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EMN00010

Chapter 5

TROUBLE RECOVERY

TROUBLESHOOTING

..............................5-1

TEMPORARY ACTION IN
EMERGENCY

............................................5-5

Impact damege.....................................5-5
Starter will not operate ........................5-6
Treatment of submerged motor .........5-8

63V-9-14-5 4/25/01 2:12 PM Page 1

Summary of Contents for 15C

Page 1: ...9 9A 15A LIT 18626 04 53 9 9A 15A OWNER S MANUAL U S A Edition ...

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Page 3: ...special precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer Yamaha continually seeks advance ments in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your machine and this manual If...

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Page 5: ...GENERAL INFORMATION BASIC COMPONENTS OPERATION MAINTENANCE TROUBLE RECOVERY INDEX CONTENTS READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR E 1 2 3 4 5 6 ...

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Page 7: ...RD 1 1 Outboard motor serial number 1 1 EMISSION CONTROL INFORMATION 1 2 SAFETY INFORMATION 1 3 IMPORTANT LABELS 1 5 Warning labels 1 5 BASIC BOATING RULES 1 6 FUELING INSTRUCTIONS 1 10 Gasoline petrol 1 11 Engine oil 1 11 PROPELLER SELECTION 1 12 START IN GEAR PROTECTION 1 13 1 ...

Page 8: ...e label attached to the port side of the clamp bracket Record your outboard motor serial num ber in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor serial number E 1 401012 YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON ...

Page 9: ... of Emission control certificate This label is attached to the bottom cowl ing 1 Emission control information label Existing Technology N A Manufactured date label This label is attached to the clamp bracket or the swivel bracket 2 Manufactured date label EMISSION CONTROL INFORMATION ENGINE FAMILY THIS ENGINE CONFORMS TO 2001 U S EPA REGULATIONS FOR MARINE SI ENGINES FELs SPARK PLUG IDLE SPEED rpm...

Page 10: ... carefully for swimmers during the engine operation 8 Stay away from swimming areas 8 When a swimmer is in the water near you shift into neutral and shut off the engine EMU00917 SAFETY INFORMATION 8 Before mounting or operating the out board motor read this entire manual Reading it should give you an under standing of the motor and its operation 8 Before operating the boat read any owner s or oper...

Page 11: ...ited States Coast Guard Consumer Affairs Staff G BC Office of Boating Public and Consumer Affairs U S Coast Guard Headquarters Washington D C 20593 0001 Boating Safety Hotline 1 800 368 5647 National Marine Manufacturers Association NMMA 401 N Michigan Ave Chicago Il 60611 Marine Retailers Association of America 155 N Michigan Ave Chicago Il 60601 ...

Page 12: ... will not start unless the shift control is in neutral position 6E0 83627 41 WARNING Be sure shift control is in neutral before starting engine except 2HP Do not touch or remove electrical parts when starting or during operation Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 6A1 83625 41 ...

Page 13: ...occur unless both vessels try to avoid each other If that is the case both vessels become Give Way vessels EMB40010 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 ...

Page 14: ...d You must stay out RULES WHEN ENCOUNTERING VESSELS There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steer ing Rules are followed Meeting you are approaching another vessel head on Crossing you are travelling across the other vessel s path Overtaking you are passing or being passed by another vessel In the following illustration ...

Page 15: ...e markers are white with black letters and orange boarders They signify speed zones restricted areas danger areas and general information of its way until you are clear of it Like wise 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 dri...

Page 16: ...toward head of naviga MAIN CHANNEL BUOYS 1 3 5 7 tion Leave to port left proceeding upstream LIGHTED BUOY Port Hand White Light Green Light old new old new old new LIGHTED BUOY Starboard Hand 2 4 6 Even number increasing toward head of naviga tion Leave to starboard right proceeding up stream White Light Red Light A LIGHTED SAFE WATER BUOY No number Marks midchannel pass on either side Letter has ...

Page 17: ...tely with dry rags 8 Do not overfill the fuel tank 8 Tighten the filler cap securely after refueling 8 If you should swallow some gasoline inhale a lot of gasoline vapor or get gasoline in your eyes get immediate medical attention 8 If any gasoline spills onto your skin immediately wash with soap and water Change clothing if gasoline spills on it 8 Touch the fuel nozzle to the filler open ing or f...

Page 18: ... ethanol can be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not recommended by Yama ha because it can cause fuel system dam age or engine performance problems EMU00858 ENGINE OIL If the recommended engine oil is not available another 2 stroke engine oil with a NMMA certified TC W3 rating may be used Recommended oil YAMALUBE 2 ...

Page 19: ...dverse effect on the engine 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 main tained Conversely a larger pitch pro peller is more suitabl...

Page 20: ...ds reduce the throttle setting to maintain the rpm in the proper operating range 1 Propeller diameter in inches 2 Propeller pitch in inches 3 Type of propeller propeller mark Refer to the section CHECKING PRO PELLER for instructions on propeller removal and installation EMU01209 START IN GEAR PROTECTION Yamaha outboard motors or Yamaha approved remote control units are equipped with start in gear ...

Page 21: ... shift lever 2 2 Engine stop button 2 3 Engine stop lanyard switch 2 3 Throttle control grip 2 4 Choke knob 2 4 Recoil starter handle 2 4 Tiller handle 2 5 Steering friction adjustment 2 6 Trim angle adjusting rod 2 6 Tilt lock mechanism 2 6 Tilt support bar 2 7 Top cowling lock lever 2 7 Carrying handle 2 7 E 1 2 3 4 5 6 ...

Page 22: ...andle 6 Gear shift lever 7 Throttle control grip 8 Throttle friction adjustment knob 9 Engine stop button Engine stop lanyard switch 0 Clamp screw q Carrying handle w Cooling water inlet e Anti cavitation plate r Trim angle adjusting rod t Clamp bracket y Rope attachment u Choke knob i Fuel tank o Fuel hose May not be exactly as shown also may not be included as standard equipment on all models ...

Page 23: ... This meter is on the fuel tank cap It shows current fuel quantity in the fuel tank approximately Fuel tank cap This cap is for filling fuel To remove it turn it counterclockwise Air Vent screw This screw is on the fuel tank cap To loosen it turn it counterclockwise EMC25010 GEAR SHIFT LEVER for Tiller control model Turning the gear shift lever towards you engages the clutch with the forward gear ...

Page 24: ... the lock plate stopping igni tion to the engine This will prevent the boat from running away under power w 8 Attach the lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard ...

Page 25: ...ion Choose the setting that offers the best performance and fuel economy for the desired operation 1 Throttle indicator EMC42310 CHOKE KNOB Pulling out this knob supplies a rich mix ture required to start or warm up the engine There are 4 operating position as shown below EMC44010 RECOIL STARTER HANDLE If equipped Pull the handle gently until resistance is felt Then vigorously pull the handle stra...

Page 26: ...table for opera tor preference An adjusting screw bolt is located within the tiller handle To increase the resistance Turn the adjusting screw bolt clockwise To decrease the resistance Turn the adjusting screw bolt counter clockwise When constant speed is desired tighten the adjusting screw bolt to maintain the desired throttle setting w Do not overtighten the friction adjusting screw bolt If ther...

Page 27: ...hten the friction screw bolt If there is too much resis tance it may be difficult to steer which could result in an accident EMU01297 TRIM ANGLE ADJUSTING ROD The position of the trim angle adjusting rod determines the minimum trim angle of the outboard motor in relation to the transom 402014 q EMD44110 TILT LOCK MECHANISM for Manual tilt model The tilt lock mechanism is used to pre vent reverse t...

Page 28: ...e the tilt lock lever in the lock posi tion while using the carrying handle Oth erwise the lower casing may fall to the grand while carrying the motor 1 Clamp bracket bar E q 2 7 403013 EMD48010 TILT SUPPORT BAR The tilt support bar keeps the outboard motor in the tilted up position 301012 q EMD62011 TOP COWLING LOCK LEVER To remove the engine top cowling turn the lock lever Then lift off the cowl...

Page 29: ...ixing 3 6 PRE OPERATION CHECKS 3 7 BREAKING IN RUNNING IN ENGINE 3 8 STARTING ENGINE 3 10 WARMING UP ENGINE 3 13 SHIFTING 3 14 Forward 3 14 Reverse 3 15 STOPPING ENGINE 3 16 TRIMMING OUTBOARD MOTOR 3 17 Adjusting trim angle 3 18 CRUISING IN SHALLOW WATER 3 20 TILTING UP DOWN 3 22 CRUISING IN OTHER CONDITIONS 3 24 Cruising in salt water 3 24 Cruising in turbid water 3 24 E 1 2 3 4 5 6 ...

Page 30: ...rne water spray while the boat is cruising Severe engine damage may result if the motor is operat ed continuously in the presence of air borne water spray NOTE During water testing check the buoyancy of the boat at rest with its maximum load Check that the static water level on the exhaust housing is low enough to pre vent water entry into the powerhead when water rises due to waves when the outbo...

Page 31: ... the specific boat motor com bination 8 Your dealer or other person experi enced in proper rigging should mount the motor If you are mounting the motor yourself you should be trained by an experienced person permanent mounted type 8 Your dealer or other person experi enced in proper outboard motor mounting should show you how to mount your motor portable type Mount the outboard motor on the center...

Page 32: ...eight is too high cavitation tends to occur thus reducing the propulsion and if the pro peller tips cut the air the engine speed will rise abnormally and cause the engine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engine efficiency Mount the engine so that the anti cavita tion plate is between the bottom of the boat and a level 25 mm 1 in be...

Page 33: ... Loose clamp screws could allow the motor to move on the transom or fall off the transom This could cause loss of control and serious injury Make sure the transom screws are tightened securely Occasionally check the screws for tight ness during operation 2 An engine restraint cable or chain should be used Attach one end to the engine restraint cable attachment point and the other to a secure mount...

Page 34: ...ditives such as aromatics and oxy genates has increased These additives are important for the engines in passen ger cars but they can have detrimental effects in marine engines because of increased deposits in the combustion chamber When enough deposits collect piston rings begin sticking Performance drops and engine wear increases dramati cally While many additives available may reduce deposits Y...

Page 35: ...ing ratio is incorrect the following problems could occur Low oil ratio Lack of oil could cause major engine trouble such as piston seizure High oil ratio Too much oil could cause fouled spark plugs smoky exgaust and heavy carbon deposits 902032 q w Oil Gasoline Petrol Break in period 1 25 After break in 1 100 Mixing ratio 25 1 Gasoline Petrol Engine oil 0 04 L 0 48 L 0 56 L 0 96 L 0 04 US qt 0 51...

Page 36: ...F40012 PRE OPERATION CHECKS w If any item in the pre operation check is not working properly have it inspected and repaired before operating the out board motor Otherwise an accident could occur EMF41110 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 8 Check fuel line connections to be sure they are tight 8 Be sure the fuel tank ...

Page 37: ...gine and engine mounting 8 Look for loose or damaged fasteners 8 Check the propeller for damage cC Do not start the engine out of water Overheating and serious engine damage can occur EMF50012 BREAKING IN RUNNING IN ENGINE Your new engine requires a period of break in running in to allow mating sur faces of moving parts to wear in evenly Correct break in running in will help ensure proper performa...

Page 38: ...ane then reduce engine speed to three quarter throttle approximately 4 000 r min Vary engine speed occasional ly Run at full throttle for one minute then allow about 10 minutes of opera tion at three quarter throttle or less to let the engine cool 4 Third through tenth hours Avoid operating at full throttle for more than 5 minutes at a time Let the engine cool between full throttle runs Vary engin...

Page 39: ...aust gases which contain carbon monoxide a col orless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 1 If there is an air vent screw on the fuel tank cap loosen it 2 or 3 turns 2 If there is a fuel joint on the motor firmly connect the fuel line to the joint...

Page 40: ...he engine stop switch w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering ...

Page 41: ...the choke knob to the original position NOTE 8 It is not necessary to use the choke when restarting a hot engine 8 If the choke knob is left pulled out the engine will stall 8 Pull the starter handle slowly until you feel resistance Then give a strong pull straight out to start the engine Repeat it if necessary 9 After the engine starts return the starter handle slowly to the original position bef...

Page 42: ...s flow of water from the pilot hole shows that the water pump is pumping water through the cooling pas sages If water is not flowing out of the pilot hole at all times while the engine is running do not continue to run the engine Overheating and serious damage could occur Stop the engine and check to see if the water inlet on the lower cas ing is blocked If the problem cannot be found and correcte...

Page 43: ...C To change the shifting position from for ward to reverse or vice versa close the throttle first so that the engine idles or runs at low speeds EMG22110 FORWARD 1 Place the throttle control grip in the fully closed position 503012 406035 N F 2 Turn the gear shift lever quickly and firmly from Neutral to Forward ...

Page 44: ...me unstable which could result in loss of control and an accident 1 Place the throttle control grip in the fully closed position for Tiller control model 2 Check that the tilt lock lever for Man ual tilt model is in the locked posi tion 503012 402014 406036 R N 3 Turn the gear shift lever quickly and firmly from Neutral to Reverse ...

Page 45: ... Push and hold the engine stop button until the engine comes to a complete stop 2 After stopping the engine disconnect the fuel line from the motor 3 Tighten the air vent screw on the fuel tank cap after stopping the engine if it is equipped NOTE The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop lanyard switch 407021 304013 902052 ...

Page 46: ...opeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed w Excessive trim for the operating condi tions either trim up or trim down can cause boat instability and can make steering the boat more difficult This increases the possibility of an accident If the boat begins to feel unstable or is hard to steer slow down and or readjust the trim an...

Page 47: ...ansom Make test runs with the trim set to differ ent angles to find the position that works best for your boat and operating condi tions w 8 Stop the engine before adjusting the trim angle 8 Use care to avoid being pinched when removing or installing the rod 8 Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any signs of instabili ty or control pro...

Page 48: ...is more air drag Excessive trim up can cause the propeller to ventilate which reduces performance further When trimmed out too much a boat may porpoise hop in the water which could throw the operator and pas sengers overboard EMG62110 Bow down When the bow of the boat is down it is easier to accelerate from a standing start onto plane Too much trim in causes the boat to plow through the water decr...

Page 49: ... does not work while the shallow water cruising system is being used Hitting an underwater obstacle could cause the engine to lift out of the water resulting in loss of control 8 Use extra care when operating in reverse Too much reverse thrust can cause the engine to lift out of the water increasing the chance of acci dent and personal injury 8 Return the engine to its normal posi tion as soon as ...

Page 50: ...gine in a partially raised position NOTE If the engine is tilted up completely the tilt lock lever automatically locks The shallow water lever is no longer effective 4 When lowering the engine push the tilt lock lever down Slightly tilt up the engine until the tilt support bar auto matically returns to the free position Then slowly lower the engine to the normal position 406042 N 402015 403056 403...

Page 51: ...om over heating can result 8 Do not tilt up the engine by pushing the steering handle as this could break the handle 8 Keep the power unit higher than the propeller at all times Otherwise water can run into the cylinder causing dam age w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinch any body parts between the drive unit and engine br...

Page 52: ...e position EMU00300 PROCEDURE FOR TILTING DOWN 1 Place the tilt lock lever in the lock position 2 Slightly tilt up the engine until the tilt support bar is released automatically 3 Tilt down the engine 402015 304013 403013 403012 4 Hold the rear of the top cowling with one hand and fully tilt the engine up 5 The tilt support bar turns to the locked position automatically ...

Page 53: ...resh water to prevent them from becoming clogged up with salt deposits NOTE Refer to cooling system flushing instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR CRUISING IN TURBID WATER It is strongly recommended that the optional chromium plated water pump kit be installed if the outboard is to be used in turbid muddy water conditions ...

Page 54: ...E MEMO ...

Page 55: ...hart 4 8 Cleaning and adjusting spark plug 4 9 Checking fuel system 4 11 Inspecting fuel filter 4 12 Adjusting idling speed 4 13 Checking wiring and connectors 4 14 Exhaust leakage 4 14 Water leakage 4 14 Greasing 4 15 Checking propeller 4 16 Changing gear oil 4 18 Cleaning fuel tank 4 19 Inspecting and replacing anode 4 20 Checking bolts and nuts 4 21 Motor exterior 4 21 Coating the boat bottom 4...

Page 56: ...Starting system 8Battery capacity V AH kc Minimum cold crank peformance Amps at 17 8 C 0 F Minimum reserve capacity minutes at 26 7 C 80 F 8Alternator output V A W 8Starting carburetion system 2 stroke L2 246 15 01 56 50 2 20 1 97 C D I B7HS 10 0 9 1 0 0 035 0 039 Tiller control Manual start 12 80 Choke valve start system DRIVE UNIT 8Gear positions Gear ratio 8Trim tilt system 8Propeller mark Forw...

Page 57: ...0 1 97 C D I B7HS 10 0 9 1 0 0 035 0 039 Tiller control Manual start 12 80 Choke valve start system Forward Neutral Reverse 2 08 27 13 Manual J Regular unleaded gasoline P O N minimum 86 25 6 6 5 5 YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC W3 certified outboard oil 100 1 Hypoid gear oil SAE 90 250 8 5 8 8 25 2 5 18 17 1 7 12 ...

Page 58: ...ional support device to secure it in the up position w 8 Never get under the lower unit while it is tilted even if a motor support bar is used Severe injury could occur if the outboard accidentally falls 8 USE CARE when transporting fuel tank whether in a boat or car DO NOT fill fuel container to maximum capacity Gasoline will expand considerably as it warms up and can build up pressure in the fue...

Page 59: ... and stabilizer Part No LUB FUELC 12 00 to each gallon of fuel NOTE The use of Yamaha Fuel Conditioner and Stabilizer eliminates the need to drain the fuel system Consult your Yamaha dealer or other qualified mechanic if the fuel sys tem is to be drained instead When transporting or storing the out board motor while removed from a boat fold the tiller handle and lean the motor on the tiller handle...

Page 60: ...the fresh water level is below the level of the anti cavitation plate or if the water supply is insufficient engine seizure may occur a 605024 q w 1 Remove the engine top cowling 2 Install the outboard motor on the water tank 3 Fill the tank with fresh water to above the level of the anti cavitation plate 4 Remove the cap a for fogging on the silencer cover 5 Run the engine at a fast idle for 10 1...

Page 61: ... the lower unit oil Refer to the Periodic Maintenance section Changing gear oil Inspect the oil for the presence of water which indi cates a leaky seal Seal replacement should be performed by an autho rized Yamaha dealership prior to use 4 Grease all grease fittings Refer to the Periodic Maintenance section Greasing EMK27010 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the out b...

Page 62: ...aha dealer for owners who have the mechanical skills tools and other equipment necessary to perform maintenance not covered by this owner s manual EMK33011 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equiva lents of the same type and of equivalent strength and materials Any part of inferi or quality may malfunction and the resulting loss of control could e...

Page 63: ...ints Greasing 7 4 15 Gear oil Change 7 7 4 18 Fuel system Inspection 7 4 11 Fuel filter Cleaning Inspection 7 7 7 4 12 Fuel tank 1 Cleaning 7 4 19 Idling speed Adjustment 7 4 13 Anode Inspection Replacement 2 2 4 20 Outboard motor Inspection 7 7 4 21 exterior Cooling water passages Cleaning 7 7 4 5 Propeller and cotter pin Inspection Replacement 7 7 4 16 4 17 Carburetor setting Inspection Adjustme...

Page 64: ...ir leak or carburetion problem in that cylinder Do not attempt to diagnose any problems yourself Instead take the outboard motor to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the spa...

Page 65: ...when you are fitting a spark plug a good esti mate 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 1 Spark plug gap 2 Spark plug I D mark NGK Spark plug torque Refer to SPECIFICATIONS page 4 1 903022 q w Initial of spark plug Plug wrench size I D mark B 21 mm 13 16 in C BK 16 mm 5 8 in D 18 3 m...

Page 66: ... found it should be repaired immediately by Yama ha 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 w Leaking fuel can result in fire or explo sion 8 Check for fuel leakage regularly 8 If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper rep...

Page 67: ...g filter cup and hoses in place Improper assembly or replacement can result in a fuel leak which could result in a fire or explosion hazard EMU00978 1 Remove the nut holding the fuel filter assembly if equipped 2 Unscrew the filter cup 1 catching any spilled fuel in a rag 3 Remove the filter element 2 and wash it in solvent Allow it to dry Inspect the filter ele ment and O ring 3 to make sure they...

Page 68: ...m 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 turn ing it counterclockwise to decrease the idling speed NOTE Correct idling speed adjustment is onl...

Page 69: ...at each connector is engaged securely EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and crank case WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head and crank case 606011 ...

Page 70: ...E 4 15 EMU00366 GREASING Yamaha marine grease Water resistant grease 103011 ...

Page 71: ...lanyard from the engine stop switch Turn off the battery cut off switch if your boat has one 8 Do not use your hand to hold the pro peller when loosening or tightening the propeller nut Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning 1 Check each of the propeller blades for wear erosion from cavitation or ven tilation or other damage 2 Check th...

Page 72: ...re installing propeller otherwise lower case and propeller boss may be damaged 3 Tighten the propeller nut to the speci fied torque 4 Align the propeller nut with the pro peller shaft hole Insert a new cotter pin in the hole and bend the cotter pin ends NOTE When the propeller nut does not align with the propeller shaft hole after tighten ing to the specified torque then tighten it more to align t...

Page 73: ...board falls on you 2 Place a suitable container under the gearcase 3 Remove the oil drain plug NOTE The oil drain plug is magnetic Remove all metal particles from the plug before rein stalling it 4 Remove the oil level plug to allow the oil to drain completely 1 Oil level plug 2 Oil drain plug cC Inspect the used oil after it has been drained If the oil is milky water is get ting into the gearcase...

Page 74: ...le and explosive 8 If you have any question about properly doing this procedure consult your Yamaha dealer 8 Keep away from sparks cigarettes flames or other sources of ignition when cleaning the fuel tank 8 Remove the fuel tank from the boat before cleaning it Work only outdoors in an area with good ventilation 8 Wipe up any spilled fuel immediately 8 Reassemble the fuel tank carefully Improper a...

Page 75: ...Clean the filter located on the end of the suction pipe in a suitable clean ing solvent Allow the filter to dry 3 Replace the gasket with a new one Reinstall the fuel meter assembly and tighten the screws firmly EML24010 INSPECTING AND REPLACING ANODE Yamaha outboard motor is protected from corrosion by sacrificial anode Check the anode periodically Remove the scales from surfaces of the anode For...

Page 76: ...RANSPORTING AND STORING OUTBOARD MOTOR 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 Consult a Yamaha dealer for touch up paint 4 21 E 102031 102025 EML44010 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clean of mari...

Page 77: ...EMN00010 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damege 5 5 Starter will not operate 5 6 Treatment of submerged motor 5 8 E 1 2 3 4 5 6 ...

Page 78: ...dure incorrect 5 Fuel pump malfunctions 6 Spark plug s fouled or incorrect type 7 Spark plug cap s fitted incorrectly 8 Poor connections or damaged ignition wiring 9 Ignition parts faulty 10 Engine stop switch lanyard not attached 11 Shift lever in gear 12 Engine inner parts damaged 1 Fill tank with clean fresh fuel 2 Fill tank with clean fresh fuel 3 Clean or replace filter 4 Read STARTING ENGINE...

Page 79: ...ion incorrect 17 Throttle valve adjustment incorrect 1 Inspect spark plug s Clean or replace with recommended type 2 Check for pinched or kinked fuel line or other obstructions in fuel system 3 Fill tank with clean fresh fuel 4 Clean or replace filter 5 Have serviced by a Yamaha dealer 6 Inspect and adjust as specified 7 Check wires for wear or breaks Tighten all loose connections Replace worn or ...

Page 80: ... propeller repaired or replaced 2 Install correct propeller to operate outboard at its recommended speed r min range 3 Adjust trim angle to achieve most efficient operation 4 Have motor adjusted to proper transom height 5 Clean boat bottom 6 Inspect spark plug s Clean or replace with recommended type 7 Remove foreign matter and clean lower unit 8 Check for pinched or kinked fuel line or other obst...

Page 81: ...ler shaft damaged 3 Weeds or other foreign matter tangled on propeller 4 Motor mounting bolt loose 5 Steering pivot loose or damaged 1 Have propeller repaired or replaced 2 Have serviced by a Yamaha dealer 3 Remove and clean propeller 4 Tighten bolt 5 Tighten or have serviced by a Yamaha dealer ...

Page 82: ...motor unsafe to operate 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 compo nents for damage Also inspect the boat damage 3 However damage is found or not found go back to a nearest harbor slowly and carefully 4 Have a Yamaha dealer inspection of the outboard motor before operating it again 607011 ...

Page 83: ...xpectedly start to move which could result in an accident 8 Be sure no one is standing behind you when pulling the starter rope It could whip behind you and injure someone 8 An unguarded rotating flywheel is very dangerous Keep loose clothing and other objects away when starting the engine Use the emergency starter rope only as instructed Do not touch the fly wheel or other moving parts when the e...

Page 84: ...012 407021 301012 3 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 On the electric start model the main switch must be on if the main switch is equipped 2 Remove the starter flywheel cover by removing the bolts NOTE On a model equipped with the start in gear protection device cable disco...

Page 85: ... Thoroughly wash away mud salt seaweed etc with fresh water 2 Remove the spark plugs and face the spark plug holes downward to allow any water mud or contaminants to drain 3 Drain the fuel from the carburetor 4 Feed fogging oil or engine oil through the carburetors and spark plug holes while cranking with the manual starter or emergency starter rope 5 Take the outboard motor to a Yamaha dealer as ...

Page 86: ...E MEMO ...

Page 87: ...EMP00010 Chapter 6 INDEX INDEX 6 1 E 1 2 3 4 5 6 ...

Page 88: ...11 Engine stop button 2 3 Engine stop lanyard switch 2 3 Exhaust leakage 4 14 F Filling fuel 3 5 Filling fuel and engine oil 3 5 Filling fuel tank 4 4 Flushing cooling system and fogging engine 4 5 Forward 3 14 Fuel hose joint 2 2 Fuel meter 2 2 Fuel tank 2 2 Fuel tank cap 2 2 Fueling instructions 1 10 G Gasohol 1 11 Gasoline petrol 1 11 Gasoline petrol and oil mixing 3 6 Gear shift lever 2 2 Grea...

Page 89: ...l grip 2 4 Throttle friction adjustment 2 5 Throttle indicator 2 4 Tiller handle 2 5 Tilt lock mechanism 2 6 Tilt support bar 2 7 Tilting up down 3 22 Top cowling lock lever 2 7 Trailering outboard motor 4 3 Transporting and storing outboard motor 4 3 Treatment of submerged motor 5 8 Trim angle adjusting rod 2 6 Trimming outboard motor 3 17 Troubleshooting 5 1 W Warming up engine 3 13 Warning labe...

Page 90: ...gistration records are checked 2 Read the Limited Warranty statement which follows these instructions This warranty applies to Yamaha outboard motors sold in the United States whether purchased sepa rately or when supplied as original equipment by a boat builder The terms also apply to original equipment packages sold in Canada with coverage provided by Yamaha Motor Canada see Warranty Guide for C...

Page 91: ...ilable in one country may not be sold or serviced in the other 6 If you need any additional information about your Yamaha or warranty coverage which your dealer cannot provide please contact us directly Yamaha Motor Corporation U S A P O Box 6555 Cypress CA 90630 Attention Customer Relations Department Telephone No 714 761 7439 Fax No 714 761 7559 Yamaha Motor Canada Ltd 480 Gordon Baker Road Toro...

Page 92: ...tor purchased and registered for use in the United States only excluding its territo ries For warranty provisions outside the United States contact the particular country s local Yamaha distributor WARRANTY REGISTRATION To be eligible for warranty coverage the outboard motor must first be registered with Yamaha Motor Cor poration U S A A warranty registration form is provided in the Owner s Manual...

Page 93: ...LSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A Post Office Box 6555 Cypress California 90630 WARRANTY QUESTIONS AND ANSWERS Q What costs are my responsibility during the warranty period A The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision dam ages Q What are some examples of abnormal strai...

Page 94: ...ation such as names addresses model engine serial number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is complied from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling deal...

Page 95: ...ll receive service If you need more information about your warranty coverage or your Yamaha outside the U S A or Canada please contact an autho rized Yamaha dealer in your country 2 Keep a copy of your sales contract or invoice for the purchase of your Yamaha and present it if you need warranty repairs This document should show the date of purchase which is important evidence the repairing dealer ...

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Page 98: ...9 9A 15A Printed in Japan March 2001 0 5 1 63V 28199 14 9 9FMH 15FMH E Printed on recycled paper ...

Page 99: ...9 9A 15A paper OWNER S MANUAL ...

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