Yamaha Building Set EMU25060 ZMU01690 User Manual

F4D

OWNER’S MANUAL

U.S.A.Edition

LIT-18626-05-97

68D-F8199-14

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Important manual information

EMU25100

al, please consult your Yamaha dealer.

To the owner

NOTE:

Thank you for choosing a Yamaha outboard

motor. This Owner’s Manual contains infor-

mation needed for proper operation, mainte-

nance and care. A thorough understanding

of these simple instructions will help you ob-

tain 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 F4MH and the standard accessories are

used as a base for the explanations and illus-

trations in this manual. Therefore some

items may not apply to every model.

EMU25130

F4D

OWNER’S MANUAL

1st Edition, January 2004

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

The Safety Alert Symbol means

ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Printed in France

EWM00780

P/N LIT-18626-05-97

WARNING

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 out-

board motor.

ECM00700

CAUTION:

A CAUTION indicates special precautions

that must be taken to avoid damage to the

outboard motor.

NOTE:

A NOTE provides key information to make

procedures easier or clearer.

Yamaha continually seeks advancements in

product design and quality. Therefore, while

this manual contains the most current prod-

uct information available at the time of print-

ing, there may be minor discrepancies

between your machine and this manual. If

there is any question concerning this manu-

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Table of contents

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

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

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

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

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

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

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

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

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

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

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

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

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

Basic boating rules (Rules of the

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

Steering and sailing rules and sound

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

Rules when encountering vessels .... 5

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Top cowling lock lever (pull up

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Forward (tiller handle and remote

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

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

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

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

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

Adjusting trim angle for manual tilt

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

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

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

Procedure for tilting up (manual tilt

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

Procedure for tilting down (manual

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

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

Cruising in shallow water (manual

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

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

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

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

Transporting and storing

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

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

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

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

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Table of contents

Lubrication (except oil injection

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

Cleaning and anticorrosion

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

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

Checking painted surface of

IMPORTANT WARRANTY

INFORMATION IF YOU USE

YOUR YAMAHA OUTSIDE

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

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

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

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

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

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

Cleaning and adjusting spark plug.. 40

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

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

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

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

Checking wiring and connectors..... 44

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

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

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

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

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

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

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

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

Inspecting and replacing anode(s).. 47

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

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

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

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

Temporary action in

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

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

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

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

Treatment of submerged motor..... 54

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

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

Important warranty information for

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

YAMAHA MOTOR

CORPORATION, U.S.A.

FOUR-STROKE OUTBOARD

MOTOR THREE-YEAR LIMITED

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

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General information

EMU25170

engine for details.

EMU25241

Identification numbers record

EMU25182

Approval label of emission control certif-

icate

This label is attached to the bottom cowling.

Outboard motor serial number

The outboard motor serial number is

stamped on the label attached to the port

side of the clamp bracket or the upper part of

the swivel bracket.

New Technology; (4-stroke/HPDI) EM

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 sto-

len.

ZMU02653

1. Approval label location

1. Outboard motor serial number location

ZMU01699

EMU25261

Manufactured date label

This label is attached to the clamp bracket or

the swivel bracket.

EMU25220

Emission control information

EMU25230

North American models

This engine conforms to U.S. Environmental

Protection Agency (EPA) regulations for ma-

rine SI engines. See the label affixed to your

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General information

EMU25280

One Star—Low Emission

The one-star label identifies engines that

meet the Air Resources Board’s 2001 ex-

haust emission standards. Engines meeting

these standards have 75% lower emissions

than conventional carbureted two-stroke en-

gines. These engines are equivalent to the

U.S. EPA’s 2006 standards for marine en-

gines.

ZMU02651

1. Manufactured date label location

Manufactured:

ZMU01702

EMU25290

Two Stars—Very Low Emission

The two-star label identifies engines that

meet the Air Resources Board’s 2004 ex-

haust emission standards. Engines meeting

these standards have 20% lower emissions

than One Star-Low-Emission engines.

ZMU04346

EMU25272

Star labels

Your outboard motor is labeled with a Cali-

fornia Air Resources Board (CARB) star la-

bel. See below for a description of your

particular label.

ZMU01703

EMU25300

ZMU04509

Three Stars—Ultra Low Emission

The three-star label identifies engines that

1. Star labels location

meet the Air Resources Board’s 2008 ex-

haust emission standards. Engines meeting

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General information

these standards have 65% lower emissions

than One Star-Low-Emission engines.

swimmers should always wear PFDs, and

everyone should wear PFDs when there

are potentially hazardous boating condi-

tions.

G Gasoline is highly flammable, and its va-

pors are flammable and explosive. Handle

and store gasoline carefully. Make sure

there are no gas fumes or leaking fuel be-

fore starting the engine.

^GThis product emits exhaust gases which

contain carbon monoxide, a colorless,

odorless gas which may cause brain dam-

age or death when inhaled. Symptoms in-

clude nausea, dizziness, and drowsiness.

Keep cockpit and cabin areas well ventilat-

ed. Avoid blocking exhaust outlets.

G Check throttle, shift, and steering for prop-

er operation before starting the engine.

^GAttach the engine stop switch lanyard cord

to a secure place on your clothing, or your

arm or leg while operating. If you acciden-

tally leave the helm, the cord will pull from

the switch, stopping the engine.

^GKnow the marine laws and regulations

where you will be boating—and obey

them. For basic boating rules, see “Rules

of the road” on page 5.

^GStay informed about the weather. Check

weather forecasts before boating. Avoid

boating in hazardous weather.

ZMU01704

EMU25360

Safety information

^GBefore mounting or operating the outboard

motor, read this entire manual. Reading it

should give you an understanding of the

motor and its operation

^GBefore operating the boat, read any own-

er’s or operator’s manuals supplied with it

and all labels. Be sure you understand

each item before operating.

^GDo not overpower the boat with this out-

board 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.

^GTell someone where you are going: leave

a Float Plan with a responsible person. Be

sure to cancel the Float Plan when you re-

turn.

^GDo not modify the outboard. Modifications

could make the motor unfit or unsafe to

use.

G Use common sense and good judgment

when boating. Know your abilities, and be

sure you understand how your boat han-

dles 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

^GNever operate after drinking alcohol or tak-

ing drugs. About 50% of all boating fatali-

ties involve intoxication.

^GHave an approved personal flotation de-

vice (PFD) on board for every occupant. It

is a good idea to wear a PFD whenever

boating. At a minimum, children and non-

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General information

EMU25401

watch for obstacles and other traffic.

G Always watch carefully for swimmers dur-

ing the engine operation.

Label

EWM01260

WARNING

^GBe sure shift control is in neutral before

starting engine. (except 2HP)

G Do not touch or remove electrical parts

when starting or during operation.

^GKeep hands, hair, and clothes away

from flywheel and other rotating parts

while engine is running.

^GStay away from swimming areas.

G When a swimmer is in the water near you

shift into neutral and shut off the engine.

Be informed about boating safety. Additional

publications and information can be obtained

from many organizations, including the fol-

lowing:

United States Coast Guard

EMU25431

Consumer Affairs Staff (G-BC)

Office of Boating, Public, and Consumer Af-

fairs

U.S. Coast Guard Headquarters

Washington, D.C. 20593-0001

Boating Safety Hotline: 1-800-368-5647

National Marine Manufacturers Associa-

tion (NMMA)

Label

EWM01300

WARNING

G This engine is equipped with a neutral

starting device.

^GThe engine will not start unless the shift

control is in neutral position.

EMU25441

401 N. Michigan Ave.

Chicago, Il 60611

Label

EWM01311

Marine Retailers Association of America

155 N. Michigan Ave.

Chicago, Il 60601

EMU25380

WARNING

LEAKING FUEL COULD CAUSE A FIRE.

Before tilting up the engine or laying it on

its side:

^GTurn the fuel cock to the “closed” posi-

tion.

Important labels

EMU25395

Warning labels

^GTighten the air-vent screw on the fuel

tank cap.

EMU25464

Caution labels

ZMU02654

ZMU02655

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General information

EMU25481

Stand-on vessel

Label

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.

ECM01200

CAUTION:

Store the engine only as shown.

Otherwise, engine damage could result

from Leaking oil.

EMU25500

Give-way vessel

Basic boating rules (Rules of

The vessel which does not have the right-of-

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 brief-

ly 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 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 agen-

cies. You should be aware of these rules,

and follow them whenever you encounter

another vessel on the water.

“The general prudential rule”

This rule is called Rule 2 in the International

Rules and says,

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 pro-

vided for your convenience only. Consult

your local U.S. Coast Guard Auxiliary or De-

partment of Motor Vehicles for a complete

set of rules governing the waters in which

“In obeying and construing these rules due

regard shall be had to all dangers of naviga-

tion and collision, and to any special circum-

stances, which may render a departure from

the above rules necessary in order to avoid

immediate danger.”

In other words, follow the standard rules ex-

cept when a collision will occur unless both

vessels try to avoid each other. If that is the

case, both vessels become “Give-Way” ves-

you will be using your boat.

EMU25510

Steering and sailing rules and sound

signals

sels.

EMU25520

Whenever two vessels on the water meet

one another, one vessel has the right-of-

way; it is called the “stand-on” vessel. The

vessel which does not have the right-of-way

is called the “give-way” or “burdened” vessel.

These rules determine which vessel has the

right-of-way, and what each vessel should

do.

Rules when encountering vessels

There are three main situations which you

may encounter with other vessels which

could lead to a collision unless the Steering

Rules are followed:

Meeting: (you are approaching another ves-

sel head-on)

Crossing: (you are traveling across the oth-

er vessel’s path)

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General information

Overtaking: (you are passing or being risk of collision, the vessel which has the oth-

passed by another vessel)

er on the starboard (right) side must keep out

In the following illustration, your boat is in the of the way of the other. If the other vessel is

center. You should give the right-of-way to on your right, you must keep out of its way;

any vessels shown in white area (you are the you are the Give-Way vessel. If the other

Give-Way vessel). Any vessels in the shad- vessel is on your port (left) side, remember

ed area must yield to you (they are the Give- that you should maintain course and direc-

Way vessels). Both you and the meeting tion, provided the other vessel gives you the

vessel must alter course to avoid each other. right-of-way as it should.

Meeting

Overtaking

If you are meeting another power vessel If you are passing another vessel, you are

head on, and are close enough to run the risk the “Give-Way” vessel. This means that the

of collision, neither of you has the right-of- other vessel is expected to maintain its

way! Both of you should alter course to avoid course and speed. You must stay out of its

an accident. You should keep the other ves- way until you are clear of it. Likewise, if an-

sel on your port (left) side. This rule doesn’t other vessel is passing you, you should

apply if both of you will clear one another if maintain your speed and direction so that the

you continue on your set course and speed. other vessel can steer itself around you.

EMU25530

Other special situations

There are three other rules you should be

aware of when driving your boat around oth-

er 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 wa-

ter vessels, the operator should sound a pro-

longed blast on the whistle (4 to 6 seconds).

Crossing

When two power driven vessels are crossing

each other’s path close enough to run the

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General information

If another vessel is around the bend, it too ter into port, and black buoys are to port (left)

should sound the whistle. Even if no reply is side. When navigating out of port, your posi-

heard, however, the vessel should still pro- tion with respect to the buoys should be re-

ceed around the bend with caution. If you versed; red buoys should be to port and

navigate such waters with your boat, you will black buoys to starboard.

need to carry a portable air horn, available Many bodies of water used by boaters are

from local marine supply stores.

Fishing vessel right-of-way

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 dis-

tinctive shapes and colors to show regulato-

ry or advisory information. These markers

are white with black letters and orange

boarders. They signify speed zones, restrict-

ed areas, danger areas, and general infor-

mation.

All vessels which are fishing with nets, lines

or trawls are considered to be “fishing ves-

sels” 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

Remember, markings may vary by geo-

graphic location. Always consult local boat-

ing authorities before driving your boat in

unfamiliar waters.

Sailing vessels should normally be given the

right-of-way. The exceptions to this are:

1. When the sailing vessel is overtaking

the power-driven vessel, the power-driv-

en 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 navi-

gate 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 navigat-

ing in a particular direction. The markings on

these buoys are oriented from the perspec-

tive of being entered from seaward (the boat-

er is going towards the port). This means that

red buoys are passed on the starboard

(right) side when proceeding from open wa-

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General information

ZMU01708

EMU25540

EWM00010

away from sparks, flames, or other

sources of ignition.

Fueling instructions

^GStop engine before refueling.

G Refuel in a well-ventilated area. Refuel

portable fuel tanks off the boat.

^GTake care not to spill gasoline. If gaso-

line spills, wipe it up immediately with

WARNING

GASOLINE AND ITS VAPORS ARE HIGH-

LY FLAMMABLE AND EXPLOSIVE!

^GDo not smoke when refueling, and keep

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General information

EMU25680

dry rags.

Engine oil

G Do not overfill the fuel tank.

^GTighten the filler cap securely after re-

fueling.

G If you should swallow some gasoline,

inhale a lot of gasoline vapor, or get

gasoline in your eyes, get immediate

medical attention.

Recommended engine oil:

4-stroke motor oil with a combination

of corresponding SAE and API as

shown in the chart

Engine oil quantity (excluding oil filter):

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

^GIf any gasoline spills onto your skin, im-

mediately wash with soap and water.

Change clothing if gasoline spills on it.

^GTouch the fuel nozzle to the filler open-

ing or funnel to help prevent electro-

static sparks.

ECM00010

CAUTION:

Use only new clean gasoline which has

been stored in clean containers and is not

contaminated with water or foreign mat-

ter.

ECM01050

CAUTION:

EMU25570

All 4-stroke engines are shipped from the

factory without engine oil.

Gasoline

If knocking or pinging occurs, use a different

brand of gasoline or premium unleaded fuel.

Recommended gasoline:

Regular unleaded gasoline with a min-

imum octane rating of 86 (Pump Oc-

tane Number) = (R+M)/2

Gasohol

There are two types of gasohol: gasohol con-

taining ethanol and that containing metha-

nol. Gasohol containing ethanol can be used

if ethanol content does not exceed 10% and

the fuel meets minimum octane ratings.

Yamaha does not recommended gasohol

containing methanol because it can cause

fuel system damage or engine performance

problems.

ZMU01710

EMU25741

Propeller selection

The performance of your outboard motor will

be critically affected by your choice of propel-

ler, as an incorrect choice could adversely

affect performance and could also seriously

damage the motor. Engine speed depends

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General information

on the propeller size and boat load. If engine the engine in the proper operating range.

speed is too high or too low for good engine

For instructions on propeller removal and in-

performance, this will have an adverse effect

stallation, see page 44.

on the engine.

EMU25770

Yamaha outboard motors are fitted with pro-

pellers chosen to perform well over a range

Start-in-gear protection

Yamaha outboard motors or Yamaha-ap-

of applications, but there may be uses where

proved remote control units are equipped

a propeller with a different pitch would be

with start-in-gear protection device(s). This

more appropriate. For a greater operating

feature permits the engine to be started only

load, a smaller-pitch propeller is more suit-

when it is in neutral. Always select neutral

able as it enables the correct engine speed

before starting the engine.

to be maintained. Conversely, a larger-pitch

propeller is more suitable for a smaller oper-

ating 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 ap-

plication.

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

ZMU02656

1. Propeller diameter in inches

2. Propeller pitch in inches

3. Type of propeller (propeller mark)

NOTE:

Select a propeller which will allow the engine

to reach the middle or upper half of the oper-

ating range at full throttle with the maximum

boat load. If operating conditions such as

light boat loads then allow the engine r/min to

rise above the maximum recommended

range, reduce the throttle setting to maintain

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Basic components

EMU25795

Main components

NOTE:

* May not be exactly as shown; also may not be included as standard equipment on all mod-

els.

F4D

ZMU04483

1. Top cowling

15. Clamp screw

2. Top cowling lock lever

3. Carrying handle

4. Steering friction screw

5. Anti-cavitation plate

6. Propeller

16. Rope attachment

17. Fuel joint

18. Choke knob

19. Gear shift lever

20. Fuel tank*

7. Cooling water inlet

8. Trim rod

9. Clamp bracket

EMU25802

Fuel tank

If your model was equipped with a portable

10. Tiller handle

fuel tank, its function is as follows.

EWM00020

11. Air vent screw

12. Fuel tank cap

WARNING

The fuel tank supplied with this engine is

13. Manual starter handle

14. Engine stop button/Engine stop lanyard

switch

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Basic components

EMU25841

its dedicated fuel reservoir and must not

be used as a fuel storage container. Com-

mercial users should conform to relevant

licensing or approval authority regula-

tions.

Fuel gauge

This gauge is located on either the fuel tank

cap or on the fuel joint base. It shows the ap-

proximate amount of fuel remaining in the

tank.

EMU25850

Fuel tank cap

This cap seals the fuel tank. When removed,

the tank can be filled with fuel. To remove the

cap, turn it counterclockwise.

EMU25860

Air vent screw

This screw is on the fuel tank cap. To loosen

the screw, turn it counterclockwise.

EMU25872

ZMU01992

Fuel cock

The fuel cock turns on and off the supply of

fuel from the fuel tank to the engine.

1. Air vent screw

2. Fuel gauge

3. Fuel joint

4. Fuel tank cap

EMU25821

Fuel tank

If your model included a fuel tank, its parts

and functions are as follows.

ZMU02659

1. Fuel cock

EMU25881

To stop fuel flow to the engine, turn the lever

ZMU02658

or knob to close position.

Always turn the lever or knob to close posi-

tion when the engine is not running.

1. Air vent screw

2. Built-in fuel tank

3. Fuel tank cap

EMU25830

Fuel joint

This joint is used to connect the fuel line.

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Basic components

ZMU02652

ZMU02659

1. “OPEN” position for the portable tank

1. Close position

EMU25911

EMU25901

Tiller handle

Open

To change direction, move the tiller handle to

the left or right as necessary.

The fuel cock has two open positions, one for

selecting fuel flow from the built-in fuel tank,

and one for an external tank.

Fuel flows to the carburetor with the lever or

knob in either open position. These are the

normal running positions.

ZMU02662

EMU25921

Gear shift lever

Pulling the gear shift lever towards you puts

the engine in forward gear so that the boat

moves ahead. Pushing the lever away from

you puts the engine in reverse gear so that

the boat moves astern.

ZMU02661

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

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Basic components

ZMU02665

ZMU02663

1. Throttle indicator

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

EMU25970

Throttle friction adjuster

A friction device provides adjustable resis-

tance to movement of the throttle grip or the

remote control lever, and can be set accord-

ing to operator preference.

To increase resistance, turn the adjuster

clockwise. To decrease resistance, turn the

EMU25941

Throttle grip

The throttle grip is on the tiller handle. Turn

the grip counterclockwise to increase speed

and clockwise to decrease speed.

adjuster counterclockwise.

EWM00030

WARNING

Do not overtighten the friction adjuster. If

there is too much resistance, it could be

difficult to move throttle lever or grip,

which could result in an accident.

ZMU02664

EMU25961

Throttle indicator

The fuel consumption curve on the throttle

indicator shows the relative amount of fuel

consumed for each throttle position. Choose

the setting that offers the best performance

and fuel economy for the desired operation.

ZMU02666

When constant speed is desired, tighten the

adjuster to maintain the desired throttle set-

ting.

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Basic components

EMU25990

Engine stop lanyard switch

The lock plate must be attached to the en-

gine stop switch for the engine to run. The

lanyard should be attached to a secure place

on the operator’s clothing, or arm or leg.

Should the operator fall overboard or leave

the helm, the lanyard will pull out the lock

plate, stopping ignition to the engine. This

will prevent the boat from running away un-

ZMU02667

der power.

EWM00120

1. Lanyard

2. Lock plate

WARNING

^GAttach the engine stop switch lanyard

to a secure place on your clothing, or

your arm or leg while operating.

EMU26001

Engine stop button

To open the ignition circuit and stop the en-

^GDo not attach the lanyard to clothing

that could tear loose. Do not route the

lanyard where it could become entan-

gled, preventing it from functioning.

^GAvoid accidentally pulling the lanyard

during normal operation. Loss of en-

gine 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.

gine, push this button.

ZMU02668

EMU26011

NOTE:

Choke knob for pull type

To supply the engine with the rich fuel mix-

ture required to start, pull out this knob.

The engine cannot be started with the lock

plate removed.

ZMU02669

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Basic components

EMU26070

difficult to steer, which could result in an

accident.

Manual starter handle

To start the engine, first gently pull the han-

dle out until resistance is felt. From that posi-

tion, then pull the handle straight out quickly

to crank the engine.

EMU26261

Trim rod (tilt pin)

The position of the trim rod determines the

minimum trim angle of the outboard motor in

relation to the transom.

ZMU02670

EMU26121

ZMU02672

Steering friction adjuster

A friction device provides adjustable resis-

tance to the steering mechanism, and can be

set according to operator preference. An ad-

justing screw or bolt is located on the swivel

bracket.

EMU26312

Tilt lock mechanism

The tilt lock mechanism is used to prevent

the outboard motor from lifting out of the wa-

ter when in reverse gear.

ZMU04497

ZMU02671

1. Tilt lock lever

To increase resistance, turn the adjuster

clockwise.

To decrease resistance, turn the adjuster

counterclockwise.

EWM00040

To lock it, set the tilt lock lever in the “

(lock) position. To release, push the tilt lock

lever in the “ ” (release) position.

EMU26330

”

WARNING

Do not overtighten the friction adjuster. If

there is too much resistance, it could be

Tilt support bar

The tilt support bar keeps the outboard motor

in the tilted up position.

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Basic components

EMU26450

Carrying handle

A carrying handle is provided on the rear of

the outboard motor. It enables you to carry

the outboard motor easily with one hand.

ZMU02674

EMU26382

Top cowling lock lever (pull up type)

To remove the engine top cowling, pull up

the lock lever(s) and lift off the cowling.

When installing the cowling, check to be sure

it fits properly in the rubber seal. Then lock

the cowling by moving the lever(s) down-

ward.

ZMU02676

1. Carrying handle

ZMU02675

1. Top cowling lock lever(s)

ZMU04522

1. Top cowling lock lever(s)

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Operation

EMU26901

specific boat and motor combination.

Installation

EWM00830

ECM00110

WARNING

CAUTION:

Improper mounting of the outboard mo-

tor could result in hazardous conditions

such as poor handling, loss of control, or

fire hazards. Observe the following:

G For permanently mounted models, your

dealer or other person experienced in

proper rigging should mount the motor.

If you are mounting the motor yourself,

you should be trained by an experi-

enced person.

Incorrect engine height or obstructions

to smooth water flow (such as the design

or condition of the boat, or accessories

such as transom ladders or depth finder

transducers) can create airborne water

spray while the boat is cruising. Severe

engine damage may result if the motor is

operated continuously in the presence of

airborne water spray.

G For portable models, your dealer or oth-

er person experienced in proper out-

board motor mounting should show

you how to mount your motor.

NOTE:

During water testing check the buoyancy of

the boat, at rest, with its maximum load.

Check that the static water level on the ex-

haust housing is low enough to prevent wa-

ter entry into the powerhead, when water

rises due to waves when the outboard is not

running.

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.

EMU26910

Mounting the outboard motor

EWM00820

WARNING

^GOverpowering a boat could cause se-

vere instability. Do not install an out-

board motor with more horsepower

than the maximum rating on the capac-

ity plate of the boat. If the boat does not

have a capacity plate, consult the boat

manufacturer.

G The information presented in this sec-

tion is intended as reference only. It is

not possible to provide complete in-

structions for every possible boat and

motor combination. Proper mounting

depends in part on experience and the

ZMU01760

1. Center line (keel line)

EMU26920

Mounting height

To run your boat at optimum efficiency, the

water resistance (drag) of the boat and out-

board motor must be made as little as possi-

ble. The mounting height of the outboard

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Operation

motor greatly affects the water resistance. If

the mounting height is too high, cavitation

tends to occur, thus reducing the propulsion;

and if the propeller tips cut the air, the engine

speed will rise abnormally and cause the en-

gine to overheat. If the mounting height is too

low, the water resistance will increase and

thereby reduce engine efficiency. Mount the

outboard motor so that the anti-cavitation

plate is between the bottom of the boat and

a level 25 mm (1 in.) below it.

come loose due to engine vibration.

EWM00640

WARNING

Loose clamp screws could allow the out-

board motor to fall off or move on the

transom. This could cause loss of control

and serious injury. Make sure the tran-

som screws are tightened securely. Oc-

casionally check the screws for tightness

during operation.

0–25mm

ZMU02012

(0–1in.)

ZMU02011

2. If the engine restraint cable attachment

is equipped on your engine, an engine

restraint cable or chain should be used.

Attach one end to the engine restraint

cable attachment and the other to a se-

cure mounting point on the boat. Other-

wise the engine could be completely lost

if it accidentally falls off the transom.

NOTE:

^GThe optimum mounting height of the out-

board motor is affected by the boat and

motor combination and the desired use.

Test runs at different heights can help de-

termine the optimum mounting height.

Consult your Yamaha dealer or boat man-

ufacturer for further information on deter-

mining the proper mounting height.

G For instructions on setting the trim angle of

the outboard motor, see page 27.

EMU26970

Clamping the outboard motor

1. Place the outboard motor on the tran-

som so that it is positioned as close to

the center as possible. Tighten the tran-

som clamp screws evenly and securely.

Occasionally check the clamp screws

for tightness during operation of the out-

board motor because they could be-

ZMU02013

3. Secure the clamp bracket to the transom

using the bolts provided with the out-

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Operation

board (if packed). For details, consult

your Yamaha dealer.

Run the engine at 2000 r/min or at ap-

proximately half throttle.

EWM00650

2. For the second hour of operation:

Run the engine at 3000 r/min or at ap-

proximately three-quarter throttle.

3. For the next eight hours of operation:

Avoid continuous operation at full throt-

tle for more than five minutes at a time.

4. After the first 10 hours:

WARNING

Avoid using bolts, nuts or washers other

than those contained in the engine pack-

aging. If used, they must be of at least the

same quality of material and strength and

must be tightened securely. After tighten-

ing, test run the engine and check their

tightness.

Operate the engine normally.

EMU27101

Preoperation checks

EWM00080

WARNING

If any item in the preoperation check is

not working properly, have it inspected

and repaired before operating the out-

board motor. Otherwise an accident

could occur.

ECM00120

ZMU02637

CAUTION:

Do not start the engine out of water. Over-

heating and serious engine damage can

occur.

1. Bolts

EMU30171

Breaking in engine

EMU27110

Fuel

Your new engine requires a period of break-

in to allow mating surfaces of moving parts to

wear in evenly. Correct break-in will help en-

sure proper performance and longer engine

^GCheck to be sure you have plenty of fuel

for your trip.

^GMake sure there are no fuel leaks or gaso-

line fumes.

^GCheck fuel line connections to be sure they

are tight (if equipped Yamaha fuel tank or

boat tank).

^GBe sure the fuel tank is positioned on a se-

cure, flat surface, and that the fuel line is

not twisted or flattened, or likely to contact

sharp objects (if equipped Yamaha fuel

life.

ECM00800

CAUTION:

Failure to follow the break-in procedure

could result in reduced engine life or

even severe engine damage.

EMU27080

Procedure for 4-stroke models

Run the engine under load (in gear with a

propeller installed) as follows.

1. For the first hour of operation:

tank or boat tank).

EMU27130

Controls

G Check throttle, shift, and steering for prop-

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Operation

er operation before starting the engine.

G The controls should work smoothly, with-

out binding or unusual free play.

^GLook for loose or damaged connections.

G Check operation of the starter and stop

switches when the outboard motor is in the

water.

EMU27140

Engine

ZMU02678

^GCheck the engine and engine mounting.

^GLook for loose or damaged fasteners.

G Check the propeller for damage.

EMU27163

1. Lower level mark

2. Oil dipstick

3. Upper level mark

Checking the engine oil level

1. Put the outboard motor in an upright po-

sition (not tilted).

2. Remove oil dipstick and wipe it clean.

3. Completely insert the dipstick and re-

move it again.

NOTE:

Be sure to completely insert the dipstick into

the dipstick guide.

EMU30540

Filling fuel

4. Check the oil level using the dipstick to

be sure the level falls between the upper

and lower marks. Fill with oil if it is below

the lower mark, or drain to the specified

level if it is above the upper mark.

EWM00060

WARNING

Gasoline and its vapors are highly flam-

mable and explosive. Keep away from

sparks, cigarettes, flames, or other

sources of ignition.

1. Remove the fuel tank cap.

2. Carefully fill the fuel tank.

ZMU02677

1. Oil dipstick

ZMU04536

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Operation

water near you.

G When the air vent screw is loosened,

gasoline vapor will be released. Gaso-

line is highly flammable, and its vapors

are flammable and explosive. Refrain

from smoking, and keep away from

open flames and sparks while loosen-

ing the air vent screw.

^GThis product emits exhaust gases

which contain carbon monoxide, a col-

orless, odorless gas which could cause

brain damage or death when inhaled.

Symptoms include nausea, dizziness,

and drowsiness. Keep cockpit and cab-

in areas well ventilated. Avoid blocking

exhaust outlets.

ZMU04484

3. Securely close the cap after filling the

tank. Wipe up any spilled fuel.

Fuel tank capacity:

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

NOTE:

1. For the built in tank, loosen the air vent

screw on the fuel tank cap by one turn.

For the external fuel tank, loosen it on

the fuel tank cap by 2 or 3 turns.

The upper fuel level mark is indicated on the

built-in fuel tank.

ZMU04537

1. Upper level mark

2. Select the fuel tank using the fuel cock

or open the fuel cock.

EMU27450

Operating engine

EMU27472

Feeding fuel

EWM00420

WARNING

^GBefore 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

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Operation

ZMU02894

ZMU02681

EMU27490

Starting engine

EMU27505

Manual start models (tiller control)

1. Place the gear shift lever in neutral.

ZMU02680

3. If you are using an external fuel tank,

connect the fuel joints securely and

squeeze the primer pump with the outlet

end up until you feel it become firm (if

equipped the fuel joint).

ZMU02682

NOTE:

The start-in-gear protection device prevents

the engine from starting except when in neu-

tral.

2. Attach the engine stop switch lanyard to

a secure place on your clothing, or your

arm or leg. Then install the lock plate on

the other end of the lanyard into the en-

gine stop switch.

EWM00120

ZMU02679

WARNING

G Attach the engine stop switch lanyard

to a secure place on your clothing, or

your arm or leg while operating.

G Do not attach the lanyard to clothing

that could tear loose. Do not route the

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Operation

lanyard where it could become entan-

gled, preventing it from functioning.

^GAvoid accidentally pulling the lanyard

during normal operation. Loss of en-

gine 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.

ZMU02669

NOTE:

^GIt is not necessary to use the choke when

starting a warm engine.

G If the choke knob is left in the “

”

(start) position while the engine is running,

the engine will run poorly or stall.

5. Pull the manual starter handle slowly un-

til you feel resistance. Then give a

strong pull straight out to crank and start

the engine. Repeat if necessary.

ZMU02683

3. Place the throttle grip in the “

”

(start) position.

ZMU02670

ZMU02684

6. After the engine starts, slowly return the

manual starter handle to its original po-

sition before releasing it.

7. Slowly return the throttle grip to the fully

closed position.

4. Pull out / turn the choke knob fully. After

the engine starts, replace / return the

knob to the home position.

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Operation

2. Check for a steady flow of water from the

cooling water pilot hole.

ECM00510

CAUTION:

A flow of water from the hole on the ex-

haust cover shows that the water pump is

pumping water through the cooling pas-

sages. If water is not flowing out of the

hole at all times while the engine is run-

ning, overheating and serious damage

could occur. Stop the engine and check

whether the cooling water inlet on the

lower case or the cooling water pilot hole

is blocked. Consult your Yamaha dealer if

the problem cannot be located and cor-

rected.

ZMU02685

NOTE:

^GWhen the engine is cold, it needs to be

warmed up. For further information, see

page 25.

^GIf the engine does not start on the first try,

repeat the procedure. If the engine fails to

start after 4 or 5 tries, open the throttle a

small amount (between 1/8 and 1/4) and

try again. Also if the engine is warm and

fails to start, open the throttle a same

amount and try to start the engine again. If

the engine still fails to start, see page 49.

EMU27670

Warming up engine

EMU27731

ZMU02686

Manual start models

EMU27740

1. After starting the engine, return the

choke knob to the halfway position. For

approximately the first 5 minutes after

starting, warm up the engine by operat-

ing at one fifth throttle or less. After the

engine has warmed up, push the choke

knob in fully. Failure to do so will shorten

engine life.

Shifting

EWM00180

WARNING

Before shifting, make sure there are no

swimmers or obstacles in the water near

you.

ECM00220

NOTE:

CAUTION:

^GIf the choke knob is left pulled out after the

engine starts, the engine will stall.

G In temperatures of -5°C or less, leave the

choke knob pulled out fully for approxi-

mately 30 seconds after starting.

To change the boat direction or shifting

position from forward to reverse or vice-

versa, first close the throttle so that the

engine idles (or runs at low speeds).

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Operation

EMU27763

an accident.

Forward (tiller handle and remote

1. Place the throttle grip in the fully closed

position.

control models)

Tiller control models

1. Place the throttle grip in the fully closed

position.

ZMU02685

2. Move the gear shift lever quickly and

firmly from neutral to reverse.

ZMU02685

2. Move the gear shift lever quickly and

firmly from neutral to forward.

ZMU02688

NOTE:

ZMU02687

The outboard motor can turn 360° in its

bracket (full-pivot system). The boat can also

be backed up by simply turning the outboard

motor around 180° with the steering handle

facing toward you.

Remote control models

1. Pull up the neutral interlock trigger (if

equipped) and move the remote control

lever quickly and firmly from neutral to

forward.

EMU27801

EMU27820

Stopping engine

Before stopping the engine, first let it cool off

for a few minutes at idle or low speed. Stop-

ping the engine immediately after operating

Reverse

EWM00190

WARNING

When operating in reverse, go slowly. Do

not open the throttle more than half. Oth-

erwise the boat could become unstable,

which could result in loss of control and

at high speed is not recommended.

EMU27832

Procedure

1. Push and hold the engine stop button

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Operation

until the engine comes to a complete

stop.

ZMU02689

NOTE:

ZMU02668

If the outboard motor is equipped with an en-

gine stop switch lanyard, the engine can also

be stopped by pulling the lanyard and remov-

ing the lock plate from the engine stop

switch.

2. After stopping the engine, tighten the air

vent screw on the fuel tank cap and set

the fuel cock lever or knob to the closed

position, if equipped.

EMU27861

Trimming outboard motor

The trim angle of the outboard motor helps

determine the position of the bow of the boat

in the water. Correct trim angle will help im-

prove performance and fuel economy while

reducing strain on the engine. Correct trim

angle depends upon the combination of

boat, engine, and propeller. Correct trim is

also affected by variables such as the load in

the boat, sea conditions, and running speed.

EWM00740

WARNING

Excessive trim for the operating condi-

tions (either trim up or trim down) can

cause boat instability and can make

steering the boat more difficult. This in-

creases 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.

ZMU02660

3. Disconnect the fuel line if you are using

an external fuel tank.

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Operation

ZMU02691

1. Trim rod

3. Reposition the rod in the desired hole.

To raise the bow (“trim-out”), move the rod

away from the transom.

To lower the bow (“trim-in”), move the rod to-

ward the transom.

Make test runs with the trim set to different

angles to find the position that works best for

ZMU02690

your boat and operating conditions.

EWM00400

1. Trim operating angle

WARNING

EMU27871

^GStop the engine before adjusting the

trim angle.

^GUse care to avoid being pinched when

removing or installing the rod.

^GUse caution when trying a trim position

for the first time. Increase speed gradu-

ally and watch for any signs of instabil-

ity or control problems. Improper trim

angle can cause loss of control.

Adjusting trim angle for manual tilt

models

There are 4 or 5 holes provided in the clamp

bracket to adjust the outboard motor trim an-

gle.

1. Stop the engine.

2. Remove the trim rod from the clamp

bracket while slightly tilting the outboard

motor up.

NOTE:

The outboard motor trim angle can be

changed approximately 4 degrees by shifting

the trim rod one hole.

EMU27911

Adjusting boat trim

When the boat is on plane, a bow-up attitude

results in less drag, greater stability and effi-

ciency. This is generally when the keel line of

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Operation

the boat is up about 3 to 5 degrees. With the and making it hard to increase speed. Oper-

bow up, the boat may have a greater tenden- ating with excessive trim-in at higher speeds

cy to steer to one side or the other. Compen- also makes the boat unstable. Resistance at

sate for this as you steer. The trim tab can the bow is greatly increased, heightening the

also be adjusted to help offset this effect. danger of “bow steering” and making opera-

When the bow of the boat is down, it is easier tion difficult and dangerous.

to accelerate from a standing start onto

plane.

NOTE:

Depending on the type of boat, the outboard

Bow Up

motor trim angle may have little effect on the

trim of the boat when operating.

Too much trim-out puts the bow of the boat

too high in the water. Performance and econ-

omy are decreased because the hull of the

boat is pushing the water and there is more

air drag. Excessive trim-out can also cause

the propeller to ventilate, which reduces per-

formance further, and the boat may “por-

poise” (hop in the water), which could throw

the operator and passengers overboard.

EMU27920

Tilting up and down

If the engine will be stopped for some time or

if the boat is moored in shallows, the out-

board motor should be tilted up to protect the

propeller and casing from damage by colli-

sion with obstructions, and also to reduce

salt corrosion.

Bow Down

Too much trim-in causes the boat to “plow”

through the water, decreasing fuel economy

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Operation

when in reverse or when the outboard

motor is turned 180° (facing the rear).

EMU27964

Procedure for tilting up (manual tilt

models)

1. Place the gear shift lever in neutral (if

equipped) and face the outboard motor

forward.

ZMU02692

EWM00220

WARNING

Be sure all people are clear of the out-

board motor when tilting up and down,

also be careful not to pinch any body

parts between the drive unit and engine

bracket.

ZMU02682

EWM00230

WARNING

2. On full-pivot system models, tighten the

steering friction adjuster by turning it

clockwise to prevent the motor from

turning freely.

Leaking fuel is a fire hazard. Tighten the

air vent screw and place the fuel cock in

the closed position if the outboard motor

will be tilted for more than a few minutes.

Otherwise fuel may leak.

ECM00230

CAUTION:

^GBefore tilting the outboard motor, fol-

low the procedure under “Stopping en-

gine”in this chapter. Never tilt the

outboard motor while the engine is run-

ning. Severe damage from overheating

can result.

^GDo not tilt up the engine by pushing the

tiller handle because this could break

the handle.

ZMU02696

3. Tighten the air vent screw. On models

equipped with a fuel joint, disconnect the

fuel line from the outboard motor.

^GKeep the power unit higher than the

propeller at all times. Otherwise water

could run into the cylinder and cause

damage.

^GThe outboard motor cannot be tilted

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Operation

ZMU02694

6. Tilt support knob equipped models: Hold

the rear of the top cowling with one

hand, fully tilt the outboard motor up,

and push the tilt support knob into the

clamp bracket.

7. Tilt support lever equipped models: Hold

the rear handle and tilt the engine up ful-

ly until the tilt support lever automatically

locks.

ZMU02689

NOTE:

Tilt support lever/bar equipped models: If the

motor is not facing forward, the tilt support le-

ver/bar cannot automatically turn to the

locked position. If the tilt support lever/bar

does not automatically lock, swing the motor

a little to the left and right.

4. Close the fuel cock.

EMU28031

Procedure for tilting down (manual

tilt models)

1. Slightly tilt the outboard motor up.

2. If the tilt support bar equipped: Slowly tilt

the outboard motor down while pulling

the tilt support bar lever up.

ZMU02660

5. Tilt support bar equipped models: Hold

the rear of the top cowling or the rear

handle (if equipped) with one hand and

tilt the outboard motor up fully until the

tilt support bar automatically locks.

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Operation

ing the shallow water cruising system.

G Run the boat at the lowest possible

speed when using the shallow water

cruising system. The tilt lock mecha-

nism does not work while the shallow

water cruising system is being used.

Hitting an underwater obstacle could

cause the outboard motor to lift out of

the water, resulting in loss of control.

^GDo not rotate the outboard motor 180°

and operate the boat in reverse. Place

the gear shift in reverse to operate the

boat in reverse.

ZMU02673

3. If the tilt support knob equipped: pull out

it, then slowly tilt the engine down.

4. Loosen the steering friction adjuster by

turning it counterclockwise, and adjust

the steering friction according to opera-

G Use extra care when operating in re-

verse. Too much reverse thrust can

cause the outboard motor to lift out of

the water, increasing the chance of ac-

cident and personal injury.

tor preference.

EWM00720

WARNING

^GReturn the outboard motor to its normal

position as soon as the boat is back in

deeper water.

If there is too much resistance it could be

difficult to steer, which could result in an

accident.

ECM00260

CAUTION:

Do not tilt the outboard motor up so that

the cooling water inlet on the lower unit is

above the surface of the water when set-

ting up for and cruising in shallow water.

Otherwise severe damage from overheat-

ing can result.

ZMU02695

EMU28060

Cruising in shallow water

The outboard motor can be tilted up partially

to allow operation in shallow water.

EMU28071

Cruising in shallow water (manual tilt

models)

EWM00710

ZMU02697

WARNING

G Place the gear shift in neutral before us-

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Operation

EMU28101

Procedure

1. Place the gear shift lever in neutral and

face the outboard motor forward.

ZMU02673

NOTE:

The outboard motor is equipped with 2 or 3

positions for shallow water cruising.

ZMU02682

EMU28190

2. Slightly tilt the outboard motor up until

the tilt support bar automatically turns to

the lock position to support the engine.

Cruising in other conditions

Cruising in salt water

After operating in salt water, wash out the

cooling water passages with fresh water to

prevent them from becoming clogged with

salt deposits.

NOTE:

For cooling system flushing instructions, see

page 35.

Cruising in turbid water

Yamaha strongly recommends that you use

the optional chromium-plated water pump kit

if you use the outboard motor in turbid (mud-

dy) water conditions.

ZMU04542

3. To lower the outboard motor to the nor-

mal running position, first slightly tilt the

outboard motor up. Then pull up the tilt

support bar lever and slowly tilt the en-

gine down.

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Maintenance

EMU28213

Tiller

Specifications

Dimension:

Starting system:

Manual

Overall length:

717 mm (28.2 in)

Overall width:

361 mm (14.2 in)

Overall height S:

1029 mm (40.5 in)

Overall height L:

1156 mm (45.5 in)

Transom height S:

435 mm (17.1 in)

Transom height L:

562 mm (22.1 in)

Weight (AL) S:

Starting carburetion system:

Choke valve

Valve clearance (cold engine) IN:

0.08–0.12 mm (0.0032–0.0047 in)

Valve clearance (cold engine) EX:

0.08–0.12 mm (0.0032–0.0047 in)

Drive unit:

Gear positions:

Forward-neutral-reverse

Gear ratio:

2.08 (27/13)

Trim and tilt system:

Manual tilt

22.0 kg (49 lb)

Weight (AL) L:

Propeller mark:

23.0 kg (51 lb)

Performance:

Fuel and oil:

Recommended fuel:

Full throttle operating range:

4000–5000 r/min

Maximum output:

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

min)

Unleaded regular gasoline

Min. pump octane:

Fuel tank capacity:

1.10 L (0.291 US gal) (0.2420

Imp.gal)

Idling speed (in neutral):

1500 50 r/min

Engine:

Recommended engine oil:

4-stroke outboard motor oil

Engine oil grade API:

API SE, SF, SG, SH, SJ

Engine oil type SAE:

SAE10W30 or SAE10W40

Lubrication:

Type:

4-stroke S

Displacement:

112.0 cm (6.83 cu.in)

Bore × stroke:

59.0 × 41.0 mm (2.32 × 1.61 in)

Ignition system:

TCI

Spark plug (NGK):

BR6HS

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

Control system:

Wet sump

Engine oil quantity (excluding oil filter):

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

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

100.0 cm (3.38 US oz) (3.53 Imp.oz)

Tightening torque for engine:

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Maintenance

Spark plug:

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

Engine oil drain bolt:

sition using a motor support device such as

a transom saver bar. Consult your Yamaha

dealer for further details.

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

EMU28222

Transporting and storing

outboard motor

EWM00690

WARNING

^GLeaking 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.

^GUSE CARE when transporting fuel tank,

whether in a boat or car.

^GDO NOT fill fuel container to maximum

capacity. Gasoline will expand consid-

erably as it warms up and can build up

pressure in the fuel container. This can

cause fuel leakage and a potential fire

hazard.

ZMU02699

EMU28235

Clamp screw mounting models

When transporting or storing the outboard

motor while removed from a boat, keep the

outboard motor in the attitude shown.

EWM00700

WARNING

Never get under the lower unit while it is

tilted, even if a motor support bar is used.

Severe injury could occur if the outboard

motor accidentally falls.

ZMU02699

ECM00660

CAUTION:

Do not use the tilt support lever or knob

when trailering the boat. The outboard

motor could shake loose from the tilt sup-

port and fall. If the motor cannot be trail-

ered in the normal running position, use

an additional support device to secure it

in the tilt position.

ZMU02700

The outboard motor should be trailered and

stored in the normal running position. If there

is insufficient road clearance in this position,

then trailer the outboard motor in the tilt po-

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Maintenance

and storing it. If storing or transporting

the outboard motor on its side (not up-

right), put it on a cushion after draining

the engine oil.

G Do not place the outboard motor on its

side before the cooling water has

drained from it completely, otherwise

water may enter the cylinder through

the exhaust port and cause engine trou-

ble.

ZMU02701

G Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

EMU28301

Procedure

EMU28372

Flushing in a test tank

1. Wash the outboard motor body using

fresh water. For further information, see

page 38.

ZMU04507

2. 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:

Place a towel or something similar under the

outboard motor to protect it from damage.

NOTE:

EMU28241

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.

Storing outboard motor

When storing your Yamaha outboard motor

for prolonged periods of time (2 months or

longer), several important procedures must

be performed to prevent excessive damage.

It is advisable to have your outboard motor

serviced by an authorized Yamaha dealer

prior to storage. However, you, the owner,

with a minimum of tools, can perform the fol-

3. Remove the engine top cowling and si-

lencer cover.

4. Install the outboard motor on the test

tank.

lowing procedures.

ECM01080

CAUTION:

^GTo prevent problems which can be

caused by oil entering the cylinder from

the sump, keep the outboard motor in

the attitude shown when transporting

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Maintenance

when starting or during operation.

G Keep hands, hair, and clothes away

from the flywheel and other rotating

parts while the engine is running.

7. Run the engine at a fast idle for 10–15

minutes in neutral position.

8. Just prior to turning off the engine, quick-

ly spray “Yamaha Stor-Rite Engine

Fogging Oil” (Part No. LUB-STRRT-12-

00) alternately into each carburetor or

the fogging hole of the silencer cover, if

equipped. When properly done, the en-

gine will smoke excessively and almost

stall.

9. Remove the outboard motor from the

test tank.

10. Drain the cooling water completely out

of the motor. Clean the body thoroughly.

11. Install the silencer cover/cap and top

1. Water surface

2. Lowest water level

5. Fill the tank with fresh water to above the

level of the anti-cavitation plate.

ECM00300

CAUTION:

Do not run the engine without supplying

it with cooling water. Either the engine

water pump will be damaged or the en-

gine will be damaged from overheating.

Before starting the engine, be sure to

supply water to the cooling water passag-

es.

cowling.

EMU28400

Lubrication (except oil injection

models)

1. Grease the spark plug threads and in-

stall the spark plug(s) and torque to

proper specification. For information on

spark plug installation, see page 40.

2. Change the gear oil. For instructions,

see page 46. Inspect the oil for the pres-

ence of water that indicates a leaky seal.

Seal replacement should be performed

by an authorized Yamaha dealer prior to

use.

ECM00290

CAUTION:

If the fresh water level is below the level

of the anti-cavitation plate, or if the water

supply is insufficient, engine seizure may

occur.

6. Cooling system flushing is essential to

prevent the cooling system from clog-

ging up with salt, sand, or dirt. In addi-

tion, fogging of the engine is mandatory

to prevent excessive engine damage

due to rust. Perform the flushing and

3. Grease all grease fittings. For further de-

tails, see page 40.

EMU28420

Cleaning and anticorrosion

measures

fogging at the same time.

EWM00090

1. Wash down the exterior of the outboard

motor with fresh water and dry off com-

pletely.

WARNING

^GDo not touch or remove electrical parts

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Maintenance

EMU28483

EWM01070

2. Spray the outboard motor exterior with

Periodic maintenance

“Yamaha Silicone Protectant” (Part No.

LUB-SILCNE-13-00).

WARNING

ECM01330

CAUTION:

Be sure to turn off the engine when you

perform maintenance unless otherwise

specified. If you or the owner is not famil-

iar with machine servicing, this work

should be done by your Yamaha dealer or

other qualified mechanic.

If equipped Electronic Fuel Injection: Do

not spray when the engine is running. Al-

so, do not spray near the silencer and ox-

ygen sensor cover or into the engine.

Otherwise the oxygen sensor for Elec-

tronic Fuel Injection system could be

damaged.

Maintenance, replacement, or repair of

the emission control devices and sys-

tems may be performed by any marine

engine repair establishment or individual.

All warranty repairs, however, including

those to the emission control system,

must be performed by an authorized

Yamaha marine dealership.

A service manual is available for purchase

through your Yamaha dealer for owners who

have the mechanical skills, tools, and other

equipment necessary to perform mainte-

3. Wax the cowling with a non-abrasive

wax such as “Yamaha Silicone Wax”

(Part No. ACC-11000-15-02).

EMU28450

Cleaning the outboard motor

After use, wash the exterior of the outboard

motor with fresh water. Flush the cooling

system with fresh water.

nance not covered by this owner’s manual.

EMU28510

Replacement parts

If replacement parts are necessary, use only

genuine Yamaha parts or parts of the same

type and of equivalent strength and materi-

als. Any part of inferior quality may malfunc-

tion, and the resulting loss of control could

endanger the operator and passengers.

Yamaha genuine parts and accessories are

available from your Yamaha dealer.

ZMU02703

NOTE:

For cooling system flushing instructions, see

page 35.

EMU28460

Checking painted surface of motor

Check the motor for scratches, nicks, or flak-

ing paint. Areas with damaged paint are

more likely to corrode. If necessary, clean

and paint the areas. A touch-up paint is avail-

able from your Yamaha dealer.

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Maintenance

EMU28521

Maintenance chart

Frequency of maintenance operations may be adjusted according to the operating condi-

tions, but the following table gives general guidelines. Refer to the sections in this chapter for

explanations of each owner-specific action.

The “ ” symbol indicates the check-ups which you may carry out yourself.

The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Initial

Every

50 hours

100

hours (6

months)

200

hours (1

year)

Item

Actions

10 hours

(1 month)

months)

Inspection / replace-

ment

Inspection / replace-

ment

Anode(s) (external)

Anode(s) (internal)

Cooling water pas-

sages

Cleaning

Cowling clamp

Inspection

Inspection / replace-

ment

Fuel ﬁlter (disposable)

Fuel system

Inspection

Fuel tank (built-in tank) Inspection / cleaning

Fuel tank (Yamaha por-

Inspection / cleaning

table tank)

Gear oil

Change

Greasing points

Greasing

Idling speed (carbure-

tor models)

Inspection / adjustment

Inspection / replace-

ment

Propeller and cotter pin

Shift link / shift cable

Thermostat

Inspection / adjustment

Inspection

Throttle link / throttle

cable / throttle pick-up

timing

Inspection / adjustment

Water pump

Engine oil

Inspection

Inspection / change

Cleaning / adjustment /

replacement

Spark plug(s)

Valve clearance (OHC,

OHV)

Inspection / adjustment

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Maintenance

NOTE:

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

water after each use.

EMU28931

Greasing

Yamaha marine grease (Water resistant grease)

F4D

ZMU02706

EMU28950

be careful not to damage the insulator. A

damaged insulator could allow external

Cleaning and adjusting spark plug

EWM00560

sparks, which could lead to explosion or

fire.

WARNING

When removing or installing a spark plug,

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Maintenance

The spark plug is an important engine com- any dirt from the threads and screw in the

ponent and is easy to inspect. The condition spark plug to the correct torque.

of the spark plug can indicate something

Spark plug torque:

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

about the condition of the engine. For exam-

ple, if the center electrode porcelain is very

white, this could indicate an intake air leak or

carburetion problem in that cylinder. Do not

NOTE:

If a torque-wrench is not available when you

attempt to diagnose any problems yourself.

are fitting a spark plug, a good estimate of

Instead, take the outboard motor to a

the correct torque is 1/4 to 1/2 a turn past fin-

Yamaha dealer. You should periodically re-

ger-tight. Have the spark plug adjusted to the

move and inspect the spark plug because

correct torque as soon as possible with a

torque-wrench.

heat and deposits will cause the spark plug

to slowly break down and erode. If electrode

EMU28961

erosion becomes excessive, or if carbon and

Checking fuel system

other deposits are excessive, you should re-

place the spark plug with another of the cor-

rect type.

EWM00900

WARNING

Gasoline and its vapors are highly flam-

mable and explosive. Keep away from

sparks, cigarettes, flames, or other

sources of ignition.

Standard spark plug:

BR6HS

Before fitting the spark plug, measure the

electrode gap with a wire thickness gauge;

adjust the gap to specification if necessary.

EWM00910

WARNING

Leaking fuel can result in fire or explo-

sion.

G Check for fuel leakage regularly.

^GIf any fuel leakage is found, the fuel

system must be repaired by a qualified

mechanic. Improper repairs can make

the outboard unsafe to operate.

Check the fuel lines for leaks, crack, or mal-

function. If a problem is found, your Yamaha

dealer or other qualified mechanic should re-

pair it immediately.

1. Spark plug gap

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

Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)

When fitting the plug, always clean the gas-

ket surface and use a new gasket. Wipe off

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Maintenance

EMU29040

Inspecting idling speed

EWM00450

WARNING

^GDo not touch or remove electrical parts

when starting or during operation.

G Keep hands, hair, and clothes away

from the flywheel and other rotating

parts while the engine is running.

G 2-hp models: The propeller rotates

whenever the engine is running. Do not

move the throttle control lever from the

start position during warm-up. The boat

could unexpectedly start to move,

which could result in an accident.

ECM00490

CAUTION:

This procedure must be performed while

the outboard motor is in the water. A

flushing attachment or test tank can be

used.

ZMU04505

Checkpoints

^GFuel system parts leakage

^GFuel line joint leakage

A diagnostic tachometer should be used for

this procedure. Results may vary depending

on whether testing is conducted with the

flushing attachment, in a test tank, or with the

outboard motor in the water.

^GFuel line cracks or other damage

^GFuel connector leakage

EMU28990

Checking fuel filter

Check the fuel filter periodically. The fuel fil-

ter is a one piece, disposable type. If foreign

matter is found in the filter, replace it. For re-

placement of the fuel filter, consult your

Yamaha dealer.

1. Start the engine and allow it to warm up

fully in neutral until it is running smooth-

ly.

2-hp model: Warm the engine with the

throttle in the start position or less. If the

outboard is mounted on a boat, be sure

the boat is tightly moored.

NOTE:

Correct idling speed inspection is only possi-

ble if the engine is fully warmed up. If not

warmed up fully, the idle speed will measure

higher than normal. If you have difficulty ver-

ifying the idle speed, or the idle speed re-

quires adjustment, consult a Yamaha dealer

ZMU02708

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Maintenance

or other qualified mechanic.

2. Verify whether the idle speed is set to

specification. For idle speed specifica-

tions, see page 34.

EMU29103

Changing engine oil

EWM00760

WARNING

^GAvoid draining the engine oil immedi-

ately after stopping the engine. The oil

is hot and should be handled with care

to avoid burns.

^GBe sure the outboard motor is securely

fastened to the transom or a stable

stand.

ZMU02699

2. Prepare a suitable container that holds a

larger amount than the engine oil capac-

ity. Loosen and remove the drain screw

while holding the container under the

drain hole. Then remove the oil filler cap.

Let the oil drain completely. Wipe up any

spilled oil immediately.

ECM00970

CAUTION:

G Do not overfill the oil, and be sure the

outboard motor is upright (not tilted)

when checking and changing the en-

gine oil.

^GIf the oil level is above the upper level

mark, drain until the level meets the

specified capacity. Overfilling the oil

could cause leakage or damage.

ZMU02709

ECM01240

CAUTION:

1. Drain screw

Change the engine oil after the first 10

hours of operation, and every 100 hours

or at 6-month intervals thereafter. Other-

wise the engine will wear quickly.

3. Put a new gasket on the oil drain screw.

Apply a light coat of oil to the gasket and

install the drain screw.

NOTE:

Tightening torque:

See page 34

Change the engine oil when the oil is still

warm.

NOTE:

1. Put the outboard motor in an upright po-

sition (not tilted).

If a torque wrench is not available when you

are installing the drain plug, finger tighten the

bolt just until the gasket comes into contact

with the surface of the drain hole. Then tight-

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Maintenance

en 1/4 - 1/2 turn. Have the drain plug torqued

to the correct value with a torque wrench as

soon as possible.

curely.

EMU29120

Exhaust leakage

Start the engine and check that no exhaust

leaks from the joints between the exhaust

cover, cylinder head, and body cylinder.

EMU29130

4. Add the correct amount of oil through the

filler hole. Install the filler cap.

Water leakage

Start the engine and check that no water

leaks from the joints between the exhaust

cover, cylinder head, and body cylinder.

EMU29140

Engine oil leakage

Check for oil leaks on the around the engine.

NOTE:

ZMU02677

If any leaks are found, consult your Yamaha

dealer.

1. Oil ﬁller cap

EMU29171

Checking propeller

Engine oil grade/capacity:

See page 34

EWM00321

WARNING

You could be seriously injured if the en-

gine accidentally starts when you are

near the propeller.

^GBefore inspecting, removing, or install-

ing the propeller, remove the spark

plug caps from the spark plugs. Also,

place the shift control in neutral, turn

5. Start the engine and make sure that

there are no oil leaks.

6. Turn off the engine and wait 3 minutes.

Recheck the oil level using the dipstick

to be sure the level falls between the up-

per and lower marks. Fill with oil if it is

below the lower mark, or drain to the

specified level if it is above the upper

mark.

the main switch to “

” (off) and re-

move the key, and remove the lanyard

from the engine stop switch. Turn off

the battery cut-off switch if your boat

has one.

NOTE:

^GFor disposal of used oil consult your

Yamaha dealer.

G Do not use your hand to hold the pro-

peller when loosening or tightening the

propeller nut. Put a wood block be-

tween the anti-cavitation plate and the

propeller to prevent the propeller from

turning.

G The oil should be changed more often

when the engine is operated under ad-

verse conditions such as extended trolling.

EMU29111

Checking wiring and connectors

^GCheck that each grounding wire is properly

secured.

G Check that each connector is engaged se-

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Maintenance

NOTE:

If the shear pin equipped: it is designed to

break if the propeller hits a hard underwater

obstacle to help protect the propeller and

drive mechanism. The propeller will then

spin freely on the shaft. If this happens, the

shear pin must be replaced.

EMU29193

Removing the propeller

1. Straighten the cotter pin and pull it out

using a pair of pliers.

ZMU02710

2. Remove the propeller nut, washer, and

spacer (if equipped).

ZMU02711

Checkpoints

G Check each of the propeller blades for

wear, erosion from cavitation or ventila-

tion, or other damage.

G Check the propeller shaft for damage.

^GCheck the splines / shear pin for wear or

damage.

ZMU02713

1. Cotter pin

2. Propeller nut

3. Washer

4. Propeller

5. Thrust washer

G Check for fish line tangled around the pro-

peller shaft.

3. Remove the propeller and thrust wash-

er.

EMU30370

Installing the propeller

ECM00340

CAUTION:

G Be sure to install the thrust washer be-

fore installing the propeller, otherwise

the lower case and propeller boss

could be damaged.

ZMU02712

^GBe sure to use a new cotter pin and

bend the ends over securely. Otherwise

^GCheck the propeller shaft oil seal for dam-

age.

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Maintenance

the propeller could come off during op-

eration and be lost.

occur if the outboard motor accidental-

ly falls.

1. Apply Yamaha marine grease or a cor- 1. Tilt the outboard motor so that the gear

rosion resistant grease to the propeller

shaft.

oil drain screw is at the lowest point pos-

sible.

2. Install the spacer (if equipped), thrust 2. Place a suitable container under the

washer, and propeller on the propeller

shaft.

gear case.

3. Remove the gear oil drain screw.

3. Install the spacer (if equipped) and the

washer. Tighten the propeller nut until

there is no forward-and-backward

movement.

4. Align the propeller nut with the propeller

shaft hole. Insert a new cotter pin in the

hole and bend the cotter pin ends.

ZMU02715

1. Gear oil drain screw

2. Oil level plug

NOTE:

If the magnetic gear oil drain screw

equipped: remove all metal particles from

the screw before installing it.

ZMU02714

NOTE:

4. Remove the oil level plug to allow the oil

to drain completely.

ECM00710

If the propeller nut does not align with the

propeller shaft hole after tightening it, loosen

the nut until it aligns with the hole.

CAUTION:

EMU29280

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 re-

pair of the lower unit seals.

Changing gear oil

EWM00800

WARNING

^GBe sure the outboard motor is securely

fastened to the transom or a stable

stand. You could be severely injured if

the outboard motor falls on you.

G Never get under the lower unit while it

is tilted, even when the tilt support lever

or knob is locked. Severe injury could

NOTE:

For disposal of used oil consult your Yamaha

dealer.

5. With the outboard motor in a vertical po-

sition, and using a flexible or pressur-

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Maintenance

ized filling device, inject the gear oil into

the gear oil drain screw hole.

plosion hazard.

G Dispose of old gasoline according to lo-

cal regulations.

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

1. Empty the fuel tank into an approved

container.

2. Pour a small amount of suitable solvent

into the tank. Install the cap and shake

the tank. Drain the solvent completely.

3. Remove the screws holding the fuel joint

assembly. Pull the assembly out of the

tank.

100.0 cm (3.38 US oz) (3.53 Imp.oz)

ZMU02716

6. When the oil begins to flow out of the oil

level plug hole, insert and tighten the oil

level plug.

7. Insert and tighten the gear oil drain

4. Clean the filter (located on the end of the

suction pipe) in a suitable cleaning sol-

vent. Allow the filter to dry.

5. Replace the gasket with a new one. Re-

install the fuel joint assembly and tighten

screw.

EMU29302

Cleaning fuel tank

EWM00920

WARNING

Gasoline is highly flammable, and its va-

pors are flammable and explosive.

G If you have any question about properly

doing this procedure, consult your

Yamaha dealer.

G Keep away from sparks, cigarettes,

flames, or other sources of ignition

when cleaning the fuel tank.

the screws firmly.

EMU29312

Inspecting and replacing anode(s)

Yamaha outboard motors are protected from

corrosion by sacrificial anodes. Inspect the

external anodes periodically. Remove scales

from the surfaces of the anodes. Consult a

Yamaha dealer for replacement of external

anodes.

G Remove the fuel tank from the boat be-

fore cleaning it. Work only outdoors in

an area with good ventilation.

ECM00720

CAUTION:

Do not paint anodes, as this would render

them ineffective.

G Wipe up any spilled fuel immediately.

^GReassemble the fuel tank carefully. Im-

proper assembly can result in a fuel

leak, which could result in a fire or ex-

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Maintenance

more rapid engine corrosion.

NOTE:

Inspect ground leads attached to external

anodes on equipped models. Consult a

Yamaha dealer for inspection and replace-

ment of internal anodes attached to the pow-

er unit.

ZMU01943

ZMU02717

EMU29390

Checking top cowling

Check the fitting of the top cowling by push-

ing it with both hands. If it is loose have it re-

paired by your Yamaha dealer.

ZMU04477

EMU29400

Coating the boat bottom

A clean hull improves boat performance. The

boat bottom should be kept as clean of ma-

rine growth as possible. If necessary, the

boat bottom can be coated with an anti-foul-

ing paint approved for your area to inhibit

marine growth.

Do not use anti-fouling paint which includes

copper or graphite. These paints can cause

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Trouble Recovery

EMU29422

A. Fill tank with clean, fresh fuel.

Troubleshooting

A problem in the fuel, compression, or igni-

tion systems can cause poor starting, loss of

power, or other problems. This section de-

scribes basic checks and possible remedies,

and covers all Yamaha outboard motors.

Therefore some items may not apply to your

model.

Q. Is fuel filter clogged?

A. Clean or replace filter.

Q. Is starting procedure incorrect?

A. See page 23.

Q. Has fuel pump malfunctioned?

If your outboard motor requires repair, bring

it to your Yamaha dealer.

A. Have serviced by a Yamaha dealer.

If the engine trouble warning indicator is

flashing, consult your Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrect

type?

A. Inspect spark plug(s). Clean or replace

with recommended type.

Starter will not operate.

Q. Is battery capacity weak or low?

A. Check battery condition. Use battery of

recommended capacity.

Q. Are spark plug cap(s) fitted incorrectly?

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

Q. Are battery connections loose or corrod-

ed?

Q. Is ignition wiring damaged or poorly con-

nected?

A. Tighten battery cables and clean battery

terminals.

A. Check wires for wear or breaks. Tighten

all loose connections. Replace worn or bro-

ken wires.

Q. Is fuse for electric start relay or electric cir-

cuit blown?

Q. Are ignition parts faulty?

A. Check for cause of electric overload and

repair. Replace fuse with one of correct am-

perage.

A. Have serviced by a Yamaha dealer.

Q. Is engine stop switch lanyard not at-

tached?

Q. Are starter components faulty?

A. Attach lanyard.

A. Have serviced by a Yamaha dealer.

Q. Are engine inner parts damaged?

A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear?

A. Shift to neutral.

Engine idles irregularly or stalls.

Q. Are spark plug(s) fouled or of incorrect

type?

Engine will not start (starter operates).

Q. Is fuel tank empty?

A. Fill tank with clean, fresh fuel.

A. Inspect spark plug(s). Clean or replace

with recommended type.

Q. Is fuel contaminated or stale?

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Trouble Recovery

Q. Is fuel system obstructed?

A. Return to home position.

A. Check for pinched or kinked fuel line or

other obstructions in fuel system.

Q. Is motor angle too high?

A. Return to normal operating position.

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

Q. Is carburetor clogged?

A. Have serviced by a Yamaha dealer.

Q. Is fuel filter clogged?

A. Clean or replace filter.

Q. Is fuel joint connection incorrect?

A. Connect correctly.

Q. Have ignition parts failed?

A. Have serviced by a Yamaha dealer.

Q. Is throttle valve adjustment incorrect?

A. Have serviced by a Yamaha dealer.

Q. Has warning system activated?

A. Find and correct cause of warning.

Q. Is battery cable disconnected?

A. Connect securely.

Q. Is spark plug gap incorrect?

A. Inspect and adjust as specified.

Warning buzzer sounds or indicator

lights.

Q. Is ignition wiring damaged or poorly con- Q. Is cooling system clogged?

nected?

A. Check water intake for restriction.

A. Check wires for wear or breaks. Tighten

all loose connections. Replace worn or bro- Q. Is engine oil level low?

ken wires.

A. Fill oil tank with specified engine oil.

Q. Is specified engine oil not being used?

A. Check and replace oil as specified.

Q. Is heat range of spark plug incorrect?

A. Inspect spark plug and replace it with rec-

ommended type.

Q. Is thermostat faulty or clogged?

A. Have serviced by a Yamaha dealer.

Q. Is specified engine oil not being used?

A. Check and replace oil with specified type.

Q. Are carburetor adjustments incorrect?

A. Have serviced by a Yamaha dealer.

Q. Is engine oil contaminated or deteriorat-

ed?

Q. Is fuel pump damaged?

A. Replace oil with fresh, specified type.

A. Have serviced by a Yamaha dealer.

Q. Is oil filter clogged?

Q. Is air vent screw on fuel tank closed?

A. Open air vent screw.

A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunc-

tioned?

Q. Is choke knob pulled out?

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Trouble Recovery

A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangled

on gear housing?

Q. Is load on boat improperly distributed?

A. Remove foreign matter and clean lower

A. Distribute load to place boat on an even unit.

plane.

Q. Is fuel system obstructed?

Q. Is water pump or thermostat faulty?

A. Have serviced by a Yamaha dealer.

A. Check for pinched or kinked fuel line or

other obstructions in fuel system.

Q. Is there excess water in fuel filter cup?

A. Drain filter cup.

Q. Is fuel filter clogged?

A. Clean or replace filter.

Engine power loss.

Q. Is propeller damaged?

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

A. Have propeller repaired or replaced.

Q. Is spark plug gap incorrect?

Q. Is propeller pitch or diameter incorrect?

A. Install correct propeller to operate out-

A. Inspect and adjust as specified.

board at its recommended speed (r/min) Q. Is ignition wiring damaged or poorly con-

range.

nected?

A. Check wires for wear or breaks. Tighten

all loose connections. Replace worn or bro-

Q. Is trim angle incorrect?

A. Adjust trim angle to achieve most efficient ken wires.

operation.

Q. Have ignition parts failed?

Q. Is motor mounted at incorrect height on A. Have serviced by a Yamaha dealer.

transom?

A. Have motor adjusted to proper transom Q. Is specified engine oil not being used?

height.

A. Check and replace oil with specified type.

Q. Has warning system activated?

A. Find and correct cause of warning.

Q. Is thermostat faulty or clogged?

A. Have serviced by a Yamaha dealer.

Q. Is boat bottom fouled with marine growth? Q. Is air vent screw closed?

A. Clean boat bottom. A. Open the air vent screw.

Q. Are spark plug(s) fouled or of incorrect Q. Is fuel pump damaged?

type?

A. Have serviced by a Yamaha dealer.

A. Inspect spark plug(s). Clean or replace

with recommended type.

Q. Is fuel joint connection incorrect?

A. Connect correctly.

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Trouble Recovery

board motor unsafe to operate.

Q. Is heat range of spark plug incorrect?

A. Inspect spark plug and replace it with rec-

ommended type.

If the outboard motor hits an object in the wa-

ter, follow the procedure below.

Q. Is high pressure fuel pump drive belt bro-

ken?

A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shift

lever position?

A. Have serviced by a Yamaha dealer.

Engine vibrates excessively.

Q. Is propeller damaged?

A. Have propeller repaired or replaced.

1. Stop the engine immediately.

2. Inspect the control system and all com-

ponents for damage. Also inspect the

boat for damage.

3. Whether damage is found or not, return

to the nearest harbor slowly and careful-

ly.

Q. Is propeller shaft damaged?

A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangled

on propeller?

A. Remove and clean propeller.

4. Have a Yamaha dealer inspect the out-

board motor before operating it again.

EMU29531

Starter will not operate

Q. Is motor mounting bolt loose?

A. Tighten bolt.

If the starter mechanism does not operate

(the engine cannot be cranked with the start-

er), the engine can be started with an emer-

gency starter rope.

EWM01020

Q. Is steering pivot loose or damaged?

A. Tighten or have serviced by a Yamaha

dealer.

WARNING

G Use this procedure only in an emergen-

cy and only to return to port for repairs.

^GWhen the emergency starter rope is

used to start the engine, the start-in-

gear protection device does not oper-

ate. Make sure the remote control lever

is in neutral. Otherwise the boat could

unexpectedly start to move, which

could result in an accident.

EMU29431

Temporary action in

emergency

EMU29440

Impact damage

EWM00870

WARNING

The outboard motor can be seriously

damaged by a collision while operating or

trailering. Damage could make the out-

^GAttach the engine stop switch lanyard

to a secure place on your clothing, or

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Trouble Recovery

your arm or leg while operating.

G Do not attach the lanyard to clothing

that could tear loose. Do not route the

cord where it could become entangled,

preventing it from functioning.

^GAvoid accidentally pulling the lanyard

during normal operation. Loss of en-

gine 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.

ZMU02718

1. Start-in-gear protection cable

2. Choke cable

^GBe sure no one is standing behind you

when pulling the starter rope. It could

whip behind you and injure someone.

^GAn unguarded, rotating flywheel is very

dangerous. Keep loose clothing and

other objects away when starting the

engine. Use the emergency starter rope

only as instructed. Do not touch the fly-

wheel or other moving parts when the

engine is running. Do not install the

starter mechanism or top cowling after

the engine is running.

3. Remove the start-in-gear protection ca-

ble end by pulling it out from the lever of

the starter after loosening the nut.

^GDo not touch the ignition coil, spark

plug wire, spark plug cap, or other elec-

trical components when starting or op-

erating the motor. You could get an

electrical shock.

ZMU02719

4. Remove the starter after removing the

three bolts.

EMU29621

Emergency starting engine

1. Remove the top cowling.

2. Remove the start-in-gear protection ca-

ble and the choke cable from the holder

on the starter. After removing the choke

cable, confirm that the cable end is con-

tacted with the silencer by pushing it in-

side.

ZMU02720

5. Reinstall two bolts to secure the fuel

tank.

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Trouble Recovery

9. Give a strong pull straight out to crank

and start the engine. Repeat if neces-

sary.

ZMU02721

6. Prepare the engine for starting. For fur-

ther information, see page 23. Be sure

the engine is in neutral and that the en-

gine stop switch lanyard lock plate is at-

tached to the engine stop switch.

ZMU02722

EMU29760

Treatment of submerged motor

If the outboard motor is submerged, immedi-

ately take it to a Yamaha dealer. Otherwise

some corrosion may begin almost immedi-

ately.

If you cannot immediately take the outboard

motor to a Yamaha dealer, follow the proce-

dure below in order to minimize engine dam-

age.

EMU29783

Procedure

ZMU02682

1. Thoroughly wash away mud, salt, sea-

weed, and so on, with fresh water.

ZMU02683

ZMU02703

7. Insert the knotted end of the emergency

starter rope into the notch in the flywheel

rotor and wind the rope several turns

around the flywheel clockwise.

8. Pull the rope slowly until resistance is

felt.

2. Remove the spark plug(s), then face the

spark plug holes downward to allow any

water, mud, or contaminants to drain.

3. Drain the fuel from the carburetor, fuel

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Trouble Recovery

filter, and fuel line. Drain the engine oil

completely.

ZMU02724

4. Fill the sump with the fresh engine oil.

Engine oil capacity:

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

5. Feed engine fogging oil or engine oil

through the carburetor(s) and spark plug

holes while cranking the engine with the

manual starter or emergency starter

rope.

ZMU02725

6. Take the outboard motor to a Yamaha

dealer as soon as possible.

ECM00400

CAUTION:

Do not attempt to run the outboard motor

until it has been completely inspected.

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Consumer information

EMU29811

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

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Consumer information

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Consumer information

EMU29830

YAMAHA MOTOR CORPORATION, U.S.A.

FOUR-STROKE OUTBOARD MOTOR

THREE-YEAR LIMITED WARRANTY

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Consumer information

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Consumer information

EMU29840

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR

YAMAHA OUTSIDE U.S.A. OR CANADA

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Printed in France

April 2004–0.5 × 1 !

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