Page 1
OWNER’S MANUAL
Read this manual carefully before operating this
outboard motor.
F4B
F5A
F6C
6EC-F8199-77-E0
Page 2
Read this manual carefully before operating this outboard motor. Keep this
manual onboard in a waterproof bag when boating. This manual should stay
with the outboard motor if it is sold.
Page 3
Important manual information
TIP:
TIP:
EMU25108
To the owner
Thank you for selecting a Yamaha outboard
motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding of
these simple instructions will help you obtain
maximum enjoyment from your new Yamaha.
If you have any question about the operation
or maintenance of your outboard motor,
please consult a Yamaha dealer.
In this Owner’s Manual particularly important
information is distinguished in the following
ways.
: This is the safety alert symbol. It is used
to alert you to potential personal injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.
EWM00782
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
ECM00702
A NOTICE indicates special precautions
that must be taken to avoid damage to the
outboard motor or other property.
between your machine and this manual. If
there is any question concerning this manual,
please consult your Yamaha dealer.
To ensure long product life, Yamaha recommends that you use the product and perform
the specified periodic inspections and maintenance by correctly following the instructions in the owner’s manual. Any damage
resulting from neglect of these instructions is
not covered by warranty.
Some countries have laws or regulations restricting users from taking the product out of
the country where it was purchased, and it
may be impossible to register the product in
the destination country. Additionally, the warranty may not apply in certain regions. When
planning to take the product to another country, consult the dealer where the product was
purchased for further information.
If the product was purchased used, please
consult your closest dealer for customer reregistration, and to be eligible for the specified services.
The F4BMH, F5AMH, F6CMH 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.
EMU45001
A TIP provides key information to make procedures easier or clearer.
Yamaha continually seeks advancements in
product design and quality. Therefore, while
this manual contains the most current product information available at the time of printing, there may be minor discrepancies
F4B, F5A, F6C
OWNER’S MANUAL
©2022 by Yamaha Motor Co., Ltd.
1st Edition, December 2021
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Thailand
Page 4
Table of contents
Safety information ............................. 1
Outboard motor safety.................... 1
Propeller............................................. 1
Rotating parts..................................... 1
Hot parts ............................................ 1
Electric shock..................................... 1
Engine shut-off cord (lanyard)............ 1
Gasoline ............................................. 1
Gasoline exposure and spills ............. 1
Carbon monoxide .............................. 2
Modifications...................................... 2
Boating safety ................................. 2
Alcohol and drugs.............................. 2
Personal flotation devices (PFDs) ...... 2
People in the water ............................ 2
Passengers......................................... 2
Overloading........................................ 2
Avoid collisions .................................. 3
Collisions with floating or submerged
objects ............................................ 3
Weather.............................................. 3
Passenger training ............................. 4
Boating safety publications................ 4
Laws and regulations......................... 4
General information .......................... 5
Identification numbers record ......... 5
Outboard motor serial number........... 5
EC Declaration of Conformity
(DoC) ............................................ 5
CE Marking / UKCA Marking .......... 5
Read manuals and labels ................ 7
Warning labels ................................... 7
Specifications and requirements... 10
Specifications................................ 10
Installation requirements............... 11
Boat horsepower rating.................... 11
Mounting the outboard motor.......... 11
Battery requirements..................... 11
To use the battery ............................ 11
Propeller selection ........................ 12
Start-in-gear protection ............... 12
Engine oil requirements ................ 12
Fuel requirements ......................... 13
Gasoline ........................................... 13
Anti-fouling paint .......................... 14
Outboard motor disposal
requirements.............................. 14
Emergency equipment.................. 14
Components .................................... 15
Components diagram ................... 15
Fuel tank (built-in fuel tank) .............. 15
Fuel tank (portable fuel tank) ........... 16
Fuel cock.......................................... 16
Tiller handle ..................................... 17
Gear shift lever ................................ 17
Throttle grip...................................... 18
Throttle indicator .............................. 18
Throttle friction adjuster ................... 18
Engine shut-off cord (lanyard) and
clip ................................................ 19
Engine stop button .......................... 19
Pull-type choke knob ....................... 19
Fuel joint cap ................................... 20
Manual starter handle....................... 20
Steering friction adjuster .................. 20
Trim rod (tilt pin) ............................... 21
Tilt lock mechanism ........................ 21
Tilt support bar ................................ 21
Cowling lock lever ............................ 21
Carrying handle ................................ 22
Installation ....................................... 23
Installation..................................... 23
Mounting the outboard motor .......... 23
Clamping the outboard motor.......... 25
Operation ......................................... 26
First-time operation ...................... 26
Fill engine oil..................................... 26
Breaking in engine............................ 26
Getting to know your boat ............... 26
Page 5
Table of contents
Checks before starting engine ...... 26
Fuel level .......................................... 27
Removing top cowling ..................... 27
Fuel system...................................... 27
Controls............................................ 27
Engine shut-off cord (lanyard).......... 28
Engine oil.......................................... 28
Engine .............................................. 29
Installing top cowling ....................... 29
Filling fuel ...................................... 30
Operating engine........................... 31
Sending fuel ..................................... 32
Starting engine................................. 33
Checks after starting engine ......... 35
Cooling water ................................... 35
Warming up engine ....................... 36
Warming up...................................... 36
Checks after engine warm up ....... 36
Shifting ............................................. 36
Stop switches................................... 36
Shifting .......................................... 36
Stopping boat .............................. 37
Stopping engine ............................ 37
Procedure......................................... 37
Trimming outboard motor ............. 38
Adjusting trim angle for manual tilt
models .......................................... 39
Adjusting boat trim........................... 39
Tilting up and down ...................... 40
Procedure for tilting up .................... 41
Procedure for tilting down................ 42
Shallow water ............................... 42
Cruising in shallow water ................. 42
Cruising in other conditions .......... 44
Cleaning the outboard motor........... 50
Checking painted surface of
outboard motor............................. 51
Periodic maintenance ................... 51
Replacement parts........................... 51
Severe operating conditions ............ 51
Maintenance chart 1......................... 52
Maintenance chart 2......................... 54
Greasing ........................................... 55
Cleaning and adjusting spark plug... 56
Checking fuel filter ........................... 56
Inspecting idle speed ....................... 57
Changing engine oil.......................... 57
Why Yamalube ................................. 59
Checking electrical connectors and
electrical leads.............................. 59
Checking propeller ........................... 60
Removing propeller.......................... 60
Installing propeller............................ 61
Changing gear oil ............................. 61
Inspecting and replacing anode
(external) ....................................... 62
Trouble Recovery............................ 64
Troubleshooting............................ 64
Temporary action in emergency ... 66
Impact damage ................................ 66
Starter will not operate..................... 66
Emergency engine starting............... 67
Treatment of submerged motor.... 69
INDEX ............................................... 70
Maintenance .................................... 45
Transporting and storing outboard
motor.......................................... 45
Dismounting and transporting the
outboard motor............................. 45
Storing outboard motor.................... 48
Procedure......................................... 49
Lubrication ....................................... 50
Page 6
Safety information
EMU33623
Outboard motor safety
Observe these precautions at all times.
EMU36502
Propeller
People can be injured or killed if they come in
contact with the propeller. The propeller can
keep moving even when the motor is in neutral, and sharp edges of the propeller can cut
even when stationary.
Stop the engine when a person is in the
water near you.
Keep people out of reach of the propeller,
even when the engine is off.
EMU40272
Rotating parts
Hands, feet, hair, jewelry, clothing, personal
flotation device (PFD) straps, etc., can become entangled with internal rotating parts of
the engine, resulting in serious injury or
death.
Keep the top cowling in place whenever possible. Do not remove or replace the top cowling with the engine running.
Only operate the engine with the top cowling
removed according to the specific instructions in the manual. Keep hands, feet, hair,
jewelry, clothing, PFD straps, etc., away from
any exposed moving parts.
EMU33641
Hot parts
During and after operation, engine parts are
hot enough to cause burns. Avoid touching
any parts under the top cowling until the engine has cooled.
EMU33651
Electric shock
Do not touch any electrical parts while starting or operating the engine. They can cause
shock or electrocution.
EMU33672
Engine shut-off cord (lanyard)
Attach the engine shut-off cord so that the
engine stops if the operator falls overboard or
leaves the helm. This prevents the boat from
running away under power and leaving people stranded, or running over people or objects.
Always attach the engine shut-off cord to a
secure place on your clothing or your arm or
leg while operating. Do not remove it to leave
the helm while the boat is moving. Do not attach the cord to clothing that could tear
loose, or route the cord where it could become entangled, preventing it from functioning.
Do not route the cord where it is likely to be
accidentally pulled out. If the cord is pulled
during operation, the engine will shut off and
you will lose most steering control. The boat
could slow rapidly, throwing people and objects forward.
EMU33811
Gasoline
Gasoline and its vapors are highly flammable and explosive. Always, refuel according
to the procedure on page 31 to reduce the
risk of fire and explosion.
EMU33821
Gasoline exposure and spills
Take care not to spill gasoline. If gasoline
spills, wipe it up immediately with dry rags.
Dispose of rags properly.
If any gasoline spills onto your skin, immediately wash with soap and water. Change
clothing if gasoline spills on it.
If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get
immediate medical attention. Never siphon
fuel by mouth.
1
Page 7
Safety information
EMU33901
Carbon monoxide
This product emits exhaust gases which contain carbon monoxide, a colorless, odorless
gas which may cause brain damage or death
when inhaled. Symptoms include nausea,
dizziness, and drowsiness. Keep cockpit and
cabin areas well ventilated. Avoid blocking
exhaust outlets.
EMU33781
Modifications
Do not attempt to modify this outboard motor. Modifications to your outboard motor
may reduce safety and reliability, and render
the outboard unsafe or illegal to use.
EMU33742
Boating safety
This section includes a few of the many important safety precautions that you should
follow when boating.
EMU33711
Alcohol and drugs
Never operate after drinking alcohol or taking
drugs. Intoxication is one of the most common factors contributing to boating fatalities.
EMU40281
Personal flotation devices (PFDs)
Have an approved PFD on board for every
occupant. Yamaha recommends that you
must wear a PFD whenever boating. At a
minimum, children and non-swimmers
should always wear PFDs, and everyone
should wear PFDs when there are potentially
hazardous boating conditions.
EMU33732
People in the water
Always watch carefully for people in the water, such as swimmers, skiers, or divers,
whenever the engine is running. When someone is in the water near the boat, shift into
neutral and stop the engine.
Stay away from swimming areas. Swimmers
can be hard to see.
The propeller can keep moving even when
the motor is in neutral. Stop the engine when
a person is in the water near you.
EMU33752
Passengers
Consult your boat manufacturer’s instructions for details about appropriate passenger
locations in your boat and be sure all passengers are positioned properly before accelerating and when operating above an idle
speed. Standing or sitting in non-designated
locations may result in being thrown either
overboard or within the boat due to waves,
wakes, or sudden changes in speed or direction. Even when people are positioned properly, alert your passengers if you must make
any unusual maneuver. Always avoid jumping waves or wakes.
EMU33763
Overloading
Do not overload the boat. Consult the boat
capacity plate or boat manufacturer for maximum weight and number of passengers. Be
sure that weight is properly distributed according to the boat manufacturer’s instructions. Overloading or incorrect weight
distribution can compromise the boat’s handling and lead to an accident, capsizing or
swamping.
2
Page 8
Safety information
ZMU06025
EMU33773
Avoid collisions
Scan constantly for people, objects, and other boats. Be alert for conditions that limit your
visibility or block your vision of others.
Operate defensively at safe speeds and keep
a safe distance away from people, objects,
and other boats.
Do not follow directly behind other boats or
waterskiers.
Avoid sharp turns or other maneuvers that
make it hard for others to avoid you or understand where you are going.
Avoid areas with submerged objects or
shallow water.
Ride within your limits and avoid aggres-
sive maneuvers to reduce the risk of loss of
control, ejection, and collision.
Take early action to avoid collisions. Re-
member, boats do not have brakes, and
stopping the engine or reducing throttle
can reduce the ability to steer. If you are not
sure that you can stop in time before hitting
an obstacle, apply throttle and turn in another direction.
The passengers and any loose equipment
or luggage could be thrown forward due to
the sudden deceleration.
Parts of the outboard motor could come
loose as a result of the impact and could be
thrown into the boat.
The boat or outboard motor could be dam-
aged as a result of the impact.
When you operate the boat in an area where
there might be floating objects or obstacles in
the water, be sure to adjust the trim angle of
the outboard motor, slow down, and operate
carefully. For further information, see page
42.
If the outboard motor hits a floating object or
an obstacle in the water, make sure that there
are no abnormalities with the boat and the
outboard motor. If anything abnormal is
found, return to the nearest harbor at low
speed and have a Yamaha dealer inspect the
outboard motor.
EMU48100
Collisions with floating or submerged
objects
If the outboard motor hits a floating object or
an obstacle in the water while cruising, the
following could occur:
3
EMU33791
Weather
Stay informed about the weather. Check
weather forecasts before boating. Avoid
boating in hazardous weather.
Page 9
EMU33881
Passenger training
Make sure at least one other passenger is
trained to operate the boat in the event of an
emergency.
EMU33891
Boating safety publications
Be informed about boating safety. Additional
publications and information can be obtained
from many boating organizations.
EMU33602
Laws and regulations
Know the marine laws and regulations where
you will be boating—and obey them. Several
sets of rules prevail according to geographic
location, but all are basically the same as the
International Rules of the Road.
Safety information
4
Page 10
General information
1
YAMAHA
THAI YAMAHA MOTOR CO.,LTD.
MADE IN THAILAND
PAYS D’ORIGINE THAÏLANDE
3412
1
6EE-G3394-80
15210499
EMU25172
Identification numbers record
EMU25186
Outboard motor serial number
The outboard motor serial number is
stamped on the label attached to the port
side of the clamp bracket.
Record your outboard motor serial number in
the spaces provided to assist you in ordering
spare parts from your Yamaha dealer or for
reference in case your outboard motor is stolen.
1. Outboard motor serial number location
EMU38984
EC Declaration of Conformity
(DoC)
This declaration is included with outboard
motors that conform to European regulations.
This outboard motor conforms to certain portions of the European Parliament directive relating to machinery.
Each conformed outboard motor accompanied with EC DoC. EC DoC contains the following information;
Manufacturer
Model name
Engine code
Applied directives
EMU48442
CE Marking / UKCA Marking
This label is affixed to outboard motors that
conform to European regulations.
1. Serial number
2. Model name
3. Motor transom height
4. Engine code
5
1. CE marking location
Page 11
CE marking
Outboard motors affixed with this “CE” marking conform with the directives of;
2006/42/EC, 2014/30/EU, and 2013/53/EU.
UKCA marking
This product is in compliance with the Recreational Craft Regulations 2017, Electromagnetic Compatibility Regulations 2016 and
Supply of Machinery (Safety) Regulations
2008.
General information
6
Page 12
General information
4
5
3
1
2
EMU33524
Read manuals and labels
Before operating or working on this outboard motor:
Read this manual.
Read any manuals supplied with the boat.
Read all labels on the outboard motor and the boat.
If you need any additional information, contact your Yamaha dealer.
EMU33836
Warning labels
If these labels are damaged or missing, contact your Yamaha dealer for replacements.
7
Page 13
General information
6EE-G2794-40
1
2
3
6EE-G2794-50
6EE-H1994-40
6EE-H1994-50
6EE-H1995-40
6EE-H1995-50
6EE-G2698-50
4
6EE-G2698-40
EMU35282
Contents of labels
The above warning labels mean as follows.
1
EWM01692
Emergency starting does not have startin-gear protection. Ensure shift control is
in neutral before starting engine.
2
EWM01682
Keep hands, hair, and clothing away
from rotating parts while the engine is
running.
Do not touch or remove electrical parts
when starting or during operation.
3
EWM01672
Read Owner’s Manuals and labels.
Wear an approved personal flotation de-
vice (PFD).
Attach engine shut-off cord (lanyard) to
your PFD, arm, or leg so the engine
stops if you accidentally leave the helm,
which could prevent a runaway boat.
8
Page 14
General information
E10E5
BB8-F817K-30
5
ZMU05696
ZMU05664
ZMU05665
ZMU05666
4
EWM01702
Gasoline is highly flammable and explosive. Shut off engine before refueling.
Tighten tank cap and air vent screw when
not in use.
EMU33851
Other labels
EMU35133
Symbols
The following symbols mean as follows.
Notice/Warning
Read Owner’s Manual
Hazard caused by continuous rotation
Electrical hazard
9
Page 15
Specifications and requirements
TIP:
EMU38092
Specifications
“(AL)” stated in the specification data below
represents the numerical value for the aluminum propeller installed.
EMU48360
Dimension and weight:
Overall length:
750 mm (29.5 in)
Overall width:
403 mm (15.9 in)
Overall height S:
1039 mm (40.9 in)
Overall height L:
1166 mm (45.9 in)
Motor transom height S:
435 mm (17.1 in)
Motor transom height L:
562 mm (22.1 in)
Dry weight (AL) S:
27 kg (60 lb)
Dry weight (AL) L:
28 kg (62 lb)
Performance:
Full throttle operating range:
4000–5000 r/min (F4BMH)
4500–5500 r/min (F5AMH, F6CMH)
Rated power:
2.9 kW (4 HP) (F4BMH)
3.7 kW (5 HP) (F5AMH)
4.4 kW (6 HP) (F6CMH)
Idle speed (in neutral):
1450–1550 r/min
Power unit:
Type:
4-stroke OHV S1 2 valves
Total displacement:
139 cm³ (8.5 c.i.)
Bore × stroke:
62.0 × 46.0 mm (2.44 × 1.81 in)
Ignition system:
CDI
Spark plug (NGK):
CR6HSB
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
Steering system:
Tiller handle
Starting system:
Manual starter
Starting carburetion system:
Choke valve
Valve clearance IN (cold engine):
0.08–0.12 mm (0.0032–0.0047 in)
Valve clearance EX (cold engine):
0.08–0.12 mm (0.0032–0.0047 in)
Lower unit:
Gear shift positions:
Forward-neutral-reverse
Gear ratio:
2.08 (27/13)
Trim and tilt system:
Manual tilt
Propeller mark:
BA
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Min. research octane number (RON):
90
Fuel tank capacity:
12 L (3.17 US gal, 2.64 Imp.gal)
Fuel tank capacity (built in type):
1.1 L (0.29 US gal, 0.24 Imp.gal)
Recommended engine oil:
YAMALUBE 4 or 4-stroke outboard
motor oil
10
Page 16
Specifications and requirements
EMU40171
Mounting the outboard motor
EWM02431
Recommended engine oil grade 1:
SAE 10W-30/10W-40/5W-30
API SE/SF/SG/SH/SJ/SL
Engine oil quantity:
0.6 L (0.63 US qt, 0.53 Imp.qt)
Lubrication system:
Wet sump
Recommended gear oil:
YAMALUBE outboard gear oil or Hypoid
gear oil
Recommended gear oil grade:
SAE 90 API GL-4
Gear oil quantity:
0.100 L (0.106 US qt, 0.088 Imp.qt)
Noise and vibration level:
Operator sound pressure level (ICOMIA
39/94):
77.5 dB(A)
Vibration on tiller handle (ICOMIA 38/94):
5.5 m/s²
EMU33556
Installation requirements
EMU33566
Boat horsepower rating
EWM01561
Overpowering a boat can cause severe instability.
Before installing the outboard motor(s), confirm that the total horsepower of your outboard motor(s) does not exceed the boat’s
maximum horsepower rating. See the boat’s
capacity plate or contact the manufacturer.
Improper mounting of the outboard motor
could result in hazardous conditions, such
as poor handling, loss of control, or fire
hazards. If you are not able to mount the
outboard motor properly, consult a
Yamaha dealer.
To lift and mount the outboard motor, two
people are necessary. For further information, see page 23.
EMU25695
Battery requirements
EMU25733
To use the battery
ECM01091
A battery cannot be connected to models
that do not have a rectifier or Rectifier
Regulator.
If you wish to use a battery, your outboard
motor must be equipped with the following
parts.
Rectifier or Rectifier Regulator
Lighting coil
If you do not know if your outboard motor is
equipped with these parts, consult your
Yamaha dealer.
Using maintenance-free sealed batteries or
gel cell batteries is not recommended because they may not be compatible with
Yamaha’s charging system for this outboard
motor.
Install an optional Rectifier Regulator or use
accessories rated to withstand 18 volts or
higher with the above models. Consult your
Yamaha dealer for details on installing an optional Rectifier Regulator.
11
Page 17
Specifications and requirements
-
x
123
EMU34196
Propeller selection
Next to selecting an outboard motor, selecting the right propeller is one of the most important purchasing decisions a boater can
make. The type, size, and design of your propeller have a direct impact on acceleration,
top speed, fuel economy, and even engine
life. Yamaha designs and manufactures propellers for every Yamaha outboard motor and
every application.
Your outboard motor came with a Yamaha
propeller selected to perform well over a
range of applications, but there may be uses
where a different propeller would be more
appropriate.
Your Yamaha dealer can help you select the
right propeller for your boating needs. Select
a propeller that will allow the engine to reach
the middle or upper half of the operating
range at full throttle with the maximum boatload. Generally, select a larger pitch propeller
for a smaller operating load and a smaller
pitch propeller for a heavier load. If you carry
loads that vary widely, select the propeller
that lets the engine run in the proper range for
your maximum load but remember that you
may need to reduce your throttle setting to
stay within the recommended engine speed
range when carrying lighter loads.
To check the propeller, see page 60.
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
EMU39192
Start-in-gear protection
Yamaha outboard motors are equipped with
start-in-gear protection device. This feature
permits the engine to be started only when it
is in neutral. Always select neutral before
starting the engine.
EMU39693
Engine oil requirements
Select an oil grade according to the average
temperatures in the area where the outboard
motor will be used.
Recommended engine oil:
YAMALUBE 4 or 4-stroke outboard
motor oil
Recommended engine oil grade 1:
SAE 10W-30/10W-40/5W-30
API SE/SF/SG/SH/SJ/SL
Recommended engine oil grade 2:
SAE 15W-40/20W-40/20W-50
API SH/SJ/SL
Engine oil quantity:
0.6 L (0.63 US qt, 0.53 Imp.qt)
If oil grades listed under Recommended engine oil grade 1 are not available, select an alternative oil grade listed under
Recommended engine oil grade 2.
12
Page 18
Specifications and requirements
TIP:
ZMU06854
122˚F
50˚C
104
40
86
30
68
SAE API
SE
SF
SG
SH
SJ
SL
20
50
10
32
0
14
-10
-4
-20
10W–30
10W–40
5W–30
ZMU06855
122˚F
50˚C
104
40
86
30
68
SAE API
SH
SJ
SL
20
50
10
32
0
14
-10
-4
-20
15W–40
20W–40
20W–50
Recommended engine oil grade 1
Recommended engine oil grade 2
EMU36361
Fuel requirements
EMU40203
Gasoline
Use a good quality gasoline that meets the
minimum octane rating. If knocking or pinging occurs, use a different brand of gasoline
or premium unleaded fuel.
Recommended fuel:
Regular unleaded gasoline
Min. research octane number (RON):
90
ECM01982
Do not use leaded gasoline. Leaded
gasoline can seriously damage the engine.
13
Avoid getting water and contaminants in
the fuel tank. Contaminated fuel can
cause poor performance or engine dam-
age. Use only fresh gasoline that has
been stored in clean containers.
E5 E10
This mark identifies the recommended fuel
for this outboard motor as specified by Eu-
ropean regulation (EN228).
Check that gasoline nozzle has the same
identifier when fueling.
Gasohol
There are two types of gasohol: gasohol containing ethanol (E5 and E10) and that containing methanol. Ethanol can be used if the
ethanol content does not exceed 10% and
the fuel meets the minimum octane ratings.
E85 is a fuel containing 85% ethanol and
must not be used in your outboard motor. All
ethanol blends containing more than 10%
ethanol can cause fuel system damage or
cause engine starting and running problems.
Yamaha does not recommend gasohol containing methanol because it can cause fuel
system damage or engine performance problems.
It is recommended that you install a waterseparating marine fuel filter assembly (10 micron minimum) between your boat’s fuel tank
and outboard motor when using ethanol. Ethanol is known to allow moisture to be ab-
Page 19
Specifications and requirements
sorbed into boat fuel tanks and systems.
Moisture in the fuel can cause corrosion of
metallic fuel system components, starting
and running complaints and require additional fuel system maintenance.
EMU36331
Anti-fouling paint
A clean hull improves boat performance. The
boat bottom should be kept as clean of marine growth as possible. If necessary, the
boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth.
Do not use anti-fouling paint which includes
copper or graphite. These paints can cause
more rapid engine corrosion.
EMU40302
Outboard motor disposal re-
quirements
Never illegally discard (dump) the outboard
motor. Yamaha recommends consulting the
dealer about discarding the outboard motor.
EMU36353
Emergency equipment
Keep the following items onboard in case
there is trouble with the outboard motor.
A tool kit with assorted screwdrivers, pliers,
wrenches (including metric sizes), and
electrical tape.
Waterproof flashlight with extra batteries.
An extra engine shut-off cord (lanyard) with
clip.
Spare parts, such as an extra set of spark
plugs.
Consult your Yamaha dealer for details.
14
Page 20
Components
TIP:
1
2
3
11
12
13
15
14
21
19 18
20 16
17
22
23
24
25
4
5
6
26
8
7
9
10
EMU46722
Components diagram
* May not be exactly as shown; also may not be included as standard equipment on all models
(order from dealer).
1. Top cowling
2. Cowling lock lever
3. Carrying handle
4. Anti-cavitation plate
5. Propeller
6. Cooling water inlet
7. Trim rod
8. Clamp bracket
9. Steering friction adjuster
10.Fuel tank cap
11.Air vent screw
12.Manual starter handle
13.Throttle friction adjuster
14.Tiller handle
15.Throttle grip
15
16.Fuel joint
17.Fuel joint cap
18.Fuel cock
19.Engine shut-off cord (lanyard)
20.Engine stop button/Engine shut-off switch
21.Choke knob
22.Clamp screw
23.Restraint cable attachment
24.Tilt support bar
25.Gear shift lever
26.Anode
EMU39545
Fuel tank (built-in fuel tank)
This outboard motor is equipped with a builtin fuel tank and its parts are as follows.
Page 21
Fuel tank cap
1
2
3
1
2
3
This cap seals the fuel tank. When removed,
the tank can be filled with fuel. To remove the
cap, turn it counterclockwise.
Air vent screw
This screw is on the fuel tank cap. To loosen
the screw, turn it counterclockwise.
1. Air vent screw
2. Fuel tank cap
3. Built-in fuel tank
EMU39357
Fuel tank (portable fuel tank)
This model can be equipped with an optional
portable fuel tank. The parts of the fuel tank
are as follows.
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.
Air vent screw
This screw is on the fuel tank cap. To loosen
the screw, turn it counterclockwise.
Fuel joint
This joint is used to connect the fuel line.
Components
1. Fuel joint
2. Fuel tank cap
3. Air vent screw
EWM00021
The fuel tank supplied with this engine is
its dedicated fuel reservoir and must not
be used as a fuel storage container. Commercial users should conform to relevant
licensing or approval authority regulations.
EMU40091
Fuel cock
The fuel cock turns on and off the supply of
fuel from the fuel tank to the engine.
The fuel cock has 3 positions: the closed position, built-in fuel tank position, and portable
fuel tank position. Depending on how the outboard motor will be used, align the fuel cock
with the appropriate position indicated on the
label that is affixed to the outboard motor.
16
Page 22
Components
6EE-F4591-00
1
3
24
6EE-F4591-00
1
2
6EE-F4591-00
1
2
3
1
1. Fuel cock
2. Closed position
3. Built-in fuel tank position
4. Portable fuel tank position
EMU39211
Close
To stop the fuel flow from the fuel tank to the
carburetor, align the fuel cock with the closed
position.
When the engine is not running, always align
the fuel cock with the closed position.
1. Fuel cock
2. Closed position
EMU39223
Open
To send fuel from the fuel tank to the carburetor, align the fuel cock with the position for
the built-in fuel tank or portable fuel tank according to which fuel tank is being used.
When using the built-in fuel tank, align the
fuel cock with the built-in fuel tank position.
When using a portable fuel tank, align the fuel
cock with the portable fuel tank position.
1. Fuel cock
2. Built-in fuel tank position
3. Portable fuel tank position
EMU25914
Tiller handle
To change direction, move the tiller handle to
the left or right as necessary.
1. Tiller handle
EMU25925
Gear shift lever
Move the gear shift lever forward to engage
the forward gear or rearward to engage the
reverse gear.
17
Page 23
Components
1
2
3
1
A
B
0 % 100
12
3
4 4
3
12
1. Forward position
2. Neutral position
3. Reverse position
EMU39701
Throttle grip
The throttle grip is on the tiller handle. Turn
the grip “A” to increase speed and “B” to decrease speed.
1. Throttle grip
EMU39713
Throttle indicator
The throttle indicator shows the throttle position. When the 100% position of the throttle
indicator is aligned with the notch in the tiller
handle, the throttle is fully opened. When the
0% position of the throttle indicator is aligned
with the notch in the tiller handle, the throttle
is fully closed.
1. Fully open
2. Fully closed
3. Throttle indicator
4. Notch
The engine start mark “ ” on the throttle indicator shows the throttle position for starting
the engine.
1. Start mark “ ”
2. Notch
EMU39244
Throttle friction adjuster
The throttle friction adjuster provides adjustable resistance when the throttle grip is
turned, and can be set according to operator
preference.
To increase resistance, turn the throttle friction adjuster clockwise.
To decrease resistance, turn the throttle friction adjuster counterclockwise. When constant speed is desired, tighten the throttle
friction adjuster to maintain the desired throttle setting. WARNING! Do not overtighten
18
Page 24
Components
1
1
3
2
1
the throttle friction adjuster. If there is too
much resistance, it could be difficult to
turn the throttle grip, which could result in
an accident.
[EWM02262]
1. Engine shut-off switch
2. Engine shut-off cord (lanyard)
3. Clip
1. Throttle friction adjuster
EMU25996
Engine shut-off cord (lanyard) and clip
The clip must be attached to the engine shutoff switch for the engine to run. The cord
should be attached to a secure place on the
operator’s clothing, or arm or leg. Should the
operator fall overboard or leave the helm, the
cord will pull out the clip, stopping ignition to
the engine. This will prevent the boat from
running away under power. WARNING! At-
tach the engine shut-off cord to a secure
place on your clothing, or your arm or leg
while operating. Do not attach the cord to
clothing that could tear loose. Do not
route the cord where it could become entangled, preventing it from functioning.
Avoid accidentally pulling the cord during
normal operation. Loss of engine power
means the loss of most steering control.
Also, without engine power, the boat
could slow rapidly. This could cause people and objects in the boat to be thrown
forward.
[EWM00123]
EMU26004
Engine stop button
The engine stop button stops the engine
when the button is pushed.
1. Engine stop button
EMU26015
Pull-type choke knob
Pull the choke knob to supply a rich fuel mixture to the engine.
19
Page 25
Components
1
1
1
1
1. Choke knob
EMU39724
Fuel joint cap
The fuel joint is equipped with the fuel joint
cap. WARNING! When not using a portable
fuel tank, make sure to install the fuel joint
cap. Otherwise, injury could result from
striking the fuel joint accidentally.
1. Fuel joint cap
EMU26075
[EWM02412]
Manual starter handle
The manual starter handle is used to crank
and start the engine.
1. Manual starter handle
EMU39253
Steering friction adjuster
EWM02271
Do not overtighten the steering friction adjuster. If there is too much resistance, it
could be difficult to steer, which could result in an accident.
The steering friction adjuster provides adjustable resistance to the steering mechanism,
and can be set according to operator preference. The steering friction adjuster is located
on the port side of the outboard motor.
1. Steering friction adjuster
To increase resistance, turn the steering friction adjuster clockwise.
To decrease resistance, turn the steering friction adjuster counterclockwise.
20
Page 26
Components
1
1
2
1
1
1
2
3
EMU40102
Trim rod (tilt pin)
The trim rod (tilt pin) is used to adjust the trim
angle of the outboard motor in relation to the
angle of the boat transom.
1. Tilt lock
When the gear shift lever is moved to the neutral position or forward position, the outboard
motor can be tilted up.
1. Trim rod
EMU39364
Tilt lock mechanism
The tilt lock mechanism is used to prevent the
outboard motor from lifting out of the water
when the gear shift lever is in the reverse position.
When the gear shift lever is moved to the reverse position, the tilt lock mechanism operates to prevent the outboard motor from
being tilted up.
1. Gear shift lever
2. Reverse position
EMU39833
Tilt support bar
Use the tilt support bar to keep the outboard
motor in the tilted up position or a shallow
water cruising position.
1. Tilt support bar
2. Tilted up position
3. Shallow water cruising position
EMU39264
Cowling lock lever
The cowling lock lever(s) is used to secure the
top cowling.
21
Page 27
1. Cowling lock lever
1
1
EMU39373
Carrying handle
The carrying handle is used to carry the outboard motor. For information on carrying and
transporting the outboard motor, see page
45.
Components
1. Carrying handle
22
Page 28
Installation
1
ZMU06836
1
2
EMU39732
Installation
The information presented in this section is
intended as reference only. It is not possible
to provide complete instructions for every
possible boat and motor combination. Proper
mounting depends in part on experience and
the specific boat and motor combination.
EWM02342
Overpowering a boat could cause se-
vere instability. Do not mount an outboard motor with more horsepower
than the maximum rating on the capacity plate of the boat. If the boat does not
have a capacity plate, consult the boat
manufacturer.
Improper mounting of the outboard mo-
tor could result in hazardous conditions,
such as poor handling, loss of control,
or fire hazards. If you are not able to
mount the outboard motor properly,
consult a Yamaha dealer.
EMU39563
Mounting the outboard motor
EWM02301
Do not hold the top cowling or tiller handle
when mounting or dismounting the outboard motor. Otherwise, the outboard motor could fall.
(1) Be sure to mount the outboard motor
while the boat is on land. If the boat is on
the water, move it to an area on land.
(2) To prevent steering movement, turn the
steering friction adjuster clockwise.
1. Steering friction adjuster
(3) Turn the tiller handle 180° so that it is
pointing rearward.
(4) Hold the carrying handle and the hand-
grip on the front side of the bottom cowling and lift up the outboard motor using
two people.
1. Carrying handle
2. Handgrip
23
Page 29
(5) Mount the outboard motor on the center
ZMU06835
1
1
0-25 mm
(0-1 in)
2
1
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.
Installation
1. Steering friction adjuster
EMU39742
Mounting height
To run your boat at optimum efficiency, the
water resistance (drag) of the boat and outboard motor must be made as little as possible. The mounting height of the outboard
motor greatly affects the water resistance. If
the mounting height is too high, cavitation
tends to occur, thus reducing the propulsion;
and if the propeller tips cut the air, the engine
speed will rise abnormally and cause the engine to overheat. If the mounting height is too
low, the water resistance will increase and
thereby reduce engine efficiency. Mount the
outboard motor so that the anti-cavitation
plate is between the bottom of the boat and
a level 25 mm (1 in) below it.
1. Center line (keel line)
(6) Turn the steering friction adjuster coun-
terclockwise to set the steering friction
according to operator preference.
WARNING! If there is too much resistance it could be difficult to steer,
which could result in an accident.
[EWM00722]
1. Idle hole
2. Anti-cavitation plate
24
Page 30
Installation
TIP:
1
1
ECM02171
Check that the idle hole stays high
enough to keep out water getting inside
engine even if the boat is in stationary
with maximum load.
Incorrect engine height or obstructions
to the smooth flow of water (such as the
design or condition of the boat) can create airborne water spray while the boat
is cruising. If the motor is operated continuously in the presence of airborne
water spray, enough water could enter
the engine through the intake opening
on the top cowling to cause severe engine damage. Eliminate the cause of the
airborne water spray.
The optimum mounting height of the out-
board motor is affected by the boat and
motor combination and the desired use.
Test runs at different heights can help determine the optimum mounting height.
Consult your Yamaha dealer or boat manufacturer for further information on determining the proper mounting height.
For instructions on setting the trim angle of
the outboard motor, see page 38.
transom. This could cause loss of
control and serious injury. Make sure
the clamp screws are tightened securely. Occasionally check the screws
for tightness during operation.
1. Clamp screw
[EWM00643]
(2) Attach one end to the restraint cable at-
tachment 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.
EMU39753
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 clamp
screws evenly and securely. Occasionally check the clamp screws for tightness
during operation of the outboard motor
because they could become loose due
to engine vibration. WARNING! Loose
clamp screws could allow the outboard motor to fall off or move on the
25
1. Restraint cable attachment
Page 31
Operation
TIP:
ZMU01710
EMU36382
First-time operation
EMU36393
Fill engine oil
The engine is shipped from the factory without engine oil. If your dealer did not fill the oil,
you must fill it before starting the engine.
NOTICE: Check that the engine is filled
with oil before first-time operation to avoid
severe engine damage.
The engine is shipped with the following tag,
which should be removed after engine oil is
filled for the first time. For more information
on checking the engine oil level, see page 28.
[ECM01782]
life. NOTICE: Failure to follow the break-in
procedure could result in reduced engine
life or even severe engine damage.
EMU40061
[ECM00802]
Procedure for 4-stroke models
Your new engine requires a period of 10
hours break-in to allow mating surfaces of
moving parts to wear in evenly.
Run the engine in the water, under load (in
gear with a propeller installed) as follows. For
10 hours for breaking in engine avoid extended idling, rough water and crowded areas.
(1) For the first hour of operation:
Run the engine at varying speeds up to
2000 r/min or approximately half throttle.
(2) For the second hour of operation:
Run the engine at 3000 r/min or at approximately three-quarter throttle.
(3) Remaining 8 hours:
Run the engine at any speed. However,
avoid operating at full throttle for more
than 5 minutes at a time.
(4) After the first 10 hours:
Operate the engine normally.
EMU30175
Breaking in engine
Your new engine requires a period of breakin to allow mating surfaces of moving parts to
wear in evenly. Correct break-in will help ensure proper performance and longer engine
EMU36402
Getting to know your boat
All boats have unique handling characteristics. Operate cautiously while you learn how
your boat handles under different conditions
and various trim angles (see page 38).
EMU36414
Checks before starting engine
EWM01922
If any item in “Checks before starting engine” is not working properly, have it inspected and repaired before operating the
outboard motor. Otherwise, an accident
could occur.
26
Page 32
Operation
1
ZMU06851
ECM00121
Do not start the engine out of water. Overheating and serious engine damage can
occur.
EMU36561
Fuel level
Be sure you have plenty of fuel for your trip. A
good rule is to use 1/3 of your fuel to get to
the destination, 1/3 to return, and to keep 1/3
as an emergency reserve. With the boat level
on a trailer or in the water, check the fuel level. For fuel filling instructions, see page 30.
EMU39841
Removing top cowling
For the following checks, remove the top
cowling from the bottom cowling.
To remove the top cowling, pull the cowling
lock lever up and lift up the top cowling.
EWM00911
Leaking fuel can result in fire or explosion.
Check for fuel leakage regularly.
If any fuel leakage is found, the fuel sys-
tem must be repaired by a qualified me-
chanic. Improper repairs can make the
outboard unsafe to operate.
EMU36453
Check for fuel leaks
Check for fuel leaks or gasoline fumes in
the boat.
Check for fuel leakage from the fuel sys-
tem.
Check the fuel tank and fuel lines for
cracks, swellings, or other damage.
EMU39852
Controls
Move the tiller handle fully to the left and
right to check that operation is smooth.
Turn the throttle grip from the fully closed
position to the fully open position. Check
that the throttle grip turns smoothly and
that it completely returns to the fully closed
position.
Check the throttle cable and throttle link for
loose or damaged connections.
1. Cowling lock lever
EMU36443
Fuel system
EWM00061
Gasoline and its vapors are highly flammable and explosive. Keep away from sparks,
cigarettes, flames, or other sources of ignition.
27
Page 33
Check the shift link and start-in-gear pro-
TIP:
ZMU06852
ZMU06874
ZMU06873
1
2
1
2
tection cable for loose or damaged connections.
Operation
EMU39385
Engine oil
(1) Place the outboard motor in an upright
position (not tilted). NOTICE: If the mo-
tor is not level, the oil level indicated
on the dipstick may not be accurate.
[ECM01791]
(2) Remove the top cowling.
(3) Remove the oil filler cap and wipe the at-
tached oil dipstick clean.
1. Oil filler cap
2. Oil lubrication check window
EMU36484
Engine shut-off cord (lanyard)
Inspect the engine shut-off cord and clip for
damage, such as cuts, breaks, and wear.
1. Clip
2. Engine shut-off cord (lanyard)
The oil lubrication check window does not indicate the engine oil level. Use the oil lubrication check window to make sure that the
engine is being lubricated with oil while it is
running.
(4) Install the oil filler cap and tighten it com-
pletely.
(5) Remove the oil filler cap again and check
that the oil level on the dipstick is between the upper and lower marks. If the
oil level is not at the proper level, add or
extract oil until the oil is between the upper and lower marks.
28
Page 34
Operation
1
2
3
1
2
3
1
1
1. Oil dipstick
2. Upper mark
3. Lower mark
(6) Install the oil filler cap and tighten it com-
pletely.
(7) Install the top cowling.
EMU27154
Engine
Check the engine and engine mounting.
Look for loose or damaged fasteners.
Check the propeller for damage.
Check for engine oil leaks.
2. Manual starter handle
3. Rubber seal
(3) Hook the top cowling hook onto the bot-
tom cowling, and then make sure that
the fuel tank cap and manual starter handle fit properly into their respective holes.
1. Hook
(4) Check to be sure the rubber seal is seat-
ed correctly between the top cowling
and the bottom cowling.
(5) Pull the cowling lock lever down to se-
cure the top cowling.
EMU39862
Installing top cowling
(1) Check the rubber seal for damage. If the
rubber seal is damaged, have it replaced
by a Yamaha dealer.
(2) Align the fuel tank cap and manual start-
er handle with their respective holes in
the top cowling.
1. Fuel tank cap
29
1. Cowling lock lever
(6) Check the fitting of the top cowling by
pushing it with both hands. NOTICE: If
the top cowling is not installed correctly, water spray under the top
cowling can damage the engine, or
the top cowling can blow off at high
speeds.
[ECM01992]
Page 35
EMU39874
ZMU06739
1
ZMU06810
Filling fuel
EWM01951
Be sure the outboard motor is securely
fastened to the transom or a stable stand.
EWM01831
Operation
If you use a portable container to store and
dispense fuel, only use a locally approved
GASOLINE container.
To prevent electrostatic sparks, discharge
any built-up static electricity from your
body before refueling.
Filling fuel for built-in fuel tank
(1) Remove the fuel tank cap.
Gasoline and its vapors are highly flam-
mable and explosive. Always refuel according to this procedure to reduce the
risk of fire and explosion.
Gasoline is poisonous and can cause in-
jury or death. Handle gasoline with care.
Never siphon gasoline by mouth. If you
should swallow some gasoline or inhale
a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin,
wash with soap and water. If gasoline
spills on your clothing, change your
clothes.
Before refueling, check the following points:
Securely moor the boat in a well-ventilated
area and stop the engine. If the boat is
trailered, make sure that it is stable.
Do not smoke and keep away from sparks,
flames, static electric discharge, or other
sources of ignition.
1. Fuel tank cap
(2) Fill the fuel tank, but do not overfill it.
WARNING! Do not overfill. Otherwise
fuel can expand and overflow if the
temperature increases.
[EWM02611]
Fuel tank capacity (built in type):
1.1 L (0.29 US gal, 0.24 Imp.gal)
(3) Tighten the fuel tank cap securely.
(4) Wipe up any spilled gasoline immediate-
ly with dry rags. Dispose of rags properly
according to local laws or regulations. If
30
Page 36
Operation
2
1
1
ZMU06832
you use a portable container to store and
dispense fuel, only use a locally ap-
proved GASOLINE container.
Filling fuel for portable fuel tank (optional)
(1) Disconnect the fuel hose, and then install
the fuel joint cap. WARNING! When not
using a portable fuel tank, make sure
to install the fuel joint cap. Otherwise,
injury could result from striking the
fuel joint accidentally.
1. Fuel hose
2. Fuel joint cap
(2) Remove the portable fuel tank from the
boat.
(3) Remove the fuel tank cap.
1. Fuel tank cap
(4) Fill the fuel tank, but do not overfill it.
WARNING! Do not overfill. Otherwise
fuel can expand and overflow if the
temperature increases.
[EWM02412]
[EWM02611]
(5) Tighten the fuel tank cap securely.
(6) Wipe up any spilled gasoline immediate-
ly with dry rags. Dispose of rags properly
according to local laws or regulations. If
you use a portable container to store and
dispense fuel, only use a locally approved GASOLINE container.
EMU27453
Operating engine
EWM00421
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.
31
Page 37
EMU39396
1
6EE-F4591-00
1
1
1
1
1
Sending fuel
Sending fuel for built-in fuel tank
(1) Loosen the air vent screw by 1 or 2 turns.
1. Air vent screw
(2) Align the fuel cock with the built-in fuel
tank position.
Operation
1. Primer pump
(4) Install the top cowling.
Sending fuel for portable fuel tank (optional)
(1) Loosen the air vent screw on the porta-
ble fuel tank by 2 or 3 turns.
1. Built-in fuel tank position
(3) Remove the top cowling, and then
squeeze the primer pump in the bottom
cowling repeatedly until you feel it be-
come slightly firm.
1. Air vent screw
(2) If there is fuel in the built-in fuel tank,
loosen the air vent screw by 1 or 2 turns
to prevent pressure from increasing inside the tank due to fuel expansion.
1. Air vent screw
32
Page 38
Operation
2
1
1
6EE-F4591-00
1
1
1
(3) Remove the fuel joint cap. Align the fuel
joint on the fuel line with the fuel joint on
the motor and connect the fuel line se-
curely between the tank and the out-
board motor while pinching the joint so
that the primer pump arrow is pointing
toward the outboard motor.
1. Fuel hose
2. Fuel joint cap
1. Portable fuel tank position
(5) Send fuel to the carburetor by squeezing
the primer pump repeatedly, with the arrow pointing up, until you feel it become
firm. While the engine is running, make
sure to keep the portable fuel tank horizontal. Otherwise, fuel cannot be drawn
from the fuel tank.
1. Arrow
(4) Align the fuel cock with the portable fuel
tank position.
33
1. Arrow
EMU27496
Starting engine
EWM01601
Before starting the engine, make sure that
the boat is tightly moored and that you can
steer clear of any obstructions. Be sure
there are no swimmers in the water near
you.
Page 39
EMU39407
TIP:
1
ZMU06744
12
ZMU06865
Manual start
EWM01842
Failure to attach the engine shut-off
cord could result in a runaway boat if
operator is ejected. Attach the engine
shut-off cord to a secure place on your
clothing, or your arm or leg while operating. Do not attach the cord to clothing
that could tear loose. Do not route the
cord where it could become entangled,
preventing it from functioning.
Avoid accidentally pulling the cord dur-
ing normal operation. Loss of engine
power means the loss of most steering
control. Also, without engine power, the
boat could slow rapidly. This could
cause people and objects in the boat to
be thrown forward.
(1) Move the gear shift lever to the neutral
position.
Operation
(3) Align the engine start mark “ ” on the
throttle grip with the notch in the tiller
handle.
1. Neutral position
(2) Attach the engine shut-off cord to a se-
cure place on your clothing, or your arm
or leg. Then, install the clip on the other
end of the cord to the engine shut-off
switch.
1. Start mark “ ”
2. Notch
If the ambient temperature is -15°C (5°F) or
less, turn the throttle grip so that the engine
start mark “ ” is positioned past the notch in
the tiller handle.
(4) Pull out the choke knob fully.
34
Page 40
Operation
TIP:
1
ZMU06746
ZMU06818
1. Choke knob
It is not necessary to use the choke when
starting a warm engine, such as immediately
after the outboard motor has been operated
under a load.
(5) Pull the manual starter handle slowly un-
til you feel resistance. Then give a strong
pull straight out to crank and start the en-
gine. If the engine does not start on the
first try, repeat the procedure.
(6) After the engine starts, slowly return the
manual starter handle to its original posi-
tion before releasing it.
(7) Warm up the engine. For further informa-
tion, see page 36.
(8) Return the choke knob to its original po-
sition gradually.
(9) Slowly return the throttle grip to the fully
closed position.
EMU36511
Checks after starting engine
EMU36524
Cooling water
Check for a steady flow of water from the
cooling water pilot hole. A continuous flow of
water from the pilot hole indicates that the
water pump is pumping water through the
cooling water passages. If the cooling water
passages are frozen, it may take a while for
water to start flowing out of the pilot hole.
ECM01811
If water is not flowing out of the pilot hole
at all times while the engine is running,
overheating and serious damage could
occur. Stop the engine and check whether
the cooling water inlet on the lower case
or the cooling water pilot hole is blocked.
Consult your Yamaha dealer if the problem cannot be located and corrected.
35
Page 41
TIP:
1. Cooling water pilot hole
1
EMU27671
Warming up engine
EMU40073
Warming up
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. NOTICE: Failure to
do so will shorten engine life.
If the choke knob is left pulled out after the
engine starts, the engine will stall.
In temperatures of -5°C (23°F) or less, leave
the choke knob pulled out fully for approximately 30 seconds after starting.
EMU36532
[ECM04550]
Checks after engine warm up
EMU36542
Shifting
While the boat is tightly moored, and without
applying throttle, confirm that the engine
shifts smoothly into forward and reverse, and
back to neutral.
Operation
EMU36973
Stop switches
Perform the following procedure to check
that the engine stop button and engine shutoff switch operate properly.
Start the engine, and then check that the
engine stops when the engine stop button
is pushed.
Restart the engine, and then check that the
engine stops when the clip is pulled from
the engine shut-off switch.
Check that the engine cannot be started
with the clip removed from the engine shutoff switch.
EMU39343
Shifting
EWM00181
Before shifting, make sure there are no
swimmers or obstacles in the water near
you.
ECM02221
Before shifting the outboard motor, turn
the throttle grip to the fully closed position
and let the engine speed return to idle
speed. Otherwise, the shift mechanism
could be damaged.
To shift to forward or reverse
Move the gear shift lever to the forward position or reverse position.
36
Page 42
Operation
1
2
3
1
1
1
3
2
1. Forward position
2. Neutral position
3. Reverse position
To shift to neutral
(1) Close the throttle so that the engine
slows to idle speed.
(2) Move the gear shift lever to the neutral
position.
The boat is not equipped with a separate
braking system. Water resistance stops it after the throttle lever is moved back to idle.
The stopping distance varies depending on
gross weight, water surface conditions, and
wind direction.
EMU27823
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.
EMU39413
Procedure
(1) Push and hold the engine stop button
until the engine stops completely. The
engine can also be stopped by pulling
the engine shut-off cord and removing
the clip from the engine shut-off switch.
1. Neutral position
EMU39883
Stopping boat
EWM02322
Do not use the reverse function to slow
down or stop the boat as it could cause
you to lose control, be ejected, or impact
the load or other parts of the boat. This
could increase the risk of serious injury. It
could also damage the shift mechanism.
37
1. Engine stop button
1. Engine shut-off switch
2. Engine shut-off cord (lanyard)
Page 43
Operation
1
1
6EE-F4591-00
1
1
2
1
3. Clip
(2) Tighten the air vent screw on the fuel
tank cap.
1. Air vent screw
1. Air vent screw
(3) Align the fuel cock with the closed posi-
tion.
1. Closed position
(4) When using a portable fuel tank, discon-
nect the fuel hose, and then install the
fuel joint cap. WARNING! When not us-
ing a portable fuel tank, make sure to
install the fuel joint cap. Otherwise, injury could result from striking the fuel
joint accidentally.
1. Fuel hose
2. Fuel joint cap
EMU27865
[EWM02412]
Trimming outboard motor
EWM00741
Excessive trim for the operating conditions (either trim up or trim down) can
cause boat instability and can make steering the boat more difficult. This increases
the possibility of an accident. If the boat
begins to feel unstable or is hard to steer,
slow down and/or readjust the trim angle.
The trim angle of the outboard motor helps
determine the position of the bow of the boat
in the water. Correct trim angle will help improve performance and fuel economy while
reducing strain on the engine. Correct trim
angle depends upon the combination of
boat, engine, and propeller. Correct trim is
also affected by variables such as the load in
the boat, sea conditions, and running speed.
38
Page 44
Operation
TIP:
1
1
A
B
(2) Tilt the outboard motor up, and then re-
move the trim rod from the clamp bracket.
1. Trim rod
(3) Change the position of the trim rod in di-
rection “A” to raise the bow (“trim-out”).
Change the position of the trim rod in direction “B” to lower the bow (“trim-in”).
1. Trim operating angle
EMU39273
Adjusting trim angle for manual tilt
models
EWM00401
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.
There are 5 holes provided in the clamp
bracket to adjust the outboard motor trim angle.
(1) Stop the engine.
39
The outboard motor trim angle changes approximately 4 degrees when the trim rod position is changed by 1 hole.
(4) Make test runs with the outboard motor
set at different trim angles to find the position that works best for your boat and
operating conditions.
EMU27913
Adjusting boat trim
When the boat is on plane, a bow-up attitude
results in less drag, greater stability and efficiency. This is generally when the keel line of
the boat is up about 3 to 5 degrees. With the
bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. When the bow of
the boat is down, it is easier to accelerate
from a standing start onto plane.
Page 45
Bow Up
TIP:
ZMU06840
Too much trim-out puts the bow of the boat
too high in the water. Performance and economy are decreased because the hull of the
boat is pushing the water and there is more
air drag. Excessive trim-out can also cause
the propeller to ventilate, which reduces performance further, and the boat may “porpoise” (hop in the water), which could throw
the operator and passengers overboard.
Operation
Depending on the type of boat, the outboard
motor trim angle may have little effect on the
trim of the boat when operating.
EMU39593
Tilting up and down
If the engine will be stopped for some time or
if the boat is moored in shallows, the outboard motor should be tilted up to protect the
propeller and lower case from damage due to
collisions with obstructions, and also to reduce salt corrosion.
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.
EWM00223
Make sure that no one is near the outboard motor when tilting the outboard
motor up or down. Otherwise, body parts
could be crushed between the outboard
motor and the clamp bracket.
40
Page 46
Operation
6EE-F4591-00
1
1
1
1
1
EWM02313
Leaking fuel is a fire hazard. When the outboard motor will be tilted up for more than
a few minutes, tighten the air vent screw
and fuel tank cap and align the fuel cock
with the closed position. Otherwise, fuel
may leak.
ECM02162
Before tilting the outboard motor up, fol-
low the procedure under “Stopping engine” in this chapter. Never tilt the
outboard motor up while the engine is
running. Severe damage from overheating can result.
Do not tilt the outboard motor up by
pushing the tiller handle because this
could break the handle.
The outboard motor cannot be tilted
when in reverse.
EMU39553
Procedure for tilting up
(1) Align the fuel cock with the closed posi-
tion.
1. Neutral position
(3) To prevent steering movement, turn the
steering friction adjuster clockwise.
1. Steering friction adjuster
(4) Tighten the air vent screw.
1. Closed position
(2) Move the gear shift lever to the neutral
position.
41
1. Air vent screw
(5) When using a portable fuel tank, discon-
nect the fuel hose, and then install the
fuel joint cap. WARNING! When not us-
ing a portable fuel tank, make sure to
Page 47
install the fuel joint cap. Otherwise, in-
2
1
1
2
1
1
jury could result from striking the fuel
joint accidentally.
1. Fuel hose
2. Fuel joint cap
[EWM02412]
(6) Hold the rear of the top cowling and fully
tilt the outboard motor up. Slightly lower
the outboard motor from the fully tilted
up position and fit the tilt support bar se-
curely into the holder located on the
clamp bracket.
Operation
1. Tilt support bar
(3) Turn the steering friction adjuster coun-
terclockwise to set the steering friction
according to operator preference.
WARNING! If there is too much resistance it could be difficult to steer,
which could result in an accident.
[EWM00722]
1. Tilt support bar
2. Holder
EMU39572
Procedure for tilting down
(1) Slightly tilt the outboard motor up.
(2) Slowly tilt the outboard motor down
while pulling the tilt support bar up.
1. Steering friction adjuster
EMU28063
Shallow water
EMU39892
Cruising in shallow water
EWM02392
Operate the boat at the lowest possible
speed when cruising in shallow water.
Hitting an underwater obstacle could
cause the outboard motor to lift out of
the water, resulting in loss of control.
42
Page 48
Operation
1
1
2
1
1
When cruising in shallow water, do not
operate in reverse. Reverse thrust can
cause the outboard motor to lift out of
the water, increasing the chance of an
accident and personal injury.
ECM00261
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.
1. Cooling water inlet
EMU39584
Procedure for shallow water cruising
(1) Move the gear shift lever to the neutral
position.
(2) Hold the rear of the top cowling and
slightly tilt the outboard motor up until
the tilt support bar automatically locks.
The outboard motor can be operated in
this position for shallow water cruising.
The outboard motor is equipped with 3
shallow water cruising positions.
1. Shallow water cruising position
2. Tilt support bar
EMU40042
Procedure for returning to normal cruising
(1) To tilt the outboard motor down to the
normal running position, move the gear
shift lever to the neutral position.
1. Neutral position
43
1. Neutral position
(2) Slightly tilt the outboard motor up, and
then slowly tilt the outboard motor down
while pulling the tilt support bar up.
Page 49
1. Tilt support bar
1
EMU35392
Cruising in other conditions
Cruising in salt water
After operating in salt water, flush the cooling
water passages with fresh water to prevent
them from becoming clogged. Also rinse the
outside of the outboard motor with fresh water.
Cruising in muddy, turbid, or acidic water
Water in some areas can be acidic or with a
lot of sediment in it, such as muddy or turbid
(cloudy) water. After operating in such water,
flush the cooling passages with fresh water to
prevent corrosion. Also rinse the outside of
the outboard motor with fresh water.
Operation
44
Page 50
Maintenance
EMU39905
Transporting and storing out-
board motor
EWM02631
USE CARE when transporting fuel tank,
whether in a boat or car.
DO NOT fill fuel container to maximum
capacity. Gasoline will expand considerably as it warms up and can build up
pressure in the fuel container. This can
cause fuel leakage and a potential fire
hazard.
Leaking fuel is a fire hazard. When
transporting and storing the outboard
motor, close the fuel cock to prevent
fuel from leaking.
Never get under the outboard motor
while it is tilted. Severe injury could occur if the outboard motor accidentally
falls.
Do not use the tilt support bar when
trailering the boat. The outboard motor
could shake loose from the tilt support
and fall. If the outboard motor cannot be
trailered in the normal running position,
use an additional support device to secure it in the tilt position.
ECM02441
When storing the outboard motor for prolonged time, fuel must be drained from the
fuel tank. The deteriorated fuel could clog
the fuel line causing engine start difficulty
or malfunction.
Close the fuel cock on the outboard motor,
and then tighten the built-in fuel tank cap
and its air vent screw.
Tighten the portable fuel tank cap and its
air vent screw.
When the outboard motor is tilted pro-
longed time for mooring or trailering the
boat, disconnect the fuel line and close the
fuel cock on the outboard motor. Tighten
the built-in fuel tank cap and its air vent
screw. Also tighten the portable fuel tank
cap and its air vent screw.
The outboard motor should be transported
and stored in the normal running position. If
there is insufficient road clearance in this position, then trailer the outboard motor in the
tilt position using a motor support device
such as a transom saver bar. Consult your
Yamaha dealer for further details.
EMU39424
Dismounting and transporting the
outboard motor
EWM02301
Do not hold the top cowling or tiller handle
when mounting or dismounting the outboard motor. Otherwise, the outboard motor could fall.
To dismount the outboard motor
(1) Stop the engine and land the boat.
(2) Tighten the fuel tank cap and air vent
screw securely.
When storing or transporting the outboard
motor, make sure to follow the procedure listed below.
Disconnect the fuel line from the outboard
motor.
45
Page 51
Maintenance
1
2
6EE-F4591-00
1
1
2
1
1
ZMU06836
1. Air vent screw
2. Fuel tank cap
(3) Align the fuel cock with the closed posi-
tion.
1. Closed position
(4) When using a portable fuel tank, discon-
nect the fuel hose from the fuel joint, and
then install the fuel joint cap. WARNING!
When not using a portable fuel tank,
make sure to install the fuel joint cap.
Otherwise, injury could result from
striking the fuel joint accidentally.
[EWM02412]
1. Fuel hose
2. Fuel joint cap
(5) To prevent steering movement, turn the
steering friction adjuster clockwise.
1. Steering friction adjuster
(6) Turn the tiller handle 180° so that it is
pointing rearward.
(7) Loosen the clamp screws.
46
Page 52
Maintenance
1
2
ZMU06835
ZMU06761
ZMU06806
(8) Hold the carrying handle and the hand-
grip on the front side of the bottom cowling and lift up the outboard motor using
two people to dismount it from the boat.
1. Carrying handle
2. Handgrip
To transport the outboard motor horizontally
When transporting the outboard motor on its
side, observe the following precautions.
Tighten the clamp screws completely and
place a mat or something similar under the
outboard motor. Otherwise, the outboard
motor could be damaged or vibration dur-
ing transport could cause a small amount
of oil or cooling water to leak out. NOTICE:
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 valve and cause engine trouble.
[ECM05010]
If the front side of the outboard motor is
facing down, turn the clamp bracket 90° so
that it does not contact the ground, and
then turn the steering friction adjuster
clockwise to secure the bracket.
To transport the outboard motor
When transporting or storing the outboard
motor while removed from a boat, it is recommended that you use an outboard motor
stand.
47
Page 53
Do not place the outboard motor on its side
ZMU06762
ZMU06807
ZMU08581
ZMU08565
in an attitude other than those shown in the
preceding illustrations.
Maintenance
EMU39914
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, the following procedures can be performed by the owner.
ECM02214
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 valve and cause engine trouble.
Transport and store the outboard motor
as specified in “Dismounting and trans-
porting the outboard motor”.
Store the outboard motor in a dry, well-
ventilated place, not in direct sunlight.
48
Page 54
Maintenance
6EE-F4591-00
1
1
1
3
1
2
3
EMU28306
Procedure
EMU39613
Flushing in a test tank
ECM00302
Before starting the engine, make sure to
supply water to the cooling water passages. Otherwise, the engine could overheat
and be damaged.
Cooling system flushing is essential to prevent the cooling system from clogging up
with salt, sand, or dirt. In addition, fogging/lubricating of the engine is mandatory to prevent excessive engine damage due to rust.
Perform the flushing and fogging at the same
time.
(1) Wash the outboard motor body using
fresh water. NOTICE: Do not spray wa-
ter into the air intake.
[ECM01841] For further
information, see page 50.
(2) When using the built-in fuel tank, com-
pletely drain the fuel from the tank, and
then align the fuel cock with the closed
position and tighten the air vent screw.
For draining of the built-in fuel tank, consult a Yamaha dealer.
(3) When using a portable fuel tank, discon-
nect the fuel hose, install the fuel joint
cap, and then align the fuel cock with the
closed position.
1. Closed position
(4) Remove the top cowling and fogging
hole cap.
1. Cap
(5) Remove the propeller. For further infor-
mation, see page 60.
(6) Install the outboard motor on the test
tank.
1. Water surface
2. Lowest water level
3. Cooling water inlet
(7) Fill the test tank with fresh water to
above the level of the anti-cavitation
plate. NOTICE: If the fresh water level
is below the level of the anti-cavitation
plate, or if the water supply is insufficient, engine seizure may occur.
[ECM00292]
(8) Move the gear shift lever to the neutral
position.
49
Page 55
Maintenance
TIP:
ZMU06823
1
(9) Start the engine and run it for a few min-
utes at engine idle speed. WARNING!
Do not touch or remove electrical
parts when starting or during operation. Keep hands, hair, and clothes
away from the flywheel and other rotating parts while the engine is running.
[EWM00092]
(10) Before the engine stops, quickly spray
“Fogging Oil” into the fogging hole of the
silencer. When properly done, the engine
will smoke excessively and stop.
(11) If “Fogging Oil” is not available, run the
engine at engine idle speed until the fuel
system empties and the engine stops.
Check that the engine has stopped, and
then remove the spark plug. Pour a teaspoonful of clean engine oil into the cylinder. Crank several times manually.
Install the spark plug.
(12) Remove the outboard motor from the
test tank.
(13) Drain the cooling water completely out of
the outboard motor. Clean the body
thoroughly.
(14) Install the fogging hole cap and top cowl-
ing.
(15) Install the propeller. For further informa-
tion, see page 61.
EMU41072
Lubrication
(1) Change the gear oil. For instructions, see
page 61. Check the gear oil for the presence of water that indicates a leaky seal.
Seal replacement should be performed
by an authorized Yamaha dealer prior to
use.
(2) Lubricate all grease fittings. For further
details, see page 55.
For long-term storage, fogging the engine
with fogging oil is recommended. Contact
your Yamaha dealer for information about
fogging oil and procedures for your outboard
motor.
EMU44342
Cleaning the outboard motor
When cleaning the outboard motor, the top
cowling must be installed.
(1) Wash the exterior of the outboard motor
using fresh water. NOTICE: Do not
spray water into the air intake.
1. Air intake
(2) Drain the cooling water completely out of
the outboard motor. Clean the body
thoroughly.
[ECM01841]
50
Page 56
Maintenance
EMU28463
Checking painted surface of outboard
motor
Check the outboard motor for scratches,
nicks, or flaking paint. Areas with damaged
paint are more likely to corrode. If necessary,
clean and paint the areas. Touch-up paint is
available from your Yamaha dealer.
EMU37077
Periodic maintenance
EWM01982
These procedures require mechanical
skills, tools, and supplies. If you do not
have the proper skills, tools, or supplies to
perform a maintenance procedure, have a
Yamaha dealer or other qualified mechanic do the work.
The procedures involve disassembling the
motor and exposing dangerous parts. To
reduce the risk of injury from moving, hot,
or electrical parts:
Turn off the engine and keep engine
shut-off cord (lanyard) with you when
you perform maintenance unless otherwise specified.
Allow the engine to cool before handling
hot parts or fluids.
Always completely reassemble the mo-
tor before operation.
EMU34152
Severe operating conditions
Severe operating conditions involve one or
more of the following types of operation on a
regular basis:
Operating continuously at or near maxi-
mum engine speed (rpm) for many hours
Operating continuously at a low engine
speed (rpm) for many hours
Operating without sufficient time for engine
to warm up and cool down
Frequent quick acceleration and decelera-
tion
Frequent shifting
Frequently starting and stopping the en-
gine(s)
Operation that fluctuates often between
light and heavy cargo loads
Outboard motors operating under any of
these above conditions require more frequent maintenance. Yamaha recommends
that you do this service twice as often as
specified in the maintenance chart. For example, if a particular service should be done
at 50 hours, do it instead at 25 hours. This will
help prevent more rapid deterioration of engine components.
EMU28512
Replacement parts
If replacement parts are necessary, use only
genuine Yamaha parts or parts of equivalent
design and quality. Any part of inferior quality
may malfunction, and the resulting loss of
control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from your Yamaha dealer.
51
Page 57
Maintenance
TIP:
EMU46073
Maintenance chart 1
Refer to the sections in this chapter for explanations of each owner-specific action.
The maintenance cycle on these charts assume usage of 100 hours per year and regular
flushing of the cooling water passages. Maintenance frequency should be adjusted when
operating the engine under adverse conditions such as extended trolling.
Disassembly or repairs may be necessary depending on the outcome of maintenance
checks.
Expendable or consumable parts and lubricants will lose their effectiveness over time and
through normal usage regardless of the warranty period.
When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should
be flushed with clean water after each use.
The “ ” symbol indicates the check-ups which you may carry out yourself.
The “ ” symbol indicates work to be carried out by your Yamaha dealer.
Initial Every
Item Actions
Anode (external)
Anode(s) (internal)
*1
Anode(s) (internal)
*2
Cooling water
leakage
Cowling lock lever Inspection 27, 29
Engine starting
condition/noise
Engine idle
speed/noise
Engine oil Replacement 57
Engine oil filter
(crankcase)
Fuel filter (disposal
type)
Fuel filter (inside
built-in fuel tank)
Inspection or replacement as necessary
Inspection or replacement as necessary
Replacement —
Inspection or replacement as necessary
Inspection 31
Inspection —
Inspection, cleaning or replacement
as necessary
Replacement —
Inspection and
cleaning as necessary
20 hours
(3
months)
100 hours
(1 year)
300 hours
(3 years)
500 hours
(5 years)
Page
62
—
—
—
—
52
Page 58
Maintenance
Initial Every
Item Actions
Fuel line Inspection —
Fuel line
Fuel pump
Fuel/engine oil
leakage
Gear oil Replacement 61
Greasing points Greasing 55
Impeller/water
pump housing
Impeller/water
pump housing
Propeller/propeller
nut/cotter pin
Shift link
Spark plug
Spark plug
cap/spark plug
wire
Water from the
cooling water pilot
hole
Throttle link/throttle cable
Thermostat
Valve clearance
Cooling water inlet Inspection 15
Stop switch
Inspection or replacement as necessary
Inspection or replacement as necessary
Inspection —
Inspection or replacement as necessary
Replacement —
Inspection or replacement as necessary
Inspection, adjustment or replacement as necessary
Inspection or replacement as necessary
Inspection or replacement as necessary
Inspection 35
Inspection, adjustment or replacement as necessary
Inspection or replacement as necessary
Inspection and adjustment
Inspection or replacement as necessary
20 hours
(3
months)
100 hours
(1 year)
300 hours
(3 years)
500 hours
(5 years)
Page
—
—
—
60
—
56
—
—
—
—
—
53
Page 59
Item Actions
Connector connections/lead connections
Fuel tank (optional
Yamaha p o rta ble
fuel tank)
Fuel tank (built-in
tank)
EMU46000
Inspection or replacement as necessary
Inspection and
cleaning as necessary
Inspection and
cleaning as necessary
*1 thermostat cover
*2 thermostat cover
EMU46082
Maintenance chart 2
Item Actions
Exhaust guide/exhaust manifold
Inspection or replacement as necessary
Initial Every
20 hours
months)
(3
100 hours
(1 year)
Every
1000 hours
300 hours
(3 years)
Maintenance
500 hours
(5 years)
Page
—
—
—
Page
—
54
Page 60
Maintenance
ZMU06764
EMU28946
Greasing
Yamalube grease A (water resistant grease)
Yamaha grease D (corrosion resistant grease; for propeller shaft)
55
Page 61
Maintenance
TIP:
1
11
22
33
EMU39297
Cleaning and adjusting spark plug
The spark plug is an important engine component. The condition of the spark plug can
indicate something about the condition of the
engine. For example, if the center electrode
porcelain is very white, this could indicate an
intake air leak or carburetion problem in that
cylinder. Do not attempt to diagnose any
problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should
periodically remove and inspect the spark
plug because heat and deposits will cause
the spark plug to slowly break down and
erode.
(1) Remove the spark plug cap from the
spark plug.
(3) Be sure to use the specified spark plug,
otherwise the engine may not operate
properly. Before fitting the spark plug,
measure the electrode gap with a wire
thickness gauge; replace it if out of specification.
1. Spark plug gap
2. Spark plug part number
3. Spark plug I.D. mark (NGK)
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
(4) When fitting the plug, wipe off any dirt
from the threads, and then screw it in to
the correct torque.
1. Spark plug cap
(2) Remove the spark plug. If electrode ero-
sion becomes excessive, or if carbon
and other deposits are excessive, you
should replace the spark plug with another of the correct type. WARNING!
When removing or installing a spark
plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead
to explosion or fire.
Standard spark plug:
CR6HSB
[EWM00562]
Spark plug torque:
13 N·m (1.3 kgf·m, 9.6 lb·ft)
If a torque-wrench is not available when you
are reinstalling a spark plug, a good estimate
of the correct torque is 1/12 turn past fingertight. When you are installing a new spark
plug, a good estimate of the correct torque is
1/2 turn past finger-tight.
EMU39922
Checking fuel filter
The fuel filters are located in the filler hole of
the built-in fuel tank and in the bottom cowling. Check the fuel filters periodically. If for-
56
Page 62
Maintenance
1
1
ZMU06766
eign material is found in the filters, clean or
replace them. For cleaning or replacement of
the fuel filters, consult a Yamaha dealer.
1. Fuel filter
EMU40141
Inspecting idle speed
ECM02231
When checking the engine idle speed,
make sure to supply water to the cooling
water passages by placing the outboard
motor in the water or by using a flushing
attachment or test tank.
To check the engine idle speed, a diagnostic
tachometer is required. For checking or adjustment of the engine idle speed, consult a
Yamaha dealer.
ECM01711
Change the engine oil after the first 20
hours of operation or 3 months, and every
100 hours or at 1-year intervals thereafter.
Otherwise the engine will wear quickly.
To prevent spilling oil where it could cause
damage to nature, it is strongly recommended that you use an oil changer to change the
engine oil. If an oil changer is not available,
drain the engine oil by removing the drain
screw. If you are not familiar with the procedure for changing the engine oil, consult your
Yamaha dealer.
(1) Put the outboard motor in an upright po-
sition (not tilted). NOTICE: If the out-
board motor is not level, the oil level
indicated on the oil dipstick may not
be accurate.
[ECM01862]
EMU3951E
Changing engine oil
EWM00761
Avoid draining the engine oil immediate-
ly 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.
57
(2) Start the engine. Warm it up and keep
the idle speed for 5-10 minutes.
(3) Stop the engine and leave it for 5-10 min-
utes.
(4) Remove the top cowling.
(5) Remove the oil filler cap.
Page 63
Maintenance
TIP:
TIP:
TIP:
TIP:
1
2
1
1
2
1. Oil filler cap
2. Oil lubrication check window
The oil lubrication check window does not indicate the engine oil level. Use the oil lubrication check window to make sure that the
engine is being lubricated with oil while it is
running.
(6) Insert the tube of the oil changer into the
oil filler hole, and then extract the engine
oil completely using the oil changer.
1. Oil changer
When using an oil changer, skip steps 7 and
8.
(7) Prepare a suitable container that holds a
larger amount than the engine oil capacity. Remove the drain screw and gasket
while holding the container under the
drain hole. Let the oil drain completely.
Wipe up any spilled oil immediately.
1. Drain screw
2. Gasket
If the oil does not drain easily, change the tilt
angle or turn the outboard motor to port and
starboard to drain the oil.
(8) Put a new gasket on the oil drain screw.
Apply a light coat of oil to the gasket and
install the drain screw.
Drain screw tightening torque:
18 N·m (1.8 kgf·m, 13 lb·ft)
If a torque wrench is not available when you
are installing the drain screw, finger tighten
the screw just until the gasket comes into
contact with the surface of the drain hole.
Then tighten 1/4 to 1/2 turn more. Tighten the
drain screw to the correct torque with a
torque wrench as soon as possible.
(9) Add the correct amount of oil through the
filler hole. NOTICE: Overfilling the oil
could cause leakage or damage. If the
oil level is above the upper mark, ex-
tract oil until the oil is between the up-
per and lower marks.
[ECM02183]
58
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Maintenance
TIP:
1
2
3
Recommended engine oil:
YAMALUBE 4 or 4-stroke outboard
motor oil
Engine oil quantity:
0.6 L (0.63 US qt, 0.53 Imp.qt)
(10) Install the oil filler cap and tighten it com-
pletely.
(11) Wait 5-10 minutes until the oil settles.
(12) Remove the oil filler cap and wipe the at-
tached oil dipstick clean.
(13) Install the oil filler cap and tighten it com-
pletely.
(14) Remove the oil filler cap again and check
that the oil level on the dipstick is be-
tween the upper and lower marks. If the
oil level is not at the proper level, add or
extract oil until the oil is between the up-
per and lower marks.
1. Oil dipstick
2. Upper mark
3. Lower mark
(15) Install the top cowling.
(16) Start the engine and make sure that
there are no oil leaks. NOTICE: If there
are oil leaks, stop the engine and find
the cause. Consult your Yamaha deal-
er if the problem cannot be located
and corrected. Continued operation
with a problem could cause severe
engine damage.
[ECM02151]
(17) Dispose of used oil according to local
regulations.
For more information on the disposal of
used oil, consult your Yamaha dealer.
Change the oil more often when operating
the engine under adverse conditions such
as extended trolling.
EMU48060
Why Yamalube
YAMALUBE oil is a Genuine YAMAHA Part
born of the engineers’ passion and belief that
engine oil is an important liquid engine component. We form teams of specialists in the
fields of mechanical engineering, chemistry,
electronics and track testing, and have them
develop the engine together with the oil it will
use. Yamalube oils take full advantage of the
base oil’s qualities and blend in the ideal balance of additives to make sure the final oil
clears our performance standards. Thus,
Yamalube mineral, semisynthetic and synthetic oils have their own distinct characters
and value. Yamaha’s experience gained over
many years of research and development
into oil since the 1960’s helps make
Yamalube the best choice for your Yamaha
engine.
EMU39773
Checking electrical connectors and
electrical leads
For checking of the following items for the
connectors and leads, consult a Yamaha
dealer.
59
Page 65
Check that each connector is connected
ZMU06879
1
5
4
3
2
1
securely.
Check that each ground lead is secured
properly.
EMU39303
Checking propeller
EWM02281
You could be seriously injured if the engine accidentally starts when you are near
the propeller. Before inspecting, removing, or installing the propeller, place the
gear shift lever in neutral, and remove the
clip from the engine shut-off switch.
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.
Maintenance
1. Propeller shaft
Check the propeller shaft oil seal for dam-
age.
EMU30663
Removing propeller
EMU39311
Spline models
(1) Straighten the cotter pin and pull it out
using a pair of pliers.
(2) Remove the propeller nut and washer.
WARNING! Do not use your hand to
hold the propeller when loosening the
propeller nut.
[EWM01891]
Checkpoints
Check each of the propeller blades for ero-
sion from cavitation or ventilation, or other
damage.
Check the propeller shaft for damage.
Check the splines for wear or damage.
Check for fish line tangled around the pro-
peller shaft.
1. Cotter pin
2. Propeller nut
3. Washer
4. Propeller
5. Thrust washer
(3) Remove the propeller and thrust washer.
60
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Maintenance
TIP:
5
4
3
2
1
EMU30673
Installing propeller
EMU39327
Spline models
ECM00502
Make sure to use a new cotter pin and
bend the ends over securely. Otherwise,
the propeller could come off during operation and be lost.
(1) Apply Yamalube Marine Grease or
Yamaha grease D (corrosion resistant
grease) to the propeller shaft.
(2) Install the thrust washer and propeller
onto the propeller shaft. NOTICE: Make
sure to install the thrust washer before
installing the propeller. Otherwise, the
lower case and propeller boss could
be damaged.
(3) Install the washer and tighten the propel-
ler nut until there is no looseness in the
propeller.
[ECM01882]
NOTICE: Do not reuse the cotter pin.
Otherwise, the propeller can come off
during operation.
[ECM01892]
If the propeller nut hole does not align with
the propeller shaft hole after tightening the
propeller nut, tighten the nut further or loosen
the nut to align the holes.
EMU39785
Changing gear oil
EWM02351
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.
1. Cotter pin
2. Propeller nut
3. Washer
4. Propeller
5. Thrust washer
(4) Align the propeller nut hole with the pro-
peller shaft hole. Insert a new cotter pin
in the holes and bend the cotter pin ends.
61
(1) Put the outboard motor in an upright po-
sition (not tilted).
(2) Place a suitable container under the gear
case.
(3) Remove the gear oil drain screw and
gasket.
Page 67
Maintenance
TIP:
1
2
ZMU06780
1. Gear oil drain screw
2. Oil level plug
(4) Remove the oil level plug and gasket to
allow the oil to drain completely.
NOTICE: Check the used gear oil after
it has been drained. If the gear oil is
milky or contains water or a large
amount of metal particles, the gear
case may be damaged. Have a
Yamaha dealer check and repair the
outboard motor.
[ECM00714]
For disposal of used oil, consult your Yamaha
dealer.
(5) Using a flexible or pressurized filling de-
vice, inject the gear oil into the gear oil
drain screw hole.
Recommended gear oil:
YAMALUBE outboard gear oil or Hypoid gear oil
Recommended gear oil grade:
SAE 90 API GL-4
Gear oil quantity:
0.100 L (0.106 US qt, 0.088 Imp.qt)
(6) Put a new gasket on the oil level plug.
When the oil begins to flow out of the oil
level plug hole, insert and tighten the oil
level plug.
Tightening torque:
7 N·m (0.7 kgf·m, 5.2 lb·ft)
(7) Put a new gasket on the gear oil drain
screw. Insert and tighten the gear oil
drain screw.
Tightening torque:
7 N·m (0.7 kgf·m, 5.2 lb·ft)
EMU39333
Inspecting and replacing anode (external)
Yamaha outboard motors are protected from
corrosion by sacrificial anode. Inspect the external anode periodically. Remove scales
from the surface of the anode. Consult a
Yamaha dealer for replacement of the external anode.
ECM00721
Do not paint anodes, as this would render
them ineffective.
62
Page 68
Maintenance
1
1. Anode
63
Page 69
Trouble Recovery
EMU39524
Troubleshooting
This section describes the likely causes and
remedies for problems, such as those in the
fuel, compression, and ignition systems, poor
starting, and loss of power. Please note that
all of the items in this section may not apply
to your model.
If your outboard motor requires repair, bring
it to a Yamaha dealer.
Engine will not start.
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 fuel pump malfunctioning?
A. Have serviced by a Yamaha dealer.
Q. Is spark plug fouled or of incorrect type?
A. Inspect spark plug. Clean or replace with
recommended type.
A. Install clip to engine shut-off switch.
Q. Are engine inner parts damaged?
A. Have serviced by a Yamaha dealer.
Engine idles irregularly or stalls.
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. Are electrical parts malfunctioning?
A. Have serviced by a Yamaha dealer.
Q. Is spark plug gap incorrect?
A. Replace spark plug.
Q. Is spark plug wiring damaged or poorly
connected?
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires.
Q. Is spark plug cap fitted incorrectly?
A. Check and re-fit cap.
Q. Is spark plug wiring damaged or poorly
connected?
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires.
Q. Are electrical parts malfunctioning?
A. Have serviced by a Yamaha dealer.
Q. Is clip on engine shut-off cord (lanyard) installed?
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Is thermostat malfunctioning 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 malfunctioning?
A. Have serviced by a Yamaha dealer.
Q. Is air vent screw tightened?
64
Page 70
Trouble Recovery
A. Loosen air vent screw.
Q. Is choke knob pulled out?
A. Return to home position.
Q. Is carburetor clogged?
A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect?
A. Connect correctly.
Q. Is throttle cable adjustment incorrect?
A. Have serviced by a Yamaha dealer.
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 outboard motor mounted at incorrect
height on transom?
A. Have outboard motor adjusted to proper
transom height.
Q. Is boat bottom fouled with marine growth?
A. Clean boat bottom.
Q. Is spark plug fouled or of incorrect type?
A. Inspect spark plug. Clean or replace with
recommended type.
Q. Are weeds or other foreign material tangled on gear housing?
A. Remove foreign material 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. Replace spark plug.
Q. Is spark plug wiring damaged or poorly
connected?
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires.
Q. Are electrical parts malfunctioning?
A. Have serviced by a Yamaha dealer.
Q. Is specified fuel not being used?
A. Replace fuel with specified type.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Is thermostat malfunctioning or clogged?
A. Have serviced by a Yamaha dealer.
Q. Is air vent screw tightened?
A. Loosen air vent screw.
Q. Is fuel pump malfunctioning?
A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect?
65
Page 71
Trouble Recovery
A. Connect correctly.
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 material tangled on propeller?
A. Remove and clean propeller.
Q. Is steering pivot loose or damaged?
A. Have serviced by a Yamaha dealer.
EMU29435
Temporary action in emergen-
cy
EMU29442
Impact damage
EWM00871
The outboard motor can be seriously
damaged by a collision while operating or
trailering. Damage could make the outboard motor unsafe to operate.
If the outboard motor hits an object in the water, follow the procedure below.
(1) Stop the engine immediately.
(2) Check the control system and all compo-
nents for damage. Also, check the boat
for damage.
(3) Whether damage is found or not, return
to the nearest harbor slowly and carefully.
(4) Have a Yamaha dealer check the out-
board motor before operating it again.
EMU39792
Starter will not operate
If the starter mechanism does not operate
(the engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.
EWM02362
Use this procedure only for emergency
engine starting to return to the nearest
port for repairs.
When the emergency starter rope is
used to start the engine, the start-ingear protection device does not operate. Make sure that the shift lever is in
the neutral position. Otherwise, the boat
could unexpectedly start to move, which
could result in an accident.
Attach the engine shut-off cord to a se-
cure place on your clothing, or your arm
or leg while operating the boat.
Do not attach the cord to clothing that
could tear loose. Do not route the cord
where it could become entangled, preventing it from functioning.
Avoid accidentally pulling the cord dur-
ing normal operation. Loss of engine
power means the loss of most steering
control. Also, without engine power, the
boat could slow rapidly. This could
cause people and objects in the boat to
be thrown forward.
66
Page 72
Trouble Recovery
1
1
2
1
1
2
1
Make sure that no one is standing be-
hind you when pulling the starter rope. It
could whip behind you and injure someone.
An unguarded, rotating flywheel is very
dangerous. Keep loose clothing and
other objects away when starting the
engine. Use the emergency starter rope
only as instructed. Do not touch the flywheel or other moving parts when the
engine is running. Do not install the
starter mechanism or top cowling after
the engine is running.
Do not touch the ignition coil, spark plug
wire, spark plug cap, or other electrical
components when starting or operating
the outboard motor. You could get an
electrical shock.
EMU39534
Emergency engine starting
Before performing the following procedure,
make sure to read the emergency starting label on the manual starter/flywheel magnet
cover.
1. Neutral position
(2) Remove the top cowling.
(3) Loosen the nut, and then disconnect the
start-in-gear protection cable.
1. Start-in-gear protection cable
2. Nut
(4) Remove the manual starter/flywheel
magnet cover by removing the bolts.
1. Emergency starting label
(1) Move the gear shift lever to the neutral
position.
67
1. Bolt
2. Manual starter/flywheel magnet cover
(5) Reinstall 2 bolts to secure the fuel tank.
Page 73
(6) Insert the knotted end of the emergency
TIP:
ZMU06783
1
2
ZMU06744
12
ZMU06785
1
starter rope into the notch in the flywheel
magnet and wind the rope several turns
around the flywheel magnet clockwise.
Trouble Recovery
(8) Align the engine start mark “ ” on the
throttle grip with the notch in the tiller
handle.
1. Start mark “ ”
2. Notch
(9) Give a strong pull straight out to crank
and start the engine.
1. Notch
2. Emergency starter rope
(7) Attach the engine shut-off cord to a se-
cure place on your clothing, or your arm
or leg. Then, install the clip on the other
end of the cord to the engine shut-off
switch.
If the engine does not start after several attempts, pull out the choke knob.
1. Choke knob
68
Page 74
Trouble Recovery
EMU33502
Treatment of submerged motor
If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise
some corrosion may begin almost immediately. NOTICE: Do not attempt to run the
outboard motor until it has been completely inspected.
[ECM00402]
69
Page 75
INDEX
A
Alcohol and drugs...................................2
Anode (external), inspecting and
replacing............................................. 62
Anti-fouling paint .................................. 14
Avoid collisions.......................................3
B
Battery requirements............................11
Boat horsepower rating........................ 11
Boating safety......................................... 2
Boating safety publications .................... 4
Breaking in engine................................ 26
C
Carbon monoxide................................... 2
Carrying handle .................................... 22
CE Marking / UKCA Marking.................. 5
Checks after engine warm up............... 36
Checks after starting engine................. 35
Checks before starting engine.............. 26
Choke knob .......................................... 19
Clamping the outboard motor .............. 25
Cleaning the outboard motor ............... 50
Collisions with floating or submerged
objects.................................................. 3
Components diagram........................... 15
Control functions, checking.................. 27
Cooling water ....................................... 35
Cowling lock lever ................................ 21
Cruising in salt water or other
conditions...........................................44
D
Dismounting and transporting the
outboard motor .................................. 45
E
EC Declaration of Conformity (DoC)....... 5
Electric shock ......................................... 1
Electrical connectors and leads,
checking............................................. 59
Emergency engine starting................... 67
Emergency equipment ......................... 14
Emergency, temporary action in........... 66
Engine, checking ..................................29
Engine oil .............................................. 28
Engine oil, changing .............................57
Engine oil, filling.................................... 26
Engine oil requirements........................ 12
Engine shut-off cord (lanyard) .......... 1, 28
Engine shut-off cord (lanyard) and
clip...................................................... 19
Engine stop button ............................... 19
F
Filling fuel..............................................30
First-time operation ..............................26
Flushing in a test tank........................... 49
Fuel cock .............................................. 16
Fuel filter, checking............................... 56
Fuel joint cap ........................................ 20
Fuel leaks, checking for........................ 27
Fuel level...............................................27
Fuel requirements................................. 13
Fuel system...........................................27
Fuel tank (built-in fuel tank) ..................15
Fuel tank (portable fuel tank) ................ 16
G
Gasoline............................................1, 13
Gasoline exposure and spills.................. 1
Gear oil, changing................................. 61
Gear shift lever...................................... 17
Greasing ...............................................55
H
Hot parts................................................. 1
I
Identification numbers record.................5
Idle speed, inspecting........................... 57
Impact damage.....................................66
Installation requirements ......................11
L
Laws and regulations.............................. 4
Lubrication............................................50
70
Page 76
INDEX
M
Maintenance chart 1............................. 52
Maintenance chart 2............................. 54
Manual starter handle........................... 20
Modifications .......................................... 2
Mounting height.................................... 24
Mounting the outboard motor ........ 11, 23
O
Operating engine .................................. 31
Outboard motor disposal
requirements ......................................14
Outboard motor (painted surface),
checking............................................. 51
Outboard motor safety ...........................1
Outboard motor serial number............... 5
Overloading ............................................ 2
P
Passenger training.................................. 4
Passengers............................................. 2
People in the water................................. 2
Periodic maintenance........................... 51
Personal flotation devices (PFDs)........... 2
Propeller ................................................. 1
Propeller, checking............................... 60
Propeller, installing ............................... 61
Propeller, removing ..............................60
Propeller selection................................ 12
R
Read manuals and labels ....................... 7
Replacement parts ............................... 51
Rotating parts......................................... 1
Starter will not operate .........................66
Starting engine......................................33
Start-in-gear protection........................ 12
Steering friction adjuster....................... 20
Stop switches ....................................... 36
Stopping boat....................................... 37
Stopping engine ...................................37
Storing outboard motor ........................ 48
Submerged outboard motor................. 69
T
Throttle friction adjuster........................18
Throttle grip ..........................................18
Throttle indicator................................... 18
Tiller handle ..........................................17
Tilt lock mechanism.............................. 21
Tilt support bar .....................................21
Tilting up and down.............................. 40
To use the battery................................. 11
Top cowling, installing.......................... 29
Top cowling, removing .........................27
Transporting and storing outboard
motor ..................................................45
Trim rod (tilt pin).................................... 21
Trimming outboard motor.....................38
Troubleshooting....................................64
W
Warming up engine...............................36
Warning labels ........................................ 7
Weather .................................................. 3
Y
Yamalube..............................................59
S
Sending fuel..........................................32
Severe operating conditions................. 51
Shallow water ....................................... 42
Shifting.................................................. 36
Shifting (checks after engine warm
up) ...................................................... 36
Spark plug, cleaning and adjusting ...... 56
Specifications ....................................... 10
71
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Page 78
Printed in Thailand
January 2022
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