Yamaha 15 fmhs инструкция по эксплуатации

9.9 15

OWNERS MANUAL

LIT-18626-08-34 63V-28199-1E

U.S.A.Edition Read this manual carefully before operating this outboard motor.

DIC183

ZMU01690

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

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Important manual information EMU31283

To the owner Thank you for choosing a Yamaha outboard motor. This Owners Manual contains infor- mation needed for proper operation, mainte- nance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owners Manual particularly important information is distinguished in the following ways.

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

WARNING EWM00781

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

NOTICE ECM00701

A NOTICE indicates special precautions that must be taken to avoid damage to the outboard motor or other property.

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

Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between

your machine and this manual. If there is any question concerning this manual, please con- sult your Yamaha dealer.

TIP: The 9.9MH, 15MH and the standard accesso- ries are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model. EMU25111

9.9, 15 OWNERS MANUAL

2009 by Yamaha Motor Corporation, USA

1st edition, February 2009 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA

is expressly prohibited. Printed in Japan

P/N LIT-18626-08-34

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Table of contents

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

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

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

Boating organizations…………………. 4 Basic boating rules

(Rules of the road) ………………….. 4 Steering and sailing rules and sound

signals……………………………………… 4 Rules when encountering vessels…… 5 Other special situations …………………. 6

General information ……………………..8 Identification numbers record………. 8

Outboard motor serial number ……….. 8 Read manuals and labels……………. 9

Warning labels……………………………… 9 Specifications and requirements……………………………… 12

Specifications ………………………….. 12 Installation requirements …………… 13

Boat horsepower rating ……………….. 13 Mounting motor ………………………….. 13

Battery requirements………………… 13 Without a rectifier or Rectifier

Regulator ……………………………….. 13 Propeller selection …………………… 13 Start-in-gear protection …………….. 14 Engine oil requirements ……………. 14 Fuel requirements ……………………. 14

Gasoline ……………………………………. 14 Ring Free Fuel Additive……………….. 15

Muddy or acidic water ………………. 15 Anti-fouling paint ……………………… 15 Motor disposal requirements……… 15 Emergency equipment ……………… 15 Emission control information……… 16

North American models ……………….. 16 Components ……………………………… 17

Components diagram……………….. 17 Fuel tank……………………………………. 17 Fuel joint ……………………………………. 18 Fuel gauge ………………………………… 18 Fuel tank cap……………………………… 18 Air vent screw…………………………….. 18 Tiller handle……………………………….. 18 Gear shift lever …………………………… 18 Throttle grip ……………………………….. 18 Throttle indicator…………………………. 19 Throttle friction adjuster ……………….. 19 Engine shut-off cord (lanyard)

and clip…………………………………… 19 Engine stop button ……………………… 20 Choke knob ……………………………….. 20 Manual starter handle………………….. 20 Steering friction adjuster………………. 20 Trim rod (tilt pin) …………………………. 21 Tilt lock mechanism…………………….. 21 Tilt support bar …………………………… 21 Cowling lock lever(s) (turn type) ……. 22 Carrying handle ………………………….. 22

Installation ………………………………… 23 Installation………………………………. 23

Mounting the outboard motor ……….. 23 Clamping the outboard motor ……….. 24

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Table of contents

Operation ………………………………….. 26 First-time operation ………………….. 26

Breaking in engine………………………. 26 Getting to know your boat ……………. 26

Checks before starting engine …… 26 Fuel level …………………………………… 26 Remove cowling …………………………. 27 Fuel system……………………………….. 27 Controls …………………………………….. 27 Engine shut-off cord (lanyard) ………. 27 Oil …………………………………………….. 28 Engine ………………………………………. 28 Install cowling …………………………….. 28

Filling fuel and engine oil…………… 28 Filling fuel for portable tank ………….. 28 Gasoline and oil mixing (100:1)…….. 29

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

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

Warming up engine ………………….. 33 Choke start models …………………….. 33

Checks after engine warm-up ……. 33 Shifting ……………………………………… 33 Stop switches …………………………….. 34

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

Procedure………………………………….. 35 Trimming outboard motor………….. 35

Adjusting trim angle for manual tilt models …………………………………… 36

Adjusting boat trim………………………. 36 Tilting up and down ………………….. 37

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

Procedure for tilting down (manual tilt models)………………….. 38

Shallow water………………………….. 39 Cruising in shallow water

(manual tilt models)………………….. 39

Cruising in other conditions……….. 40 Maintenance ……………………………… 41

Transporting and storing outboard motor…………………………………… 41 Clamp screw mounting models …….. 41 Storing outboard motor………………… 41 Procedure………………………………….. 42 Lubrication…………………………………. 43 Cleaning and anticorrosion

measures ……………………………….. 43 Cleaning the outboard motor ………… 43 Checking painted surface of motor… 43

Periodic maintenance ………………. 43 Replacement parts ……………………… 44 Maintenance interval guidelines ……. 44 Maintenance chart 1……………………. 45 Maintenance chart 2……………………. 46 Greasing……………………………………. 47 Cleaning and adjusting spark plug … 48 Checking fuel filter ………………………. 48 Inspecting idling speed………………… 48 Checking wiring and connectors …… 49 Checking propeller ……………………… 49 Removing propeller …………………….. 50 Installing propeller ………………………. 50 Changing gear oil ……………………….. 51 Cleaning fuel tank……………………….. 52 Inspecting and replacing anode(s) … 53

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

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

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Table of contents

Treatment of submerged motor….. 59 Consumer information……………….. 60

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY…………………………. 60

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA …………. 63

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1

Safety information EMU33622

Outboard motor safety Observe these precautions at all times. EMU36501

Propeller People can be injured or killed if they come in contact with the propeller. The propeller can keep moving even when the motor is in neu- tral, and sharp edges of the propeller can cut even 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 parts Hands, feet, hair, jewelry, clothing, PFD straps, 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 cowling with the engine running. Only operate the engine with the cowling re- moved according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, PFD straps, etc. away from any ex- posed moving parts. EMU33640

Hot parts During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the en- gine has cooled. EMU33650

Electric shock Do not touch any electrical parts while starting or operating the engine. They can cause shock 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 or leaves 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 a secure place on your clothing or your arm or leg while operating. Do not remove it to leave the 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 be accidentally pulled out. If the cord is pulled during operation, the engine will shut off and you will lose most steering control. The boat could slow rapidly, throwing people and ob- jects forward. EMU33810

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

Gasoline exposure and spills Take care not to spill gasoline. If gasoline spills, 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. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gaso- line vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth. EMU33900

Carbon monoxide This product emits exhaust gases which con- tain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking ex- haust outlets.

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Safety information

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EMU33780

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

Alcohol and drugs Never operate after drinking alcohol or taking drugs. Intoxication is one of the most common factors contributing to boating fatalities. EMU33720

Personal flotation devices Have an approved personal flotation device (PFD) on board for every occupant. Yamaha recommends that you must wear a PFD whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating condi- tions. EMU33731

People in the water Always 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 into neutral and stop the engine. Stay away from swimming areas. Swimmers can be hard to see. The propeller can keep moving even when the motor is in neutral. Stop the engine when a person is in the water near you. EMU33751

Passengers Consult your boat manufacturers instructions for details about appropriate passenger loca- tions in your boat and be sure all passengers are 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 any unusual maneuver. Always avoid jumping waves or wakes. EMU33760

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

Avoid collisions Scan constantly for people, objects, and other boats. Be alert for conditions that limit your visibility or block your vision of others.

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

waterskiers.

ZMU06025

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Safety information

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

Avoid areas with submerged objects or shallow water.

Ride within your limits and avoid aggressive maneuvers 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, and stopping the engine or reducing throttle can reduce the ability to steer. If you are not sure that you can stop in time before hitting an obstacle, apply throttle and turn in anoth- er direction.

EMU33790

Weather Stay informed about the weather. Check weather forecasts before boating. Avoid boat- ing in hazardous weather. EMU33800

Accident reporting Boat operators are required by law to file a Boating Accident Report with their state boat- ing law enforcement agency if their boat is in- volved in any of the following accidents: 1. There is loss of life or probable loss of life. 2. There is personal injury that requires

medical attention beyond first aid. 3. There is property damage to boats or oth-

er property over a certain amount. 4. There is complete loss of a boat. Contact local law enforcement personnel if a report is necessary. EMU33870

Boat education and training Operators should take a boating safety course. This may be required in your state. Many of the organizations listed in the next section can provide information about cours- es in your area.

You may also want to consider an Internet- based program for basic boater education. The Online Boating Safety Course provided by the BoatU.S. Foundation, is approved by the National Association of State Boating Law Administrators (NASBLA) and recognized by the United States Coast Guard. Most, but not all, states accept this course to meet their minimum requirements. While it cannot re- place an in-depth course such as one offered by the U.S. Coast Guard, U.S. Power Squad- ron, or other organization, this online course does provide a general overview of the basics in boating safety, requirements, navigation, and operation. Upon successful completion of the course, the user can download a certifi- cate of completion immediately or, for a small charge, request one by mail. To take this free course, go to boatus.org. EMU33880

Passenger training Make sure at least one other passenger is trained to operate the boat in the event of an emergency. EMU33890

Boating safety publications Be informed about boating safety. Additional publications and information can be obtained from many boating organizations. EMU33590

Laws and regulations Know the marine laws and regulations where you will be boating- and obey them. Several sets of rules prevail according to geographic location, but all are basically the same as the International Rules of the Road. The rules presented in the following section are con- densed- and have been provided for your convenience only.

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Safety information

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Contact the U.S. Coast Guard, the National Association of State Boating Law Administra- tors, or your local Power Squadron for a com- plete set of rules governing the waters in which you will be using your boat. EMU33681

Boating organizations The following organizations provide boating safety training and information about boating safety and laws.

United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Af- fairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647 www.uscgboating.org

United States Power Squadrons 1-888-FOR-USPS (1-888-367-8777) www.usps.org

Boat Owners Association of The United States 1-800-336-BOAT (1-800-336-2628) www.boatus.com

National Association of State Boating Law Administrators (NASBLA) 1500 Leestown Road, Suite 330 Lexington, KY 40511 859-225-9497 www.nasbla.org

National Marine Manufacturers Associa- tion (NMMA) 200 East Randolph Drive Suite 5100 Chicago, IL 60601

www.nmma.org

Marine Retailers Association of America 155 N. Michigan Ave. Chicago, IL 60304 www.mraa.com

EMU33690

Basic boating rules (Rules of the road)

Just as there are rules that apply when you are driving on streets and highways, there are waterway rules that apply when you are driv- ing your boat. These rules are used interna- tionally. (For USA: and are also enforced by the United States Coast Guard and local agencies.) You should be aware of these rules, and follow them whenever you encoun- ter another vessel on the water. EMU33700

Steering and sailing rules and sound signals Whenever two vessels on the water meet one another, one vessel has the right-of-way; it is called the stand-on vessel. The vessel that does not have the right-of-way is called the give-way or burdenedvessel. These rules determine which vessel has the right-of-way, and what each vessel should do.

Stand-on vessel The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision. When you main- tain your direction and speed, the other vessel will be able to determine how best to avoid you.

Give-way vessel The vessel that does not have the right-of- way has the duty to take positive and timely action to stay out of the way of the Stand-On

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vessel. Normally, you should not cross in front of the vessel with the right-of-way. You should slow down or change directions briefly and pass behind the other vessel. You should al- ways move in such a way that the operator of the other vessel can see what you are doing. The general prudential rule This rule is called Rule 2 in the International Rules and says, In obeying and construing these rules due regard shall be had to all dangers of naviga- tion and collision, and to any special circum- stances, which may render a departure from the above rules necessary in order to avoid immediate danger. In other words, follow the standard rules ex- cept when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become Give-Way ves- sels. EMU25521

Rules when encountering vessels There are three main situations that you may encounter with other vessels which could lead to a collision unless the Steering Rules are fol- lowed: Meeting: (you are approaching another ves- sel head-on) Crossing: (you are traveling across the other vessels path) Overtaking: (you are passing or being passed by another vessel) In the following illustration, your boat is in the center. You should give the right-of-way to any vessels shown in white area (you are the Give-Way vessel). Any vessels in the shaded area must yield to you (they are the Give-Way vessels). Both you and the meeting vessel must alter course to avoid each other.

Meeting If you are meeting another power vessel head on, and are close enough to run the risk of col- lision, neither of you has the right-of-way Both of you should alter course to avoid an acci- dent. You should keep the other vessel on your port (left) side. This rule doesnt apply if both of you will clear one another if you con- tinue on your set course and speed.

Crossing When two power driven vessels are crossing each others path close enough to run the risk of collision, the vessel which has the other on the starboard (right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; you are the Give-Way vessel. If the other vessel is on your port (left) side, remember that you should maintain course and direction, provid- ed the other vessel gives you the right-of-way as it should.

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Overtaking If you are passing another vessel, you are the Give-Way vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you. EMU25531

Other special situations There are three other rules you should be aware of when driving your boat around other vessels. Narrow channels and bends When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a power- driven vessel is preparing to go around a bend that may obstruct the view of other water vessels, the operator should sound a pro- longed blast on the whistle (4 to 6 seconds). If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still pro- ceed around the bend with caution. If you nav- igate such waters with your boat, you will need to carry a portable air horn, available from local marine supply stores.

Fishing vessel right-of-way All vessels that are fishing with nets, lines or trawls are considered to be fishing vessels under the International Rules. Vessels with trolling lines are not considered fishing ves- sels. Fishing vessels have the right-of-way re- gardless of position. Fishing vessels cannot, however, impede the passage of other ves- sels in narrow channels. Sailing vessel right-of-way Sailing vessels should normally be given the right-of-way. The exceptions to this are: 1. When the sailing vessel is overtaking the

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

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

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

Reading buoys and other markers The waters of the United States are marked for safe navigation by the lateral system of buoyage. Simply put, buoys and markers have an arrangement of shapes, colors, num- bers and lights to show which side of the buoy a boater should pass on when navigating in a particular direction. The markings on these buoys are oriented from the perspective of be- ing entered from seaward (the boater is going towards the port). This means that red buoys are passed on the starboard (right) side when proceeding from open water into port, and black buoys are to port (left) side. When navi- gating out of port, your position with respect to the buoys should be reversed; red buoys should be to port and black buoys to star- board.

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Many bodies of water used by boaters are en- tirely within the boundaries of a particular state. The Uniform State Waterway Marking System has been devised for these waters. This system uses buoys and signs with dis- tinctive shapes and colors to show regulatory or advisory information. These markers are

white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geograph- ic location. Always consult local boating au- thorities before driving your boat in unfamiliar waters.

ZMU01708

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General information

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EMU25171

Identification numbers record EMU25183

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

1. Outboard motor serial number location

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General information

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EMU33520

Read manuals and labels Before 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 labels If these labels are damaged or missing, contact your Yamaha dealer for replacements. 9.9, 15

ZMU06037

1

2

3

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General information

10

EMU33843

Symbols The following symbols mean as follows.

Notice/Warning

Read Owners Manual

1 2

3

ZMU05697

ZMU05696

ZMU05664

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General information

11

Hazard caused by continuous rotation

Electrical hazard

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

Engine start/ Engine cranking

ZMU05665

ZMU05666

ZMU05667

ZMU05668

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Specifications and requirements

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EMU31480

Specifications TIP: (AL) stated in the specification data below represents the numerical value for the alumi- num propeller installed. Likewise, (SUS) represents the value for stainless steel propeller installed and (PL) for plastic propeller installed. EMU2821E

Dimension: Overall length:

873 mm (34.4 in) Overall width:

332 mm (13.1 in) Overall height S:

1040 mm (40.9 in) Transom height S:

440 mm (17.3 in) Weight (AL) S:

36.0 kg (79 lb) Performance:

Full throttle operating range: 45005500 r/min

Maximum output: 15MH 11.0 kW@5000 r/min (15 HP@5000 r/min) 9.9MH 7.3 kW@5000 r/min (9.9 HP@5000 r/min)

Idling speed (in neutral): 750 50 r/min

Engine: Type:

2-stroke L Displacement:

246.0 cm Bore stroke:

56.0 50.0 mm (2.20 1.97 in) Ignition system:

CDI

Spark plug (NGK): B7HS-10

Spark plug gap: 0.91.0 mm (0.0350.039 in)

Control system: Tiller

Starting system: Manual

Starting carburetion system: Choke valve

Alternator output: 80 W

Drive unit: Gear positions:

Forward-neutral-reverse Gear ratio:

2.08 (27/13) Trim and tilt system:

Manual tilt Propeller mark:

J Fuel and oil:

Recommended fuel: Regular unleaded gasoline

Min. pump octane: 86

Fuel tank capacity: 24.0 L (6.34, US gal, 5.28 Imp.gal)

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

Fuel:oil ratio: Regular gasoline:

100 :1 Lubrication:

Pre-mixed fuel and oil Recommended gear oil:

Hypoid gear oil SAE#90 Gear oil quantity:

0.250 L (0.264 US qt, 0.220 Imp.qt)

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Tightening torque for engine: Spark plug:

25.0 Nm (2.55 kgf-m, 18.4 ft-lb) Propeller nut:

17.0 Nm (1.73 kgf-m, 12.5 ft-lb) EMU33554

Installation requirements EMU33563

Boat horsepower rating

WARNING EWM01560

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 boats capacity plate or contact the manufacturer. EMU33571

Mounting motor

WARNING EWM01570

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

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

Your dealer or other person experienced in proper rigging should mount the motor using correct equipment and complete rigging in- structions. For further information, see page 23.

EMU25694

Battery requirements EMU25730

Without a rectifier or Rectifier Regula- tor

NOTICE ECM01090

A battery cannot be connected to models that do not have a rectifier or Rectifier Regulator.

If you wish to use a battery with the models without a rectifier or Rectifier Regulator, install an optional Rectifier Regulator. Using a maintenance-free battery with the above models can shorten the life of the bat- tery significantly. Install an optional Rectifier Regulator or use accessories rated to withstand 18 volts or higher with the above models. Consult your Yamaha dealer for details on installing an op- tional Rectifier Regulator. EMU34192

Propeller selection Next to selecting an outboard, choosing the right propeller is one of the most important purchasing decisions a boater can make. The type, size, and design of your propeller have a direct impact on acceleration, top speed, fuel economy, and even engine life. Yamaha designs and manufactures propellers for ev- ery Yamaha outboard motor and every appli- cation. Your outboard motor came with a Yamaha propeller chosen to perform well over a range of applications, but there may be uses where a different propeller would be more appropri- ate. Your Yamaha dealer can help you select the right propeller for your boating needs. Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat-

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Specifications and requirements

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load. Generally, chose a larger pitch propeller for a smaller operating load and a smaller pitch propeller for a heavier load. If you carry loads that vary widely, chose the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle setting to stay within the recommended engine speed range when carrying lighter loads. For instructions on propeller removal and in- stallation, see page 49.

EMU25770

Start-in-gear protection Yamaha outboard motors or Yamaha-ap- proved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is in neutral. Always select neutral before starting the engine. EMU25651

Engine oil requirements

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

EMU36360

Fuel requirements EMU36781

Gasoline Use a good quality gasoline that meets the minimum octane rating. If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. Yamaha recomends that you use alcohol-free (see Gasohol) gas- oline whenever possible.

NOTICE ECM01981

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

Avoid getting water and contaminants in the fuel tank. Contaminated fuel can cause poor performance or engine dam- age. Use only fresh gasoline that has been stored in clean containers.

Gasohol There are two types of gasohol: gasohol con- taining ethanol (E10) and that containing methanol. Ethanol can be used if the ethanol content does not exceed 10% and the fuel meets the minimum octane ratings. E85 is a fuel containing 85% ethanol and must not be used in your outboard motor. All ethanol blends containing more than 10% ethanol can cause fuel system damage or cause engine starting and running problems. Yamaha does not recommend gasohol containing methanol because it can cause fuel system damage or engine performance problems. It is recommended that you install a water- separating marine fuel filter assembly (10 mi- cron minimum) between your boats fuel tank and outboard motor when using ethanol. Eth-

1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark)

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

ZMU04606

-x 1 2 3

Recommended gasoline: Regular unleaded gasoline with a mini- mum Octane rating of 86 (Pump Oc- tane Number) = (R+M)/2

U63V1EE0.book Page 14 Tuesday, March 3, 2009 10:50 AM

Specifications and requirements

15

anol is known to allow moisture to be ab- sorbed into boat fuel tanks and systems. Moisture in the fuel can cause corrosion of metallic fuel system components, starting and running complaints and require additional fuel system maintenance. EMU27270

Ring Free Fuel Additive Gasoline is a precise blend of many different substances, each chosen to give certain char- acteristics. Gasoline blends have been changing in recent years in response to con- cerns about pollution and resulting emissions regulations. One of the most obvious changes has been the elimination of lead from most fu- els. As gasoline has changed, the amount of addi- tives such as aromatics and oxygenates has increased. These additives are important for the engines in passenger cars, but they can have detrimental effects in marine engines, because of increased deposits in the combus- tion chamber. When enough deposits collect, piston rings begin sticking. Performance drops and engine wear increases dramatical- ly. While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free Fuel Additive has repeatedly proven its ability to clean com- bustion deposits from inside the engine, nota- bly the critical piston-ring-land area, and fuel system components. Follow product labeling for use instructions. EMU36880

Muddy or acidic water Yamaha strongly recommends that you have your 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 not be required. EMU36330

Anti-fouling paint A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bot- tom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.

EMU36341

Motor disposal requirements Never illegally discard (dump) the motor. Yamaha recommends consulting the dealer about discarding the motor. EMU36351

Emergency equipment Keep the following items onboard in case there is trouble with the motor. A tool kit with assorted screwdrivers, pliers,

wrenches (including metric sizes), and electrical 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.

U63V1EE0.book Page 15 Tuesday, March 3, 2009 10:50 AM

Specifications and requirements

16

EMU25221

Emission control information EMU25230

North American models This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for ma- rine SI engines. See the label affixed to your engine for details. EMU30390

Approval label of emission control certifi- cate This label is attached to the bottom cowling. Existing Technology; N/A

EMU25262

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

1. Approval label location

ZMU06058

1

1. Manufactured date label location

Manufactured:

ZMU04346

U63V1EE0.book Page 16 Tuesday, March 3, 2009 10:50 AM

Components

17

EMU2579M

Components diagram TIP: * May not be exactly as shown; also may not be included as standard equipment on all models. 9.9, 15

EMU25802

Fuel tank If your model was equipped with a portable fuel tank, its function is as follows.

WARNING EWM00020

The fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Com- mercial users should conform to relevant licensing or approval authority regula- tions.

1. Top cowling 2. Cowling lock lever 3. Cooling water pilot hole 4. Tilt lock lever 5. Manual starter handle 6. Gear shift lever 7. Engine stop button/Engine shut-off switch 8. Tiller handle 9. Throttle friction adjuster 10.Clamp screw 11.Carrying handle 12.Choke knob 13.Restraint cable attachment 14.Clamp bracket 15.Trim rod 16.Anti-cavitation plate

17.Cooling water inlet 18.Propeller* 19.Fuel hose

U63V1EE0.book Page 17 Tuesday, March 3, 2009 10:50 AM

Components

18

EMU25830

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

Fuel gauge This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the ap- proximate amount of fuel remaining in the tank. EMU25850

Fuel tank cap This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise. EMU25860

Air vent screw This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise. EMU25911

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

EMU25922

Gear shift lever Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead. Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern.

EMU25941

Throttle grip The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed.

1. Fuel joint 2. Fuel gauge 3. Fuel tank cap 4. Air vent screw

ZMU02284

3

1

4

2

1. Forward 2. Neutral 3. Reverse

U63V1EE0.book Page 18 Tuesday, March 3, 2009 10:50 AM

Components

19

EMU25961

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

EMU25975

Throttle friction adjuster A friction device provides adjustable resis- tance to movement of the throttle grip or the remote control lever, and can be set accord- ing to operator preference. To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. WARNING! Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident. [EWM00032]

When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting. EMU25993

Engine shut-off cord (lanyard) and clip The clip must be attached to the engine shut- off switch for the engine to run. The cord should be attached to a secure place on the operators clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power. WARNING! At- tach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. Avoid acci- dentally pulling the cord during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and ob- jects in the boat to be thrown forward. [EWM00122]

1. Throttle indicator

U63V1EE0.book Page 19 Tuesday, March 3, 2009 10:50 AM

Components

20

EMU26001

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

EMU26030

Choke knob To supply the engine with the rich fuel mixture required to start, pull out this knob. The choke knob has the 4 operating positions shown in the following illustration.

EMU26070

Manual starter handle To start the engine, first gently pull the handle out until resistance is felt. From that position, then pull the handle straight out quickly to crank the engine.

EMU26122

Steering friction adjuster A friction device provides adjustable resis- tance to the steering mechanism, and can be set according to operator preference. An ad- justing screw or bolt is located on the swivel bracket.

1. Cord 2. Clip 3. Engine shut-off switch

1. Use to start a hot engine 2. Use to warm up a cold engine or restart a

warm engine 3. Use to warm up a cold engine or restart a

warm engine 4. Use to start a cold engine

U63V1EE0.book Page 20 Tuesday, March 3, 2009 10:50 AM

Components

21

To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.

WARNING EWM00040

Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident.

EMU26261

Trim rod (tilt pin) The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.

EMU30440

Tilt lock mechanism The tilt lock mechanism is used to prevent the outboard motor from lifting out of the water when in reverse gear.

To tilt the outboard motor up, set the tilt lock lever to the (up) position. To tilt the out- board motor down, set the tilt lock lever to the (down) position. EMU26332

Tilt support bar The tilt support bar keeps the outboard motor in the tilted up position.

NOTICE ECM01660

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

1. Tilt lock lever

U63V1EE0.book Page 21 Tuesday, March 3, 2009 10:50 AM

Components

22

EMU26373

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

EMU26430

Carrying handle A carrying handle is included on the clamp bracket. After setting the handle up, it enables you to carry the outboard motor easily with one hand. To set up the carrying handle, proceed as fol- lows: 1. Place the tilt lock lever in the lock posi-

tion. 2. Securely hook the arm on the carrying

handle end to the clamp bracket bar.

NOTICE ECM00080

Place the tilt lock lever in the lock position while using the carrying handle. Other- wise, the lower unit could fall to the ground while carrying the motor.

1. Cowling lock lever(s)

1. Carrying handle 2. Clamp bracket bar

U63V1EE0.book Page 22 Tuesday, March 3, 2009 10:50 AM

Installation

23

EMU26902

Installation The information presented in this section is in- tended as reference only. It is not possible to provide complete instructions for every possi- ble boat and motor combination. Proper mounting depends in part on experience and the specific boat and motor combination.

WARNING EWM01590

Overpowering a boat could cause se- vere instability. Do not install an out- board motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer.

Improper mounting of the outboard mo- tor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. For permanently mount- ed models, your dealer or other person experienced in proper rigging should mount the motor.

EMU26911

Mounting the outboard motor

WARNING EWM01720

Your dealer or other person experienced in proper outboard motor mounting should show you how to mount your out- board motor.

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

EMU26923

Mounting height To run your boat at optimum efficiency, the water resistance (drag) of the boat and out- board motor must be made as little as possi- ble. The mounting height of the outboard motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the en- gine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in) below it.

1. Center line (keel line)

ZMU017601

ZMU02011

025mm (01in)

U63V1EE0.book Page 23 Tuesday, March 3, 2009 10:50 AM

Installation

24

NOTICE ECM01631

Check that the idle hole stays high enough to keep out water getting inside engine even if the boat is in stationary with maximum load.

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

TIP: The optimum mounting height of the out-

board motor is affected by the boat and mo- tor combination and the desired use. Test runs at different heights can help determine the optimum mounting height. Consult your Yamaha dealer or boat manufacturer for further information on determining the prop- er mounting height.

For instructions on setting the trim angle of the outboard motor, see page 35.

EMU26972

Clamping the outboard motor 1. Place the outboard motor on the transom

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

allow the outboard motor to fall off or move on the transom. This could cause loss of control and serious inju- ry. Make sure the transom screws are tightened securely. Occasionally check the screws for tightness during operation. [EWM00641]

2. If the restraint cable attachment is equipped on your engine, a restraint ca- ble or chain should be used. Attach one end to the restraint cable attachment and the other to a secure mounting point on the boat. Otherwise the engine could be completely lost if it accidentally falls off the transom.

3. Secure the clamp bracket to the transom using the bolts provided with the out- board (if packed). For details, consult your Yamaha dealer. WARNING! Avoid using bolts, nuts or washers other than those contained in the engine

ZMU02012

ZMU02013

U63V1EE0.book Page 24 Tuesday, March 3, 2009 10:50 AM

Installation

25

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

U63V1EE0.book Page 25 Tuesday, March 3, 2009 10:50 AM

Operation

26

EMU36381

First-time operation EMU30174

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

EMU27050

Gasoline and engine oil mixing chart (25:1)

NOTICE ECM00150

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

EMU27074

Procedure for pre-mixed models Run 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 possible speed. 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-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3000 r/min or less.

3. Next two hours: Accelerate at full throttle onto plane, then reduce engine speed to three-quarter throttle (approximately 4000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three-quarter throttle or less to let the engine cool.

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

5. After the first 10 hours: Operate the engine normally. Use the standard premix ratio of gasoline and oil. For details on mixing fuel and oil, see page 28.

EMU36400

Getting to know your boat Different boats handle differently. Operate cautiously while you learn how your boat han- dles under different conditions and with differ- ent trim angles (see page 35). EMU36412

Checks before starting engine

WARNING EWM01920

If any item in the checks before starting engine is not working properly, have it in- spected and repaired before operating the outboard motor. Otherwise an accident could occur.

NOTICE ECM00120

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

EMU37141

Fuel level Be sure you have plenty of fuel for your trip. A good rule is to use 1/3 of your fuel to get to the destination, 1/3 to return, and to keep 1/3 as

1. : Gasoline 2. : Engine oil

U63V1EE0.book Page 26 Tuesday, March 3, 2009 10:50 AM

Operation

27

an emergency reserve. With the boat level on a trailer or in the water, check the fuel level. For fuel filling instructions, see page 28. EMU36570

Remove cowling For the following checks, remove the top cowling from the engine. To remove the en- gine top cowling, release the lock lever and lift off the cowling.

EMU36442

Fuel system

WARNING EWM00060

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

WARNING EWM00910

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 the outboard 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.

EMU37320

Check the fuel filter Check that the fuel filter is clean and free of water. If any water is found in the fuel, or if a significant amount of debris is found, the fuel tank should be checked and cleaned by a Yamaha dealer.

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 it turns smoothly and that it completely re- turns to the fully closed position.

Look for loose or damaged connections of the throttle and shift cables.

EMU36481

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

ZMU06092

1. Cord 2. Clip

U63V1EE0.book Page 27 Tuesday, March 3, 2009 10:50 AM

Operation

28

EMU27120

Oil Check to be sure you have plenty of oil for

your trip. EMU27141

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

Install cowling 1. 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 not installed correctly, water spray under the cowling can damage the engine, or the cowling can blow off at high speeds. [ECM01990]

After installing, check the fitting of the top cowling by pushing it with both hands. If the top cowling is loose, have it repaired by your Yamaha dealer.

EMU27234

Filling fuel and engine oil EMU27247

Filling fuel for portable tank

WARNING EWM01830

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

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

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

and tighten the air vent screw on the fuel tank cap.

3. Engine shut-off switch

ZMU06117

U63V1EE0.book Page 28 Tuesday, March 3, 2009 10:50 AM

Operation

29

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 from sparks, flames, static electric discharge, or other sources of ignition.

6. If you use a portable container to store and dispense fuel, use only an approved GASOLINE container.

7. Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.

8. Fill the fuel tank, but do not overfill. Fuel can 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)

NOTICE ECM00811

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, or if 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 cause fouled spark plugs, smoky exhaust, and heavy carbon deposits.

Fuel tank capacity: 24.0 L (6.34, US gal, 5.28 Imp.gal)

ZMU06621

ZMU02301

Gasoline to engine oil ratio

Break-in period See page 26

After break-in 100:1

ZMU02834

U63V1EE0.book Page 29 Tuesday, March 3, 2009 10:50 AM

Operation

30

If equipped with a portable fuel tank 1. 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 are mixed.

If equipped with a built-in fuel tank 1. Pour oil into a clean fuel can, and then

add gasoline. 2. Replace the fuel can cap and close tight-

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

oughly. 4. Make sure that the oil and gasoline are

mixed. 5. Pour the gasoline and oil mixture into the

built-in fuel tank.

TIP: If using a permanently installed tank, pour the oil gradually as the gasoline is being added to the tank. EMU27451

Operating engine EMU27466

Sending fuel (portable tank)

WARNING EWM00420

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

When the air vent screw is loosened, gasoline vapor will be released. Gaso- line is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw.

This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which could cause brain damage or death when inhaled. Symp- toms include nausea, dizziness, and

1. : Gasoline 2. : Engine oil

1. Engine oil 2. Gasoline

100:1 1 L

(0.26 US gal, 0.22 Imp gal)

12 L

(3.2 US gal, 2.6 Imp gal)

14 L

(3.7 US gal, 3.1 Imp gal)

24 L

(6.3 US gal, 5.3 Imp gal)

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

U63V1EE0.book Page 30 Tuesday, March 3, 2009 10:50 AM

Operation

31

drowsiness. Keep cockpit and cabin ar- eas well ventilated. Avoid blocking ex- haust outlets.

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

2. If there is a fuel joint on the motor, firmly connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank.

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

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

EMU27493

Starting engine

WARNING EWM01600

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

EMU27532

Manual start models

WARNING EWM01840

Failure to attached engine shut-off cord could result in a runaway boat if opera- tor is ejected. Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning.

ZMU02295

ZMU02024

1. Arrow

U63V1EE0.book Page 31 Tuesday, March 3, 2009 10:50 AM

Operation

32

Avoid accidentally pulling the cord dur- ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

1. Place the gear shift lever in neutral.

TIP: The start-in-gear protection device prevents the 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 arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.

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

4. Pull out / turn the choke knob fully. Place the choke knob back in to the second or third position to warm up the engine after starting. When the engine has fully warmed up, replace the choke knob back in to its home position.

TIP: It is not necessary to use the choke when

starting a warm engine. If the choke knob is left in the pulled out po-

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

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

U63V1EE0.book Page 32 Tuesday, March 3, 2009 10:50 AM

Operation

33

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

7. Slowly return the throttle grip to the fully closed position.

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

warmed up. For further information, see page 33.

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

EMU36510

Checks after starting engine EMU36520

Cooling water Check for a steady flow of water from the cool- ing water pilot hole. A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passag- es. If the cooling passages are frozen, it may take a while for water to start flowing out of the pilot hole.

NOTICE ECM01810

If water is not flowing out of the pilot hole at all times while the engine is running, overheating and serious damage could occur. Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the prob- lem cannot be located and corrected.

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

Warming up engine EMU27683

Choke start models After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life. Gradually return the choke knob to its home position as the engine warms up. EMU36530

Checks after engine warm-up EMU36540

Shifting While tightly moored, and without applying throttle, confirm that the engine shifts smooth- ly into forward and reverse, and back to neu- tral.

ZMU02856

U63V1EE0.book Page 33 Tuesday, March 3, 2009 10:50 AM

Operation

34

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.

EMU34550

Shifting

WARNING EWM00180

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

NOTICE ECM01610

Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back 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 neutral Move the gear shift lever firmly and crisply for- ward (for forward gear) or backward (for re- verse gear). Be sure to check that the tilt lock lever is in the lock/down position (if equipped) before operating in reverse.

To shift from in gear (forward/reverse) to neu- tral 1. Close the throttle so that the engine

slows to idle speed.

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

ZMU02030

U63V1EE0.book Page 34 Tuesday, March 3, 2009 10:50 AM

Operation

35

EMU31742

Stopping boat

WARNING EWM01510

Do not use the reverse function to slow down or stop the boat as it could cause you to lose control, be ejected, or impact the steering wheel or other parts of the boat. This could increase the risk of se- rious injury. It could also damage the shift mechanism.

Do not shift into reverse while traveling at planing speeds. Loss of control, boat swamping, or damage to the boat could occur.

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

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

Procedure 1. Push and hold the engine stop button un-

til the engine comes to a complete stop.

2. After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to the closed position, if equipped.

3. Disconnect the fuel line if you are using an external fuel tank.

TIP: If the outboard motor is equipped with an en- gine shut-off cord, the engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch. EMU27862

Trimming outboard motor

WARNING EWM00740

Excessive trim for the operating condi- tions (either trim up or trim down) can cause boat instability and can make steer- ing the boat more difficult. This increases

ZMU02301

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Operation

36

the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.

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

EMU27872

Adjusting trim angle for manual tilt models There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim an- gle. 1. Stop the engine. 2. 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 rod away from the transom. To lower the bow (trim-in), move the rod to- ward the transom. Make test runs with the trim set to different an- gles to find the position that works best for your boat and operating conditions.

WARNING EWM00400

Stop the engine before adjusting the trim angle.

Use care to avoid being pinched when removing or installing the rod.

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

TIP: The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim rod one hole. EMU27911

Adjusting boat trim When the boat is on plane, a bow-up attitude results in less drag, greater stability and effi- ciency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden-

1. Trim operating angle

ZMU02043

1

1. Trim rod

U63V1EE0.book Page 36 Tuesday, March 3, 2009 10:50 AM

Operation

37

cy to steer to one side or the other. Compen- sate for this as you steer. The trim tab can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.

Bow Up Too much trim-out puts the bow of the boat too high in the water. Performance and econ- omy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces perfor- mance further, and the boat may porpoise (hop in the water), which could throw the op- erator and passengers overboard.

Bow Down Too much trim-in causes the boat to plow through the water, decreasing fuel economy and making it hard to increase speed. Operat- ing with excessive trim-in at higher speeds also makes the boat unstable. Resistance at

the bow is greatly increased, heightening the danger of bow steering and making opera- tion difficult and dangerous.

TIP: Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating. EMU27934

Tilting up and down If the engine will be stopped for some time or if the boat is moored in shallows, the outboard motor should be tilted up to protect the propel- ler and lower casing from damage by collision with obstructions, and also to reduce salt cor- rosion.

WARNING EWM00221

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

WARNING EWM00250

Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, discon- nect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.

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Operation

38

NOTICE ECM00241

Before tilting the outboard motor, stop the engine by following the procedure on page 35. Never tilt the outboard mo- tor while the engine is running. Severe damage from overheating can result.

Do not tilt up the engine by pushing the tiller handle (if equipped) because this could break the handle.

EMU32662

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

2. Disconnect the fuel line from the out- board motor.

3. Place the tilt lock lever (if equipped) in the release/up position.

4. Pull up the shallow water lever (if equipped).

5. Hold the rear of the top cowling with one hand and tilt the engine up fully.

6. Push the tilt support knob into the clamp bracket. Or the tilt support bar will turn to the lock position automatically. NOTICE: Do not use the tilt support lever or knob when trailering the boat. The out- board motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal run- ning position, use an additional sup- port device to secure it in the tilt position. For more detailed informa- tion, see page 41. [ECM01641]

EMU28022

Procedure for tilting down (manual tilt models) 1. Place the tilt lock lever in the re-

lease/down position or return the shallow water lever to its original position.

U63V1EE0.book Page 38 Tuesday, March 3, 2009 10:50 AM

Operation

39

2. Slightly tilt the engine up until the tilt sup- port bar is automatically released.

3. Slowly tilt the engine down. EMU28061

Shallow water EMU28073

Cruising in shallow water (manual tilt models)

WARNING EWM01781

Run the boat at the lowest possible speed when using the shallow water cruising system. The tilt lock mecha- nism does not work while the shallow water cruising system is being used. Hit- ting an underwater obstacle could cause the outboard motor to lift out of the water, resulting in loss of control.

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

NOTICE ECM00260

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

EMU32741

Procedure 1. Place the gear shift lever in neutral.

2. Place the tilt lock lever in the release/up position.

3. Slightly tilt the outboard motor up. The tilt support bar will lock automatically, sup- porting the outboard motor in a partially raised position. This outboard motor has 2 positions for shallow water cruising.

ZMU02868

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Operation

40

4. To return the outboard motor to the nor- mal running position, place the gear shift lever in neutral.

5. Place the tilt lock lever in the lock/down position, then slightly tilt the outboard mo- tor up until the tilt support bar automati- cally returns to the free position.

6. Slowly lower the outboard motor to the normal position.

EMU28195

Cruising in other conditions Cruising in salt water After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh wa- ter. Cruising in muddy, turbid, or acidic water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (see page 15) if you use the outboard motor in

acidic water or water with a lot of sediment in it, such as muddy or turbid (cloudy) water. Af- ter operating in such water, flush the cooling passages with fresh water to prevent corro- sion. Also rinse the outside of the outboard motor with fresh water.

ZMU02048

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Maintenance

41

EMU28227

Transporting and storing out- board motor

WARNING EWM00693

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

DO NOT fill fuel container to maximum capacity. Gasoline will expand consider- ably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.

WARNING EWM01860

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

NOTICE ECM00660

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

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

EMU28236

Clamp screw mounting models When transporting or storing the outboard motor while removed from a boat, keep the outboard motor in the attitude shown.

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

Storing outboard motor When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer pri- or to storage. However, you, the owner, with a minimum of tools, can perform the following procedures.

U63V1EE0.book Page 41 Tuesday, March 3, 2009 10:50 AM

Maintenance

42

NOTICE ECM01411

Do not place the outboard motor on its side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trouble.

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

EMU28304

Procedure EMU28376

Flushing in a test tank

NOTICE ECM00300

Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the engine will be damaged from overheating. Before starting the engine, be sure to supply wa- ter to the cooling water passages.

1. Wash the outboard motor body using fresh water. NOTICE: Do not spray wa- ter into the air intake. [ECM01840] For further information, see page 43.

2. Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer to each gallon of fuel.

TIP: The use of Yamaha Fuel Conditioner and Stabilizer eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead. 3. Remove the engine top cowling and si-

lencer cover. 4. Install the outboard motor on the test

tank.

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

6. Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fog- ging of the engine is mandatory to pre- vent excessive engine damage due to rust. Perform the flushing and fogging at the same time. WARNING! Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. [EWM00091]

7. Run the engine at a fast idle for 1015 minutes in neutral position.

8. Just prior to turning off the engine, quickly spray Yamaha Stor-Rite Engine Fogging Oil alternately into each carburetor or the fogging hole of the silencer cover, if equipped. When properly done, the en- gine will smoke excessively and almost stall.

9. Remove the outboard motor from the test tank.

1. Water surface 2. Lowest water level

ZMU02051

1

2

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Maintenance

43

10. Drain the cooling water completely out of the motor. Clean the body thoroughly.

11. Install the silencer cover/cap and top cowling.

EMU28402

Lubrication 1. Install the spark plug(s) and torque to

proper specification. For information on spark plug installation, see page 48.

2. Change the gear oil. For instructions, see page 51. Inspect the oil for the presence of water that indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use.

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

TIP: For long-term storage, fogging the engine with oil is recommended. Contact your Yamaha dealer for information about fogging oil and procedures for your engine. EMU28423

Cleaning and anticorrosion measures 1. Wash down the exterior of the outboard

motor with fresh water and dry off com- pletely. NOTICE: Do not spray water into the air intake. [ECM01840]

2. Spray the outboard motor exterior with Yamaha Silicone Protectant.

3. Wax the cowling with a non-abrasive wax such as Yamaha Silicone Wax.

EMU28451

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

EMU28460

Checking painted surface of motor Check the motor for scratches, nicks, or flak- ing paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer. EMU37081

Periodic maintenance

WARNING EWM01981

These procedures require mechanical skills, tools, and supplies. If you do not have the proper skills, tools, or supplies to perform a maintenance procedure, have a Yamaha dealer or other qualified mechan- ic do the work. The procedures involve disassembling the 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 when you perform maintenance unless other- wise specified.

Allow the engine to cool before handling hot parts or fluids.

Always completely reassemble the mo- tor before operation.

Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine

U63V1EE0.book Page 43 Tuesday, March 3, 2009 10:50 AM

Maintenance

44

repair establishment or individual. All war- ranty repairs, however, including those to the emission control system, must be per- formed by an authorized Yamaha marine dealership. A service manual is available for purchase through your Yamaha dealer for owners who have the mechanical skills, tools, and other equipment necessary to perform mainte- nance not covered by this owners manual. EMU28511

Replacement parts If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and pas- sengers. Yamaha genuine parts and acces- sories are available from your Yamaha dealer. EMU35520

Maintenance interval guidelines The service intervals provided in the Mainte- nance Chart were developed based upon typical use that includes operating at varied speeds, with sufficient time for engine warm up and cool-down, a medium to light load, and an average cruising speed near the 3000 to 4000 rpm range. As with any engine, howev- er, if your normal operating conditions are dif- ferent, you should consider service more often than shown, especially how often you change your engine and gear oil. Examples might include extended wide-open-throttle use or long periods of trolling or idling, carry- ing heavy loads, or frequent starting and stop- ping or shifting. More frequent maintenance will often pay off many times over in increased engine life and greater owner satisfaction. Consult your Yamaha dealer for additional maintenance recommendations.

U63V1EE0.book Page 44 Tuesday, March 3, 2009 10:50 AM

Maintenance

45

EMU34445

Maintenance chart 1 TIP: 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 maintenance checks.

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

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

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

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

Anode(s) (cylinder head, thermostat cov- er)

Inspection or replace- ment as necessary

Anodes (exhaust cover, cooling water passage cover, Rectifier Regula- tor cover)

Replacement

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 (can be dis- assembled)

Inspection or replace- ment as necessary

Fuel line(High pres- sure) Inspection

Fuel line(High pres- sure)

Inspection or replace- ment as necessary

Fuel line(Low pres- sure) Inspection

Fuel line(Low pres- sure)

Inspection or replace- ment as necessary

U63V1EE0.book Page 45 Tuesday, March 3, 2009 10:50 AM

Maintenance

46

EMU34451

Maintenance chart 2

Fuel pump Inspection or replace- ment as necessary

Fuel/engine oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Impeller/water pump housing

Inspection or replace- ment as necessary

Impeller/water pump housing Replacement

Propeller/propeller nut/cotter pin

Inspection or replace- ment as necessary

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

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

Spark plug caps/spark plug wires

Inspection or replace- ment as necessary

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

Inspection or replace- ment as necessary

Wire harness connec- tions/wire coupler con- nections

Inspection or replace- ment as necessary

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

Item Actions Every

1000 hours

Exhaust guide/exhaust manifold

Inspection or replace- ment as necessary

Item Actions

Initial Every

20 hours (3 months)

100 hours (1 year)

300 hours (3 years)

500 hours (5 years)

U63V1EE0.book Page 46 Tuesday, March 3, 2009 10:50 AM

Maintenance

47

EMU28932

Greasing Yamaha marine grease (Water resistant grease) 9.9, 15

U63V1EE0.book Page 47 Tuesday, March 3, 2009 10:50 AM

Maintenance

48

EMU28956

Cleaning and adjusting spark plug The spark plug is an important engine compo- nent and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to di- agnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. 1. Remove the spark plug caps from the

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

sion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type. WARNING! When remov- ing or installing a spark plug, be care- ful not to damage the insulator. A damaged 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 operate properly. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; replace it if out of spec- ification.

4. When fitting the plug, wipe off any dirt from the threads, and then screw it in to the correct torque.

TIP: If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past finger- tight. Have the spark plug adjusted to the cor- rect torque as soon as possible with a torque- wrench. EMU37450

Checking fuel filter Check the fuel filter periodically. If any water or foreign matter is found in the filter, clean or replace it. For cleaning or replacement of the fuel filter, consult your Yamaha dealer. EMU29043

Inspecting idling speed

WARNING EWM00451

Do not touch or remove electrical parts when starting or during operation.

Standard spark plug: B7HS-10

1. Spark plug gap 2. Spark plug part number 3. Spark plug I.D. mark (NGK)

Spark plug gap: 0.91.0 mm (0.0350.039 in)

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

U63V1EE0.book Page 48 Tuesday, March 3, 2009 10:50 AM

Maintenance

49

Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running.

NOTICE ECM00490

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

If the boat is not equipped with a tachometer for the outboard motor, use a diagnostic ta- chometer for this procedure. Results may vary 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, see page 12. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other 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

WARNING EWM01881

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

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

Checkpoints Check each of the propeller blades for ero-

sion from cavitation or ventilation, or other damage.

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

peller shaft.

ZMU02087

ZMU01897

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Maintenance

50

Check the propeller shaft oil seal for dam- age.

EMU30662

Removing propeller EMU29197

Spline models 1. 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 not use your hand to hold the propeller when loosening the propeller nut. [EWM01890]

3. Remove the propeller, washer (if equipped), and thrust washer.

EMU30672

Installing propeller EMU29233

Spline models

NOTICE ECM00500

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

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

2. Install the spacer (if equipped), thrust washer, washer (if equipped), and pro- peller on the propeller shaft. NOTICE: Be sure to install the thrust washer before installing the propeller, otherwise the lower case and propeller boss could be damaged. [ECM01880]

3. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque.

4. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends. NOTICE: Do not reuse the cotter pin installed. Otherwise the propeller can come off during operation. [ECM01890]

1. Cotter pin 2. Propeller nut 3. Washer 4. Propeller 5. Thrust washer

ZMU02877

23

45

1 Propeller nut tightening torque: 17.0 Nm (1.73 kgf-m, 12.5 ft-lb)

U63V1EE0.book Page 50 Tuesday, March 3, 2009 10:50 AM

Maintenance

51

TIP: If the propeller nut does not align with the pro- peller shaft hole after tightening to the speci- fied torque, tighten the nut further to align it with the hole. EMU29287

Changing gear oil

WARNING EWM00800

Be sure the outboard motor is securely fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you.

Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe injury could oc- cur if the outboard motor accidentally falls.

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

2. Place a suitable container under the gear case.

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

TIP: If a magnetic gear oil drain screw is

equipped, remove all metal particles from the screw before installing it.

Always use new gaskets. Do not reuse the removed gaskets.

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

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

tion. Using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole.

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

1. Gear oil drain screw 2. Oil level plug

ZMU02064

2

1

Recommended gear oil: Hypoid gear oil SAE#90

Gear oil quantity: 0.250 L (0.264 US qt, 0.220 Imp.qt)

ZMU02065

U63V1EE0.book Page 51 Tuesday, March 3, 2009 10:50 AM

Maintenance

52

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

EMU29302

Cleaning fuel tank

WARNING EWM00920

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

doing this procedure, consult your Yamaha dealer.

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

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

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

proper assembly can result in a fuel leak, which could result in a fire or 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 solvent into the tank. Install the cap and shake the tank. Drain the solvent completely.

3. Remove the screws holding the fuel joint assembly. Pull the assembly out of the tank.

4. Clean the filter (located on the end of the suction pipe) in a suitable cleaning sol- vent. Allow the filter to dry.

5. Replace the gasket with a new one. Re- install the fuel joint assembly and tighten the 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

ZMU02324

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Maintenance

53

EMU29312

Inspecting and replacing anode(s) Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.

NOTICE ECM00720

Do not paint anodes, as this would render them ineffective.

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

ZMU02067

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Trouble Recovery

54

EMU29427

Troubleshooting A problem in the fuel, compression, or ignition systems can cause poor starting, loss of pow- er, or other problems. This section describes basic checks and possible remedies, and cov- ers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble-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 battery terminals.

Q. Is fuse for electric start relay or electric cir- cuit blown? A. Check for cause of electric overload and repair. 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 31.

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

Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

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

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

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

Q. Is engine 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 incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Q. Is fuel system obstructed?

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

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

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

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

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

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

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

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.

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

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

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

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

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

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

Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height.

Q. 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 incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type.

Q. Are weeds or other foreign matter tangled on gear housing?

A. Remove foreign matter and clean lower unit.

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

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

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

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

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

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

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

Q. 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?

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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 shift lever position? A. Have serviced by a Yamaha dealer.

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

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

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

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

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

Temporary action in emergency EMU29440

Impact damage

WARNING EWM00870

The outboard motor can be seriously dam- aged by a collision while operating or trailering. 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 boat for damage.

3. Whether damage is found or not, return to 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 operate If the starter mechanism does not operate (the engine cannot be cranked with the start- er), the engine can be started with an emer- gency starter rope.

WARNING EWM01022

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

When the emergency starter rope is used to start the engine, the start-in- gear protection device does not operate. Make sure the remote control lever is in neutral. 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 arm or leg while operating the boat.

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

Avoid accidentally pulling the cord dur- ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

Make sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure some- one.

An unguarded, rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the en- gine. Use the emergency starter rope only as instructed. Do not touch the fly- wheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running.

Do not touch the ignition coil, spark plug wire, spark plug cap, or other electrical components when starting or operating the motor. You could get an electrical shock.

EMU29562

Emergency starting engine 1. 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 31. Be sure the engine is in neutral and that the clip is attached to the engine shut-off switch. The main switch must be (on), if equipped.

5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms up.

6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise.

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

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EMU33501

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

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EMU29820

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY

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EMU29841

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA

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