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688-9-S9-1 5/24/00 3:58 PM Page 1 E EMU01419* 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.
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688-9-S9-1 5/24/00 3:58 PM Page 3 CONTENTS E GENERAL INFORMATION 1 BASIC COMPONENTS 2 OPERATION 3 MAINTENANCE 4 TROUBLE RECOVERY 5 INDEX 6 READ THIS OWNER’S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR.
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688-9-S9-1 5/24/00 3:58 PM Page 5 E EMB00010 Chapter 1 GENERAL INFORMATION IDENTIFICATION NUMBERS RECORD ..1-1 Outboard motor serial number...........1-1 Key number...........................................1-1 EMISSION CONTROL INFORMATION...1-2 1 2 SAFETY INFORMATION..........................1-3 FUELING INSTRUCTIONS.......................1-5 Gasoline (Petrol) ...................................1-6 Engine oil...............................................1-6 BATTERY REQUIREMENT.......................
688-9-S9-1 5/24/00 3:58 PM Page 6 E EMU00005 IDENTIFICATION NUMBERS RECORD EMU00007 OUTBOARD MOTOR SERIAL NUMBER YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON 1 401012 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.
688-9-S9-1 5/24/00 3:58 PM Page 7 E 60/75/85 EMU01385 EMISSION CONTROL INFORMATION q EMU01390 U.S. INSULAR AREAS w Engines affixed with the label pictured below conform to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details. 1 Emission control information label EMISSION CONTROL INFORMATION ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.
688-9-S9-1 5/24/00 3:58 PM Page 8 E EMU00918 SAFETY Q INFORMATION 8 Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation. 8 Before operating the boat, read any owner’s or operator’s manuals supplied with it and all labels. Be sure you understand each item before operating. 8 Do not overpower the boat with this outboard motor. Overpowering the boat could result in loss of control.
688-9-S9-1 5/24/00 3:58 PM Page 9 E 8 This product emits exhaust gases which contain 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 exhaust outlets. 8 Check throttle, shift, and steering for proper operation before starting the engine. 8 Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating.
688-9-S9-1 5/24/00 3:58 PM Page 10 E EMU00016 FUELING INSTRUCTIONS w GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! 8 Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. 8 Stop engine before refueling. 8 Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. 8 Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. 8 Do not overfill the fuel tank.
688-9-S9-1 5/24/00 3:58 PM Page 11 E EMU00024 GASOLINE (PETROL) Recommended gasoline (petrol): Regular grade gasoline (petrol) If knocking or pinging occurs, use a different brand of gasoline (petrol) or premium grade fuel. EEMU01356 ENGINE OIL Recommended engine oil: YAMALUBE, TWO STROKE MOTOR OIL FOR MARINE If the recommended engine oil is not available, another 2-stroke engine oil with a NMMA-certified TC-W3 rating may be used.
688-9-S9-1 5/24/00 3:58 PM Page 12 E EMU00032 BATTERY REQUIREMENT cC Do not use the battery that does not meet the specified capacity. If different battery from the specification is used, the electric system may perform poorly or be overloaded, causing electrical system damage. Choose battery which meets the following specifications for Electric start model.
688-9-S9-1 5/24/00 3:58 PM Page 13 E Yamaha dealers stock a range of propellers, and can advise you and install a propeller on your outboard that is best suited to your application. NOTE: At full throttle and under a maximum boat load, the engine’s rpm should be within the upper half of the full throttle operating range, as listed in “SPECIFICATIONS” on page 4-1. Select a propeller which fulfills this requirement.
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688-9-S9-2 5/24/00 3:56 PM Page 1 E EMC00010 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-3 Fuel tank ................................................2-3 Remote control .....................................2-4 Choke knob ...........................................2-8 Trim tab .................................................2-8 Trim angle adjusting rod .....................2-9 Tachometer .......
688-9-S9-2 5/24/00 3:56 PM Page 2 E EMU01206 MAIN COMPONENTS 60/75/85 !3 q !2 701016 !1 w !4 !5 3 e 4 5 2 6 1 r t y !0 x1000 r/min YAMAHA 801023 !6 u o 7 YAMAHA 801011 i 101181* 902016 1 2 3 4 5 6 7 8 9 0 q w e *r *t y Top cowling Tilt support lever Clamp bracket Trim angle adjusting rod Anti-cavitation plate Trim tab (Anode) Propeller Cooling water inlet Battery lead Anode Choke knob Cowling lock lever Remote control box Trim meter Tachometer Fuel tank * May not be exactly
688-9-S9-2 5/24/00 3:56 PM Page 3 E EMU01206 MAIN COMPONENTS 115 !0 q o 701016 !1 !2 w 3 4 5 2 6 1 x1000 r/min 7 YAMAHA 801011 i e r y u YAMAHA 801023 !3 t 101192 902016 1 2 3 4 5 6 7 8 9 0 q w e Top cowling Tilt support lever Anti-cavitation plate Trim tab (Anode) Propeller Cooling water inlet Battery lead Anode Cowling lock lever Remote control box Trim meter Tachometer Fuel tank * May not be exactly as shown; also may not be included as standard equipment on all models.
688-9-S9-2 5/24/00 3:56 PM Page 4 E EMC20010 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS EMC21012 FUEL TANK If your model was equipped with a portable fuel tank, its function is as follows. w q e r 902016 1 2 3 4 Fuel hose joint Fuel meter(If equipped) Fuel tank cap Air vent screw(If equipped) Fuel hose joint This connector is provided for connecting or disconnecting fuel hose. Fuel meter (If equipped) This meter is on the fuel hose connector.
688-9-S9-2 5/24/00 3:56 PM Page 5 E EMC81210 REMOTE CONTROL y q Both the shifter and the throttle are actuated by the remote control lever. In addition, this remote control also has the electrical switches.
688-9-S9-2 5/24/00 3:56 PM Page 6 E N Neutral throttle lever To open the throttle without shifting into either Forward or Reverse, place the remote control lever in the Neutral position and lift the neutral throttle lever. q w 701033* NOTE: The neutral throttle lever will operate only when the remote control lever is in Neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position.
688-9-S9-2 5/24/00 3:56 PM Page 7 E EMC50310 OFF ON START Choke switch While the main switch is being pressed in at “ON” or “START”, the choke system will switch on, to supply a rich mixture required to start the engine. (When the key is released, it will switch off automatically.) 701042 EMU00934 OFF ON START q w 701026* Engine Stop Lanyard Switch The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run.
688-9-S9-2 5/24/00 3:56 PM Page 8 E EMU01331 UP DN UP DN 701034 Power Trim/Tilt Switch The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the remote control lever grip. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.
688-9-S9-2 5/24/00 3:56 PM Page 9 E EMC42010 CHOKE KNOB Pulling out this knob (setting it to ON) supplies a rich mixture required to start the engine. 305034 NOTE: The choke knob for Remote control model has the same function as the choke switch on the remote control box. EMD04011 TRIM TAB The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force. w An improperly adjusted trim tab may cause difficult steering.
688-9-S9-2 5/24/00 3:56 PM Page 10 E EMD06011 TRIM ANGLE ADJUSTING ROD 60/75/85 The outboard motor fully trim-in angle setting in relation to the transam can be adjusted by changing the position of the trim angle adjusting-rod. EMD24110 404016 TACHOMETER This meter shows the engine speed. EMD26010 3 TRIM METER (for Power trim and tilt model) 4 5 2 This meter shows the trim angle of your outboard.
688-9-S9-2 5/24/00 3:56 PM Page 11 E EMD60010 TILT SUPPORT LEVER To keep the outboard motor in the tiltedup position, lock the tilt support lever to the clamp bracket. 403011* EMD63110 TOP COWLING LOCK LEVERS 301042 To remove the engine top cowling, pull up the front lock lever and push the rear lock lever(s) down. Then lift off the cowling. When replacing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by returning the levers to the locked position.
688-9-S9-2 5/24/00 3:56 PM Page 12 E EMD80010 WARNING SYSTEM cC Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem can not be located and corrected. EMD82211 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate. 701054 8 Engine speed will be limited to about 2,000 r/min to help protect the engine.
688-9-S9-3 5/24/00 3:55 PM Page 1 E EMF00010 Chapter 3 OPERATION INSTALLATION ........................................3-1 Mounting the outboard motor............3-2 FILLING FUEL AMD ENGINE OIL ...........3-4 Filling fuel..............................................3-4 Gasoline (petrol) and oil mixing .........3-4 PRE-OPERATION CHECKS ......................3-6 BREAKING IN (RUNNING IN) ENGINE ..3-7 1 2 3 STARTING ENGINE .................................3-9 WARMING UP ENGINE .........................
688-9-S9-3 5/24/00 3:55 PM Page 2 E EMF10010 INSTALLATION cC Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat or accessories such as transom ladders/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.
688-9-S9-3 5/24/00 3:55 PM Page 3 E EMF12011 MOUNTING THE OUTBOARD MOTOR w Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Observe the following: 8 The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat/motor combination. Proper mounting depends in part on experience and the specific boat/motor combination.
688-9-S9-3 5/24/00 3:55 PM Page 4 E w Overpowering a boat may cause severe instability. Do not install an outboard 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. EMU01299 104012 Mounting Height To run your boat at optimum efficiency, the water-resistance (drag) of the boat and outboard motor must be made as little as possible.
688-9-S9-3 5/24/00 3:55 PM Page 5 E EMF31010 FILLING FUEL AND ENGINE OIL FILLING FUEL 1) 2) 3) Remove the fuel tank cap. Fill the fuel tank carefully. Close the cap securely after refueling. Wipe up any spilled fuel. Fuel tank capacity: Refer to SPECIFICATIONS, Page 4-1. EMU00201 GASOLINE (PETROL) AND OIL MIXING q Pre-mix model Engine oil : Gasoline (Petrol) 1) w Break-in period 1 : 25 After break-in 1 : 50 Pour oil and gasoline into the fuel tank, in that order.
688-9-S9-3 5/24/00 3:55 PM Page 6 E cC 8 Avoid using any oil other than the designated type. 8 Use a thoroughly blended fuel-oil mixture. 8 If the mixture is not thoroughly blended, or if the mixing ratio is incorrect, the following problems could occur: 8 Low oil ratio: Lack of oil could cause major engine trouble, such as piston seizure. 8 High oil ratio: Too much oil could cause fouled spark plugs, smoky exhaust, and heavy carbon deposits. Mixing ratio 25 : 1 Gasoline (Petrol) 1L 12 L 14 L 24 L (0.
688-9-S9-3 5/24/00 3:55 PM Page 7 E EMF40110 PRE-OPERATION CHECKS w If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur. Fuel Check to be sure you have plenty of fuel for your trip. Make sure there are no fuel leaks or gasoline fumes. Be sure the fuel hose is not being flattened or kinked by objects in the boat, and that there are no sharp objects near it.
688-9-S9-3 5/24/00 3:55 PM Page 8 E cC Do not start the engine out of water. Overheating and serious engine damage can occur. EMF50011 BREAKING IN (RUNNING IN) ENGINE Your new engine requires a period of break-in (running-in) to allow mating surfaces of moving parts to wear-in evenly. Correct break-in (running-in) will help ensure proper performance and longer engine life. cC Failure to follow the break-in (running-in) procedure may result in reduced engine life or even severe engine damage.
688-9-S9-3 5/24/00 3:55 PM Page 9 E EMU00226 Run the engine under load (in gear with a propeller installed) 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 (approximately 3,000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 r/min or less.
688-9-S9-3 5/24/00 3:55 PM Page 10 E EMU01147 STARTING ENGINE w 902043 8 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. 8 When the air vent screw is loosened, gasoline (petrol) vapor will be released. Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive.
688-9-S9-3 5/24/00 3:55 PM Page 11 E 3) 902025 Squeeze the primer bulb with the outlet end up until you feel it become firm. EMU00247 PROCEDURE FOR REMOTE CONTROL MODEL N 4) Place the remote control lever in the Neutral position. NOTE: The start-in-gear protection device prevents the engine from starting except when in Neutral. 701015 OFF ON 5) START Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg.
688-9-S9-3 5/24/00 3:55 PM Page 12 E EMU00945* 701063 Electric Start Model 7) Open the throttle slightly lifting the neutral throttle lever upwards partially. You may need to change the throttle opening slightly depending on engine temperature. After the engine starts, return the throttle to the original position. NOTE: 8 As a starting point, lift the lever just until you feel resistance, then lift slightly more.
688-9-S9-3 5/24/00 3:55 PM Page 13 E cC 8 Do not turn the main switch to “START” when the engine is running. 8 Do not keep the starter-motor turning for more than 5 seconds. The battery will rapidly become exhausted and it will be impossible for it to start the engine. If the engine does not start within 5 seconds, return the main switch to “ON”, wait 10 seconds, and then crank the engine again.
688-9-S9-3 5/24/00 3:55 PM Page 14 E EMG00010 WARMING UP ENGINE 1) 2) 309014 Before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (Failure to do this will shorten engine life.) Check for a steady flow of water from the cooling-water pilot hole. cC A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages.
688-9-S9-3 5/24/00 3:55 PM Page 15 E EMG20310 SHIFTING w Before shifting, make sure there are no swimmers or obstacles in the water near you. cC To change the shifting position from forward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speeds). N F FORWARD 701043 N Pull up the neutral interlock trigger (If equipped) and move the remote control lever quickly and firmly from Neutral to Forward.
688-9-S9-3 5/24/00 3:55 PM Page 16 E EMG38010 STOPPING ENGINE Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended. EMG41211 PROCEDURE ON OFF START 1) 701023 Turn the main switch to “OFF”. NOTE: The engine can also be stopped by pulling the lanyard from the engine stop switch (then turning the main switch to “OFF”).
688-9-S9-3 5/24/00 3:55 PM Page 17 E EMU01412 TRIMMING OUTBOARD MOTOR The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The 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.
688-9-S9-3 5/24/00 3:55 PM Page 18 E ADJUSTING TRIM ANGLE EMU01145 Hydro-tilt Model w 8 Stop the engine before adjusting the trim angle. 8 Be sure all people are clear of the outboard motor when adjusting the tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket. 8 Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim angle can cause loss of control.
688-9-S9-3 5/24/00 3:55 PM Page 19 E EMU01401 Power Trim/Tilt Model w UP DN 8 Be sure all people are clear of the outboard motor when adjusting the trim/tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket. 8 Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems.
688-9-S9-3 5/24/00 3:55 PM Page 20 E EMU00282 Bow Up When the boat is on plane, a bow-up attitude result in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. When trimmed out, the boat may have more 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. q 105011 w Too much trim-out puts the bow of the boat too high in the water.
688-9-S9-3 5/24/00 3:55 PM Page 21 E EMH10110 TILTING UP/DOWN 000817 If the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion. cC 8 Before tilting the motor, follow the procedures under “STOPPING ENGINE”. Never tilt the motor while the engine is running. Severe damage from overheating can result.
688-9-S9-3 5/24/00 3:55 PM Page 22 E EMU00292 PROCEDURE FOR TILTING UP Hydro-tilt model 1) Remove the fuel-line connection from the motor. 2) Place the tilt-lock lever in the release position. 3) Hold the rear of the top cowling with one hand, tilt the engine up, and turn the tilt-support lever toward you and support the engine.
688-9-S9-3 5/24/00 3:55 PM Page 23 E EMU00294 PROCEDURE FOR TILTING UP Power trim/tilt model 1) Remove the fuel-line connection from the motor.(If the fuel connector is provided on the motor.) 2) Push the power trim/tilt switch “UP” until the outboard has tilted up completely. 3) Turn the tilt-support lever toward you and support the engine. 304034* UP DN UP DN 701034 w After tilting the engine, be sure to support it with the tilt-support lever.
688-9-S9-3 5/24/00 3:55 PM Page 24 E EMU00303 PROCEDURE FOR TILTING DOWN Power trim/tilt model 1) 2) 3) 411021 3-23 Push the power trim/tilt switch “UP” until the engine is supported by the tilt rod. Release the tilt-support lever. Push the power trim/tilt switch “DN” (Down) to lower the engine to the desired position.
688-9-S9-3 5/24/00 3:55 PM Page 25 E EMH60010 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 cloggedup with salt deposits. NOTE: Refer to cooling system flushing instructions in “TRANSPORTING AND STORING OUTBOARD MOTOR”.
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688-9-S9-4 5/24/00 3:51 PM Page 1 E EMK00010 Chapter 4 MAINTENANCE 1 SPECIFICATION DATA.............................4-1 TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-4 Trailering outboard motor...................4-5 Storing outboard motor ......................4-6 PERIODIC MAINTENANCE....................4-10 Replacement parts .............................4-10 Maintenance chart..............................4-11 Cleaning and adjusting spark plug...4-12 Checking fuel system...
688-9-S9-4 5/24/00 3:51 PM Page 2 E EMK13010* SPECIFICATION DATA Model Item Unit 60FET DIMENSIONS 8Overall Length 8Overall Width 8Overall Height 8Tramson Height 8Weight L/X L/X L/X mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.) 713 (28.1) 364 (14.3) 1,374 (54.1) / 1,501 (59.1) 521 (20.5) / 648 (25.5) 106 (234) / 109 (240) r/min kW (HP) r/min 4,500 ~ 5,500 44.1 (60.
688-9-S9-4 5/24/00 3:51 PM Page 3 E 75AED 75AET 85AED 726 (28.6) 374 (14.7) 1,422 (56.0) / 1,548 (60.9) 521 (20.5) / 647 (25.5) 113 (249) / 116 (256) 726 (28.6) 374 (14.7) 1,422 (56.0) / 1,548 (60.9) 521 (26.5) / 647 (25.5) 121 (267) / 124 (273) 726 (28.6) 374 (14.7) 1,422 (56.0) / 1,548 (60.9) 521 (20.5) / 647 (25.5) 113 (249) / 116 (256) 4,500 ~ 5,500 55.2 at 5,000 r/min 750 ~ 850 4,500 ~ 5,500 55.2 (75.0) at 5,000 r/min 750 ~ 850 4,500 ~ 5,500 62.
688-9-S9-4 5/24/00 3:51 PM Page 4 E EMK13010* SPECIFICATION DATA Model Item Unit 85AET DIMENSIONS 8Overall Length 8Overall Width 8Overall Height 8Tramson Height 8Weight L/X L/X L/X mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.) 726 (28.6) 374 (14.7) 1,422 (56.0) / 1,548 (60.9) 521 (20.5) / 647 (255) 121 (267) / 124 (273) r/min kW (HP) r/min 4,500 ~ 5,500 62.5 (85.
688-9-S9-4 5/24/00 3:51 PM Page 5 E 115BET — 828 (32.6) 600 (23.6) 1,435 (56.5) / — 516 (20.3) / — 156 (344) / — 4,500 ~ 5,500 84.6 (115.0) at 5,000 r/min 700 ~ 800 2-stroke, V 4 1,730 (105.57) 90.0 ´ 68.0 (3.54 ´ 2.68) C.D.I system BR8HS-10 0.9 ~ 1.0 (0.035 ~ 0.039) Remote control Electric start 12 - 70 (252) ~ 100 (360) 12 - 10 Choke valve start system Forward-Neutral-Reverse 2.0 (13 : 26) Power trim / tilt K Regular grade gasoline (petrol) 24 (6.3, 5.
688-9-S9-4 5/24/00 3:51 PM Page 6 E EMU01369 TRANSPORTING AND STORING OUTBOARD MOTOR w 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. EMU00326 TRAILERING OUTBOARD MOTOR 000940 The motor should be trailered and stored in the normal running position.
688-9-S9-4 5/24/00 3:51 PM Page 7 E EMK17010 STORING OUTBOARD MOTOR Procedure 1) Using fresh water, flush the coolingwater passages (Refer to “Flushing cooling system”) and wash the motor body. (Refer to “MOTOR EXTERIOR”). 2) Remove the fuel-line connections from the motor. 3) Run the engine at idling speed until the carburetor is empty. 4) Completely drain the water out of the outboard motor, and thoroughly clean the body.
688-9-S9-4 5/24/00 3:51 PM Page 8 E EMK23511 Flushing cooling system 8 Flushing in a water tank 1) Fit the outboard motor on the water tank, and fill the tank with fresh water to above the level of the anti-cavitation plate. 2) Shift into Neutral, start the engine, and run at low speed for a few minutes. cC q w If the fresh water level is below the level of the anticavitation plate, or if the water supply is insufficient, engine seizure may occur.
688-9-S9-4 5/24/00 3:51 PM Page 9 E 605014 8 Flushing with the flushing attachment 1) Fit the flushing attachment (option) in position on the lower casing, with rubber cups covering the water intake opening. The attachment must be installed from the front of the lower casing. 2) Connect a garden hose between the flushing attachment and the water tap. 3) Shift into “NEUTRAL”, and start the engine while supplying water, then keep it running at low speed for a few minutes.
688-9-S9-4 5/24/00 3:51 PM Page 10 E EMK29010 Battery Care w Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL; Flush with water. INTERNAL; Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. EYES; Flush with water for 15 minutes and get prompt medical attention.
688-9-S9-4 5/24/00 3:51 PM Page 11 E EMK30110* PERIODIC MAINTENANCE w Be sure to turn off the engine when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic. EMK33011 REPLACEMENT PARTS If replacement parts are necessary, use only genuine Yamaha parts or equivalents of the same type and of equivalent strength and materials.
688-9-S9-4 5/24/00 3:51 PM Page 12 E MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. The mark (●) indicates the check-ups which you may carry out yourself. The mark (1) indicates work to be carried out by your Yamaha dealer.
688-9-S9-4 5/24/00 3:51 PM Page 13 E EMU01202 CLEANING AND ADJUSTING SPARK PLUG w When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire. 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.
8-9-S9-4 5/24/00 3:51 PM Page 14 E When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque. Spark plug torque: Refer to “SPECIFICATIONS”, page 4-1. NOTE: 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 correct torque as soon as possible with a torque-wrench.
688-9-S9-4 5/24/00 3:51 PM Page 15 E 60/75/85 EMK38010 CHECKING FUEL SYSTEM w Gasoline (petrol) and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition. Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by Yamaha dealer or other qualified mechanic. Checking points 8 Fuel system parts leakage. 8 Fuel hose joint leakage. 8 Fuel hose cracks or other damage.
688-9-S9-4 5/24/00 3:51 PM Page 16 E EMK50000 CLEANING FUEL FILTER w Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly doing this procedure, consult your Yamaha dealer. 8 Do not perform this procedure on a hot or running engine. Allow the engine to cool. 8 There will be fuel in the fuel filter. Keep away from sparks, cigarettes, flames or other sources of ignition. 8 This procedure will allow some fuel to spill.
688-9-S9-4 5/24/00 3:51 PM Page 17 E 5) 60/75/85 q 6) w e 207013 1 2 3 4 Attach the filter assembly to the bracket with that the fuel hoses are attached to the filter assembly. Run the engine and check the filter and lines for leaks. Filter element O-ring Filter cap Filter housing EMK50210* Cleaning the fuel filter 115 1) 2) 3) 115 4) 5) Slightly loosen the filter cup ring nut. Remove the filter cup, catching any spilled fuel in a rag. Remove the filter element, and wash it in solvent.
688-9-S9-4 5/24/00 3:51 PM Page 18 E EMK54110 ADJUSTING IDLING SPEED w 8 Do not touch or remove electrical parts when starting or during operation. 8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running. cC This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used. Procedure NOTE: A diagnostic tachometer should be used for this procedure.
688-9-S9-4 5/24/00 3:51 PM Page 19 E EMU01329 60/75/85 REPLACING FUSE If the fuse has blown on an Electric start model, open the fuse holder and replace the fuse with a new one of proper amperage. q w 205016 115 w Be sure to use the specified fuse. An incorrect fuse or a piece of wire may allow excessive current flow. This could cause electrical system damage and a fire hazard. q NOTE: If the new fuse blows again immediately, consult a Yamaha dealer.
688-9-S9-4 5/24/00 3:51 PM Page 20 E EMK78010 CHECKING WIRING AND CONNECTORS 1) 2) 606012 Check that each grounding wire is properly secured. Check that each connector is engaged securely. EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head and crank case. WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head and crank case.
688-9-S9-4 5/24/00 3:51 PM Page 21 E EMU00909 GREASING E Yamaha grease A (Water resistant grease) Yamaha grease D (Corrosion resistant grease) *1 60/75/85 103031 *1.
688-9-S9-4 5/24/00 3:51 PM Page 22 E EMU00909 GREASING E Yamaha grease A (Water resistant grease) Yamaha grease D (Corrosion resistant grease) *1 115 *1.
688-9-S9-4 5/24/00 3:51 PM Page 23 E EML02011 CHECKING POWER TRIM AND TILT SYSTEM w 8 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 accidentally falls. 8 Make sure no one is under the outboard before performing this test. 1) 411024 Check the power trim and tilt unit for any sign of oil leaks.
688-9-S9-4 5/24/00 3:51 PM Page 24 E EML08011* CHECKING PROPELLER w 210012 602051 You could be seriously injured if the engine accidentally starts while you are near the propeller. 8 Before inspecting, removing or installing the propeller, remove the spark plug caps from the spark plugs. Also, put the shift control in Neutral, put the main switch in the “OFF” position 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.
688-9-S9-4 5/24/00 3:51 PM Page 25 E EMU00397 Installing the Propeller cC 8 Be sure to install the thrust washer before installing propeller, otherwise, lower case and propeller boss may be damaged. 8 Be sure to use a new cotter pin and bend the ends over securely. Otherwise, the propeller could come off during operation and be lost. 1) 2) 3) Apply Yamaha Marine grease or Corrosion resistant grease to the propeller-shaft. Install the thrust washer and propeller on the propeller-shaft.
688-9-S9-4 5/24/00 3:51 PM Page 26 E EML20010 CHANGING GEAR OIL w 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 accidentally falls. 1) Put the outboard in a vertical position (not tilted). w Be sure the outboard is securely fastened to the transom or a stable stand. You could be severely injured if the outboard falls on you. 000940 2) 3) 1 2 Place a suitable container under the gearcase.
688-9-S9-4 5/24/00 3:51 PM Page 27 E NOTE: For disposal of used oil consult your Yamaha dealer. 5) 601015 With the outboard motor in an vertical position, using a flexible or pressurized filling device, inject outboard motor hypoid gear oil (SAE 90) into the oil drain plug hole. Gear oil capacity: Refer to “SPECIFICATIONS”, page 4-1. 6) 7) 4-26 When oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. Insert and tighten the oil drain plug.
688-9-S9-4 5/24/00 3:51 PM Page 28 E EML22010 CLEANING FUEL TANK w Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly doing this procedure, consult your Yamaha dealer. 8 Keep away from sparks, cigarettes, flames or other sources of ignition when cleaning the fuel tank. 8 Remove the fuel tank from the boat before cleaning it. Work only outdoors in an area with good ventilation. 8 Wipe up any spilled fuel immediately.
688-9-S9-4 5/24/00 3:51 PM Page 29 E EML24010 60/75/85/115 INSPECTING AND REPLACING ANODE Yamaha outboard motor is protected from corrosion by a sacrificial anode(s). 604015 Check the anode periodically. Remove the scales from surfaces of the anode. For the replacement of the anode, consult a Yamaha dealer. 60/75/85 cC Do not paint the anode, for this would render it ineffective.
688-9-S9-4 5/24/00 3:51 PM Page 30 E EML26010 CHECKING BATTERY (for Electric start model) w Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: 8 Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury. 8 Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): 8 SKIN[C4]Flush with water.
688-9-S9-4 5/24/00 3:51 PM Page 31 E cC A poorly maintained battery will quickly deteriorate. 1) Check the electrolyte level at least once a month. Fill to the manufacturer’s recommended level when necessary. Top up only with distilled water (or pure de-ionized water suitable to use in batteries). cC Ordinary tap-water contains minerals harmhul to a battery, and should not be used for topping-up. 2) 3) 4-30 Keep the battery always in a good state of charge.
688-9-S9-4 5/24/00 3:51 PM Page 32 E EMU01279 Connecting the Battery w Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder. cC q EL L E V EL ER V U P P ER LE LOW w e 901012 8 Make sure the main switch (on applicable models) is “OFF” before working on the battery. 8 Reversal of the battery leads will damage the rectifier.
688-9-S9-4 5/24/00 3:51 PM Page 33 E EML40010 CHECKING BOLTS AND NUTS 1) 2) Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torques. Check the tightening torques of other bolts and nuts. EML42011 MOTOR EXTERIOR Cleaning the Outboard Motor After use, wash the exterior of the outboard with fresh water. Flush the cooling system with fresh water.
688-9-S9-4 5/24/00 3:51 PM Page 34 E -MEMO-
688-9-S9-5 5/24/00 3:54 PM Page 1 E EMN00010 Chapter 5 TROUBLE RECOVERY 1 TROUBLESHOOTING ..............................5-1 TEMPORARY ACTION IN EMERGENCY ............................................5-5 Impact damage.....................................5-5 Power trim/tilt will not operate ...........5-6 Starter will not operate ........................5-7 Treatment of submerged motor .........
688-9-S9-5 5/24/00 3:54 PM Page 2 E EMU01204¯ TROUBLESHOOTING A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.) If your outboard motor requires repair, bring it to a Yamaha dealer. Trouble Possible Cause 1. Battery capacity weak or low. 2.
688-9-S9-5 5/24/00 3:54 PM Page 3 E Trouble Possible Cause 1. Spark plug(s) fouled or incorrect type. 2. Fuel system obstructed. 3. Fuel contaminated or stale. 4. Fuel filter clogged. 5. Failed ignition parts. 6. Warning system activated. 7. Spark plug gap incorrect. 8. Poor connections or damaged ignition wiring. C. Engine idles irregularly or stalls. 9. Specified engine oil not used. 10. Thermostat faulty or clogged. 11. Carburetor adjustments incorrect. 12. Fuel pump damaged. 13.
688-9-S9-5 5/24/00 3:54 PM Page 4 E Trouble Possible Cause 1. Cooling system clogged. 2. Engine oil level low. 3. Heat range of spark plug incorrect. 4. Specified engine oil not used. D. Warning buzzer sounds or indicator lamp lights. 5. Engine oil contaminated or deteriorated. 6. Oil filter clogged. 7. Oil feed/injection pump malfunctions. 8. Load on boat improperly distributed. 9. Water pump/thermostat faulty. 10. Excess water in fuel filter cup. 1. Propeller damaged. 2.
688-9-S9-5 5/24/00 3:54 PM Page 5 E Trouble Possible Cause 13. Poor connections or damaged ignition wiring. 14. Failed ignition parts. 15. Specified engine oil not used. 16. Thermostat faulty or clogged. E. Engine power loss. 17. Air vent screw closed. 18. Fuel pump damaged. 19. Fuel joint connection incorrect. 20. Heat range of spark plug incorrect. 21. Engine not responding properly to shift lever position. 1. Propeller damaged. 2. Propeller shaft damaged. F. Engine vibrates excessively. 3.
688-9-S9-5 5/24/00 3:54 PM Page 6 E EMN20010 TEMPORARY ACTION IN EMERGENCY EMH80010 IMPACT DAMAGE w The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate. 607011 If the outboard motor hits any object in the water, follow the procedure below; 1) Stop the engine immediately . 2) Inspect control system and all components for damage . Also, inspect the boat damage .
688-9-S9-5 5/24/00 3:54 PM Page 7 E POWER TRIM/TILT WILL NOT OPERATE 60/75/85 60/75/85 q 411012* 115 q 411025 If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit, the engine can be tilted manually. Loosen the manual valve screw clockwise until it stops. Put the engine in the desired position, then tighten the manual valve screw counterclockwise.
688-9-S9-5 5/24/00 3:54 PM Page 8 E EMN30210 STARTER WILL NOT OPERATE If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be started with an emergency starter rope. w 8 Use this procedure only in an emergency and only to return to port for repairs. 8 When the emergency starter rope is used to start the engine, the start-ingear protection device does not operate. Make sure the transmission is in neutral.
688-9-S9-5 5/24/00 3:54 PM Page 9 E Procedure 1) Remove the top cowling. 2) Remove the flywheel cover by removing the bolts. 3) 208022 OFF ON START 701026 Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch. The main switch must be on. NOTE: 8 In this case, choke switch will not operate. Pull out the choke knob when engine is cold.
688-9-S9-5 5/24/00 3:54 PM Page 10 E EMN50011 TREATMENT OF SUBMERGED MOTOR 107012 If the outboard motor is submerged, immediately take it a Yamaha dealer. Otherwise, some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure bellow for taking care to minimize engine damage. 1) 2) 3) 4) 107013 5) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.
688-9-S9-6 5/24/00 3:53 PM Page 1 E EMP00010 Chapter 6 INDEX 1 INDEX........................................................
688-9-S9-6 5/24/00 3:53 PM Page 2 E EMP10010 INDEX A Adjusting idling speed ..........................4-17 Adjusting trim angle..............................3-17 Air vent screw...........................................2-3 B Battery care...............................................4-9 Battery requirement.................................1-7 Bow down...............................................3-19 Bow up ....................................................3-19 Breaking in (running in) engine.........
688-9-S9-6 5/24/00 3:53 PM Page 3 E Propeller selection ...................................1-8 R Remote control.........................................2-4 Remote control lever ...............................2-4 Replacement parts.................................4-10 Replacing fuse........................................4-18 Reverse ...................................................3-14 S Safety information ...................................1-3 Shifting...................................................
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shiro A5 5/30/00 2:20 PM Page 1
688-9-S9 \ 00.5.25 2:57 PM y [ W 1(1,1) 60F/75A/85A/115B OW YAMAHA MOTOR CO., LTD. Printed in Japan April 2000—0.
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