67K-9-14 hyoshi 4/10/02 2:48 PM Page 1 (2,1) SX150B SX200B OWNER’S MANUAL U.S.A.
67K-9-14 hyoshi 4/10/02 2:48 PM Page 2 (1,1)
67K-9-14-1 2/28/02 11:23 AM Page 1 E EMU01449 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.
67K-9-14-1 2/28/02 11:23 AM Page 3 CONTENTS EMU00003 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.
67K-9-14-1 2/28/02 11:23 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..........................1-3 IMPORTANT LABELS ..............................1-5 3 BASIC BOATING RULES .........................1-6 FUELING INSTRUCTIONS.....................1-10 Gasoline ..............................................
7K-9-14-1 2/28/02 11:23 AM 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.
67K-9-14-1 2/28/02 11:23 AM Page 7 E EMU01385 EMISSION CONTROL INFORMATION q EMU01386 NORTH AMERICAN MODELS w 108035 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. 1 Emission control information label EMISSION CONTROL INFORMATION ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S.
67K-9-14-1 2/28/02 11:23 AM Page 8 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.
67K-9-14-1 2/28/02 11:23 AM Page 9 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.
67K-9-14-1 2/28/02 11:23 AM Page 10 E EMU00014 q IMPORTANT LABELS w w WARNING LABELS 1 WARNING 6 Be sure shift control is in neutral 6before starting engine. (except 2HP) 6 Do not touch or remove electrical parts 6 when starting or during operation. 6 Keep hands,hair,and clothes away from flywheel 6and other rotating parts while engine is running. r 001464 6A1-83625-41 2 WARNING e Hot surface under this cover during and after operation.
67K-9-14-1 2/28/02 11:23 AM Page 11 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.
67K-9-14-1 2/28/02 11:23 AM Page 12 E RULES WHEN ENCOUNTERING VESSELS There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed: Meeting (you are approaching another vessel head-on) Crossing (you are traveling across the other vessel’s path) Overtaking (you are passing or being passed by another vessel) In the following illustration, your boat is in the center.
67K-9-14-1 2/28/02 11:23 AM Page 13 E 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. 2. 3. OTHER SPECIAL SITUATIONS There are three other rules you should be aware of when driving your boat around other vessels. Narrow channels and bends When navigating in narrow channels, you should keep to the right when it is safe and practical to do so.
67K-9-14-1 2/28/02 11:23 AM Page 14 E 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 O AN N White Light C H D A R Odd number. increasing toward head of navigation.Leave to port (left) proceeding upstream.
67K-9-14-1 2/28/02 11:23 AM Page 15 E EMU00017 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.
67K-9-14-1 2/28/02 11:23 AM Page 16 E EMU01804 GASOLINE 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. EMU00027 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings.
67K-9-14-1 2/28/02 7:10 PM Page 17 E EMU01775 BATTERY REQUIREMENT cC Do not use a battery that does not meet the specified capacity. If a battery which does not meet specifications is used, the electric system could perform poorly or be overloaded, causing electric system damage. For electric start models, choose a battery which meets the following specifications. EMU01860 Minimum cold cranking amps (CCA/SAE): 380 amps at -18°C (-0.
67K-9-14-1 2/28/02 11:23 AM Page 18 E EMU01395 PROPELLER SELECTION The performance of your outboard motor will be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine.
67K-9-14-1 2/28/02 11:23 AM Page 19 E 14-1/2x17-M 1 23 1 Propeller diameter (in inches) 2 Propeller pitch (in inches) 3 Type of propeller (propeller mark) Refer to the section “CHECKING PROPELLER” for instructions on propeller removal and installation. 602022 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.
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67K-9-14-2 2/28/02 11:19 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 Digital speedometer...........................2-10 Tilt support lever ...........
67K-9-14-2 2/28/02 11:19 AM Page 2 E EMU01206 MAIN COMPONENTS w q !0 o w w i !1 u !3 !2 YAMAHA SPEED y t 1 2 3 4 *5 6 7 8 9 Top cowling Top cowling lock levers Anti-cavitation plate Trim tab (Anode) Propeller Cooling water inlet Clamp bracket Tilt support lever Flushing device Km/h knot mph e r * * * * 0 q w e r km mile TRIP TIME set BATT mode !4 Power trim and tilt switch Remote control box (Side mount type) Digital tachometer Digital speedometer Remote oil tank * May not be exac
67K-9-14-2 2/28/02 11:19 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.
67K-9-14-2 2/28/02 11:19 AM Page 4 E EMU00099 Neutral Interlock Trigger To shift out of Neutral, the neutral interlock trigger of the remote control lever must first be pulled up. UP DN EMU00100 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.
67K-9-14-2 2/28/02 11:19 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.
67K-9-14-2 2/28/02 11:19 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.
67K-9-14-2 2/28/02 11:19 AM Page 7 E EMU00113 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. 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.
67K-9-14-2 2/28/02 11:19 AM Page 8 E EMU01125 POWER TRIM/TILT SWITCH UP DOWN 302012 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.
67K-9-14-2 2/28/02 11:19 AM Page 9 E EMU01614 DIGITAL TACHOMETER q w e t y r u 001078 This gauge contains the tachometer, trim meter, hour meter, oil level indicator, and the overheat warning indicator. 1 2 3 4 5 6 7 Tachometer Trim meter Hour meter Oil level 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.
67K-9-14-2 2/28/02 11:19 AM Page 10 E EMU01620 001087 Hour Meter This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off.
67K-9-14-2 2/28/02 11:19 AM Page 11 E EMU01553 Overheat Warning Indicator If the engine temperature rises too high, the warning indicator will start to blink. Refer to “OVERHEAT WARNING” for details. q 1 Overheat warning indicator 001052 cC Do not continue to operate the engine if a warning device has activated. If necessary, refer to the “TROUBLESHOOTING” section in this manual. Consult your dealer if the problem cannot be located and corrected.
67K-9-14-2 2/28/02 11:19 AM Page 12 E EMU00141 YAMAHA SPEED Km/h knot mph km mile TRIP TIME set BATT mode 802034 Speedometer The meter will show the boat speed. NOTE: The speedometer displays km/h, mph, or knots, depending upon operator preference. Select the desired unit of measurement by setting the selector switch on the back of the meter. See the illustration for setting.
67K-9-14-2 2/28/02 11:19 AM Page 13 E EMU01275 YAMAHA SPEED Km/h knot mph km mile TRIP TIME set BATT mode 802025* Clock This meter shows the current time. Repeatedly push and release the “mode” button until the indicator on the face of the meter points to “TIME.” To set the clock, be sure the meter is in the “TIME” mode. Press the “set” button; the hour display will begin blinking. Press the “mode” button until the desired hour is displayed.
67K-9-14-2 2/28/02 11:19 AM Page 14 E EMU00145 YAMAHA SPEED Km/h knot mph w q km mile TRIP TIME set BATT mode 802031 Warning indicator 8 Fuel warning If the fuel level decreases to one segment the fuel level warning segment 1 begins blinking. 8 Low battery voltage warning If battery voltage drops, the display 2 will be automatically turned on and it begins blinking. cC Do not continue to operate the engine if a warning device has activated. Refer to the TROUBLESHOOTING section in this manual.
67K-9-14-2 2/28/02 11:19 AM Page 15 E 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. 301021 301022 EMU01146 FLUSHING DEVICE q This device 1 is used to clean the cooling water passages of the motor using a garden hose and tap water.
67K-9-14-2 2/28/02 11:19 AM Page 16 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. EMU01476 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate.
67K-9-14-2 2/28/02 11:19 AM Page 17 E EMU00172 OIL LEVEL WARNING / OIL FILTER CLOGGING WARNING This engine has an oil level warning system. If oil level falls below lower limit, the warning device will activate. (1); Included (—); N/A Warning device activation Tiller control model Remote control model The engine speed will automatically decrease to about 2,000 r/min. 1 The oil level warning indicator will come on. 1 The buzzer will sound.
67K-9-14-2 2/28/02 11:19 AM Page 18 E – MEMO –
67K-9-14-3 2/28/02 11:20 AM Page 1 E EMU00174 Chapter 3 OPERATION INSTALLATION ........................................3-1 Mounting the outboard motor............3-2 FILLING FUEL AND ENGINE OIL ............3-4 Filling fuel..............................................3-4 Filling oil ................................................3-5 PRE-OPERATION CHECKS ......................3-8 Operation after a long period of storage...................................................3-9 BREAKING IN ENGINE ...........
67K-9-14-3 2/28/02 11:20 AM 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.
67K-9-14-3 2/28/02 11:20 AM 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.
67K-9-14-3 2/28/02 11:20 AM 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.
67K-9-14-3 2/28/02 11:20 AM Page 5 E EMU00186 FILLING FUEL AND ENGINE OIL EMU01031 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. EMU01019 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.
67K-9-14-3 2/28/02 11:20 AM Page 6 E EMU01800 FILLING OIL This engine uses the oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operating conditions. No fuel premixing is needed (except during break-in). Simply pour gasoline into the fuel tank and oil into the oil tank. Convenient indicator segments indicate the status of the oil supply. For details on reading the indicator segments, see “Oil level indicator” in this chapter.
67K-9-14-3 2/28/02 11:20 AM Page 7 E cC When the engine is operated for the first time or stored for a period of time, a minimum of 5 liters (5.3 US qt, 4.4 Imp qt) of oil should be kept in the remote oil tank. Otherwise the oil-feed pump chamber will not be filled with oil, and no oil will be supplied.
67K-9-14-3 2/28/02 11:20 AM Page 8 E EMU01543 Oil Level Indicator The various oil level system functions are as follows: Oil level indicator (Digital tachometer) Oil level indicator (Analog tachometer) Engine oil tank Remote oil tank More than 300 cm3 (0.32 US qt, 0.26 Imp qt) More than 1,500 cm3 (1.6 US qt, 1.31 Imp qt) • No refilling necessary. Yellow More than 300 cm3 (0.32 US qt, 0.26 Imp qt) 1,500 cm3 (1.6 US qt, 1.31 Imp qt) or less • Add oil, refer to “FILLING OIL.
67K-9-14-3 2/28/02 11:20 AM Page 9 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.
67K-9-14-3 2/28/02 11:20 AM Page 10 E EMU00211 Engine 8 Check the engine and engine mounting. 8 Look for loose or damaged fasteners. 8 Check the propeller for damage. 8 Check that the battery is in good condition and battery connections are secure. EMU01792 OPERATION AFTER A LONG PERIOD OF STORAGE When operating the engine after a long period (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.
67K-9-14-3 2/28/02 11:20 AM Page 11 E EMU01779 BREAKING IN ENGINE Your new engine requires a period of break-in to allow mating surfaces of moving parts to wear in evenly. Correct breakin will help ensure proper performance and longer engine life. cC 8 Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage. 8 Premix fuel must be used during breakin in addition to oil in the oil injection system. 8 After break-in, use gasoline only.
67K-9-14-3 2/28/02 11:20 AM Page 12 E EMU01788 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.
67K-9-14-3 2/28/02 11:20 AM Page 13 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.
67K-9-14-3 2/28/02 11:20 AM Page 14 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.
67K-9-14-3 2/28/02 11:20 AM Page 15 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.
67K-9-14-3 2/28/02 11:20 AM Page 16 E EMU01198 WARMING UP ENGINE 1) 2) 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 309013 A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages.
67K-9-14-3 2/28/02 11:20 AM Page 17 E EMU00261 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 EMU00264 FORWARD 701043 N Pull up the neutral interlock trigger (If equipped) and move the remote control lever quickly and firmly from Neutral to Forward.
67K-9-14-3 2/28/02 11:20 AM Page 18 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.
67K-9-14-3 2/28/02 11:20 AM Page 19 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.
67K-9-14-3 2/28/02 11:20 AM Page 20 E ADJUSTING TRIM ANGLE EMU01401 Power Trim/Tilt Model w 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.
67K-9-14-3 2/28/02 11:20 AM Page 21 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.
67K-9-14-3 2/28/02 11:20 AM Page 22 E EMU01200 TILTING UP/DOWN 000856 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.
67K-9-14-3 2/28/02 11:20 AM Page 23 E EMU01201 UP PROCEDURE FOR TILTING UP Power trim/tilt model UP DOWN 1) 2) DN 702014 3) If there is a fuel joint or a fuel cock on the boat, disconnect the fuel line or close the fuel cock. Push the power trim/tilt switch “UP” until the outboard has tilted up completely. Turn the tilt-support lever toward you and support the engine. w After tilting the engine, be sure to support it with the tilt-support lever.
67K-9-14-3 2/28/02 11:20 AM Page 24 E EMU00303 PROCEDURE FOR TILTING DOWN Power trim/tilt model 1) 2) 3) 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.
67K-9-14-4 2/28/02 11:21 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 ..............................................
67K-9-14-4 3/1/02 1:25 PM Page 2 E EMU00318* SPECIFICATION DATA Model Unit Item SX150TRB DIMENSIONS Overall Length Overall Width Overall Height Transom height Weight* X X X mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.) 823 (32.4) 577 (22.7) 1,742 (68.6) 642 (25.3) 206 (454) PERFORMANCE Full throttle operating range Maximum output Idling speed (Neutral) r/min kW (HP) @ r/min r/min 4,500 ~ 5,500 110.3 (150.
67K-9-14-4 2/28/02 7:15 PM Page 3 E SX200TRB — 823 (32.4) 577 (22.7) 1,742 (68.6) 642 (25.3) 206 (454) 4,500 ~ 5,500 147.1 (200.0) @ 5,000 700 ~ 760 2-stroke, 90°V6 2,596 (158.4) 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 380 502 124 12-35 Electronic Fuel Injection Forward-Neutral-Reverse 1.
67K-9-14-4 2/28/02 11:21 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. 000891 EMU00326 TRAILERING OUTBOARD MOTOR The motor should be trailered and stored in the normal running position.
K-9-14-4 2/28/02 11:21 AM Page 5 E EMU01777 STORING OUTBOARD MOTOR When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent expensive damage. This is especially important for your oil injection-equipped outboard motor due to the lean oil ratios used at idle prior to shutting the engine off for the season. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage.
67K-9-14-4 2/28/02 11:21 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.
67K-9-14-4 2/28/02 11:21 AM Page 7 E EMU00350* Lubrication 1) Remove the spark plug(s). Spray a “Yamaha Stor-Rite Engine Fogging Oil” into each cylinder for 5 seconds. Grease the spark plug threads and reinstall the spark plug(s) and torque to proper specification. (Refer to “CLEANING AND ADJUSTING SPARK PLUG”.) 2) Turn the engine over with the stop lanyard disconnected to work the fogging oil into the piston rings. 3) Fill the oil tanks. This prevents the formation of condensation.
67K-9-14-4 2/28/02 11:21 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.
67K-9-14-4 2/28/02 11:21 AM Page 9 E EMU01569 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.
67K-9-14-4 2/28/02 11:21 AM Page 10 E EMU00362* MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating conditions, “but the following table gives general guidelines. The mark (6) indicates the check-ups which you may carry out yourself. The mark (1) indicates work to be carried out by your Yamaha dealer.
67K-9-14-4 2/28/02 11:21 AM Page 11 E EMU00366 GREASING Yamaha marine grease (Water resistant grease) 4-10
67K-9-14-4 2/28/02 11:21 AM Page 12 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.
67K-9-14-4 2/28/02 11:21 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.
67K-9-14-4 2/28/02 11:21 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.
67K-9-14-4 2/28/02 11:21 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.
67K-9-14-4 2/28/02 11:21 AM Page 16 E 5) Tighten the ring nut approximately an additional 1/4 turn until ring nut is tight. Align one of the four larger ring nut tabs into the slot of the locking tab. Install the locking tab bolt and tighten. 6) Run the engine and check the filter and lines for leaks. NOTE: If any water is in the fuel, the red ring in the fuel filter unit will float. If so, remove the cup and drain the water.
67K-9-14-4 2/28/02 11:21 AM Page 17 E A diagnostic tachometer should be used for this procedure. 1) Start the engine and allow it to warm up fully in Neutral until it is running smoothly. If the outboard is mounted on a boat, be sure the boat is tightly moored. 2) Adjust the throttle stop-screw 1 to set the idling speed to specification (see “SPECIFICATIONS” on page 4-1) by turning the stop-screw clockwise to increase the idling speed, and turning it counterclockwise to decrease the idling speed.
67K-9-14-4 2/28/02 11:21 AM Page 18 E r e t EMU01330 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. w q w 000855 t 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.
67K-9-14-4 2/28/02 11:21 AM Page 19 E EMU00993 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 w e Check the power trim and tilt unit for any sign of oil leaks.
67K-9-14-4 2/28/02 11:21 AM Page 20 E EMU00388 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.
67K-9-14-4 2/28/02 11:21 AM Page 21 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.
67K-9-14-4 2/28/02 11:21 AM Page 22 E EMU01460 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/knob is locked. Severe injury could occur if the outboard accidentally falls. 1) Tilt the outboard motor so that the oil drain plug is at the lowest point possible. 2) Place a suitable container under the gear-case.
67K-9-14-4 2/28/02 11:21 AM Page 23 E 5) With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the oil drain plug hole. Gear oil grade/capacity: Refer to “SPECIFICATIONS,” page 4-1. 6) 601033 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.
67K-9-14-4 2/28/02 11:21 AM Page 24 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.
67K-9-14-4 2/28/02 11:21 AM Page 25 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. 1) 2) 3) 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.
67K-9-14-4 2/28/02 11:21 AM Page 26 E cC 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. 8 Connect the RED lead first when installing the battery and disconnect the RED lead last when removing it. Otherwise, the electrical system can be damaged. 8 The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine.
67K-9-14-4 2/28/02 11:21 AM Page 27 E r e t y q w Use of smaller wire could lead to a fire. 1 2 3 4 w 901014* Battery for starting Battery for accessories Large red lead for starting battery Small red lead for accessory battery charging (optional part) 5 Large black lead 6 Negative connecting cable NOTE: If a battery selector switch is desired, consult your YAMAHA dealer about correct wiring. EMU01280 Disconnecting the Battery Disconnect the BLACK lead from the NEGATIVE (-) terminal first.
67K-9-14-4 2/28/02 11:21 AM Page 28 E EMU01172 CLEANING COOLING-WATER PASSAGES Flushing device equipped model Perform this procedure right after operation for the most thorough flushing. 1) After shutting off the engine, unscrew the garden-hose connector 2 from the fitting 1 on the bottom cowling. 2) Screw the garden-hose connector 2 onto a garden hose 3 which is connected to a fresh-water supply.
67K-9-14-4 2/28/02 11:21 AM Page 29 E EMU00412 Checking Painted Surface of Motor Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from a Yamaha dealer. EMU00413 COATING THE BOAT BOTTOM 102025 A clean hull improves boat performance. The boat bottom should be kept as clean of marine growths as possible.
67K-9-14-4 2/28/02 11:21 AM Page 30 E – MEMO –
67K-9-14-5 2/28/02 11:22 AM Page 1 E EMU00414 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 Low oil level warning activates ........5-10 Treatment of submerged motor.......
67K-9-14-5 2/28/02 11:22 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. A. Starter will not operate. 5.
67K-9-14-5 2/28/02 11:22 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. Fuel pump damaged. 12. Air vent screw on the fuel tank closed. 13.
67K-9-14-5 2/28/02 11:22 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.
67K-9-14-5 2/28/02 11:22 AM Page 5 E Trouble Possible Cause 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. 1. Propeller damaged. 2. Propeller shaft damaged. F. Engine vibrates excessively. 3. Weeds or other foreign matter tangled on propeller. 4. Motor mounting bolt loose. 5. Steering pivot loose or damaged. 5-4 Remedy 16. Have serviced by a Yamaha dealer. 17.
67K-9-14-5 2/28/02 11:22 AM Page 6 E EMU00416 TEMPORARY ACTION IN EMERGENCY EMU01492 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 the control system and all components for damage. Also, inspect the boat for damage.
67K-9-14-5 2/28/02 11:22 AM Page 7 E EMU00424 STARTER WILL NOT OPERATE If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be manually started with an emergency starter rope. However, the engine can not be manually started if the battery has low voltage. If the battery is discharged to 9 volts or below, the electrical fuel pump will not operate. w 8 Use this procedure only in an emergency and only to return to port for repairs.
67K-9-14-5 2/28/02 11:22 AM Page 8 E EMU00430 Emergency Starting Engine 1) Remove the top cowling. 301022 301021 2) 3) Remove the flywheel cover. 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. 4) Turn the main switch to START and back to OFF several times to inject some fuel into the combustion chambers, then put the switch in the ON position.
67K-9-14-5 2/28/02 11:22 AM Page 9 E EMU00438 ENGINE FAILS TO OPERATE If the engine speed becomes erratic or the engine stops unexpectedly, or if the engine does not start, the following emergency circuit procedure may allow you to return to port for repairs. Before using this procedure, be sure to check the “TROUBLESHOOTING” section. Eliminate causes such as low fuel or overheating before using this procedure.
67K-9-14-5 2/28/02 11:22 AM Page 10 E If an engine fails to start, use the following procedure. 1) Adjust the trim angle so that the engine is vertical or trimmed in. 000891 2) q w Disconnect the Yellow/White emergency connector. The ignition timing advance circuit of the microcomputer is bypassed. 1 CDI unit 2 Yellow / White cord 3) Open the throttle slightly without shifting using the neutral throttle lever or the free accelerator.
67K-9-14-5 2/28/02 11:22 AM Page 11 E EMU01191 LOW OIL LEVEL WARNING ACTIVATES q If the oil level is allowed to drop too low, the red segment will appear on the oil level indicator, the buzzer will sound, and engine speed will be limited to about 2,000 r/min. If this happens, a reserve amount of oil can be pumped from the remote oil tank 3 to the engine oil tank 2 using the emergency switch 1. w Be sure to stop the engine before performing this procedure.
67K-9-14-5 2/28/02 11:22 AM Page 12 E NOTE: 8 Reserve oil capacity is maximum 1,500 cm3 (1.6 US qt, 1.31 Imp qt). 8 The oil feed pump will not operate if the engine is tilted more than 35°. Put the engine in the down position before operating the emergency switch.
67K-9-14-5 2/28/02 11:22 AM Page 13 E EMU00446 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. EMU00449 1) 2) 3) 107013 4) 5) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.
67K-9-14-5 2/28/02 11:22 AM Page 14 E – MEMO –
67K-9-14-6 2/28/02 11:23 AM Page 1 E EMU00450 Chapter 6 1 INDEX INDEX........................................................
67K-9-14-6 2/28/02 11:23 AM Page 2 E EMU00451 INDEX A Adjusting idling speed ..........................4-15 Adjusting trim angle..............................3-19 B Basic boating rules ..................................1-6 Battery care...............................................4-7 Battery requirement ..............................1-12 Bow down...............................................3-20 Bow up ....................................................3-20 Breaking in engine ..........................
67K-9-14-6 2/28/02 11:23 AM Page 3 E N Neutral interlock trigger ..........................2-3 Neutral throttle lever ...............................2-3 O Oil level indicator..............................2-9, 3-7 Oil level warning/oil filter clogging warning ...................................................2-16 Operation after a long period of storage ......................................................3-9 Operations of controls and other functions ...................................................
67K-9-14-6 2/28/02 11:23 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.
67K-9-14-6 2/28/02 11:23 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.
67K-9-14-6 2/28/02 11:23 AM Page 6 EMU00912* YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. is proud of its heritage and reputation for producing products with high standards of quality and workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Outboard Limited Warranty is your assurance of this commitment.
67K-9-14-6 2/28/02 11:23 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 dealer are excluded from warranty coverage.
67K-9-14-6 2/28/02 11:23 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.
67K-9-14-6 2/28/02 11:23 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.
67K-9-14 hyoshi 4/10/02 2:48 PM Page 1 (1,1) OWN Printed in Japan March 2002-0.
Warranty card 2/27/02 11:47 AM Page 1 OUTBOARD MOTOR WARRANTY REGISTRATION ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD Please complete and mail this card. This information is necessary to accurately register your unit for warranty. Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.
Warranty card 2/27/02 11:47 AM Page 2 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT
