owner’s manual - yamaha motor australia | yamaha … thank you for choosing a yamaha outboard...

Read this manual carefully before operating thisoutboard motor.

OWNER’S MANUAL

4AC5C

6E0-28199-28-E0

U6E028E0.book Tuesday, February 10, 2009 3:19 PM

Read this manual carefully before operating this outboard motor. Keep thismanual onboard in a waterproof bag when boating. This manual should staywith the outboard motor if it is sold.

U6E028E0.book Page 1 Tuesday, February 10, 2009 3:19 PM

Important manual informationEMU25105

To the ownerThank you for choosing a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understanding ofthese simple instructions will help you obtainmaximum enjoyment from your new Yamaha.If you have any question about the operationor maintenance of your outboard motor,please consult a Yamaha dealer.In this Owner’s Manual particularly importantinformation is distinguished in the followingways.

: This is the safety alert symbol. It is usedto alert you to potential personal injury haz-ards. Obey all safety messages that followthis symbol to avoid possible injury or death.

WARNINGEWM00781

A WARNING indicates a hazardous situa-tion which, if not avoided, could result indeath or serious injury.

NOTICEECM00701

A NOTICE indicates special precautionsthat must be taken to avoid damage to theoutboard motor or other property.

TIP:A TIP provides key information to make pro-cedures easier or clearer.

Yamaha continually seeks advancements inproduct design and quality. Therefore, whilethis manual contains the most current productinformation available at the time of printing,there may be minor discrepancies between

your machine and this manual. If there is anyquestion concerning this manual, please con-sult your Yamaha dealer.To ensure long product life, Yamaha recom-mends that you use the product and performthe specified periodic inspections and mainte-nance by correctly following the instructions inthe owner’s manual. Any damage resultingfrom neglect of these instructions is not cov-ered by warranty.Some countries have laws or regulations re-stricting users from taking the product out ofthe country where it was purchased, and itmay be impossible to register the product inthe destination country. Additionally, the war-ranty may not apply in certain regions. Whenplanning to take the product to another coun-try, consult the dealer where the product waspurchased for further information.If the product was purchased used, pleaseconsult your closest dealer for customer re-registration, and to be eligible for the specifiedservices.

TIP:The 4ACMH, 5CMH and the standard acces-sories are used as a base for the explanationsand illustrations in this manual. Thereforesome items may not apply to every model.EMU25121

4AC, 5COWNER’S MANUAL

©2009 by Yamaha Motor Co., Ltd.1st Edition, February 2009

All rights reserved.Any reprinting or unauthorized usewithout the written permission of

Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan


Table of contents

Safety information.............................1Outboard motor safety .................... 1

Propeller ............................................. 1Rotating parts ..................................... 1Hot parts............................................. 1Electric shock ..................................... 1Engine shut-off cord (lanyard) ............ 1Gasoline ............................................. 1Gasoline exposure and spills ............. 1Carbon monoxide ............................... 1Modifications ...................................... 2

Boating safety ................................. 2Alcohol and drugs............................... 2Personal flotation devices .................. 2People in the water............................. 2Passengers ........................................ 2Overloading ........................................ 2Avoid collisions................................... 2Weather.............................................. 3Passenger training ............................. 3Boating safety publications................. 3Laws and regulations ......................... 3

General information ..........................4Identification numbers record.......... 4

Outboard motor serial number ........... 4EC Declaration of Conformity

(DoC)............................................ 4CE Marking ..................................... 4C-Tick label ..................................... 4Read manuals and labels................ 6

Warning labels.................................... 6Specifications and requirements... 10

Specifications ................................ 10Installation requirements ............... 11

Boat horsepower rating .................... 11Mounting motor ................................ 11

Battery requirements..................... 11Without a rectifier or Rectifier

Regulator ...................................... 11

Propeller selection ........................ 11Start-in-gear protection ................. 12Engine oil requirements ................ 12Fuel requirements ......................... 12

Gasoline ........................................... 12Muddy or acidic water ................... 13Anti-fouling paint ........................... 13Motor disposal requirements......... 13Emergency equipment .................. 13

Components .................................... 14Components diagram.................... 14

Fuel tank........................................... 15Fuel tank........................................... 16Fuel joint ........................................... 16Fuel gauge ....................................... 16Fuel tank cap.................................... 16Air vent screw................................... 16Fuel cock .......................................... 16Open................................................. 17Tiller handle...................................... 17Gear shift lever ................................. 17Throttle grip ...................................... 18Throttle indicator............................... 18Throttle friction adjuster .................... 18Engine shut-off cord (lanyard) and

clip................................................. 19Engine stop button ........................... 19Choke knob ...................................... 19Manual starter handle....................... 19Steering friction adjuster................... 20Trim rod (tilt pin) ............................... 20Tilt support bar ................................. 20Cowling lock lever(s) (turn type) ....... 20

Installation ....................................... 21Installation..................................... 21

Mounting the outboard motor ........... 21Clamping the outboard motor ........... 22

Operation ......................................... 24First-time operation ....................... 24

Breaking in engine............................ 24Getting to know your boat ................ 24

Checks before starting engine ...... 24Fuel level .......................................... 25


Table of contents

Remove cowling ............................... 25Fuel system...................................... 25Controls ............................................ 25Engine shut-off cord (lanyard) .......... 25Oil ..................................................... 25Engine .............................................. 26Install cowling ................................... 26

Filling fuel and engine oil............... 26Filling fuel for portable tank .............. 26Filling fuel for built-in tank................. 27Gasoline and oil mixing (100:1)........ 28

Operating engine........................... 30Sending fuel (portable tank) ............. 30Sending fuel ..................................... 31Starting engine ................................. 32

Checks after starting engine ......... 33Cooling water ................................... 33

Warming up engine ....................... 34Choke start models .......................... 34

Checks after engine warm-up ....... 34Shifting ............................................. 34Stop switches ................................... 34

Shifting .......................................... 34Stopping boat ................................ 35Stopping engine ............................ 35

Procedure......................................... 35Trimming outboard motor.............. 36

Adjusting trim angle for manual tilt models .......................................... 37

Adjusting boat trim............................ 37Tilting up and down ....................... 38

Procedure for tilting up (manual tilt models)....................... 38

Procedure for tilting down (manual tilt models)....................... 40

Shallow water................................ 40Cruising in shallow water

(manual tilt models)....................... 40Cruising in other conditions........... 41

Maintenance..................................... 42Transporting and storing outboard

motor .......................................... 42Clamp screw mounting models ........ 42

Storing outboard motor..................... 42Procedure......................................... 43Lubrication........................................ 44Cleaning the outboard motor ............ 44Checking painted surface of motor... 44

Periodic maintenance ................... 44Replacement parts ........................... 44Severe operating conditions............. 44Maintenance chart 1......................... 45Maintenance chart 2......................... 47Greasing........................................... 47Cleaning and adjusting spark plug ... 48Checking fuel filter ............................ 48Inspecting idling speed..................... 49Checking wiring and connectors ...... 49Checking propeller ........................... 49Removing propeller .......................... 50Installing propeller ............................ 50Changing gear oil ............................. 51Cleaning fuel tank............................. 52Inspecting and replacing anode(s) ... 53

Trouble Recovery............................ 54Troubleshooting ............................ 54Temporary action in emergency ... 57

Impact damage................................. 57Starter will not operate ..................... 57Emergency starting engine............... 58

Treatment of submerged motor .... 59


1

Safety informationEMU33622

Outboard motor safetyObserve these precautions at all times.EMU36501

PropellerPeople can be injured or killed if they come incontact with the propeller. The propeller cankeep moving even when the motor is in neu-tral, and sharp edges of the propeller can cuteven when stationary.� Stop the engine when a person is in the wa-

ter near you.� Keep people out of reach of the propeller,

even when the engine is off.EMU33630

Rotating partsHands, feet, hair, jewelry, clothing, PFDstraps, etc. can become entangled with inter-nal rotating parts of the engine, resulting in se-rious injury or death.Keep the top cowling in place whenever pos-sible. Do not remove or replace the cowlingwith the engine running.Only operate the engine with the cowling re-moved according to the specific instructions inthe manual. Keep hands, feet, hair, jewelry,clothing, PFD straps, etc. away from any ex-posed moving parts.EMU33640

Hot partsDuring and after operation, engine parts arehot enough to cause burns. Avoid touchingany parts under the top cowling until the en-gine has cooled.EMU33650

Electric shockDo not touch any electrical parts while startingor operating the engine. They can causeshock or electrocution.EMU33671

Engine shut-off cord (lanyard)Attach the engine shut-off cord so that the en-gine stops if the operator falls overboard orleaves the helm. This prevents the boat from

running away under power and leaving peo-ple stranded, or running over people or ob-jects.Always attach the engine shut-off cord to asecure place on your clothing or your arm orleg while operating. Do not remove it to leavethe helm while the boat is moving. Do not at-tach the cord to clothing that could tear loose,or route the cord where it could become en-tangled, preventing it from functioning.Do not route the cord where it is likely to beaccidentally pulled out. If the cord is pulledduring operation, the engine will shut off andyou will lose most steering control. The boatcould slow rapidly, throwing people and ob-jects forward.EMU33810

GasolineGasoline and its vapors are highly flam-mable and explosive. Always, refuel accord-ing to the procedure on page 30 to reduce therisk of fire and explosion.EMU33820

Gasoline exposure and spillsTake care not to spill gasoline. If gasolinespills, wipe it up immediately with dry rags.Dispose of rags properly.If any gasoline spills onto your skin, immedi-ately wash with soap and water. Changeclothing if gasoline spills on it.If you swallow gasoline, inhale a lot of gaso-line vapor, or get gasoline in your eyes, getimmediate medical attention. Never siphonfuel by mouth.EMU33900

Carbon monoxideThis product emits exhaust gases which con-tain carbon monoxide, a colorless, odorlessgas which may cause brain damage or deathwhen inhaled. Symptoms include nausea,dizziness, and drowsiness. Keep cockpit andcabin areas well ventilated. Avoid blocking ex-haust outlets.


Safety information

2

EMU33780

ModificationsDo not attempt to modify this outboard motor.Modifications to your outboard motor may re-duce safety and reliability, and render the out-board unsafe or illegal to use.EMU33740

Boating safetyThis section includes a few of the many im-portant safety precautions that you should fol-low when boating.EMU33710

Alcohol and drugsNever operate after drinking alcohol or takingdrugs. Intoxication is one of the most commonfactors contributing to boating fatalities.EMU33720

Personal flotation devicesHave an approved personal flotation device(PFD) on board for every occupant. Yamaharecommends that you must wear a PFDwhenever boating. At a minimum, childrenand non-swimmers should always wearPFDs, and everyone should wear PFDs whenthere are potentially hazardous boating condi-tions.EMU33731

People in the waterAlways watch carefully for people in the wa-ter, such as swimmers, skiers, or divers,whenever the engine is running. When some-one is in the water near the boat, shift intoneutral and stop the engine.Stay away from swimming areas. Swimmerscan be hard to see.The propeller can keep moving even whenthe motor is in neutral. Stop the engine whena person is in the water near you.EMU33751

PassengersConsult your boat manufacturer’s instructionsfor details about appropriate passenger loca-tions in your boat and be sure all passengersare positioned properly before accelerating

and when operating above an idle speed.Standing or sitting in non-designated loca-tions may result in being thrown either over-board or within the boat due to waves, wakes,or sudden changes in speed or direction.Even when people are positioned properly,alert your passengers if you must make anyunusual maneuver. Always avoid jumpingwaves or wakes.EMU33760

OverloadingDo not overload the boat. Consult the boat ca-pacity plate or boat manufacturer for maxi-mum weight and number of passengers. Besure that weight is properly distributed ac-cording to the boat manufacturers instruc-tions. Overloading or incorrect weightdistribution can compromise the boats han-dling and lead to an accident, capsizing orswamping.EMU33772

Avoid collisionsScan constantly for people, objects, and otherboats. Be alert for conditions that limit yourvisibility or block your vision of others.

Operate defensively at safe speeds and keepa safe distance away from people, objects,and other boats.� Do not follow directly behind other boats or

waterskiers.

ZMU06025


Safety information

3

� Avoid sharp turns or other maneuvers thatmake it hard for others to avoid you or un-derstand where you are going.

� Avoid areas with submerged objects orshallow water.

� Ride within your limits and avoid aggressivemaneuvers to reduce the risk of loss of con-trol, ejection, and collision.

� Take early action to avoid collisions. Re-member, boats do not have brakes, andstopping the engine or reducing throttle canreduce the ability to steer. If you are notsure that you can stop in time before hittingan obstacle, apply throttle and turn in anoth-er direction.

EMU33790

WeatherStay informed about the weather. Checkweather forecasts before boating. Avoid boat-ing in hazardous weather.EMU33880

Passenger trainingMake sure at least one other passenger istrained to operate the boat in the event of anemergency.EMU33890

Boating safety publicationsBe informed about boating safety. Additionalpublications and information can be obtainedfrom many boating organizations.EMU33600

Laws and regulationsKnow the marine laws and regulations whereyou will be boating- and obey them. Severalsets of rules prevail according to geographiclocation, but all are basically the same as theInternational Rules of the Road.


General information

4

EMU25171

Identification numbers recordEMU25183

Outboard motor serial numberThe outboard motor serial number is stampedon the label attached to the port side of theclamp bracket.Record your outboard motor serial number inthe spaces provided to assist you in orderingspare parts from your Yamaha dealer or forreference in case your outboard motor is sto-len.

EMU37290

EC Declaration of Conformity (DoC)

This outboard motor conforms to certain por-tions of the European Parliament directive re-lating to machinery.Each conformed outboard motor accompa-nied with EC DoC.EC DoC contains the fol-lowing information;

� Name of Engine Manufacture� Model name� Product code of model (Approved model

code)� Code of conformed directivesEMU25203

CE MarkingOutboard motors affixed with this “CE”mark-ing conform with the directives of; 98/37/EC,94/25/EC - 2003/44/EC and 2004/108/EC.

EMU25213

C-Tick labelEngines affixed with this label conform to cer-tain portion(s) of the Australian Radio Com-munications Act.

1. Outboard motor serial number location

1. CE marking location

ZMU06040


General information

5

1. C-Tick label location

ZMU01697


General information

6

EMU33520

Read manuals and labelsBefore operating or working on this motor:� Read this manual.� Read any manuals supplied with the boat.� Read all labels on the outboard motor and the boat.If you need any additional information, contact your Yamaha dealer.EMU33831

Warning labelsIf these labels are damaged or missing, contact your Yamaha dealer for replacements.4AC, 5C

ZMU06033

4

1

2

3


General information

7

EMU35281

Contents of labelsThe above warning labels mean as follows.1

WARNINGEWM01691

Emergency starting does not have start-in-gear protection. Ensure shift control isin neutral before starting engine.

2

WARNINGEWM01681

� Keep hands, hair, and clothing awayfrom rotating parts while the engine isrunning.

� Do not touch or remove electrical partswhen starting or during operation.

3

WARNINGEWM01671

� Read Owner’s Manuals and labels.� Wear an approved personal flotation de-

vice (PFD).� Attach engine shut-off cord (lanyard) to

your PFD, arm, or leg so the enginestops if you accidentally leave the helm,which could prevent a runaway boat.

ZMU05924

1 2

3 4


General information

8

4

WARNINGEWM01701

Gasoline is highly flammable and explo-sive. Shut off engine before refueling.Tighten tank cap and air vent screw whennot in use.

EMU33843

SymbolsThe following symbols mean as follows.

Notice/Warning

Read Owner’s Manual

Hazard caused by continuous rotation

Electrical hazard

Remote control lever/gear shift lever operat-ing direction, dual direction

ZMU05696

ZMU05664

ZMU05665

ZMU05666

ZMU05667


General information

9

Engine start/ Engine cranking

ZMU05668


Specifications and requirements

10

EMU31480

SpecificationsTIP:“(AL)” stated in the specification data belowrepresents the numerical value for the alumi-num propeller installed.Likewise, “(SUS)” represents the value forstainless steel propeller installed and “(PL)”for plastic propeller installed.EMU2821E

Dimension:Overall length:

677 mm (26.7 in)Overall width:

322 mm (12.7 in)Overall height S:

1011 mm (39.8 in)Overall height L:

1138 mm (44.8 in)Transom height S:

444 mm (17.5 in)Transom height L:

571 mm (22.5 in)Weight (AL) S:

21.0 kg (46 lb)Weight (AL) L:

21.5 kg (47 lb)Performance:

Full throttle operating range:4500–5500 r/min

Maximum output:4ACMH 2.9 kW@5000 r/min (4 HP@5000 r/min)5CMH 3.7 kW@5000 r/min (5 HP@5000 r/min)

Idling speed (in neutral):1150 ±50 r/min

Engine:Type:

2-stroke S

Displacement:4ACMH 83.0 cm³5CMH 103.0 cm³

Bore × stroke:4ACMH 50.0 × 42.0 mm (1.97 × 1.65 in)5CMH 54.0 × 45.0 mm (2.13 × 1.77 in)

Ignition system:CDI

Spark plug (NGK):B7HSBR7HS

Spark plug gap:0.6–0.7 mm (0.024–0.028 in)

Control system:Tiller

Starting system:Manual

Starting carburetion system:Choke valve

Alternator output:40/60 W

Drive unit:Gear positions:

Forward-neutral-reverseGear ratio:

2.08 (27/13)Trim and tilt system:

Manual tiltPropeller mark:

BBA

Fuel and oil:Recommended fuel:

Regular unleaded gasolineFuel tank capacity:

5CMH 12.0 L (3.17 US gal, 2.64 Imp.gal)Fuel tank capacity (built in type):

2.8 L (0.74 US gal, 0.62 Imp.gal)Recommended engine oil:

YAMALUBE 2-stroke outboard motor oilFuel:oil ratio:



11

Regular gasoline:100 :1

Lubrication:Pre-mixed fuel and oil

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:0.100 L (0.106 US qt, 0.088 Imp.qt)

Tightening torque for engine:Spark plug:

25.0 Nm (2.55 kgf-m, 18.4 ft-lb)Noise and vibration level:

Operator sound pressure level (ICOMIA 39/94 and 40/94):

4ACMH 81.6 dB(A) (*CE)Vibration on tiller handle (ICOMIA 38/94):

4ACMH 3.4 m/s² (*CE)EMU33554

Installation requirementsEMU33563

Boat horsepower rating

WARNINGEWM01560

Overpowering a boat can cause severe in-stability.

Before installing the outboard motor(s), con-firm that the total horsepower of your motor(s)does not exceed the boats maximum horse-power rating. See the boat’s capacity plate orcontact the manufacturer.EMU33571

Mounting motor

WARNINGEWM01570

� Improper mounting of the outboard mo-tor could result in hazardous conditionssuch as poor handling, loss of control,or fire hazards.

� Because the motor is very heavy, spe-cial equipment and training is requiredto mount it safely.

Your dealer or other person experienced inproper rigging should mount the motor usingcorrect equipment and complete rigging in-structions. For further information, see page21.EMU25694

Battery requirementsEMU25730

Without a rectifier or Rectifier Regula-tor

NOTICEECM01090

A battery cannot be connected to modelsthat do not have a rectifier or RectifierRegulator.

If you wish to use a battery with the modelswithout a rectifier or Rectifier Regulator, installan optional Rectifier Regulator.Using a maintenance-free battery with theabove models can shorten the life of the bat-tery significantly.Install an optional Rectifier Regulator or useaccessories rated to withstand 18 volts orhigher with the above models. Consult yourYamaha dealer for details on installing an op-tional Rectifier Regulator.EMU34192

Propeller selectionNext to selecting an outboard, choosing theright propeller is one of the most importantpurchasing decisions a boater can make. Thetype, size, and design of your propeller havea direct impact on acceleration, top speed,fuel economy, and even engine life. Yamahadesigns and manufactures propellers for ev-ery Yamaha outboard motor and every appli-cation.Your outboard motor came with a Yamahapropeller chosen to perform well over a rangeof applications, but there may be uses wherea different propeller would be more appropri-ate.



12

Your Yamaha dealer can help you select theright propeller for your boating needs. Selecta propeller that will allow the engine to reachthe middle or upper half of the operatingrange at full throttle with the maximum boat-load. Generally, chose a larger pitch propellerfor a smaller operating load and a smallerpitch propeller for a heavier load. If you carryloads that vary widely, chose the propellerthat lets the engine run in the proper range foryour maximum load but remember that youmay need to reduce your throttle setting tostay within the recommended engine speedrange when carrying lighter loads.For instructions on propeller removal and in-stallation, see page 49.

EMU25770

Start-in-gear protectionYamaha outboard motors or Yamaha-ap-proved remote control units are equipped withstart-in-gear protection device(s). This featurepermits the engine to be started only when itis in neutral. Always select neutral beforestarting the engine.

EMU25651

Engine oil requirements

If the recommended engine oil is not avail-able, another 2-stroke engine oil with anNMMA-certified TC-W3 rating may be used.EMU36360

Fuel requirementsEMU36771

GasolineUse a good quality gasoline that meets theminimum octane rating. If knocking or pingingoccurs, use a different brand of gasoline orpremium unleaded fuel. Yamaha recomendsthat you use alcohol-free (see Gasohol) gas-oline whenever possible.

NOTICEECM01981

� Do not use leaded gasoline. Leaded gas-oline can seriously damage the engine.

� Avoid getting water and contaminants inthe fuel tank. Contaminated fuel cancause poor performance or engine dam-age. Use only fresh gasoline that hasbeen stored in clean containers.

GasoholThere are two types of gasohol: gasohol con-taining ethanol (E10) and that containingmethanol. Ethanol can be used if the ethanolcontent does not exceed 10% and the fuelmeets the minimum octane ratings. All etha-nol blends containing more than 10% ethanolcan cause fuel system damage or cause en-gine starting and running problems. Yamaha

1. Propeller diameter in inches2. Propeller pitch in inches3. Type of propeller (propeller mark)

ZMU04604

-x1 2 3

Recommended engine oil:YAMALUBE 2-stroke outboard motor oil

Recommended gasoline:Regular unleaded gasoline



13

does not recommend gasohol containingmethanol because it can cause fuel systemdamage or engine performance problems.EMU36880

Muddy or acidic waterYamaha strongly recommends that you haveyour dealer install the optional chromium-plat-ed water pump kit if you use the outboard mo-tor in muddy or acidic water conditions.However, depending on the model it might notbe required.EMU36330

Anti-fouling paintA clean hull improves boat performance. Theboat bottom should be kept as clean of marinegrowth as possible. If necessary, the boat bot-tom can be coated with an anti-fouling paintapproved for your area to inhibit marinegrowth.Do not use anti-fouling paint which includescopper or graphite. These paints can causemore rapid engine corrosion.

EMU36341

Motor disposal requirementsNever illegally discard (dump) the motor.Yamaha recommends consulting the dealerabout discarding the motor.EMU36351

Emergency equipmentKeep the following items onboard in casethere is trouble with the motor.

� A tool kit with assorted screwdrivers, pliers,wrenches (including metric sizes), andelectrical tape.

� Waterproof flashlight with extra batteries.� An extra engine shut-off cord (lanyard) with

clip.� Spare parts, such as an extra set of spark

plugs.Consult your Yamaha dealer for details.


Components

14

EMU2579M

Components diagramTIP:* May not be exactly as shown; also may not be included as standard equipment on all models.4AC

1. Air vent screw2. Fuel tank cap3. Top cowling4. Cowling lock lever5. Steering friction adjuster6. Anti-cavitation plate7. Propeller8. Cooling water inlet9. Trim rod10.Clamp bracket11.Clamp screw12.Tiller handle13.Throttle friction adjuster14.Manual starter handle15.Choke knob16.Engine stop button/Engine shut-off switch

17.Restraint cable attachment18.Tilt support bar19.Fuel cock20.Gear shift lever


Components

15

5C

EMU25802

Fuel tankIf your model was equipped with a portablefuel tank, its function is as follows.

WARNINGEWM00020

The fuel tank supplied with this engine isits dedicated fuel reservoir and must notbe used as a fuel storage container. Com-mercial users should conform to relevantlicensing or approval authority regula-tions.

1. Air vent screw2. Fuel tank cap3. Top cowling4. Cowling lock lever5. Steering friction adjuster6. Anti-cavitation plate7. Propeller8. Cooling water inlet9. Trim rod10.Clamp bracket11.Clamp screw12.Tiller handle13.Throttle friction adjuster14.Manual starter handle15.Choke knob16.Engine stop button/Engine shut-off switch17.Restraint cable attachment18.Tilt support bar19.Gear shift lever20.Fuel cock21.Fuel tank*


Components

16

EMU25821

Fuel tankIf your model included a fuel tank, its partsand functions are as follows.

EMU25830

Fuel jointThis joint is used to connect the fuel line.EMU25841

Fuel gaugeThis gauge is located on either the fuel tankcap or on the fuel joint base. It shows the ap-proximate amount of fuel remaining in thetank.EMU25850

Fuel tank capThis cap seals the fuel tank. When removed,the tank can be filled with fuel. To remove thecap, turn it counterclockwise.

EMU25860

Air vent screwThis screw is on the fuel tank cap. To loosenthe screw, turn it counterclockwise.EMU25872

Fuel cockThe fuel cock turns on and off the supply offuel from the fuel tank to the engine.

EMU25881

CloseTo stop fuel flow to the engine, turn the leveror knob to close position.Always turn the lever or knob to close positionwhen the engine is not running.

1. Air vent screw2. Fuel gauge3. Fuel joint4. Fuel tank cap

1. Air vent screw2. Fuel tank cap

ZMU01992

3 24 1

1. Fuel cock

1. Fuel cock


Components

17

EMU25891

OpenWith the lever/knob in this position, fuel flowsto the carburetor.Normal running is done with the lever/knob inthis position.

EMU25901

OpenThe fuel cock has two open positions, one forselecting fuel flow from the built-in fuel tank,and one for an external tank.Fuel flows to the carburetor with the lever orknob in either open position. These are thenormal running positions.

EMU25911

Tiller handleTo change direction, move the tiller handle tothe left or right as necessary.

EMU25922

Gear shift leverPulling the gear shift lever towards you putsthe engine in forward gear so that the boatmoves ahead. Pushing the lever away fromyou puts the engine in reverse gear so that theboat moves astern.

1. Close position

1. Close position

1. Open position

1. “OPEN” position for the built-in tank2. “OPEN” position for the portable tank


Components

18

EMU25941

Throttle gripThe throttle grip is on the tiller handle. Turnthe grip counterclockwise to increase speedand clockwise to decrease speed.

EMU25961

Throttle indicatorThe fuel consumption curve on the throttle in-dicator shows the relative amount of fuel con-sumed for each throttle position. Choose thesetting that offers the best performance andfuel economy for the desired operation.

EMU25975

Throttle friction adjusterA friction device provides adjustable resis-tance to movement of the throttle grip or theremote control lever, and can be set accord-ing to operator preference.To increase resistance, turn the adjusterclockwise. To decrease resistance, turn theadjuster counterclockwise. WARNING! Donot overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to move the remote control leveror throttle grip, which could result in anaccident. [EWM00032]

When constant speed is desired, tighten theadjuster to maintain the desired throttle set-ting.

1. Forward “ ”2. Neutral “ ”3. Reverse “ ”

1. Throttle indicator


Components

19

EMU25993

Engine shut-off cord (lanyard) and clipThe clip must be attached to the engine shut-off switch for the engine to run. The cordshould be attached to a secure place on theoperator’s clothing, or arm or leg. Should theoperator fall overboard or leave the helm, thecord will pull out the clip, stopping ignition tothe engine. This will prevent the boat fromrunning away under power. WARNING! At-tach the engine shut-off cord to a secureplace on your clothing, or your arm or legwhile operating. Do not attach the cord toclothing that could tear loose. Do not routethe cord where it could become entangled,preventing it from functioning. Avoid acci-dentally pulling the cord during normaloperation. Loss of engine power meansthe loss of most steering control. Also,without engine power, the boat could slowrapidly. This could cause people and ob-jects in the boat to be thrown forward.[EWM00122]

EMU26001

Engine stop buttonTo open the ignition circuit and stop the en-gine, push this button.

EMU26020

Choke knobTo supply the engine with the rich fuel mixturerequired to start, turn this knob to the right.

EMU26070

Manual starter handleTo start the engine, first gently pull the handleout until resistance is felt. From that position,then pull the handle straight out quickly tocrank the engine.

1. Cord2. Clip3. Engine shut-off switch


Components

20

EMU26122

Steering friction adjusterA friction device provides adjustable resis-tance to the steering mechanism, and can beset according to operator preference. An ad-justing screw or bolt is located on the swivelbracket.

To increase resistance, turn the adjusterclockwise.To decrease resistance, turn the adjustercounterclockwise.

WARNINGEWM00040

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to steer, which could result in anaccident.

EMU26261

Trim rod (tilt pin)The position of the trim rod determines theminimum trim angle of the outboard motor inrelation to the transom.

EMU26332

Tilt support barThe tilt support bar keeps the outboard motorin the tilted up position.

NOTICEECM01660

Do not use the tilt support bar when traile-ring the boat. The outboard motor couldshake loose from the tilt support and fall.If the motor cannot be trailered in the nor-mal running position, use an additionalsupport device to secure it in the tilt posi-tion.

EMU26373

Cowling lock lever(s) (turn type)To remove the engine top cowling, turn thecowling lock lever(s) and lift off the cowling.When installing the cowling, check to be sureit fits properly in the rubber seal. Then lock thecowling again by returning the cowling lock le-ver(s) to the lock position.

1. Cowling lock lever(s)


Installation

21

EMU26902

InstallationThe information presented in this section is in-tended as reference only. It is not possible toprovide complete instructions for every possi-ble boat and motor combination. Propermounting depends in part on experience andthe specific boat and motor combination.

WARNINGEWM01590

� Overpowering a boat could cause se-vere instability. Do not install an out-board motor with more horsepower thanthe maximum rating on the capacityplate of the boat. If the boat does nothave a capacity plate, consult the boatmanufacturer.

� Improper mounting of the outboard mo-tor could result in hazardous conditionssuch as poor handling, loss of control,or fire hazards. For permanently mount-ed models, your dealer or other personexperienced in proper rigging shouldmount the motor.

EMU26911

Mounting the outboard motor

WARNINGEWM01720

Your dealer or other person experiencedin proper outboard motor mountingshould show you how to mount your out-board motor.

The outboard motor should be mounted sothat the boat is well balanced. Otherwise, theboat could be hard to steer. For single-engineboats, mount the outboard motor on the cen-terline (keel line) of the boat.

EMU26923

Mounting heightTo run your boat at optimum efficiency, thewater resistance (drag) of the boat and out-board motor must be made as little as possi-ble. The mounting height of the outboardmotor greatly affects the water resistance. Ifthe mounting height is too high, cavitationtends to occur, thus reducing the propulsion;and if the propeller tips cut the air, the enginespeed will rise abnormally and cause the en-gine to overheat. If the mounting height is toolow, the water resistance will increase andthereby reduce engine efficiency. Mount theoutboard motor so that the anti-cavitationplate is between the bottom of the boat and alevel 25 mm (1 in) below it.

1. Center line (keel line)

ZMU017601

ZMU02011

0–25mm(0–1in)


Installation

22

NOTICEECM01631

� Check that the idle hole stays highenough to keep out water getting insideengine even if the boat is in stationarywith maximum load.

� Incorrect engine height or obstructionsto the smooth flow of water (such as thedesign or condition of the boat, or ac-cessories such as transom ladders ordepth finder transducers) can create air-borne water spray while the boat iscruising. If the motor is operated contin-uously in the presence of airborne waterspray, enough water could enter the en-gine through the intake opening on thecowling to cause severe engine dam-age. Eliminate the cause of the airbornewater spray.

TIP:� The optimum mounting height of the out-

board motor is affected by the boat and mo-tor combination and the desired use. Testruns at different heights can help determinethe optimum mounting height. Consult yourYamaha dealer or boat manufacturer forfurther information on determining the prop-er mounting height.

� For instructions on setting the trim angle ofthe outboard motor, see page 36.

EMU26972

Clamping the outboard motor1. Place the outboard motor on the transom

so that it is positioned as close to the cen-ter as possible. Tighten the transomclamp screws evenly and securely. Oc-casionally check the clamp screws fortightness during operation of the out-board motor because they could becomeloose due to engine vibration.WARNING! Loose clamp screws could

allow the outboard motor to fall off ormove on the transom. This couldcause loss of control and serious inju-ry. Make sure the transom screws aretightened securely. Occasionallycheck the screws for tightness duringoperation. [EWM00641]

2. If the restraint cable attachment isequipped on your engine, a restraint ca-ble or chain should be used. Attach oneend to the restraint cable attachment andthe other to a secure mounting point onthe boat. Otherwise the engine could becompletely lost if it accidentally falls offthe transom.

3. Secure the clamp bracket to the transomusing the bolts provided with the out-board (if packed). For details, consultyour Yamaha dealer. WARNING! Avoidusing bolts, nuts or washers otherthan those contained in the engine

ZMU02012

ZMU02013


Installation

23

packaging. If used, they must be of atleast the same quality of material andstrength and must be tightened se-curely. After tightening, test run theengine and check their tightness.[EWM00651]


Operation

24

EMU36381

First-time operationEMU30174

Breaking in engineYour new engine requires a period of break-into allow mating surfaces of moving parts towear in evenly. Correct break-in will help en-sure proper performance and longer enginelife. NOTICE: Failure to follow the break-inprocedure could result in reduced enginelife or even severe engine damage. [ECM00801]

EMU31241

Gasoline and engine oil mixing chart (25:1,50:1)For models without CE marking (25:1)

For models with CE marking (50:1)

NOTICEECM00150

Be sure to mix gasoline and oil complete-ly, otherwise the engine may be damaged.

EMU27074

Procedure for pre-mixed modelsRun the engine under load (in gear with a pro-peller installed) for 10 hours as follows.

1. First 10 minutes:Run the engine at the lowest possiblespeed. A fast idle in neutral is best.

2. Next 50 minutes:Do not exceed half throttle (approximate-ly 3000 r/min). Vary engine speed occa-sionally. If you have an easy-planingboat, accelerate at full throttle onto plane,then immediately reduce the throttle to3000 r/min or less.

3. Next two hours:Accelerate at full throttle onto plane, thenreduce engine speed to three-quarterthrottle (approximately 4000 r/min). Varyengine speed occasionally. Run at fullthrottle for one minute, then allow about10 minutes of operation at three-quarterthrottle or less to let the engine cool.

4. Remaining seven hours:Run the engine at any speed. However,avoid operating at full throttle for morethan 5 minutes at a time.

5. After the first 10 hours:Operate the engine normally. Use thestandard premix ratio of gasoline and oil.For details on mixing fuel and oil, seepage 26.

EMU36400

Getting to know your boatDifferent boats handle differently. Operatecautiously while you learn how your boat han-dles under different conditions and with differ-ent trim angles (see page 36).EMU36412

Checks before starting engine

WARNINGEWM01920

If any item in the checks before startingengine is not working properly, have it in-spected and repaired before operating theoutboard motor. Otherwise an accidentcould occur.

1. : Gasoline2. : Engine oil



Operation

25

NOTICEECM00120

Do not start the engine out of water. Over-heating and serious engine damage canoccur.

EMU37141

Fuel levelBe sure you have plenty of fuel for your trip. Agood rule is to use 1/3 of your fuel to get to thedestination, 1/3 to return, and to keep 1/3 asan emergency reserve. With the boat level ona trailer or in the water, check the fuel level.For fuel filling instructions, see page 26.EMU36570

Remove cowlingFor the following checks, remove the topcowling from the engine. To remove the en-gine top cowling, release the lock lever and liftoff the cowling.

EMU36442

Fuel system

WARNINGEWM00060

Gasoline and its vapors are highly flam-mable and explosive. Keep away fromsparks, cigarettes, flames, or other sourc-es of ignition.

WARNINGEWM00910

Leaking fuel can result in fire or explosion.� Check for fuel leakage regularly.

� If any fuel leakage is found, the fuel sys-tem must be repaired by a qualified me-chanic. Improper repairs can make theoutboard unsafe to operate.

EMU36451

Check for fuel leaks� Check for fuel leaks or gasoline fumes in

the boat.� Check for fuel leakage from the fuel system.� Check the fuel tank and fuel lines for

cracks, swellings, or other damages.EMU36891

Controls� Move the tiller handle fully to the left and

right to make sure operation is smooth.� Turn the throttle grip from the fully closed to

the fully open position. Make sure that itturns smoothly and that it completely re-turns to the fully closed position.

� Look for loose or damaged connections ofthe throttle and shift cables.

EMU36481

Engine shut-off cord (lanyard)Inspect the engine shut-off cord for damage,such as cuts, breaks, and wear.

EMU27120

Oil� Check to be sure you have plenty of oil for

your trip.

ZMU06089

1. Cord2. Clip3. Engine shut-off switch


Operation

26

EMU27141

Engine� Check the engine and engine mounting.� Look for loose or damaged fasteners.� Check the propeller for damage.EMU36953

Install cowling1. Be sure that a cowling lock lever is re-

leased.2. Be sure that the rubber seal is seated all

the way around the top cowling.3. Place the top cowling on bottom cowling.4. Check to be sure the rubber seal fits cor-

rectly all the way around the engine.5. Move the lever to lock the cowling as

shown. NOTICE: If the cowling is notinstalled correctly, water spray underthe cowling can damage the engine, orthe cowling can blow off at highspeeds. [ECM01990]

After installing, check the fitting of the topcowling by pushing it with both hands. If thetop cowling is loose, have it repaired by yourYamaha dealer.

EMU27234

Filling fuel and engine oilEMU27247

Filling fuel for portable tank

WARNINGEWM01830

� Gasoline and its vapors are highly flam-mable and explosive. Always refuel ac-cording to this procedure to reduce therisk of fire and explosion.

� Gasoline is poisonous and can cause in-jury or death. Handle gasoline with care.Never siphon gasoline by mouth. If youshould swallow some gasoline or inhalea lot of gasoline vapor, or get some gas-oline in your eyes, see your doctor im-mediately. If gasoline spills on yourskin, wash with soap and water. If gaso-line spills on your clothing, change yourclothes.

1. Be sure the engine is stopped.2. Disconnect the fuel line from the fuel tank

and tighten the air vent screw on the fueltank cap.

ZMU06114


Operation

27

3. Remove the portable tank from the boat.4. Be sure you are in a well-ventilated out-

door area, either securely moored or trail-ered.

5. Do not smoke and keep away fromsparks, flames, static electric discharge,or other sources of ignition.

6. If you use a portable container to storeand dispense fuel, use only an approvedGASOLINE container.

7. Touch the fuel nozzle to the filler openingor funnel to help prevent electrostaticsparks.

8. Fill the fuel tank, but do not overfill. Fuelcan expand and overflow if the tempera-ture increases.

9. Tighten the filler cap securely.10. Wipe up any spilled gasoline immediately

with dry rags. Dispose rags properly ac-cording to local laws or regulations.

EMU37532

Filling fuel for built-in tank

WARNINGEWM01950

Be sure the outboard motor is securelyfastened to the transom or a stable stand.

WARNINGEWM01830

� Gasoline and its vapors are highly flam-mable and explosive. Always refuel ac-cording to this procedure to reduce therisk of fire and explosion.

� Gasoline is poisonous and can cause in-jury or death. Handle gasoline with care.Never siphon gasoline by mouth. If youshould swallow some gasoline or inhalea lot of gasoline vapor, or get some gas-oline in your eyes, see your doctor im-mediately. If gasoline spills on yourskin, wash with soap and water. If gaso-line spills on your clothing, change yourclothes.

1. Be sure the engine is stopped.2. Disconnect the fuel line from the portable

fuel tank and tighten the air vent screw onthe fuel tank cap (if equipped portablefuel tank).

Fuel tank capacity:5CMH 12.0 L (3.17 US gal, 2.64 Imp.gal)

ZMU06621 ZMU04484


Operation

28

3. Remove the portable tank from the boat.4. Be sure you are in a well-ventilated out-

door area, either securely moored or trail-ered.

5. Do not smoke and keep away fromsparks, flames, static electric discharge,or other sources of ignition.

6. If you use a portable container to storeand dispense fuel, only use a locally ap-proved GASOLINE container.

7. Touch the fuel nozzle to the filler openingor funnel to help prevent electrostaticsparks.

8. Fill the fuel tank, but do not overfill. Fuelcan expand and overflow if the tempera-ture increases.

9. Tighten the filler cap securely.10. Wipe up any spilled gasoline immediately

with dry rags. Dispose rags properly ac-cording to local laws or regulations.

EMU27406

Gasoline and oil mixing (100:1)

NOTICEECM00811

� Avoid using any oil other than the spec-ified type.

� Use a thoroughly blended fuel-oil mix-ture.

� If the mixture is not thoroughly mixed, orif the mixing ratio is incorrect, the fol-lowing problems could occur.

� Low oil ratio: Lack of oil could cause ma-jor engine trouble, such as piston sei-zure.

� High oil ratio: Too much oil could causefouled spark plugs, smoky exhaust, andheavy carbon deposits.

Fuel tank capacity:2.8 L (0.74 US gal, 0.62 Imp.gal)

ZMU06621

Gasoline to engine oil ratio

Break-in period See page 24

After break-in 100:1


Operation

29

If equipped with a portable fuel tank1. Pour oil into the portable fuel tank, and

then add gasoline.

2. Replace the fuel tank cap and close tight-ly.

3. Shake the fuel tank to mix the fuel thor-oughly.

4. Make sure that the oil and gasoline aremixed.

If equipped with a built-in fuel tank1. Pour oil into a clean fuel can, and then

add gasoline.

2. Replace the fuel can cap and close tight-ly.

3. Shake the fuel can to mix the fuel thor-oughly.

4. Make sure that the oil and gasoline aremixed.

5. Pour the gasoline and oil mixture into thebuilt-in fuel tank.

TIP:If using a permanently installed tank, pour theoil gradually as the gasoline is being added tothe tank.


1. Engine oil2. Gasoline

100:11 L

(0.26 US gal, 0.22 Imp gal)

12 L


14 L


24 L


0.01 L

(0.01 US qt, 0.01 Imp qt)

0.12 L

(0.13 US qt, 0.11 Imp qt)

0.14 L

(0.15 US qt, 0.12 Imp qt)

0.24 L

(0.25 US qt, 0.21 Imp qt)

ZMU04910

1. Engine oil2. Gasoline


Operation

30

EMU27451

Operating engineEMU27466

Sending fuel (portable tank)

WARNINGEWM00420

� Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in thewater near you.

� When the air vent screw is loosened,gasoline vapor will be released. Gaso-line is highly flammable, and its vaporsare flammable and explosive. Refrainfrom smoking, and keep away fromopen flames and sparks while looseningthe air vent screw.

� This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which could cause braindamage or death when inhaled. Symp-toms include nausea, dizziness, anddrowsiness. Keep cockpit and cabin ar-eas well ventilated. Avoid blocking ex-haust outlets.

1. If there is an air vent screw on the fueltank cap, loosen it 2 or 3 turns.

2. If there is a fuel joint on the motor, firmlyconnect the fuel line to the joint. Thenfirmly connect the other end of the fuelline to the joint on the fuel tank.

TIP:Wipe up any spilled gasoline immediately withdry rags. Dispose rags properly according tolocal laws or regulations.3. Squeeze the primer pump, with the arrow

pointing up, until you feel it become firm.During engine operation place the tankhorizontally, otherwise fuel cannot bedrawn from the fuel tank.

1. Arrow

ZMU02024


Operation

31

EMU27474

Sending fuel

WARNINGEWM00420

� Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in thewater near you.

� When the air vent screw is loosened,gasoline vapor will be released. Gaso-line is highly flammable, and its vaporsare flammable and explosive. Refrainfrom smoking, and keep away fromopen flames and sparks while looseningthe air vent screw.

� This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which could cause braindamage or death when inhaled. Symp-toms include nausea, dizziness, anddrowsiness. Keep cockpit and cabin ar-eas well ventilated. Avoid blocking ex-haust outlets.

1. For the built in tank, loosen the air ventscrew on the fuel tank cap by one turn.For the external fuel tank, loosen it on thefuel tank cap by 2 or 3 turns.

2. Select the fuel tank using the fuel cock oropen the fuel cock.

3. If you are using an external fuel tank, con-nect the fuel joints securely and squeezethe primer pump, with the arrow pointingup, until you feel it become firm (ifequipped the fuel joint).


Operation

32

EMU27493

Starting engine

WARNINGEWM01600

Before starting the engine, make sure thatthe boat is tightly moored and that you cansteer clear of any obstructions. Be surethere are no swimmers in the water nearyou.

EMU27508

Manual start models (tiller control)

WARNINGEWM01840

� Failure to attached engine shut-off cordcould result in a runaway boat if opera-tor is ejected. Attach the engine shut-offcord to a secure place on your clothing,or your arm or leg while operating. Donot attach the cord to clothing that couldtear loose. Do not route the cord whereit could become entangled, preventing itfrom functioning.

� Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power, theboat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

1. Place the gear shift lever in neutral.

TIP:The start-in-gear protection device preventsthe engine from starting except when in neu-tral.2. Attach the engine shut-off cord to a se-

cure place on your clothing, or your armor leg. Then install the clip on the otherend of the cord into the engine shut-offswitch.

3. Place the throttle grip in the “ ”(start) position.

4. Pull out / turn the choke knob fully. Afterthe engine starts, replace / return theknob to the home position.


Operation

33

TIP:� It is not necessary to use the choke when

starting a warm engine.� If the choke knob is left in the “ ” (start)

position while the engine is running, the en-gine will run poorly or stall.

5. Pull the manual starter handle slowly untilyou feel resistance. Then give a strongpull straight out to crank and start the en-gine. Repeat if necessary.

6. After the engine starts, slowly return themanual starter handle to its original posi-tion before releasing it.

7. Slowly return the throttle grip to the fullyclosed position.

TIP:� When the engine is cold, it needs to be

warmed up. For further information, seepage 34.

� If the engine does not start on the first try,repeat the procedure. If the engine fails tostart after 4 or 5 tries, open the throttle asmall amount (between 1/8 and 1/4) and tryagain. Also if the engine is warm and fails tostart, open the throttle a same amount andtry to start the engine again. If the enginestill fails to start, see page 54.

EMU36510

Checks after starting engineEMU36520

Cooling waterCheck for a steady flow of water from the cool-ing water pilot hole. A continuous flow of waterfrom the pilot hole shows that the water pumpis pumping water through the cooling passag-es. If the cooling passages are frozen, it maytake a while for water to start flowing out of thepilot hole.

NOTICEECM01810

If water is not flowing out of the pilot holeat all times while the engine is running,overheating and serious damage couldoccur. Stop the engine and check whetherthe cooling water inlet on the lower case or

ZMU02030


Operation

34

the cooling water pilot hole is blocked.Consult your Yamaha dealer if the prob-lem cannot be located and corrected.

Check that no water leaks from the joints be-tween the exhaust cover, cylinder head, andbody cylinder.EMU27670

Warming up engineEMU27683

Choke start modelsAfter starting the engine, allow it to idle for 3minutes to warm up. Failure to do so willshorten engine life. Gradually return thechoke knob to its home position as the enginewarms up.EMU36530

Checks after engine warm-upEMU36540

ShiftingWhile tightly moored, and without applyingthrottle, confirm that the engine shifts smooth-ly into forward and reverse, and back to neu-tral.EMU36970

Stop switches� Press the engine stop button and make

sure the engine stops.� Confirm that removing the clip from the en-

gine shut-off switch stops the engine.� Confirm that the engine cannot be started

with the clip removed from the engine shut-off switch.

EMU34610

Shifting

WARNINGEWM00180

Before shifting, make sure there are noswimmers or obstacles in the water nearyou.

NOTICEECM01610

Warm up the engine before shifting intogear. Until the engine is warm, the idlespeed may be higher than normal. Highidle speed can prevent you from shiftingback to neutral. If this occurs, stop the en-gine, shift to neutral, then restart the en-gine and allow it to warm up.

To shift out of neutralMove the gear shift lever firmly and crisply for-ward (for forward gear) or backward (for re-verse gear).

To shift from in gear (forward/reverse) to neu-tral1. Close the throttle so that the engine

slows to idle speed.


Operation

35

2. After the engine is at idle speed in gearmove the gear shift lever firmly and crisp-ly into the neutral position.

TIP:The outboard motor can turn 360° in its brack-et (full-pivot system). The boat can also bebacked up by simply turning the outboard mo-tor around 180° with the steering handle fac-ing toward you.EMU31742

Stopping boat

WARNINGEWM01510

� Do not use the reverse function to slowdown or stop the boat as it could causeyou to lose control, be ejected, or impactthe steering wheel or other parts of theboat. This could increase the risk of se-rious injury. It could also damage theshift mechanism.

� Do not shift into reverse while travelingat planing speeds. Loss of control, boatswamping, or damage to the boat couldoccur.

The boat is not equipped with a separatebraking system. Water resistance stops it af-ter the throttle lever is moved back to idle. Thestopping distance varies depending on grossweight, water surface conditions, and wind di-rection.EMU27821

Stopping engineBefore stopping the engine, first let it cool offfor a few minutes at idle or low speed. Stop-ping the engine immediately after operating athigh speed is not recommended.EMU27833

Procedure1. Push and hold the engine stop button un-

til the engine comes to a complete stop.

2. After stopping the engine, tighten the airvent screw on the fuel tank cap and setthe fuel cock lever or knob to the closedposition, if equipped.


Operation

36

3. Disconnect the fuel line if you are usingan external fuel tank.

TIP:If the outboard motor is equipped with an en-gine shut-off cord, the engine can also bestopped by pulling the cord and removing theclip from the engine shut-off switch.

EMU27862

Trimming outboard motor

WARNINGEWM00740

Excessive trim for the operating condi-tions (either trim up or trim down) cancause boat instability and can make steer-ing the boat more difficult. This increasesthe possibility of an accident. If the boatbegins to feel unstable or is hard to steer,slow down and/or readjust the trim angle.

The trim angle of the outboard motor helpsdetermine the position of the bow of the boatin the water. Correct trim angle will help im-prove performance and fuel economy whilereducing strain on the engine. Correct trim an-gle depends upon the combination of boat,engine, and propeller. Correct trim is also af-fected by variables such as the load in theboat, sea conditions, and running speed.

1. Trim operating angle

ZMU02043

1


Operation

37

EMU27872

Adjusting trim angle for manual tilt modelsThere are 4 or 5 holes provided in the clampbracket to adjust the outboard motor trim an-gle.1. Stop the engine.2. Tilt the outboard motor up, and then re-

move the trim rod from the clamp bracket.

3. Reposition the rod in the desired hole.To raise the bow (“trim-out”), move the rodaway 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 an-gles to find the position that works best foryour boat and operating conditions.

WARNINGEWM00400

� Stop the engine before adjusting thetrim angle.

� Use care to avoid being pinched whenremoving or installing the rod.

� Use caution when trying a trim positionfor the first time. Increase speed gradu-ally and watch for any signs of instabilityor control problems. Improper trim an-gle can cause loss of control.

TIP:The outboard motor trim angle can bechanged approximately 4 degrees by shiftingthe trim rod one hole.EMU27911

Adjusting boat trimWhen the boat is on plane, a bow-up attituderesults in less drag, greater stability and effi-ciency. This is generally when the keel line ofthe boat is up about 3 to 5 degrees. With thebow up, the boat may have a greater tenden-cy to steer to one side or the other. Compen-sate for this as you steer. The trim tab canalso be adjusted to help offset this effect.When the bow of the boat is down, it is easierto accelerate from a standing start onto plane.

Bow UpToo much trim-out puts the bow of the boattoo high in the water. Performance and econ-omy are decreased because the hull of theboat is pushing the water and there is more airdrag. Excessive trim-out can also cause thepropeller to ventilate, which reduces perfor-mance further, and the boat may “porpoise”(hop in the water), which could throw the op-erator and passengers overboard.

1. Trim rod


Operation

38

Bow DownToo much trim-in causes the boat to “plow”through the water, decreasing fuel economyand making it hard to increase speed. Operat-ing with excessive trim-in at higher speedsalso makes the boat unstable. Resistance atthe bow is greatly increased, heightening thedanger of “bow steering” and making opera-tion difficult and dangerous.

TIP:Depending on the type of boat, the outboardmotor trim angle may have little effect on thetrim of the boat when operating.EMU27922

Tilting up and downIf the engine will be stopped for some time orif the boat is moored in shallows, the outboardmotor should be tilted up to protect the propel-ler and lower casing from damage by collisionwith obstructions, and also to reduce salt cor-rosion.

WARNINGEWM00221

Be sure all people are clear of the out-board motor when tilting up and down,Body parts can be crushed between themotor and the clamp bracket when the mo-tor is trimmed or tilted.

WARNINGEWM00230

Leaking fuel is a fire hazard. Tighten theair vent screw and place the fuel cock inthe closed position if the outboard motorwill be tilted for more than a few minutes.Otherwise fuel may leak.

NOTICEECM00231

� Before tilting the outboard motor, followthe procedure under “Stopping engine”in this chapter. Never tilt the outboardmotor while the engine is running. Se-vere damage from overheating can re-sult.

� Do not tilt up the engine by pushing thetiller handle because this could breakthe handle.

� Keep the power unit higher than the pro-peller at all times. Otherwise water couldrun into the cylinder and cause damage.

� The outboard motor cannot be tiltedwhen in reverse or when the outboardmotor is turned 180° (facing the rear).

EMU34620

Procedure for tilting up (manual tilt models)1. Place the gear shift lever in neutral and

face the outboard motor forward.


Operation

39

2. Tighten the steering friction adjuster byturning it clockwise to prevent the motorfrom turning freely.

3. Tighten the air vent screw.

4. Close the fuel cock.

5. Hold the rear of the top cowling or therear handle (if equipped) with one handand tilt the outboard motor up fully untilthe tilt support bar automatically locks.

NOTICEECM01670

Do not use the tilt support bar when traile-ring the boat. The outboard motor couldshake loose from the tilt support and fall.If the motor cannot be trailered in the nor-mal running position, use an additionalsupport device to secure it in the tilt posi-tion. For more detailed information, seepage 42.

TIP:If the motor is not facing forward, the tilt sup-port bar cannot automatically turn to thelocked position. If the tilt support bar does notautomatically lock, swing the motor a little tothe left and right.


Operation

40

EMU28033

Procedure for tilting down (manual tilt models)1. Slightly tilt the outboard motor up.2. If equipped with the tilt support bar: Slow-

ly tilt the outboard motor down while pull-ing the tilt support bar lever up.

3. If equipped with the tilt support knob: Pullthe knob out, and then slowly tilt the out-board motor down.

4. If equipped with the tilt support lever:Slowly tilt the outboard motor down whilepulling the tilt support lever up.

5. Loosen the steering friction adjuster byturning it counterclockwise, and adjustthe steering friction according to operatorpreference. WARNING! If there is toomuch resistance it could be difficult tosteer, which could result in an acci-dent. [EWM00721]

EMU28061

Shallow waterEMU35691

Cruising in shallow water (manual tilt models)

WARNINGEWM00711

� Run the boat at the lowest possiblespeed when using the shallow watercruising system. The tilt lock mecha-nism does not work while the shallowwater cruising system is being used. Hit-

ting an underwater obstacle couldcause the outboard motor to lift out ofthe water, resulting in loss of control.

� Do not rotate the outboard motor 180°and operate the boat in reverse. Placethe gear shift in reverse to operate theboat in reverse.

� Use extra care when operating in re-verse. Too much reverse thrust cancause the outboard motor to lift out ofthe water, increasing the chance of acci-dent and personal injury.

NOTICEECM00260

Do not tilt the outboard motor up so thatthe cooling water inlet on the lower unit isabove the surface of the water when set-ting up for and cruising in shallow water.Otherwise severe damage from overheat-ing can result.

EMU28102

Procedure1. Place the gear shift lever in neutral and

face the outboard motor forward.


Operation

41

2. Slightly tilt the outboard motor up until thetilt support bar automatically turns to thelock position to support the engine. Theoutboard motor is equipped with 2 or 3positions for shallow water cruising.

3. To lower the outboard motor to the nor-mal running position, first slightly tilt theoutboard motor up. Then pull up the tiltsupport bar lever and slowly tilt the en-gine down.

EMU28195

Cruising in other conditionsCruising in salt waterAfter operating in salt water, flush the coolingwater passages with fresh water to preventthem from becoming clogged. Also rinse theoutside of the outboard motor with fresh wa-ter.Cruising in muddy, turbid, or acidic waterYamaha strongly recommends that you usethe optional chromium-plated water pump kit(see page 13) if you use the outboard motor inacidic water or water with a lot of sediment init, such as muddy or turbid (cloudy) water. Af-ter operating in such water, flush the coolingpassages with fresh water to prevent corro-sion. Also rinse the outside of the outboardmotor with fresh water.


Maintenance

42

EMU28227

Transporting and storing out-board motor

WARNINGEWM00693

� USE CARE when transporting fuel tank,whether in a boat or car.

� DO NOT fill fuel container to maximumcapacity. Gasoline will expand consider-ably as it warms up and can build uppressure in the fuel container. This cancause fuel leakage and a potential firehazard.

WARNINGEWM01860

Leaking fuel is a fire hazard. When trans-porting and storing the outboard motor,close the fuel cock to prevent fuel fromleaking. Never get under the engine whileit is tilted. Severe injury could occur if theoutboard motor accidentally falls.

NOTICEECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboard mo-tor could shake loose from the tilt supportand fall. If the motor cannot be trailered inthe normal running position, use an addi-tional support device to secure it in the tiltposition.

The outboard motor should be trailered andstored in the normal running position. If thereis insufficient road clearance in this position,then trailer the outboard motor in the tilt posi-tion using a motor support device such as atransom saver bar. Consult your Yamahadealer for further details.

EMU28235

Clamp screw mounting modelsWhen transporting or storing the outboardmotor while removed from a boat, keep theoutboard motor in the attitude shown.

TIP:Place a towel or something similar under theoutboard motor to protect it from damage.EMU30272

Storing outboard motorWhen storing your Yamaha outboard motorfor prolonged periods of time (2 months orlonger), several important procedures mustbe performed to prevent excessive damage.It is advisable to have your outboard motorserviced by an authorized Yamaha dealer pri-or to storage. However, you, the owner, with aminimum of tools, can perform the followingprocedures.


Maintenance

43

NOTICEECM01411

� Do not place the outboard motor on itsside before the cooling water hasdrained from it completely, otherwisewater may enter the cylinder through theexhaust port and cause engine trouble.

� Store the outboard motor in a dry, well-ventilated place, not in direct sunlight.

EMU28304

ProcedureEMU28315

Flushing in a water tank1. Wash the outboard motor body using

fresh water. NOTICE: Do not spray wa-ter into the air intake. [ECM01840] For furtherinformation, see page 44.

2. Place the fuel cock in the closed positionand disconnect the fuel line if equipped.Tighten the air vent screw, if equipped.

3. Remove the engine top cowling and si-lencer cover.

4. Install the outboard motor on the testtank.

5. Fill the tank with fresh water to above thelevel of the anti-cavitation plate. NOTICE:If the fresh water level is below the lev-el of the anti-cavitation plate, or if thewater supply is insufficient, engineseizure may occur. [ECM00291]

6. Cooling system flushing is essential toprevent the cooling system from cloggingup with salt, sand, or dirt. In addition, fog-ging/lubricating of the engine is mandato-ry to prevent excessive engine damagedue to rust. Perform the flushing and fog-ging at the same time. WARNING! Donot touch or remove electrical partswhen starting or during operation.Keep hands, hair, and clothes awayfrom the flywheel and other rotatingparts while the engine is running.[EWM00091]

7. Run the engine at a fast idle for a fewminutes in neutral position.

8. Just prior to turning off the engine, quicklyspray “Fogging Oil” alternately into eachcarburetor or the fogging hole of the si-lencer cover, if equipped. When properlydone, the engine will smoke excessivelyand almost stall.

9. If “Fogging Oil” is not available, run theengine at a fast idle until the fuel systemempties and the engine stops.

10. Remove the outboard motor from the testtank.

11. Install the silencer cover or fogging holecap, and the top cowling.

12. Drain the cooling water completely out ofthe motor. Clean the body thoroughly.

13. If “Fogging Oil” is not available, removethe spark plug(s). Pour a teaspoonful ofclean engine oil into each cylinder. Crankseveral times manually. Replace thespark plug(s).

14. Drain the fuel from both the built-in andportable fuel tanks, on equipped models.

TIP:Portable fuel tank equipped models: Store theportable fuel tank in a dry, well-ventilatedplace, not in direct sunlight.

1. Lowest water level2. Water surface

ZMU02704

2

1


Maintenance

44

EMU28402

Lubrication1. Install the spark plug(s) and torque to

proper specification. For information onspark plug installation, see page 48.

2. Change the gear oil. For instructions, seepage 51. Inspect the oil for the presenceof water that indicates a leaky seal. Sealreplacement should be performed by anauthorized Yamaha dealer prior to use.

3. Grease all grease fittings. For further de-tails, see page 47.

TIP:For long-term storage, fogging the enginewith oil is recommended. Contact yourYamaha dealer for information about foggingoil and procedures for your engine.EMU28451

Cleaning the outboard motorAfter use, wash the exterior of the outboardmotor with fresh water. Flush the cooling sys-tem with fresh water.

EMU28460

Checking painted surface of motorCheck the motor for scratches, nicks, or flak-ing paint. Areas with damaged paint are morelikely to corrode. If necessary, clean and paintthe areas. A touch-up paint is available fromyour Yamaha dealer.

EMU37074

Periodic maintenance

WARNINGEWM01981

These procedures require mechanicalskills, tools, and supplies. If you do nothave the proper skills, tools, or supplies toperform a maintenance procedure, have aYamaha dealer or other qualified mechan-ic do the work.The procedures involve disassemblingthe motor and exposing dangerous parts.To reduce the risk of injury from moving,hot, or electrical parts:� Turn off the engine and keep engine

shut-off cord (lanyard) with you whenyou perform maintenance unless other-wise specified.

� Allow the engine to cool before handlinghot parts or fluids.

� Always completely reassemble the mo-tor before operation.

EMU28511

Replacement partsIf replacement parts are necessary, use onlygenuine Yamaha parts or parts of equivalentdesign and quality. Any part of inferior qualitymay malfunction, and the resulting loss ofcontrol could endanger the operator and pas-sengers. Yamaha genuine parts and acces-sories are available from your Yamahadealer.EMU34151

Severe operating conditionsSevere operating conditions involve one ormore of the following types of operation on aregular basis:� Operating continuously at or near maxi-

mum engine speed (rpm) for many hours� Operating continuously at a low engine

speed (rpm) for many hours


Maintenance

45

� Operating without sufficient time for engineto warm up and cool down

� Frequent quick acceleration and decelera-tion

� Frequent shifting� Frequently starting and stopping the en-

gine(s)� Operation that fluctuates often between

light and heavy cargo loads

Outboard motors operating under any ofthese above conditions require more frequentmaintenance. Yamaha recommends that youdo this service twice as often as specified inthe maintenance chart. For example, if a par-ticular service should be done at 50 hours, doit instead at 25 hours. This will help preventmore rapid deterioration of engine compo-nents.

EMU34445

Maintenance chart 1TIP:� Refer to the sections in this chapter for explanations of each owner-specific action.� The maintenance cycle on these charts assume usage of 100 hours per year and regular

flushing of the cooling water passages. Maintenance frequency should be adjusted when op-erating the engine under adverse conditions such as extended trolling.

� Disassembly or repairs may be necessary depending on the outcome of maintenancechecks.

� Expendable or consumable parts and lubricants will lose their effectiveness over time andthrough normal usage regardless of the warranty period.

� When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine shouldbe flushed with clean water after each use.

The “ ” symbol indicates the check-ups which you may carry out yourself.The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

20 hours (3 months)

100 hours (1 year)

300 hours (3 years)

500 hours (5 years)

Anode(s) (external) Inspection or replace-ment as necessary

Cooling water leakage Inspection or replace-ment as necessary

Cowling lock lever Inspection

Engine starting condi-tion/noise Inspection

Engine idling speed/noise Inspection

Fuel filter (inside built-in fuel tank)

Inspection and clean-ing as necessary

Fuel filter (disposal type) Replacement

Fuel line(High pres-sure) Inspection


Maintenance

46

Fuel line(High pres-sure)

Inspection or replace-ment as necessary

Fuel line(Low pres-sure) Inspection

Fuel line(Low pres-sure)


Fuel pump Inspection or replace-ment as necessary

Fuel/engine oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Impeller/water pump housing


Impeller/water pump housing Replacement

Propeller/propeller nut/cotter pin


Shift link/shift cableInspection, adjustment or replacement as nec-essary

Spark plug(s) Inspection or replace-ment as necessary

Spark plug caps/spark plug wires


Water from the cooling water pilot hole Inspection

Throttle link/throttle ca-ble/throttle pick-up tim-ing

Inspection, adjustment or replacement as nec-essary

Thermostat Inspection or replace-ment as necessary

Water inlet Inspection

Main switch/stop switch/choke switch


Wire harness connec-tions/wire coupler con-nections


(Yamaha) Fuel tank Inspection and clean-ing as necessary

Fuel tank (built-in tank) Inspection and clean-ing as necessary

Item Actions

Initial Every

20 hours (3 months)

100 hours (1 year)

300 hours (3 years)

500 hours (5 years)


Maintenance

47

EMU34451

Maintenance chart 2

EMU28941

GreasingYamaha grease A (water resistant grease)Yamaha grease D (corrosion resistant grease; for propeller shaft)4AC, 5C

Item ActionsEvery

1000 hours

Exhaust guide/exhaust manifold



Maintenance

48

EMU28956

Cleaning and adjusting spark plugThe spark plug is an important engine compo-nent and is easy to inspect. The condition ofthe spark plug can indicate something aboutthe condition of the engine. For example, if thecenter electrode porcelain is very white, thiscould indicate an intake air leak or carburetionproblem in that cylinder. Do not attempt to di-agnose any problems yourself. Instead, takethe outboard motor to a Yamaha dealer. Youshould periodically remove and inspect thespark plug because heat and deposits willcause the spark plug to slowly break downand erode.1. Remove the spark plug caps from the

spark plugs.2. Remove the spark plug. If electrode ero-

sion becomes excessive, or if carbon andother deposits are excessive, you shouldreplace the spark plug with another of thecorrect type. WARNING! When remov-ing or installing a spark plug, be care-ful not to damage the insulator. Adamaged insulator could allow exter-nal sparks, which could lead to explo-sion or fire. [EWM00561]

3. Be sure to use the specified spark plug,otherwise the engine may not operateproperly. Before fitting the spark plug,measure the electrode gap with a wirethickness gauge; replace it if out of spec-ification.

4. When fitting the plug, wipe off any dirtfrom the threads, and then screw it in tothe correct torque.

TIP:If a torque-wrench is not available when youare fitting a spark plug, a good estimate of thecorrect torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the cor-rect torque as soon as possible with a torque-wrench.EMU28990

Checking fuel filterCheck the fuel filter periodically. The fuel filteris a one piece, disposable type. If foreign mat-ter is found in the filter, replace it. For replace-ment of the fuel filter, consult your Yamahadealer.

Standard spark plug:B7HSBR7HS

1. Spark plug gap2. Spark plug part number3. Spark plug I.D. mark (NGK)

Spark plug gap:0.6–0.7 mm (0.024–0.028 in)

Spark plug torque:25.0 Nm (2.55 kgf-m, 18.4 ft-lb)


Maintenance

49

EMU29043

Inspecting idling speed

WARNINGEWM00451

� Do not touch or remove electrical partswhen starting or during operation.

� Keep hands, hair, and clothes away fromthe flywheel and other rotating partswhile the engine is running.

NOTICEECM00490

This procedure must be performed whilethe outboard motor is in the water. A flush-ing attachment or test tank can be used.

If the boat is not equipped with a tachometerfor the outboard motor, use a diagnostic ta-chometer for this procedure. Results mayvary depending on whether testing is conduct-ed with the flushing attachment, in a test tank,or with the outboard motor in the water.1. Start the engine and allow it to warm up

fully in neutral until it is running smoothly.2. Once the engine has warmed up, verify

whether the idle speed is set to specifica-tion. For idle speed specifications, seepage 10. If you have difficulty verifyingthe idle speed, or the idle speed requiresadjustment, consult a Yamaha dealer orother qualified mechanic.

EMU29113

Checking wiring and connectors� Check that each connector is engaged se-

curely.� Check that each ground lead is properly se-

cured.EMU32112

Checking propeller

WARNINGEWM01881

You could be seriously injured if the en-gine accidentally starts when you are nearthe propeller. Before inspecting, remov-ing, or installing the propeller, place theshift control in neutral, turn the mainswitch to “ ” (off) and remove the key,and remove the clip from the engine shut-off switch. Turn off the battery cut-offswitch if your boat has one.

Do not use your hand to hold the propellerwhen loosening or tightening the propellernut. Put a wood block between the anti-cavi-tation plate and the propeller to prevent thepropeller from turning.

Checkpoints� Check each of the propeller blades for ero-

sion from cavitation or ventilation, or otherdamage.

� Check the propeller shaft for damage.� Check the splines for wear or damage.� Check for fish line tangled around the pro-

peller shaft.


Maintenance

50

� Check the propeller shaft oil seal for dam-age.

EMU30662

Removing propellerEMU29197

Spline models1. Straighten the cotter pin and pull it out us-

ing a pair of pliers.2. Remove the propeller nut, washer, and

spacer (if equipped). WARNING! Do notuse your hand to hold the propellerwhen loosening the propeller nut.[EWM01890]

3. Remove the propeller, washer (ifequipped), and thrust washer.

EMU30672

Installing propellerEMU30372

Spline models

NOTICEECM00500

Be sure to use a new cotter pin and bendthe ends over securely. Otherwise the pro-peller could come off during operation andbe lost.

1. Apply Yamaha marine grease or a corro-sion resistant grease to the propellershaft.

2. Install the spacer (if equipped), thrustwasher, and propeller on the propellershaft. NOTICE: Be sure to install thethrust washer before installing thepropeller, otherwise the lower caseand propeller boss could be damaged.[ECM01880]

3. Install the spacer (if equipped) and thewasher. Tighten the propeller nut untilthere is no forward-and-backward move-ment.

4. Align the propeller nut with the propellershaft hole. Insert a new cotter pin in thehole and bend the cotter pin ends.NOTICE: Do not reuse the cotter pininstalled. Otherwise the propeller cancome off during operation. [ECM01890]

1. Cotter pin2. Propeller nut3. Washer4. Propeller5. Thrust washer


Maintenance

51

TIP:If the propeller nut does not align with the pro-peller shaft hole after tightening it, loosen thenut until it aligns with the hole.EMU29287

Changing gear oil

WARNINGEWM00800

� Be sure the outboard motor is securelyfastened to the transom or a stablestand. You could be severely injured ifthe outboard motor falls on you.

� Never get under the lower unit while it istilted, even when the tilt support lever orknob is locked. Severe injury could oc-cur if the outboard motor accidentallyfalls.

1. Tilt the outboard motor so that the gear oildrain screw is at the lowest point possi-ble.

2. Place a suitable container under the gearcase.

3. Remove the gear oil drain screw and gas-ket. NOTICE: If there is an excessivequantity of metal particles on the mag-netic gear oil drain screw, this can in-dicate lower unit problem. Consultyour Yamaha dealer. [ECM01900]

TIP:� If a magnetic gear oil drain screw is

equipped, remove all metal particles fromthe screw before installing it.

� Always use new gaskets. Do not reuse theremoved gaskets.

4. Remove the oil level plug and gasket toallow the oil to drain completely.NOTICE: Inspect the used oil after ithas been drained. If the oil is milky,water is getting into the gear casewhich can cause gear damage. Con-sult a Yamaha dealer for repair of thelower unit seals. [ECM00711]

TIP:For disposal of used oil, consult your Yamahadealer.5. Put the outboard motor in a vertical posi-

tion. Using a flexible or pressurized fillingdevice, inject the gear oil into the gear oildrain screw hole.

6. Put a new gasket on the oil level plug.When the oil begins to flow out of the oillevel plug hole, insert and tighten the oillevel plug.

1. Gear oil drain screw2. Oil level plug

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:0.100 L (0.106 US qt, 0.088 Imp.qt)


Maintenance

52

7. Put a new gasket on the gear oil drainscrew. Insert and tighten the gear oildrain screw.

EMU29302

Cleaning fuel tank

WARNINGEWM00920

Gasoline is highly flammable, and its va-pors are flammable and explosive.� If you have any question about properly

doing this procedure, consult yourYamaha dealer.

� Keep away from sparks, cigarettes,flames, or other sources of ignitionwhen cleaning the fuel tank.

� Remove the fuel tank from the boat be-fore cleaning it. Work only outdoors inan area with good ventilation.

� Wipe up any spilled fuel immediately.� Reassemble the fuel tank carefully. Im-

proper assembly can result in a fuelleak, which could result in a fire or ex-plosion hazard.

� Dispose of old gasoline according to lo-cal regulations.

1. Empty the fuel tank into an approved con-tainer.

2. Pour a small amount of suitable solventinto the tank. Install the cap and shakethe tank. Drain the solvent completely.

3. Remove the screws holding the fuel jointassembly. Pull the assembly out of thetank.

4. Clean the filter (located on the end of thesuction 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 tightenthe screws firmly.

Tightening torque:9.0 Nm (0.92 kgf-m, 6.6 ft-lb)

Tightening torque:9.0 Nm (0.92 kgf-m, 6.6 ft-lb)

ZMU03231


Maintenance

53

EMU29312

Inspecting and replacing anode(s)Yamaha outboard motors are protected fromcorrosion by sacrificial anodes. Inspect theexternal anodes periodically. Remove scalesfrom the surfaces of the anodes. Consult aYamaha dealer for replacement of externalanodes.

NOTICEECM00720

Do not paint anodes, as this would renderthem ineffective.

TIP:Inspect ground leads attached to external an-odes on equipped models. Consult a Yamahadealer for inspection and replacement of inter-nal anodes attached to the power unit.


Trouble Recovery

54

EMU29427

TroubleshootingA problem in the fuel, compression, or ignitionsystems can cause poor starting, loss of pow-er, or other problems. This section describesbasic checks and possible remedies, and cov-ers all Yamaha outboard motors. Thereforesome items may not apply to your model.If your outboard motor requires repair, bring itto your Yamaha dealer.If the engine trouble-alert indicator is flashing,consult your Yamaha dealer.

Starter will not operate.Q. Is battery capacity weak or low?A. Check battery condition. Use battery of rec-ommended capacity.

Q. Are battery connections loose or corrod-ed?A. Tighten battery cables and clean batteryterminals.

Q. Is fuse for electric start relay or electric cir-cuit blown?A. Check for cause of electric overload andrepair. Replace fuse with one of correct am-perage.

Q. Are starter components faulty?A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear?A. Shift to neutral.

Engine will not start (starter operates).Q. Is fuel tank empty?A. Fill tank with clean, fresh fuel.

Q. Is fuel contaminated or stale?A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged?A. Clean or replace filter.

Q. Is starting procedure incorrect?A. See page 32.

Q. Has fuel pump malfunctioned?A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replace withrecommended type.

Q. Are spark plug cap(s) fitted incorrectly?A. Check and re-fit cap(s).

Q. Is ignition wiring damaged or poorly con-nected?A. Check wires for wear or breaks. Tighten allloose connections. Replace worn or brokenwires.

Q. Are ignition parts faulty?A. Have serviced by a Yamaha dealer.

Q. Is engine shut-off cord (lanyard) not at-tached?A. Attach cord.

Q. Are engine inner parts damaged?A. Have serviced by a Yamaha dealer.

Engine idles irregularly or stalls.Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replace withrecommended type.

Q. Is fuel system obstructed?


Trouble Recovery

55

A. Check for pinched or kinked fuel line or oth-er obstructions in fuel system.



Q. Have ignition parts failed?A. Have serviced by a Yamaha dealer.

Q. Has alert system activated?A. Find and correct cause of alert.

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


Q. Is specified engine oil not being used?A. Check and replace oil as specified.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Are carburetor adjustments incorrect?A. Have serviced by a Yamaha dealer.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw on fuel tank closed?A. Open air vent screw.

Q. Is choke knob pulled out?

A. Return to home position.

Q. Is motor angle too high?A. Return to normal operating position.

Q. Is carburetor clogged?A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect?A. Connect correctly.

Q. Is throttle valve adjustment incorrect?A. Have serviced by a Yamaha dealer.

Q. Is battery cable disconnected?A. Connect securely.

Alert buzzer sounds or indicator lights.Q. Is cooling system clogged?A. Check water intake for restriction.

Q. Is engine oil level low?A. Fill oil tank with specified engine oil.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is engine oil contaminated or deteriorated?A. Replace oil with fresh, specified type.

Q. Is oil filter clogged?A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunc-tioned?A. Have serviced by a Yamaha dealer.


Trouble Recovery

56

Q. Is load on boat improperly distributed?A. Distribute load to place boat on an evenplane.

Q. Is water pump or thermostat faulty?A. Have serviced by a Yamaha dealer.

Q. Is there excess water in fuel filter cup?A. Drain filter cup.

Engine power loss.Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller pitch or diameter incorrect?A. Install correct propeller to operate outboardat its recommended speed (r/min) range.

Q. Is trim angle incorrect?A. Adjust trim angle to achieve most efficientoperation.

Q. Is motor mounted at incorrect height ontransom?A. Have motor adjusted to proper transomheight.

Q. Has alert system activated?A. Find and correct cause of alert.

Q. Is boat bottom fouled with marine growth?A. Clean boat bottom.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replace withrecommended type.

Q. Are weeds or other foreign matter tangledon gear housing?

A. Remove foreign matter and clean lowerunit.

Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line or oth-er obstructions in fuel system.



Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


Q. Have electrical parts failed?A. Have serviced by a Yamaha dealer.

Q. Is specified fuel not being used?A. Replace fuel with specified type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw closed?A. Open the air vent screw.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect?


Trouble Recovery

57

A. Connect correctly.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is high pressure fuel pump drive belt bro-ken?A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shiftlever position?A. Have serviced by a Yamaha dealer.

Engine vibrates excessively.Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged?A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangledon propeller?A. Remove and clean propeller.

Q. Is motor mounting bolt loose?A. Tighten bolt.

Q. Is steering pivot loose or damaged?A. Tighten or have serviced by a Yamahadealer.EMU29433

Temporary action in emergencyEMU29440

Impact damage

WARNINGEWM00870

The outboard motor can be seriously dam-aged by a collision while operating ortrailering. Damage could make the out-board motor unsafe to operate.

If the outboard motor hits an object in the wa-ter, follow the procedure below.

1. Stop the engine immediately.2. Inspect the control system and all compo-

nents for damage. Also inspect the boatfor damage.

3. Whether damage is found or not, returnto the nearest harbor slowly and careful-ly.

4. Have a Yamaha dealer inspect the out-board motor before operating it again.

EMU29533

Starter will not operateIf 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.

WARNINGEWM01022

� Use this procedure only in an emergen-cy to return to the nearest port for re-pairs.

� When the emergency starter rope isused to start the engine, the start-in-gear protection device does not operate.Make sure the remote control lever is inneutral. Otherwise the boat could unex-pectedly start to move, which could re-sult in an accident.

� Attach the engine shut-off cord to a se-cure place on your clothing, or your armor leg while operating the boat.


Trouble Recovery

58

� Do not attach the cord to clothing thatcould tear loose. Do not route the cordwhere it could become entangled, pre-venting it from functioning.

� Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power, theboat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

� Make sure no one is standing behindyou when pulling the starter rope. Itcould whip behind you and injure some-one.

� An unguarded, rotating flywheel is verydangerous. Keep loose clothing andother objects away when starting the en-gine. Use the emergency starter ropeonly as instructed. Do not touch the fly-wheel or other moving parts when theengine is running. Do not install thestarter mechanism or top cowling afterthe engine is running.

� Do not touch the ignition coil, spark plugwire, spark plug cap, or other electricalcomponents when starting or operatingthe motor. You could get an electricalshock.

EMU29562

Emergency starting engine1. Remove the top cowling.2. Remove the start-in-gear protection ca-

ble from the starter, if equipped.3. Remove the starter/flywheel cover after

removing the bolt(s).

4. Prepare the engine for starting. For fur-ther information, see page 32. Be surethe engine is in neutral and that the clip isattached to the engine shut-off switch.The main switch must be “ ” (on), ifequipped.

5. If equipped the choke knob, pull out itwhen the engine is cold. After the enginestarts, gradually return the choke knob toits home position as the engine warmsup.

6. Insert the knotted end of the emergencystarter rope into the notch in the flywheelrotor and wind the rope several turnsaround the flywheel clockwise.

7. Give a strong pull straight out to crankand start the engine. Repeat if neces-sary.


Trouble Recovery

59

EMU33501

Treatment of submerged motorIf the outboard motor is submerged, immedi-ately take it to a Yamaha dealer. Otherwisesome corrosion may begin almost immediate-ly. NOTICE: Do not attempt to run the out-board motor until it has been completelyinspected. [ECM00401]


YAMAHA MOTOR CO., LTD.

Printed on recycled paperPrinted in JapanMarch 2009–0.3 × 1 CR


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