6N6-9-1B Hyoshi 2/20/04 5:11 PM Page 1 115D OWNER’S MANUAL Printed in Japan April 2004–0.2 × 1 ! Printed on recycled paper U.S.A.
6N6-9-1B Hyoshi 2/20/04 5:11 PM Page 2 EMU25060 ZMU01690 Read this owner’s manual carefully before operating your outboard motor.
Important manual information EMU25100 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.
Table of contents General information .......................... 1 Identification numbers record.......... 1 Outboard motor serial number .......... 1 Key number....................................... 1 Emission control information ........... 1 North American models..................... 1 Safety information ........................... 2 Important labels............................... 3 Warning labels .................................. 3 Basic boating rules (Rules of the road) ...........................
Table of contents control models) ............................. 33 Reverse (automatic reverse lock and power trim and tilt models)..... 33 Stopping engine ............................ 33 Procedure ....................................... 33 Trimming outboard motor.............. 34 Adjusting trim angle ........................ 34 Adjusting boat trim .......................... 35 Tilting up and down ....................... 36 Procedure for tilting up .................... 36 Procedure for tilting down ......
General information EMU25170 Identification numbers record EMU25182 Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket or the upper part of the swivel bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen. 1.
General information ● EMISSION CONTROL INFORMATION ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES. REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. g/kw-hr FELs : IDLE SPEED : rpm IN NEUTRAL SPARK PLUG : SPARK PLUG GAP (mm) : DISPLACEMENT : cm 3 FUEL : GASOLINE ADVERTISED POWER : EX VALVE LASH (mm) : IN kw ● ZMU04304 EMU25261 Manufactured date label This label is attached to the clamp bracket or the swivel bracket.
General information er operation before starting the engine. Attach the engine stop switch lanyard cord to a secure place on your clothing, or your arm or leg while operating. If you accidentally leave the helm, the cord will pull from the switch, stopping the engine. ● Know the marine laws and regulations where you will be boating—and obey them. For basic boating rules, see “Rules of the road” on page 4. ● Stay informed about the weather. Check weather forecasts before boating.
General information while engine is running. EMU25451 Label ENGINE OIL ONLY ● Pour the engine oil into this oil tank, not gasoline. RECOMMENDED OIL: YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC-W3 certified ouboard oil. EWM01270 WARNING Do not add gasoline to the oil tank. Fire explosion could result. EMU25500 Basic boating rules (Rules of the road) Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat.
General information Rules are followed: Meeting: (you are approaching another vessel head-on) Crossing: (you are traveling across the other vessel’s path) Overtaking: (you are passing or being passed by another vessel) In the following illustration, your boat is in the center. You should give the right-of-way to any vessels shown in white area (you are the Give-Way vessel). Any vessels in the shaded area must yield to you (they are the GiveWay vessels).
General information EMU25530 Other special situations There are three other rules you should be aware of when driving your boat around other vessels. Narrow channels and bends When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a powerdriven vessel is preparing to go around a bend that may obstruct the view of other water vessels, the operator should sound a prolonged blast on the whistle (4 to 6 seconds).
General information ZMU01708 EMU25540 Fueling instructions EWM00010 WARNING GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! ● Do not smoke when refueling, and keep 7 ● ● ● away from sparks, flames, or other sources of ignition. Stop engine before refueling. Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. Take care not to spill gasoline.
General information ● ● ● ● ● dry rags. Do not overfill the fuel tank. Tighten the filler cap securely after refueling. If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it. Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
General information EMU25711 Battery specifications x Minimum cold cranking amps (CCA/ SAE): 380.0 A Minimum marine cranking amps (MCA/ ABYC): 502.0 A Minimum reserve capacity (RC/SAE): 124 minutes EMU25741 Propeller selection The performance of your outboard motor will be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load.
Basic components EMU25795 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. 115D 1 12 11 13 2 3 14 15 16 4 10 9 5 6 17 18 19 8 7 ZMU04764 1. Top cowling 2. Power trim and tilt switch 3. Flushing device 4. Tilt support lever 5. Anti-cavitation plate 6. Trim tab (anode) 7. Propeller* 8. Cooling water inlet 9. Anode 10. Clamp bracket 11. Top cowling release lever 12. Choke knob 13. Cooling water pilot hole 14.
Basic components 6. Throttle 7. Fully open EMU26201 Neutral interlock trigger To shift out of neutral, first pull the neutral interlock trigger up. 1. Power trim and tilt switch 2. Remote control lever 3. Neutral interlock trigger 4. Neutral throttle lever 5. Main switch / choke switch 6. Engine stop lanyard switch 7. Throttle friction adjuster 1. Neutral interlock trigger EMU26190 Remote control lever Moving the lever forward from the neutral position engages forward gear.
Basic components adjuster counterclockwise. EWM00030 WARNING Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move throttle lever or grip, which could result in an accident. 1. Fully open 2. Fully closed EMU26221 Choke switch To activate the choke system, press in the main switch while the key is turned to the “ ” (on) or “ ” (start) position. The choke system will then supply the rich fuel mixture required to start the engine.
Basic components during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward. NOTE: The engine cannot be started with the lock plate removed. ● “ ” (off) With the main switch in the “ ” (off) position, the electrical circuits are off, and the key can be removed.
Basic components UP DN ZMU03517 EMU26151 Power trim and tilt switch on bottom engine cowling The power trim and tilt switch is located on the side of the bottom engine cowling. Pressing the switch “ ” (up) trims the outboard motor up, then tilts it up. Pressing the switch “ ” (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current position.
Basic components EMU26400 Top cowling release lever 3 The top cowling can be removed by operating the cowling release lever. Pulling the front lever unlocks the top cowling for removal. 2 1 B A ZMU02525 1. Trim tab 2. Bolt 3. Cap ZMU03518 A B ZMU01863 EMU26340 When installing the top cowling: 1. Set the top cowling straight down onto the engine, being careful to avoid catching spark plug wires or other wires. 2. Align the three cowling hooks with the locks on the bottom cowling. 3.
Basic components ● ● ● ● cable is operating correctly before reinstalling the top cowling. When the release lever is operated, both the front and rear cowling hooks should be released at the same time. If not, adjust the rear clamp cable adjusters. Make sure the cable operates smoothly and is free of corrosion. Check that the cable is properly secured in the holder. When reinstalling the cowling, ensure that both the front and rear locks have operated properly.
Basic components EMU26540 Oil level indicators (three indicators) The indicators on the gauge show the status of the oil level. For details on how to read the indicators, see page 29. ECM00030 CAUTION: Do not operate the engine without oil. Serious engine damage will occur. 1 ZMU01867 1. Oil level indicator EMU26581 Overheat warning indicator (digital type) 1 ZMU04580 If the engine temperature rises too high, the warning indicator will start to blink.
Basic components 3. Selector switch (for fuel sensor) EMU26610 Trim meter This gauge shows the trim angle of your outboard motor. 1. Speedometer 2. Fuel gauge 3. Trip meter/clock/voltmeter 4. Warning indicator(s) ZMU04581 NOTE: After the main switch is first turned on, all segments of the display come on as a test. After a few seconds, the gauge will change to normal operation. Watch the gauge when turning on the main switch to make sure all segments come on.
Basic components EMU26690 Trip meter This gauge displays the distance the boat has traveled since the gauge was last reset. Press the “ ” (mode) button repeatedly until the indicator on the face of the gauge points to “ ” (trip). To reset the trip meter to zero, press the “ ” (set) and “ ” (mode) buttons at the same time. ZMU01869 EMU26650 Hour meter (digital type) This meter shows the number of hours the engine has been run.
Basic components ZMU01745 NOTE: The clock operates on battery power. Disconnecting the battery will stop the clock. Reset the clock after connecting the battery. EMU26710 EMU26720 Fuel warning indicator If the fuel level decreases to one segment, the fuel level warning segment will begin to blink. ECM00880 Fuel gauge CAUTION: The fuel level is indicated by eight segments. When all segments are showing, the fuel tank is full.
Basic components vice has activated. For charging the battery, consult your Yamaha dealer. ZMU01757 1. Low battery indicator EMU26801 Warning system ECM00090 CAUTION: Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU26812 ZMU04766 ● The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel). Overheat warning This engine has an overheat warning device.
Basic components ● The buzzer will sound. ZMU02630 ZMU03025 EMU26843 Oil level warning and oil filter clogging warning If the warning system has been activated, stop the engine and check for the cause. Oil injection models This engine has an oil level warning system. If the oil level falls below the lower limit, the warning system will activate. Activation of warning device ● Engine speed will automatically decrease to about 2000 r/min. ● The oil level warning indicator will light.
Basic components 1 1.
Operation EMU26901 Installation ECM00110 CAUTION: Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat, or accessories such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operated continuously in the presence of airborne water spray. NOTE: During water testing check the buoyancy of the boat, at rest, with its maximum load.
Operation motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is in alignment with the bottom of the boat. life.
Operation 3. 4. 5. throttle to 3000 r/min or less. Second hour: 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 threequarter throttle or less to let the engine cool. Third through tenth hours: Avoid operating at full throttle for more than 5 minutes at a time. Let the engine cool between full-throttle runs.
Operation 3. Watch for oil flowing through the oil feed pipes. After any air in the oil lines has been expelled, the oil injection system should supply oil normally. If no oil is flowing after 10 minutes of idling, consult your Yamaha dealer. ZMU04141 ECM00130 CAUTION: Be sure to take the above steps when operating the engine after a long period of storage. Otherwise engine seizure could occur.
Operation or explosion could result. Engine oil tank capacity: See page 40 OFF ON START To fill the engine oil tank, proceed as follows: 1. Pour engine oil into the remote oil tank. ZMU04144 4. Operate the engine normally. ECM00570 CAUTION: ZMU04142 2. Turn on the main switch. The Yamaha oil injection system will automatically feed oil from the remote oil tank to the engine oil tank. When the engine is operated for the first time or stored for a period of time, a minimum of 5 liters (5.
Operation EMU27321 Oil level indicator operation The various functions of the oil level system are as follows: EMU27381 Oil level indicator Electric start models Oil level warning indicator (digital tachometer) Oil level warning indicator (analog tachometer) Engine oil tank Remote oil tank more than 300 more than cm3 Green (0.32 US qt, 0.26 Imp qt) more than 300 Yellow Red–Yellow– Green cm3 (0.32 US qt, 0.26 Imp qt) 300 cm3 (0.32 US qt, 0.26 Imp qt) or less 1500 cm3 (1.6 US qt, 1.
Operation EMU27450 Operating engine EMU27480 Feeding fuel EWM00420 WARNING ● ● ● 1. 2. 3. Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you. When the air vent screw is loosened, gasoline vapor will be released. Gasoline is highly flammable, and its vapors are flammable and explosive.
Operation ● lanyard where it could become entangled, preventing it from functioning. Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward. N ZMU02314 NOTE: ● ● 3. Turn the main switch to “ ” (on). 5.
Operation cooling water pilot hole. ECM00510 CAUTION: OFF ON START ZMU03262 7. Immediately after the engine starts, release the main switch and allow it to return to “ ” (on). ECM00191 CAUTION: ● ● Never turn the main switch to “ ” (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine.
Operation lever quickly and firmly from neutral to reverse. EMU27763 Forward (tiller handle and remote control models) Tiller control models 1. Place the throttle grip in the fully closed position. 2. Move the gear shift lever quickly and firmly from neutral to forward. Remote control models 1. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward.
Operation engine stop switch, then turning the main switch to “ ” (off). EMU27861 Trimming outboard motor The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help improve performance and fuel economy while reducing strain on the engine. Correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.
Operation Adjust the outboard motor trim angle using the power trim and tilt switch. results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane. 1.
Operation Bow Down Too much trim-in causes the boat to “plow” through the water, decreasing fuel economy and making it hard to increase speed. Operating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making operation difficult and dangerous. bracket. EWM00250 WARNING Leaking fuel is a fire hazard.
Operation from marine growth and corrosion which could damage the power trim and tilt mechanism. 4. Push the tilt support knob into the clamp bracket or pull the tilt support lever toward you to support the engine. ZMU03452 EMU28052 Procedure for tilting down ZMU03432 Power trim and tilt models / power tilt models 1. Push the power tilt / power trim and tilt switch “ ” (up) until the outboard motor is supported by the tilt rod and the tilt support lever / tilt support knob becomes free. 2.
Operation DN ting up for and cruising in shallow water. Otherwise severe damage from overheating can result. UP DN EMU28183 Procedure for power trim and tilt / power tilt models 1. Place the gear shift lever in neutral. ZMU01936 DN 2. ZMU04147 Slightly tilt the outboard motor up to the desired position using the power trim / tilt switch. EMU28060 Cruising in shallow water The outboard motor can be tilted up partially to allow operation in shallow water.
Operation mal running position, press the power trim / tilt switch and slowly tilt the outboard motor down. EMU28190 Cruising in other conditions Cruising in salt water After operating in salt water, wash out the cooling water passages with fresh water to prevent them from becoming clogged with salt deposits. NOTE: For cooling system flushing instructions, see page 41.
Maintenance EMU28215 Specifications Dimension: Overall length: 808 mm (31.8 in) Overall width: 582 mm (22.9 in) Overall height L: 1472 mm (58.0 in) Overall height X: 1599 mm (63.0 in) Transom height L: 516 mm (20.3 in) Transom height X: 642 mm (25.3 in) Weight (without propeller) L: 163.0 kg (359 lb) Weight (without propeller) X: 167.0 kg (368 lb) Performance: Full throttle operating range: 4500–5500 r/min Maximum output: 84.
Maintenance Tightening torque for engine: Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) Propeller nut: 55.0 Nm (40.6 ft-lb) (5.61 kgf-m) EMU28222 Transporting and storing outboard motor EWM00690 WARNING ● ● ● Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. USE CARE when transporting fuel tank, whether in a boat or car. DO NOT fill fuel container to maximum capacity.
Maintenance 2. page 44. Fill the fuel tank with fresh fuel and add one ounce of “Yamaha Fuel Conditioner and Stabilizer” (Part No. LUB-FUELC12-00) to each gallon of fuel. NOTE: The use of “Yamaha Fuel Conditioner and Stabilizer” eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead. 3. 4. Remove the top cowling and silencer cover/cap. Remove the propeller.
Maintenance NOTE: A flushing attachment is available from your Yamaha dealer. EMU28410 Lubrication (oil injection models) 1. 2. 3. 4. Grease the spark plug threads and install the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 48. Fill the oil tanks. This prevents the formation of condensation. For models with a remote oil tank, it may be necessary to manually override the control unit to completely fill the engine oil tank. Change the gear oil.
Maintenance 3. 4. tilled water. Store the battery on a level surface in a cool, dry, well-ventilated place out of direct sunlight. Once a month, check the specific gravity of the electrolyte and recharge as required to prolong battery life. 4. EMU28440 Flushing power unit and let the water flush through the cooling passages for about 15 minutes. Turn off the water and disconnect the garden hose. When flushing is complete, reinstall the garden hose connector on the fitting on the bottom cowling.
Maintenance NOTE: For cooling system flushing instructions, see page 41. EMU28460 Checking painted surface of motor Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer. EMU28483 Periodic maintenance EWM01070 WARNING Be sure to turn off the engine when you perform maintenance unless otherwise specified.
Maintenance EMU28521 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer.
Maintenance Initial Item Spark plug(s) Actions 10 hours (1 month) 50 hours (3 months) Every 100 hours (6 months) 200 hours (1 year) Cleaning / adjustment / replacement NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.
Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) 115D ZMU04149 EMU28951 Cleaning and adjusting spark plug sparks, which could lead to explosion or fire. EWM00560 WARNING When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine.
Maintenance ple, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.
Maintenance EMU29001 Cleaning fuel filter 1. Remove the nut holding the fuel filter assembly if equipped. ZMU04150 Checkpoints Fuel system parts leakage ● Fuel line joint leakage ● Fuel line cracks or other damage ● Fuel connector leakage ● ZMU04151 2. EMU28980 Inspecting fuel filter 3. EWM00310 WARNING Gasoline is highly flammable, and its vapors are flammable and explosive. ● If you have any question about properly doing this procedure, consult your Yamaha dealer.
Maintenance cup. Firmly screw the cup onto the filter housing. Attach the filter assembly to the bracket so that the fuel hoses are attached to the filter assembly. Run the engine and check the filter and lines for leaks. 5. 6. EMU29040 Inspecting idling speed EWM00450 NOTE: Correct idling speed inspection is only possible if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal.
Maintenance 1 2 ZMU03458 ZMU03915 EMU29120 Exhaust leakage Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head, and body cylinder. 1. Tilt rod 2. Trim rods 4. EMU29130 Water leakage Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head, and body cylinder. Use the tilt support lever to lock the motor in the up position.
Maintenance ● ZMU04156 7. Activate the trim-up switch until the tilt rod is fully extended. Unlock the tilt support lever. the main switch to “ ” (off) and remove the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one. Do not use your hand to hold the propeller when loosening or tightening the propeller nut. Put a wood block between the anti-cavitation plate and the propeller to prevent the propeller from turning. ZMU01896 ZMU02635 8.
Maintenance 3. Remove the propeller and thrust washer. EMU29230 Installing the propeller ECM00340 CAUTION: ● ● Check the propeller shaft oil seal for damage. ● NOTE: If the shear pin equipped: it is designed to break if the propeller hits a hard underwater obstacle to help protect the propeller and drive mechanism. The propeller will then spin freely on the shaft. If this happens, the shear pin must be replaced. EMU29193 Removing the propeller 1. 2.
Maintenance align it with the hole. to drain completely. ECM00710 EMU29280 CAUTION: Changing gear oil EWM00800 WARNING ● ● Be sure the outboard motor is securely fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you. Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor accidentally falls. 1. 2. 3. Inspect the used oil after it has been drained.
Maintenance external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes. ECM00720 CAUTION: Do not paint anodes, as this would render them ineffective. NOTE: Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit. ZMU01901 contains sulfuric acid and therefore is poisonous and highly caustic.
Maintenance ommended level when necessary. Top up only with distilled water (or pure deionized water suitable to use in batteries). ● ● ● 2. Always keep the battery in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month or more, remove the battery from the boat and store it in a cool, dark place. Completely recharge the battery before using it.
Maintenance ZMU04679 EMU29400 Coating the boat bottom A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
Trouble Recovery EMU29422 Troubleshooting A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. This section describes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble warning indicator is flashing, consult your Yamaha dealer. Starter will not operate. Q.
Trouble Recovery Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer. Q. Has warning system activated? A. Find and correct cause of warning. Q. Is spark plug gap incorrect? A. Inspect and adjust as specified. Q. Is ignition wiring damaged or poorly connected? A.
Trouble Recovery A. Have serviced by a Yamaha dealer. Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. Q. Are weeds or other foreign matter tangled on gear housing? A. Remove foreign matter and clean lower unit. Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer. Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is there excess water in fuel filter cup? A. Drain filter cup.
Trouble Recovery board motor unsafe to operate. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type. If the outboard motor hits an object in the water, follow the procedure below. Q. Is high pressure fuel pump drive belt broken? A. Have serviced by a Yamaha dealer. Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer. Engine vibrates excessively. Q. Is propeller damaged? A. Have propeller repaired or replaced.
Trouble Recovery EMU29531 Starter will not operate If the starter mechanism does not operate (the engine cannot be cranked with the starter), the engine can be started with an emergency starter rope. 2 EWM01020 1 WARNING ● ZMU04152 ● 1. Fuse holder 2. Fuse (20 A, 30 A) NOTE: Consult your Yamaha dealer if the new fuse immediately blows again.
Trouble Recovery ● 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. OFF ON START EMU29561 Emergency starting engine 1. 2. 3. Remove the top cowling. Remove the start-in-gear protection cable from the starter, if equipped. Remove the starter/flywheel cover after removing the bolt(s). ZMU01906 5.
Trouble Recovery OFF ON START ZMU03466 EMU29670 Engine fails to operate ZMU01906 3. EMU29740 Low oil level warning activates Lift the emergency switch to pump reserve oil into the engine oil tank from the remote oil tank. If the oil level is allowed to drop too low, the red segment will appear on the oil level indicator, the buzzer will sound, and engine speed will be limited to about 2000 r/min.
Trouble Recovery 5. mal operation. The yellow segment will continue to be displayed on the oil level indicator. Start the engine and return to the nearest port for more oil. NOTE: The maximum reserve oil capacity is 1500 cm3 (1.6 US qt, 1.31 Imp qt). The oil-feed pump will not operate if the engine is tilted up more than 35°. Put the engine in the upright position (not tilted) before using the emergency switch.
Trouble Recovery ZMU01910 3. 4. Drain the fuel from the carburetor, fuel filter, and fuel line. Feed fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking with the manual starter or emergency starter rope. ZMU01911 5. Take the outboard motor to a Yamaha dealer as soon as possible. ECM00400 CAUTION: Do not attempt to run the outboard motor until it has been completely inspected.
Consumer information EMU29811 Important warranty information for U.S.A.
Consumer information 69
Consumer information EMU29820 YAMAHA MOTOR CORPORATION, U.S.A.
Consumer information 71
Consumer information 72
Consumer information EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A.
6N6-9-1B Hyoshi 2/20/04 5:11 PM Page 1 115D OWNER’S MANUAL Printed in Japan April 2004–0.2 × 1 ! Printed on recycled paper U.S.A.
Warranty card 2/27/02 11:47 AM Page 1 OUTBOARD MOTOR WARRANTY REGISTRATION ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD Please complete and mail this card. This information is necessary to accurately register your unit for warranty. Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.
Warranty card 2/27/02 11:47 AM Page 2 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT
