking fuel system...................... 41

Checking fuel filter .......................... 42

Inspecting idling speed ................... 42

Changing engine oil ........................ 43

Checking wiring and connectors ..... 44

Exhaust leakage ............................. 44

Water leakage................................. 44

Engine oil leakage........................... 44

Checking propeller .......................... 44

Removing the propeller................... 45

Installing the propeller..................... 45

Changing gear oil............................ 46

Cleaning fuel tank ........................... 47

Inspecting and replacing anode(s).. 47

Checking top cowling ...................... 48

Coating the boat bottom.................. 48

Trouble Recovery............................ 49

Troubleshooting ............................ 49

Temporary action in

emergency .................................. 52

Impact damage ............................... 52

Starter will not operate .................... 52

Emergency starting engine ............. 53

Treatment of submerged motor..... 54

Procedure ....................................... 54

Consumer information....................56

Important warranty information for

U.S.A. and Canada ..................... 56

YAMAHA MOTOR

CORPORATION, U.S.A.
FOUR-STROKE OUTBOARD
MOTOR THREE-YEAR LIMITED

WARRANTY ................................ 58

IMPORTANT WARRANTY

INFORMATION IF YOU USE
YOUR YAMAHA OUTSIDE

U.S.A. OR CANADA ................... 60

1

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.

EMU25220

Emission control information

EMU25230

North American models

This engine conforms to U.S. Environmental
Protection Agency (EPA) regulations for ma­rine SI engines. See the label affixed to your

engine for details.

EMU25241

Approval label of emission control certif­icate

This label is attached to the bottom cowling.
New Technology; (4-stroke/HPDI) EM

EMU25261

Manufactured date label

This label is attached to the clamp bracket or
the swivel bracket.

1. Outboard motor serial number location

1. Approval label location

1

ZMU02653

ZMU01699

General information

2

EMU25272

Star labels

Your outboard motor is labeled with a Cali­fornia Air Resources Board (CARB) star la­bel. See below for a description of your
particular label.

EMU25280

One Star—Low Emission

The one-star label identifies engines that
meet the Air Resources Board’s 2001 ex­haust emission standards. Engines meeting
these standards have 75% lower emissions
than conventional carbureted two-stroke en­gines. These engines are equivalent to the
U.S. EPA’s 2006 standards for marine en­gines.

EMU25290

Two Stars—Very Low Emission

The two-star label identifies engines that
meet the Air Resources Board’s 2004 ex­haust emission standards. Engines meeting
these standards have 20% lower emissions
than One Star-Low-Emission engines.

EMU25300

Three Stars—Ultra Low Emission

The three-star label identifies engines that
meet the Air Resources Board’s 2008 ex­haust emission standards. Engines meeting

1. Manufactured date label location

1. Star labels location

ZMU02651

1

Manufactured:

ZMU04346

ZMU04509

1

ZMU01702

ZMU01703

General information

3

these standards have 65% lower emissions
than One Star-Low-Emission engines.

EMU25360

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 own­er’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
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 non-

swimmers 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 cord
to a secure place on your clothing, or your
arm or leg while operating. If you acciden­tally leave the helm, the cord will pull from
the switch, stopping the engine.

●

Know the marine laws and regulations
where you will be boating—and obey
them. For basic boating rules, see “Rules
of the road” on page 5.

●

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

ZMU01704

General information

4

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.
Be informed about boating safety. Additional
publications and information can be obtained
from many organizations, including the fol­lowing:

United States Coast Guard

Consumer Affairs Staff (G-BC)
Office of Boating, Public, and Consumer Af­fairs
U.S. Coast Guard Headquarters
Washington, D.C. 20593-0001
Boating Safety Hotline: [phone]

National Marine Manufacturers Associa­tion (NMMA)

401 N. Michigan Ave.
Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave.
Chicago, Il 60601

EMU25380

Important labels

EMU25395

Warning labels

EMU25401

Label

WARNING

EWM01260

●

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

WARNING

EWM01300

●

This engine is equipped with a neutral
starting device.

●

The engine will not start unless the shift
control is in neutral position.

EMU25441

Label

WARNING

EWM01311

LEAKING FUEL COULD CAUSE A FIRE.
Before tilting up the engine or laying it on
its side:

●

Turn the fuel cock to the “closed” posi­tion.

●

Tighten the air-vent screw on the fuel
tank cap.

EMU25464

Caution labels

ZMU02654

ZMU02655

General information

5

EMU25481

Label

CAUTION:

ECM01200

Store the engine only as shown.
Otherwise, engine damage could result
from Leaking oil.

EMU25500

Basic boating rules (Rules of

the road)

Just as there are rules which apply when you
are driving on streets and high ways, there
are waterway rules which apply when you
are driving your boat. These rules are used
internationally, and are also enforced by the
United States Coast Guard and local agen­cies. You should be aware of these rules,
and follow them whenever you encounter
another vessel on the water.
Several sets of rules prevail according to
geographic location, but are all basically the
same as the International Rules of the Road.
The rules presented here in your Owner’s
Manual are condensed, and have been pro­vided for your convenience only. Consult
your local U.S. Coast Guard Auxiliary or De­partment of Motor Vehicles for a complete
set of rules governing the waters in which
you will be using your boat.

EMU25510

Steering and sailing rules and sound
signals

Whenever two vessels on the water meet
one another, one vessel has the right-of­way; it is called the “stand-on” vessel. The
vessel which does not have the right-of-way
is called the “give-way” or “burdened” vessel.
These rules determine which vessel has the
right-of-way, and what each vessel should
do.

Stand-on vessel

The vessel with the right-of-way has the duty
to continue its course and speed, except to
avoid an immediate collision. When you
maintain your direction and speed, the other
vessel will be able to determine how best to
avoid you.

Give-way vessel

The vessel which does not have the right-of­way has the duty to take positive and timely
action to stay out of the way of the Stand-On
vessel. Normally, you should not cross in
front of the vessel with the right-of-way. You
should slow down or change directions brief­ly and pass behind the other vessel. You
should always move in such a way that the
operator of the other vessel can see what
you are doing.

“The general prudential rule”

This rule is called Rule 2 in the International
Rules and says,
“In obeying and construing these rules due
regard shall be had to all dangers of naviga­tion and collision, and to any special circum­stances, which may render a departure from
the above rules necessary in order to avoid
immediate danger.”
In other words, follow the standard rules ex­cept when a collision will occur unless both
vessels try to avoid each other. If that is the
case, both vessels become “Give-Way” ves­sels.

EMU25520

Rules when encountering vessels

There are three main situations which you
may encounter with other vessels which
could lead to a collision unless the Steering
Rules are followed:

Meeting:

(you are approaching another ves-

sel head-on)

Crossing:

(you are traveling across the oth-

er vessel’s path)

General information

6

Overtaking:

(you are passing or being
passed by another vessel)
In the following illustration, your boat is in the
center. You should give the right-of-way to
any vessels shown in white area (you are the
Give-Way vessel). Any vessels in the shad­ed area must yield to you (they are the Give­Way vessels). Both you and the meeting
vessel must alter course to avoid each other.

Meeting

If you are meeting another power vessel
head on, and are close enough to run the risk
of collision, neither of you has the right-of­way! Both of you should alter course to avoid
an accident. You should keep the other ves­sel on your port (left) side. This rule doesn’t

apply if both of you will clear one another if
you continue on your set course and speed.

Crossing

When two power driven vessels are crossing
each other’s path close enough to run the

risk of collision, the vessel which has the oth­er on the starboard (right) side must keep out
of the way of the other. If the other vessel is
on your right, you must keep out of its way;
you are the Give-Way vessel. If the other
vessel is on your port (left) side, remember
that you should maintain course and direc­tion, provided the other vessel gives you the
right-of-way as it should.

Overtaking

If you are passing another vessel, you are
the “Give-Way” vessel. This means that the
other vessel is expected to maintain its
course and speed. You must stay out of its
way until you are clear of it. Likewise, if an­other vessel is passing you, you should
maintain your speed and direction so that the
other vessel can steer itself around you.

EMU25530

Other special situations

There are three other rules you should be
aware of when driving your boat around oth­er vessels.

Narrow channels and bends

When navigating in narrow channels, you
should keep to the right when it is safe and
practical to do so. If the operator of a power­driven vessel is preparing to go around a
bend that may obstruct the view of other wa­ter vessels, the operator should sound a pro­longed blast on the whistle (4 to 6 seconds).

General information

7

If another vessel is around the bend, it too
should sound the whistle. Even if no reply is
heard, however, the vessel should still pro­ceed around the bend with caution. If you
navigate such waters with your boat, you will
need to carry a portable air horn, available
from local marine supply stores.

Fishing vessel right-of-way

All vessels which are fishing with nets, lines
or trawls are considered to be “fishing ves­sels” under the International Rules. Vessels
with trolling lines are not considered fishing
vessels. Fishing vessels have the right-of­way regardless of position. Fishing vessels
cannot, however, impede the passage of
other vessels in narrow channels.

Sailing vessel right-of-way

Sailing vessels should normally be given the
right-of-way. The exceptions to this are:

1. When the sailing vessel is overtaking

the power-driven vessel, the power-driv­en vessel has the right-of-way.

2. Sailing vessels should keep clear of any

fishing vessel.

3. In a narrow channel, a sailing vessel

should not hamper the safe passage of
a power-driven vessel which can navi­gate only in such a channel.

Reading buoys and other markers

The waters of the United states are marked
for safe navigation by the lateral system of
buoyage. Simply put, buoys and markers
have an arrangement of shapes, colors,
numbers and lights to show which side of the
buoy a boater should pass on when navigat­ing in a particular direction. The markings on
these buoys are oriented from the perspec­tive of being entered from seaward (the boat­er is going towards the port). This means that
red buoys are passed on the starboard
(right) side when proceeding from open wa-

ter into port, and black buoys are to port (left)
side. When navigating out of port, your posi­tion with respect to the buoys should be re­versed; red buoys should be to port and
black buoys to starboard.
Many bodies of water used by boaters are
entirely within the boundaries of a particular
state. The Uniform State Waterway Marking
System has been devised for these waters.
This system uses buoys and signs with dis­tinctive shapes and colors to show regulato­ry or advisory information. These markers
are white with black letters and orange
boarders. They signify speed zones, restrict­ed areas, danger areas, and general infor­mation.
Remember, markings may vary by geo­graphic location. Always consult local boat­ing authorities before driving your boat in
unfamiliar waters.

General information

8

EMU25540

Fueling instructions

WARNING

EWM00010

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 gaso­line spills, wipe it up immediately with

ZMU01708

General information

9

dry rags.

●

Do not overfill the fuel tank.

●

Tighten the filler cap securely after re­fueling.

●

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.

CAUTION:

ECM00010

Use only new clean gasoline which has
been stored in clean containers and is not
contaminated with water or foreign mat­ter.

EMU25570

Gasoline

If knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel.

Gasohol

There are two types of gasohol: gasohol con­taining ethanol and that containing metha­nol. Gasohol containing ethanol can be used
if ethanol content does not exceed 10% and
the fuel meets minimum octane ratings.
Yamaha does not recommended gasohol
containing methanol because it can cause
fuel system damage or engine performance
problems.

EMU25680

Engine oil

CAUTION:

ECM01050

All 4-stroke engines are shipped from the
factory without engine oil.

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

Recommended gasoline:

Regular unleaded gasoline with a min­imum octane rating of 86 (Pump Oc­tane Number) = (R+M)/2

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):

0.5 L (0.53 US qt) (0.44 Imp.qt)

ZMU01710

General information

10

on the propeller size and boat load. If engine
speed is too high or too low for good engine
performance, this will have an adverse effect
on the engine.
Yamaha outboard motors are fitted with pro­pellers chosen to perform well over a range
of applications, but there may be uses where
a propeller with a different pitch would be
more appropriate. For a greater operating
load, a smaller-pitch propeller is more suit­able as it enables the correct engine speed
to be maintained. Conversely, a larger-pitch
propeller is more suitable for a smaller oper­ating load.
Yamaha dealers stock a range of propellers,
and can advise you and install a propeller on
your outboard that is best suited to your ap­plication.

NOTE:

Select a propeller which will allow the engine
to reach the middle or upper half of the oper­ating range at full throttle with the maximum
boat load. If operating conditions such as
light boat loads then allow the engine r/min to
rise above the maximum recommended
range, reduce the throttle setting to maintain

the engine in the proper operating range.

For instructions on propeller removal and in­stallation, see page 44.

EMU25770

Start-in-gear protection

Yamaha outboard motors or Yamaha-ap­proved remote control units are equipped
with start-in-gear protection device(s). This
feature permits the engine to be started only
when it is in neutral. Always select neutral
before starting the engine.

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

ZMU02656

7-1/4 x7-1/4-BA

1

23

11

Basic components

EMU25795

Main components

NOTE:

* May not be exactly as shown; also may not be included as standard equipment on all mod­els.

F4D

EMU25802

Fuel tank

If your model was equipped with a portable
fuel tank, its function is as follows.

WARNING

EWM00020

The fuel tank supplied with this engine is

1

2

4

8

7

6

9

3

5

10

2

11

14

18

17

16

13

12

15

19

ZMU04483

20

1. Top cowling

2. Top cowling lock lever

3. Carrying handle

4. Steering friction screw

5. Anti-cavitation plate

6. Propeller

7. Cooling water inlet

8. Trim rod

9. Clamp bracket

10. Tiller handle

11. Air vent screw

12. Fuel tank cap

13. Manual starter handle

14. Engine stop button/Engine stop lanyard
switch

15. Clamp screw

16. Rope attachment

17. Fuel joint

18. Choke knob

19. Gear shift lever

20. Fuel tank*

Basic components

12

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.

EMU25821

Fuel tank

If your model included a fuel tank, its parts
and functions are as follows.

EMU25830

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,
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.

EMU25872

Fuel cock

The fuel cock turns on and off the supply of
fuel from the fuel tank to the engine.

EMU25881

Close

To stop fuel flow to the engine, turn the lever
or knob to close position.
Always turn the lever or knob to close posi­tion when the engine is not running.

1. Air vent screw

2. Fuel gauge

3. Fuel joint

4. Fuel tank cap

1. Air vent screw

2. Built-in fuel tank

3. Fuel tank cap

ZMU01992

3

2

4

1

ZMU02658

1

3

2

1. Fuel cock

ZMU02659

1

Basic components

13

EMU25901

Open

The fuel cock has two open positions, one for
selecting fuel flow from the built-in fuel tank,
and one for an external tank.
Fuel flows to the carburetor with the lever or
knob in either open position. These are the
normal running positions.

EMU25911

Tiller handle

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

EMU25921

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.

1. Close position

1. “OPEN” position for the built-in tank

ZMU02659

1

ZMU02661

1

1. “OPEN” position for the portable tank

ZMU02652

1

ZMU02662

Basic components

14

EMU25941

Throttle grip

The throttle grip is on the tiller handle. Turn
the grip counterclockwise to increase speed
and clockwise to decrease speed.

EMU25961

Throttle indicator

The fuel consumption curve on the throttle
indicator shows the relative amount of fuel
consumed for each throttle position. Choose
the setting that offers the best performance
and fuel economy for the desired operation.

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.

WARNING

EWM00030

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.

When constant speed is desired, tighten the
adjuster to maintain the desired throttle set­ting.

1. Forward “”

2. Neutral “”

3. Reverse “”

2

N

1

F

3

R

ZMU02663

ZMU02664

1. Throttle indicator

1

ZMU02665

ZMU02666

Basic components

15

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.

WARNING

EWM00120

●

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 engine cannot be started with the lock
plate removed.

EMU26001

Engine stop button

To open the ignition circuit and stop the en­gine, push this button.

EMU26011

Choke knob for pull type

To supply the engine with the rich fuel mix­ture required to start, pull out this knob.

1. Lanyard

2. Lock plate

2

1

ZMU02667

ZMU02668

ZMU02669

Basic components

16

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.

EMU26121

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.

To increase resistance, turn the adjuster
clockwise.
To decrease resistance, turn the adjuster
counterclockwise.

WARNING

EWM00040

Do not overtighten the friction adjuster. If
there is too much resistance, it could be

difficult to steer, which could result in an
accident.

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.

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.

To lock it, set the tilt lock lever in the “”
(lock) position. To release, push the tilt lock
lever in the “” (release) position.

EMU26330

Tilt support bar

The tilt support bar keeps the outboard motor
in the tilted up position.

ZMU02670

ZMU02671

1. Tilt lock lever

ZMU02672

ZMU04497

1

Basic components

17

EMU26382

Top cowling lock lever (pull up type)

To remove the engine top cowling, pull up
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 by moving the lever(s) down­ward.

EMU26450

Carrying handle

A carrying handle is provided on the rear of
the outboard motor. It enables you to carry
the outboard motor easily with one hand.

1. Top cowling lock lever(s)

1. Top cowling lock lever(s)

ZMU02674

ZMU02675

1

ZMU04522

1

1. Carrying handle

ZMU02676

1

18

Operation

EMU26901

Installation

CAUTION:

ECM00110

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

WARNING

EWM00820

●

Overpowering a boat could cause se­vere instability. Do not install an out­board motor with more horsepower
than the maximum rating on the capac­ity plate of the boat. If the boat does not
have a capacity plate, consult the boat
manufacturer.

●

The information presented in this sec­tion is intended as reference only. It is
not possible to provide complete in­structions for every possible boat and
motor combination. Proper mounting
depends in part on experience and the

specific boat and motor combination.

WARNING

EWM00830

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.

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

1. Center line (keel line)

ZMU01760

1

Operation

19

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.

NOTE:

●

The optimum mounting height of the out­board motor is affected by the boat and
motor combination and the desired use.
Test runs at different heights can help de­termine the optimum mounting height.
Consult your Yamaha dealer or boat man­ufacturer for further information on deter­mining the proper mounting height.

●

For instructions on setting the trim angle of
the outboard motor, see page 27.

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.

WARNING

EWM00640

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.

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.

3. Secure the clamp bracket to the transom
using the bolts provided with the out-

ZMU02011

0–25mm
(0–1in.)

ZMU02012

ZMU02013

Operation

20

board (if packed). For details, consult
your Yamaha dealer.

WARNING

EWM00650

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.

EMU30171

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.

CAUTION:

ECM00800

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

WARNING

EWM00080

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.

CAUTION:

ECM00120

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 gaso­line 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 se­cure, 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-

1. Bolts

ZMU02637

1

Operation

21

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.

NOTE:

Be sure to completely insert the dipstick into
the dipstick guide.

EMU30540

Filling fuel

WARNING

EWM00060

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. Carefully fill the fuel tank.

1. Oil dipstick

ZMU02677

1

1. Lower level mark

2. Oil dipstick

3. Upper level mark

ZMU02678

2

3

1

ZMU04536

Operation

22

3. Securely close the cap after filling the
tank. Wipe up any spilled fuel.

NOTE:

The upper fuel level mark is indicated on the
built-in fuel tank.

EMU27450

Operating engine

EMU27472

Feeding fuel

WARNING

EWM00420

●

Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the

water near you.

●

When the air vent screw is loosened,
gasoline vapor will be released. Gaso­line is highly flammable, and its vapors
are flammable and explosive. Refrain
from smoking, and keep away from
open flames and sparks while loosen­ing the air vent screw.

●

This product emits exhaust gases
which contain carbon monoxide, a col­orless, odorless gas which could cause
brain damage or death when inhaled.
Symptoms include nausea, dizziness,
and drowsiness. Keep cockpit and cab­in areas well ventilated. Avoid blocking
exhaust outlets.

1. For the built in tank, loosen the air vent
screw on the fuel tank cap by one turn.
For the external fuel tank, loosen it on
the fuel tank cap by 2 or 3 turns.

2. Select the fuel tank using the fuel cock
or open the fuel cock.

Fuel tank capacity:

1.10 L (0.291 US gal) (0.2420 Imp.gal)

1. Upper level mark

ZMU04484

ZMU04537

1

Operation

23

3. If you are using an external fuel tank,
connect the fuel joints securely and
squeeze the primer pump with the outlet
end up until you feel it become firm (if
equipped the fuel joint).

EMU27490

Starting engine

EMU27505

Manual start models (tiller control)

1. Place the gear shift lever in neutral.

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.

WARNING

EWM00120

●

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

ZMU02681

ZMU02680

ZMU02679

ZMU02894

N

ZMU02682

Operation

24

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.

3. Place the throttle grip in the “”
(start) position.

4. Pull out / turn the choke knob fully. After
the engine starts, replace / return the
knob to the home position.

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.

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.

ZMU02683

ZMU02684

ZMU02669

ZMU02670

Operation

25

NOTE:

●

When the engine is cold, it needs to be
warmed up. For further information, see
page 25.

●

If the engine does not start on the first try,
repeat the procedure. If the engine fails to
start after 4 or 5 tries, open the throttle a
small amount (between 1/8 and 1/4) and
try again. Also if the engine is warm and
fails to start, open the throttle a same
amount and try to start the engine again. If
the engine still fails to start, see page 49.

EMU27670

Warming up engine

EMU27731

Manual start models

1. After starting the engine, return the
choke knob to the halfway position. For
approximately the first 5 minutes after
starting, warm up the engine by operat­ing at one fifth throttle or less. After the
engine has warmed up, push the choke
knob in fully. Failure to do so will shorten
engine life.

NOTE:

●

If the choke knob is left pulled out after the
engine starts, the engine will stall.

●

In temperatures of -5°C or less, leave the
choke knob pulled out fully for approxi­mately 30 seconds after starting.

2. Check for a steady flow of water from the
cooling water pilot hole.

CAUTION:

ECM00510

A flow of water from the hole on the ex­haust cover shows that the water pump is
pumping water through the cooling pas­sages. If water is not flowing out of the
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.

EMU27740

Shifting

WARNING

EWM00180

Before shifting, make sure there are no
swimmers or obstacles in the water near
you.

CAUTION:

ECM00220

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).

ZMU02685

ZMU02686

Operation

26

EMU27763

Forward (tiller handle and remote
control models)

Tiller control models

1. Place the throttle grip in the fully closed
position.

2. Move the gear shift lever quickly and
firmly from neutral to forward.

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.

EMU27801

Reverse

WARNING

EWM00190

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.

1. Place the throttle grip in the fully closed
position.

2. Move the gear shift lever quickly and
firmly from neutral to reverse.

NOTE:

The outboard motor can turn 360° in its
bracket (full-pivot system). The boat can also
be backed up by simply turning the outboard
motor around 180° with the steering handle
facing toward you.

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.

EMU27832

Procedure

1. Push and hold the engine stop button

ZMU02685

ZMU02687

N

F

ZMU02685

ZMU02688

R

N

Operation

27

until the engine comes to a complete
stop.

2. After stopping the engine, tighten the air
vent screw on the fuel tank cap and set
the fuel cock lever or knob to the closed
position, if equipped.

3. Disconnect the fuel line if you are using
an external fuel tank.

NOTE:

If the outboard motor is equipped with an en­gine stop switch lanyard, the engine can also
be stopped by pulling the lanyard and remov­ing the lock plate from the engine stop
switch.

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
also affected by variables such as the load in
the boat, sea conditions, and running speed.

WARNING

EWM00740

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.

ZMU02668

ZMU02660

ZMU02689

Operation

28

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.

2. Remove the trim rod from the clamp
bracket while slightly tilting the outboard
motor up.

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.

WARNING

EWM00400

●

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.

NOTE:

The outboard motor trim angle can be
changed approximately 4 degrees by shifting
the trim rod one hole.

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

1. Trim operating angle

ZMU02690

1

1. Trim rod

ZMU02691

1

Operation

29

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.

Bow Up

Too much trim-out puts the bow of the boat
too high in the water. Performance and econ­omy are decreased because the hull of the
boat is pushing the water and there is more
air drag. Excessive trim-out can also cause
the propeller to ventilate, which reduces per­formance further, and the boat may “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.

NOTE:

Depending on the type of boat, the outboard
motor trim angle may have little effect on the
trim of the boat when operating.

EMU27920

Tilting up and down

If the engine will be stopped for some time or
if the boat is moored in shallows, the out­board motor should be tilted up to protect the
propeller and casing from damage by colli­sion with obstructions, and also to reduce
salt corrosion.

Operation

30

WARNING

EWM00220

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.

WARNING

EWM00230

Leaking fuel is a fire hazard. Tighten the
air vent screw and place the fuel cock in
the closed position if the outboard motor
will be tilted for more than a few minutes.
Otherwise fuel may leak.

CAUTION:

ECM00230

●

Before tilting the outboard motor, fol­low the procedure under “Stopping en­gine”in this chapter. 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 because this could break
the handle.

●

Keep the power unit higher than the
propeller at all times. Otherwise water
could run into the cylinder and cause
damage.

●

The outboard motor cannot be tilted

when in reverse or when the outboard
motor is turned 180° (facing the rear).

EMU27964

Procedure for tilting up (manual tilt
models)

1. Place the gear shift lever in neutral (if
equipped) and face the outboard motor
forward.

2. On full-pivot system models, tighten the
steering friction adjuster by turning it
clockwise to prevent the motor from
turning freely.

3. Tighten the air vent screw. On models
equipped with a fuel joint, disconnect the
fuel line from the outboard motor.

ZMU02692

N

ZMU02682

ZMU02696

Operation

31

4. Close the fuel cock.

5. Tilt support bar equipped models: Hold
the rear of the top cowling or the rear
handle (if equipped) with one hand and
tilt the outboard motor up fully until the
tilt support bar automatically locks.

6. Tilt support knob equipped models: Hold
the rear of the top cowling with one
hand, fully tilt the outboard motor up,
and push the tilt support knob into the
clamp bracket.

7. Tilt support lever equipped models: Hold
the rear handle and tilt the engine up ful­ly until the tilt support lever automatically
locks.

NOTE:

Tilt support lever/bar equipped models: If the
motor is not facing forward, the tilt support le­ver/bar cannot automatically turn to the
locked position. If the tilt support lever/bar
does not automatically lock, swing the motor
a little to the left and right.

EMU28031

Procedure for tilting down (manual
tilt models)

1. Slightly tilt the outboard motor up.

2. If the tilt support bar equipped: Slowly tilt
the outboard motor down while pulling
the tilt support bar lever up.

ZMU02689

ZMU02660

ZMU02694

Operation

32

3. If the tilt support knob equipped: pull out
it, then slowly tilt the engine down.

4. Loosen the steering friction adjuster by
turning it counterclockwise, and adjust
the steering friction according to opera­tor preference.

WARNING

EWM00720

If there is too much resistance it could be
difficult to steer, which could result in an
accident.

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)

WARNING

EWM00710

●

Place the gear shift in neutral before us-

ing 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 re­verse. 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.

CAUTION:

ECM00260

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.

ZMU02673

ZMU02695

ZMU02697

Operation

33

EMU28101

Procedure

1. Place the gear shift lever in neutral and
face the outboard motor forward.

2. Slightly tilt the outboard motor up until
the tilt support bar automatically turns to
the lock position to support the engine.

3. To lower the outboard motor to the nor­mal running position, first slightly tilt the
outboard motor up. Then pull up the tilt
support bar lever and slowly tilt the en­gine down.

NOTE:

The outboard motor is equipped with 2 or 3
positions for shallow water cruising.

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 35.

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.

N

ZMU02682

ZMU04542

ZMU02673

34

Maintenance

EMU28213

Specifications

Dimension:

Overall length:

717 mm (28.2 in)

Overall width:

361 mm (14.2 in)

Overall height S:

1029 mm (40.5 in)

Overall height L:

1156 mm (45.5 in)

Transom height S:

435 mm (17.1 in)

Transom height L:

562 mm (22.1 in)

Weight (AL) S:

22.0 kg (49 lb)

Weight (AL) L:

23.0 kg (51 lb)

Performance:

Full throttle operating range:

4000–5000 r/min

Maximum output:

2.9 kW@4500 r/min (4 HP@4500 r/
min)

Idling speed (in neutral):

1500 ±50 r/min

Engine:

Type:

4-stroke S

Displacement:

112.0 cm

3

(6.83 cu.in)

Bore × stroke:

59.0 × 41.0 mm (2.32 × 1.61 in)

Ignition system:

TCI

Spark plug (NGK):

BR6HS

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Control system:

Tiller

Starting system:

Manual

Starting carburetion system:

Choke valve

Valve clearance (cold engine) IN:

0.08–0.12 mm (0.0032–0.0047 in)

Valve clearance (cold engine) EX:

0.08–0.12 mm (0.0032–0.0047 in)

Drive unit:

Gear positions:

Forward-neutral-reverse

Gear ratio:

2.08 (27/13)

Trim and tilt system:

Manual tilt

Propeller mark:

BA

Fuel and oil:

Recommended fuel:

Unleaded regular gasoline

Min. pump octane:

86

Fuel tank capacity:

1.10 L (0.291 US gal) (0.2420
Imp.gal)

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):

0.5 L (0.53 US qt) (0.44 Imp.qt)

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

100.0 cm

3

(3.38 US oz) (3.53 Imp.oz)

Tightening torque for engine:

Maintenance

35

Spark plug:

25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Engine oil drain bolt:

20.0 Nm (15.0 ft-lb) (2.0 kgf-m)

EMU28222

Transporting and storing

outboard motor

WARNING

EWM00690

●

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 consid­erably as it warms up and can build up
pressure in the fuel container. This can
cause fuel leakage and a potential fire
hazard.

WARNING

EWM00700

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.

CAUTION:

ECM00660

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 po-

sition 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.

ZMU02699

ZMU02699

ZMU02700

Maintenance

36

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.

CAUTION:

ECM01080

●

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

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

EMU28372

Flushing in a test tank

1. Wash the outboard motor body using
fresh water. For further information, see
page 38.

2. Fill the fuel tank with fresh fuel and add
one ounce of “Yamaha Fuel Conditioner
and Stabilizer” (Part No. LUB-FUELC­12-00) to each gallon of fuel.

NOTE:

The use of “Yamaha Fuel Conditioner and
Stabilizer” eliminates the need to drain the
fuel system. Consult your Yamaha dealer or
other qualified mechanic if the fuel system is
to be drained instead.

3. Remove the engine top cowling and si­lencer cover.

4. Install the outboard motor on the test
tank.

ZMU02701

ZMU04507

Maintenance

37

5. Fill the tank with fresh water to above the
level of the anti-cavitation plate.

CAUTION:

ECM00300

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.

CAUTION:

ECM00290

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.

6. Cooling system flushing is essential to
prevent the cooling system from clog­ging up with salt, sand, or dirt. In addi­tion, fogging of the engine is mandatory
to prevent excessive engine damage
due to rust. Perform the flushing and
fogging at the same time.

WARNING

EWM00090

●

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.

7. Run the engine at a fast idle for 10–15
minutes in neutral position.

8. Just prior to turning off the engine, quick­ly spray “Yamaha Stor-Rite Engine
Fogging Oil” (Part No. LUB-STRRT-12-

00) alternately into each carburetor or
the fogging hole of the silencer cover, if
equipped. When properly done, the en­gine will smoke excessively and almost
stall.

9. Remove the outboard motor from the
test tank.

10. Drain the cooling water completely out
of the motor. Clean the body thoroughly.

11. Install the silencer cover/cap and top
cowling.

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 40.

2. Change the gear oil. For instructions,
see page 46. Inspect the oil for the pres­ence of water that indicates a leaky seal.
Seal replacement should be performed
by an authorized Yamaha dealer prior to
use.

3. Grease all grease fittings. For further de­tails, see page 40.

EMU28420

Cleaning and anticorrosion
measures

1. Wash down the exterior of the outboard
motor with fresh water and dry off com­pletely.

1. Water surface

2. Lowest water level

Maintenance

38

2. Spray the outboard motor exterior with
“Yamaha Silicone Protectant” (Part No.
LUB-SILCNE-13-00).

CAUTION:

ECM01330

If equipped Electronic Fuel Injection: Do
not spray when the engine is running. Al­so, do not spray near the silencer and ox­ygen sensor cover or into the engine.
Otherwise the oxygen sensor for Elec­tronic Fuel Injection system could be
damaged.

3. Wax the cowling with a non-abrasive
wax such as “Yamaha Silicone Wax”
(Part No. ACC-11000-15-02).

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 35.

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.

EMU28483

Periodic maintenance

WARNING

EWM01070

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.

Maintenance, replacement, or repair of
the emission control devices and sys­tems may be performed by any marine
engine repair establishment or individual.
All warranty repairs, however, including
those to the emission control system,
must be performed by an authorized
Yamaha marine dealership.

A service manual is available for purchase
through your Yamaha dealer for owners who
have the mechanical skills, tools, and other
equipment necessary to perform mainte­nance not covered by this owner’s manual.

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.

ZMU02703

Maintenance

39

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.

Item Actions

Initial Every

10 hours

(1 month)

50 hours

(3

months)

100
hours (6
months)

200

hours (1

year)

Anode(s) (external)

Inspection / replace­ment

Anode(s) (internal)

Inspection / replace­ment

Cooling water pas­sages

Cleaning

Cowling clamp Inspection

Fuel filter (disposable)

Inspection / replace­ment

Fuel system Inspection

Fuel tank (built-in tank) Inspection / cleaning

Fuel tank (Yamaha por­table tank)

Inspection / cleaning

Gear oil Change

Greasing points Greasing

Idling speed (carbure­tor models)

Inspection / adjustment

Propeller and cotter pin

Inspection / replace­ment

Shift link / shift cable Inspection / adjustment

Thermostat Inspection

Throttle link / throttle
cable / throttle pick-up
timing

Inspection / adjustment

Water pump Inspection

Engine oil Inspection / change

Spark plug(s)

Cleaning / adjustment /
replacement

Valve clearance (OHC,
OHV)

Inspection / adjustment

Maintenance

40

NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushed with clean
water after each use.

EMU28931

Greasing

Yamaha marine grease (Water resistant grease)

F4D

EMU28950

Cleaning and adjusting spark plug

WARNING

EWM00560

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.

ZMU02706

Maintenance

41

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.

Before fitting the spark plug, measure the
electrode gap with a wire thickness gauge;
adjust the gap to specification if necessary.

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.

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.

EMU28961

Checking fuel system

WARNING

EWM00900

Gasoline and its vapors are highly flam­mable and explosive. Keep away from
sparks, cigarettes, flames, or other
sources of ignition.

WARNING

EWM00910

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.

Standard spark plug:

BR6HS

1. Spark plug gap

2. Spark plug I.D. mark (NGK)

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Spark plug torque:

25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Maintenance

42

Checkpoints

●

Fuel system parts leakage

●

Fuel line joint leakage

●

Fuel line cracks or other damage

●

Fuel connector leakage

EMU28990

Checking fuel filter

Check the fuel filter periodically. The fuel fil­ter is a one piece, disposable type. If foreign
matter is found in the filter, replace it. For re­placement of the fuel filter, consult your
Yamaha dealer.

EMU29040

Inspecting idling speed

WARNING

EWM00450

●

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.

CAUTION:

ECM00490

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

ZMU04505

ZMU02708

Maintenance

43

or other qualified mechanic.

2. Verify whether the idle speed is set to
specification. For idle speed specifica­tions, see page 34.

EMU29103

Changing engine oil

WARNING

EWM00760

●

Avoid draining the engine oil immedi­ately 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.

CAUTION:

ECM00970

●

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.

CAUTION:

ECM01240

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).

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.

3. Put a new gasket on the oil drain screw.
Apply a light coat of oil to the gasket and
install the drain screw.

NOTE:

If a torque wrench is not available when you
are installing the drain plug, finger tighten the
bolt just until the gasket comes into contact
with the surface of the drain hole. Then tight-

1. Drain screw

Tightening torque:

See page 34

ZMU02699

1

ZMU02709

Maintenance

44

en 1/4 - 1/2 turn. Have the drain plug torqued
to the correct value with a torque wrench as
soon as possible.

4. Add the correct amount of oil through the
filler hole. Install the filler cap.

5. Start the engine and make sure that
there are no oil leaks.

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.

NOTE:

●

For disposal of used oil consult your
Yamaha dealer.

●

The oil should be changed more often
when the engine is operated 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 se-

curely.

EMU29120

Exhaust leakage

Start the engine and check that no exhaust
leaks from the joints between the exhaust
cover, cylinder head, and body cylinder.

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.

EMU29171

Checking propeller

WARNING

EWM00321

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. Oil filler cap

Engine oil grade/capacity:

See page 34

ZMU02677

1

Maintenance

45

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.

●

Check the propeller shaft oil seal for dam­age.

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).

3. Remove the propeller and thrust wash­er.

EMU30370

Installing the propeller

CAUTION:

ECM00340

●

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

ZMU02710

ZMU02711

ZMU02712

1. Cotter pin

2. Propeller nut

3. Washer

4. Propeller

5. Thrust washer

1

2

3

4

5

ZMU02713

Maintenance

46

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 until
there is no forward-and-backward
movement.

4. Align the propeller nut with the propeller
shaft hole. Insert a new cotter pin in the
hole and bend the cotter pin ends.

NOTE:

If the propeller nut does not align with the
propeller shaft hole after tightening it, loosen
the nut until it aligns with the hole.

EMU29280

Changing gear oil

WARNING

EWM00800

●

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.

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.

CAUTION:

ECM00710

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 pressur-

ZMU02714

1. Gear oil drain screw

2. Oil level plug

ZMU02715

2

1

Maintenance

47

ized filling device, inject the gear oil into
the gear oil drain screw hole.

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.

EMU29302

Cleaning fuel tank

WARNING

EWM00920

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. Im­proper assembly can result in a fuel
leak, which could result in a fire or ex-

plosion 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.

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.

CAUTION:

ECM00720

Do not paint anodes, as this would render
them ineffective.

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

100.0 cm

3

(3.38 US oz) (3.53 Imp.oz)

ZMU02716

Maintenance

48

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.

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.

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.

ZMU02717

ZMU04477

ZMU01943

49

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 23.

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.

Trouble Recovery

50

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.

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?

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 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?

Trouble Recovery

51

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. 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.

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. 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.

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52

Q. Is heat range of spark plug incorrect?
A. Inspect spark plug and replace it with rec­ommended type.

Q. Is high pressure fuel pump drive belt bro­ken?
A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shift
lever position?
A. Have serviced by a Yamaha dealer.

Engine vibrates excessively.

Q. Is propeller damaged?
A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged?
A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangled
on propeller?
A. Remove and clean propeller.

Q. Is motor mounting bolt loose?
A. Tighten bolt.

Q. Is steering pivot loose or damaged?
A. Tighten or have serviced by a Yamaha
dealer.

EMU29431

Temporary action in

emergency

EMU29440

Impact damage

WARNING

EWM00870

The outboard motor can be seriously
damaged by a collision while operating or
trailering. Damage could make the out-

board motor unsafe to operate.

If the outboard motor hits an object in the wa­ter, follow the procedure below.

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.

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.

WARNING

EWM01020

●

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

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53

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
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.

EMU29621

Emergency starting engine

1. Remove the top cowling.

2. Remove the start-in-gear protection ca­ble and the choke cable from the holder
on the starter. After removing the choke
cable, confirm that the cable end is con­tacted with the silencer by pushing it in­side.

3. Remove the start-in-gear protection ca­ble end by pulling it out from the lever of
the starter after loosening the nut.

4. Remove the starter after removing the
three bolts.

5. Reinstall two bolts to secure the fuel
tank.

1. Start-in-gear protection cable

2. Choke cable

ZMU02718

1

2

ZMU02719

ZMU02720

Trouble Recovery

54

6. Prepare the engine for starting. For fur­ther information, see page 23. Be sure
the engine is in neutral and that the en­gine stop switch lanyard lock plate is at­tached to the engine stop switch.

7. Insert the knotted end of the emergency
starter rope into the notch in the flywheel
rotor and wind the rope several turns
around the flywheel clockwise.

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

ZMU02721

N

ZMU02682

ZMU02683

ZMU02722

ZMU02703

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55

filter, and fuel line. Drain the engine oil
completely.

4. Fill the sump with the fresh engine oil.

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.

CAUTION:

ECM00400

Do not attempt to run the outboard motor
until it has been completely inspected.

Engine oil capacity:

0.5 L (0.53 US qt) (0.44 Imp.qt)

ZMU02724

ZMU02725

56

Consumer information

EMU29811

Important warranty information for U.S.A. and Canada

Consumer information

57

Consumer information

58

EMU29830

YAMAHA MOTOR CORPORATION, U.S.A.

FOUR-STROKE OUTBOARD MOTOR

THREE-YEAR LIMITED WARRANTY

Consumer information

59

Consumer information

60

EMU29840

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR

YAMAHA OUTSIDE U.S.A. OR CANADA

Printed in France
April 2004–0.5

× 1 !

Warranty card 12/6/01 7:40 PM Page 1

Warranty card 12/6/01 7:40 PM Page 2