Yamaha 40B Owner'S Manual Download Page 84

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4-21

Thrust washer

Propeller

Spacer

Washer

Propeller nut

Cotter pin

Installation

Apply Yamaha Marine grease (water-
resistant grease) to the propeller-
shaft.

Slide the propeller over the propeller-
shaft.

Be  sure  to  install  the  thrust  washer
before  installing  propeller,  otherwise,
lower  case  and  propeller  boss  may  be
damaged.

Tighten the propeller nut to the speci-
fied torque.

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 the hole.

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.

602041

602053

Tightening torque:

Refer to “SPECIFICATIONS” page 4-1.

63B-9-1A-4 2/28/02 5:14 PM Page 22

Summary of Contents for 40B

Page 1: ...40B 50B OWNER S MANUAL U S A Edition LIT 18626 04 92 ...

Page 2: ......

Page 3: ...ecial 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 t...

Page 4: ......

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

Page 6: ......

Page 7: ...Outboard motor serial number 1 1 Key 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 BATTERY REQUIREMENT 1 12 PROPELLER SELECTION 1 13 START IN GEAR PROTECTION 1 14 1 ...

Page 8: ...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 EMU00008 KEY NUMBER If main key switch is equipped your key identification number is stamped on your key as shown in the illustration Record this number in the space provided for ref erence if you need a new key 1 Key number...

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: ...fully Make sure there are no gas fumes or leaking fuel before starting the engine Q 8 This product emits exhaust gases which contain carbon monoxide a colorless odorless gas which may cause brain damage or death when inhaled Symp toms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 8 Check throttle shift and steering for proper op...

Page 11: ...ny 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 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: ...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: ... dened vessel These rules determine which vessel has the right of way and what each vessel should do Stand on vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision When you maintain your direction and speed the other vessel will be able to determine how best to avoid you Give way vessel The vessel which does not have the right ...

Page 14: ... 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 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 the risk of...

Page 15: ...he passage of other vessels in narrow channels 1 8 Sailing vessel right of way Sailing vessels should normally be given the right of way The exceptions to this are 1 When the sailing vessel is overtaking the power driven vessel the power driven vessel has the right of way 2 Sailing vessels should keep clear of any fishing vessel 3 In a narrow channel a sailing vessel should not hamper the safe pas...

Page 16: ...g 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 RG L PORT BUOY identification and location purposes channel is to left of bu...

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: ...d 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 E 1 11 Recommended gasoline Regular unleaded gasoline with a minimum octane rating of 86 Pump Octane Number R M 2 EMU00858 ENGINE OIL If the recommended engine oil is not available another 2 stroke engine oil with a NMMA ce...

Page 19: ...d 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 EMU01859 Minimum cold cranking amps CCA SAE 245 amps at 18 C 0 4 F Minimum marine cranking amps MCA ABYC 323 amps at 0 C 32 F Minimum reserve capacity RC SAE 52 minutes E 1 12 ...

Page 20: ...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 21: ...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 diameter in in...

Page 22: ...E MEMO ...

Page 23: ...OLS AND OTHER FUNCTIONS 2 2 Fuel tank 2 2 Remote control 2 3 Power trim tilt switch 2 7 Warning indicator 2 8 Digital tachometer 2 9 Trim tab 2 12 Tilt support lever 2 13 Top cowling lock lever 2 13 WARNING SYSTEM 2 14 Overheat warning 2 14 Oil level warning oil filter clogging warning 2 15 ...

Page 24: ... Clamp bracket 4 Battery lead 5 Anode 6 Cooling water inlet 7 Propeller 8 Trim tab Anode 9 Anti cavitation plate 0 Anode q Trim angle adjusting rod w Tilt support lever e Top cowling r Remote control box t Digital tachometer May not be exactly as shown also may not be included as standard equipment on all models ...

Page 25: ...screw If equipped EMC31010 Fuel hose joint This connector is provided for connecting or disconnecting fuel hose EMC41110 Fuel meter This meter is on the fuel tank cap It shows current fuel quantity in the fuel tank approximately EMC51010 Fuel tank cap This cap is for filling fuel To remove it turn it counterclockwise EMC61010 Air vent screw This screw is on the fuel tank cap To loosen it turn it c...

Page 26: ...ch if equipped 7 Throttle friction adjusting screw 701011 w q e r t y u R N F q w e r t y u u t r y 701031 EMC50010 Remote control lever Moving the lever forward from the Neu tral position engages Forward gear Pulling the lever back from Neutral engages Reverse The engine will contin ue to run at idle until the lever is moved about 35 a detent can be felt Moving the lever farther opens the throttl...

Page 27: ...lever will operate only when the remote control lever is in Neu tral The remote control lever will operate only when the neutral throttle lever is in the closed position 1 Fully open 2 Fully closed N 701033 w q 701036 ON START OFF 701021 EMC48110 Main switch The main switch controls the ignition sys tem its operation is described below 8 OFF Electrical circuits switched off The key can be removed ...

Page 28: ...te 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 NOTE Refer to the sections ADJUSTING TRIM ANGLE and TILTING UP DOWN in Chapter 3 for instructions on usage UP DN 701034 UP DN ...

Page 29: ...er 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 in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control...

Page 30: ...tton is released the motor will stop in its current position E EMC87011 Throttle friction adjusting screw A friction device in the remote control box provides resistance to movement of the remote control lever This is adjustable for operator preference An adjusting screw is located at the front of the remote control box w Do not overtighten the friction adjusting screw If there is too much resista...

Page 31: ...increas ing the risk of collision with another boat or an obstacle NOTE Refer to the section Adjusting Trim Angle and Tilting Up Down for instructions on usage 303016 q 303012 q EMU00120 WARNING INDICATOR If the engine develops a condition which is cause for warning the indicator on the front of the bottom cowling lights up The three indicators mounted on the bot tom cowling also indicate level of...

Page 32: ...icator 1 Tachometer 2 Trim meter 3 Hour meter 4 Oil level indicator 5 Overheat warning indicator 6 Set button 7 Mode button NOTE All segments of the display will light momentarily after the main switch is turned on and will return to normal there after q t w u y e r 001078 001082 001049 EMU00136 Tachometer This meter shows the engine speed ...

Page 33: ... EMU01620 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 8 Changing the display format Pressing the MODE button changes the display format in the following circular pattern Total hours Trip hours Display off 8 Resetting the trip hours Simult...

Page 34: ...e has activated If neces sary refer to the TROUBLESHOOTING section in this manual Consult your deal er if the problem cannot be located and corrected EMU00138 Oil Level Indicator This indicator shows the engine oil level If the oil level falls below the lower limit the warning indicator will start to blink Refer to the sections FILLING OIL and OIL LEVEL WARNING for details 1 Oil level indicator cC...

Page 35: ...ced to be sure steering is correct Be sure you have tightened the bolt after adjusting the trim tab 1 Trim tab 2 Bolt 3 Cap If equipped cC The trim tab also serves as an anode to protect the engine from electroche mical corrosion Never paint the trim tab as it will become ineffective as an anode Boat tends to The rear end of trim tab veer To the left Turn the left port side port side A in the figu...

Page 36: ...on lock the tilt support lever to the clamp bracket 403011 EMD62011 TOP COWLING LOCK LEVER To remove the engine top cowling turn the lock lever 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 lever upward 1 Top cowling lock lever ...

Page 37: ...t for clogging 1 Digital tachometer EMD80010 WARNING SYSTEM cC Do not continue to operate the engine if the warning device has activated Consult your Yamaha dealer if the problem can not be located and corrected Warning device activation The engine speed will automatically decrease to about 2 000 r min The overheat warning indicator will come on The buzzer will sound Tiller Remote control control ...

Page 38: ...ause NOTE The warning for oil filter clogging is simi lar to the warnings for low oil level and overheating For easy troubleshooting it is advisable to check for engine overheating first then oil level and finally oil filter clogging 303012 303022 213024 q Warning device activation The engine speed will automatically decrease to about 2 000 r min The oil level warning indicator will come on The bu...

Page 39: ...OPERATION CHECKS 3 8 Operation after a long period of storage 3 9 BREAKING IN ENGINE 3 10 STARTING ENGINE 3 12 WARMING UP ENGINE 3 15 SHIFTING 3 16 Forward 3 16 Reverse 3 16 STOPPING ENGINE 3 17 TRIMMING OUTBOARD MOTOR 3 18 Adjusting trim angle 3 19 TILTING UP DOWN 3 21 CRUISING IN OTHER CONDITIONS 3 32 Cruising in salt water 3 32 Cruising in turbid water 3 32 ...

Page 40: ...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 41: ...the specific boat motor combination 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 l...

Page 42: ... If the mounting 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 in alignment with the bottom of the bo...

Page 43: ...ion 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 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 increase...

Page 44: ...uring 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 To fill the engine oil tank proceed as fol lows w Do not add gasoline into the oil tank Fire or explosion could result Engine oil tank capacity See Chapter 4 Specifi...

Page 45: ... oil filler access cap on top of the top cowling counterclockwise and open it 2 Open the oil tank filler cap by pulling a tab on the cap 3 Slowly fill the engine oil into the engine oil tank 4 After filling replace the all caps securely 1 Oil filler access cap 2 Oil tank filler cap ...

Page 46: ...g tachome ter Bottom cowling Engine oil tank No refilling necessary Green Add oil refer to oil filling Yellow Buzzer sounds in remote control box and engine speed is limited to about 2 000 r min to help conserve oil Check oil filter for clogging more than 4 50 cm3 0 48 US qt 0 40 Imp qt from 450 cm3 0 48 US qt 0 40 Imp qt down to 200 cm3 0 21 US qt 0 18 Imp qt 200 cm3 0 21 US qt 0 18 Imp qt or les...

Page 47: ...ions 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 likely to contact sharp objects EMF43010 Controls 8 Check throttle shift and steering for proper operation before starting the engine 8 The controls should work smoothly without binding or unusual free play 8 Look for loose or damaged connec tions 8 Ch...

Page 48: ...rt the engine 2 Start the engine Leave it idling w 8 Do not touch or remove electrical parts when starting or during operation 8 Keep hands hair and clothes away from the flywheel and other rotating parts while the engine is running 3 Watch for oil flowing through the oil feed pipes After any air in the oil lines has been expelled the oil injec tion system should supply oil normal ly If no oil is ...

Page 49: ... break in 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 break in in addition to oil in the oil injection system Break in time 10 hours Gasoline to engine oil premix ratio during break in 50 1 ...

Page 50: ...ur 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 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...

Page 51: ...its 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 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 th...

Page 52: ...lock plate on the other end of the lanyard in the 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 from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of e...

Page 53: ...witch to START when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds with the main switch in the START position If the engine does not start within 5 seconds return the main switch to ON wait 10 seconds and then crank the engine again If the starter motor is run con tinuously for more than 5 seconds the battery will rapidly become exhausted and it will be impos...

Page 54: ...ough 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 corrected consult your Yama ha dealer NOTE After the engine starts warm up opera tion is a...

Page 55: ...MU00264 FORWARD Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from Neutral to Forward N R 701044 EMU00269 REVERSE w When operating in reverse go slowly Do not open the throttle more than half Oth erwise the boat may become unstable which could result in loss of control and an accident Pull up the neutral interlock trigger if equipped and mov...

Page 56: ... the main switch to OFF NOTE The engine can also be stopped by pulling the lanyard from the engine stop switch then turning the main switch to OFF ON START OFF 701023 304036 902052 2 If the fuel joints are provided discon nect 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 4 Remove the key if the ...

Page 57: ...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 58: ...ilt switch located on the bottom engine cowling if equipped only when the boat is at a complete stop with the engine off The outboard motor trim angle can be adjusted operating the power trim tilt switch 1 To raise the bow trim out push the switch UP To lower the bow trim in push the switch DN Make test runs with the trim set to differ ent angles to find the position that works best for your boat ...

Page 59: ... 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 105011 q 105013 w 105015 e 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 b...

Page 60: ...mage from 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 en...

Page 61: ...403011 2 Push the power trim and tilt switch UP until the outboard has tilted up completely 3 Turn the tilt support lever toward engine bracket and support the engine w After tilting the engine be sure to sup port it with the tilt support lever Other wise the engine could fall back down suddenly if oil in the power trim and tilt unit should lose pressure ...

Page 62: ...ORING 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 3 23 411035 EMG64110 PROCEDURE FOR TILTING DOWN Power trim and tilt model 1 Push the power trim and tilt switch UP until the engine is supported by the tilt rod 2 Release the tilt support lever 3 Push t...

Page 63: ...lug 4 12 Checking fuel system 4 14 Cleaning fuel filter 4 15 Adjusting idling speed 4 16 Checking water drain under engine oil tank 4 17 Replacing fuse 4 18 Checking wiring and connectors 4 18 Exhaust leakage 4 18 Water leakage 4 18 Checking power trim and tilt system 4 19 Checking propeller 4 20 Changing gear oil 4 22 Cleaning fuel tank 4 23 Inspecting and replacing anode 4 24 Checking battery 4 ...

Page 64: ...tem 8Propeller mark FUEL AND OIL TIGHTNING TORQUE 8Fuel Fuel tank capacity L US gal Imp gal 8Recommended engine oil Lubrication Engine oil capacity engine oil tank L US qt Imp qt 8Recommended gearcase oil Gear oil quantity cm3 US oz Imp oz EMK10011 SPECIFICATIONS 8Spark plug N m kgf m lb ft 8Propeller nut N m kgf m lb ft 4 500 5 500 29 4 40 at 5 000 r min 750 850 646 25 4 360 14 2 1 319 51 9 533 2...

Page 65: ...ystem B8HS 10 0 9 1 0 0 035 0 039 Remote control Electric start 245 323 52 12 6 Prime start system Regular unleaded gasoline P O N minimum 86 YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC W3 certified outboard oil oil injection system 1 5 1 6 1 3 Hypoid gear oil SAE 90 430 14 5 15 1 25 2 5 18 35 3 5 25 50TRB 4 500 5 500 36 8 50 at 5 000 r min 750 850 ...

Page 66: ...Do not use the tilt support lever knob when trailering the boat The outboard motor could shake loose from the tilt support and fall If the motor can not be trailered in the down position use an additional 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 fal...

Page 67: ...son It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to stor age However the following procedures can be performed by you the owner with a minimum of tools EMK21010 Filling Fuel Tank Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer Part No LUB FUELC 12 00 to each gallon of fuel NOTE The use of Yamaha Fuel Condit...

Page 68: ...ine top cowling and silencer cover 2 Install the outboard motor on the water tank and fill the tank with fresh water to above the level of the anti cavitation plate 1 Water surface 2 Lowest water level cC If the fresh water level is below the level of the anti cavitation plate or if the water supply is insufficient engine seizure may occur w 8 Do not tough or remove electrical parts when starting ...

Page 69: ...oard at high speed while on the flushing attachment or overheating could occur w 8 Do not touch or remove electrical parts when starting or during operation 8 Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 3 Run the engine at a fast idle for 10 15 minutes 4 Just prior to turning off the engine quickly spray Yamaha Stor Rite Engine Fogging Oil Part N...

Page 70: ...eces sary to manually override the control unit to completely fill the engine main tank Refer to Oil level warning sec tion 4 Change the lower unit oil Refer to CHANGING GEAR OIL Inspect the oil for the presence of water which indicates a leaky seal Seal replace ment should be performed by an authorized Yamaha dealership prior to use 5 Grease all grease fittings Refer to GREASING EMK27011 Cleaning...

Page 71: ...g in a closed space Always wear eye protection when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE Batteries vary among manufacturers Therefore the following procedures may not always apply Consult your battery manufacturer s instructions 1 Disconnect and remove the battery from the boat Always disconnect the black negative lead first to prevent the risk of shorting 2 Clean the battery ...

Page 72: ...the emission control system must be performed by an authorized Yamaha marine dealership A service manual is available for purchase through a Yamaha 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 o...

Page 73: ...tion 4 15 Fuel tank 2 Cleaning 4 24 Throttle link Inspection Adjustment 1 Idling speed Inspection Adjustment 4 17 Spark plug Cleaning Adjustment 4 13 Replacement Oil tank water drain Cleaning 4 18 Oil pump Inspection Adjustment 1 Power trim and tilt system 1 Inspection 4 20 Wiring Connector Inspection Reconnect 4 19 Exhaust leakage Inspection 4 19 Water leakage Inspection 4 19 Grease points Greasi...

Page 74: ...E 4 11 EMU00366 GREASING Yamaha marine grease Water resistant grease ...

Page 75: ...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 76: ...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 903022 q w Spark plug torque Refer to SPECIFICATIONS page 4 1 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 77: ...und 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 repair...

Page 78: ...e up any spilled fuel immediately 8 The fuel filter must be reassembled carefully with O ring filter cup and hoses in place Improper assembly can result in a fuel leak which could result in a fire or explosion hazard To clean the fuel filter 1 Remove the nut holding the fuel filter assembly if equipped 2 Unscrew the filter cup catching any spilled fuel in a rag 3 Remove the filter element and wash...

Page 79: ...when starting or during operation 8 Keep hands hair and clothes away from flywheel and other rotating parts while engine is running cC This procedure must be performed while the outboard motor is in the water A flushing attachment or test tank can be used Procedure NOTE A diagnostic tachometer should be used for this procedure 1 Start the engine and allow it to warm up fully in Neutral until it is...

Page 80: ...up If not warmed up fully the speed setting will tend to be too high If you have diffi culty obtaining the specified idle consult a Yamaha dealer or other qualified mechanic 1 Throttle stop screw 213012 q w 204014 q EMK58010 CHECKING WATER DRAIN UNDER ENGINE OIL TANK A translucent water drain hose is connect ed from the bottom of the oil tank to the filler neck If water or foreign matter col lects...

Page 81: ...azard NOTE If the new fuse blows again immediately consult a Yamaha dealer 1 Fuse holder 2 Fuse 20A 205015 q w 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 LEAKAG...

Page 82: ...ign of oil leaks 2 Operate each of the power trim and tilt switches on remote control and engine bottom cowling If equipped to check that all switches work 3 Tilt up the motor and check that the trim and tilt rod 1 is pushed out com pletely 4 Check that the trim and tilt rod is free of corrosion or other flaws 5 Operate the motor to trim and tilt down Check that the trim and tilt rod operates smoo...

Page 83: ...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 the splines for wear and dam age 3 Check for fish line wind...

Page 84: ... 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 the hole cC Be sure to use a new cotter pin and bend the ends over securely Oth...

Page 85: ...that the oil drain plug is at the lowest point possi ble 2 Place a suitable container under the gear case 3 Remove the oil drain plug 1 NOTE The oil drain plug is magnetic Remove all metal particles from the plug before rein stalling it 4 Remove the oil level plug 2 to allow the oil to drain completely cC Inspect the used oil after it has been drained If the oil is milky water is get ting into the...

Page 86: ...petrol is highly flammable and its vapors are flammable and explosive 8 If you have any question about properly doing this procedure consult your Yamaha dealer 8 Keep away from sparks cigarettes flames or other sources of ignition when cleaning the fuel tank 8 Remove the fuel tank from the boat before cleaning it Work only outdoors in an area with good ventilation 8 Wipe up any spilled fuel immedi...

Page 87: ... 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 902054 604012 405011 EML24010 INSPECTING AND REPLACING ANODE Yamaha outboard motor is protected from corrosion by a sacrificial anode s Check the anode periodically Remove the scales from ...

Page 88: ... with water for 15 minutes and get immediate medical attention Antidote INTERNAL 8 Drink large quantities of water or milk followed by milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventive mea sures 8 Charge batteries in a well ventilated area 8 Keep batteries away from fire sp...

Page 89: ...and should not be used for topping up 2 Keep the battery always in a good state of charge Installing a voltmeter will help you monitor your battery If you will not use the boat for a month or more remove the battery from the boat and store it in a cool dark place Completely recharge the battery before using it 3 If the battery will be stored for longer than a month check the specific grav ity of t...

Page 90: ... cC 8 Make sure the main switch on applica ble models is OFF before working on the battery 8 Reversal of the battery leads will dam age 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 ...

Page 91: ...s Consult a Yamaha dealer for touch up paint 102024 102025 EML44010 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clean of marine growths as possible If neces sary the boat bottom can be coated with an anti fouling paint approved for your area to inhibit marine growth Do not use anti fouling paint which includes copper or graphite These paints can...

Page 92: ...E MEMO ...

Page 93: ...hapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Power trim tilt will not operate 5 5 Starter will not operate 5 6 Engine fails to operate 5 8 Treatment of submerged motor 5 10 ...

Page 94: ...ric overload and repair Replace fuse with one of correct amperage 4 Have serviced by a Yamaha dealer 5 Shift to neutral B Engine will not start Starter operates 1 Fuel tank empty 2 Fuel contaminated or stale 3 Fuel filter clogged 4 Starting procedure 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 igniti...

Page 95: ...ve adjustment incorrect 19 Battery lead disconnected 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 Find and correct cause of warning 7 Inspect and adjust as specified 8 Check wires for wear or breaks Tighten al...

Page 96: ...ged 2 Propeller pitch or diameter incorrect 3 Trim angle incorrect 4 Motor mounted at incorrect height on transom 5 Warning system activated 6 Boat bottom fouled with marine growth 7 Spark plug s fouled or incorrect type 8 Weeds or other foreign matter tangled on gear housing 9 Fuel system obstructed 10 Fuel filter clogged 11 Fuel contaminated or stale 12 Spark plug gap incorrect 1 Have propeller ...

Page 97: ...amaha dealer 15 Check and replace oil with specified type 16 Have serviced by a Yamaha dealer 17 Open the air vent screw 18 Have serviced by a Yamaha dealer 19 Connect correctly 20 Inspect spark plug and replace it with recommended type E Engine power loss F Engine vibrates excessively 1 Propeller damaged 2 Propeller shaft damaged 3 Weeds or other foreign matter tangled on propeller 4 Motor mounti...

Page 98: ...ect the boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and carefully 4 Have a Yamaha dealer inspect the outboard motor before operating it again 607011 EMG65110 POWER TRIM TILT WILL NOT OPERATE If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit the engine can be ...

Page 99: ...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 100: ...e the engine is in Neutral and that the lanyard is attached to the engine stop switch The main switch must be on if the main switch is equipped on the elec tric start model NOTE Prime start model If the engine will not start with this proce dure refer to ENGINE FAILS TO OPER ATE 4 To start the engine with emergency starter rope insert the knotted end of the rope into the notch in the flywheel roto...

Page 101: ...4011 OPEN CLOSE 902025 N 701014 2 Open the emergency starter valve located behind the silencer cover on the front side 3 Squeeze the priming pump two or three times to feed fuel 4 Turn the neutral throttle lever on the remote control box upwards It is necessary to change the throttle opening slightly depending on the engine temperature cC The operation of the neutral throttle lever is possible onl...

Page 102: ...ossible for the starter motor to start the engine 7 Return the neutral throttle lever slow ly to its home position so that the engine does not stall 8 After the engine starts return the emergency starter valve if used to CLOSE w When starting or operating the engine do not touch the ignition coil high volt age wire spark plug cap or other electri cal parts carrying high voltage Keep loose clothing...

Page 103: ...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 a Yamaha dealer as...

Page 104: ...E MEMO ...

Page 105: ...EMP00010 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 106: ... bottom 4 28 Cold engine fails to start 5 8 Connecting the battery 4 27 Cruising in other conditions 3 32 Cruising in salt water 3 32 Cruising in turbid water 3 32 D Digital tachometer 2 9 Disconnecting the battery 4 27 E Emission control information 1 2 Engine fails to operate 5 8 Engine oil 1 11 Engine stop lanyard switch 2 6 Exhaust leakage 4 18 F Filling fuel 3 4 Filling fuel tank 4 4 Filling ...

Page 107: ...emote control lever 2 3 Replacement parts 4 9 Replacing fuse 4 18 Reverse 3 16 Ring free fuel additive 3 4 S Safety information 1 3 Shifting 3 16 Specifications 4 1 Start in gear protection 1 14 Starter will not operate 5 6 Starting engine 3 12 Stopping engine 3 17 Storing outboard motor 4 4 T Tachometer 2 9 Temporary action in emergency 5 5 Throttle friction adjusting screw 2 7 Tilt support lever...

Page 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 116: ...Printed in Japan March 2002 0 5 1 63B 28199 1A 40VETO 50HETO E Printed on recycled paper ...

Page 117: ...r au détail OUTBOARD MOTOR MODEL AND SERIAL NUMBER From I D label on clamp bracket MODÉLE ET NO DE SÉRIE DU MOTEUR HORS BORD sur l étiquette d identification de la presse de fixation For Dealer Use Only A l usage du concessionnaire YAMAHA DEALER NUMBER NO DU CONCESSIONNAIRE YAMAHA DEALER NAME NOM DU CONCESSIONNAIRE DATE SOLD DATE DE LIVRAISON OWNER S NAME NOM DU PROPRIÉTAIRE ADDRESS ADRESSE PHONE ...

Page 118: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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