6H3-9-1W Hyoshi 08.2.11 9:35 AM ページ 1 70 OWNER’S MANUAL q Read this manual carefully before operating this outboard motor. U.S.A.
6H3-9-1W Hyoshi 08.2.11 9:35 AM ページ 2 EMU25062 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.
Important manual information EMU31283 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 Safety information............................. 1 Outboard motor safety .................... 1 Propeller............................................ 1 Rotating parts.................................... 1 Hot parts ........................................... 1 Electric shock .................................... 1 Power trim and tilt ............................. 1 Engine shut-off cord (lanyard)........... 1 Gasoline ............................................
Table of contents type).............................................. 26 Instruments and indicators ............ 28 Digital tachometer ......................... 28 Tachometer ..................................... 28 Trim meter....................................... 28 Hour meter ...................................... 28 Oil level indicator (digital type) ........ 29 Overheat-alert indicator .................. 29 Analog tachometer ........................ 29 Oil level indicators (three indicators) ........
Table of contents Checking fuel filter .......................... 64 Inspecting idling speed ................... 64 Checking water in engine oil tank ............................................... 65 Checking wiring and connectors ..... 65 Checking propeller .......................... 65 Removing propeller ......................... 66 Installing propeller ........................... 66 Changing gear oil ............................ 67 Cleaning fuel tank ...........................
Safety information EMU33622 Outboard motor safety Observe these precautions at all times. EMU36500 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 neutral, and sharp edges of the propeller can cut even when stationary. ● Shut off the engine when a person is in the water near you. ● Keep people out of reach of the propeller, even when the engine is off.
Safety information 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, immediately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth.
Safety information dling and lead to an accident, capsizing or swamping. EMU33771 Avoid collisions Scan constantly for people, objects, and other boats. Be alert for conditions that limit your visibility or block your vision of others. ZMU06025 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.
Safety information 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.
Safety information EMU33700 Steering and sailing rules and sound signals Whenever two vessels on the water meet one another, one vessel has the right-ofway; it is called the “stand-on” vessel. The vessel that does not have the right-of-way is called the “give-way” or “burdened”vessel. These rules determine which vessel has the right-of-way, and what each vessel should do. 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.
Safety information EMU25531 Other special situations Crossing When two power driven vessels are crossing each other’s path close enough to run the risk of collision, the vessel which has the other on the starboard (right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; you are the Give-Way vessel.
Safety information Reading buoys and other markers The waters of the United States are marked for safe navigation by the lateral system of buoyage. Simply put, buoys and markers have an arrangement of shapes, colors, numbers and lights to show which side of the buoy a boater should pass on when navigating in a particular direction. The markings on these buoys are oriented from the perspective of being entered from seaward (the boater is going towards the port).
Safety information ZMU01708 8
General information 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 stolen. 1. Key number 1 ZMU02931 1.
General information 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.
General information 1 2 3 ZMU05670 11
General information EMU33843 Symbols The following symbols mean as follows.
Specifications and requirements EMU31480 Specifications TIP: “(AL)” stated in the specification data below represents the numerical value for the aluminum propeller installed. Likewise, “(SUS)” represents the value for stainless steel propeller installed and “(PL)” for plastic propeller installed. EMU2821C Dimension: Overall length: 713 mm (28.1 in) Overall width: 364 mm (14.3 in) Overall height L: 1374 mm (54.1 in) Transom height L: 521 mm (20.5 in) Weight (without propeller) L: 104.
Specifications and requirements Gear oil quantity: 0.610 L (0.645 US qt, 0.537 Imp.qt) Tightening torque for engine: Spark plug: 25.0 Nm (2.55 kgf-m, 18.4 ft-lb) Propeller nut: 35.0 Nm (3.57 kgf-m, 25.8 ft-lb) EMU33553 Installation requirements EMU33563 Boat horsepower rating EWM01560 WARNING Overpowering a boat can cause severe instability. ● move suddenly and unexpectedly, possibly causing a collision or throwing passengers overboard.
Specifications and requirements boat. WARNING! Do not put flammable items, or loose heavy or metal objects in the same compartment as the battery. Fire, explosion or sparks could result. For instructions on propeller removal and installation, see page 65. [EWM01820] EMU36300 x Multiple batteries 1 To connect multiple batteries, such as for multiple engine configurations or for an accessory battery, consult your Yamaha dealer about battery selection and correct wiring.
Specifications and requirements comends that you use alcohol-free (see Gasohol) gasoline whenever possible. Recommended gasoline: Regular unleaded gasoline with a minimum Octane rating of 86 (Pump Octane Number) = (R+M)/2 ECM01980 NOTICE ● ● Do not use leaded gasoline. Leaded gasoline can seriously damage the engine. Avoid getting water and contaminants in the fuel tank. Contaminated fuel can cause poor performance or engine damage. Use only fresh gasoline that has been stored in clean containers.
Specifications and requirements rine 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. rine SI engines. See the label affixed to your engine for details. EMU30390 Approval label of emission control certificate This label is attached to the bottom cowling.
Specifications and requirements 1 1.
Components EMU2579H Components diagram TIP: * May not be exactly as shown; also may not be included as standard equipment on all models. 70 12 13 14 15 1 11 10 2 9 8 16 7 6 3 4 5 ZMU04945 1. Top cowling 2. Top cowling lock lever 3. Anti-cavitation plate 4. Trim tab (anode) 5. Propeller 6. Cooling water inlet 7. Anode 8. Trim rod 9. Clamp bracket 10. Tilt support knob 11. Power trim and tilt switch 12. Tachometer* 13. Trim meter* 14. Digital tachometer* 15.
Components 1 3 4 2 ZMU03157 1. Fuel joint 2. Fuel gauge 3. Fuel tank cap 4. Air vent screw EMU25830 Fuel joint 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 shut-off switch 7. Throttle friction adjuster This joint is used to connect the fuel line. EMU25841 EMU26190 Fuel gauge Remote control lever This gauge is located on either the fuel tank cap or on the fuel joint base.
Components 6. Throttle 7. Fully open EMU26201 Neutral interlock trigger To shift out of neutral, first pull the neutral interlock trigger up. 1. Fully open 2. Fully closed EMU25911 Tiller handle To change direction, move the tiller handle to the left or right as necessary. 1. Neutral interlock trigger EMU26211 Neutral throttle lever To open the throttle without shifting into either forward or reverse, put the remote control lever in the neutral position and lift the neutral throttle lever.
Components 1. Forward “ ” 2. Neutral “ ” 1. Throttle indicator EMU25973 3. Reverse “ ” EMU25941 Throttle grip The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed. EMU25961 Throttle indicator The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation.
Components When constant speed is desired, tighten the adjuster to maintain the desired throttle setting. 1. Cord 2. Clip 3. Engine shut-off switch EMU25993 Engine shut-off cord (lanyard) and clip The clip must be attached to the engine shutoff switch for the engine to run. The cord should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine.
Components EMU26090 Main switch The main switch controls the ignition system; its operation is described below. ● “ ” (off) With the main switch in the “ ” (off) position, the electrical circuits are off, and the key can be removed. ● “ ” (on) With the main switch in the “ ” (on) position, the electrical circuits are on, and the key cannot be removed. ” (start) ● “ With the main switch in the “ ” (start) position, the starter motor turns to start the engine.
Components distract the operator, increasing the risk of collision with another boat or an obstacle. UP DOWN ZMU03096 EMU26244 Trim tab with anode EWM00840 WARNING EMU26153 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, and then tilts it up. Pressing the switch “ ” (down) tilts the outboard motor down and trims it down.
Components A 1 2 B ZMU03097 ZMU03194 ECM00660 1. Trim tab 2. Bolt NOTICE Bolt tightening torque: 36.0 Nm (3.6 kgf-m, 26 ft-lb) 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. Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall.
Components 1 ZMU02596 1.
Instruments and indicators EMU31414 Digital tachometer The tachometer shows the engine speed and has the following functions. All segments of the display will light momentarily after the main switch is turned on and will return to normal thereafter. 1 ● the power trim and tilt switch. If the trim angle of your motor exceeds the trim operating range, the top segment on the trim meter display will blink. 2 3 ZMU01869 4 5 6 7 ZMU01891 1. Tachometer 2. Trim meter 3. Hour meter 4.
Instruments and indicators EMU26551 Oil level indicator (digital type) This indicator shows the engine oil level. If the oil level falls below the lower limit, the alert indicator will start to blink. For further information, see page 31. 1 ECM00030 NOTICE Do not operate the engine without oil. Serious engine damage will occur. ZMU01868 1. Overheat-alert indicator EMU26471 Analog tachometer This gauge shows the engine speed and has the following functions. 1 1 ZMU01867 1.
Instruments and indicators 1 ZMU04580 1. Oil level indicators EMU26611 Analog trim meter This gauge shows the trim angle of your outboard motor. ZMU04581 Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired setting with the power trim and tilt switch.
Engine control system EMU26803 Alert system ECM00091 NOTICE Do not continue to operate the engine if a alert device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU2681A Overheat alert This engine has an overheat-alert device. If the engine temperature rises too high, the alert device will activate. ● The engine speed will automatically decrease to about 2000 r/min.
Engine control system make troubleshooting easier, check for engine overheating first, then oil level, and finally oil filter clogging. ZMU04586 ● 1 The oil level-alert indicator will light or blink. ZMU03828 1. Oil filter ZMU03942 ● The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel). If the alert system has been activated, stop the engine and check for the cause.
Installation EMU26902 Installation The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat and motor combination. Proper mounting depends in part on experience and the specific boat and motor combination. EWM01590 1 WARNING ● ● Overpowering a boat could cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat.
Installation ZMU01762 ECM01630 NOTICE ● ● During water testing, check the buoyancy of the boat, at rest, with its maximum load. Check that the static water level on the exhaust housing is low enough to prevent water entry into the power head when water rises due to waves when the outboard is not running.
Operation EMU36380 First-time operation EMU27020 Breaking in engine 2. Your new engine requires a period of breakin to allow mating surfaces of moving parts to wear in evenly. Correct break-in will help ensure proper performance and longer engine life. ECM00140 NOTICE ● ● 3. Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage. Premix fuel must be used during breakin in addition to oil in the oil injection system.
Operation dent could occur. EMU36440 Fuel system ECM00120 EWM00060 NOTICE WARNING Do not start the engine out of water. Overheating and serious engine damage can occur. EMU37141 Fuel level Gasoline and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition. EWM00910 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 an emergency reserve.
Operation ZMU06184 EMU36900 Controls Tiller handle models: ● Turn 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 returns to the fully closed position. ● Look for loose or damaged connections of the throttle and shift cables under the engine cowling. Remote control models: ● Turn the steering wheel full-right and fullleft.
Operation od (12 months) of storage, proceed as follows: 1. Use a 50:1 gasoline-oil mixture to start the engine. 2. Start the engine. Leave it idling. 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] 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.
Operation EMU29158 Checking power trim and tilt system 1 EWM01930 WARNING ● ● ● 1. 2. 3. Never get under the lower unit while it is tilted, even when the tilt support lever is locked. Severe injury could occur if the outboard motor accidentally falls. Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted. Be sure no one is near the outboard motor before performing this check. Check the power trim and tilt unit for any sign of oil leaks.
Operation ture increases. properly connected or the battery will not start the engine. Refer to the battery manufacturer’s instructions for checks for your particular battery. Fuel tank capacity: 25 L (6.60 US gal, 5.50 Imp.gal) EMU27234 Filling fuel and engine oil EMU27246 Filling fuel for portable tank EWM01830 WARNING ● ● Gasoline and its vapors are highly flammable and explosive. Always refuel according to this procedure to reduce the risk of fire and explosion.
Operation ZMU03369 2. Open the oil tank filler cap by pulling the tab on the cap. ZMU03370 3. Slowly pour the engine oil into the engine oil tank. 2 1 ZMU03371 1. Oil filler access cap 2. Oil tank filler cap 4. After filling, replace the all caps securely.
Operation EMU27321 Oil level indicator operation The various functions of the oil level system are as follows: EMU27364 Electric start models Oil level-alert indicator (digital tachometer) Oil level-alert indicator (analog tachometer/ bottom cowling) Engine oil tank Green Remarks more than 770 cm3 (0.81 US qt, 0.68 Imp qt) Yellow from 770 cm3 (0.81 US qt, 0.68 Imp qt) down to 280 cm3 (0.30 US qt, 0.25 Imp qt) Red No refilling necessary. Add oil; see page 40. ● 280 cm3 (0.30 US qt, 0.
Operation tank cap, loosen it 2 or 3 turns. ZMU02022 1. Arrow 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. EMU27492 Starting engine EWM01600 WARNING 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.
Operation 1. Place the gear shift lever in neutral. 4. Turn the main switch to “ ” (start), and hold it for a maximum of 5 seconds. 5. Immediately after the engine starts, release the main switch and allow it to return to “ ” (on). NOTICE: Never turn the main switch to “ ” (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds.
Operation ● 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. page 46. If the engine is warm and fails to start, open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 71. EMU27664 Electric start and remote control models EWM01840 WARNING ● ● 1. Failure to attached engine shut-off cord could result in a runaway boat if operator is ejected.
Operation “ ” (on), wait 10 seconds, then crank the engine again. [ECM00192] TIP: ● ● When the engine is cold, it needs to be warmed up. For further information, see page 46. If the engine is warm and fails to start, open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 71. EMU36510 Checks after starting engine EMU36520 Cooling water Check for a steady flow of water from the cooling water pilot hole.
Operation EMU33492 Shifting EWM00180 WARNING Before shifting, make sure there are no swimmers or obstacles in the water near you. ECM01610 NOTICE 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 engine, shift to neutral, then restart the engine and allow it to warm up. To shift out of neutral 1. Pull the neutral interlock trigger up (if equipped).
Operation ● 2. After the engine is at idle speed in gear move the remote control lever / gear shift lever firmly and crisply into the neutral position. pact the steering wheel or other parts of the boat. This could increase the risk of serious 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.
Operation ZMU02041 4. Remove the key if the boat will be left unattended. TIP: The engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch, then turning the main switch to “ ” (off). EMU27862 Trimming outboard motor EWM00740 2. After stopping the engine, disconnect the fuel line if there is a fuel joint on the outboard motor. ZMU03834 3. Tighten the air vent screw on the fuel tank cap (if equipped).
Operation UP DN 1 ZMU03110 1. Trim operating angle 1. Power trim and tilt switch EMU27884 Adjusting trim angle (Power trim and tilt) EWM00753 WARNING ● ● ● Be sure all people are clear of the outboard motor when adjusting the trim angle. Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted. Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems.
Operation angles to find the position that works best for your boat and operating conditions. EMU27911 Adjusting boat trim When the boat is on plane, a bow-up attitude 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.
Operation duce salt corrosion. EWM00221 WARNING Be sure all people are clear of the outboard motor when tilting up and down, Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted. EWM00250 WARNING Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, disconnect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.
Operation and tilt switch “ ” (down) to retract the trim rods. NOTICE: Be sure to retract the trim rods completely during mooring. This protects the rods from marine growth and corrosion which could damage the power trim and tilt mechanism. [ECM00251] UP ZMU03837 3. Pull the tilt support lever toward you to support the engine. WARNING! After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever.
Operation DN ting up for and cruising in shallow water. Otherwise severe damage from overheating can result. UP DN EMU32912 Procedure for power trim and tilt models 1. Place the remote control lever / gear shift lever in neutral. ZMU01936 DN 2. ZMU03838 EMU28061 Shallow water EMU32851 Power trim and tilt models The outboard motor can be tilted up partially to allow operation in shallow water.
Operation 3. UP UP DN To return the outboard motor to the normal running position, press the power trim and tilt switch and slowly tilt the outboard motor down. EMU28194 Cruising in other conditions ZMU01935 UP ZMU03847 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 water and, if possible, rinse the power head under the cowling.
Maintenance EMU28226 Transporting and storing outboard motor EWM00692 WARNING ● ● USE CARE when transporting fuel tank, whether in a boat or car. DO NOT fill fuel container to maximum capacity. Gasoline will expand considerably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard. EWM01860 WARNING Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the fuel cock to prevent fuel from leaking.
Maintenance 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 top cowling and silencer cover/cap. Remove the propeller. 4. Install the flushing attachment over the cooling water inlet. NOTICE: Do not run the engine without supplying it with cooling water.
Maintenance 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. 2. 3. Wash down the exterior of the outboard motor with fresh water and dry off completely. NOTICE: Do not spray water into the air intake. [ECM01840] Spray the outboard motor exterior with “Yamaha Silicone Protectant”.
Maintenance have the mechanical skills, tools, and other equipment necessary to perform maintenance not covered by this owner’s 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 passengers. Yamaha genuine parts and accessories are available from your Yamaha dealer.
Maintenance 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 operating the engine under adverse conditions such as extended trolling. ● Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
Maintenance Initial Item Fuel line(High pressure) Fuel line(Low pressure) Fuel line(Low pressure) Fuel pump Actions Replacement Greasing points Greasing Impeller/water pump housing Impeller/water pump housing Inspection or replacement as necessary Oil tank water drain Inspection or cleaning Oil injection pump/oil feed pump Power trim & tilt unit/ Operation,noise and oil leakage Propeller/Propeller nut/ Cotter pin PCV (Pressure Control Valve) Inspection or Adjustment Thermostat 500 hours (5 year
Maintenance Initial Item Actions Water inlet Inspection Main switch/stop switch/choke switch Wire harness connections/Wire coupler connections Inspection or replacement as necessary (Yamaha) Meter/gauge Inspection (Yamaha) Fuel tank Inspection and cleaning as necessary 20 hours (3 months) Every 100 hours (1 year) 300 hours (3 years) Inspection or replacement as necessary EMU34451 Maintenance chart 2 Every Item Actions 1000 hours Guide exhaust/exhaust manifold 62 Inspection or replacement
Maintenance EMU28932 Greasing Yamaha marine grease (Water resistant grease) 70 ZMU03125 EMU28955 Cleaning and adjusting spark plug The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself.
Maintenance lead to explosion or fire. [EWM00561] Standard spark plug: B8HS-10 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; adjust the gap to specification if necessary. EMU37450 Checking fuel filter Check the fuel filter periodically. If any water or foreign matter is found in the filter, clean or replace it.
Maintenance TIP: 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. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechanic. 2. Verify whether the idle speed is set to specification. For idle speed specifications, see page 13.
Maintenance ● ● ● ● Check each of the propeller blades for wear, erosion 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 propeller shaft. 2. Propeller nut 3. Washer 4. Spacer 5. Propeller 6. Thrust washer 1 3 6 4 5 ● Check the propeller shaft oil seal for damage. EMU30661 Removing propeller EMU29197 Spline models 1. Straighten the cotter pin and pull it out using a pair of pliers. 2.
Maintenance 3. before installing the propeller, otherwise the lower case and propeller boss could be damaged. [ECM01880] Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque. Propeller nut tightening torque: 35.0 Nm (3.57 kgf-m, 25.8 ft-lb) 4. occur if the outboard motor accidentally falls. 1. 2. 3. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.
Maintenance TIP: For disposal of used oil, consult your Yamaha dealer. 5. Put the outboard motor in a vertical position. Using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole. Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: 0.610 L (0.645 US qt, 0.537 Imp.qt) pors are flammable and explosive. ● If you have any question about properly doing this procedure, consult your Yamaha dealer.
Maintenance the screws firmly. EMU29322 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. ECM00720 NOTICE Do not paint anodes, as this would render them ineffective. TIP: Inspect ground leads attached to external anodes on equipped models.
Maintenance 3. ing, consult your Yamaha dealer. Check the battery connections. They should be clean, secure, and covered by an insulating cover. WARNING! Bad connections can produce shorting or arcing and cause an explosion. cables must be clean and properly connected, or the battery will not start the engine. EMU29371 Disconnecting the battery 1. [EWM01910] EMU29333 Connecting the battery EWM00570 2.
Trouble Recovery EMU29427 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-alert 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 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 connected? A.
Trouble Recovery Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. 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. Q. Is fuel filter clogged? A. Clean or replace filter. Engine power loss. Q.
Trouble Recovery Q. Is fuel joint connection incorrect? A. Connect correctly. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type. trailering. Damage could make the outboard motor unsafe to operate. 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.
Trouble Recovery EMU29533 Starter will not operate 1 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. EWM01022 WARNING 2 ● ZMU02561 1. Fuse holder 2. Fuse (20 A) ● Consult your Yamaha dealer if the new fuse immediately blows again.
Trouble Recovery ● 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. ZMU03140 EMU29574 Emergency starting engine 1. 2. 3. Remove the top cowling. Disconnect the start-in-gear protection cable from the starter, if equipped.
Trouble Recovery 1 1 TIP: When the engine does not start with this procedure, see page 77. EMU29671 Engine fails to operate EMU29691 Ignition system malfunction If the battery voltage is low or in the unlikely event of an ignition system malfunction, the engine speed may become erratic or the engine may stop. In such a situation, follow the procedure below. 1. Remove the CDI unit cover or electrical cover, if equipped. 2. Disconnect the yellow cord (emergency circuit) of the CDI unit to return to port.
Trouble Recovery OPEN CLOSE ZMU03844 3. Squeeze the primer pump two or three times to feed fuel. 5. Turn the main switch to “ ” (on). OFF ON START ZMU03144 ZMU03142 6. 4. Open the throttle slightly without shifting using the throttle grip, neutral throttle lever or free accelerator. It is necessary to change the throttle opening slightly depending on the engine temperature. After the engine starts, return the throttle to its original position. N Turn the main switch to “ ” (start).
Trouble Recovery ON START ZMU03922 7. After the engine starts, close the emergency starter valve (if used), then return the throttle to its original position. OPEN CLOSE ZMU03145 TIP: When the starter mechanism malfunctions, see page 75. EMU33501 Treatment of submerged motor If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immediately. NOTICE: 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 81
Consumer information EMU29820 YAMAHA MOTOR CORPORATION, U.S.A.
Consumer information 83
Consumer information 84
Consumer information EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA 85
6H3-9-1W Hyoshi 08.2.
6H3-9-1W Hyoshi 08.2.11 9:35 AM ページ 4 Printed in Japan April 2008–0.
