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LIT-18626-05-81
User Manual
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Yamaha LIT-18626-05-81, 6M8-F8199-18 User Manual

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OWNER’S MANUAL
8D
U.S.A.Edition
LIT-18626-05-81
6M8-F8199-18
Read this owner’s manual carefully before operating your outboard motor.
ZMU01690

Important manual information

To the owner

Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains infor­mation needed for proper operation, mainte­nance and care. A thorough understanding of these simple instructions will help you ob­tain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important information is distinguished in the following ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
EWM00780
WARNING
Failure to follow WARNING instructions could result in severe injury or death the machine operator, a bystander, or a person inspecting or repairing the out­board motor.
ECM00700
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
to
al, please consult your Yamaha dealer.
NOTE:
The 8MH 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.
8D
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation, USA
1st Edition, January 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in France
P/N LIT-18626-05-81
NOTE:
A NOTE provides key information to make procedures easier or clearer.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current prod­uct information available at the time of print­ing, there may be minor discrepancies between your machine and this manual. If there is any question concerning this manu-

Table of contents

General information .......................... 1
Identification numbers record.......... 1
Outboard motor serial number .......... 1
Emission control information ........... 1
North American models..................... 1
Safety information ........................... 2
Important labels............................... 3
Warning labels ..................................3
Basic boating rules (Rules of the
road) .............................................. 4
Steering and sailing rules and sound
signals............................................. 4
Rules when encountering vessels .... 4
Other special situations..................... 5
Fueling instructions ......................... 7
Gasoline............................................ 8
Engine oil ..........................................8
Propeller selection........................... 8
Start-in-gear protection ................... 9
Basic components ..........................10
Main components.......................... 10
Fuel tank .........................................10
Fuel joint ......................................... 11
Fuel gauge ...................................... 11
Fuel tank cap .................................. 11
Air vent screw ................................. 11
Tiller handle .................................... 11
Gear shift lever................................ 11
Throttle grip..................................... 11
Throttle indicator .............................12
Throttle friction adjuster................... 12
Engine stop lanyard switch .............12
Engine stop button .......................... 13
Choke knob for pull type .................13
Manual starter handle .....................13
Steering friction adjuster .................13
Trim rod (tilt pin).............................. 14
Shallow water lever......................... 14
Tilt support knob ............................. 14
Top cowling lock lever(s) (turn
type).............................................. 14
Operation .........................................16
Installation ..................................... 16
Mounting the outboard motor.......... 16
Clamping the outboard motor ......... 17
Breaking in engine ........................ 18
Gasoline and engine oil mixing
chart (25:1).................................... 18
Procedure for pre-mixed models..... 18
Preoperation checks ..................... 19
Fuel .................................................19
Oil.................................................... 19
Controls........................................... 19
Engine ............................................. 19
Filling fuel and engine oil .............. 19
Filling fuel for portable tank ............. 19
Gasoline and oil mixing (100:1)....... 20
Operating engine .......................... 20
Feeding fuel (portable tank) ............20
Starting engine ................................ 21
Warming up engine....................... 23
Choke start models .........................23
Shifting.......................................... 23
Forward (tiller handle and remote
control models) .............................23
Reverse (manual tilt and hydro tilt
models) ......................................... 24
Stopping engine............................ 24
Procedure........................................ 24
Trimming outboard motor.............. 25
Adjusting trim angle for manual tilt
models ..........................................26
Adjusting boat trim ..........................26
Tilting up and down....................... 27
Procedure for tilting up (manual tilt
models) ......................................... 28
Procedure for tilting down (manual
tilt models)..................................... 29
Cruising in shallow water .............. 29
Cruising in shallow water (manual
tilt models)..................................... 29
Cruising in other conditions........... 30
Maintenance .................................... 31
Specifications................................ 31
Transporting and storing
outboard motor ........................... 31
Clamp screw mounting models ....... 32
Storing outboard motor ...................32
Procedure........................................ 33
Lubrication (except oil injection
models) ......................................... 34
Cleaning and anticorrosion
measures ...................................... 34
Cleaning the outboard motor .......... 34
Checking painted surface of
motor............................................. 34
Periodic maintenance.................... 34
Replacement parts.......................... 35
Maintenance chart .......................... 36
Greasing ......................................... 37
Cleaning and adjusting spark plug.. 37
Checking fuel system...................... 38
Checking fuel filter .......................... 39
Inspecting idling speed ................... 39
Checking wiring and connectors ..... 40
Exhaust leakage ............................. 40
Water leakage................................. 40
Checking propeller .......................... 40
Removing the propeller................... 41
Installing the propeller..................... 41
Changing gear oil............................ 42
Cleaning fuel tank ...........................42
Inspecting and replacing anode(s).. 43
Checking top cowling ...................... 43
Coating the boat bottom.................. 44
Trouble Recovery............................ 45
Troubleshooting ............................ 45
Temporary action in emergency.... 48
Impact damage ...............................48
Starter will not operate .................... 48
Emergency starting engine .............49
Treatment of submerged motor..... 50
Procedure ....................................... 50
Consumer information.................... 52
Important warranty information for
U.S.A. and Canada ..................... 52
YAMAHA MOTOR
CORPORATION, U.S.A. OUTBOARD MOTOR TWO
YEAR LIMITED WARRANTY ...... 54
IMPORTANT WARRANTY
INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE
U.S.A. OR CANADA ...................57
Table of contents

General information

Identification numbers record

Outboard motor serial number
The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket or the upper part of the swivel bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto­len.
1
ZMU02836
1. Outboard motor serial number location
engine for details.
Approval label of emission control certif­icate
This label is attached to the bottom cowling. Existing Technology; N/A
1
ZMU02839
1. Approval label location

Emission control information

North American models
This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for ma­rine SI engines. See the label affixed to your
1
ZMU02896
Manufactured date label
This label is attached to the clamp bracket or the swivel bracket.
1
ZMU02838
1. Manufactured date label location
Manufactured:
ZMU04346

Safety information

●
Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation
●
Before operating the boat, read any own­er’s or operator’s manuals supplied with it and all labels. Be sure you understand each item before operating.
●
Do not overpower the boat with this out­board motor. Overpowering the boat could result in loss of control. The rated power of the outboard should be equal to or less than the rated horsepower capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer.
General information
●
Do not modify the outboard. Modifications could make the motor unfit or unsafe to use.
●
Never operate after drinking alcohol or tak­ing drugs. About 50% of all boating fatali­ties involve intoxication.
●
Have an approved personal flotation de­vice (PFD) on board for every occupant. It is a good idea to wear a PFD whenever boating. At a minimum, children and non­swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating condi­tions. Gasoline is highly flammable, and its va-
●
pors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel be­fore starting the engine.
●
This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain dam­age or death when inhaled. Symptoms in­clude nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilat­ed. Avoid blocking exhaust outlets. Check throttle, shift, and steering for prop-
●
er operation before starting the engine.
●
Attach the engine stop switch lanyard cord to a secure place on your clothing, or your arm or leg while operating. If you acciden­tally leave the helm, the cord will pull from the switch, stopping the engine.
●
Know the marine laws and regulations where you will be boating—and obey them. For basic boating rules, see “Rules of the road” on page 4.
●
Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.
●
Tell someone where you are going: leave
2
General information
a Float Plan with a responsible person. Be sure to cancel the Float Plan when you re­turn.
●
Use common sense and good judgment when boating. Know your abilities, and be sure you understand how your boat han­dles under the different boating conditions you may encounter. Operate within your limits, and the limits of your boat. Always operate at safe speeds, and keep a careful watch for obstacles and other traffic. Always watch carefully for swimmers dur-
●
ing the engine operation.
●
Stay away from swimming areas. When a swimmer is in the water near you
●
shift into neutral and shut off the engine. Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the fol­lowing:
United States Coast Guard
Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Af­fairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647
National Marine Manufacturers Associa­tion (NMMA)
401 N. Michigan Ave. Chicago, Il 60611
Marine Retailers Association of America
155 N. Michigan Ave. Chicago, Il 60601

Important labels

Warning labels
ZMU02841
ZMU02842
Label
EWM01260
WARNING
●
Be sure shift control is in neutral before starting engine. (except 2HP)
●
Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away
●
from flywheel and other rotating parts while engine is running.
Label
EWM01300
WARNING
This engine is equipped with a neutral
●
3
General information
starting device.
●
The engine will not start unless the shift
control is in neutral position.
Basic boating rules (Rules of
the road)
Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast Guard and local agen­cies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water. Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the Road. The rules presented here in your Owner’s Manual are condensed, and have been pro­vided for your convenience only. Consult your local U.S. Coast Guard Auxiliary or De­partment of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat.
Steering and sailing rules and sound signals
Whenever two vessels on the water meet one another, one vessel has the right-of­way; it is called the “stand-on” vessel. The vessel which does not have the right-of-way is called the “give-way” or “burdened” vessel. These rules determine which vessel has the right-of-way, and what each vessel should do.
Stand-on vessel
The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision. When you maintain your direction and speed, the other
vessel will be able to determine how best to avoid you.
Give-way vessel
The vessel which does not have the right-of­way has the duty to take positive and timely action to stay out of the way of the Stand-On vessel. Normally, you should not cross in front of the vessel with the right-of-way. You should slow down or change directions brief­ly and pass behind the other vessel. You should always move in such a way that the operator of the other vessel can see what you are doing.
“The general prudential rule”
This rule is called Rule 2 in the International Rules and says, “In obeying and construing these rules due regard shall be had to all dangers of naviga­tion and collision, and to any special circum­stances, which may render a departure from the above rules necessary in order to avoid immediate danger.” In other words, follow the standard rules ex­cept when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become “Give-Way” ves­sels.
Rules when encountering vessels
There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed:
Meeting:
sel head-on)
Crossing:
er vessel’s path)
Overtaking:
passed by another vessel) In the following illustration, your boat is in the center. You should give the right-of-way to any vessels shown in white area (you are the
(you are approaching another ves-
(you are traveling across the oth-
(you are passing or being
4
General information
Give-Way vessel). Any vessels in the shad­ed area must yield to you (they are the Give­Way vessels). Both you and the meeting vessel must alter course to avoid each other.
Meeting
If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of­way! Both of you should alter course to avoid an accident. You should keep the other ves­sel on your port (left) side. This rule doesn’t apply if both of you will clear one another if you continue on your set course and speed.
Crossing
When two power driven vessels are crossing each other’s path close enough to run the risk of collision, the vessel which has the oth­er on the starboard (right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; you are the Give-Way vessel. If the other
vessel is on your port (left) side, remember that you should maintain course and direc­tion, provided the other vessel gives you the right-of-way as it should.
Overtaking
If you are passing another vessel, you are the “Give-Way” vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if an­other vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.
Other special situations
There are three other rules you should be aware of when driving your boat around oth­er vessels.
Narrow channels and bends
When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a power­driven vessel is preparing to go around a bend that may obstruct the view of other wa­ter vessels, the operator should sound a pro­longed blast on the whistle (4 to 6 seconds). If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still pro­ceed around the bend with caution. If you navigate such waters with your boat, you will
5
General information
need to carry a portable air horn, available from local marine supply stores.
Fishing vessel right-of-way
All vessels which are fishing with nets, lines or trawls are considered to be “fishing ves­sels” under the International Rules. Vessels with trolling lines are not considered fishing vessels. Fishing vessels have the right-of­way regardless of position. Fishing vessels cannot, however, impede the passage of other vessels in narrow channels.
Sailing vessel right-of-way
Sailing vessels should normally be given the right-of-way. The exceptions to this are:
1. When the sailing vessel is overtaking
the power-driven vessel, the power-driv­en vessel has the right-of-way.
2. Sailing vessels should keep clear of any
fishing vessel.
3. In a narrow channel, a sailing vessel
should not hamper the safe passage of a power-driven vessel which can navi­gate only in such a channel.
Reading buoys and other markers
The waters of the United states are marked for safe navigation by the lateral system of buoyage. Simply put, buoys and markers have an arrangement of shapes, colors, numbers and lights to show which side of the buoy a boater should pass on when navigat­ing in a particular direction. The markings on these buoys are oriented from the perspec­tive of being entered from seaward (the boat­er is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open wa­ter into port, and black buoys are to port (left) side. When navigating out of port, your posi­tion with respect to the buoys should be re­versed; red buoys should be to port and black buoys to starboard.
Many bodies of water used by boaters are entirely within the boundaries of a particular state. The Uniform State Waterway Marking System has been devised for these waters. This system uses buoys and signs with dis­tinctive shapes and colors to show regulato­ry or advisory information. These markers are white with black letters and orange boarders. They signify speed zones, restrict­ed areas, danger areas, and general infor­mation. Remember, markings may vary by geo­graphic location. Always consult local boat­ing authorities before driving your boat in unfamiliar waters.
6
General information

Fueling instructions

EWM00010
WARNING
GASOLINE AND ITS VAPORS ARE HIGH­LY FLAMMABLE AND EXPLOSIVE!
●
Do not smoke when refueling, and keep
7
ZMU01708
away from sparks, flames, or other sources of ignition.
●
Stop engine before refueling.
●
Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat.
●
Take care not to spill gasoline. If gaso­line spills, wipe it up immediately with
General information
dry rags.
●
Do not overfill the fuel tank.
Tighten the filler cap securely after re-
●
fueling.
●
If you should swallow some gasoline,
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.
If any gasoline spills onto your skin, im-
●
mediately wash with soap and water.
Change clothing if gasoline spills on it.
Touch the fuel nozzle to the filler open-
●
ing or funnel to help prevent electro-
static sparks.
ECM00010
CAUTION:
Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign mat­ter.
Gasoline
If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.
Recommended gasoline:
Regular unleaded gasoline with a min­imum octane rating of 86 (Pump Oc­tane Number) = (R+M)/2
Gasohol
There are two types of gasohol: gasohol con­taining ethanol and that containing metha­nol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Yamaha does not recommended gasohol containing methanol because it can cause fuel system damage or engine performance problems.
Engine oil
If the recommended engine oil is not avail­able, another 2-stroke engine oil with an NMMA-certified TC-W3 rating may be used.
Recommended engine oil:
YAMALUBE 2-stroke outboard motor oil

Propeller selection

The performance of your outboard motor will be critically affected by your choice of propel­ler, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine. Yamaha outboard motors are fitted with pro­pellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suit­able as it enables the correct engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable for a smaller oper­ating load. Yamaha dealers stock a range of propellers, and can advise you and install a propeller on your outboard that is best suited to your ap­plication.
8
General information
—
×
9 1
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
NOTE:
Select a propeller which will allow the engine to reach the middle or upper half of the oper­ating range at full throttle with the maximum boat load. If operating conditions such as light boat loads then allow the engine r/min to rise above the maximum recommended range, reduce the throttle setting to maintain the engine in the proper operating range.
7 2
N
3
ZMU02844
For instructions on propeller removal and in­stallation, see page 40.
Start-in-gear protection
Yamaha outboard motors or Yamaha-ap­proved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is in neutral. Always select neutral before starting the engine.
9

Basic components

Main components

NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all mod­els.
8D
15
14
13 12
11 10
9
8
7
1. Manual starter handle
2. Engine stop button/Engine stop lanyard switch
3. Choke knob
4. Throttle grip
5. Throttle friction adjuster
6. Clamp screw
7. Cooling water inlet
8. Anti-cavitation plate
9. Trim rod
10. Shallow water lever
11. Rope attachment
12. Tilt support knob
13. Cooling water pilot hole
14. Gear shift lever
1
3
4
5
2
6
16
ZMU04490
15. Top cowling
16. Fuel tank*

Fuel tank

If your model was equipped with a portable fuel tank, its function is as follows.
EWM00020
WARNING
The fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Com­mercial users should conform to relevant licensing or approval authority regula-
10
Basic components
tions.
1. Air vent screw
2. Fuel gauge
3. Fuel joint
4. Fuel tank cap
4
3
1
2
ZMU01992
Fuel joint
This joint is used to connect the fuel line.
Fuel gauge
This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the ap­proximate amount of fuel remaining in the tank.
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.

Tiller handle

To change direction, move the tiller handle to the left or right as necessary.
ZMU02846

Gear shift lever

Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead. Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern.
R
N
F
123
ZMU02847
1. Neutral “”
2. Forward “”
3. Reverse “”
Throttle grip
The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.
11
ZMU02848
Throttle indicator
The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation.
1
ZMU02849
1. Throttle indicator
Throttle friction adjuster
A friction device provides adjustable resis­tance to movement of the throttle grip or the remote control lever, and can be set accord­ing to operator preference. To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.
EWM00030
WARNING
Do not overtighten the friction adjuster. If
Basic components
there is too much resistance, it could be difficult to move throttle lever or grip, which could result in an accident.
ZMU02850
When constant speed is desired, tighten the adjuster to maintain the desired throttle set­ting.

Engine stop lanyard switch

The lock plate must be attached to the en­gine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away un­der power.
EWM00120
WARNING
Attach the engine stop switch lanyard
●
to a secure place on your clothing, or your arm or leg while operating. Do not attach the lanyard to clothing
●
that could tear loose. Do not route the lanyard where it could become entan­gled, preventing it from functioning.
●
Avoid accidentally pulling the lanyard during normal operation. Loss of en­gine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This
12
Basic components
could cause people and objects in the
boat to be thrown forward.
NOTE:
The engine cannot be started with the lock plate removed.
1
2
ZMU02851
1. Lock plate
2. Lanyard
Engine stop button
To open the ignition circuit and stop the en­gine, push this button.
ZMU02860
Manual starter handle
To start the engine, first gently pull the han­dle out until resistance is felt. From that posi­tion, then pull the handle straight out quickly to crank the engine.
ZMU02852
Choke knob for pull type
To supply the engine with the rich fuel mix­ture required to start, pull out this knob.
13
Steering friction adjuster
A friction device provides adjustable resis­tance to the steering mechanism, and can be set according to operator preference. An ad­justing screw or bolt is located on the swivel bracket.
Basic components
ZMU04508
To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.
EWM00040
WARNING
Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident.
Trim rod (tilt pin)
The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.
ZMU02854
Tilt support knob
To keep the outboard motor in the tilted up position, push the tilt support knob under the swivel bracket.
ZMU02855
Top cowling lock lever(s) (turn type)
To remove the engine top cowling, turn the lock lever(s) and lift off the cowling. When in­stalling the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by returning the lever(s) to the lock position.
ZMU02853
Shallow water lever
Pushing this lever down will tilt the motor up partially to provide more clearance when op­erating in shallow water.
14
Basic components
1
ZMU02862
1. Top cowling lock lever(s)
15

Operation

Installation

ECM00110
CAUTION:
Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat, or accessories such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operated continuously in the presence of airborne water spray.
NOTE:
During water testing check the buoyancy of the boat, at rest, with its maximum load. Check that the static water level on the ex­haust housing is low enough to prevent wa­ter entry into the powerhead, when water rises due to waves when the outboard is not running.
Mounting the outboard motor
EWM00820
WARNING
Overpowering a boat could cause se-
●
vere instability. Do not install an out-
board motor with more horsepower
than the maximum rating on the capac-
ity plate of the boat. If the boat does not
have a capacity plate, consult the boat
manufacturer.
●
The information presented in this sec-
tion is intended as reference only. It is
not possible to provide complete in-
structions for every possible boat and
motor combination. Proper mounting
depends in part on experience and the
specific boat and motor combination.
EWM00830
WARNING
Improper mounting of the outboard mo­tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Observe the following:
●
For permanently mounted models, your dealer or other person experienced in proper rigging should mount the motor. If you are mounting the motor yourself, you should be trained by an experi­enced person.
●
For portable models, your dealer or oth­er person experienced in proper out­board motor mounting should show you how to mount your motor.
Mount the outboard motor on the center line (keel line) of the boat, and ensure that the boat itself is well balanced. Otherwise the boat will be hard to steer. For boats without a keel or which are asymmetrical, consult your dealer.
1
1. Center line (keel line)
Mounting height
To run your boat at optimum efficiency, the water resistance (drag) of the boat and out­board motor must be made as little as possi­ble. The mounting height of the outboard
ZMU01760
16
Operation
motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the en­gine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in.) below it.
0–25mm (0–1in.)
ZMU02011
NOTE:
The optimum mounting height of the out-
●
board motor is affected by the boat and
motor combination and the desired use.
Test runs at different heights can help de-
termine the optimum mounting height.
Consult your Yamaha dealer or boat man-
ufacturer for further information on deter-
mining the proper mounting height.
●
For instructions on setting the trim angle of
the outboard motor, see page 25.
Clamping the outboard motor
1. Place the outboard motor on the tran-
som so that it is positioned as close to the center as possible. Tighten the tran­som clamp screws evenly and securely. Occasionally check the clamp screws for tightness during operation of the out­board motor because they could be-
come loose due to engine vibration.
EWM00640
WARNING
Loose clamp screws could allow the out­board motor to fall off or move on the transom. This could cause loss of control and serious injury. Make sure the tran­som screws are tightened securely. Oc­casionally check the screws for tightness during operation.
ZMU02012
2. If the engine restraint cable attachment is equipped on your engine, an engine restraint cable or chain should be used. Attach one end to the engine restraint cable attachment and the other to a se­cure mounting point on the boat. Other­wise the engine could be completely lost if it accidentally falls off the transom.
ZMU02013
3. Secure the clamp bracket to the transom using the bolts provided with the out-
17
Operation
board (if packed). For details, consult your Yamaha dealer.
EWM00650
WARNING
Avoid using bolts, nuts or washers other than those contained in the engine pack­aging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tighten­ing, test run the engine and check their tightness.
1
ZMU02637
1. Bolts

Breaking in engine

Your new engine requires a period of break­in to allow mating surfaces of moving parts to wear in evenly. Correct break-in will help en­sure proper performance and longer engine life.
ECM00800
CAUTION:
Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage.
Gasoline and engine oil mixing chart (25:1)
1. : Gasoline
2. : Engine oil
ECM00150
CAUTION:
Be sure to mix gasoline and oil complete­ly, otherwise the engine may be dam­aged.
Procedure for pre-mixed models
Run the engine under load (in gear with a propeller installed) as follows.
1. First 10 minutes: Run the engine at the lowest possible speed. A fast idle in neutral is best.
2. Next 50 minutes: Do not exceed half throttle (approxi­mately 3000 r/min). Vary engine speed occasionally. If you have an easy-plan­ing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3000 r/min or less.
3. Second hour: Accelerate at full throttle onto plane, then reduce engine speed to three-quar­ter throttle (approximately 4000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three­quarter throttle or less to let the engine
18
Operation
cool.
4. Third through tenth hours: Avoid operating at full throttle for more than 5 minutes at a time. Let the engine cool between full-throttle runs. Vary en­gine speed occasionally.
5. After the first 10 hours: Operate the engine normally. Use the standard premix ratio of gasoline and oil. For details on mixing fuel and oil, see page 20.

Preoperation checks

EWM00080
WARNING
If any item in the preoperation check is not working properly, have it inspected and repaired before operating the out­board motor. Otherwise an accident could occur.
ECM00120
CAUTION:
Do not start the engine out of water. Over­heating and serious engine damage can occur.
Fuel
Check to be sure you have plenty of fuel
●
for your trip.
●
Make sure there are no fuel leaks or gaso­line fumes. Check fuel line connections to be sure they
●
are tight (if equipped Yamaha fuel tank or boat tank). Be sure the fuel tank is positioned on a se-
●
cure, flat surface, and that the fuel line is not twisted or flattened, or likely to contact sharp objects (if equipped Yamaha fuel tank or boat tank).
Oil
●
Check to be sure you have plenty of oil for your trip.
Controls
●
Check throttle, shift, and steering for prop­er operation before starting the engine.
●
The controls should work smoothly, with­out binding or unusual free play. Look for loose or damaged connections.
●
●
Check operation of the starter and stop switches when the outboard motor is in the water.
Engine
●
Check the engine and engine mounting.
●
Look for loose or damaged fasteners.
●
Check the propeller for damage.

Filling fuel and engine oil

Filling fuel for portable tank
EWM00060
WARNING
Gasoline and its vapors are highly flam­mable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition.
1. Remove the fuel tank cap.
2. Fill the fuel tank carefully.
3. Close the cap securely after refueling. Wipe up any spilled fuel.
Fuel tank capacity (if equipped Yamaha fuel tank):
12L
19
Operation
Gasoline and oil mixing (100:1)
Gasoline to engine
oil ratio
Break-in period See page 18
After break-in 100:1
If equipped with a portable fuel tank
1. Pour oil into the portable fuel tank, and then add gasoline.
1. Engine oil
2. Gasoline
2. Replace the fuel tank cap and close tightly.
3. Shake the fuel tank to mix the fuel thor­oughly.
4. Make sure that the oil and gasoline are mixed.
If equipped with a built-in fuel tank
1. Pour oil into a clean fuel can, and then add gasoline.
2. Replace the fuel can cap and close tight­ly.
3. Shake the fuel can to mix the fuel thor­oughly.
4. Make sure that the oil and gasoline are mixed.
5. Pour the gasoline and oil mixture into the built-in fuel tank.
NOTE:
If using a permanently installed tank, pour the oil gradually as the gasoline is being add­ed to the tank.

Operating engine

Feeding fuel (portable tank)
EWM00420
WARNING
●
Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you.
●
When the air vent screw is loosened, gasoline vapor will be released. Gaso­line is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosen­ing the air vent screw.
●
This product emits exhaust gases which contain carbon monoxide, a col­orless, odorless gas which could cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cab­in areas well ventilated. Avoid blocking exhaust outlets.
1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.
20
Operation
2. If there is a fuel joint on the motor, firmly connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank.
from the fuel tank.
4. Squeeze the primer pump with the outlet end up until you feel it become firm.
ZMU02025
Starting engine
Manual start models (tiller control)
1. Place the gear shift lever in neutral.
ZMU02024
3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp.
NOTE:
During engine operation place the tank hori­zontally, otherwise fuel cannot be drawn
21
NOTE:
The start-in-gear protection device prevents the engine from starting except when in neu­tral.
2. Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the en­gine stop switch.
EWM00120
WARNING
●
Attach the engine stop switch lanyard
to a secure place on your clothing, or your arm or leg while operating. Do not attach the lanyard to clothing
●
that could tear loose. Do not route the lanyard where it could become entan­gled, preventing it from functioning.
●
Avoid accidentally pulling the lanyard during normal operation. Loss of 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.
Operation
ZMU02860
NOTE:
It is not necessary to use the choke when
●
starting a warm engine. If the choke knob is left in the “”
●
(start) position while the engine is running, the engine will run poorly or stall.
5. Pull the manual starter handle slowly un­til you feel resistance. Then give a strong pull straight out to crank and start the engine. Repeat if necessary.
3. Place the throttle grip in the “” (start) position.
6. After the engine starts, slowly return the
7. Slowly return the throttle grip to the fully
4. Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position.
manual starter handle to its original po­sition before releasing it.
closed position.
22
Operation
ZMU02030
NOTE:
When the engine is cold, it needs to be
●
warmed up. For further information, see page 23. If the engine does not start on the first try,
●
repeat the procedure. If the engine fails to start after 4 or 5 tries, open the throttle a small amount (between 1/8 and 1/4) and try again. Also if the engine is warm and fails to start, open the throttle a same amount and try to start the engine again. If the engine still fails to start, see page 45.
Warming up engine
Choke start models
1. After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life. Gradually re­turn the choke knob to its home position as the engine warms up.
2. Check for a steady flow of water from the cooling water pilot hole.
ECM00510
CAUTION:
A flow of water from the hole on the ex­haust cover shows that the water pump is pumping water through the cooling pas­sages. If water is not flowing out of the hole at all times while the engine is run­ning, overheating and serious damage
could occur. Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and cor­rected.
ZMU02856
Shifting
EWM00180
WARNING
Before shifting, make sure there are no swimmers or obstacles in the water near you.
ECM00220
CAUTION:
To change the boat direction or shifting position from forward to reverse or vice­versa, first close the throttle so that the engine idles (or runs at low speeds).
Forward (tiller handle and remote control models)
Tiller control models
1. Place the throttle grip in the fully closed position.
23
Operation
ZMU02030
2. Move the gear shift lever quickly and firmly from neutral to forward.
N
F
ZMU02866
Remote control models
1. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward.
Reverse (manual tilt and hydro tilt models)
EWM00190
WARNING
When operating in reverse, go slowly. Do not open the throttle more than half. Oth­erwise the boat could become unstable, which could result in loss of control and an accident.
Tiller control models
1. Place the throttle grip in the fully closed position.
ZMU02030
2. On models equipped with a tilt lock le­ver, check that it is in the lock/down po­sition.
3. Move the gear shift lever quickly and firmly from neutral to reverse.
N
R
ZMU02867
Remote control models
1. Check that the tilt lock lever is in the lock position.
2. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to reverse.

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.
Procedure
1. Push and hold the engine stop button
24
Operation
until the engine comes to a complete stop.
2. After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to the closed position, if equipped.
be stopped by pulling the lanyard and remov­ing the lock plate from the engine stop switch.

Trimming outboard motor

The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help im­prove performance and fuel economy while reducing strain on the engine. Correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.
EWM00740
WARNING
Excessive trim for the operating condi­tions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This in­creases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.
3. Disconnect the fuel line if you are using an external fuel tank.
NOTE:
If the outboard motor is equipped with an en­gine stop switch lanyard, the engine can also
25
1
ZMU02858
1. Trim operating angle
Adjusting trim angle for manual tilt models
There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim an­gle.
1. Stop the engine.
2. Remove the trim rod from the clamp bracket while slightly tilting the outboard motor up.
Operation
1
ZMU02859
1. Trim rod
3. Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom. To lower the bow (“trim-in”), move the rod to­ward the transom. Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.
EWM00400
WARNING
●
Stop the engine before adjusting the trim angle. Use care to avoid being pinched when
●
removing or installing the rod. Use caution when trying a trim position
●
for the first time. Increase speed gradu­ally and watch for any signs of instabil­ity or control problems. Improper trim angle can cause loss of control.
NOTE:
The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim rod one hole.
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
26
Operation
the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden­cy to steer to one side or the other. Compen­sate for this as you steer. The trim tab can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.
Bow Up
Too much trim-out puts the bow of the boat too high in the water. Performance and econ­omy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces per­formance further, and the boat may “por- poise” (hop in the water), which could throw the operator and passengers overboard.
Bow Down
Too much trim-in causes the boat to “plow” through the water, decreasing fuel economy
and making it hard to increase speed. Oper­ating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making opera­tion difficult and dangerous.
NOTE:
Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.

Tilting up and down

If the engine will be stopped for some time or if the boat is moored in shallows, the out­board motor should be tilted up to protect the propeller and casing from damage by colli­sion with obstructions, and also to reduce salt corrosion.
EWM00220
WARNING
Be sure all people are clear of the out­board motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket.
EWM00230
WARNING
Leaking fuel is a fire hazard. Tighten the air vent screw and place the fuel cock in the closed position if the outboard motor
27
will be tilted for more than a few minutes. Otherwise fuel may leak.
ECM00230
CAUTION:
●
Before tilting the outboard motor, fol­low the procedure under “Stopping en­gine”in this chapter. Never tilt the outboard motor while the engine is run­ning. Severe damage from overheating can result.
●
Do not tilt up the engine by pushing the tiller handle because this could break the handle.
●
Keep the power unit higher than the propeller at all times. Otherwise water could run into the cylinder and cause damage.
●
The outboard motor cannot be tilted when in reverse or when the outboard motor is turned 180° (facing the rear).
Procedure for tilting up (manual tilt models)
1. Place the gear shift lever in neutral.
Operation
3. Place the tilt lock lever (if equipped) in the release/up position.
4. Pull up the shallow water lever (if equipped).
ZMU02854
5. Hold the rear of the top cowling with one hand and tilt the engine up fully.
6. Push the tilt support knob into the clamp bracket. Or the tilt support bar will turn to the lock position automatically.
2. Disconnect the fuel line from the out­board motor.
ZMU02887
28
Operation
Procedure for tilting down (manual tilt models)
1. Slightly tilt the engine up.
2. On models equipped with a tilt support knob, pull it out.
ZMU02888
3. Slowly tilt the engine down.
Cruising in shallow water
The outboard motor can be tilted up partially to allow operation in shallow water.
Cruising in shallow water (manual tilt models)
EWM00710
WARNING
●
Place the gear shift in neutral before us­ing the shallow water cruising system.
●
Run the boat at the lowest possible speed when using the shallow water cruising system. The tilt lock mecha­nism does not work while the shallow water cruising system is being used. Hitting an underwater obstacle could cause the outboard motor to lift out of the water, resulting in loss of control.
●
Do not rotate the outboard motor 180° and operate the boat in reverse. Place the gear shift in reverse to operate the boat in reverse.
●
Use extra care when operating in re-
verse. Too much reverse thrust can cause the outboard motor to lift out of the water, increasing the chance of ac­cident and personal injury.
●
Return the outboard motor to its normal position as soon as the boat is back in deeper water.
ECM00260
CAUTION:
Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set­ting up for and cruising in shallow water. Otherwise severe damage from overheat­ing can result.
ZMU02868
Procedure
1. Place the gear shift lever in neutral.
2. Slightly tilt the outboard motor up. Pull up the shallow water lever.
29
ZMU02854
3. The shallow water lever will lock, sup­porting the outboard motor in a partially raised position.
4. When lowering the outboard motor, slightly tilt it up and push the shallow wa­ter lever down. Slowly lower the out­board motor to the normal position.
Cruising in other conditions
Cruising in salt water
After operating in salt water, wash out the cooling water passages with fresh water to prevent them from becoming clogged with salt deposits.
NOTE:
For cooling system flushing instructions, see page 31.
Operation
Cruising in turbid water
Yamaha strongly recommends that you use the optional chromium-plated water pump kit if you use the outboard motor in turbid (mud­dy) water conditions.
30

Maintenance

Specifications

Dimension:
Overall length:
802 mm (31.6 in)
Overall width:
343 mm (13.5 in)
Overall height S:
977 mm (38.5 in)
Transom height S:
436 mm (17.2 in)
Weight (AL) S:
27.0 kg (60 lb)
Performance:
Full throttle operating range:
4500–5500 r/min
Maximum output:
5.9 kW@5000 r/min (8 HP@5000 r/min)
Idling speed (in neutral):
900 ±50 r/min
Engine:
Type:
2-stroke L
Displacement:
165.0 cm
Bore × stroke:
50.0 × 42.0 mm (1.97 × 1.65 in)
Ignition system:
CDI
Spark plug (NGK):
B7HS-10
Spark plug gap:
0.9–1.0 mm (0.035–0.039 in)
Control system:
Tiller
Starting system:
Manual
Starting carburetion system:
Choke valve
Drive unit:
3
(10.07 cu.in)
Gear positions:
Forward-neutral-reverse
Gear ratio:
2.08 (27/13)
Trim and tilt system:
Manual tilt
Propeller mark:
N
Fuel and oil:
Recommended fuel:
Regular gasoline
Min. pump octane:
86
Recommended engine oil:
YAMALUBE 2-stroke outboard motor oil
Fuel:oil ratio:
Regular gasoline:
100 :1
Lubrication:
Pre-mixed fuel and oil
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
160.0 cm
3
(5.41 US oz) (5.64 Imp.oz)
Tightening torque for engine:
Spark plug:
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
Propeller nut:
17.0 Nm (12.5 ft-lb) (1.73 kgf-m)
Transporting and storing
outboard motor
EWM00690
WARNING
Leaking fuel is a fire hazard. When
●
transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. USE CARE when transporting fuel tank,
●
31
Maintenance
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.
EWM00700
WARNING
Never get under the lower unit while it is tilted, even if a motor support bar is used. Severe injury could occur if the outboard motor accidentally falls.
ECM00660
CAUTION:
Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt sup­port and fall. If the motor cannot be trail­ered in the normal running position, use an additional support device to secure it in the tilt position.
The outboard motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the tilt po­sition using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details.
ZMU02870
Clamp screw mounting models
When transporting or storing the outboard motor while removed from a boat, keep the outboard motor in the attitude shown.
ZMU02869
NOTE:
Place a towel or something similar under the outboard motor to protect it from damage.
Storing outboard motor
When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the fol­lowing procedures.
ECM01411
CAUTION:
●
Do not place the outboard motor on its side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trou­ble.
●
Store the outboard motor in a dry, well­ventilated place, not in direct sunlight.
32
Maintenance
Procedure
Flushing in a test tank
1. Wash the outboard motor body using fresh water. For further information, see page 34.
2. Fill the fuel tank with fresh fuel and add one ounce of “Yamaha Fuel Conditioner and Stabilizer” (Part No. LUB-FUELC­12-00) to each gallon of fuel.
NOTE:
The use of “Yamaha Fuel Conditioner and Stabilizer” eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead.
3. Remove the engine top cowling and si­lencer cover.
4. Install the outboard motor on the test tank.
1
2
ZMU02051
1. Water surface
2. Lowest water level
5. Fill the tank with fresh water to above the level of the anti-cavitation plate.
ECM00300
CAUTION:
Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the en-
gine will be damaged from overheating. Before starting the engine, be sure to supply water to the cooling water passag­es.
ECM00290
CAUTION:
If the fresh water level is below the level of the anti-cavitation plate, or if the water supply is insufficient, engine seizure may occur.
6. Cooling system flushing is essential to prevent the cooling system from clog­ging up with salt, sand, or dirt. In addi­tion, fogging of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flushing and fogging at the same time.
EWM00090
WARNING
●
Do not touch or remove electrical parts when starting or during operation.
●
Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.
7. Run the engine at a fast idle for 10–15 minutes in neutral position.
8. Just prior to turning off the engine, quick­ly spray “Yamaha Stor-Rite Engine Fogging Oil” (Part No. LUB-STRRT-12-
00) alternately into each carburetor or the fogging hole of the silencer cover, if equipped. When properly done, the en­gine will smoke excessively and almost stall.
9. Remove the outboard motor from the test tank.
10. Drain the cooling water completely out of the motor. Clean the body thoroughly.
11. Install the silencer cover/cap and top cowling.
33
Lubrication (except oil injection models)
1. Grease the spark plug threads and in­stall the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 37.
2. Change the gear oil. For instructions, see page 42. Inspect the oil for the pres­ence of water that indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use.
3. Grease all grease fittings. For further de­tails, see page 37.
Cleaning and anticorrosion measures
1. Wash down the exterior of the outboard motor with fresh water and dry off com­pletely.
2. Spray the outboard motor exterior with “Yamaha Silicone Protectant” (Part No. LUB-SILCNE-13-00).
ECM01330
CAUTION:
If equipped Electronic Fuel Injection: Do not spray when the engine is running. Al­so, do not spray near the silencer and ox­ygen sensor cover or into the engine. Otherwise the oxygen sensor for Elec­tronic Fuel Injection system could be damaged.
3. Wax the cowling with a non-abrasive wax such as “Yamaha Silicone Wax” (Part No. ACC-11000-15-02).
Cleaning the outboard motor
After use, wash the exterior of the outboard motor with fresh water. Flush the cooling system with fresh water.
Maintenance
NOTE:
For cooling system flushing instructions, see page 31.
Checking painted surface of motor
Check the motor for scratches, nicks, or flak­ing paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is avail­able from your Yamaha dealer.

Periodic maintenance

EWM01070
WARNING
Be sure to turn off the engine when you perform maintenance unless otherwise specified. If you or the owner is not famil­iar with machine servicing, this work should be done by your Yamaha dealer or other qualified mechanic.
Maintenance, replacement, or repair of the emission control devices and sys­tems may be performed by any marine engine repair establishment or individual. All warranty repairs, however, including those to the emission control system, must be performed by an authorized Yamaha marine dealership.
A service manual is available for purchase through your Yamaha dealer for owners who
34
Maintenance
have the mechanical skills, tools, and other equipment necessary to perform mainte­nance not covered by this owner’s manual.
Replacement parts
If replacement parts are necessary, use only genuine Yamaha parts or parts of the same type and of equivalent strength and materi­als. Any part of inferior quality may malfunc­tion, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from your Yamaha dealer.
35
Maintenance

Maintenance chart

Frequency of maintenance operations may be adjusted according to the operating condi­tions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. The “” symbol indicates the check-ups which you may carry out yourself. The “” symbol indicates work to be carried out by your Yamaha dealer.
Initial Every
Item Actions
Anode(s) (external)
Anode(s) (internal)
Cooling water pas­sages
Cowling clamp Inspection
Fuel filter (disposable)
Fuel system Inspection
Fuel tank (Yamaha por­table tank)
Gear oil Change
Greasing points Greasing
Idling speed (carbure­tor models)
Propeller and cotter pin
Shift link / shift cable Inspection / adjustment
Thermostat Inspection
Throttle link / throttle cable / throttle pick-up timing
Water pump Inspection
Spark plug(s)
Inspection / replace­ment
Inspection / replace­ment
Cleaning
Inspection / replace­ment
Inspection / cleaning
Inspection / adjustment
Inspection / replace­ment
Inspection / adjustment
Cleaning / adjustment / replacement
10 hours
(1 month)
50 hours
(3
months)
100 hours (6 months)
200
hours (1
year)
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.
36
Maintenance
Greasing
Yamaha marine grease (Water resistant grease)
8D

Cleaning and adjusting spark plug

EWM00560
WARNING
When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or
37
ZMU02872
fire.
The spark plug is an important engine com­ponent and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For exam­ple, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not
Maintenance
attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically re­move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should re­place the spark plug with another of the cor­rect type.
Standard spark plug:
B7HS-10
Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification if necessary.
NOTE:
If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past fin­ger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.

Checking fuel system

EWM00900
WARNING
Gasoline and its vapors are highly flam­mable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition.
EWM00910
WARNING
Leaking fuel can result in fire or explo­sion.
●
Check for fuel leakage regularly.
●
If any fuel leakage is found, the fuel system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate.
1. Spark plug gap
2. Spark plug I.D. mark (NGK)
Spark plug gap:
0.9–1.0 mm (0.035–0.039 in)
When fitting the plug, always clean the gas­ket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque.
Spark plug torque:
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
Check the fuel lines for leaks, crack, or mal­function. If a problem is found, your Yamaha dealer or other qualified mechanic should re­pair it immediately.
38
Maintenance
ZMU04491
Checkpoints
●
Fuel system parts leakage
●
Fuel line joint leakage
●
Fuel line cracks or other damage
●
Fuel connector leakage

Checking fuel filter

Check the fuel filter periodically. The fuel fil­ter is a one piece, disposable type. If foreign matter is found in the filter, replace it. For re­placement of the fuel filter, consult your Yamaha dealer.
ZMU02874

Inspecting idling speed

EWM00450
WARNING
Do not touch or remove electrical parts
●
when starting or during operation.
●
Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.
●
2-hp models
: The propeller rotates whenever the engine is running. Do not move the throttle control lever from the start position during warm-up. The boat could unexpectedly start to move, which could result in an accident.
ECM00490
CAUTION:
This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used.
A diagnostic tachometer should be used for this procedure. Results may vary depending on whether testing is conducted with the flushing attachment, in a test tank, or with the outboard motor in the water.
1. Start the engine and allow it to warm up fully in neutral until it is running smooth­ly. 2-hp model: Warm the engine with the throttle in the start position or less. If the outboard is mounted on a boat, be sure the boat is tightly moored.
NOTE:
Correct idling speed inspection is only possi­ble if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty ver­ifying the idle speed, or the idle speed re­quires adjustment, consult a Yamaha dealer
39
Maintenance
or other qualified mechanic.
2. Verify whether the idle speed is set to specification. For idle speed specifica­tions, see page 31.

Checking wiring and connectors

●
Check that each grounding wire is properly secured. Check that each connector is engaged se-
●
curely.
ZMU02875
Exhaust leakage
Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head, and body cylinder.
Water leakage
Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head, and body cylinder.

Checking propeller

EWM00321
WARNING
You could be seriously injured if the en­gine accidentally starts when you are near the propeller.
●
Before inspecting, removing, or install­ing the propeller, remove the spark plug caps from the spark plugs. Also, place the shift control in neutral, turn
the main switch to “” (off) and re- move the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one. Do not use your hand to hold the pro-
●
peller 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.
ZMU02876
ZMU01897
Checkpoints
●
Check each of the propeller blades for wear, erosion from cavitation or ventila­tion, or other damage.
●
Check the propeller shaft for damage.
●
Check the splines / shear pin for wear or damage.
●
Check for fish line tangled around the pro­peller shaft.
40
Maintenance
Check the propeller shaft oil seal for dam-
●
age.
NOTE:
If the shear pin equipped: it is designed to break if the propeller hits a hard underwater obstacle to help protect the propeller and drive mechanism. The propeller will then spin freely on the shaft. If this happens, the shear pin must be replaced.
Removing the propeller
1. Straighten the cotter pin and pull it out using a pair of pliers.
2. Remove the propeller nut, washer, and spacer (if equipped).
1
3. Remove the propeller and thrust wash­er.
Installing the propeller
ECM00340
CAUTION:
●
Be sure to install the thrust washer be­fore installing the propeller, otherwise the lower case and propeller boss could be damaged.
●
Be sure to use a new cotter pin and bend the ends over securely. Otherwise the propeller could come off during op­eration and be lost.
1. Apply Yamaha marine grease or a cor­rosion resistant grease to the propeller shaft.
2. Install the spacer(if equipped), thrust washer, and propeller on the propeller shaft.
3. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque.
4. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.
1. Cotter pin
2. Propeller nut
3. Washer
4. Propeller
5. Thrust washer
41
2
3
4
5
ZMU02877
ZMU02063
NOTE:
If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to
Maintenance
align it with the hole.
Changing gear oil
EWM00800
WARNING
Be sure the outboard motor is securely
●
fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you. Never get under the lower unit while it
●
is tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor accidental­ly falls.
1. Tilt the outboard motor so that the gear oil drain screw is at the lowest point pos­sible.
2. Place a suitable container under the gear case.
3. Remove the gear oil drain screw.
2
to drain completely.
ECM00710
CAUTION:
Inspect the used oil after it has been drained. If the oil is milky, water is getting into the gear case which can cause gear damage. Consult a Yamaha dealer for re­pair of the lower unit seals.
NOTE:
For disposal of used oil consult your Yamaha dealer.
5. With the outboard motor in a vertical po­sition, and using a flexible or pressur­ized filling device, inject the gear oil into the gear oil drain screw hole.
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
160.0 cm
3
(5.41 US oz) (5.64 Imp.oz)
1
ZMU02879
1. Gear oil drain screw
2. Oil level plug
NOTE:
If the magnetic gear oil drain screw equipped: remove all metal particles from the screw before installing it.
4. Remove the oil level plug to allow the oil
ZMU02880
6. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug.
7. Insert and tighten the gear oil drain screw.
Cleaning fuel tank
EWM00920
WARNING
Gasoline is highly flammable, and its va-
42
Maintenance
pors are flammable and explosive.
●
If you have any question about properly doing this procedure, consult your Yamaha dealer.
●
Keep away from sparks, cigarettes, flames, or other sources of ignition when cleaning the fuel tank.
●
Remove the fuel tank from the boat be­fore cleaning it. Work only outdoors in an area with good ventilation.
●
Wipe up any spilled fuel immediately. Reassemble the fuel tank carefully. Im-
●
proper assembly can result in a fuel leak, which could result in a fire or ex­plosion hazard.
●
Dispose of old gasoline according to lo­cal regulations.
1. Empty the fuel tank into an approved container.
2. Pour a small amount of suitable solvent into the tank. Install the cap and shake the tank. Drain the solvent completely.
3. Remove the screws holding the fuel joint assembly. Pull the assembly out of the tank.
Inspecting and replacing anode(s)
Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.
ECM00720
CAUTION:
Do not paint anodes, as this would render them ineffective.
NOTE:
Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replace­ment of internal anodes attached to the pow­er unit.
4. Clean the filter (located on the end of the suction pipe) in a suitable cleaning sol­vent. Allow the filter to dry.
5. Replace the gasket with a new one. Re­install the fuel joint assembly and tighten the screws firmly.
43
ZMU02881
Checking top cowling
Check the fitting of the top cowling by push­ing it with both hands. If it is loose have it re­paired by your Yamaha dealer.
ZMU02882
Coating the boat bottom
A clean hull improves boat performance. The boat bottom should be kept as clean of ma­rine growth as possible. If necessary, the boat bottom can be coated with an anti-foul­ing paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
Maintenance
ZMU01943
44

Trouble Recovery

Troubleshooting

A problem in the fuel, compression, or igni­tion systems can cause poor starting, loss of power, or other problems. This section de­scribes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble warning indicator is flashing, consult your Yamaha dealer.
Starter will not operate.
Q. Is battery capacity weak or low? A. Check battery condition. Use battery of recommended capacity.
Q. Are battery connections loose or corrod­ed? A. Tighten battery cables and clean battery terminals.
Q. Is fuse for electric start relay or electric cir­cuit blown? A. Check for cause of electric overload and repair. Replace fuse with one of correct am­perage.
Q. Are starter components faulty? A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear? A. Shift to neutral.
Engine will not start (starter operates).
Q. Is fuel tank empty? A. Fill tank with clean, fresh fuel.
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Is starting procedure incorrect? A. See page 21.
Q. Has fuel pump malfunctioned? A. Have serviced by a Yamaha dealer.
Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
Q. Are spark plug cap(s) fitted incorrectly? A. Check and re-fit cap(s).
Q. Is ignition wiring damaged or poorly con­nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro­ken wires.
Q. Are ignition parts faulty? A. Have serviced by a Yamaha dealer.
Q. Is engine stop switch lanyard not at­tached? A. Attach lanyard.
Q. Are engine inner parts damaged? A. Have serviced by a Yamaha dealer.
Engine idles irregularly or stalls.
Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
45
Trouble Recovery
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.
Q. Has warning system activated? A. Find and correct cause of warning.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con­nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro­ken wires.
A. Return to home position.
Q. Is motor angle too high? A. Return to normal operating position.
Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect? A. Connect correctly.
Q. Is throttle valve adjustment incorrect? A. Have serviced by a Yamaha dealer.
Q. Is battery cable disconnected? A. Connect securely.
Warning buzzer sounds or indicator lights.
Q. Is cooling system clogged? A. Check water intake for restriction.
Q. Is engine oil level low? A. Fill oil tank with specified engine oil.
Q. Is specified engine oil not being used? A. Check and replace oil as specified.
Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.
Q. Are carburetor adjustments incorrect? A. Have serviced by a Yamaha dealer.
Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.
Q. Is air vent screw on fuel tank closed? A. Open air vent screw.
Q. Is choke knob pulled out?
Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec­ommended type.
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Is engine oil contaminated or deteriorat­ed? A. Replace oil with fresh, specified type.
Q. Is oil filter clogged? A. Have serviced by a Yamaha dealer.
Q. Has oil feed/injection pump malfunc­tioned?
46
Trouble Recovery
A. Have serviced by a Yamaha dealer.
Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane.
Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer.
Q. Is there excess water in fuel filter cup? A. Drain filter cup.
Engine power loss.
Q. Is propeller damaged? A. Have propeller repaired or replaced.
Q. Is propeller pitch or diameter incorrect? A. Install correct propeller to operate out­board at its recommended speed (r/min) range.
Q. Is trim angle incorrect? A. Adjust trim angle to achieve most efficient operation.
Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height.
Q. Are weeds or other foreign matter tangled on gear housing? A. Remove foreign matter and clean lower unit.
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con­nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro­ken wires.
Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Has warning system activated? A. Find and correct cause of warning.
Q. Is boat bottom fouled with marine growth? A. Clean boat bottom.
Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
47
Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.
Q. Is air vent screw closed? A. Open the air vent screw.
Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect? A. Connect correctly.
Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec­ommended type.
Q. Is high pressure fuel pump drive belt bro­ken? A. Have serviced by a Yamaha dealer.
Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer.
Trouble Recovery
board motor unsafe to operate.
If the outboard motor hits an object in the wa­ter, follow the procedure below.
Engine vibrates excessively.
Q. Is propeller damaged? A. Have propeller repaired or replaced.
Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer.
Q. Are weeds or other foreign matter tangled on propeller? A. Remove and clean propeller.
Q. Is motor mounting bolt loose? A. Tighten bolt.
Q. Is steering pivot loose or damaged? A. Tighten or have serviced by a Yamaha dealer.
Temporary action in
emergency
Impact damage
EWM00870
WARNING
The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the out-
1. Stop the engine immediately.
2. Inspect the control system and all com­ponents for damage. Also inspect the boat for damage.
3. Whether damage is found or not, return to the nearest harbor slowly and careful­ly.
4. Have a Yamaha dealer inspect the out­board motor before operating it again.
Starter will not operate
If the starter mechanism does not operate (the engine cannot be cranked with the start­er), the engine can be started with an emer­gency starter rope.
EWM01020
WARNING
●
Use this procedure only in an emergen­cy and only to return to port for repairs. When the emergency starter rope is
●
used to start the engine, the start-in­gear protection device does not oper­ate. Make sure the remote control lever is in neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.
●
Attach the engine stop switch lanyard to a secure place on your clothing, or
48
Trouble Recovery
your arm or leg while operating.
●
Do not attach the lanyard to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. Avoid accidentally pulling the lanyard
●
during normal operation. Loss of en­gine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.
●
Be sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure someone.
●
An unguarded, rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the fly­wheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.
●
Do not touch the ignition coil, spark plug wire, spark plug cap, or other elec­trical components when starting or op­erating the motor. You could get an electrical shock.
Emergency starting engine
1. Remove the top cowling.
2. Remove the start-in-gear protection ca­ble from the starter, if equipped.
3. Remove the starter/flywheel cover after removing the bolt(s).
ZMU02883
4. Prepare the engine for starting. For fur­ther information, see page 21. Be sure the engine is in neutral and that the en­gine stop switch lanyard lock plate is at­tached to the engine stop switch. The main switch must be “” (on), if equipped.
ZMU02884
49
5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms
Trouble Recovery
up.
ZMU02860
6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise.
ZMU02885
7. Give a strong pull straight out to crank and start the engine. Repeat if neces­sary.

Treatment of submerged motor

If the outboard motor is submerged, immedi­ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi­ately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the proce­dure below in order to minimize engine dam­age.
Procedure
1. Thoroughly wash away mud, salt, sea-
weed, and so on, with fresh water.
ZMU01909
2. Remove the spark plugs and face the spark plug holes downward to allow any water, mud, or contaminants to drain.
ZMU01910
3. Drain the fuel from the carburetor, fuel filter, and fuel line.
4. Feed fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking with the manual starter or emergency starter rope.
ZMU01911
50
Trouble Recovery
5. Take the outboard motor to a Yamaha dealer as soon as possible.
ECM00400
CAUTION:
Do not attempt to run the outboard motor until it has been completely inspected.
51

Consumer information

Important warranty information for U.S.A. and Canada
52
Consumer information
53
Consumer information
YAMAHA MOTOR CORPORATION, U.S.A.
OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY
54
Consumer information
55
Consumer information
56
Consumer information
IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR
YAMAHA OUTSIDE U.S.A. OR CANADA
57
Printed in France April 2004–0.5
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