Yamaha 4AC Owner'S Manual Download Page 20 | Manualshive

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Components

15

5C

EMU25802

Fuel tank

If your model was equipped with a portable
fuel tank, its function is as follows.

WARNING

EWM00020

The fuel tank supplied with this engine is
its dedicated fuel reservoir and must not
be used as a fuel storage container. Com-
mercial users should conform to relevant
licensing or approval authority regula-
tions.

1. Air vent screw

2. Fuel tank cap
3. Top cowling

4. Cowling lock lever

5. Steering friction adjuster
6. Anti-cavitation plate

7. Propeller

8. Cooling water inlet
9. Trim rod

10.Clamp bracket

11.Clamp screw
12.Tiller handle

13.Throttle friction adjuster

14.Manual starter handle
15.Choke knob

16.Engine stop button/Engine shut-off switch

17.Restraint cable attachment
18.Tilt support bar

19.Gear shift lever

20.Fuel cock
21.Fuel tank*

U6E028E0.book Page 15 Tuesday, February 10, 2009 3:19 PM

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Summary of Contents for 4AC

Page 1: ...Read this manual carefully before operating this outboard motor OWNER S MANUAL 4AC 5C 6E0 28199 28 E0 U6E028E0 book Page 1 Tuesday February 10 2009 3 19 PM ...

Page 2: ...arefully before operating this outboard motor Keep this manual onboard in a waterproof bag when boating This manual should stay with the outboard motor if it is sold U6E028E0 book Page 1 Tuesday February 10 2009 3 19 PM ...

Page 3: ... discrepancies between your machine and this manual If there is any question concerning this manual please con sult your Yamaha dealer To ensure long product life Yamaha recom mends that you use the product and perform the specified periodic inspections and mainte nance by correctly following the instructions in the owner s manual Any damage resulting from neglect of these instructions is not cov ...

Page 4: ...ut a rectifier or Rectifier Regulator 11 Propeller selection 11 Start in gear protection 12 Engine oil requirements 12 Fuel requirements 12 Gasoline 12 Muddy or acidic water 13 Anti fouling paint 13 Motor disposal requirements 13 Emergency equipment 13 Components 14 Components diagram 14 Fuel tank 15 Fuel tank 16 Fuel joint 16 Fuel gauge 16 Fuel tank cap 16 Air vent screw 16 Fuel cock 16 Open 17 T...

Page 5: ...al tilt models 40 Shallow water 40 Cruising in shallow water manual tilt models 40 Cruising in other conditions 41 Maintenance 42 Transporting and storing outboard motor 42 Clamp screw mounting models 42 Storing outboard motor 42 Procedure 43 Lubrication 44 Cleaning the outboard motor 44 Checking painted surface of motor 44 Periodic maintenance 44 Replacement parts 44 Severe operating conditions 4...

Page 6: ...he boat from running away under power and leaving peo ple stranded or running over people or ob jects Always attach the engine shut off cord to a secure place on your clothing or your arm or leg while operating Do not remove it to leave the helm while the boat is moving Do not at tach the cord to clothing that could tear loose or route the cord where it could become en tangled preventing it from f...

Page 7: ... in neutral Stop the engine when a person is in the water near you EMU33751 Passengers Consult your boat manufacturer s instructions for details about appropriate passenger loca tions in your boat and be sure all passengers are positioned properly before accelerating and when operating above an idle speed Standing or sitting in non designated loca tions may result in being thrown either over board...

Page 8: ...ttle and turn in anoth er direction EMU33790 Weather Stay informed about the weather Check weather forecasts before boating Avoid boat ing in hazardous weather EMU33880 Passenger training Make sure at least one other passenger is trained to operate the boat in the event of an emergency EMU33890 Boating safety publications Be informed about boating safety Additional publications and information can...

Page 9: ...or tions of the European Parliament directive re lating to machinery Each conformed outboard motor accompa nied with EC DoC EC DoC contains the fol lowing information Name of Engine Manufacture Model name Product code of model Approved model code Code of conformed directives EMU25203 CE Marking Outboard motors affixed with this CE mark ing conform with the directives of 98 37 EC 94 25 EC 2003 44 E...

Page 10: ...General information 5 1 C Tick label location ZMU01697 U6E028E0 book Page 5 Tuesday February 10 2009 3 19 PM ...

Page 11: ...als supplied with the boat Read all labels on the outboard motor and the boat If you need any additional information contact your Yamaha dealer EMU33831 Warning labels If these labels are damaged or missing contact your Yamaha dealer for replacements 4AC 5C ZMU06033 4 1 2 3 U6E028E0 book Page 6 Tuesday February 10 2009 3 19 PM ...

Page 12: ...r and clothing away from rotating parts while the engine is running Do not touch or remove electrical parts when starting or during operation 3 WARNING EWM01671 Read Owner s Manuals and labels Wear an approved personal flotation de vice PFD Attach engine shut off cord lanyard to your PFD arm or leg so the engine stops if you accidentally leave the helm which could prevent a runaway boat ZMU05924 1...

Page 13: ...vent screw when not in use EMU33843 Symbols The following symbols mean as follows Notice Warning Read Owner s Manual Hazard caused by continuous rotation Electrical hazard Remote control lever gear shift lever operat ing direction dual direction ZMU05696 ZMU05664 ZMU05665 ZMU05666 ZMU05667 U6E028E0 book Page 8 Tuesday February 10 2009 3 19 PM ...

Page 14: ...General information 9 Engine start Engine cranking ZMU05668 U6E028E0 book Page 9 Tuesday February 10 2009 3 19 PM ...

Page 15: ...00 r min 5CMH 3 7 kW 5000 r min 5 HP 5000 r min Idling speed in neutral 1150 50 r min Engine Type 2 stroke S Displacement 4ACMH 83 0 cm 5CMH 103 0 cm Bore stroke 4ACMH 50 0 42 0 mm 1 97 1 65 in 5CMH 54 0 45 0 mm 2 13 1 77 in Ignition system CDI Spark plug NGK B7HS BR7HS Spark plug gap 0 6 0 7 mm 0 024 0 028 in Control system Tiller Starting system Manual Starting carburetion system Choke valve Alt...

Page 16: ...ment and complete rigging in structions For further information see page 21 EMU25694 Battery requirements EMU25730 Without a rectifier or Rectifier Regula tor NOTICE ECM01090 A battery cannot be connected to models that do not have a rectifier or Rectifier Regulator If you wish to use a battery with the models without a rectifier or Rectifier Regulator install an optional Rectifier Regulator Using...

Page 17: ...avail able another 2 stroke engine oil with an NMMA certified TC W3 rating may be used EMU36360 Fuel requirements EMU36771 Gasoline Use a good quality gasoline that meets the minimum octane rating If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Yamaha recomends that you use alcohol free see Gasohol gas oline whenever possible NOTICE ECM01981 Do not use lead...

Page 18: ... can be coated with an anti fouling paint approved for your area to inhibit marine growth Do not use anti fouling paint which includes copper or graphite These paints can cause more rapid engine corrosion EMU36341 Motor disposal requirements Never illegally discard dump the motor Yamaha recommends consulting the dealer about discarding the motor EMU36351 Emergency equipment Keep the following item...

Page 19: ...ever 5 Steering friction adjuster 6 Anti cavitation plate 7 Propeller 8 Cooling water inlet 9 Trim rod 10 Clamp bracket 11 Clamp screw 12 Tiller handle 13 Throttle friction adjuster 14 Manual starter handle 15 Choke knob 16 Engine stop button Engine shut off switch 17 Restraint cable attachment 18 Tilt support bar 19 Fuel cock 20 Gear shift lever U6E028E0 book Page 14 Tuesday February 10 2009 3 19...

Page 20: ... approval authority regula tions 1 Air vent screw 2 Fuel tank cap 3 Top cowling 4 Cowling lock lever 5 Steering friction adjuster 6 Anti cavitation plate 7 Propeller 8 Cooling water inlet 9 Trim rod 10 Clamp bracket 11 Clamp screw 12 Tiller handle 13 Throttle friction adjuster 14 Manual starter handle 15 Choke knob 16 Engine stop button Engine shut off switch 17 Restraint cable attachment 18 Tilt ...

Page 21: ...ed with fuel To remove the cap turn it counterclockwise EMU25860 Air vent screw This screw is on the fuel tank cap To loosen the screw turn it counterclockwise EMU25872 Fuel cock The fuel cock turns on and off the supply of fuel from the fuel tank to the engine EMU25881 Close To stop fuel flow to the engine turn the lever or knob to close position Always turn the lever or knob to close position wh...

Page 22: ...pen position These are the normal running positions EMU25911 Tiller handle To change direction move the tiller handle to the left or right as necessary EMU25922 Gear shift lever Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern 1 Close position 1 Close p...

Page 23: ...n device provides adjustable resis tance to movement of the throttle grip or the remote control lever and can be set accord ing to operator preference To increase resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise WARNING Do not overtighten the friction adjuster If there is too much resistance it could be difficult to move the remote control lever or t...

Page 24: ...could become entangled preventing it from functioning Avoid acci dentally pulling the cord during normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause people and ob jects in the boat to be thrown forward EWM00122 EMU26001 Engine stop button To open the ignition circuit and stop the en gine push this but...

Page 25: ...the outboard motor in relation to the transom EMU26332 Tilt support bar The tilt support bar keeps the outboard motor in the tilted up position NOTICE ECM01660 Do not use the tilt support bar when traile ring the boat The outboard motor could shake loose from the tilt support and fall If the motor cannot be trailered in the nor mal running position use an additional support device to secure it in ...

Page 26: ...on experienced in proper outboard motor mounting should show you how to mount your out board motor The outboard motor should be mounted so that the boat is well balanced Otherwise the boat could be hard to steer For single engine boats mount the outboard motor on the cen terline keel line of the boat EMU26923 Mounting height To run your boat at optimum efficiency the water resistance drag of the b...

Page 27: ...ard motor see page 36 EMU26972 Clamping the outboard motor 1 Place the outboard motor on the transom so that it is positioned as close to the cen ter as possible Tighten the transom clamp screws evenly and securely Oc casionally check the clamp screws for tightness during operation of the out board motor because they could become loose due to engine vibration WARNING Loose clamp screws could allow...

Page 28: ...used they must be of at least the same quality of material and strength and must be tightened se curely After tightening test run the engine and check their tightness EWM00651 U6E028E0 book Page 23 Tuesday February 10 2009 3 19 PM ...

Page 29: ... onto plane then immediately reduce the throttle to 3000 r min or less 3 Next two hours Accelerate at full throttle onto plane then reduce engine speed to three quarter throttle approximately 4000 r min Vary engine speed occasionally Run at full throttle for one minute then allow about 10 minutes of operation at three quarter throttle or less to let the engine cool 4 Remaining seven hours Run the ...

Page 30: ...xplosion Check for fuel leakage regularly If any fuel leakage is found the fuel sys tem must be repaired by a qualified me chanic Improper repairs can make the outboard unsafe to operate EMU36451 Check for fuel leaks Check for fuel leaks or gasoline fumes in the boat Check for fuel leakage from the fuel system Check the fuel tank and fuel lines for cracks swellings or other damages EMU36891 Contro...

Page 31: ... with both hands If the top cowling is loose have it repaired by your Yamaha dealer EMU27234 Filling fuel and engine oil EMU27247 Filling fuel for portable tank WARNING EWM01830 Gasoline and its vapors are highly flam mable and explosive Always refuel ac cording to this procedure to reduce the risk of fire and explosion Gasoline is poisonous and can cause in jury or death Handle gasoline with care...

Page 32: ...lt in tank WARNING EWM01950 Be sure the outboard motor is securely fastened to the transom or a stable stand WARNING EWM01830 Gasoline and its vapors are highly flam mable and explosive Always refuel ac cording to this procedure to reduce the risk of fire and explosion Gasoline is poisonous and can cause in jury or death Handle gasoline with care Never siphon gasoline by mouth If you should swallo...

Page 33: ...r cap securely 10 Wipe up any spilled gasoline immediately with dry rags Dispose rags properly ac cording to local laws or regulations EMU27406 Gasoline and oil mixing 100 1 NOTICE ECM00811 Avoid using any oil other than the spec ified type Use a thoroughly blended fuel oil mix ture If the mixture is not thoroughly mixed or if the mixing ratio is incorrect the fol lowing problems could occur Low o...

Page 34: ... mix the fuel thor oughly 4 Make sure that the oil and gasoline are mixed 5 Pour the gasoline and oil mixture into the built in fuel tank TIP If using a permanently installed tank pour the oil gradually as the gasoline is being added to the tank 1 Gasoline 2 Engine oil 1 Engine oil 2 Gasoline 100 1 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...

Page 35: ...ch could cause brain damage or death when inhaled Symp toms include nausea dizziness and drowsiness Keep cockpit and cabin ar eas well ventilated Avoid blocking ex haust 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 Then firmly connect the other end of the fuel line to the joint ...

Page 36: ...ich contain carbon monoxide a colorless odorless gas which could cause brain damage or death when inhaled Symp toms include nausea dizziness and drowsiness Keep cockpit and cabin ar eas well ventilated Avoid blocking ex haust outlets 1 For the built in tank loosen the air vent screw on the fuel tank cap by one turn For the external fuel tank loosen it on the fuel tank cap by 2 or 3 turns 2 Select ...

Page 37: ... preventing it from functioning Avoid accidentally pulling the cord dur ing normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause people and objects in the boat to be thrown forward 1 Place the gear shift lever in neutral TIP The start in gear protection device prevents the engine from starting except wh...

Page 38: ...ls to start after 4 or 5 tries open the throttle a small amount between 1 8 and 1 4 and try again Also if the engine is warm and fails to start open the throttle a same amount and try to start the engine again If the engine still fails to start see page 54 EMU36510 Checks after starting engine EMU36520 Cooling water Check for a steady flow of water from the cool ing water pilot hole A continuous f...

Page 39: ...button and make sure the engine stops Confirm that removing the clip from the en gine shut off switch stops the engine Confirm that the engine cannot be started with the clip removed from the engine shut off switch EMU34610 Shifting WARNING EWM00180 Before shifting make sure there are no swimmers or obstacles in the water near you NOTICE ECM01610 Warm up the engine before shifting into gear Until ...

Page 40: ...to reverse while traveling at planing speeds Loss of control boat swamping or damage to the boat could occur The boat is not equipped with a separate braking system Water resistance stops it af ter the throttle lever is moved back to idle The stopping distance varies depending on gross weight water surface conditions and wind di rection EMU27821 Stopping engine Before stopping the engine first let...

Page 41: ...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 angle The trim angle of the outboard motor helps determine the position of the bow of the boat in the water Correct trim angle will help im prove performance and fuel economy while reducing strain on the engine Correct trim an gle depends upon the ...

Page 42: ...use loss of control TIP The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim rod one hole EMU27911 Adjusting boat trim When the boat is on plane a bow up attitude results in less drag greater stability and effi ciency This is generally when the keel line of the boat is up about 3 to 5 degrees With the bow up the boat may have a greater tenden cy to steer to one...

Page 43: ...d down Body parts can be crushed between the motor and the clamp bracket when the mo tor is trimmed or tilted WARNING EWM00230 Leaking fuel is a fire hazard Tighten the air vent screw and place the fuel cock in the closed position if the outboard motor will be tilted for more than a few minutes Otherwise fuel may leak NOTICE ECM00231 Before tilting the outboard motor follow the procedure under Sto...

Page 44: ... use the tilt support bar when traile ring the boat The outboard motor could shake loose from the tilt support and fall If the motor cannot be trailered in the nor mal running position use an additional support device to secure it in the tilt posi tion For more detailed information see page 42 TIP If the motor is not facing forward the tilt sup port bar cannot automatically turn to the locked posi...

Page 45: ...711 Run the boat at the lowest possible speed when using the shallow water cruising system The tilt lock mecha nism does not work while the shallow water cruising system is being used Hit ting an underwater obstacle could cause the outboard motor to lift out of the water resulting in loss of control Do not rotate the outboard motor 180 and operate the boat in reverse Place the gear shift in revers...

Page 46: ...ter After operating in salt water flush the cooling water passages with fresh water to prevent them from becoming clogged Also rinse the outside of the outboard motor with fresh wa ter Cruising in muddy turbid or acidic water Yamaha strongly recommends that you use the optional chromium plated water pump kit see page 13 if you use the outboard motor in acidic water or water with a lot of sediment ...

Page 47: ...tional support device to secure it in the tilt position The outboard motor should be trailered and stored in the normal running position If there is insufficient road clearance in this position then trailer the outboard motor in the tilt posi tion using a motor support device such as a transom saver bar Consult your Yamaha dealer for further details EMU28235 Clamp screw mounting models When transp...

Page 48: ...amage due to rust Perform the flushing and fog ging at the same time WARNING Do not touch or remove electrical parts when starting or during operation Keep hands hair and clothes away from the flywheel and other rotating parts while the engine is running EWM00091 7 Run the engine at a fast idle for a few minutes in neutral position 8 Just prior to turning off the engine quickly spray Fogging Oil a...

Page 49: ... mechanical skills tools and supplies If you do not have the proper skills tools or supplies to perform a maintenance procedure have a Yamaha dealer or other qualified mechan ic do the work The procedures involve disassembling the motor and exposing dangerous parts To reduce the risk of injury from moving hot or electrical parts Turn off the engine and keep engine shut off cord lanyard with you wh...

Page 50: ...en op erating the engine under adverse conditions such as extended trolling Disassembly or repairs may be necessary depending on the outcome of maintenance checks Expendable or consumable parts and lubricants will lose their effectiveness over time and through normal usage regardless of the warranty period When operating in salt water muddy other turbid cloudy acidic water the engine should be flu...

Page 51: ...Inspection or replace ment as necessary Spark plug caps spark plug wires Inspection or replace ment as necessary Water from the cooling water pilot hole Inspection Throttle link throttle ca ble throttle pick up tim ing Inspection adjustment or replacement as nec essary Thermostat Inspection or replace ment as necessary Water inlet Inspection Main switch stop switch choke switch Inspection or repla...

Page 52: ...Yamaha grease A water resistant grease Yamaha grease D corrosion resistant grease for propeller shaft 4AC 5C Item Actions Every 1000 hours Exhaust guide exhaust manifold Inspection or replace ment as necessary U6E028E0 book Page 47 Tuesday February 10 2009 3 19 PM ...

Page 53: ... damaged insulator could allow exter nal sparks which could lead to explo sion or fire EWM00561 3 Be sure to use the specified spark plug otherwise the engine may not operate properly Before fitting the spark plug measure the electrode gap with a wire thickness gauge replace it if out of spec ification 4 When fitting the plug wipe off any dirt from the threads and then screw it in to the correct t...

Page 54: ...d or the idle speed requires adjustment consult a Yamaha dealer or other qualified mechanic EMU29113 Checking wiring and connectors Check that each connector is engaged se curely Check that each ground lead is properly se cured EMU32112 Checking propeller WARNING EWM01881 You could be seriously injured if the en gine accidentally starts when you are near the propeller Before inspecting remov ing o...

Page 55: ...ost 1 Apply Yamaha marine grease or a corro sion resistant grease to the propeller shaft 2 Install the spacer if equipped thrust washer and propeller on the propeller shaft NOTICE Be sure to install the thrust washer before installing the propeller otherwise the lower case and propeller boss could be damaged ECM01880 3 Install the spacer if equipped and the washer Tighten the propeller nut until t...

Page 56: ...oblem Consult your Yamaha dealer ECM01900 TIP If a magnetic gear oil drain screw is equipped remove all metal particles from the screw before installing it Always use new gaskets Do not reuse the removed gaskets 4 Remove the oil level plug and gasket to allow the oil to drain completely NOTICE Inspect the used oil after it has been drained If the oil is milky water is getting into the gear case wh...

Page 57: ...fully Im proper assembly can result in a fuel leak which could result in a fire or ex plosion hazard Dispose of old gasoline according to lo cal regulations 1 Empty the fuel tank into an approved con tainer 2 Pour a small amount of suitable solvent into the tank Install the cap and shake the tank Drain the solvent completely 3 Remove the screws holding the fuel joint assembly Pull the assembly out...

Page 58: ...m the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes NOTICE ECM00720 Do not paint anodes as this would render them ineffective TIP Inspect ground leads attached to external an odes on equipped models Consult a Yamaha dealer for inspection and replacement of inter nal anodes attached to the power unit U6E028E0 book Page 53 Tuesday February 10 2009 3 19 PM ...

Page 59: ...hift lever in gear A Shift to neutral Engine will not start starter operates Q Is fuel tank empty A Fill tank with clean fresh fuel Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is fuel filter clogged A Clean or replace filter Q Is starting procedure incorrect A See page 32 Q Has fuel pump malfunctioned A Have serviced by a Yamaha dealer Q Are spark plug s fouled or of incorr...

Page 60: ...screw on fuel tank closed A Open air vent screw Q Is choke knob pulled out A Return to home position Q Is motor angle too high A Return to normal operating position Q Is carburetor clogged A Have serviced by a Yamaha dealer Q Is fuel joint connection incorrect A Connect correctly Q Is throttle valve adjustment incorrect A Have serviced by a Yamaha dealer Q Is battery cable disconnected A Connect s...

Page 61: ...th recommended type Q Are weeds or other foreign matter tangled on gear housing A Remove foreign matter and clean lower unit Q Is fuel system obstructed A Check for pinched or kinked fuel line or oth er obstructions in fuel system Q Is fuel filter clogged A Clean or replace filter Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is spark plug gap incorrect A Inspect and adjust a...

Page 62: ...d motor unsafe to operate If the outboard motor hits an object in the wa ter follow the procedure below 1 Stop the engine immediately 2 Inspect the control system and all compo nents for damage Also inspect the boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and careful ly 4 Have a Yamaha dealer inspect the out board motor before operating it again EMU29533 Sta...

Page 63: ...ne is running Do not touch the ignition coil spark plug wire spark plug cap or other electrical components when starting or operating the motor You could get an electrical shock EMU29562 Emergency starting engine 1 Remove the top cowling 2 Remove the start in gear protection ca ble from the starter if equipped 3 Remove the starter flywheel cover after removing the bolt s 4 Prepare the engine for s...

Page 64: ...oard motor is submerged immedi ately take it to a Yamaha dealer Otherwise some corrosion may begin almost immediate ly NOTICE Do not attempt to run the out board motor until it has been completely inspected ECM00401 U6E028E0 book Page 59 Tuesday February 10 2009 3 19 PM ...

Page 65: ...U6E028E0 book Page 60 Tuesday February 10 2009 3 19 PM ...

Page 66: ...YAMAHA MOTOR CO LTD Printed on recycled paper Printed in Japan March 2009 0 3 1 CR U6E028E0 book Page 1 Tuesday February 10 2009 3 19 PM ...

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