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Yamaha 2A, Owner'S Manual

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Yamaha 2A Owner'S Manual Download Page 63

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EMK00010

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
Cleaning and adjusting spark 
plug....................................................4-10
Checking fuel system .......................4-12
Inspecting and replacing fuel 
filter ...................................................4-13
Adjusting idling speed .....................4-14
Checking wiring and connectors.....4-15
Exhaust leakage................................4-15
Water leakage ...................................4-15
Greasing............................................4-16
Checking propeller; shear pin and
cotter pin ...........................................4-19
Changing gear oil .............................4-22
Cleaning fuel tank.............................4-23
Inspecting and replacing anode......4-24
Checking bolts and nuts ..................4-25
Motor exterior...................................4-25
Coating boat bottom ........................4-25

 6A1-9-1L 4  4/20/01 11:58 AM  Page 1

Summary of Contents for 2A

Page 1: ...2A 3A 5A LIT 18626 04 51 2A 3A 5A OWNER S MANUAL U S A Edition ...

Page 2: ......

Page 3: ...al 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 ther...

Page 4: ......

Page 5: ...1 2 3 4 5 6 E TROUBLE RECOVERY MAINTENANCE OPERATION BASIC COMPONENTS GENERAL INFORMATION CONTENTS INDEX READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR EMA20010 ...

Page 6: ......

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

Page 8: ...amp bracket 2 hp model attached the upper part of the swivel bracket Record your outboard motor serial num ber in the spaces provided to assist you in ordering spare parts from your Yama ha dealer or for reference in case your outboard motor is stolen 1 Outboard motor serial number 2 2 hp model outboard motor serial number YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON ...

Page 9: ...abel 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...

Page 10: ... obstacles and other traffic 8 Always watch carefully for swimmers during the engine operation 8 Stay away from swimming areas 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 operator s manuals supplied with it and all la...

Page 11: ...y orga nizations 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 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: ... hair and clothes away from flywheel and other rotating parts while engine is running 6A1 83625 41 1 WARNING LEAKING FUEL COULD CAUSE A FIRE Before tilting up the engine or laying it on its side Turn the fuel cock to the closed position Tighten the air vent screw on the fuel tank cap 6A1 2415A 41 2 WARNING This engine is equipped with a neutral starting device The engine will not start unless the ...

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 international ly and are also enforced by the United States Coast Guard and...

Page 14: ...and are close enough to run the risk of collision neither of you has the right of way Both of you should alter course to avoid an accident You 102045 should keep the other vessel on your port left side This rule doesn t apply if both of you will clear one another if you continue on your set course and speed Crossing When two power driven vessels are crossing each other s path close enough to run t...

Page 15: ...k letters and orange boarders They signify speed zones restricted areas danger areas and gen eral information maintain 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 b...

Page 16: ...d 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 no lateral significance used for No number Topmost band red preferred Top Mark White Light White Light OR OR LIGHTED PREFERRED CHANNEL TO RB L...

Page 17: ... 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 funne...

Page 18: ...anol 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 engine oil YAMALUBE...

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: ... the engine s rpm should be within the upper half of the full throttle operating range as listed in SPECIFICA TIONS on page 4 1 Select a propeller which fulfills this requirement If operating under conditions which allow the engine s rpm to rise above the maxi mum recommended range such as light boat loads reduce the throttle setting to maintain the rpm in the proper operating range 1 Propeller di...

Page 21: ...uel tank 2 4 Gear shift lever 2 5 Engine stop button 2 6 Throttle control 2 6 Choke knob 2 7 Recoil starter handle 2 7 Tiller handle 2 8 Fuel cock 2 8 Throttle friction adjustment 2 9 Steering friction adjustment 2 10 Trim angle adjusting rod 2 10 Tilt support knob 2 11 Tilt support bar 2 11 Top cowling lock lever 2 12 ...

Page 22: ...plate 5 Propeller 6 Cooling water inlet 7 Clamp bracket 8 Transom clamp handle 9 Tiller handle 0 Fuel cock q Recoil starter handle w Engine stop button e Choke knob r Trim angle adjusting rod t Rope attachment y Tilt support knob u Throttle control lever May not be exactly as shown also may not be included as standard equipment on all models 2 ...

Page 23: ... Throttle control grip 8 Throttle friction knob 9 Engine stop button 0 Gear shift lever q Fuel cock w Choke knob e Rope attachment r Carrying handle t Transom clamp handle y Tilt support bar lever u Clamp bracket i Trim angle adjusting rod o Anti cavitation plate p Cooling water inlet a Propeller May not be exactly as shown also may not be included as standard equipment on all models 3 ...

Page 24: ...7 Propeller 8 Cooling water inlet 9 Trim angle adjusting rod 0 Clamp bracket q Transom clamp handle w Tiller handle e Throttle control grip r Throttle friction adjusting knob t Recoil starter handle y Choke knob u Engine stop button i Rope attachment o Tilt support bar lever p Fuel hose connector a Gear shift lever s Fuel cock May not be exactly as shown also may not be included as standard equipm...

Page 25: ... If equipped 3 Fuel tank cap 4 Air vent screw If equipped Fuel hose joint This connector is provided for connecting or disconnecting fuel hose Fuel meter 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 ...

Page 26: ...e forward gear so that the boat moves ahead 1 Neutral 2 Forward EMC25010 GEAR SHIFT LEVER for Tiller control model 5 Turning the gear shift lever towards you engages the clutch with the forward gear so that the boat moves ahead Turning the lever away from you engages the reverse gear so that the boat moves astern 1 Neutral 2 Forward 3 Reverse 5 3 ...

Page 27: ...e knob upward increases speed 3 5 The throttle grip is on the steering han dle Turn the grip counterclockwise to increase speed and clockwise to decrease speed Throttle indicator The fuel consumption curve on the throt tle indicator shows the relative amount of fuel consumed for each throttle posi tion Choose the setting that offers the best performance and fuel economy for the desired operation 1...

Page 28: ...ture required to start the engine 209012 2 5 3 EMC44010 RECOIL STARTER HANDLE Pull the handle gently until resistance is felt Then vigorously pull the handle straight out to crank the engine to start it EMC42210 CHOKE KNOB 3 Pulling out this knob setting it to ON supplies a rich mixture required to start the engine ...

Page 29: ...ver knob in this position fuel does not flow Always turn the knob to this position when the engine is not run ning OPEN 2 3 With the lever knob in this position fuel flows to the carburetor Normal running is done with the lever knob in this posi tion 5 There are two OPEN positions on the fuel cock for selecting the fuel flow from the built in tank or the separate tank 2 OPEN position for the built...

Page 30: ...grip This is adjustable for oper ator preference An adjusting screw knob is located within the steering handle To increase the resistance Turn the adjusting screw knob clock wise To decrease the resistance Turn the adjusting screw knob counter clockwise When constant speed is desired tighten the adjusting screw knob to maintain the desired throttle setting w Do not overtighten the friction adjusti...

Page 31: ...rease the resistance Turn the adjusting screw bolt clockwise To decrease the resistance Turn the adjusting screw bolt counter clockwise w Do not overtighten 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 out...

Page 32: ...10 TILT SUPPORT KNOB 2 To keep the outboard motor in the tilted up position push the tilt support knob under the swivel bracket 2 3 5 EMD48010 TILT SUPPORT BAR 3 5 The tilt support bar keeps the outboard motor in the tilted up position ...

Page 33: ...eplacing the cowling check to be sure it fits properly in the rubber seal Then lock the cowling again by moving the levers downward 5 To remove the engine top cowling push the lock lever downward Then lift off the cowling When replacing the cowl ing check to be sure it fits properly in the rubber seal Then lock the cowling again by moving the lever upward 3 5 ...

Page 34: ...E MEMO ...

Page 35: ... and oil mixing 3 6 PRE OPERATION CHECKS 3 8 BREAKING IN RUNNING IN ENGINE 3 9 STARTING ENGINE 3 11 WARMING UP ENGINE 3 15 SHIFTING 3 16 Forward 3 16 Reverse 3 17 STOPPING ENGINE 3 18 TRIMMING OUTBOARD MOTOR 3 19 Adjusting trim angle 3 20 CRUISING IN SHALLOW WATER 3 22 TILTING UP DOWN 3 24 CRUISING IN OTHER CONDITIONS 3 27 Cruising in salt water 3 27 Cruising in turbid water 3 27 ...

Page 36: ...borne 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 Check that the static water level on the exhaust housing is low enough to prevent water entry into the powerhead when water rises due to waves when the outboa...

Page 37: ...ence and 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 th...

Page 38: ...g height 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...

Page 39: ...ne vibration w 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 ...

Page 40: ...ics Gasoline blends have been changing in recent years in response to concerns about pollution and resulting emissions regulations One of the most obvious changes has been the elimination of lead from most fuels As gasoline has changed the amount of additives such as aromatics and oxy genates has increased These additives are important for the engines in passen ger cars but they can have detriment...

Page 41: ...nd gasoline into the fuel tank in that order 1 Oil 2 Gasoline Petrol 2 Then mix the fuel thoroughly by shaking 3 Make sure the oil is mixed with gaso line Oil Gasoline Petrol Break in period 1 25 After break in 1 100 cC 8 Avoid using any oil other than the des ignated type 8 Use a thoroughly blended fuel oil mix ture 8 If the mixture is not thoroughly blend ed or if the mixing ratio is incorrect t...

Page 42: ... L 6 3 US gal 5 3 Imp gal 0 04 L 0 04 US qt 0 04 Imp ql 0 48 L 0 51 US qt 0 42 Imp qt 0 56 L 0 59 US qt 0 49 Imp qt 0 96 L 1 01 US qt 0 84 Imp qt Engine oil Mixing ratio 100 1 Gasoline Petrol Engine oil 1 L 0 26 US gal 0 22 Imp gal 12 L 3 2 US gal 2 6 Imp gal 14 L 3 7 US gal 3 1 Imp gal 24 L 6 3 US gal 5 3 Imp gal 0 01 L 0 01 US qt 0 01 Imp ql 0 12 L 0 13 US qt 0 11 Imp qt 0 14 L 0 15 US qt 0 12 I...

Page 43: ...ons to be sure they are tight 8 Be sure the fuel tank is positioned on a secure flat surface and that the fuel hose is not twisted or flattened or like ly to contact sharp objects EMF42110 Oil 8 Check to be sure you have plenty of oil for your trip EMF43010 Controls 8 Check throttle shift and steering for proper operation before starting the engine 8 The controls should work smoothly without bindi...

Page 44: ...UNNING 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 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 Break in running in time 10 hours Break in running in premix ...

Page 45: ...less 3 Second hour Accelerate at full throttle onto plane 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 oper ation 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...

Page 46: ...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 8 This product emits exhaust 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 Avo...

Page 47: ... 3 5 OPEN OPEN 5 3 If you select the separate fuel tank connect the fuel joints securely and squeeze the primer bulb with the out let end up until you feel it become firm 5 902061 5 2 Set the fuel cock in the OPEN posi tion ...

Page 48: ...t lever in Neutral position except for 2 hp NOTE 5 The start in gear protection device per mits the engine to be started only when it is in Neutral 5 Place the throttle control lever grip in the START position After the engine starts return the throttle to the fully closed position ...

Page 49: ...oke knob in the START position After the engine starts return the knob to the RUN position NOTE 8 If the engine is warm place the choke knob in the RUN position 8 If the choke knob is left in the START position during running the engine will run poorly or stall 7 Pull the starter handle slowly until you feel resistance Then give a strong pull straight out to start the engine Repeat it if necessary...

Page 50: ...Check a flow of water with exhaust gas from the hole on exhaust cover 3 5 2 Check for a steady flow of water from the cooling water pilot hole cC A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages 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 an...

Page 51: ... or shifting position from forward to reverse or vice versa close the throttle first so that the engine idles or runs at low speeds FORWARD 2 When the engine is started the propeller turns and the boat begins to move for ward 3 5 1 Place the throttle control grip in the fully closed position 2 Turn the gear shift lever quickly and firmly from Neutral to Forward 3 5 3 5 ...

Page 52: ...ing handle facing to the rear to back up the boat 310023 2 3 5 5 1 Place the throttle control grip in the fully closed position 2 Turn the gear shift lever quickly and firmly from Neutral to Reverse w When operating in Reverse go slowly Do not open the throttle more than half Otherwise the boat may become unsta ble which could result in loss of control and an accident ...

Page 53: ...erating at high speed is not recommended EMG40711 PROCEDURE 1 Push and hold the engine stop switch until the engine comes to a complete stop 2 After stopping the engine tighten the air vent screw and set the fuel cock lever knob to the closed position 5 3 Disconnect the fuel joints after using the separate fuel tank CLOSE 315021 2 3 5 2 3 5 ...

Page 54: ...at engine and propeller 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 read...

Page 55: ...ve the rod toward the transom 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 posi tion for the first time Increase speed gradually and watch for any signs of ins...

Page 56: ...t is pushing the water and there 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 EMU00283 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 bo...

Page 57: ...mecha nism 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 a...

Page 58: ... engine until the tilt support bar is turned to the locked position automatically to support the engine 3 When bringing the engine to the home position slightly tilt up the engine and slowly tilt the engine down pulling up the lever of the tilt support bar NOTE The outboard motor is provided 2 or 3 positions for shallow water cruising ...

Page 59: ...ngine 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 8 The outboard cannot be tilted when in Reverse or when the outboard is turned 180 facing to the rear w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinc...

Page 60: ...vent screw If the fuel connector is provided on the motor remove the fuel line con nection from the motor 2 Put the fuel cock lever in the closed position 222012 315021 3 CLOSE 2 3 5 CLOSE 315016 3 Place the gear shift lever in Neutral and face the motor forward ...

Page 61: ...h the tilt support knob into the clamp bracket 3 5 5 The tilt support bar turns to the locked position automatically EMU00298 PROCEDURE FOR TILTING DOWN 1 Slightly tilt up the engine 2 2 Pull out the tilt support knob then tilt down the engine 3 5 2 Tilt down the engine pulling up the lever of the tilt support bar 2 3 5 ...

Page 62: ...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 63: ... 4 9 Cleaning and adjusting spark plug 4 10 Checking fuel system 4 12 Inspecting and replacing fuel filter 4 13 Adjusting idling speed 4 14 Checking wiring and connectors 4 15 Exhaust leakage 4 15 Water leakage 4 15 Greasing 4 16 Checking propeller shear pin and cotter pin 4 19 Changing gear oil 4 22 Cleaning fuel tank 4 23 Inspecting and replacing anode 4 24 Checking bolts and nuts 4 25 Motor ext...

Page 64: ... V A W 9Starting carburetion system 2 stroke L1 43 2 62 39 36 1 54 1 42 C D I B5HS 0 6 0 7 0 024 0 028 Tiller control Manual start Choke valve start system DRIVE UNIT 9Gear positions Gear ratio 9Trim tilt system 9Propeller mark Forward 2 08 27 13 Manual A FUEL AND OIL TIGHTENING TORQUE 9Fuel Fuel tank capacity L US gal Imp gal 9Recommended engine oil Fuel oil ratio 9Recommended gear oil Gear oil q...

Page 65: ...eutral 2 08 27 13 Manual BS 25 2 5 18 17 1 7 12 Regular unleaded gasoline P O N minimum 86 2 8 0 74 0 62 25 6 6 5 5 YAMALUBE 2 STOROKE OUTBOARD OIL or an equivqlent TC W3 certified outboard oil 100 1 Hypoid gear oil SAE 90 100 3 4 3 5 3MHA 5MHA 628 24 7 997 39 3 289 11 4 441 17 4 16 5 36 3 4 500 5 500 2 2 3 at 5 000 r min 1 150 1 250 2 stroke L1 70 4 27 46 42 1 82 1 65 C D I B6HS 10 0 9 1 0 0 035 ...

Page 66: ...onal 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 maxi mum capacity Gasoline will expand considerably as it warms up and can build up pressure in the fue...

Page 67: ...g water can run into the cylinder which could result in dam age EMU00328 STORING OUTBOARD MOTOR When storing your Yamaha outboard 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 Precision Blend equipped outboard due to the lean oil ratios used at idle prior to shutting the engine off f...

Page 68: ...nic if the fuel system is to be drained instead 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 fog ging of the engine is mandatory to pre vent expensive engine damage due to rust Perform the flushing and fogging at the same time w 8 Do not touch or remove electrical parts whe...

Page 69: ...k 3 Fill the tank with fresh water to above the level of the anti cavitation plate 4 Run the engine at a fast idle for 10 15 minutes 5 Just prior to turning off the engine quickly spray Yamaha Stor Rite Engine Fogging Oil Part No LUB STRRT 12 00 alternately into each carburetor When properly done the engine will smoke excessively and almost stall 6 Remove the motor from the water tank 7 Install th...

Page 70: ... 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 71: ...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 72: ...tion 4 13 Replacement Fuel tank 1 Cleaning 4 23 Idling speed Inspection 4 14 Adjustment Anode s Inspection 1 1 4 24 Replacement Outboard motor Inspection 4 25 exterior Cooling water Flushing 4 6 passages 2 Propeller Cotter pin Inspection 4 19 Shear pin Replacement Carburetor setting Inspection 1 1 Adjustment Ignition timing Inspection 1 1 Adjustment Bolts Nuts Retightening 1 1 4 25 Interval Item I...

Page 73: ...air 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 sp...

Page 74: ... available 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 Initial of spark Plug wrench size plug I D mark B 21 mm 13 16 in C BK 16 mm 5 8 in D 18 3 m...

Page 75: ... 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 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 quali fied mechanic Improper repairs c...

Page 76: ...o cool 8 There will be fuel in the fuel filter Keep away from sparks cigarettes flames or other sources of ignition 8 The procedure will allow some fuel to spill Catch fuel in a rag Wipe up any spilled fuel immediately 8 Improper replacement can result in a fuel leak which could result in a fire or explosion hazard Check the fuel filter periodically The fuel filter is a one piece disposable type I...

Page 77: ... performed while the outboard motor is in the water A flushing attachment or test tank can be used 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 2 hp model Warm the engine with the throttle in the Start position or less If the outboard is mounted on a boat be sure the boat is tightly moored 2 Adjus...

Page 78: ... or other qualified mechanic EMK78010 CHECKING WIRING AND CONNECTORS 1 Check that each grounding wire is properly secured 2 Check that each connector is engaged securely EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and crank case WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhau...

Page 79: ...4 16 E EMU00366 GREASING Yamaha marine grease Water resistant grease 2 103081 ...

Page 80: ...4 17 E EMU00366 GREASING Yamaha marine grease Water resistant grease 3 103082 ...

Page 81: ...4 18 E EMU00366 GREASING Yamaha marine grease Water resistant grease 5 103091 ...

Page 82: ... 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 2 1 Check each of the propeller blades for wear erosion from cavitation or ventilation or other damage 2 Check the shear pin for wear or dam age The shear pin is designed to break if the propeller...

Page 83: ...he hole in the propeller with the recess in the propeller shaft Insert a new cotter pin in the hole and bend the cotter pin ends cC 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 NOTE There is a holder on the steering handle for spare shear and cotter pins Be sure to replace a pin in the holder if one is used 3 5 ...

Page 84: ...r before installing propeller otherwise lower case and propeller boss may be damaged 3 Tighten the propeller nut to the spec ified 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 tight ening to the specified torque then tight en it more to ...

Page 85: ...e stand You could be severely injured if the out 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 reinstalling 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 ...

Page 86: ...y flammable and its vapors are flammable and explo sive 8 If you have any question about prop erly 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 Reass...

Page 87: ...the tank 2 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 hose joint assembly and tighten the screws firmly 5 2 3 EML24010 INSPECTING AND REPLACING ANODE Yamaha outboard motor is protected from corrosion by sacrificial anode Check the anode periodically Remove the scales from sur...

Page 88: ...em flushing instruc tions in TRANSPORTING 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 EMP60000 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clea...

Page 89: ...1 2 3 4 5 6 E EMN00010 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Starter will not operate 5 6 Treatment of submerged motor 5 9 ...

Page 90: ...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 91: ...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 92: ... 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 93: ...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 94: ...board 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 com ponents 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 ...

Page 95: ... is running Do not move the throttle control lever from the start position during warm up Otherwise the boat could unex pectedly 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 t...

Page 96: ...nism by removing three bolts 4 Prepare the engine for starting See STARTING ENGINE for procedures 5 To start the engine with the emer gency starter rope insert the knotted end of the rope into the notch in the flywheel rotor and wind the rope one or two turns clockwise Then give a strong pull straight out to crank the engine Repeat if necessary 2 ...

Page 97: ...he starter 4 Prepare the engine for starting See STARTING ENGINE for procedures Be sure the engine is in Neutral 5 To start the engine with emergency starter rope insert the knotted end of the rope into the notch in the fly wheel rotor and wind the rope sever al turns clockwise Then give a strong pull straight out to crank the engine Repeat if necessary 3 5 5 ...

Page 98: ...mize engine damage 1 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...

Page 99: ...1 2 3 4 5 6 E EMP00010 Chapter 6 INDEX INDEX 6 1 ...

Page 100: ...djustment 2 10 Stopping engine 3 18 Storing outboard motor 4 4 EMP10010 INDEX A Adjusting idling speed 4 14 Adjusting trim angle 3 20 Air vent screw 2 4 B Basic Boating rules 1 6 Breaking in running in engine 3 9 C Changing gear oil 4 22 Checking bolts and nuts 4 25 Checking fuel system 4 12 Checking painted surface of motor 4 25 Checking propeller shear pin and cotter pin 4 19 Checking wiring and...

Page 101: ...port bar 2 11 Tilt support knob 2 11 Tilting up down 3 24 Top cowling lock lever 2 12 Trailering outboard motor 4 3 Transporting and storing outboard motor 4 3 Treatment of submerged motor 5 9 Trim angle adjusting rod 2 10 Trimming outboard motor 3 19 Troubleshooting 5 1 W Warming up engine 3 15 Water leakage 4 14 Warranty information Next page ...

Page 102: ...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 103: ...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 104: ...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 105: ...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 106: ...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 107: ...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 110: ...2A 3A 5A Printed in Japan March 2001 0 5 1 6A1 28199 1L 2BMH 3AMH 5CMH E Printed on recycled paper ...

Page 111: ...2A 3A 5A OWNER S MANUAL ...

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