Yamaha TRP150, TRP150 OX66 V MAX User Manual

OWNER’S MANUAL

DX150A

U.S.A.Edition

LIT-18626-04-60

EMU01448

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!

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YOUR SAFETY IS INVOLVED!

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

NOTE:

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

* Yamaha continually seeks advance-

ments 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 manual,
please consult your Yamaha dealer.

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Failure to follow WARNING instructions
could result in severe injury or death to
the machine operator, a bystander, or a
person inspecting or repairing the out­board motor.

EMU01446

DX150A

OWNER'S MANUAL

©2001 by Yamaha Motor Corporation, USA

1st Edition, April 2001

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-18626-04-60

NOTE:

The DX150 and its standard accessories
are used as a base for the explanations
and illustrations in this manual.
Therefore, some items may not apply to
every model.

EMU00003

CONTENTS

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GENERAL INFORMATION

BASIC COMPONENTS

OPERATION

MAINTENANCE

1

2

3

4

TROUBLE RECOVERY

INDEX

READ THIS OWNER’S MANUAL CAREFULLY

BEFORE OPERATING YOUR OUTBOARD MOTOR.

5

6

EMU00004

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Chapter 1

1

GENERAL

INFORMATION

IDENTIFICATION NUMBERS RECORD ..1-1

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

Key number...........................................1-1

EMISSION CONTROL INFORMATION...1-2

SAFETY INFORMATION..........................1-3

IMPORTANT LABELS ..............................1-5

BASIC BOATING RULES .........................1-6

FUELING INSTRUCTIONS.....................1-10

Gasoline (petrol).................................1-11

Engine oil ............................................1-11

BATTERY REQUIREMENT ....................1-12

PROPELLER SELECTION .......................1-12

START-IN-GEAR PROTECTION ............1-14

2

3

4

5

6

1

904011*

123

YAMAHA

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401012

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EMU00005

IDENTIFICATION NUMBERS

RECORD

EMU00007

OUTBOARD MOTOR SERIAL NUMBER

YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON

The outboard motor serial number is
stamped on the label attached to the port
side of the clamp-bracket.
Record your outboard motor serial num­ber in the spaces provided to assist you in
ordering spare parts from your Yamaha
dealer or for reference in case your out­board motor is stolen.

1 Outboard motor serial number

EMU00008

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 Key number

1-1

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EMISSION CONTROL INFORMATION

ENGINE FAMILY :

THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.
FELs :
SPARK PLUG :

IDLE SPEED :

rpm IN NEUTRAL

SPARK PLUG GAP (mm) :

g/kw-hr

Manufactured:

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108032

EMU01385

EMISSION CONTROL

INFORMATION

EMU01386

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.

1 Emission control information label

Existing Technology ; N/A

Manufactured date label

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

2 Manufactured date label

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EMU00917

SAFETY

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8 Before mounting or operating the out-

board motor, read this entire manual.
Reading it should give you an under­standing of the motor and its operation.

8 Before operating the boat, read any

owner’s or operator’s manuals supplied
with it and all labels. Be sure you under­stand each item before operating.

8 Do not overpower the boat with this

outboard motor. Overpowering the
boat could result in loss of control. The
rated power of the outboard should be
equal to or less than the rated horse­power capacity of the boat. If the rated
horsepower capacity of the boat is
unknown, consult the dealer or boat
manufacturer.

8 Do not modify the outboard.

Modifications could make the motor
unfit or unsafe to use.

8 Never operate after drinking alcohol or

taking drugs. About 50% of all boating
fatalities involve intoxication.

8 Have an approved personal flotation

device (PFD) on board for every occu­pant. It is a good idea to wear a PFD
whenever boating. At a minimum, chil­dren and non-swimmers should always
wear PFDs, and everyone should wear
PFDs when there are potentially haz­ardous boating conditions.

8 Gasoline is highly flammable, and its

vapors are flammable and explosive.
Handle and store gasoline carefully.
Make sure there are no gas fumes or
leaking fuel before starting the engine.

INFORMATION

8 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.

8 Check throttle, shift, and steering for

proper operation before starting the
engine.

8 Attach the engine stop switch lanyard

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

8 Know the marine laws and regulations

where you will be boating - and obey
them. Refer to “RULES OF THE ROAD”
section for basic boating rules.

8 Stay informed about the weather.

Check weather forecasts before boating.
Avoid boating in hazardous weather.

8 Tell someone where you are going:

leave a Float Plan with a responsible
person. Be sure to cancel the Float Plan
when you return.

8 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.

8 Always watch carefully for swimmers

during the engine operation.

8 Stay away from swimming areas.

1-3

8 When a swimmer is in the water near

you shift into neutral and shut off the
engine.

8 Be informed about boating safety.

Additional publications and information
can be obtained from many organiza­tions, including the following:

United States Coast Guard

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

National Marine Manufacturers

Association (NMMA)

401 N. Michigan Ave.
Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave.
Chicago, Il 60601

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EMU00014

WARNING

6K1-83623-4 1

YAMAHA

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.

WARNING

6

Be sure shift control is in neutral

6

before starting engine. (except 2HP)

6

Do not touch or remove electrical parts

6

when starting or during operation.

6

Keep hands,hair,and clothes away from flywheel

6

and other rotating parts while engine is running.

6A1-83625 -41

WARNING

Hot surface under this cover
during and after operation.
To avoid burns, do not touch
finned resistor with bare hands.

65L-83625-40

YAMAHA

ENGINE OIL ONLY

WARNING

6E5-13437- 43

Pour the engine oil into this oil tank, not gasoline.

RECOMMENDED OIL:

YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC-W3 certified outborad oil.

Do not add gasoline to the oil tank.
Fire or explosion could result.

OIL TANK

CAPACITY:10.5 LITERS

11.1 U.S. qt.

9.2 IMP. qt.

CAUTION

UNLEADED GASOLINE ONLY.
Gasoline containing lead can cause

performance loss and engine damage.

Refer to Owner’s Manual.

65L-2415E-40

YAMAHA

IMPORTANT LABELS

WARNING LABELS

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905011

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CAUTION LABELS

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1-5

EMU00015

BASIC BOATING RULES

(Rules of the road)

Just as there are rules which apply when
you are driving on streets and high ways,
there are waterway rules which apply
when you are driving your boat. These
rules are used internationally, and are
also enforced by the United States Coast
Guard and local agencies. You should be
aware of these rules, and follow them
whenever you encounter another vessel
on the water.

Several sets of rules prevail according to
geographic location, but are all basically
the same as the International Rules of the
Road. The rules presented here in your
Owner’s Manual are condensed, and have
been provided for your convenience only.
Consult your local U.S. Coast Guard
Auxiliary or Department of Motor
Vehicles for a complete set of rules gov­erning the waters in which you will be
using your boat.

STEERING AND SAILING RULES AND
SOUND SIGNALS

Whenever two vessels on the water meet
one another, one vessel has the right-of­way; it is called the “stand-on” vessel.
The vessel which does not have the right­of-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.

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

“The general prudential rule”

This rule is called Rule 2 in the
International Rules and says,

‘In obeying and construing these
rules due regard shall be had to all
dangers of navigation and collision,
and to any special circumstances,
which may render a departure from
the above rules necessary in order to
avoid immediate danger.’

In other words, follow the standard rules
except when a collision will occur unless
both vessels try to avoid each other. If
that is the case, both vessels become
“Give-Way” vessels.

1-6

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102045

102046

RULES WHEN ENCOUNTERING
VESSELS

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

Meeting

(you are approaching another vessel
head-on)

Crossing

(you are traveling across the other
vessel’s path)

Overtaking

(you are passing or being passed by
another vessel)

In the following illustration, your boat is
in the center. You should give the right-of­way 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 Give-Way vessels). Both you
and the meeting vessel must alter course
to avoid each other.

side. This rule doesn’t apply if both of you
will clear one another if you continue on
your set course and speed.

102044

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.

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-way! Both of you should alter
course to avoid an accident. You should
keep the other vessel on your port (left)

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

1-7

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

2. Sailing vessels should keep clear of
any fishing vessel.

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

Reading buoys and other markers

The waters of the United states are
marked for safe navigation by the lateral
system of buoyage. Simply put, buoys
and markers have an arrangement of
shapes, colors, numbers and lights to
show which side of the buoy a boater
should pass on when navigating in a par­ticular direction. The markings on these
buoys are oriented from the perspective
of being entered from seaward (the
boater is going towards the port). This
means that red buoys are passed on the
starboard (right) side when proceeding
from open water into port, and black
buoys are to port (left) side. When navi­gating out of port, your position with
respect to the buoys should be reversed;
red buoys should be to port and black
buoys to starboard.
Many bodies of water used by boaters are
entirely within the boundaries of a partic­ular state. The Uniform State Waterway
Marking System has been devised for
these waters. This system uses buoys and
signs with distinctive shapes and colors
to show regulatory or advisory informa­tion. These markers are white with black
letters and orange boarders. They signify
speed zones, restricted areas, danger
areas, and general information.

1-8

1

11

A

1

11

Proceeding toward head

of navigation from seaward

CAN BUOY

Odd number. Leave to port.

OR

SECONDARY CHANNEL BUOYS

STARTS NEW NUMBERING SYSTEM

old new

C " 1

"

NUN BUOY

Even number. Leave to starboard

N

"

2

"

No change

BUOY

COLOR CODE

BLACK

RED

GREEN

"

A

"

"

2

"

"

1

"

"

3

"

"

4

"

"

5

"

"

7

"

N

"

2

"

"

6

"

C

"

1

"

RB

"

L

"

RG

"

L

"

or

SECONDARY CHANNEL

MAIN CHANNEL

old

new

22

22

22

AA

LL

LL

Odd number. increasing toward head of naviga-

MAIN CHANNEL BUOYS

"

1

" "

3

" "

5

" "

7

"

tion.Leave to port (left) proceeding upstream.

LIGHTED BUOY (Port Hand)`

White Light

Green Light

old

new

old

new

old

new

LIGHTED BUOY (Starboard Hand)`

"

2

" "

4

" "

6

"

Even number,increasing toward head of naviga­tion. Leave to starboard (right) proceeding up­stream.

White Light Red Light

"

A

"

LIGHTED SAFE WATER BUOY

No number. Marks midchannel, pass on either
side. Letter has no lateral significance, used for

No nu mber . T opmo st ban d red

-

pre ferr ed

Top Mark
White Light

White Light

OR

OR

LIGHTED PREFERRED CHANNEL TO

RB

"

L

"

RG

"

L

"

PORT BUOY

identification and location purposes.

channel is to left of buoy. L etter ha s no la teral
significance, used for iden tification and location
purposes.

Red Light

Red or
White Light

OR

102052

Remember, markings may vary by geo­graphic location. Always consult local
boating authorities before driving your
boat in unfamiliar waters.

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EMU00017

FUELING INSTRUCTIONS

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GASOLINE AND ITS VAPORS ARE HIGH­LY FLAMMABLE AND EXPLOSIVE!
8 Do not smoke when refueling, and

keep away from sparks, flames, or
other sources of ignition.

8 Stop engine before refueling.
8 Refuel in a well-ventilated area. Refuel

portable fuel tanks off the boat.

8 Take care not to spill gasoline. If gaso-

line spills, wipe it up immediately with
dry rags.

8 Do not overfill the fuel tank.
8 Tighten the filler cap securely after

refueling.

8 If you should swallow some gasoline

inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.

8 If any gasoline spills onto your skin,

immediately wash with soap and
water. Change clothing if gasoline spills
on it.

8 Touch the fuel nozzle to the filler open-

ing or funnel to help prevent electrosta­tic sparks.

cC

8 Use only new clean gasoline which has

been stored in clean containers and is
not contaminated with water or foreign
matter.

8 Do not use leaded gasoline(petrol).

Leaded gasoline will cause damage to
the oxygen sensor for Electronic Fuel
Injection system.

1-10

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EMU00019

GASOLINE (PETROL)

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

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

EMU00027

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. Gasohol containing
methanol is not recommended by
Yamaha because it can cause fuel system
damage or engine performance prob­lems.

EMU00858

ENGINE OIL

Recommended engine oil:
YAMALUBE 2 STROKE OUTBOARD OIL

If the recommended engine oil is not
available, another 2-stroke engine oil with
a NMMA-certified TC-W3 rating may be
used.

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EMU00031

BATTERY REQUIREMENT

cC

Do not use the battery that does not
meet the specified capacity. If different
battery from the specification is used, the
electric system may perform poorly or be
overloaded, causing electrical system
damage.

Choose battery which meets the following
specifications for Electric start model.

Minimum cold crank performance
500 Amps at -17.8°C (0°F)
Minimum reserve capacity
140 minutes at 26.7°C (80°F)

EMU01395*

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.

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25-MF

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602023

Yamaha outboard motors are fitted with
propellers chosen to perform well over a
range of applications, but there may be
uses where a propeller with a different
pitch would be more appropriate. For a
greater operating load, a smaller-pitch
propeller is more suitable as it enables
the correct engine speed to be main­tained. Conversely, a larger-pitch pro­peller is more suitable for a smaller oper­ating load.

Yamaha dealers stock a range of pro­pellers, and can advise you and install a
propeller on your outboard that is best
suited to your application.

NOTE:

At full throttle and under a maximum
boat load, the engine’s rpm should be
within the upper half of the full throttle
operating range, as listed in “SPECIFICA­TIONS” on page 4-1. Select a propeller
which fulfills this requirement.
If operating under conditions which allow
the engine’s rpm to rise above the maxi­mum recommended range (such as light
boat loads), reduce the throttle setting to
maintain the rpm in the proper operating
range.

1 Propeller diameter (in inches)
2 Propeller pitch (in inches)

Refer to the section “CHECKING PRO­PELLER” for instructions on propeller
removal and installation.

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EMU01209

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 Neutral.
Always select Neutral before starting the
engine.

1-14

-MEMO-

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EMU00037

Chapter 2

BASIC COMPONENTS

MAIN COMPONENTS..............................2-1

OPERATIONS OF CONTROLS AND

OTHER FUNCTIONS ................................2-2

Remote control .....................................2-2

Power trim/tilt switch ...........................2-6

Digital tachometer................................2-7

Digital speedometer.............................2-9

Fuel management meter ...................2-12

Tilt support lever ................................2-17

Top cowling lock levers .....................2-17

Flushing device...................................2-17

WARNING SYSTEM ..............................2-18

Overheat warning...............................2-18

Oil level warning / Oil filter clogging

warning ...............................................2-19

1

2

3

4

5

6

EMU01206

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!1

!0

101014*

!2

101103

TRIP TIME BATT

Km/h
knot
mph

km
mile

SPEED

YAMAHA

set

mode

!4

!0

!5

!6

!3

!1

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MAIN COMPONENTS

1 Power trim and tilt switch
2 Flushing device
3 Tilt support lever
4 Anti-cavitation plate
5 Propeller
6 Cooling water inlet
7 Anode
8 Clamp bracket

9 Power trim and tilt unit
0 Cowling lock lever

q Top cowling
w Cooling water pilot hole

* e Remote control box (Side mount type)
* r Digital tachometer
* t Digital speedometer
* y Remote oil tank

* May not be exactly as shown; also may not

be included as standard equipment on all
models.

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701011

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701031

EMU00039

OPERATIONS OF CONTROLS

AND OTHER FUNCTIONS

EMU00096

REMOTE CONTROL

Both the shifter and the throttle are actu­ated by the remote control lever. In addi­tion, this control also has the electrical
switches.

1 Remote control lever
2 Neutral interlock trigger
3 Neutral throttle lever
4 Main switch
5 Engine stop lanyard switch
6 Power trim/tilt switch
7 Throttle friction adjusting screw

EMU00098

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.

1 Neutral
2 Forward
3 Reverse
4 Shift
5 Fully closed
6 Throttle
7 Fully open

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EMU00099

Neutral Interlock Trigger

UP
DN

000323

N

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701033

To shift out of Neutral, the neutral inter­lock trigger of the remote control lever
must first be pulled up.

EMU00100

Neutral Throttle Lever

To open the throttle without shifting into
either Forward or Reverse, place the
remote control lever in the Neutral posi­tion and lift the neutral throttle lever.

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

EMU00101

Main switch

The main switch controls the ignition sys­tem; its operation is described below.

8 OFF

Electrical circuits switched off.
(The key can be removed.)

8 ON

Electrical circuits switched on.
(The key cannot be removed.)

8 START

Starter-motor will turn and start engine.
(When the key is released, it returns auto­matically to “ON”.)

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000569

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EMU00934

Engine Stop Lanyard Switch

The lock-plate 1 must be attached to the
engine stop lanyard switch for the engine
to run. The lanyard 2 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.

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8 Attach the lanyard to a secure place on

your clothing, your arm or leg while
operating.

8 Do not attach the lanyard to clothing

that could tear loose. Do not route the
lanyard in such a way that it could
become entangled, preventing it from
functioning.

8 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.

2-4

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UP
DN

701034

UP
DN

EMU01331

Power Trim/Tilt Switch

The power trim/tilt adjusts the motor
angle in relation to the transom. The
power trim/tilt switch is located on the
remote control lever grip. Pushing the
switch “UP” trims the motor up, then tilts
the motor up. Pressing the switch “DN”
tilts the motor down and trims the motor
down. When the switch button is
released, the motor will stop in its current
position.

NOTE:

Refer to the sections “ADJUSTING TRIM
ANGLE” and “TILTING UP/DOWN” in
Chapter 3 for instructions on usage.

EMU01155

Throttle Friction Adjusting Screw

A friction device in the remote control box
provides adjustable resistance to move­ment of the remote control lever, and can
be set according to operator preference.
An adjusting screw is located on the front
of the remote control box.

Resistance Screw

Increase Turn clockwise

Decrease Turn counterclockwise

w

Do not overtighten the friction adjusting
screw. If there is too much resistance, it

701035

may be difficult to move the lever, which
could result in an accident.

2-5

E

302012

UP

DOWN

EMU01125

POWER TRIM/TILT SWITCH

The power trim/tilt adjusts the motor
angle in relation to the transom. The
power trim/tilt switch is located on the
side of the bottom engine cowling.
Pushing the switch “UP” trims the motor
up, then tilts the motor up. Pressing the
switch “DN” tilts the motor down and
trims the motor down. When the switch
button is released, the motor will stop in
its current position.

w

Use the power trim/tilt switch located on
the bottom engine cowling only when
the boat is at a complete stop with the
engine off. Attempting to use the cowl­ing-mounted power trim/tilt 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.

NOTE:

Refer to the section “Adjusting Trim
Angle” and “Tilting Up/Down” for instruc­tions on usage.

2-6

E

001082

q

t

w

u

y

e

r

001078

EMU01614

DIGITAL TACHOMETER

This gauge contains the tachometer, trim
meter, hour meter, oil level indicator, and
the overheat warning indicator.

1 Tachometer
2 Trim meter
3 Hour meter
4 Oil level indicator
5 Overheat warning indicator
6 Set button
7 Mode button

NOTE:

All segments of the display will light
momentarily after the main switch is
turned on and will return to normal there­after.

EMU00136

Tachometer

This meter shows the engine speed.

001049

001050

EMU01109

Trim Meter

This meter shows the trim angle of your
outboard motor.

NOTE:

8 Memorize the trim angles that work

best for your boat under different condi­tions. Adjust the trim angle to the
desired setting by operating the power
trim and tilt switch.

8 If the trim angle of your motor exceeds

the trim operating range, the top seg­ment on the trim meter display will start
to blink.

2-7

001051

q

001087

E

EMU01620

Hour Meter

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.
8 Changing the display format

Pressing the MODE button changes the
display format in the following circular
pattern:
Total hours - Trip hours - Display off

8 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.

EMU00138

Oil-Level Indicator

This indicator shows the engine oil level.
If the oil level falls below the lower limit,
the warning indicator will start to blink.
Refer to the sections “FILLING OIL” and
“OIL LEVEL WARNING” for details.

1 Oil-level indicator

cC

Do not operate the engine without oil.
Serious engine damage will occur.

2-8

E

802016*

TRIP TIME BATT

Km/h
knot
mph

km
mile

SPEED

YAMAHA

set

mode

q

w

e

r

001052

q

EMU01553

Overheat Warning Indicator

If the engine temperature rises too high,
the warning indicator will start to blink.
Refer to “OVERHEAT WARNING” for
details.

1 Overheat warning indicator

cC

Do not continue to operate the engine if a
warning device has activated. If neces­sary, refer to the “TROUBLESHOOTING”
section in this manual. Consult your deal­er if the problem cannot be located and
corrected.

EMU00140

DIGITAL SPEEDOMETER

This meter contains the speedometer, fuel
meter with warning, trip meter, clock and
voltmeter with warning.

1 Speedometer
2 Fuel meter
3 Trip meter/clock/voltmeter
4 Warning indicator

NOTE:

After the main switch is first turned on, all
portions of the meter come on as a check.
After a few seconds, the meters will
change to normal operation. Watch the
meter when turning on the main switch to
make sure all segments come on.

2-9

q

w

e

802023*

802024*

TRIP TIME BATT

Km/h
knot
mph

km
mile

SPEED

YAMAHA

set

mode

802034

TRIP TIME BATT

Km/h
knot
mph

km

mile

SPEED

YAMAHA

set

mode

E

EMU00141

Speedometer

The meter will show the boat speed.

NOTE:

The speedometer displays km/h, mph, or
knots, depending upon operator prefer­ence. Select the desired unit of measure­ment by setting the selector switch on the
back of the meter. See the illustration for
setting.

1 Cap
2 Selector switch (For speed unit)
3 Selector switch (For fuel sender)

EMU01274

Trip Meter

This meter displays the distance the boat
has traveled since the meter was last
reset.
Repeatedly push and release the “mode”
button until the indicator on the face of
the meter points to “TRIP”. To reset the
trip meter to “0”, press the “set” and
“mode” button together.

NOTE:

8 The trip distance is shown in kilometers

or miles depending upon the unit of
measurement selected for the
speedometer.

8 The trip distance is kept in memory by

battery power. The stored data will be
lost if the battery is disconnected.

2-10

E

802025*

TRIP TIME BATT

Km/h
knot
mph

km
mile

SPEED

YAMAHA

set

mode

802032TRIP TIME BATT

Km/h
knot
mph

km

mile

SPEED

EMU01275

Clock

This meter shows the current time.
Repeatedly push and release the “mode”
button until the indicator on the face of
the meter points to “TIME.” To set the
clock, be sure the meter 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 clock operates on battery power.
Disconnecting the battery will stop the
clock. Reset the clock after connecting the
battery.

EMU00144

Fuel meter

The fuel level is displayed by eight seg­ments. When all segments are showing,
the fuel is full.

cC

The Yamaha fuel tank sensor is different
from a conventional-type sensor. A
wrong setting of the selector switch on
the meter will give incorrect readings.
Consult Yamaha dealer for correct set­ting.

NOTE:

The fuel 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.

2-11

P S

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

802031

TRIP TIME BATT

Km/h
knot
mph

km

mile

SPEED

YAMAHA

set

mode

q

w

q

e

YAMAHA

FUEL MANAGEMENT

P S

set

Km/L
mpg

ECON SYNCTTL

mode

E

EMU00145

Warning indicator
8 Fuel warning

If the fuel level decreases to one segment
the fuel level warning segment 1 begins
blinking.

8 Low battery voltage warning

If battery voltage drops, the display 2 will
be automatically turned on and it begins
blinking.

cC

Do not continue to operate the engine if a
warning device has activated. Refer to
the TROUBLESHOOTING section in this
manual. Consult a Yamaha dealer if the
problem cannot be located and corrected.

EMU00146

FUEL MANAGEMENT METER

Optional equipment

I/h
gph

w

The meter contains the fuel flow meter,
fuel consumption meter, fuel economy
meter, twin engine speed synchronizer,
water separator warning indicator.

1 Fuel flow meter
2 Fuel consumption / Fuel economy meter /

Twin engine speed synchronizer

3 Water separator warning indicator

(Operates only if the sensor has been
installed.)

NOTE:

After the main switch is first turned on, all
portions of the meter come on as a check.
After a few seconds, the meters will
change to normal operation. Watch the
meter when turning on the main switch to
make sure all segments come on.

2-12

E

YAMAHA

P S

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

set

mode

2 65431

ON

(liter)

l/h

(gallon)

gph

q

EMU00147

Fuel Flow Meter

The meter displays fuel flow within one
hour, at the rate of current engine opera­tion.
If twin engines are installed on your boat,
the meter will display total fuel flow of
Port and Starboard side engine. It also
displays PS indication at the same time.
By pressing “set” button, the meter will
display fuel flow of starboard side engine
and S indication.
By pressing “set” button again, the meter
will display fuel flow of port side engine
and P indication.
By pressing “set” button again, the meter
will display total fuel flow.

NOTE:

8 The meter displays gallon/hour and liter

depending upon operator preference.
Select the desired unit of measurement
by setting the selector switch 1 on the
back of the meter during installation.

8 Fuel consumption meter and Fuel econ-

omy meter will indicate same unit of
measurement.

2-13

P S

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

FUEL MANAGEMENT

I/h
gph

Km

P S

ECON SYNCTTL

mp

/L

g

E

EMU01276

Fuel Consumption Meter

This meter displays the total amount of
fuel consumed since the meter was last
reset.
Repeatedly push and release the “mode”
button until the indicator on the face of
the meter points to total (“TTL”). To reset
the total fuel consumption to “0”, press
the “set” and “mode” buttons together.

EMU01277

Fuel Economy

This meter displays the distance per liter
or gallon when cruising for reference use
by the operator.
Repeatedly push and release the “mode”
button until the indicator on the face of
the meter points to “ECON.”

NOTE:

If twin engines are installed on your boat,
the meter will display only the total fuel
economy of both engines.

2-14

E

NOTE:

8 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).

8 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).

8 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.

2-15

P S

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

q
w
e

r
t

P S

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

000341

FUEL MANAGEMENT

I/h
gph

P S

ECON SYNCTTL

Km/L
mpg

E

EMU01278

Twin Engine Speed Synchronizer

This meter displays the difference in
engine speed (r/min) between the Port
and Starboard engines for reference pur­poses when synchronizing the two
engines’ speeds.
Repeatedly push and release the “mode”
button until the indicator on the face of
the meter points to “SYNC”.

1 Port side engine speed is higher
2 Port side engine speed is slightly higher
3 Engine speed is synchronized evenly

between Port and Starboard side engines

4 Starboard side engine speed is slightly

higher

5 Starboard side 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.

EMU01207

Water Separator Warning Indicator

If the water which has been separated
from fuel in the water trap exceeds a spe­cific volume, the indicator will blink show­ing the need for water to be drained.

NOTE:

This indicator only operates when a water
separator sensor is equipped.

2-16

E

301021

403033

EMU00157

TILT SUPPORT LEVER

To keep the outboard motor in the tilted­up position, lock the tilt support lever to
the clamp bracket.

EMU00163

TOP COWLING LOCK LEVERS

To remove the engine top cowling, pull
up the front and rear lock levers. Then lift
off the cowling. When replacing the cowl­ing, check to be sure it fits properly in the
rubber seal. Then lock the cowling again
by moving the levers downward.

301022

q

000825

EMU01146

FLUSHING DEVICE

This device 1 is used to clean the cooling
water passages of the motor using a gar­den hose and tap water.

NOTE:

Refer to “Cleaning Cooling-water
Passages” in Chapter 4 for instructions on
usage.

2-17

701054

605022

001053

E

EMU00169

WARNING SYSTEM

cC

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

EMU00170

OVERHEAT WARNING

This engine has an overheat warning
device. If the engine temperature rises too
high, the warning device will activate.
(1); Included (—); N/A

Activation of Tiller Remote
warning device control control

model model

The engine speed
will automatically
decrease to about
2,000 r/min.
The overheat
warning indicator 1
will come on.

The buzzer will sound.

1

1

If the warning system has been activated,
stop the engine and check the water inlet
for clogging.

2-18

E

701054

EMU00172

OIL LEVEL WARNING / OIL FILTER
CLOGGING WARNING

This engine has an oil level warning sys­tem. If oil level falls below lower limit, the
warning device will activate.

(1); Included (—); N/A

001054

q

213022

Warning device Tiller Remote
activation control control

model model

The engine speed
will automatically
decrease to about

1

2,000 r/min.

The oil level warning
indicator will come on.

The buzzer will sound.

1

1

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. For easy troubleshooting, it
is advisable to check for engine overheat­ing first, then oil level and finally oil filter
clogging.

1 Oil filter

q

905012

2-19

E

EMU00174

Chapter 3

OPERATION

INSTALLATION ........................................3-1

Mounting the outboard motor............3-2

FILLING FUEL AND ENGINE OIL ............3-4

Filling fuel..............................................3-4

Filling oil ................................................3-5

PRE-OPERATION CHECKS......................3-8

Operation after a long period of

storage...................................................3-9

BREAKING IN (RUNNING IN) ENGINE

STARTING ENGINE ...............................3-12

WARMING UP ENGINE .........................3-15

..3-10

1

2

3

SHIFTING ................................................3-16

Forward ...............................................3-16

Reverse................................................3-16

STOPPING ENGINE ...............................3-17

TRIMMING OUTBOARD MOTOR.........3-18

Adjusting trim angle ..........................3-19

TILTING UP/DOWN ...............................3-21

CRUISING IN OTHER CONDITIONS.....3-23

Cruising in salt water .........................3-23

Cruising in turbid water.....................3-23

4

5

6

E

EMU00175

INSTALLATION

cC

Incorrect engine height or obstructions to
smooth water flow (such as the design or
condition of the boat or accessories such
as transom ladders/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.

3-1

E

q

104016

EMU00176

MOUNTING THE OUTBOARD
MOTOR

w

Improper mounting of the outboard
motor could result in hazardous condi­tions such as poor handling, loss of con­trol, or fire hazards. Observe the follow­ing:
8 The information presented in this sec-

tion is intended as reference only. It is
not possible to provide complete
instructions for every possible
boat/motor combination. Proper
mounting depends in part on experi­ence and the specific boat/motor com­bination.

8 Your dealer or other person experi-

enced in proper rigging should mount
the motor. If you are mounting the
motor yourself, you should be trained
by an experienced person. [permanent
mounted type]

8 Your dealer or other person experi-

enced in proper outboard motor
mounting should show you how to
mount your motor. [portable type]

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 Center line (keel line)

3-2

E

w

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

EMU01300*

Mounting Height

To run your boat at optimum efficiency,
the water-resistance (drag) of the boat
and outboard motor must be made as lit­tle as possible. The mounting-height of
the outboard motor greatly affects the
water-resistance. If the mounting-height
is too high, cavitation tends to occur, thus
reducing the propulsion and causing the
engine to overheat. If the mounting­height is too low, the water-resistance will
increase and thereby reduce engine effi­ciency.

NOTE:

8 The optimum mounting height of the

outboard motor is affected by the
boat/motor combination. Test runs at
different heights can help determine the
optimum mounting height.
For further details, consult your
Yamaha dealer or boat manufacture to
determine the proper mounting height.

8 Refer to the section “TRIMMING OUT-

BOARD MOTOR” for instructions on
setting the trim angle of the outboard.

3-3

E

EMU00186

FILLING FUEL

AND ENGINE OIL

EMU01031

FILLING FUEL

1) Remove the fuel tank cap.

2) Fill the fuel tank carefully.

3) Close the cap securely after refueling.
Wipe up any spilled fuel.

EMU01019

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 emissions 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, avail­able from your Yamaha dealer. Ring Free
has repeatedly proven its ability to clean
combustion deposits from inside the
engine, notably the critical piston-ring­land area, and fuel system components.
Follow product labeling for use instruc­tions.

3-4

E

905015

ON STARTOFF

701024

EMU00190

FILLING OIL (for Precision blend
system model)

This engine uses the YAMAHA PRECI­SION BLEND SYSTEM, which provides
superior lubrication by ensuring the prop­er oil ratio for all operating conditions. No
fuel premixing is needed (except during
break-in/running-ins). Simply pour gaso­line into the fuel tank and oil into the oil
tank.
Convenient indicator segments indicate
condition of the oil supply. Refer to “Oil
level indicator”.
To fill the engine oil into the engine oil
tank, proceed as follows:

w

Do not add gasoline (Petrol) into the oil
tank. Fire or explosion could result.

Engine oil tank capacity:
Refer to “SPECIFICATION”, page 4-1

EMU00194

When remote oil tank is used

1) Pour the engine oil into the remote oil

tank.

2) Turn the main switch to “ON” to feed

the oil automatically from the remote

ON STARTOFF

oil tank to the engine oil tank by the
YAMAHA PRECISION BLEND SYS­TEM.

3) After the engine oil tank is filled up

with the oil, turn the main switch to
“OFF” to cancel the operation of the

701052

oil level warning system.

4) Operate the engine normally.

3-5

E

cC

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.

3-6E3-7

EMU00200*

Oil Level Indicator

The various oil level system functions are as follows:

Oil level indi-

cator (Digital

tachometer)

Oil level indi-

cator (Analog

tachometer)

Green

Yellow

Red Green

Engine oil

tank

More than

3

300 cm
(0.32 US qt,

0.26 Imp qt)

More than

3

300 cm
(0.32 US qt,

0.26 Imp qt)

3

300 cm
(0.32 US qt,

0.26 Imp
qt) or less

Remote oil

tank

More than
1,500 cm

3

(1.6 US qt,

1.31 Imp qt)

1,500 cm

3

(1.6 US qt,

1.31 Imp
qt) or less

More than
1,500 cm

3

(1.6 US qt,

1.31 Imp qt)

Remarks

• No refilling necessary.

• Add oil, refer to oil
filling.

• Check oil filter for clog­ging.

• Check battery cable
connection.

• Buzzer will sound.

• Engine speed is auto­matically reduced to
about 2,000 r/min.

Red

3

300 cm
(0.32 US qt,

0.26 Imp
qt) or less

1,500 cm
(1.6 US qt,

1.31 Imp
qt) or less

3

• Oil has not been added.

• Buzzer will sound.

• Engine speed is auto­matically reduced to
about 2,000 r/min.

• Refer to Chapter 5.

EMU00204

PRE-OPERATION CHECKS

w

If any item in the pre-operation check is
not working properly, have it inspected
and repaired before operating the out­board motor. Otherwise, an accident
could occur.

cC

Do not start the engine out of water.
Overheating and serious engine damage
can occur.

EMU00206

Fuel

8 Check to be sure you have plenty of fuel

for your trip.

8 Make sure there are no fuel leaks or

gasoline fumes.

8 Check fuel line connections to be sure

they are tight.

8 Be sure the fuel tank is positioned on a

secure, flat surface, and that the fuel
hose is not twisted or flattened, or likely
to contact sharp objects.

EMU00207

Oil

8 Check to be sure you have plenty of oil

for your trip.

EMU00209

Controls

8 Check throttle, shift, and steering for

proper operation before starting the
engine.

8 The controls should work smoothly,

without binding or unusual free play.

8 Look for loose or damaged connec-

tions.

8 Check operation of the starter and stop

switches when the outboard motor is in
the water.

3-8

E

E

EMU00211

Engine

8 Check the engine and engine mounting.
8 Look for loose or damaged fasteners.
8 Check the propeller for damage.
8 Check that the battery is in good condi-

tion and battery connections are secure.

EMU01174

OPERATION AFTER A LONG PERIOD
OF STORAGE (for Precision blend
system model)

When operating the engine after a long
period (12 months) of storage, proceed as
follows:

1) Use a 50 : 1 gasoline-oil mixture to
start the engine.

2) Start the engine. Leave it idling.

w

8 Do not touch or remove electrical parts

when starting or during operation.

8 Keep hands, hair, and clothes away

from flywheel and other rotating parts
while engine is running.

3) Watch for oil flowing through the oil
feed pipes. After any air in the oil
lines has been expelled, YAMAHA
PRECISION BLEND SYSTEM should
supply oil normally. If no oil has
begun flowing after 10 minutes of
idling, consult your Yamaha dealer.

cC

8 When operating the engine after a long

period of storage, be sure to take the
above steps; otherwise, engine seizure
may occur.

8 After completing the above steps, use

gasoline (petrol) only. If premix fuel is
used continually, the oxygen sensor for
Electronic Fuel Injection system could
be damaged.

3-9

E

EEMU01175

BREAKING IN (RUNNING IN)

ENGINE

Your new engine requires a period of
break-in (running-in) to allow mating sur­faces of moving parts to wear-in evenly.
Correct break-in (running-in) will help
ensure proper performance and longer
engine life.

cC

8 Failure to follow the break-in (running-

in) procedure may result in reduced
engine life or even severe engine dam­age.

8 Premix fuel must be used during break-

in (running-in) in addition to oil in the
Precision Blend System.

8 After break-in (running-in), use gaso-

line(petrol) only. If premix fuel is used
continually, the oxygen sensor for
Electronic Fuel Injection system could
be damaged.

Break-in (running-in) time:10 hours

Break-in (running-in) premix ratio

Gasoline (petrol) : Engine oil=50 : 1

EMU00225

Gasoline (Petrol)/ Engine oil mixing chart

Mixing

ratio

Gasoline
(Petrol)

Engine oil

1 L

(0.26 US gal,

0.22 Imp gal)

0.02 L

(0.02 US qt,

0.02 Imp ql)

12 L

(3.2 US gal,

2.6 Imp gal)

0.24 L

(0.25 US qt,

0.21 Imp qt)

50 : 1

14 L

(3.7 US gal,

3.1 Imp gal)

0.28 L

(0.30 US qt,

0.25 Imp qt)

cC

Make sure to mix gasoline (petrol) and oil
completely, otherwise your outboard
motor may be damaged.

3-10

24 L

(6.3 US gal,

5.3 Imp gal)

0.48 L

(0.51 US qt,

0.42 Imp qt)

E

EMU00231

Run the engine under load (in gear with a
propeller installed) as follows.

1) First 10 minutes:
Run the engine at the lowest possi­ble-speed. A fast idle in neutral is
best.

2) Next 50 minutes:
Do not exceed half throttle (approxi­mately 3,000 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 3,000 r/min or
less.

3) Second hour:
Accelerate at full throttle onto plane,
then reduce engine speed to three­quarter throttle (approximately 4,000
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) Third through tenth hours:
Avoid operating at full throttle for
more than 5 minutes at a time. Let the
engine cool between full-throttle runs.
Vary engine speed occasionally.
Avoid operating the engine at 2,000
r/min and below for more than 1 hour
at a time.

5) After the first 10 hours:
Operate the engine normally. Use
straight gasoline (petrol) in the fuel
tank; YAMAHA PRECISION BLEND
SYSTEM provides proper lubrication
for normal operation.

3-11

E

902023*

EMU01197

STARTING ENGINE

w

8 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.

8 When the air vent screw is loosened,

gasoline (petrol) vapor will be released.
Gasoline (petrol) 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.

8 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.

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 bulb with the out-

let end up until you feel it become
firm.

902025

3-12

E

000293

N

701015

EMU00248

PROCEDURE FOR REMOTE
CONTROL MODEL

4) Place the remote control lever in the
Neutral position.

NOTE:

The start-in-gear protection device per­mits the engine to be started only when it
is in Neutral.

5) 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
in the engine stop switch.

w

8 Attach the engine stop switch lanyard

to a secure place on your clothing, your
arm or leg while operating.

8 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.

8 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.

6) Turn the main switch to “ON”.

NOTE:

In case of dual-engine operation, when
the main switch is turned on, the buzzer
operates for a few seconds and stops
automatically. Should either of the dual
engines stall, the buzzer operates.

3-13

ON

START

OFF

701022

E

EMU00949

Electric Start Model

7) Turn the main switch to “START”,

and hold it for a maximum of 5 sec­onds.

8) Immediately after the engine starts,

release the main switch to return it to
“ON”.

cC

8 Do not turn the main switch to

“START” when the engine is running.

8 Do not keep the starter-motor turning

for more than 5 seconds. The battery
will rapidly become exhausted and it
will be impossible for it to start the
engine. If the engine does not start
within 5 seconds, return the main
switch to “ON”, wait 10 seconds, and
then crank the engine again.

3-14

E

309013

EMU01198

WARMING UP ENGINE

1) Before beginning operation, allow the
engine to warm up at idling speed for
3 minutes. (Failure to do this will
shorten engine life.)

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

cC

A continuous flow of water from the pilot
hole shows that the water pump is
pumping water through the cooling pas­sages. If water is not flowing out of the
pilot hole at all times while the engine is
running, do not continue to run the
engine. Overheating and serious damage
could occur. Stop the engine and check
to see if the water inlet on the lower cas­ing is blocked. If the problem cannot be
found and corrected, consult your
Yamaha dealer.

3-15

701043

N

F

E

EMU00261

SHIFTING

w

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

cC

To change the shifting position from for­ward to reverse or vice-versa, close the
throttle first so that the engine idles (or
runs at low speeds).

EMU00264

FORWARD

Pull up the neutral interlock trigger (If
equipped) and move the remote control
lever quickly and firmly from Neutral to
Forward.

N

R

EMU00269

REVERSE

w

When operating in Reverse, go slowly. Do
not open the throttle more than half.
Otherwise, the boat may become unsta­ble, which could result in loss of control

701044

and an accident.

Pull up the neutral interlock trigger (If
equipped) and move the remote control
lever quickly and firmly from Neutral to
Reverse.

3-16

E

ON

START

OFF

701023

EMU00273

STOPPING ENGINE

Let it cool off for a few minutes at idle or
low speed first. Stopping the engine
immediately after operating at high speed
is not recommended.

EMU00276

1) Turn the main switch to “OFF”.

2) If the fuel joints are provided, discon­nect the fuel line from the motor after
stopping the engine.

3) Tighten the air vent screw on the fuel
tank cap after stopping the engine, if
it is 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 lock
plate from the engine stop lanyard switch
(then turning the main switch to “OFF”).

3-17

q

000860

E

EMU01412

TRIMMING OUTBOARD

MOTOR

The trim angle of the outboard motor
helps determine the position of the bow
of the boat in the water. The correct trim
angle will help improve performance and
fuel economy while reducing strain on the
engine. The 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.

w

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.

NOTE:

Refer to the section “ADJUSTING TRIM
ANGLE” for instructions on usage.

1 Trim operating angle

3-18

E

UP
DN

701034

UP

DN

q

ADJUSTING TRIM ANGLE

EMU01401

Power Trim/Tilt Model

w

8 Be sure all people are clear of the out-

board motor when adjusting the
trim/tilt angle, also be careful not to
pinch any body parts between the drive
unit and clamp bracket.

8 Use caution when trying a trim position

for the first time. Increase speed gradu­ally and watch for any signs of instabili­ty or control problems.

8 Use the power trim/tilt switch located

on the bottom engine cowling (if
equipped) only when the boat is at a
complete stop with the engine off.

The outboard motor trim angle can be
adjusted operating the power trim/tilt
switch 1.

To raise the bow (“trim-out”), push the
switch UP.

To lower the bow (“trim-in”), push the
switch DN.

Make test runs with the trim set to differ­ent angles to find the position that works
best for your boat and operating condi­tions.

NOTE:

To adjust the trim angle while the boat is
moving, use the power trim and tilt
switch located on the remote control
device or tiller handle, if so equipped.

3-19

105011

q

w

E

EMU00282

Bow Up

When the boat is on plane, a bow-up atti­tude result in less drag, greater stability
and efficiency. This is generally when the
keel line of the boat is up about 3 to 5
degrees. When trimmed out, the boat
may have more 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.

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-up can cause the propeller
to ventilate, which reduces performance
further. When trimmed-out too much, a
boat may “porpoise” (hop in the water),
which could throw the operator and pas­sengers overboard.

EMU00283

Bow Down

When the bow of the boat is down, it is
easier to accelerate from a standing start
onto plane.

e

105013

105015

Too much trim-in causes the boat to
“plow” through the water, decreasing
fuel economy and making in 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.

1 Bow up
2 Bow down
3 Optimum angle

3-20

E

000857

EMU01200

TILTING UP/DOWN

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

cC

Before tilting the motor, follow the proce­dures under “STOPPING ENGINE”. Never
tilt the motor while the engine is running.
Severe damage from overheating can
result.

w

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
engine bracket.

w

Leaking fuel is a fire hazard. 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. (If the
fuel connector is provided on the motor.)

3-21

UP
DN

701034*

UP

DN

UP

DOWN

302012

403033

E

EMU01201

PROCEDURE FOR TILTING UP

Power trim/tilt model

1) If there is a fuel joint or a fuel cock on

the boat, disconnect the fuel line or
close the fuel cock.

2) Push the power trim/tilt switch “UP”

until the outboard has tilted up com­pletely.

3) Turn the tilt-support lever toward you

and support the engine.

w

After tilting the engine, be sure to sup­port it with the tilt-support lever.
Otherwise, the engine could fall back
down suddenly if oil in the power
trim/tilt unit should lose pressure.

4) Once the engine is supported with the

tilt-support lever, push the power
trim/tilt switch DOWN to retract the
trim rods.

cC

Be sure to retract the trim rods complete­ly during mooring. This protects the rods
from marine growths and corrosion
which could damage the power trim/tilt
mechanism.

3-22

E

EMU00303

PROCEDURE FOR TILTING DOWN

Power trim/tilt model

1) Push the power trim/tilt switch “UP”
until the engine is supported by the
tilt rod.

2) Release the tilt-support lever.

3) Push the power trim/tilt switch “DN”
(Down) to lower the engine to the
desired position.

EMU00316

CRUISING IN OTHER

CONDITIONS

CRUISING IN SALT WATER

After operating in salt water, wash out the
cooling-water passages with fresh water
to prevent them from becoming clogged­up with salt deposits.

NOTE:

Refer to cooling system flushing instruc­tions in “TRANSPORTING AND STORING
OUTBOARD MOTOR”.

CRUISING IN TURBID WATER

It is strongly recommended that the
optional chromium-plated water-pump kit
be installed if the outboard is to be used
in turbid (muddy) water conditions.

3-23

E

EMU00317

Chapter 4

MAINTENANCE

SPECIFICATION DATA.............................4-1

TRANSPORTING AND STORING

OUTBOARD MOTOR ...............................4-2

Trailering outboard motor...................4-2

Storing outboard motor ......................4-3

PERIODIC MAINTENANCE......................4-8

Replacement parts ...............................4-8

Maintenance chart................................4-9

Greasing ..............................................4-10

Cleaning and adjusting spark plug...4-11

Checking fuel system.........................4-13

Inspecting fuel filter ...........................4-14

Adjusting idling speed.......................4-15

Checking water in engine oil tank ....4-16

Replacing fuse ....................................4-17

Checking wiring and connectors ......4-17

Exhaust leakage..................................4-17

Water leakage .....................................4-17

Checking power trim and tilt

system .................................................4-18

Checking propeller .............................4-19

Changing gear oil ...............................4-22

Inspecting and replacing anode(s) ...4-23

Checking battery.................................4-24

Checking bolts and nuts ....................4-27

Motor exterior.....................................4-27

Cleaning cooling-water

passages..............................................4-28

Coating the boat bottom ...................4-29

1

2

3

4

5

6

EMU00318*

E

SPECIFICATION DATA

Item

DIMENSIONS

Overall Length mm (in.)
Overall Width mm (in.)
Overall Height L mm (in.)
Transom height L mm (in.)
Weight L kg (lb.)

PERFORMANCE

Full throttle operating range r/min
Maximum output kW (HP) @ r/min
Idling speed (Neutral) r/min

ENGINE

Type
Displacement cm

× stroke mm (in.)

Bore
Ignition system
Spark plug NGK
Spark plug gap mm (in.)
Control system
Starting system
Battery capacity V-AH
Minimum cold crank performance Amps at –17.8°C (0°F)
Minimum reserve capacity Minutes at 26.7°C (80°F)
Alternator output V-A (W)
Starting carburetion system

DRIVE UNIT

Gear positions
Gear ratio
Trim/tilt system
Propeller mark Front/Rear

FUEL AND OIL

Recommended fuel

Fuel tank capacity l (US gal, Imp gal)
Recommended engine oil

Fuel/oil premix ratio Fuel : Oil
Engine oil capacity (engine oil tank) l (US qt, Imp qt)

Recommended gear oil
Gear oil capacity cm

TIGHTENING TORQUE

Spark plug N•m (kgf•m, lb•ft)
Front Propeller nut N•m (kgf•m, lb•ft)
Rear Propeller nut N•m (kgf•m, lb•ft)

Model

(remote oil tank) l (US qt, Imp qt)

Unit DX150TRA

3

(cu.in.)

P.O.N.

3

(US oz, Imp oz)

896 (35.3)
577 (22.7)
1,573 (61.9)
453 (17.8)

210.5 (464)

4,500 ~ 5,500

110.3 (150) @5,000
700 ~ 760

2-stroke, 90°V6
2,596 (158.4)

90.0 × 68.0 (3.54 × 2.68)
C.D.I system
BR7HS-10

0.9 ~ 1.0 (0.035 ~ 0.039)
Remote control
Electric start
12-70 ~ 100
500
140
12-35
Electronic Fuel Injection

Forward-Neutral-Reverse

2.00 (26/13)
Power trim & tilt
MF/MR

Regular unleaded gasoline
(Minimum 86)
—

YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TC-W3 certified outboard oil

YAMAHA PRECISION BLEND SYSTEM

0.9 (0.95, 0.79)

10.5 (11.1, 9.24)/18.0 (19.1, 15.9)
Hypoid gear oil (SAE90)
900

25 (2.5, 18)
65 (6.5, 47)
55 (5.5, 40)

4-1

E

000858

EMU01369

TRANSPORTING AND

STORING OUTBOARD MOTOR

w

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.

EMU00326

TRAILERING OUTBOARD MOTOR

The motor should be trailered and stored
in the normal running position. If there is
insufficient road clearance in this position,
then trailer the motor in the tilt position
using a motor support device such as a
transom saver bar.
For further details, consult your Yamaha
dealer.

w

8 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 accidentally falls.

8 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.

cC

Do not use the tilt support lever/knob
when trailering the boat. The outboard
motor could shake loose from the tilt
support and fall. If the motor can not be
trailered in the down position, use an
additional support device to secure it in
the up position.

4-2

E

EMU00332

STORING OUTBOARD MOTOR

When storing your Yamaha outboard for
prolonged periods of time, (2 months or
longer), several important procedures
must be performed to prevent expensive
damage. This is especially important for
your Precision Blend equipped outboard
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 ser­viced by an authorized Yamaha dealer
prior to storage. However, the following
procedures can be performed by you, the
owner, with a minimum of tools.

cC

Do not use any chemical goods contain­ing Silicon, Phosphorus or Lead.
Otherwise, the oxygen sensor for
Electronic Fuel Injection system could be
damaged. For the detail, consult your
Yamaha dealer to use chemical goods for
storage.

EMU00335

Filling Fuel Tank

Fill the fuel tank with fresh fuel and add
one ounce of “Yamaha Fuel Conditioner
and Stabilizer” (Part No. LUB-FUELC-12-

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.

4-3

E

q

w

e

000843

EMU00338*

Flushing Cooling System and Fogging
Engine

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

w

8 Do not touch or remove electrical parts

when starting or during operation.

8 Keep hands, hair and clothes away

from flywheel and other rotating parts
while engine is running.

EMU00344

Flushing with the Flushing Device

w

Keep yourself and others away from the
propeller while engine is running.

cC

Avoid running the outboard at high
speed while flushing, or overheating
could occur.

1) Remove the top cowling and silencer

cover.

2) Unscrew the garden-hose connector

2 from the bottom cowling fitting 1.

3) Screw the garden-hose connector 2

onto a garden-hose 3 which is con­nected to a fresh-water supply.

4) Open the water tap and let the water

flush through the cooling passages.

5) Run the engine at an idle speed in

neutral for about 15 minutes.

4-4

E

6) Just prior to turning off the engine,
quickly spray “Yamaha Stor-Rite
Engine Fogging Oil” (Part No. LUB­STRRT-12-00) alternately into each
carburetor. When properly done, the
engine will smoke excessively and
almost stall.

7) After stopping the engine, turn off the
water and disconnect the garden­hose connector.

8) Reinstall the garden-hose connector
on the fitting on the bottom cooling.

9) Install the silencer cover and top
cowling.

cC

Do not leave the garden-hose connector
loose on the bottom cowling or let the
hose hang free during normal operation.
Water will leak out of the connector
instead of cooling the engine, which can
cause serious overheating. Be sure the
connector is tightened securely on the fit­ting after flushing the engine.

4-5

E

EMU00350*

Lubrication

1) Remove the spark plug(s). Spray a

“Yamaha Stor-Rite Engine Fogging
Oil” into each cylinder for 5 seconds.
Grease the spark plug threads and
reinstall the spark plug(s) and torque
to proper specification. (Refer to
“CLEANING AND ADJUSTING
SPARK PLUG”.)

2) Turn the engine over with the stop

lanyard disconnected to work the fog­ging oil into the piston rings.

3) Fill the oil tanks. This prevents the for-

mation of condensation. For models
with a remote tank, it may be neces­sary to manually override the control
unit to completely fill the engine main
tank. (Refer to Filling Oil section).

4) Change the gear-case oil. (Refer to

“CHANGING GEAR OIL”). Inspect the
oil for the presence of water which
indicates a leaky seal. Seal replace­ment should be performed by an
authorized Yamaha dealership prior
to use.

5) Grease all grease fittings. (Refer to

“GREASING”)

EMU00352

Cleaning and Anti-corrosion Measure

1) Wash down the exterior of the out-

board with fresh water and dry off
completely.

2) Spray the engine’s exterior with

“Yamaha Silicone Protectant” (Part
No. LUB-SILCNE-13-00).

cC

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

4-6

E

901015

UPPER LEVEL

LOWER LEVEL

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

EMU00353

Battery Care

w

Battery electrolyte is poisonous and dan­gerous, causing severe burns, etc. It con­tains sulfuric acid. Avoid contact with
skin, eyes, or clothing.
Antidote:
EXTERNAL; Flush with water.
INTERNAL; Drink large quantities of
water or milk. Follow with milk of mag­nesia, beaten egg, or vegetable oil. Call
physician immediately.
EYES; Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases: Keep
sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in a
closed space. Always wear eye protection
when working near batteries.
KEEP OUT OF REACH OF CHILDREN.

Batteries vary among manufacturers.
Therefore the following procedures may
not always apply. Consult your battery
manufacturer’s instructions.

1) Disconnect and remove the battery
from the boat. Always disconnect the
black negative lead 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.

4-7

E

EMK32110

PERIODIC MAINTENANCE

w

Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If the owner is not familiar with
machine servicing, this work should be
done by a Yamaha dealer or other quali­fied mechanic.

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

EMU00356

REPLACEMENT PARTS

If replacement parts are necessary, use
only genuine Yamaha parts or equiva­lents 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 a Yamaha dealer.

4-8

E

EMU00362

MAINTENANCE CHART

Frequency of maintenance operations may be adjusted according to the operating con­ditions, but the following table gives general guidelines.

The mark (6) indicates the check-ups which you may carry out yourself.
The mark (1) indicates work to be carried out by your Yamaha dealer.

Interval

Item

Spark plug(s)

Greasing points Greasing ● 4-10
Gear oil Change ● ● 4-22
Fuel system Inspection ● ● ● 4-13

Fuel filter (Water separator)
Fuel tank Cleaning ● —
Idling speed Inspection/Adjustment ● ● 4-15

Anode(s)
Outboard motor exterior Inspection ● ● ● 4-27

Cooling water passage*

Propeller/Cotter pin

Battery Inspection/Charge (every 4-24

Throttle pick-up timing Inspection/Adjustment 1 —
Bolts/Nuts Retightening ● ● ● 4-27
Oil tank water drain Cleaning ● ● ● 4-16

Oil pump Inspection/Adjustment 1 —
Power trim/tilt unit Inspection ● 4-18
Power trim/tilt operation Inspection ● ● ● 4-18
Exhaust leakage Inspection ● ● ● 4-17
Water leakage Inspection ● ● ● 4-17
Cowling clamp Inspection ● —

Throttle link Inspection/Adjustment 1 —

Throttle sensor Inspection/Adjustment 1 —
Wiring/Connector(s) Inspection/Reconnect ● ● ● 4-17

Cleaning/Adjustment/

Replacement

Cleaning/Inspection ● ● ● 4-14

Inspection/Replacement

1

Cleaning ● ● 4-28

Inspection/Replacement

*1. When operating in salt water, turbid or muddy water, the engine should be flushed with clean

water after each use.

Initial Every

10 hours

(1 months)

month)

50 hours

(3 months)

● ● ● 4-11

●/1 ●/1 4-23

● ● ● 4-19

●

100 hours

(6 months)

200 hours

(1 year)

Refer

page

4-9

EMU00366

103171

GREASING

Yamaha marine grease
(Water resistant grease)

E

4-10

E

EMU01202

CLEANING AND ADJUSTING SPARK
PLUG

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When removing or installing a spark plug,
be careful not to damage the insulator. A
damaged insulator could allow external
sparks, which could lead to explosion or
fire.

The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
something about the condition of the
engine. For example, if the center elec­trode porcelain is very white, this could
indicate an intake air leak or carburetion
problem in that cylinder. Do not attempt
to diagnose any problems yourself.
Instead, take the outboard motor to a
Yamaha dealer. You should periodically
remove and inspect the spark plug
because heat and deposits will cause the
spark plug to slowly break down and
erode. If electrode erosion becomes
excessive, or if carbon and other deposits
are excessive, you should replace the
spark plug with another of the correct
type.

Standard spark plug:
Refer to “SPECIFICATIONS”, page 4-1.

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

Spark plug gap:
Refer to “SPECIFICATIONS”, page 4-1.

4-11

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When fitting the plug, always clean the
gasket surface and use a new gasket.
Wipe off any dirt from the threads and
screw in the spark plug to the correct
torque.

Spark plug torque:
Refer to “SPECIFICATIONS”, page 4-1.

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.

Initial of spark Plug wrench size

plug I.D. mark

B 21 mm (13/16 in.)

C/BK 16 mm (5/8 in.)

D 18.3 mm (23/32 in.)

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

4-12

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EMU00369

CHECKING FUEL SYSTEM

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

Check the fuel line for leaks, cracks, or
malfunctions. If any problem is found, it
should be repaired immediately by
Yamaha dealer or other qualified mechan­ic.

Checking points

8 Fuel system parts leakage.
8 Fuel hose joint leakage.
8 Fuel hose cracks or other damage.
8 Fuel connector leakage.

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Leaking fuel can result in fire or explo­sion.

8 Check for fuel leakage regularly.
8 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.

4-13

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207052*

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EMU00370

INSPECTING FUEL FILTER

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Gasoline (petrol) is highly flammable, and
its vapors are flammable and explosive.
8 If you have any question about properly

doing this procedure, consult your
Yamaha dealer.

8 Do not perform this procedure on a hot

or running engine. Allow the engine to
cool.

8 There will be fuel in the fuel filter. Keep

away from sparks, cigarettes, flames or
other sources of ignition.

8 This procedure will allow some fuel to

spill. Catch fuel in a rag. Wipe up any
spilled fuel immediately.

8 The fuel filter must be reassembled

carefully with O-ring, filter cup, and
hoses in place. Improper assembly or
replacement can result in a fuel leak,
which could result in a fire or explosion
hazard.

EMU00979

1) Loosen and remove the locking tab

bolt and tab 1. Slightly loosen the fil­ter cup ring nut 2.

2) Remove the filter cup 3, catching any

spilled fuel in a rag.

3) Remove the filter element 4, and

wash it in solvent.
Allow it to dry. Inspect the filter ele­ment and O-ring 5 to make sure they
are in good condition. Replace them if
necessary.

4) Reinstall the filter element in the cup.

Make sure the O-ring in position in
the cup. Insert the cup and O-ring into
the filter housing 6. Screw the ring
nut onto the filter housing until the
ring is lightly seated.

4-14

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5) Tighten the ring nut approximately an
additional 1/4 turn until ring nut is
tight. Align one of the four larger ring
nut tabs into the slot of the locking
tab. Install the locking tab bolt and
tighten.

6) Run the engine and check the filter
and lines for leaks.

NOTE:

If any water is in the fuel, the red ring in
the fuel filter unit will float. If so, remove
the cup and drain the water.

EMU00991

ADJUSTING IDLING SPEED

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8 Do not touch or remove electrical parts

when starting or during operation.

8 Keep hands, hair and clothes away

from flywheel and other rotating parts
while engine is running.

cC

This procedure must be performed while
the outboard motor is in the water. A
flushing attachment or test tank can be
used.

4-15

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A diagnostic tachometer should be used
for this procedure.

1) Start the engine and allow it to warm

up fully in Neutral until it is running
smoothly. If the outboard is mounted
on a boat, be sure the boat is tightly
moored.

2) Adjust the throttle stop-screw 1 to

set the idling speed to specification
(see “SPECIFICATIONS” on page 4-1)
by turning the stop-screw clockwise
to increase the idling speed, and turn­ing it counterclockwise to decrease
the idling speed.

NOTE:

Correct idling-speed adjustment is only
possible if the engine is fully warmed-up.
If not warmed up fully, the speed setting
will tend to be too high. If you have diffi­culty obtaining the specified idle, consult
a Yamaha dealer or other qualified
mechanic.

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EMU00377

CHECKING WATER IN ENGINE OIL
TANK

There is a trap at the bottom of the engine
oil tank. If water or foreign matter is visi­ble in this trap, consult a Yamaha dealer.

1 Trap
2 Engine oil tank

213021

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EMU01330

REPLACING FUSE

If a fuse has blown, remove the electrical
cover, open the fuse holder and remove
the fuse with a fuse puller. Replace it with
a spare one of proper amperage.

w

Be sure to use the specified fuse. An
incorrect fuse or a piece of wire may
allow excessive current flow. This could
cause electrical system damage and a fire
hazard.

NOTE:

If the new fuse blows again immediately,
consult a Yamaha dealer.

1 Electrical cover
2 Fuse holder
3 Fuse (30A, 80A × 2)
4 Spare fuse (30A, 80A × 2)
5 Fuse puller

EMU00383

CHECKING WIRING AND
CONNECTORS

1) Check that each grounding wire is
properly secured.

2) Check that each connector is engaged
securely.

EMU00384

EXHAUST LEAKAGE

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

EMU00385

WATER LEAKAGE

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

4-17

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EMU00993

CHECKING POWER TRIM AND TILT
SYSTEM

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8 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 accidentally falls.

8 Make sure no one is under the out-

board 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 remote control and
engine bottom cowling (If equipped)
to check that all switches work.

3) Tilt up the motor and check that the

tilt rod 1 and trim rods 2 are pushed
out completely.

4)

Use the tilt support lever 3to lock the
motor in the UP position. Operate the
tilt down switch briefly so the motor is
supported the 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 gone completely into
the cylinders.

7) Activate the trim-up switch until the

tilt rod is fully extended. Unlock the
tilt support lever.

8) Operate the motor to tilt down. Check

that the tilt rod and trim rods operate
smoothly.

NOTE:

If any operation is abnormal, consult a
Yamaha dealer.

Recommended fluid;

Yamaha power trim & tilt fluid or
ATF (DEXRON-

4-18

II).

210012

602026

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EMU00388

CHECKING PROPELLER

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You could be seriously injured if the
engine accidentally starts while you are
near the propeller.
8 Before inspecting, removing or

installing the propeller, remove the
spark plug caps from the spark plugs.
Also, put the shift control in Neutral,
put the main switch in the “OFF” posi­tion and remove the key, and remove
the lanyard from the engine stop
switch. Turn off the battery cut-off
switch if your boat has one.

8 Do not use your hand to hold the pro-

peller when loosening or tightening the
propeller nut. Put a wood block
between the cavitation plate and the
propeller to prevent the propeller from
turning.

602035

602034

EMU00390

Propeller Checking Point

8 Check each of the propeller blades for

wear, erosion from cavitation or ventila­tion, or other damage.

8 Check the splines for wear and damage.
8 Check for fish line winding around the

propeller shaft.

8 Check the propeller shaft oil seal for

damage.

EMU00394

Removing the Propeller

1) Using the pliers provided, straighten
the cotter-pin and pull it out.

2) Remove the rear propeller nut and
propeller.

3) Straighten the lock washer tab.

4) Loosen the front propeller nut using
the special wrench in the tool kit.

5) Remove the nut and front propeller.

4-19

602034

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602064

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1 Front thrust washer
2 Front propeller
3 Lock washer
4 Front propeller nut
5 Rear thrust washer
6 Rear propeller
7 Spacer
8 Washer
9 Rear propeller nut
0 Cotter pin

EMU00399

Installing the Propeller

cC

8 The combination of front and rear pro-

peller pitch should not be changed. Set
up each propeller properly. If the pro­pellers are not installed correctly,
engine or propeller could be damaged.

8 Be sure to install the thrust washers

before installing propellers. Otherwise,
lower case and propeller boss may be
damaged.

8 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.

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602071*

1) Apply Yamaha Marine grease or a

corrosion resistant grease to the pro­peller-shafts.

2) Shift into forward. Turn the front pro-

peller shaft clockwise until free play is
removed.

3) Install the front thrust washer. Install

front propeller with one blade point­ing up and its trailing edge 2 aligned
with the center line 1 of lower case.

4) Install the lock washer on the pro-

peller-shaft. Shift into neutral and
tighten the front propeller nut using
the special wrench with a force of 20
Kg (44 lb) which is equivalent to the
specified torque with a conventional
torque wrench.

4-20

602066*

602026

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5) Bend the lock washer tab into the pro­peller nut groove.

6) Shift into forward again and reset the
front propeller with the trailing edge
of the blade pointing up with the cen­ter line of the lower case.

7) Turn the rear propeller shaft counter­clockwise until free play is removed.

8) Install the rear thrust washer. Install
the rear propeller with one blade
pointing up and its trailing edge
aligned with the center line of the
lower case.

9) Install the spacer and washer. Shift
into neutral and tighten the rear pro­peller nut using the special wrench
with a force of 18 Kg (40 lb) which is
equivalent to the specified torque
with a conventional torque wrench.

10) Install a new cotter pin in the hole and
bend the cotter pin ends.

NOTE:

If the propeller nut does not align with the
lock washer tab or the propeller shaft hole
after tightening to the specified value,
then tighten the nut further to align it with
the tab or hole.

602065

Propeller nut tightening torque :

Refer to the SPECIFICATIONS, page 4-1.

4-21

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601023*

000858

EMU00905

CHANGING GEAR OIL

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8 Be sure the outboard is securely fas-

tened to the transom or a stable stand.
You could be severely injured if the out­board falls on you.

8 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 accidentally falls.

1) Put the outboard in a vertical position

(not tilted).

2) Place a suitable container under the

gear-case.

3) Remove the oil drain plug 1.

NOTE:

The oil drain plug is magnetic. Remove all
metal particles from the plug before rein­stalling it.

4) Remove the oil level plug 2 to allow

the oil to drain completely.

cC

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.

4-22

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601024

5) With the outboard motor in an verti­cal position, using a flexible or pres­surized filling device, inject the gear
oil into the oil drain plug hole.

Gear oil grade/capacity:
Refer to SPECIFICATIONS on page 4-1.

6) When the oil begins to flow out of the
oil level plug hole, insert and tighten
the oil level plug.

7) Insert and tighten the oil drain plug.

EMU00831

INSPECTING AND REPLACING
ANODE(S)

Yamaha outboard motor is protected
from corrosion by a sacrificial anode(s).
Check the anode(s) periodically. Remove
the scales from surfaces of the anode(s).
For the inspection and replacement of the
anode(s), consult a Yamaha dealer.

cC

Do not paint the anode(s), for this would
render it ineffective.

4-23

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EMU00404

CHECKING BATTERY
(for Electric start model)

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Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is poi­sonous and highly caustic.
Always follow these preventive mea­sures:
8 Avoid bodily contact with electrolytic

fluid as it can cause severe burns or
permanent eye injury.

8 Wear protective eye gear when han-

dling or working near batteries.
Antidote (EXTERNAL):

8 SKIN - Flush with water.
8 EYES - Flush with water for 15 minutes

and get immediate medical attention.
Antidote (INTERNAL):

8 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:

8 Charge batteries in a well-ventilated

area.

8 Keep batteries away from fire, sparks,

or open flames (e.g., welding equip­ment, lighted cigarettes, etc.).

8 DO NOT SMOKE when charging or han-

dling batteries.

8 KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

4-24

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UPPER LEVEL

LOWER LEVEL

901012*

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8 A poorly maintained battery will quick-

ly deteriorate.

8 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 de-ionized water suitable to
use in batteries).

2) Keep the battery always 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.

EMU01304*

Connecting the Battery

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Mount the battery holder securely in a
dry, well-ventilated, vibration-free loca­tion in the boat. Install the fully charged
battery in the holder.

4-25

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8 Make sure the main switch (on applica-

ble models) is “OFF” before working on
the battery.

8 Reversal of the battery leads will dam-

age the rectifier.

8 Connect the RED lead first when

installing the battery and disconnect
the RED lead last when removing it.
Otherwise, the electrical system can be
damaged.

8 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.

8 Using a single battery

Connect both red cables 1 and 2 to the
(+) terminal.

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Do not leave cable 2 unconnected. If it
accidentally contacts the NEGATIVE (-)
terminal of the battery, there will be a
short circuit. Electrical system damage
and a fire could result.

1 Large red lead for starting battery
2 Small red lead for accessory battery charg-

ing (optional part)

3 Large black lead
4 Battery

8 Using an accessory battery

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 3.

4-26

102053

901014*

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Use of smaller wire could lead to a fire.

1 Battery for starting
2 Battery for accessories
3 Large red lead for starting battery
4 Small red lead for accessory battery charg-

ing (optional part)

5 Large black lead
6 Negative connecting cable

NOTE:

If a battery selector switch is desired, con­sult your YAMAHA dealer about correct
wiring.

EMU01280

Disconnecting the Battery

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

EMU00408

CHECKING BOLTS AND NUTS

1) Check that bolts securing the cylinder
head and engine and the nut securing
the flywheel are tightened with their
specified tightening torque.

2) Check the tightening torque of other
bolts and nuts.

EMU00409

MOTOR EXTERIOR

EMU00410

Cleaning the Outboard Motor

After use, wash the exterior of the out­board with fresh water.
Flush the cooling system with fresh
water.

NOTE:

Refer to Flushing Cooling System instruc­tions in “TRANSPORTING AND STORING
OUTBOARD MOTOR”.

4-27

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EMU01172

CLEANING COOLING-WATER
PASSAGES

Flushing device equipped model

Perform this procedure right after opera­tion for the most thorough flushing.

1) After shutting off the engine, unscrew

the garden-hose connector 2 from
the fitting 1 on the bottom cowling.

2) Screw the garden-hose connector 2

onto a garden hose 3 which is con­nected to a fresh-water supply.

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 3.

4) When flushing is complete, reinstall

the garden-hose connector 2 on the
fitting 1 on the bottom cowling.
Tighten the connector securely.

cC

Do not leave the garden-hose connector
loose on the bottom cowling fitting or let
the hose hang free during normal opera­tion. Water will leak out of the connector
instead of cooling the engine, which can
cause serious overheating. Be sure the
connector is tightened securely on the fit­ting after flushing the engine.

NOTE:

8 When flushing the engine with the boat

in the water, tilting up the engine until it
is completely out of the water will
achieve better results.

8 Refer to cooling system flushing

instructions in “TRANSPORTING AND
STORING OUTBOARD MOTOR”.

4-28

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102055

EMU00412

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 a Yamaha dealer.

EMU00413

COATING THE BOAT BOTTOM

A clean hull improves boat performance.
The boat bottom should be kept as clean
of marine growths 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.

4-29

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EMU00414

Chapter 5

TROUBLE RECOVERY

TROUBLESHOOTING ..............................5-1

TEMPORARY ACTION IN

EMERGENCY ............................................5-5

Impact damage.....................................5-5

Power trim/tilt will not operate ...........5-5

Starter will not operate ........................5-6

Engine fails to operate .........................5-8

Low oil level warning activates ........5-10

Treatment of submerged motor.......5-12

1

2

3

4

5

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EMU01204¯

TROUBLESHOOTING

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of
power, or other problems. The troubleshooting chart describes basic checks and possi­ble remedies. (This chart covers all Yamaha outboard motors. Therefore, some items
may not apply to your model.)
If your outboard motor requires repair, bring it to a Yamaha dealer.

Trouble Possible Cause Remedy

A. Starter will not

operate.

B. Engine will not

start (Starter
operates).

1. Battery capacity weak or low.

2. Battery connections loose or
corroded.

3. Fuse for electric start circuit blown.

4. Starter components faulty.

5. Engine stop switch lanyard not
attached.

6. Shift lever in gear.

1. Fuel tank empty.

2. Fuel contaminated or stale.

3. Fuel filter clogged.

4. Starting procedure incorrect.

5. Fuel pump malfunctions.

6. Spark plug(s) fouled or incorrect
type.

7. Spark plug cap(s) fitted incorrectly.

8. Poor connections or damaged
ignition wiring.

9. Ignition parts faulty.

10. Engine stop switch lanyard not
attached.

11. Shift lever in gear.

12. Engine inner parts damaged.

1. Check battery condition. Use
battery of recommended capacity.

2. Tighten battery cables and clean
battery terminals.

3. Check for cause of electric
overload and repair. Replace fuse
with one of correct amperage.

4. Have serviced by a Yamaha
dealer.

5. Attach lanyard.

6. Shift to neutral.

1. Fill tank with clean, fresh fuel.

2. Fill tank with clean, fresh fuel.

3. Clean or replace filter.

4. Read "STARTING ENGINE"
section.

5. Have serviced by a Yamaha
dealer.

6. Inspect spark plug(s). Clean or
replace with recommended type.

7. Check and re-fit cap(s).

8. Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.

9. Have serviced by a Yamaha
dealer.

10. Attach lanyard.

11. Shift to neutral.

12. Have serviced by a Yamaha
dealer.

5-1

Trouble Possible Cause Remedy

C. Engine idles

irregularly or stalls.

1. Spark plug(s) fouled or incorrect
type.

2. Fuel system obstructed.

3. Fuel contaminated or stale.

4. Fuel filter clogged.

5. Failed ignition parts.

6. Warning system activated.

7. Spark plug gap incorrect.

8. Poor connections or damaged
ignition wiring.

9. Specified engine oil not used.

10. Thermostat faulty or clogged.

11. Carburetor adjustments incorrect.

12. Fuel pump damaged.

13. Air vent screw on the fuel tank
closed.

14. Choke knob pulled out.

15. Motor angle too high.

16. Carburetor clogged.

17. Fuel joint connection incorrect.

18. Throttle valve adjustment incorrect.

19. Battery lead disconnected.

1. Inspect spark plug(s). Clean or
replace with recommended type.

2. Check for pinched or kinked fuel
line or other obstructions in fuel
system.

3. Fill tank with clean, fresh fuel.

4. Clean or replace filter.

5. Have serviced by a Yamaha
dealer.

6. Find and correct cause of warning.

7. Inspect and adjust as specified.

8. Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.

9. Check and replace oil as specified.

10. Have serviced by a Yamaha
dealer.

11. Have serviced by a Yamaha
dealer.

12. Have serviced by a Yamaha
dealer.

13. Open the air vent screw.

14. Return to home position.

15. Return to normal operating
position.

16. Have serviced by a Yamaha
dealer.

17. Connect correctly.

18. Have serviced by a Yamaha
dealer.

19. Connect securely.

E

5-2

Trouble Possible Cause Remedy

D. Warning buzzer

sounds or
indicator lamp
lights.

E. Engine power loss.

1. Cooling system clogged.

2. Engine oil level low.

3. Heat range of spark plug incorrect.

4. Specified engine oil not used.

5. Engine oil contaminated or
deteriorated.

6. Oil filter clogged.

7. Oil feed/injection pump
malfunctions.

8. Load on boat improperly distributed.

9. Water pump/thermostat faulty.

1. Propeller damaged.

2. Propeller pitch or diameter incorrect.

3. Trim angle incorrect.

4. Motor mounted at incorrect height
on transom.

5. Warning system activated.

6. Boat bottom fouled with marine
growth.

7. Spark plug(s) fouled or incorrect
type.

8. Weeds or other foreign matter
tangled on gear housing.

9. Fuel system obstructed.

10. Fuel filter clogged.

11. Fuel contaminated or stale.

12. Spark plug gap incorrect.

13. Poor connections or damaged
ignition wiring.

14. Failed ignition parts.

1. Check water intake for restriction.

2. Fill oil tank with specified engine
oil.

3. Inspect spark plug and replace it
with recommended type.

4. Check and replace oil with
specified type.

5. Replace oil with fresh, specified
type.

6. Have serviced by a Yamaha
dealer.

7. Have serviced by a Yamaha
dealer.

8. Distribute load to place boat on an
even plane.

9. Have serviced by a Yamaha
dealer.

1. Have propeller repaired or
replaced.

2. Install correct propeller to operate
outboard at its recommended
speed (r/min) range.

3. Adjust trim angle to achieve most
efficient operation.

4. Have motor adjusted to proper
transom height.

5. Find and correct cause of warning.

6. Clean boat bottom.

7. Inspect spark plug(s). Clean or
replace with recommended type.

8. Remove foreign matter and clean
lower unit.

9. Check for pinched or kinked fuel
line or other obstructions in fuel
system.

10. Clean or replace filter.

11. Fill tank with clean, fresh fuel.

12. Inspect and adjust as specified.

13. Check wires for wear or breaks.
Tighten all loose connections.
Replace worn or broken wires.

14. Have serviced by a Yamaha
dealer.

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5-3