67F-9-15 hyoshi 01.4.26 1:06 PM y [ W 1(2,1) F80A/F100A F80A F100A OWNER’S MANUAL paper U.S.A.
67F-9-15 hyoshi 01.4.
67F-9-15-1 4/26/01 10:47 AM Page 1 E EMU01448 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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67F-9-15-1 4/26/01 10:47 AM Page 3 EMU00003 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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67F-9-15-1 4/26/01 10:47 AM Page 5 E EMU00004 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..........................1-4 IMPORTANT LABELS ..............................1-6 BASIC BOATING RULES .........................1-7 FUELING INSTRUCTIONS.....................1-11 Gasoline (Petrol).................................
67F-9-15-1 4/26/01 10:47 AM Page 6 E EMU00005 IDENTIFICATION NUMBERS RECORD EMU00007 OUTBOARD MOTOR SERIAL NUMBER YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON q F1001 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.
67F-9-15-1 4/26/01 10:47 AM Page 7 E EMU01385 EMISSION CONTROL INFORMATION q EMU01387 NORTH AMERICAN MODELS This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details. Approval label of Emission control certificate This label is attached to the bottom cowling. w 1 Emission control information label EMISSION CONTROL INFORMATION EM ENGINE FAMILY : F1038 THIS ENGINE CONFORMS TO 2001 U.S.
67F-9-15-1 4/26/01 10:47 AM Page 8 E EMU01389 STAR LABELS q Your outboard motor is labeled with a California Air Resources Board (CARB) star label. See below for a description of your particular label. 1 Star label 000847 One Star - Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S.
67F-9-15-1 4/26/01 10:47 AM Page 9 E EMU00917 Q SAFETY 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.
67F-9-15-1 4/26/01 10:47 AM Page 10 E 8 When a swimmer is in the water near you shift into neutral and shut off the engine. 8 Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the following: United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast Guard Headquarters Washington, D.C.
67F-9-15-1 4/26/01 10:47 AM Page 11 E EMU00014* q IMPORTANT LABELS WARNING LABELS 1 WARNING 8 Be sure shift control is in neutral before starting engine. (except 2HP) 8 Do not touch or remove electrical parts F1002 when starting or during operation. 8 Keep hands,hair,and clothes away from flywheel and other rotating parts while engine is running.
67F-9-15-1 4/26/01 10:47 AM Page 12 E EMU00015 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. These rules are used internationally, and are also enforced by the United States Coast Guard and local agencies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water.
67F-9-15-1 4/26/01 10:47 AM Page 13 E RULES WHEN ENCOUNTERING VESSELS will clear one another if you continue on your set course and speed.
67F-9-15-1 4/26/01 10:47 AM Page 14 E its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you. OTHER SPECIAL SITUATIONS There are three other rules you should be aware of when driving your boat around other vessels.
67F-9-15-1 4/26/01 10:47 AM Page 15 E tion. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geographic location. Always consult local boating authorities before driving your boat in unfamiliar waters. N EL MAIN CHANNEL BUOYS A N " 6" A C H C " 1" M N N O A N White Light C H D A R Odd number. increasing toward head of navigation.
67F-9-15-1 4/26/01 10:47 AM Page 16 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.
67F-9-15-1 4/26/01 10:47 AM Page 17 E EMU00025 GASOLINE (PETROL) Recommended gasoline: Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2 If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. If unleaded gasoline is not available, then leaded regular gasoline can be used. If leaded gasoline is usually used, engine valves and related parts should be inspected after every 300 hours of operation.
67F-9-15-1 4/26/01 10:47 AM Page 18 E EMU01149 ENGINE OIL Recommended engine oil; Use a combination of corresponding SAE and API shown in the chart below; SAE 10W-30 10W-40 20W-4 API SE SF SG SH Engine oil quantity: Refer to “SPECIFICATIONS”, Page 4-1. cC All four-stroke engines are shipped from the factory without engine oil. NOTE: If the recommended engine oil is not available, then a multigrade type engine oil such as SF-CC/CD,SG-CC/CD or SH-CD can be used.
67F-9-15-1 4/26/01 10:47 AM Page 19 E EMU00031 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. Minimum cold crank performance 380 Amps at -17.8°C (0°F) Minimum reserve capacity 124 minutes at 26.
67F-9-15-1 4/26/01 10:47 AM Page 20 E Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable for a smaller operating load.
67F-9-15-1 4/26/01 10:47 AM Page 21 E EMU01209 START-IN-GEAR PROTECTION Yamaha outboard motors or Yamaha approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is Neutral. Always select Neutral before starting the engine.
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67F-9-15-2 4/26/01 9:53 AM Page 1 E EMU00037 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-2 Remote control .....................................2-2 Trim tab .................................................2-6 Power trim / tilt switch .........................2-7 Digital tachometer................................2-8 Tilt support lever ................................
67F-9-15-2 4/26/01 9:53 AM Page 2 E EMU01206 MAIN COMPONENTS w q !1 !0 w !2 o i e u r t !3 y 1 2 3 4 5 6 7 8 Top cowling Cowling lock lever Oil drain bolt Anti-cavitation plate Trim tab (Anode) Propeller Cooling water inlet Clamp bracket 9 0 q *w *e Tilt support lever Flushing device Power trim and tilt switch Remote control box Digital tachometer * May not be exactly as shown; also may not be included as standard equipment on all models.
67F-9-15-2 4/26/01 9:53 AM Page 3 E EMU00039 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS EMU00096 REMOTE CONTROL Both the shifter and the throttle are actuated by the remote control lever. In addition, this control also has the electrical switches.
67F-9-15-2 4/26/01 9:53 AM Page 4 E EMU00100 N q w 701033* 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. 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.
67F-9-15-2 4/26/01 9:53 AM Page 5 E EMU00934 q w 000569 Engine Stop Lanyard Switch The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 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 lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away under power.
67F-9-15-2 4/26/01 9:53 AM Page 6 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.
67F-9-15-2 4/26/01 9:53 AM Page 7 E EMU00113 TRIM TAB e 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 q w 603014 B A An improperly adjusted trim tab may cause difficult steering. Always test run after the trim tab has been installed or replaced to be sure steering is correct. Be sure you have tightened the bolt after adjusting the trim tab.
67F-9-15-2 4/26/01 9:53 AM Page 8 E EMU01125 UP POWER TRIM/TILT SWITCH DN F1006* The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the side of the bottom engine cowling. 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.
67F-9-15-2 4/26/01 9:53 AM Page 9 E EMU01617 DIGITAL TACHOMETER q w e t y r u 001081 This gauge contains the tachometer, trim meter, hour meter, low oil pressure warning indicator, and the overheat warning indicator. 1 2 3 4 5 6 7 Tachometer Trim meter Hour meter Low oil pressure warning indicator Overheat warning indicator Set button Mode button NOTE: All segments of the display will light momentarily after the main switch is turned on and will return to normal thereafter.
67F-9-15-2 4/26/01 9:53 AM Page 10 E EMU01109 001059 Trim Meter This meter shows the trim angle of your outboard motor. NOTE: 8 Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired setting by operating the power trim and tilt switch. 8 If the trim angle of your motor exceeds the trim operating range, the top segment on the trim meter display will start to blink.
67F-9-15-2 4/26/01 9:53 AM Page 11 E EMU01110 Low Oil Pressure Warning Indicator If oil pressure drops too low, the warning indicator will start to blink. Refer to the section “LOW OIL PRESSURE WARNING” for details. 1 Low oil pressure warning indicator q 001060 cC 8 Do not operate the engine without oil. Serious engine damage will occur. 8 The low oil pressure warning indicator does not indicate the oil level in the engine. Use the Oil Level Gauge to check the remaining oil quantity.
67F-9-15-2 4/26/01 9:53 AM Page 12 E EMU00157 TILT SUPPORT LEVER To keep the outboard motor in the tiltedup position, lock the tilt support lever to the clamp bracket. F1009 EMU00163 TOP COWLING LOCK LEVERS To remove the engine top cowling, pull up the front and rear lock levers. 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 moving the levers downward.
67F-9-15-2 4/26/01 9:53 AM Page 13 E EMU00169* WARNING SYSTEM cC Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU01017 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate.
67F-9-15-2 4/26/01 9:53 AM Page 14 E EMU01018 LOW OIL PRESSURE WARNING If oil pressure drops too low, the warning device will activate. (1):Included (—):N/A Activation of warning device 001097 Tiller control model Remote control model Engine speed will automatically decrease to about 3,000 r/min. 1 The low oil pressure warning indicator will come on. 1 The buzzer will sound. 1 If the warning system has been activated, stop the engine as soon as it is safe to do so.
67F-9-15-3 4/26/01 1:35 PM Page 1 E EMU00174 Chapter 3 OPERATION INSTALLATION ........................................3-1 Mounting the outboard motor............3-2 Filling fuel..............................................3-4 PRE-OPERATION CHECKS ......................3-5 Checking the engine oil level ..............3-6 BREAKING IN (RUNNING IN) ENGINE ..3-7 STARTING ENGINE .................................3-8 WARMING UP ENGINE .........................3-11 SHIFTING ....................................
67F-9-15-3 4/26/01 1:35 PM Page 2 E EMU00175 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.
67F-9-15-3 4/26/01 1:35 PM Page 3 E EMU00176 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.
67F-9-15-3 4/26/01 1:35 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 104014 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.
67F-9-15-3 4/26/01 1:35 PM Page 5 E EMU00187* 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. EMU00189* Ring Free Fuel Additive Gasoline is a precise blend of many different substances, each chosen to give certain characteristics. Gasoline blends have been changing in recent years in response to concerns about pollution and resulting emissions regulations.
67F-9-15-3 4/26/01 1:35 PM Page 6 E EMU00204 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. cC Do not start the engine out of water. Overheating and serious engine damage can occur. EMU00206 Fuel 8 Check to be sure you have plenty of fuel for your trip. 8 Make sure there are no fuel leaks or gasoline fumes.
67F-9-15-3 4/26/01 1:35 PM Page 7 E EMU00209 Controls 8 Check throttle, shift, and steering for proper operation before starting the engine. 8 The controls should work smoothly, without binding or unusual free play. 8 Look for loose or damaged connections. 8 Check operation of the starter and stop switches when the outboard motor is in the water. EMU00210 Engine 8 Check the engine and engine mounting. 8 Look for loose or damaged fasteners. 8 Check the propeller for damage.
67F-9-15-3 4/26/01 1:35 PM Page 8 E EMU00224 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.
67F-9-15-3 4/26/01 1:35 PM Page 9 E EMU01197 STARTING ENGINE w 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. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw.
67F-9-15-3 4/26/01 1:35 PM Page 10 E EMU00247* PROCEDURE FOR REMOTE CONTROL MODEL N 4) 701015 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. 5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock plate on the other end of the lanyard in the engine stop switch.
67F-9-15-3 4/26/01 1:35 PM Page 11 E EMU00949 OFF ON Electric Start Model 7) Turn the main switch to “START”, and hold it for a maximum of 5 seconds. 8) Immediately after the engine starts, release the main switch to return it to “ON”. START 701022 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.
67F-9-15-3 4/26/01 1:35 PM Page 12 E EMU00258 WARMING UP ENGINE 1) 2) F1012 3) Before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (Failure to do this will shorten engine life.) Be sure the low oil pressure warning indicator goes off after starting the engine. Check for a steady flow of water from the cooling-water pilot hole. cC 8 If the low oil pressure indicator does not go off after the engine starts, stop the engine.
67F-9-15-3 4/26/01 1:35 PM Page 13 E EMU00261 SHIFTING UP DN w Before shifting, make sure there are no swimmers or obstacles in the water near you. 701034** 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 EMU00264 FORWARD 701043 Pull up the neutral interlock trigger (If equipped) and move the remote control lever quickly and firmly from Neutral to Forward.
67F-9-15-3 4/26/01 1:35 PM Page 14 E EMU00273 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. EMU00276 1) 2) ON OFF START 701023 Turn the main switch to “OFF”. If the fuel joints are provided, disconnect the fuel line from the motor after stopping the engine. 3) Tighten the air vent screw on the fuel tank cap after stopping the engine, if it is equipped.
67F-9-15-3 4/26/01 1:35 PM Page 15 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.
67F-9-15-3 4/26/01 1:35 PM Page 16 E ADJUSTING TRIM ANGLE EMU01401 UP DN Power Trim/Tilt Model UP DN w q 701034* 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.
67F-9-15-3 4/26/01 1:35 PM Page 17 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.
67F-9-15-3 4/26/01 1:35 PM Page 18 E EMU01200 TILTING UP/DOWN 000837 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 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.
67F-9-15-3 4/26/01 1:35 PM Page 19 E EMU01029 PROCEDURE FOR TILTING UP UP DN Power trim/tilt model UP DN 1) 2 701034* Remove the fuel-line connection from the motor. (If the fuel connector is provided on the motor.) )Push the power trim/tilt switch “UP” until the outboard has tilted up completely. UP DN F1006* 3) Turn the tilt-support lever toward engine bracket and support the engine. w F1009 8 After tilting the engine, be sure to support it with the tilt-support lever.
67F-9-15-3 4/26/01 1:35 PM Page 20 E EMU00303 PROCEDURE FOR TILTING DOWN Power trim/tilt model 1) 2) 3) F1015 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.
67F-9-15-4 4/26/01 9:55 AM Page 1 E EMU00317 Chapter 4 MAINTENANCE SPECIFICATION DATA.............................4-1 TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-3 Trailering outboard motor...................4-3 Storing outboard motor ......................4-4 PERIODIC MAINTENANCE......................4-8 Replacement parts ...............................4-8 Maintenance chart................................4-9 Greasing ..............................................
67F-9-15-4 4/26/01 9:55 AM Page 2 E EMU00322* SPECIFICATION DATA Model Item Unit F80TRA DIMENSIONS 8Overall Length 8Overall Width 8Overall Height 8Transom height 8Weight mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.) L/X L/X L/X 817 (32.2) 479 (18.9) 1,582 (62.3) / 1,710 (67.3) 536 (21.1 ) / 664 (26.1) 172 (379) / 176 (388) PERFORMANCE 8Full throttle operating range 8Maximum output 8Idling speed (Neutral) r/min kW (HP) @ r/min r/min 5,000 ~ 6,000 58.8 (80.
67F-9-15-4 4/26/01 9:55 AM Page 3 E F100TRA — 817 (32.2) 479 (18.9) 1,582 (62.3) / 1,710 (67.3) 536 (21.1 ) / 664 (26.1) 172 (379) / 176 (388) 5,000 ~ 6,000 73.6(100.0)@5,500 800 ~ 900 4-stroke, DOHC, L4 1,596 (97.39) 79.0 × 81.4 (3.11 × 3.20) CDI system LFR5A-11 1.1 (0.043) Remote control Electric start 0.17 ~ 0.23 (0.007 ~ 0.009) 0.31 ~ 0.37 (0.012 ~ 0.015) 12-70 ~ 12-100 380 124 12-20 Prime start Forward-Neutral-Reverse 2.
67F-9-15-4 4/26/01 9:55 AM Page 4 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 The motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the motor in the tilt position using a motor support device such as a transom saver bar.
67F-9-15-4 4/26/01 9:55 AM Page 5 E EMU00330* STORING OUTBOARD MOTOR 000898 When storing your Yamaha outboard for prolonged periods of time, (2 months or longer), several important procedures must be performed to prevent expensive damage. It is advisable to have your outboard serviced by an authorized Yamaha dealer prior to storage. However, the following procedures can be performed by you, the owner, with a minimum of tools.
67F-9-15-4 4/26/01 9:55 AM Page 6 E EMU00338* Flushing Cooling System and Fogging Engine Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging of the engine is mandatory to prevent expensive engine damage due to rust. Perform the flushing and fogging at the same time. w 8 Do not touch or remove electrical parts when starting or during operation.
67F-9-15-4 4/26/01 9:55 AM Page 7 E NOTE: A flushing attachment is available from a Yamaha dealer. EMU00349 Lubrication 1) Remove the spark plug(s). Spray a Yamaha “Stor-Rite Engine Fogging Oil” into each cylinder for 10 seconds. Grease the spark plug threads and reinstall the spark plug(s) and torque to proper specification. (Refer to the “CLEANING AND ADJUSTING SPARK PLUG”). 2) Turn the engine over with the stop lanyard disconnected to work the fogging oil into the piston rings.
67F-9-15-4 4/26/01 9:55 AM Page 8 E EMU00353 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.
F-9-15-4 4/26/01 9:55 AM Page 9 E EMU00913 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. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual.
67F-9-15-4 4/26/01 9:55 AM Page 10 E EMU00361 MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. The mark (7) indicates the check-ups which you may carry out yourself. The mark (2) indicates work to be carried out by your Yamaha dealer.
67F-9-15-4 4/26/01 9:55 AM Page 11 E EMU00366 GREASING Yamaha marine grease (Water resistant grease) F1017 4-10
67F-9-15-4 4/26/01 9:55 AM Page 12 E EMU01035 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.
67F-9-15-4 4/26/01 9:55 AM Page 13 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.
67F-9-15-4 4/26/01 9:55 AM Page 14 E EMU00369 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. 8 Fuel connector leakage.
67F-9-15-4 4/26/01 9:55 AM Page 15 E EMU00370 INSPECTING 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.
67F-9-15-4 4/26/01 9:55 AM Page 16 E EMU01577 NOTE: If any water is in the fuel, the float 5 will rise. If so, remove the cup and drain the water. 1) 000137 2) 3) r w e t 4) q 000138 5) 6) 4-15 Remove the nut holding the fuel filter assembly if so equipped. Unscrew the filter cup 1, catching any spilled fuel in a rag. Remove the filter element 2, and wash it in solvent. Allow it to dry. Inspect the filter element and O-ring 3 to make sure they are in good condition. Replace them if necessary.
67F-9-15-4 4/26/01 9:55 AM Page 17 E EMU00991 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. q F1045 A diagnostic tachometer should be used for this procedure.
67F-9-15-4 4/26/01 9:55 AM Page 18 E EMU01415 CHANGING ENGINE OIL w 8 Avoid draining the engine oil immediately after stopping the engine. The oil is hot and should be handled with care to avoid burns. 8 Be sure the outboard is securely fastened to the transom or a stable stand. cC 8 Change the engine oil after the first 10 hours of operation, and every 100 hours or at 6-month intervals thereafter. Otherwise, the engine will wear quickly.
67F-9-15-4 4/26/01 9:55 AM Page 19 E NOTE: If a torque wrench is not available when you are installing the drain plug, finger tighten the bolt just until the gasket comes into contact with the surface of the drain hole. Then tighten 1/4 - 1/2 turn. Have the drain plug torqued to the correct value with a torque wrench as soon as possible. 4) w Remove the oil filler cap 2. Add the correct amount of oil through the filler hole. Reinstall the filler cap.
67F-9-15-4 4/26/01 9:55 AM Page 20 E 6) 000815 Turn off the engine and wait 3 minutes. Recheck the oil level using the dipstick to be sure the level falls between the upper and lower marks. Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark. 7) Dispose of used oil according to local regulations. NOTE: 8 For disposal of used oil consult your Yamaha dealer.
67F-9-15-4 4/26/01 9:55 AM Page 21 E EMU01330 w REPLACING FUSE If a fuse has blown, remove the electrical cover, open the fuse holder and remove the fuse with a fuse puller. Replace it with a spare one of proper amperage. t w q w r 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. NOTE: If the new fuse blows again immediately, consult a Yamaha dealer.
67F-9-15-4 4/26/01 9:55 AM Page 22 E EMU00383 CHECKING WIRING AND CONNECTORS 1) 2) Check that each grounding wire is properly secured. Check that each connector is engaged securely. EMU00384 F1030 EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head and crank case. EMU00385 WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head and crank case.
67F-9-15-4 4/26/01 9:55 AM Page 23 E EMU00992 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) q F1040 Check the power trim and tilt unit for any sign of oil leaks.
67F-9-15-4 4/26/01 9:55 AM Page 24 E EMU00388* CHECKING PROPELLER 1) 2) Remove the 5 screws and the cover. Remove the spark plug caps from the spark plugs. w F1042 F1026 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.
67F-9-15-4 4/26/01 9:55 AM Page 25 E EMU00976 q r y e w t 001146 Removing the Propeller 1) Straighten the cotter-pin 1 and pull it out using a pair of pliers. 2) Remove the propeller nut 2, washer 3 and spacer 4. 3) Remove the propeller 5 and thrust washer 6. 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.
67F-9-15-4 4/26/01 9:55 AM Page 26 E EMU00905 CHANGING GEAR OIL w 8 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. 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. 1) Put the outboard in a vertical position (not tilted). 2) Place a suitable container under the gear-case. 3) Remove the oil drain plug 1.
67F-9-15-4 4/26/01 9:55 AM Page 27 E Gear oil grade/capacity: Refer to SPECIFICATIONS on page 4-1. 6) 7) When the 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. EMU00831* INSPECTING AND REPLACING ANODE(S) 603024 Yamaha outboard motor is protected from corrosion by a sacrificial anode(s). Check the anode(s) periodically. Remove the scales from surfaces of the anode(s).
67F-9-15-4 4/26/01 9:55 AM Page 28 E EMU00404 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 - Flush with water.
67F-9-15-4 4/26/01 9:55 AM Page 29 E cC 8 A poorly maintained battery will quickly deteriorate. 8 Ordinary tap-water contains minerals harmful to a battery, and should not be used for topping-up. EL LEV EL ER V UPP ER LE W LO 901015 1) 2) 3) 4-28 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). Keep the battery always in a good state of charge.
67F-9-15-4 4/26/01 9:55 AM Page 30 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 LEV EL ER V UPP ER LE LOW 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.
67F-9-15-4 4/26/01 9:55 AM Page 31 E EMU00408* CHECKING BOLTS AND NUTS 1) 2) Check that bolts securing the engine and the nut securing the flywheel are tightened with their specified tightening torque. Check the tightening torque of other bolts and nuts. EMU01172 CLEANING COOLING-WATER PASSAGES Flushing device equipped model q e w 000845 Perform this procedure right after operation for the most thorough flushing.
67F-9-15-4 4/26/01 9:55 AM Page 32 E NOTE: 8 When flushing the engine with the boat in the water, tilting up the engine until it is completely out of the water will achieve better results. 8 Refer to cooling system flushing instructions in “TRANSPORTING AND STORING OUTBOARD MOTOR”. EMU00409 MOTOR EXTERIOR EMU00410 F1029 Cleaning the Outboard Motor After use, wash the exterior of the outboard with fresh water. Flush the cooling system with fresh water.
67F-9-15-4 4/26/01 9:55 AM Page 33 E EMU00413 COATING THE BOAT BOTTOM F1021* A clean hull improves boat performance. The boat bottom should be kept as clean of marine growths 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.
67F-9-15-4 4/26/01 9:55 AM Page 34 E -MEMO-
67F-9-15-5 4/26/01 9:56 AM Page 1 E EMN00010 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING ..............................5-1 TEMPORARY ACTION IN EMERGENCY ............................................5-5 Impact damage.....................................5-5 Power trim/tilt will not operate ...........5-5 Starter will not operate ........................5-6 Engine fails to operate .........................5-8 Treatment of submerged motor .........
67F-9-15-5 4/26/01 9:56 AM 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.
67F-9-15-5 4/26/01 9:56 AM 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.
67F-9-15-5 4/26/01 9:56 AM 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. 1. Propeller damaged. 2. Propeller pitch or diameter incorrect. 3. Trim angle incorrect.
67F-9-15-5 4/26/01 9:56 AM 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.
67F-9-15-5 4/26/01 9:56 AM Page 6 E EMU00416 TEMPORARY ACTION IN EMERGENCY EMU00417 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.
67F-9-15-5 4/26/01 9:56 AM Page 7 E EMU00423 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 gear shift lever/ remote control lever is in neutral.
67F-9-15-5 4/26/01 9:56 AM Page 8 E EMU00429* Emergency Starting Engine 1) Remove the top cowling. F1008A F1008B 2) 3) Remove the two bolts holding the flywheel cover. Lift up the rear of flywheel cover and pull it out forward. F1033 4) OFF ON START 5) 701024 6) 7) 8) 9) F1034 5-7 Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in Neutral and that the lock plate is attached to the engine stop lanyard switch. The main switch must be “ON”.
67F-9-15-5 4/26/01 9:56 AM Page 9 E EMU00435* ENGINE FAILS TO OPERATE q F1025A In the unlikely event of an ignition control system malfunction, the engine speed may become erratic or the engine may stop. In such a case, follow the procedure below. 1) Remove the electric cover 1. 2) Disconnect the connection of the yellow cord 2 (emergency circuit) to return to the nearest port. w When the connection is disconnected, the idling and low speeds are slightly higher than normal.
67F-9-15-5 4/26/01 9:56 AM Page 10 E EMU00446 TREATMENT OF SUBMERGED MOTOR 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. EMU00448 1) 2) 3) 4) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.
67F-9-15-6 4/26/01 9:57 AM Page 1 E EMU00450 Chapter 6 INDEX INDEX........................................................
67F-9-15-6 4/26/01 9:57 AM Page 2 E EMU00451 INDEX A Adjusting idling speed ..........................4-16 Adjusting trim angle..............................3-15 B Basic boating rules ..................................1-7 Battery care...............................................4-7 Battery requirement ..............................1-14 Breaking in (running in) engine..............3-7 C Changing engine oil ..............................4-17 Changing gear oil...................................
67F-9-15-6 4/26/01 9:57 AM Page 3 E P Periodic maintenance..............................4-8 Power trim/tilt switch .......................2-5, 2-7 Power trim/tilt will not operate...............5-5 Pre-operation checks ...............................3-5 Propeller selection .................................1-14 R Remote control.........................................2-2 Remote control lever ...............................2-2 Replacement parts...................................4-8 Replacing fuse..........
67F-9-15-6 4/26/01 9:57 AM Page 4 EMU01599 IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha. Yamaha is ready to stand behind your purchase with strong warranty coverage.
67F-9-15-6 4/26/01 9:57 AM Page 5 5. Your warranty applies specifically to repairs made in the country of purchase. If your U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian purchased Yamaha needs service while in the United States, Yamaha will assist the local dealer whenever possible. However, some products available in one country may not be sold or serviced in the other. 6.
67F-9-15-6 4/26/01 9:57 AM Page 6 EMU01404 YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha 1999-or-later model four-stroke outboard motors originally distributed by Yamaha Motor Corporation, U.S.A. will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.
67F-9-15-6 4/26/01 9:57 AM Page 7 SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs, shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes, are not covered by warranty. Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yamaha Outboard Motor Dealer are excluded from warranty coverage.
67F-9-15-6 4/26/01 9:57 AM Page 8 CUSTOMER SERVICE If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you.
67F-9-15-6 4/26/01 9:57 AM Page 9 EMU01178 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha. This model was manufactured as a U.S.A.
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GM6-9-05-6 0.10.
67F-9-15 hyoshi 01.4.26 1:06 PM y [ W 1(1,1) F80A/F100A OW Printed in Japan March 2001—0.
67F-9-15 hyoshi 01.4.26 1:06 PM y [ W 1(2,1) F80A/F100A F80A F100A OWNER’S MANUAL paper U.S.A.
