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LZ200
User Manual
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Yamaha Z200, LZ200 User Manual

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OWNER’S MANUAL
Z200 LZ200
U.S.A.Edition
LIT-18626-07-00
68F-28199-19
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 Z200TR, LZ200TR 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.
Z200, LZ200
OWNER’S MANUAL
©2006 by Yamaha Motor Corporation, USA
1st edition, April 2006
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in Japan
P/N LIT-18626-07-00
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
Key number....................................... 1
Emission control information ........... 1
North American models..................... 1
Star labels ......................................... 2
Safety information ........................... 3
Important labels............................... 4
Warning labels ..................................4
Caution labels ...................................5
Basic boating rules
(Rules of the road) ........................5
Steering and sailing rules and
sound signals.................................. 6
Rules when encountering vessels .... 6
Other special situations..................... 7
Fueling instructions ......................... 9
Gasoline.......................................... 10
Engine oil ........................................10
Battery requirement....................... 10
Battery specifications ...................... 11
Propeller selection......................... 11
Start-in-gear protection ................. 11
Basic components ..........................12
Main components.......................... 12
Remote control................................ 13
Remote control lever....................... 14
Neutral interlock trigger................... 14
Neutral throttle lever........................ 14
Free accelerator.............................. 15
Throttle friction adjuster................... 15
Engine stop lanyard switch .............16
Main switch .....................................16
Power trim and tilt switch on
remote control or tiller handle .......17
Power trim and tilt switch on
bottom engine cowling .................. 17
Power trim and tilt switches
(twin binnacle type)....................... 18
Trim tab with anode ........................ 18
Tilt support lever for power trim
and tilt or hydro tilt model.............. 19
Top cowling lock levers................... 19
Flushing device ............................... 20
Water separator ..............................20
Tachometer .....................................20
Digital tachometer ...........................20
Oil level indicators
(three indicators) ........................... 21
Oil level indicator (digital type) ........21
Overheat warning indicator
(digital type) ..................................21
Speedometer (digital type) ..............22
Trim meter....................................... 22
Trim meter (digital type) ..................23
Hour meter (digital type).................. 23
Trip meter........................................ 23
Clock ...............................................24
Fuel gauge ......................................24
Fuel warning indicator .....................24
Low battery voltage warning
indicator ........................................25
Fuel management meter .................25
Fuel flow meter................................ 25
Fuel consumption meter.................. 26
Fuel economy.................................. 26
Twin-engine speed synchronizer ....27
Command link multifunction
meters ........................................... 27
Tachometer unit ..............................27
Speed & fuel meter unit................... 31
Speedometer unit............................ 32
Fuel management meter .................33
Warning system ............................ 33
Overheat warning (twin engines) ....33
Oil level warning and oil filter
clogging warning ........................... 34
Operation ......................................... 36
Installation..................................... 36
Mounting the outboard motor ..........36
Breaking in engine ........................ 37
Procedure for HPDI models ............38
Preoperation checks ..................... 38
Fuel .................................................38
Oil.................................................... 39
Controls........................................... 39
Engine .............................................39
Operation after a long period of
storage .......................................... 39
Table of contents
Filling fuel and engine oil............... 40
Filling fuel for models without a
fuel joint ........................................ 40
Ring Free Fuel Additive .................. 40
Filling oil for oil injection models...... 40
Oil level indicator operation............. 42
Operating engine........................... 43
Feeding fuel ....................................43
Starting engine................................ 43
Warming up engine ....................... 45
Electric start and prime start
models .......................................... 45
Shifting .......................................... 45
Forward (tiller handle and remote
control models) ............................. 46
Reverse (automatic reverse lock
and power trim and tilt models)..... 46
Stopping engine ............................ 47
Procedure ....................................... 47
Trimming outboard motor.............. 47
Adjusting trim angle ........................ 48
Adjusting boat trim ..........................49
Tilting up and down ....................... 49
Procedure for tilting up
(power trim and tilt models /
power tilt models).......................... 50
Procedure for tilting down
(power trim and tilt models /
power tilt models).......................... 51
Cruising in shallow water .............. 52
Power trim and tilt models /
power tilt models........................... 52
Cruising in other conditions........... 53
Maintenance..................................... 54
Specifications ................................ 54
Transporting and storing outboard
motor ........................................... 55
Storing outboard motor ...................55
Procedure ....................................... 56
Lubrication (oil injection models)..... 57
Cleaning and anticorrosion
measures ...................................... 57
Battery care..................................... 57
Flushing power unit......................... 58
Cleaning the outboard motor .......... 59
Checking painted surface of
motor............................................. 59
Periodic maintenance ................... 59
Replacement parts ..........................59
Maintenance chart........................... 60
Maintenance chart (additional)........ 61
Greasing.......................................... 62
Cleaning and adjusting spark
plug ............................................... 62
Checking fuel system ......................63
Inspecting idling speed.................... 64
Checking water in engine oil tank ...64
Checking wiring and connectors .....64
Exhaust leakage.............................. 65
Water leakage .................................65
Checking power trim and tilt
system........................................... 65
Checking propeller ..........................66
Removing the propeller ...................67
Installing the Propeller..................... 67
Changing gear oil ............................68
Inspecting and replacing
anode(s)........................................ 69
Checking battery (for electric start
models) ......................................... 69
Connecting the Battery.................... 70
Disconnecting the battery................ 71
Checking top cowling ......................71
Coating the boat bottom.................. 72
Trouble Recovery............................ 73
Troubleshooting ............................ 73
Temporary action in emergency ... 76
Impact damage ...............................76
Running single engine..................... 76
Replacing fuse ................................77
Power trim and tilt / power tilt will
not operate.................................... 77
Water separator warning indicator
blinks while cruising ...................... 78
Starter will not operate ....................79
Emergency starting engine .............80
Engine fails to operate .................. 81
Low oil level warning activates........ 81
Treatment of submerged motor .... 82
Procedure........................................ 82
Table of contents
Consumer information.................... 83
Important warranty information for
U.S.A. and Canada ..................... 83
YAMAHA MOTOR
CORPORATION, U.S.A. OUTBOARD MOTOR TWO
YEAR LIMITED WARRANTY ...... 85
IMPORTANT WARRANTY
INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE
THE USA OR CANADA .............. 88

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. 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
1. Outboard motor serial number location
ZMU04426

General information

1. Key number

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 engine for details.
Approval label of emission control certif­icate
This label is attached to the bottom cowling. New Technology ; (HPDI) DFI/HO2S

Key number

If a main key switch is equipped with the mo­tor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key.
1
ZMU04741
1. Approval label location
1
General information
ZMU05380
Manufactured date label
This label is attached to the clamp bracket or the swivel bracket.
1
ZMU04726
particular label.
1
ZMU04745
1. Star labels location
One Star—Low Emission
The one-star label identifies engines that meet the Air Resources Board’s 2001 ex­haust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke en­gines. These engines are equivalent to the U.S. EPA’s 2006 standards for marine en­gines.
1. Manufactured date label location
Manufactured:
ZMU04346

Star labels

Your outboard motor is labeled with a Cali­fornia Air Resources Board (CARB) star la­bel. See below for a description of your
2
ZMU01702
Two Stars—Very Low Emission
The two-star label identifies engines that meet the Air Resources Board’s 2004 ex­haust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low-Emission engines.
ZMU01703
Three Stars—Ultra Low Emission
The three-star label identifies engines that meet the Air Resources Board’s 2008 ex­haust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low-Emission engines.
ZMU01704

Safety information

●
Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation. Before operating the boat, read any own-
●
er’s or operator’s manuals supplied with it and all labels. Be sure you understand each item before operating. Do not overpower the boat with this out-
●
board motor. Overpowering the boat could result in loss of control. The rated power of
General information
the outboard should be equal to or less than the rated horsepower capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer. Do not modify the outboard. Modifications
●
could make the motor unfit or unsafe to use. Incorrect propeller selection and incorrect
●
use may not only cause engine damage, but also adversely affect fuel consumption. Consult your dealer for correct 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
3
General information
the switch, stopping the engine.
●
Know the marine laws and regulations where you will be boating—and obey them. For basic boating rules, see “Rules of the road” on page 5. Stay informed about the weather. Check
●
weather forecasts before boating. Avoid boating in hazardous weather. Tell someone where you are going: leave
●
a Float Plan with a responsible person. Be sure to cancel the Float Plan when you re­turn.
●
Use common sense and good judgment when boating. Know your abilities, and be sure you understand how your boat han­dles under the different boating conditions you may encounter. Operate within your limits, and the limits of your boat. Always operate at safe speeds, and keep a careful 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.
●
Do not illegally discard empty containers used to replace or replenish oil. For the correct processing of empty containers, consult the dealer where you purchased the oil.
●
When replacing oils used to lubricate the product (engine or gear oil), be sure to wipe away any spilt oil. Never pour oil with­out using a funnel or similar device. If nec­essary, verify the necessary replacement procedure with the dealer.
●
Never illegally discard (dump) the product. Yamaha recommends consulting the deal-
er on discarding the product. 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

ZMU04852
ZMU01948
4
General information
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 (counter rotation models)
EWM01281
WARNING
Use only a counterclockwise rotation propeller with this engine. Counterclockwise propellers are marked with a letter “L” after the size indication. The wrong type of propeller could cause the boat to go in an unexpected direction, which could lead to an accident.
Label
ENGINE OIL ONLY
Pour the engine oil into this oil tank, not
●
gasoline. RECOMMENDED OIL: YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC-W3 certified ouboard oil.
EWM01270
WARNING
Do not add gasoline to the oil tank. Fire explosion could result.
Label
EWM01411
WARNING
Hot surface under this cover during and after operation. To avoid burns, do not touch finned resistor with bare hands.

Caution labels

ZMU04435
Label
ECM01440
CAUTION:
USE UNLEADED STRAIGHT GASOLINE ONLY
●
Gasoline containing lead can cause performance loss and engine damage. Do not use gasoline mixed with oil (pre-
●
mix).
●
Use YAMALUBE 2-stroke outboard oil or another 2-stroke engine oil with a NMMA-certified TC-W3 rate.
Refer to Owner’s manual.
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.
5
General information
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 circum-
stances, 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 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-of-
(you are approaching another ves-
(you are traveling across the oth-
(you are passing or being
6
General information
way! 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 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.
7
General information
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.
8
General information

Fueling instructions

EWM00010
WARNING
GASOLINE AND ITS VAPORS ARE HIGH­LY FLAMMABLE AND EXPLOSIVE!
●
Do not smoke when refueling, and keep
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
9
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 electro­static sparks.
ECM00010
CAUTION:
Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign mat­ter.

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

Engine oil

Use Yamalube 2-M outboard oil. If Ya­malube 2-M is not available, use only anoth­er outboard motor manufacturer’s factory­brand oil with TC-W3 rating.
Recommended engine oil:
YAMALUBE 2 STROKE OUTBOARD OIL
ECM01290
CAUTION:
Serious engine damage can result from the use of lower quality oil, including some commonly available oil brands with “TC-W3” on their label. To avoid the risk, use only Yamalube 2-M or, if necessary, another outboard motor manufacturer’s factory-brand TC-W3 oil.

Battery requirement

ECM01060
CAUTION:
Do not use a battery that does not meet the specified capacity. If a battery which does not meet specifications is used, the electric system could perform poorly or be overloaded, causing electric system damage.
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.
10
For electric start models, choose a battery which meets the following specifications.

Battery specifications

Minimum cold cranking amps (CCA/ SAE):
512.0 A Minimum marine cranking amps (MCA/ ABYC):
675.0 A Minimum reserve capacity (RC/SAE):
182 minutes
NOTE:
The engine cannot be started if battery volt­age is too low.

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.
General information
x
-
123
ZMU04608
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.
For instructions on propeller removal and in­stallation, see page 66.

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.
11

Basic components

Main components

NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all mod­els.
Z200, LZ200
11
10
9
8
7
6
5
4
1. Top cowling
2. Top cowling lock lever(s)
3. Trim tab (anode)
4. Propeller*
5. Cooling water inlet
6. Anti-cavitation plate
7. Anode
8. Tilt support lever
9. Flushing device
10. Power trim and tilt switch
11. Water separator
12. Remote control box (side mount type)*
13. Remote control box (binnacle mount type)*
14. Switch panel (for use with binnacle type)*
1
2
12 13
15
16
3
19
15. Digital tachometer*
16. Digital speedometer*
17. Tachometer*
18. Trim meter*
19. Fuel management meter*
20. Remote oil tank
20
14
17
2
18
ZMU04850
12
Basic components
1
4
1. Tachometer unit (Square type)*
2. Tachometer unit (Round type)*
3. Speedometer unit (Square type)*
4. Speed & fuel meter unit (Square type)*
5. Speed & fuel meter unit (Round type)*
6. Fuel management meter (Square type)*
2
5
3
6
ZMU05429

Remote control

The remote control lever actuates both the shifter and the throttle. The electrical switch­es are mounted on the remote control box.
1. Power trim and tilt switch
2. Remote control lever
3. Neutral interlock trigger
4. Neutral throttle lever
5. Main switch / choke switch
6. Engine stop lanyard switch
7. Throttle friction adjuster
13
Basic components
1
2
4
2
3
ZMU04569
1. Remote control lever
2. Power trim and tilt switch
3. Free accelerator
4. Throttle friction adjuster

Remote control lever

Moving the lever forward from the neutral po­sition engages forward gear. Pulling the le­ver back from neutral engages reverse. The engine will continue to run at idle until the le­ver is moved about 35° (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.
N
F
2
6
1
4
R
4
3
6
5
5
7
7
ZMU04573
1. Neutral “”
2. Forward “”
3. Reverse “”
4. Shift
5. Fully closed
6. Throttle
7. Fully open

Neutral interlock trigger

To shift out of neutral, first pull the neutral in­terlock trigger up.
1. Neutral “”
2. Forward “”
3. Reverse “”
4. Shift
5. Fully closed
6. Throttle
7. Fully open
14
1. Neutral interlock trigger

Neutral throttle lever

To open the throttle without shifting into ei­ther forward or reverse, put the remote con­trol lever in the neutral position and lift the neutral throttle lever.
Basic components
NOTE:
The neutral throttle lever will operate only when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position.
1. Fully open
2. Fully closed

Free accelerator

To open the throttle without shifting into ei­ther forward or reverse, push the free accel­erator button and move the remote control lever.
used when the remote control lever is in the neutral position. After the button is pushed, the throttle be-
●
gins to open after the remote control lever is moved at least 35°. After using the free accelerator, return the
●
remote control lever to the neutral position. The free accelerator button will return au­tomatically to its set position. The remote control will then engage forward and re­verse normally.

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.
EWM00031
WARNING
Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident.
2
3
1
ZMU04575
1. Fully open
2. Fully closed
3. Free accelerator
NOTE:
●
The free accelerator button can only be
15
Basic components
ZMU04646
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 could cause people and objects in the boat to be thrown forward.
NOTE:
The engine cannot be started with the lock plate removed.
1. Lanyard
2. Lock plate
ON
ON
OFF
OFF
START
START
2
1
ZMU04564
1. Lanyard
2. Lock plate

Main switch

The main switch controls the ignition system; its operation is described below.
●
“”
(off)
With the main switch in the “” (off) posi- tion, the electrical circuits are off, and the key can be removed.
●
“”
(on)
With the main switch in the “” (on) posi- tion, the electrical circuits are on, and the key cannot be removed.
16
●
“”
(start)
With the main switch in the “” (start) po- sition, the starter motor turns to start the en­gine. When the key is released, it returns automatically to the “” (on) position.
OFF
ON
START
OFF
ON
START
ZMU04566

Power trim and tilt switch on remote control or tiller handle

The power trim and tilt system adjusts the outboard motor angle in relation to the tran­som. Pressing the switch “” (up) trims the outboard motor up, then tilts it up. Pressing the switch “” (down) tilts the outboard mo- tor down and trims it down. When the switch is released, the outboard motor will stop in its current position.
NOTE:
For instructions on using the power trim and tilt switch, see pages 47 and 49.
Basic components

Power trim and tilt switch on bottom engine cowling

The power trim and tilt switch is located on the side of the bottom engine cowling. Press­ing the switch “” (up) trims the outboard motor up, then tilts it up. Pressing the switch “” (down) tilts the outboard motor down and trims it down. When the switch is re­leased, the outboard motor will stop in its current position.
EWM01030
WARNING
Use the power trim and tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the en­gine off. Attempting to use this switch while the boat is moving could increase the risk of falling overboard and could distract the operator, increasing the risk of collision with another boat or an obsta­cle.
17
Basic components
UP
DN
ZMU03985
NOTE:
For instructions on using the power trim and tilt switch, see page 49.

Power trim and tilt switches (twin binnacle type)

The power trim and tilt system adjusts the outboard motor angle in relation to the tran­som. Pushing the switch “” (up) trims the outboard motor up, then tilts it up. Pressing the switch “” (down) tilts the outboard mo- tor down and trims it down. When the switch is released, the outboard motor will stop in its current position.
1
DN
UP
●
For instructions on using the power trim and tilt switches, see pages 47 and 49.

Trim tab with anode

The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force.
EWM00840
WARNING
An improperly adjusted trim tab could cause difficult steering. Always test run after the trim tab has been installed or re­placed to be sure steering is correct. Be sure you have tightened the bolt after ad­justing the trim tab.
If the boat tends to veer the left (port side), turn the trim tab rear end to the port side “A” in the figure. If the boat tends to veer the right (starboard side), turn the trim tab end to the starboard side “B” in the figure.
ECM00840
CAUTION:
The trim tab also serves as an anode to protect the engine from electrochemical corrosion. Never paint the trim tab as it will become ineffective as an anode.
ZMU04601
1. Power trim and tilt switch
NOTE:
On the dual engine control, the switch on
●
the remote control grip controls both out­board motors at the same time.
18
1. Trim tab
2. Bolt
3. Cap
Basic components
1
ZMU03979
1. Tilt support lever

Top cowling lock levers

To remove the outboard motor top cowling, pull up the front and rear lock levers. Then lift off the cowling. When the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by moving the levers downward.
ECM00550
CAUTION:
The air intake grille on the top cowling is not designed as a handle and could break if used as such.
A
B
ZMU01863

Tilt support lever for power trim and tilt or hydro tilt model

To keep the outboard motor in the tilted up position, lock the tilt support lever to the clamp bracket.
1
ZMU03986
1. Top cowling lock lever(s)
19
Basic components
1
2
1. Air intake grille
2. Top cowling lock lever(s)
1
2
ZMU04437

Flushing device

This device is used to clean the cooling wa­ter passages of the motor using a garden hose and tap water.
NOTE:
For details on usage, see page 58.
ZMU05499
Activation of warning device
●
The water separator warning indicator will blink. The buzzer will sound intermittently only
●
when the gear shift is in neutral.
●
If the warning system has activated, stop the engine and consult a Yamaha dealer immediately.

Tachometer

This gauge shows the engine speed and has the following functions.
1
1
ZMU04011
1. Flushing device

Water separator

This engine has a combination fuel filter/wa­ter separator and associated warning sys­tem. If water separated from the fuel exceeds a specific volume, the warning de­vice will activate.
20
2
ZMU04577
1. Tachometer
2. Oil level indicator

Digital tachometer

The tachometer shows the engine speed and has the following functions.
NOTE:
All segments of the display will light momen-
tarily after the main switch is turned on and will return to normal thereafter.
6
7
Basic components
1
2
3
5
8
1. Tachometer
2. Trim meter
3. Hour meter
4. Oil level indicator
5. Overheat warning indicator
6. Water separator warning indicator
7. Engine trouble warning indicator
8. Set button
9. Mode button
NOTE:
The water separator and engine trouble warning indicators only operate when the en­gine is equipped with the appropriate func­tions.

Oil level indicators (three indicators)

The indicators on the gauge show the status of the oil level. For details on how to read the indicators, see page 42.
ECM00030
CAUTION:
Do not operate the engine without oil. Se­rious engine damage will occur.
4
9
ZMU01958
1
ZMU04580
1. Oil level indicators

Oil level indicator (digital type)

This indicator shows the engine oil level. If the oil level falls below the lower limit, the warning indicator will start to blink. For fur­ther information, see page 34.
ECM00030
CAUTION:
Do not operate the engine without oil. Se­rious engine damage will occur.
1
ZMU01867
1. Oil level indicator

Overheat warning indicator (digital type)

If the engine temperature rises too high, the warning indicator will start to blink. For fur­ther information on reading the indicator, see
21
Basic components
page 33.
ECM00050
CAUTION:
Do not continue to run the engine if the overheat warning indicator is on. Serious engine damage will occur.
1
ZMU01868
1. Overheat warning indicator

Speedometer (digital type)

This gauge shows the boat speed.
turning on the main switch to make sure all segments come on.
NOTE:
The speedometer displays km/h, mph, or knots, according to operator preference. Se­lect the desired unit of measurement by set­ting the selector switch on the back of the gauge. See the illustration for settings.
1. Cap
2. Selector switch (for speed unit)
3. Selector switch (for fuel sensor)

Trim meter

This gauge shows the trim angle of your out­board motor.
1. Speedometer
2. Fuel gauge
3. Trip meter/clock/voltmeter
4. Warning indicator(s)
NOTE:
After the main switch is first turned on, all segments of the display come on as a test. After a few seconds, the gauge will change to normal operation. Watch the gauge when
22
ZMU04581
NOTE:
Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired setting with the
Basic components
power trim and tilt switch.

Trim meter (digital type)

This meter shows the trim angle of your out­board motor.
NOTE:
●
Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired using the power trim and tilt switch.
●
If the trim angle of your motor exceeds the trim operating range, the top segment on the trim meter display will blink.
ZMU01869

Hour meter (digital type)

This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off.
●
Changing the display format
●
Pressing the “” (mode) button chang- es the display format in the following pat­tern:
●
Total hours→Trip hours→Display off Resetting the trip hours
●
●
Simultaneously pressing the “” (set) and “” (mode) buttons for more than 1 second while the trip hours are displayed resets the trip counter to 0 (zero).
NOTE:
The total number of hours the engine has been run cannot be reset.

Trip meter

This gauge displays the distance the boat has traveled since the gauge was last reset. Press the “” (mode) button repeatedly until the indicator on the face of the gauge points to “” (trip). To reset the trip meter to zero, press the “” (set) and “” (mode) buttons at the same time.
ZMU01870
NOTE:
●
The trip distance is shown in kilometers or miles depending upon the unit of measure­ment selected for the speedometer.
●
The trip distance is kept in memory by bat­tery power. The stored data will be lost if the battery is disconnected.
23
Basic components
tor switch.

Clock

Press the “” (mode) button repeatedly until the indicator on the face of the gauge points to “” (time). To set the clock, be sure the gauge is in the “” (time) mode. Press the “” (set) button; the hour display will begin blinking. Press the “” (mode) button until the desired hour is displayed. Press the “” (set) button again, the minute display will begin blinking. Press the “” (mode) button until the desired minute is dis­played. Press the “” (set) button again to start the clock.
NOTE:
The fuel level reading can be affected by the position of the sensor in the fuel tank and the attitude of the boat in the water. Operation with bow-up trim or continuous turning can give false readings.

Fuel warning indicator

If the fuel level decreases to one segment, the fuel level warning segment will begin to blink.
ECM00880
NOTE:
The clock operates on battery power. Dis­connecting the battery will stop the clock. Reset the clock after connecting the battery.
Do not continue to operate the engine with full throttle if a warning device has activated. Get back to the port within troll­ing engine speed.

Fuel gauge

The fuel level is indicated by eight segments. When all segments are showing, the fuel tank is full.
ECM00860
CAUTION:
The Yamaha fuel tank sensor differs from conventional sensors. Incorrectly setting the selector switch on the gauge will give false readings. Consult your Yamaha dealer on how to correctly set the selec-
ZMU01745
CAUTION:
1. Fuel level warning segment
24
Basic components

Low battery voltage warning indicator

If battery voltage drops, the display will auto­matically turn on and begin to blink.
ECM00870
CAUTION:
Get back to the port soon if a warning de­vice has activated. For charging the bat­tery, consult your Yamaha dealer.
1. Low battery indicator

Fuel management meter

The fuel management meter shows the state of the fuel consumption while the engine is running.
3. Water separator warning indicator (operates only if the sensor has been installed)
NOTE:
After the main switch is first turned on, all segments of the display come on as a test. After a few seconds, the gauge will change to normal operation. Watch the gauge when turning on the main switch to make sure all segments come on.

Fuel flow meter

The fuel flow meter displays the amount of fuel flow over a one hour period, at the cur­rent rate of engine operation. If twin engines are installed on your boat, the fuel flow meter displays the total fuel flow of both the port and starboard engines. It also displays “” (for port and starboard).
1
3
1. Fuel flow meter
2. Fuel consumption meter / Fuel economy meter / Twin engine speed synchronizer
2
ZMU01748
ZMU01749
Use the “” (set) button to rotate the fuel flow display in the following order:
●
Press the “” (set) button once to display the fuel flow of the starboard engine. An “” (for starboard) will also be displayed.
●
Press the “” (set) button a second time to display the fuel flow of the port engine. A “” (for port) will also be displayed.
●
Press the “” (set) button a third time to return the display to the total fuel flow of both engines. “” (for port and starboard) will also be displayed to indicate both the
25
Basic components
port and starboard engines.
NOTE:
●
The fuel flow meter displays gallons/hour or liters/hour according to operator prefer­ence. Select the desired unit of measure­ment by setting the selector switch on the back of the gauge during installation.
1. Selector switch
●
The fuel consumption meter and fuel economy meter will indicate the same unit of measurement.

Fuel consumption meter

This gauge displays the total amount of fuel consumed since the gauge was last reset. Press the “” (mode) button repeatedly until the indicator on the face of the gauge points to total “” (total). To reset the total fuel consumption to zero, press the “” (set) and “” (mode) buttons at the same time.
ZMU01751

Fuel economy

This gauge displays the distance per liter or gallon when cruising, and is only for refer­ence use by the operator. Press the “” (mode) button repeatedly until the indicator on the face of the gauge points to “” (economy).
ZMU01752
NOTE:
If twin engines are installed on your boat, the gauge will only display the total fuel economy of both engines.
26
NOTE:
Fuel consumption varies greatly with boat
●
design, weight, propeller used, engine trim angle, sea conditions (including wind), and throttle position. Fuel consumption also varies slightly with the type of water (salt, fresh, and contaminate levels), air temper­ature and humidity, cleanliness of the boat
bottom, engine mounting height, skill of the operator, and individual gasoline for­mulation (winter or summer fuel and amount of additives).
●
The Yamaha digital speedometer and fuel management meter calculates speed, miles traveled, and fuel economy by water movement at the stern of the boat. This distance can vary greatly from the actual distance traveled because of water cur­rents, sea swells, and the condition of the water speed sensor (partially plugged or damaged).
●
Individual engines may slightly vary in their fuel consumption due to manufacturing variations. These variations can be even greater if the engines are of different year models. In addition, variations in propel­lers, even of the same basic dimensions of the same design, can also cause a slight variation in fuel consumption.

Twin-engine speed synchronizer

This gauge displays the difference in engine speed (r/min) between the port and star­board engines for reference purposes when synchronizing the two engines’ speeds. Press the “” (mode) button repeatedly until the indicator on the face of the gauge points to “” (synchronizer).
ZMU01753
Basic components
1
2
3
4
5
ZMU01754
1. Port engine speed is higher
2. Port engine speed is slightly higher
3. Engine speed is synchronized evenly between port and starboard engines
4. Starboard engine speed is slightly higher
5. Starboard engine speed is higher
NOTE:
If the two engines’ speeds are not synchro­nized while cruising, they can be synchro­nized by adjusting trim angle or throttle.

Command link multifunction meters

Command link multifunction meters have 6 kinds of meter units; tachometer unit (square or round types), speedometer unit (square type), speed & fuel meter unit (square or round types), and fuel management meter (square type). The indicator system is slight­ly different between the round and square types. Check the model and type of your unit carefully. This manual describes mainly the warning indicators. For more details on set­ting meters or changing indicator systems, see the attached operation manual.

Tachometer unit

The tachometer shows the engine revolu­tions per minute. It has functions of trim meter, adjusting trolling speed, cooling wa­ter/engine temperature display, battery volt-
27
Basic components
age display, total hour/trip hour display, oil level display, water detection warning, en­gine trouble warning, and periodic mainte­nance notification. If optional sensors are connected to the unit, cooling water pressure display will be available. For the optional sensor, consult your Yamaha dealer. The ta­chometer unit is available in round or square types. Check your tachometer unit type.
1
2
1
1. Set button
2. Mode button
2
ZMU05417
1452
1. Set button
2. Mode button
1
5
4
7
6
8
1. Tachometer
2. Trim meter
3. Multifunction display
4. Cooling water pressure
5. Cooling water/engine temperature
6. Water detection warning indicator
7. Battery voltage
8. Oil level (2-stroke models)
ZMU05415
2
3
ZMU05452
3
6978
1. Tachometer
2. Trim meter
3. Multifunction display
4. Water detection warning indicator
5. Engine trouble warning/maintenance indica­tor
6. Cooling water pressure
7. Oil level (2-stroke models)
8. Cooling water/engine temperature
9. Battery voltage
NOTE:
The tachometer unit shows various kinds of information according to the setting made using the “” (set) and “” (mode) but- tons. For details, see the attached operation manual.
ZMU05453
28
Basic components
Preoperation checks
Place the gear shift lever in neutral and turn the main switch to “” (on). After all the dis- plays come on and the total hour display comes on, the gauge will change to normal operation. If the buzzer sounds and the wa­ter separator warning indicator blinks, con­sult your Yamaha dealer immediately.
NOTE:
To stop the buzzer, press the “” (set) or “” (mode) button.
Oil level warning
When the oil level is low while cruising, the oil level warning indicator will start to blink. The engine speed will automatically de­crease to about 2000 r/min.
engine oil level is maintained, consult your Yamaha dealer.
ECM01580
CAUTION:
Do not continue to run the engine if the oil level warning device has activated. Seri­ous engine damage will occur.
Overheat warning
If the engine temperature rises too high while cruising, the overheat warning indicator will start to blink. The engine speed will automat­ically decrease to about 2000 r/min.
ZMU05421
ZMU05419
ZMU05420
When the buzzer sounds and the oil level warning indicator blinks, check the oil level and add the oil if necessary. If the warning device has activated while the appropriate
ZMU05422
Stop the engine immediately if the buzzer sounds and the overheat warning device has activated. Check the cooling water inlet for clogging.
ECM01590
CAUTION:
Do not continue to run the engine if the
●
overheat warning indicator blinks. Seri-
29
Basic components
ous engine damage will occur.
●
Do not continue to operate the engine if a warning device has activated. Con­sult your Yamaha dealer if the problem cannot be located and corrected.
Water separator warning
This indicator will blink when water has accu­mulated in the water separator (fuel filter) while cruising. In such an event, stop the en­gine immediately and see page 76 of this manual to drain the water from the fuel filter. Get back to the port soon and consult a Yamaha dealer immediately.
ZMU05423
soon and consult a Yamaha dealer immedi­ately.
ZMU05425
ZMU05426
ECM00920
CAUTION:
In such an event, the engine will not oper­ate properly. Consult a Yamaha dealer immediately.
ZMU05424
ECM00910
CAUTION:
Gasoline mixed with water could cause damage to the engine.
Engine trouble warning
This indicator will blink when the engine mal­functions while cruising. Get back to the port
30
Low battery voltage warning
When the battery voltage drops, the low bat­tery voltage warning indicator and the bat­tery voltage value will start to blink. Get back to the port soon if the low battery voltage warning device has activated. For charging the battery, consult your Yamaha dealer.
Basic components
ZMU05427
ZMU05428

Speed & fuel meter unit

This unit shows the boat speed and has the functions of fuel meter, total fuel consump­tion display, fuel economy display, fuel flow display, and system voltage display. If op­tional sensors are connected to the unit, trip display, water surface temperature display, depth display, and clock will be available. For the optional sensor, consult your Yamaha dealer. The speed & fuel meter unit is avail­able in round or square types. Check your speed & fuel meter unit type.
1
1. Set button
2. Mode button
1
3
1. Speedometer
2. Fuel meter
3. Multifunction display
2
ZMU05432
2
ZMU05433
1
1. Set button
2. Mode button
2
ZMU05434
31
Basic components
12
3
1. Speedometer
2. Fuel meter
3. Multifunction display
ZMU05435
NOTE:
After the main switch is first turned on, all the displays come on as a test. After a few sec­onds, the gauge will change to normal oper­ation.
NOTE:
The speed & fuel meter unit shows various kinds of information according to the setting made with the “” (set) and “” (mode) buttons. For details, see the attached opera­tion manual.

Speedometer unit

This unit shows the boat speed and has functions of fuel meter and system voltage display. If optional sensors are connected to the unit, trip display, water surface tempera­ture display, depth display, and clock will be available. For the optional sensor, consult your Yamaha dealer.
1
1. Set button
2. Mode button
2
ZMU05436
1
3
1. Speedometer
2. Fuel meter
3. Multifunction display
NOTE:
After the main switch is first turned on, all the displays come on as a test. After a few sec­onds, the gauge will change to normal oper­ation.
NOTE:
The speedometer unit shows various kinds of information according to the setting made using the “” (set) and “” (mode) but- tons. In addition, the speedometer can show the desired unit of measurement such as km/ h, mph, or knots. For details, see the at­tached operation manual.
2
ZMU05437
32
Basic components

Fuel management meter

This meter has functions of fuel flow meter, total consumption display, fuel economy dis­play, and remaining fuel display.
1
1. Set button
2. Mode button
2
ZMU05438
1
ual.

Warning system

ECM00090
CAUTION:
Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem can­not be located and corrected.

Overheat warning (twin engines)

This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate. Activation of warning device
●
The engine speed will automatically de­crease to about 2000 r/min.
●
If equipped with an overheat warning indi­cator, it will light or blink.
2
ZMU05439
1. Fuel flow meter
2. Multifunction display
NOTE:
After the main switch is first turned on, all the displays come on as a test. After a few sec­onds, the gauge will change to normal oper­ation.
NOTE:
The fuel management meter shows various kinds of information when the operator uses the “” (set) and “” (mode) buttons. For details, see the attached operation man-
●
The buzzer will sound.
ZMU01757
ZMU04766
33
Basic components
OFF STARTONOFF START
If the warning system has activated, stop the engine and check the cooling water inlet for clogging.
ON
ZMU04584
on the engine not affected by overheating, turn off the main switch of the engine over­heating.

Oil level warning and oil filter clogging warning

Oil injection models
This engine has an oil level warning system. If the oil level falls below the lower limit, the warning system will activate.
Activation of warning device
Engine speed will automatically decrease
●
to about 2000 r/min.
●
The oil level warning indicator will light or blink.
ZMU03942
ZMU02630
NOTE:
Dual engine drive users: Should the overheat warning system of one engine activate, the engine will slow down and the buzzer will sound. This will cause the other engine to slow down and the buzzer to sound. To switch off the warning activation
34
ZMU04586
●
The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel).
Basic components
ZMU03025
OFF STARTONOFF START
ON
ZMU04584
If the warning system has been activated, stop the engine and check for the cause.
NOTE:
The warning for oil filter clogging is similar to the warnings for low oil level and overheat­ing. To make troubleshooting easier, check for engine overheating first, then oil level, and finally oil filter clogging.
1
1. Oil filter
ZMU01952
1. Oil filter
1
ZMU03987
35

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 out­board motor with more horsepower than the maximum rating on the capac­ity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.
●
The information presented in this sec­tion is intended as reference only. It is not possible to provide complete in­structions for every possible boat and motor combination. Proper mounting depends in part on experience and the
specific boat and motor combination.
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)
ZMU01873
36
1. Center line (keel line)
Mounting height (boat bottom)
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 in alignment with the bottom of the boat.
Operation
board motor is affected by the boat/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 47.

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.
ECM00750
CAUTION:
●
Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage.
●
Do not use premixed fuel in this engine because it could cause carbon depos­its on the fuel injector and engine trou­ble.
●
Follow the instructions for break-in carefully.
NOTE:
Leave the label pictured below on the top cowling until the break-in procedure has been completed. It may be removed after­wards.
ZMU01762
NOTE:
●
The optimum mounting height of the out-
37
Operation
ZMU01945

Procedure for HPDI models

Run the engine under load (in gear with a propeller installed) for 10 hours as follows.
1. First 10 minutes: Run the engine at the lowest possible speed. A fast idle in neutral is best.
2. Next 50 minutes: Do not exceed half throttle (approxi­mately 3000 r/min). Vary engine speed occasionally. If you have an easy-plan­ing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3000 r/min or less.
3. Next two hours: Accelerate at full throttle onto plane, then reduce engine speed to three-quar­ter throttle (approximately 4000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three-
quarter throttle or less to let the engine cool.
4. Remaining seven hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.
5. After the first 10 hours: Operate the engine normally.

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). Check the water in the fuel filter with the
●
water separator warning device. Place the gear shift lever in neutral and turn the main switch to “”(on). If the buzzer sounds and the water separator warning indicator
38
Operation
blinks, consult your Yamaha dealer imme­diately.
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, with-
●
out 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.
●
Check that the battery is in good condition and the battery connections are secure.

Operation after a long period of storage

When operating the engine after a long peri­od (12 months) of storage, proceed as fol­lows:
1. Start the engine. Leave it idling.
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.
your Yamaha dealer.
ECM00560
CAUTION:
●
Be sure to take the above steps when operating the engine after a long period of storage. Otherwise engine seizure could occur.
●
Use straight gasoline only. If premix fuel is used, the fuel injector could be damaged.
ZMU03988
2. Watch for oil flowing through the oil feed pipes. After any air in the oil lines has been expelled, the oil injection system should supply oil normally. If no oil is flowing after 10 minutes of idling, consult
39
Operation
ZMU03989

Filling fuel and engine oil

Filling fuel for models without a fuel joint

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

Ring Free Fuel Additive

Gasoline is a precise blend of many different substances, each chosen to give certain characteristics. Gasoline blends have been changing in recent years in response to con­cerns about pollution and resulting emis-
sions regulations. One of the most obvious changes has been the elimination of lead from most fuels. As gasoline has changed, the amount of ad­ditives such as aromatics and oxygenates has increased. These additives are impor­tant for the engines in passenger cars, but they can have detrimental effects in marine engines, because of increased deposits in the combustion chamber. When enough de­posits collect, piston rings begin sticking. Performance drops and engine wear in­creases dramatically. While many additives available may reduce deposits, Yamaha recommends the use of
Ring Free Fuel Additive
your Yamaha dealer.
tive
has repeatedly proven its ability to clean
, available from
Ring Free Fuel Addi-
combustion deposits from inside the engine, notably the critical piston-ring-land area, and fuel system components. Follow product la­beling for use instructions.

Filling oil for oil injection models

EWM00530
WARNING
Do not add gasoline into the oil tank. Fire or explosion could result.
This engine uses the Yamaha oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operat­ing conditions. No fuel premixing is needed. Simply pour gasoline into the fuel tank and oil into the oil tank. Convenient indicators show the status of the oil supply. For details on how to read the indicators, see page 42. To fill the engine oil tank, proceed as follows:
1. Pour engine oil into the remote oil tank.
Remote oil tank capacity:
10.5 L (11.10 US qt) (9.24 Imp.qt)
40
ZMU01877
NOTE:
The oil level lines on the remote oil tank indi­cate the amount of additional oil that can be added to the tank. The top oil level line indi­cates approximately 1.9 L (0.5 US gal, 0.4 Imp gal) can be added, and the bottom oil level line indicates approximately 3.8 L (1 US gal, 0.8 Imp gal) can be added.
2. Turn on the main switch. The Yamaha oil injection system will automatically feed oil from the remote oil tank to the engine oil tank.
3. Operate the engine normally.
ECM00570
CAUTION:
When the engine is operated for the first time or stored for a period of time, a min­imum of 5 liters (5.3 US qt, 4.4 Imp qt) of oil should be kept in the remote oil tank. Otherwise the oil-feed pump chamber will not be filled with oil, and no oil will be supplied.
Operation
41
Operation

Oil level indicator operation

The various functions of the oil level system are as follows:
Oil level indicator
Electric start models
Oil level warning
indicator
(digital
tachometer)
Oil level warning
indicator (analog
tachometer)
Green
Engine oil
tank
more than 300
3
cm
(0.32
US qt, 0.26
Imp qt)
Remote oil
tank
more than
1500 cm3 (1.6
US qt, 1.31
Imp qt)
Remarks
●
No refilling necessary.
Yellow
Red–Yellow–
Green
Red
more than 300
cm3 (0.32
US qt, 0.26
Imp qt)
300 cm3 (0.32
US qt, 0.26
Imp qt) or less
300 cm3 (0.32
US qt, 0.26
Imp qt) or less
1500 cm3 (1.6 US qt, 1.31 Imp qt) or less
more than
1500 cm3 (1.6 US qt, 1.31 Imp qt)
1500 cm3 (1.6 US qt, 1.31 Imp qt) or less
●
Add oil; see page 40.
Check oil filter for clog-
●
ging. Check battery cable
●
connection. Buzzer will sound. Engine speed is auto-
●
matically reduced to about 2000 r/min.
Oil has not been added.
●
●
Buzzer will sound.
●
Engine speed is auto­matically reduced to about 2000 r/min.
●
Buzzer sounds in remote control box and engine speed is limited to about 2000 r/min to help conserve oil.
42

Operating engine

Feeding fuel

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.
Operation
1. Arrow

Starting engine

Electric start and remote control models
1. Place the remote control lever in “” (neutral).
NOTE:
The start-in-gear protection device prevents the engine from starting except when in neu­tral.
1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns.
2. If there is a fuel joint or a fuel cock on the boat, firmly connect the fuel line to the joint or open the fuel cock.
3. Squeeze the primer pump, with the ar­row pointing up, until you feel it become firm.
43
Operation
ON
ON
N
OFF
START
START
OFF
ZMU04588
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.
ZMU04589
3. Turn the main switch to “” (on).
NOTE:
Dual engine users: When the main switch is turned on, the buzzer operates for a few sec­onds then stops automatically. The buzzer also operates if one of the engines stalls.
ON
OFF
ZMU01880
OFF
ON
OFF
ON
44
ZMU04591
4. Turn the main switch to “” (start), and hold it for a maximum of 5 seconds.
ON
OFF
START
ZMU01881
ON
START
ZMU04590
5. Immediately after the engine starts, re­lease the main switch to return it to “” (on).
ECM00191
CAUTION:
Never turn the main switch to “”
●
(start) while the engine is running.
●
Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it im­possible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, return the main switch to “” (on), wait 10 seconds, then crank the engine again.
Operation

Warming up engine

Electric start and prime start models

1. After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life.
2. Check for a steady flow of water from the cooling water pilot hole.
ECM00511
CAUTION:
A continuous flow of water from the cool­ing water pilot hole 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.
ZMU01882

Shifting

EWM00180
WARNING
Before shifting, make sure there are no swimmers or obstacles in the water near
45
Operation
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 handle models
1. Place the throttle grip in the fully closed position.
2. Move the gear shift lever quickly and firmly from neutral to forward.
Remote control models
1. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward.

Reverse (automatic reverse lock and power trim and 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 handle models
1. Place the throttle grip in the fully closed position.
2. Move the gear shift lever quickly and firmly from neutral to reverse.
Remote control models
1. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to reverse.
46
N
F
ZMU04597
N
R
ZMU04598
Operation

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. Turn the main switch to “” (off).
ON
OFF
ON
OFF
switch to “” (off).

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.
ZMU04600
2. After stopping the engine, disconnect the fuel line or close the fuel cock if there is a fuel joint or a fuel cock on the boat.
3. Tighten the air vent screw on the fuel tank cap (if equipped).
4. Remove the key if the boat will be left unattended.
NOTE:
The engine can also be stopped by pulling the lanyard and removing the clip from the engine stop switch, then turning the main
47
Operation
not adjust the trim angle with this switch while the boat is moving.
Adjust the outboard motor trim angle using the power trim and tilt switch.
1. Power trim and tilt switch
1
ZMU04718
1. Trim operating angle

Adjusting trim angle

Power trim and tilt models
EWM00751
WARNING
●
Be sure all people are clear of the out­board motor when adjusting the tilt an­gle, also be careful not to pinch any body parts between the drive unit and clamp bracket.
●
Use caution when trying a trim position for the first time. Increase speed gradu­ally and watch for any signs of instabil­ity or control problems. Improper trim angle can cause loss of control. If equipped with a power trim and tilt
●
switch located on the bottom cowling, use the switch only when the boat is at a complete stop with the engine off. Do
1
DN
UP
1. Power trim and tilt switch
1
1. Power trim and tilt switch
ZMU04601
UP
DN
ZMU04615
48
To raise the bow (trim-out), press the switch “” (up). To lower the bow (trim-in), press the switch “” (down). Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.

Adjusting boat trim

When the boat is on plane, a bow-up attitude results in less drag, greater stability and effi­ciency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden­cy to steer to one side or the other. Compen­sate for this as you steer. The trim tab can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.
Operation
Bow Down
Too much trim-in causes the boat to “plow” through the water, decreasing fuel economy and making it hard to increase speed. Oper­ating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making opera­tion difficult and dangerous.
Bow Up
Too much trim-out puts the bow of the boat too high in the water. Performance and econ­omy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces per­formance further, and the boat may “por- poise” (hop in the water), which could throw the operator and passengers overboard.
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
49
Operation
salt corrosion.
EWM00220
WARNING
Be sure all people are clear of the out­board motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket.
EWM00250
WARNING
Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, discon­nect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.
ECM00241
CAUTION:
●
Before tilting the outboard motor, stop the engine by following the procedure on page 47. Never tilt the outboard mo­tor while the engine is running. Severe damage from overheating can result.
●
Do not tilt up the engine by pushing the tiller handle (if equipped) because this could break the handle.

Procedure for tilting up (power trim and tilt models / power tilt models)

1. Place the remote control lever / gear shift lever in neutral.
N
ZMU04588
2. Disconnect the fuel line from the out­board motor or close the fuel cock.
3. Press the power trim and tilt switch / power tilt switch “” (up) until the out- board motor has tilted up completely.
UP
50
N
ZMU04602
ZMU03196
UP
ZMU03995
4. Push the tilt support knob into the clamp bracket or pull the tilt support lever to­ward you to support the engine.
ZMU03996
EWM00260
WARNING
After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever. Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit loses pres­sure.
Operation
from marine growth and corrosion which could damage the power trim and tilt mechanism.
ZMU03997

Procedure for tilting down (power trim and tilt models / power tilt models)

1. Push the power trim and tilt switch / pow­er tilt switch “” (up) until the outboard motor is supported by the tilt rod and the tilt support lever / tilt support knob be­comes free.
2. Release the tilt support lever or pull out the tilt support knob.
5. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim and tilt switch / power tilt switch “” (down) to retract the trim rods.
ECM00250
CAUTION:
Be sure to retract the trim rods complete­ly during mooring. This protects the rods
ZMU03998
3. Push the power trim and tilt switch / pow­er tilt switch “” (down) to lower the out- board motor to the desired position.
51
Operation
DN
DN
to allow operation in shallow water.
EWM00660
UP DN
WARNING
Place the gear shift in neutral before
●
setting up for shallow water cruising.
●
Return the outboard motor to its normal position as soon as the boat is back in deeper water.
ZMU01936
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.
Procedure for power trim and tilt / power
ZMU04603
tilt models
1. Place the remote control lever / gear shift lever in neutral.
DN
ZMU03999

Cruising in shallow water

The outboard motor can be tilted up partially to allow operation in shallow water.

Power trim and tilt models / power tilt models

The outboard motor can be tilted up partially
52
N
ZMU04588
Operation
2. Slightly tilt the outboard motor up to the desired position using the power trim and tilt switch / power tilt switch.
UP
UP DN
ZMU01935
UP
ZMU04602
water passages with fresh water to prevent them from becoming clogged with salt de­posits.
NOTE:
For cooling system flushing instructions, see page 55.
Cruising in turbid water
Yamaha strongly recommends that you use the optional chromium-plated water pump kit (not available for some models) if you use the outboard motor in turbid or muddy water conditions.
UP
ZMU04000
3. To return the outboard motor to the nor­mal running position, press the power trim and tilt switch / power tilt switch and slowly tilt the outboard motor down.

Cruising in other conditions

Cruising in salt water
After operating in salt water, flush the cooling
53

Maintenance

Specifications

NOTE:
“(AL)” stated in the specification data below represents the numerical value for the alumi­num propeller installed. Likewise, “(SUS)” represents the value for stainless steel propeller installed and “(PL)” for plastic propeller installed.
Dimension:
Overall length:
792 mm (31.2 in)
Overall width:
554 mm (21.8 in)
Overall height X:
1782 mm (70.2 in)
Transom height X:
643 mm (25.3 in)
Weight (without propeller) X:
216.0 kg (476 lb)
Performance:
Full throttle operating range:
4500–5500 r/min
Maximum output:
147.1 kW@5000 r/min (200 HP@5000 r/min)
Idling speed (in neutral):
700 ±30 r/min
Engine:
Type:
2-stroke V
Displacement:
2596.0 cm
Bore × stroke:
90.0 × 68.0 mm (3.54 × 2.68 in)
Ignition system:
TCI
Spark plug with resistor (NGK):
BKR7EKU
3
(158.41 cu.in)
Spark plug gap:
1.5–1.6 mm (0.059–0.063 in)
Control system:
Remote control
Starting system:
Electric
Starting carburetion system:
Electronic fuel injection
Min. cold cranking amps (CCA/SAE):
512.0 A
Min. marine cranking amps (MCA/ABYC):
675.0 A
Min. reserve capacity (RC/SAE):
182 minutes
Alternator output for battery DC:
45.0 A
Drive unit:
Gear positions:
Forward-neutral-reverse
Gear ratio:
1.86 (26/14)
Trim and tilt system:
Power trim and tilt
Propeller mark:
LZ200TR ML Z200TR M
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Min. pump octane:
86
Recommended engine oil:
YAMALUBE 2-stroke outboard motor oil
Lubrication:
Oil injection
Engine oil tank capacity:
0.9 L (0.95 US qt) (0.79 Imp.qt)
Remote oil tank capacity:
10.5 L (11.10 US qt) (9.24 Imp.qt)
Recommended gear oil:
54
Maintenance
Hypoid gear oil SAE#90
Gear oil quantity:
LZ200TR 870.0 cm3 (29.41 US oz) (30.68 Imp.oz) Z200TR 980.0 cm
3
(33.13 US oz)
(34.56 Imp.oz)
Tightening torque for engine:
Spark plug:
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
Propeller nut:
55.0 Nm (40.6 ft-lb) (5.61 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, 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 trail-
ered 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.
ZMU04720

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. This is especially important for your oil injec­tion equipped outboard motor due to the lean oil ratios used at idle prior to shutting the en­gine off for the season. 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.
ECM01070
CAUTION:
Do not use any chemical goods contain­ing Silicon, Phosphorus, or Lead. Other­wise the oxygen sensor for the Electronic Fuel Injection system could be damaged. Consult your Yamaha dealer for details
55
Maintenance
on the use of chemical goods for storage.

Procedure

Flushing with the flushing attachment
1. Wash the outboard motor body using fresh water. For further information, see page 59.
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 top cowling and propeller.
4. Install the flushing attachment over the cooling water inlet.
ECM00300
CAUTION:
Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the en­gine will be damaged from overheating. Before starting the engine, be sure to supply water to the cooling water passag­es.
ECM00310
CAUTION:
Avoid running the outboard motor at high speed while on the flushing attachment, otherwise overheating could occur.
1. Flushing attachment
5. Cooling system flushing is essential to prevent the cooling system from clog­ging up with salt, sand, or dirt. In addi­tion, fogging/lubricating of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flush­ing and fogging at the same time.
EWM00090
WARNING
●
Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away
●
from the flywheel and other rotating parts while the engine is running.
NOTE:
●
When using the flushing attachment, maintain adequate water pressure and a steady water flow.
●
If the overheat warning device is activated, turn the engine off, and consult your Yamaha dealer.
6. Run the engine at a fast idle for a few minutes in neutral position while supply­ing fresh water.
7. Just prior to turning off the engine, quick­ly spray “Yamaha Stor-Rite Engine Fogging Oil” (Part No. LUB-STRRT-12-
00) alternately into the intake silencer or
56
Maintenance
the fogging hole of the silencer cover, if equipped. When properly done, the en­gine will smoke excessively and almost stall.
8. Remove the flushing attachment and wipe off any excess water.
9. Install the top cowling and propeller.
10. Drain the cooling water completely out of the motor. Clean the body thoroughly.
NOTE:
A flushing attachment is available from your Yamaha dealer.

Lubrication (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 62.
2. Fill the oil tanks. This prevents the for­mation of condensation. For models with a remote oil tank, it may be necessary to manually override the control unit to completely fill the engine oil tank.
3. Change the gear oil. For instructions, see page 68. Inspect the oil for the pres­ence of water which indicates a leaky seal. Seal replacement should be per­formed by an authorized Yamaha dealer prior to use.
4. Grease all grease fittings. For further de­tails, see page 62.

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).
ECM01401
CAUTION:
Do not spray when the engine is running. Also, do not spray near the silencer or into the engine. Otherwise the engine could be damaged.
3. Wax the cowling with a non-abrasive wax such as “Yamaha Silicone Wax” (Part No. ACC-11000-15-02).

Battery care

EWM00330
WARNING
Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive mea­sures:
●
Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury.
●
Wear protective eye gear when han­dling or working near batteries.
Antidote (EXTERNAL):
●
SKIN - Flush with water.
●
EYES - Flush with water for 15 minutes and get immediate medical attention.
Antidote (INTERNAL):
●
Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate
medical attention. Batteries also generate explosive hydro­gen gas; therefore, you should always follow these preventive measures:
●
Charge batteries in a well-ventilated ar-
ea.
●
Keep batteries away from fire, sparks,
or open flames (for example: welding
equipment, lighted cigarettes, and so
57
Maintenance
on.)
●
DO NOT SMOKE when charging or han-
dling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN.
Batteries vary among manufacturers. There­fore the following procedures may not al­ways apply. Consult your battery manufacturer’s instructions. Procedure
1. Disconnect and remove the battery from
the boat. Always disconnect the black negative cable first to prevent the risk of shorting.
2. Clean the battery casing and terminals.
Fill each cell to the upper level with dis­tilled water.
3. Store the battery on a level surface in a
cool, dry, well-ventilated place out of di­rect sunlight.
4. Once a month, check the specific gravity
of the electrolyte and recharge as re­quired to prolong battery life.

Flushing power unit

Perform this procedure right after operation for the most thorough flushing.
ECM01530
CAUTION:
Do not perform this procedure while the engine is running. The water pump may be damaged and severe damage from overheating can result.
1. After shutting off the engine, unscrew
the garden hose connector from the fit­ting on the bottom cowling.
1
3
2
ZMU04723
1. Fitting
2. Garden hose connector
3. Garden hose adapter
2. Screw the garden hose adapter onto a garden hose, which is connected to a fresh water supply, and then connect it to the garden hose connector.
3. With the engine off, turn on the water tap and let the water flush through the cool­ing passages for about 15 minutes. Turn off the water and disconnect the garden hose adapter from the garden hose con­nector.
4. Reinstall the garden hose connector onto the fitting on the bottom cowling. Tighten the connector securely.
ECM00540
CAUTION:
Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal opera-
58
Maintenance
tion. Water will leak out of the connector instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fit­ting after flushing the engine.
NOTE:
●
When flushing the engine with the boat in the water, tilting up the outboard motor un­til it is completely out of the water will achieve better results.
●
For cooling system flushing instructions, see page 55.

Cleaning the outboard motor

After use, wash the exterior of the outboard motor with fresh water. Flush the cooling system with fresh water.
ZMU02550
NOTE:
For cooling system flushing instructions, see page 55.

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 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.
59
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.
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.
The “” symbol indicates the check-ups which you may carry out yourself. The “” symbol indicates work to be carried out by your Yamaha dealer.
Initial Every
Item Actions
Anode(s) (external)
Anode(s) (internal)
Battery Inspection / charging
Cooling water pas­sages
Cowling clamp Inspection
Fuel filter (can be dis­assembled)
Fuel system Inspection
Gear oil Change
Greasing points Greasing
Idling speed Inspection
PCV (Pressure Con­trol Valve)
Power trim and tilt unit Inspection
Propeller and cotter pin
Shift link / shift cable Inspection / adjustment
Thermostat
Throttle link / throttle cable / throttle pick-up timing
Throttle position sen­sor
Inspection / replace­ment
Inspection / replace­ment
Cleaning
Inspection / replace­ment
Inspection
Inspection / replace­ment
Inspection / replace­ment
Inspection / adjustment
Inspection / adjustment
10 hours
(1 month)
50 hours
(3
months)
100 hours (6 months)
200
hours (1
year)
60
Item Actions
Water pump
High pressure fuel pump drive belt
High pressure fuel pump oil level
Oil pump Inspection / adjustment
Oil tank water drain Inspection / cleaning
Spark plug(s)
Inspection / replace­ment
Inspection / replace­ment
Inspection / filling
Cleaning / adjustment / replacement

Maintenance chart (additional)

Item Actions
High pressure fuel pump drive belt
Fuel filter (vapor sepa­rator tank)
Replacement
Replacement
Maintenance
Initial Every
10 hours
(1 month)
500 hours (2.5 years) 1000 hours (5 years)
50 hours
(3
months)
Every
100 hours (6 months)
200
hours (1
year)
61
Maintenance

Greasing

Yamaha marine grease (Water resistant grease)
Z200, LZ200

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
62
ZMU04724
sparks, which could lead to explosion or fire.
The spark plug is an important engine com­ponent and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For exam-
Maintenance
ple, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically re­move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should re­place the spark plug with another of the cor­rect type.
Standard spark plug:
BKR7EKU
Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification if necessary.
1
2
1. Spark plug gap
2. Spark plug I.D. mark (NGK)
Spark plug gap:
1.5–1.6 mm (0.059–0.063 in)
1
ZMU01892
spark plug to the correct torque.
Spark plug torque:
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
NOTE:
If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past fin­ger-tight. Have the spark plug adjusted to the correct torque as soon as possible with a torque-wrench.

Checking fuel system

EWM00060
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.
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.
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
63
Maintenance
ZMU04004
Checkpoints
Fuel system parts leakage
●
Fuel line joint leakage
●
●
Fuel line cracks or other damage Fuel connector leakage
●

Inspecting idling speed

EWM00451
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.
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.
NOTE:
Correct idling speed inspection is only possi­ble if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty ver­ifying the idle speed, or the idle speed re­quires adjustment, consult a Yamaha dealer or other qualified mechanic.
2. Verify whether the idle speed is set to specification. For idle speed specifica­tions, see page 54.

Checking water in engine oil tank

Oil injection models
There is a water trap at the bottom of the en­gine oil tank. If water or foreign matter is vis­ible in this trap, consult your Yamaha dealer.
2
1
ZMU01895
1. Water trap
2. Engine oil tank

Checking wiring and connectors

Check that each grounding wire is properly
●
secured.
64
●
Check that each connector is engaged se­curely.
Maintenance
1
2
ZMU03458
ZMU04007

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 power trim and tilt system

EWM00430
WARNING
●
Never get under the lower unit while it is tilted, even when the tilt support lever is locked. Severe injury could occur if the outboard motor accidentally falls.
●
Make sure no one is under the outboard motor before performing this test.
1. Check the power trim and tilt unit for any sign of oil leaks.
2. Operate each of the power trim and tilt switches on the remote control and en­gine bottom cowling (if equipped) to check that all switches work.
3. Tilt the outboard motor up and check that the tilt rod and trim rods are extend­ed completely.
1. Tilt rod
2. Trim rods
4. Use the tilt support lever to lock the mo­tor in the up position. Operate the tilt down switch briefly so the motor is sup­ported by the tilt support lever.
1
ZMU04155
1. Tilt support lever
5. Check that the tilt rod and trim rods are free of corrosion or other flaws.
6. Activate the tilt-down switch until the trim rods have retracted completely into the cylinders.
65
Maintenance
ZMU04156
7. Activate the trim-up switch until the tilt rod is fully extended. Unlock the tilt sup­port lever.
ZMU03460
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.
ZMU01896
8. Tilt the outboard motor down. Check that the tilt rod and trim rods operate smoothly.
NOTE:
Consult your Yamaha dealer if any operation is abnormal.

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
66
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 pro-
●
peller shaft.
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

Spline models
1. Straighten the cotter pin and pull it out using a pair of pliers.
2. Remove the propeller nut, washer, and spacer (if equipped).
Maintenance
5. Propeller
6. Thrust washer
3. Remove the propeller and thrust wash­er.

Installing the Propeller

Spline models
EWM00770
WARNING
On counter rotation models, be sure to use a propeller intended for counter­clockwise rotation. These propellers are identified with the letter “L” after the size indication on the propeller. Otherwise the boat could move in the opposite direction from that expected.
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. Cotter pin
2. Propeller nut
3. Washer
4. Spacer
1
1. Apply Yamaha marine grease or a cor­rosion resistant grease to the propeller shaft.
2. Install the thrust washer and propeller
2
3
4
5
6
ZMU01898
on the propeller shaft.
3. Install the spacer and washer. Tighten the propeller nut to the specified torque.
Propeller nut tightening torque:
55.0 Nm (40.6 ft-lb) (5.61 kgf-m)
4. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.
67
Maintenance
2
1
ZMU01899
NOTE:
If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to align it with the hole.

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 and gasket.
1. Gear oil drain screw
2. Oil level plug
NOTE:
If a magnetic gear oil drain screw is
●
equipped, remove all metal particles from the screw before installing it. Always use new gaskets. Do not reuse the
●
removed gaskets.
4. Remove the oil level plug and gasket to allow the oil to drain completely.
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
68
Maintenance
the gear oil drain screw hole.
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
LZ200TR 870.0 cm
3
(29.41 US oz) (30.68 Imp.oz) Z200TR 980.0 cm
3
(33.13 US oz)
(34.56 Imp.oz)
ZMU01900
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.
7. Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw.

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.
ZMU01901
ZMU04008

Checking battery (for electric start models)

EWM00330
WARNING
Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive mea­sures:
Avoid bodily contact with electrolytic
●
fluid as it can cause severe burns or permanent eye injury. Wear protective eye gear when han-
●
69
Maintenance
dling or working near batteries.
Antidote (EXTERNAL):
SKIN - Flush with water.
●
●
EYES - Flush with water for 15 minutes and get immediate medical attention.
Antidote (INTERNAL):
●
Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate
medical attention. Batteries also generate explosive hydro­gen gas; therefore, you should always follow these preventive measures:
●
Charge batteries in a well-ventilated ar-
ea.
●
Keep batteries away from fire, sparks,
or open flames (for example: welding
equipment, lighted cigarettes, and so
on.)
●
DO NOT SMOKE when charging or han-
dling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN.
ECM00360
CAUTION:
●
A poorly maintained battery will quickly
deteriorate.
●
Ordinary tap water contains minerals
harmful to a battery, and should not be
used for topping up.
1. Check the electrolyte level at least once
a month. Fill to the manufacturer’s rec­ommended level when necessary. Top up only with distilled water (or pure de­ionized water suitable to use in batter­ies).
2. Always keep the battery in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month or more, re­move the battery from the boat and store it in a cool, dark place. Completely re­charge the battery before using it.
3. If the battery will be stored for longer than a month, check the specific gravity of the fluid at least once a month and re­charge the battery when it is low.
NOTE:
Consult a Yamaha dealer when charging or re-charging batteries.

Connecting the Battery

EWM00570
WARNING
Mount the battery holder securely in a dry, well-ventilated, vibration-free loca­tion in the boat. Install a fully charged bat­tery in the holder.
ECM01121
CAUTION:
●
Make sure the main switch (on applica­ble models) is “” (off) before work- ing on the battery.
●
Reversal of the battery cables will dam­age the electrical parts.
●
Connect the red battery cable first
70
when installing the battery and discon­nect the black battery cable first when removing it. Otherwise, the electrical parts can be damaged.
●
The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine.
Connect the RED lead to the POSITIVE (+) terminal first. Then connect the BLACK lead to the NEGATIVE (-) terminal.
1. Red cable
2. Black cable
3. Battery
Using an accessory battery (option)
Use a connecting cable between the (-) ter­minals of the starting battery and accessory battery. See the illustrations of the wiring connections. This cable must be made from wire equivalent to the starting battery cable.
EWM00600
WARNING
Use of smaller wire could lead to a fire.
Maintenance
3
7
4
2
1
1. Battery for accessories
2. Battery for starting
3. Large black lead
4. Large red lead for starting battery
5. Negative connecting cable
6. Power for accessories
7. Small red lead for accessory battery charg­ing (optional part)
NOTE:
If a battery selector switch is desired, consult your YAMAHA dealer about correct wiring.

Disconnecting the battery

Disconnect the BLACK cable from the NEG­ATIVE (-) terminal first. Then disconnect the RED cable from the POSITIVE (+) terminal.

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.
6
ZMU01942
5
71
Maintenance
ZMU04679

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.
72
ZMU01943

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 43.
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.
73
Trouble Recovery
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer.
Q. Has warning system activated? A. Find and correct cause of warning.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con­nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro­ken wires.
A. Return to home position.
Q. Is motor angle too high? A. Return to normal operating position.
Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect? A. Connect correctly.
Q. Is throttle valve adjustment incorrect? A. Have serviced by a Yamaha dealer.
Q. Is battery cable disconnected? A. Connect securely.
Warning buzzer sounds or indicator lights.
Q. Is cooling system clogged? A. Check water intake for restriction.
Q. Is engine oil level low? A. Fill oil tank with specified engine oil.
Q. Is specified engine oil not being used? A. Check and replace oil as specified.
Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.
Q. Are carburetor adjustments incorrect? A. Have serviced by a Yamaha dealer.
Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.
Q. Is air vent screw on fuel tank closed? A. Open air vent screw.
Q. Is choke knob pulled out?
74
Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec­ommended type.
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Is engine oil contaminated or deteriorat­ed? A. Replace oil with fresh, specified type.
Q. Is oil filter clogged? A. Have serviced by a Yamaha dealer.
Q. Has oil feed/injection pump malfunc­tioned?
Trouble Recovery
A. Have serviced by a Yamaha dealer.
Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane.
Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer.
Q. Is there excess water in fuel filter cup? A. Drain filter cup.
Engine power loss.
Q. Is propeller damaged? A. Have propeller repaired or replaced.
Q. Is propeller pitch or diameter incorrect? A. Install correct propeller to operate out­board at its recommended speed (r/min) range.
Q. Is trim angle incorrect? A. Adjust trim angle to achieve most efficient operation.
Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height.
Q. Are weeds or other foreign matter tangled on gear housing? A. Remove foreign matter and clean lower unit.
Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system.
Q. Is fuel filter clogged? A. Clean or replace filter.
Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel.
Q. Is spark plug gap incorrect? A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con­nected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or bro­ken wires.
Q. Have electrical parts failed? A. Have serviced by a Yamaha dealer.
Q. Is specified fuel not being used? A. Replace fuel with specified type.
Q. Has warning system activated? A. Find and correct cause of warning.
Q. Is boat bottom fouled with marine growth? A. Clean boat bottom.
Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.
Q. Is specified engine oil not being used? A. Check and replace oil with specified type.
Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer.
Q. Is air vent screw closed? A. Open the air vent screw.
Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer.
75
Trouble Recovery
Q. Is fuel joint connection incorrect? A. Connect correctly.
damaged by a collision while operating or trailering. Damage could make the out­board motor unsafe to operate.
Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec­ommended type.
Q. Is high pressure fuel pump drive belt bro­ken? A. Have serviced by a Yamaha dealer.
Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer.
Engine vibrates excessively.
Q. Is propeller damaged? A. Have propeller repaired or replaced.
Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer.
Q. Are weeds or other foreign matter tangled on propeller? A. Remove and clean propeller.
Q. Is motor mounting bolt loose? A. Tighten bolt.
Q. Is steering pivot loose or damaged? A. Tighten or have serviced by a Yamaha dealer.
Temporary action in
emergency

Impact damage

EWM00870
WARNING
The outboard motor can be seriously
If the outboard motor hits an object in the wa­ter, follow the procedure below.
1. Stop the engine immediately.
2. Inspect the control system and all com­ponents for damage. Also inspect the boat for damage.
3. Whether damage is found or not, return to the nearest harbor slowly and careful­ly.
4. Have a Yamaha dealer inspect the out­board motor before operating it again.

Running single engine

When using only engine in an emergency, be sure to keep the unused one tilted up and op­erate the other engine at low speed.
ECM00370
CAUTION:
If the boat is operated with one engine in the water but not running, water may run into the exhaust pipe due to wave action, causing engine trouble.
NOTE:
When you are maneuvering at low speed, such as near a dock, it is recommended that both engines be running with one in neutral gear if possible.
76
Trouble Recovery
4
3
2
3

Replacing fuse

If the fuse has blown on an electric start model, open the fuse box and use a fuse puller to replace the fuse with a spare one of the proper amperage.
EWM00630
WARNING
Be sure to use the specified fuse. An in­correct fuse or a piece of wire could allow excessive current flow. This could cause electric system damage and a fire hazard.
ECM01382
CAUTION:
If a main fuse has blown, be sure to also
●
check the other main fuse.
●
If the outboard motor is operated after a main fuse has blown charging capabili­ty will be insufficient, and the engine will not start.
5
1
1. Electrical cover
2. Fuse holder
3. Fuse (20 A × 3, 30 A, 80 A × 2)
4. Spare fuse (20 A, 30 A, 80 A)
5. Fuse puller
4
ZMU04009
1
ZMU03562
1. Fuse puller
NOTE:
Consult your Yamaha dealer if the new fuse immediately blows again.

Power trim and tilt / power tilt will not operate

If the engine cannot be tilted up or down with the power trim and tilt / the power tilt because of a discharged battery or a failure with the power trim and tilt unit / the power tilt unit, the engine can be tilted manually.
1. Loosen the manual valve screw by turn­ing it counterclockwise until it stops.
77
Trouble Recovery
1
ZMU05018
1. Manual valve screw
2. Put the engine in the desired position, then tighten the manual valve screw by turning it clockwise.

Water separator warning indicator blinks while cruising

EWM01500
WARNING
Gasoline is highly flammable, and its va­pors are flammable and explosive.
Do not perform this procedure on a hot
●
or running engine. Allow the engine to cool. There will be fuel in the fuel filter. Keep
●
away from sparks, cigarettes, flames or other sources of ignition. This procedure will allow some fuel to
●
spill. Catch fuel in a rag. Wipe up any spilled fuel immediately. The fuel filter must be reassembled
●
carefully with the O-ring, filter cup, and hoses in place. Improper assembly or replacement could result in a fuel leak, which could result in a fire or explosion hazard.
If the water separator warning indicator on the tachometer blinks, perform the following procedure.
1. Water separator warning indicator
1. Stop the engine.
2. Remove the top cowling.
3. Disconnect the water detection switch coupler.
ECM01570
CAUTION:
Be careful not to get any water on the wa­ter detection switch coupler, otherwise a malfunction could occur.
1
ZMU05502
1. Water detection switch coupler
4. Unscrew the filter cup from the filter housing.
NOTE:
Be careful not to twist the water detection switch lead when unscrewing the filter cup.
78
1
2
ZMU05501
1. Filter cup
2. Water detection switch lead
5. Drain the water in the filter cup by soak­ing it up with a rag.
NOTE:
Properly dispose of the rag.
6. Firmly screw the filter cup onto the filter housing.
NOTE:
Be careful not to twist the water detection switch lead when screwing the filter cup onto the filter housing.
7. Connect the water detection switch cou­pler securely until a click is heard.
1
ZMU05500
1. Water detection switch coupler
8. Install the top cowling.
9. Start the engine and make sure that the water separator warning indicator re-
Trouble Recovery
mains off.
NOTE:
Have a Yamaha dealer inspect the outboard motor after returning to port.

Starter will not operate

If the starter mechanism does not operate (the engine cannot be cranked with the start­er), the engine can be started manually with an emergency starter rope. However, the en­gine cannot be started manually if the battery voltage is low. If the battery is discharged to 9 volts or below, the electric fuel pump will not operate.
EWM01021
WARNING
●
Use this procedure only in an emergen­cy 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 the remote control lever is in neutral. Otherwise the boat could unexpectedly start to move, which could result in an accident.
●
Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating the boat. 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
79
Trouble Recovery
boat to be thrown forward.
●
Make 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 flywheel cover.
4. Turn on the main switch.
OFF
ON
START
ZMU02334
ON
START
OFF
ZMU04589
ZMU04443
3. Prepare the engine for starting. For fur­ther information, see page 43. Be sure the engine is in neutral and that the en­gine stop switch lanyard lock plate is at­tached to the engine stop switch.
80
ON STARTOFF
ZMU01906
5. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope around the fly­wheel several turns clockwise.
6. Give a strong pull straight out to crank the engine. Repeat if necessary.
EWM00620
WARNING
Do not install the top cowling when en-
gine is running.
ZMU04444

Engine fails to operate

Low oil level warning activates

If the oil level is allowed to drop too low, the red segment will appear on the oil level indi­cator, the buzzer will sound, and engine speed will be limited to about 2000 r/min. If this happens, a reserve amount of oil can be pumped from the remote oil tank to the en­gine oil tank using the emergency switch.
EWM01050
WARNING
Be sure to stop the engine before per­forming this procedure.
ECM00900
CAUTION:
●
If the emergency switch is held up too long, too much oil will be pumped into the engine oil tank, overflowing it. Re­lease the switch when oil reaches the upper level line on the engine oil tank. Do not use this emergency procedure
●
unless the oil level warning indicators are working.
1. Remove the top cowling.
2. Turn on the main switch.
Trouble Recovery
ON STARTOFF
ZMU01906
3. Lift the emergency switch to pump re­serve oil into the engine oil tank from the remote oil tank.
1
ZMU04010
1. Emergency switch
12
1. Engine oil tank
2. Remote oil tank
4. After using the emergency switch, turn off the main switch, then turn it back on. This resets the warning system to nor-
ZMU01908
81
Trouble Recovery
mal operation. The yellow segment will continue to be displayed on the oil level indicator.
5. Start the engine and return to the near­est port for more oil.
NOTE:
●
The maximum reserve oil capacity is 1500 cm3 (1.6 US qt, 1.31 Imp qt).
●
The oil-feed pump will not operate if the engine is tilted up more than 35°. Put the engine in the upright position (not tilted) before using the emergency switch.

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, sea­weed, and so on, with fresh water.
ZMU01910
3. Drain the fuel from the vapor separator, fuel filter, and fuel line.
4. Feed fogging oil or engine oil through the intake manifold and spark plug holes while cranking with the emergency start­er rope.
ZMU01911
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.
ZMU01909
2. Remove the spark plugs and face the spark plug holes downward to allow any water, mud, or contaminants to drain.
82

Consumer information

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

83
Consumer information
84
Consumer information
YAMAHA MOTOR CORPORATION, U.S.A.
OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY
85
Consumer information
86
Consumer information
87
Consumer information
IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR
YAMAHA OUTSIDE THE USA OR CANADA
88
Printed in Japan May 2006–0.2 × 1 !
Printed on recycled paper
YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON

OUTBOARD MOTOR WARRANTY REGISTRATION

ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD
Please complete and mail this card. This information is necessary to accurately register your unit for warranty.
Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et
OUTBOARD MOTOR MODEL AND SERIAL NUMBER (From I.D. label on clamp bracket)
MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation)
DATE SOLD
DATE DE LIVRAISON
OWNER’S NAME
NOM DU PROPRIÉTAIRE
ADDRESS
ADRESSE
PHONE NUMBER ( )
NUMÉRO DE TÉLÉPHONE
que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.
(For Dealer Use Only)
(A l’usage du concessionnaire)
YAMAHA DEALER NUMBER
NO. DU CONCESSIONNAIRE YAMAHA
DEALER NAME
NOM DU CONCESSIONNAIRE
USAGE (Check One)
UTILISATION
MONTH DAY YEAR
MOIS JOUR ANNÉE
FIRST LAST
PRÉNOM NOM DE FAMILLE
STREET
RUE
CITY STATE/PROVINCE ZIP
VILLE PROVINCE CODE POSTAL
(En cocher un.)
PLEASURE
LOISIR
COMMERCIAL
COMMERCIAL
ATTN: WARRANTY DEPARTMENT
PLACE POSTAGE HERE
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