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Yamaha 60C, Owner'S Manual

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Yamaha 60C Owner'S Manual Download Page 87

E

EMN00010

Chapter 5

TROUBLE RECOVERY

TROUBLESHOOTING

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

TEMPORARY ACTION IN
EMERGENCY

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

Impact damage .....................................5-5
Power trim/tilt will not operate............5-5
Starter will not operate.........................5-6
Engine fails to operate..........................5-8
Cold engine fails to start ......................5-8
Treatment of submerged motor .......5-11

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 6H3-9-1N 5  2/6/03 11:50  Page 1

Summary of Contents for 60C

Page 1: ...60C 70C 90C OWNER S MANUAL U S A Edition LIT 18626 05 50 ...

Page 2: ......

Page 3: ...ial 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 the...

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

Page 5: ...otor 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 2 3 4 5 6 ...

Page 6: ...11 123 YAMAHA q EMU00005 IDENTIFICATION NUMBERS RECORD EMU00007 OUTBOARD MOTOR SERIAL NUMBER The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket Record your outboard motor serial num ber in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor ser...

Page 7: ...g 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 REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS FELs SPARK PLUG DISPLACEMENT ADVE...

Page 8: ...lly Make sure there are no gas fumes or leaking fuel before starting the engine 8 This product emits exhaust gases which contain carbon monoxide a colorless 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 8 Check throttle shift and steering for proper operati...

Page 9: ...y organiza tions 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 10: ...ELS 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 1 ...

Page 11: ... 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 12: ... 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 13: ... 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 passage of a power driven vessel which can navigate only in such a channel Re...

Page 14: ...rd head of naviga MAIN CHANNEL BUOYS 1 3 5 7 tion Leave to port left proceeding upstream LIGHTED BUOY Port Hand White Light Green Light old new old new old new LIGHTED BUOY Starboard Hand 2 4 6 Even number increasing toward head of naviga tion Leave to starboard right proceeding up stream White Light Red Light A LIGHTED SAFE WATER BUOY No number Marks midchannel pass on either side Letter has no l...

Page 15: ...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 16: ...ot exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or engine performance prob lems 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 2 STROKE OUTBOARD OIL Recommended gasoline...

Page 17: ... is used the electric system could perform poorly or be overloaded causing electric system damage For electric start models choose a battery which meets the following specifications EMU01860 Minimum cold cranking amps CCA SAE 380 amps at 18 C 0 4 F Minimum marine cranking amps MCA ABYC 502 amps at 0 C 32 F Minimum reserve capacity RC SAE 124 minutes ...

Page 18: ... 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 suitable for a smaller oper ating load Yamaha dealers stock a range of pro pellers and can advise you and install a propeller on your outboard that is best suited to your application NOTE At full throttle and under a maximum ...

Page 19: ...or instructions on propeller removal and installation EMU01209 START IN GEAR PROTECTION Yamaha outboard motors or Yamaha approved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is Neutral Always select Neutral before starting the engine 13 x 17 K q w e 000933 ...

Page 20: ...E MEMO ...

Page 21: ...R FUNCTIONS 2 2 Fuel tank 2 2 Remote control 2 3 Power trim tilt switch 2 7 Trim tab 2 8 Digital tachometer 2 9 Tilt support lever 2 12 Top cowling lock levers 2 12 Flushing device 2 12 WARNING SYSTEM 2 13 Overheat warning 2 13 Oil level warning oil filter clogging warning 2 14 1 2 3 4 5 6 ...

Page 22: ...ation plate 4 Trim tab Anode 5 Propeller 6 Cooling water inlet 7 Anode 8 Trim angle adjusting rod 9 Clamp bracket 0 Tilt support lever q Power trim and tilt switch w Flushing device e Remote control box r Digital tachometer May not be exactly as shown also may not be included as standard equipment on all models ...

Page 23: ...ipped 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 it coun...

Page 24: ...switch 7 Throttle friction adjusting screw Remote control lever Moving the lever forward from the Neutral 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 throttle and the engine will begin to accelerate 1 Neutral 2 Forward 3 Reverse 4 ...

Page 25: ...emote control lever is in Neutral The remote control lever will operate only when the neutral throttle lever is in the closed position 1 Fully open 2 Fully closed 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 8 ON Electrical circuits switched on The key cannot be removed 8 START Starter motor...

Page 26: ...y under power 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 steer...

Page 27: ...ition NOTE Refer to the sections ADJUSTING TRIM ANGLE and TILTING UP DOWN in Chapter 3 for instructions on usage EMU01155 Throttle Friction Adjusting Screw A friction device in the remote control box provides adjustable resistance to move ment of the remote control lever and can be set according to operator preference An adjusting screw is located on the front of the remote control box w Do not ov...

Page 28: ...tch button is released the motor will stop in its current position w Use the power trim tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the engine off Attempting to use the cowl ing mounted power trim tilt switch while the boat is moving could increase the risk of falling overboard and could distract the operator increasing the risk of colli sion with...

Page 29: ...laced 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 cC The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode q w e 603014 603012 A B Boat tends to veer The rear end of trim tab To the left Turn the left port side port side ...

Page 30: ...icator and the overheat warning indicator 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 EMU00136 Tachometer This meter shows the engine speed ...

Page 31: ...urs Simultaneously pressing the SET and MODE buttons for more than 1 second while the trip hours are displayed resets the trip counter to 0 zero NOTE The total number of hours the engine has been run cannot be reset EMU01109 Trim Meter This meter shows the trim angle of your outboard motor NOTE 8 Memorize the trim angles that work best for your boat under different condi tions Adjust the trim angl...

Page 32: ...ivated 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 Do not o...

Page 33: ...ock lever and rear lock lever s Then lift off the cowling When replacing the cowling check to be sure it fits prop erly in the rubber seal Then lock the cowling again by returning the levers to the locked position 1 Top cowling lock lever EMU01146 FLUSHING DEVICE This device 1 is used to clean the cooling water passages of the motor using a gar den hose and tap water NOTE Refer to Cleaning Cooling...

Page 34: ...ine has an overheat warning device If the engine temperature rises too high the warning device will activate 1 Included N A If the warning system has been activated stop the engine and check the water inlet for clogging Warning device Tiller Remote activation control control model model The engine speed will automatically 1 decrease to about 2 000 r min The overheat warning indicator 1 will come o...

Page 35: ... and check for the cause 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 1 Oil filter Warning device Tiller Remote activation control control model model The engine speed will automatically 1 decrease to about 2 000 r m...

Page 36: ...770 cm3 0 81 US qt 0 68 Imp qt down to 280 cm3 0 30 US qt 0 25 Imp qt Add oil refer to oil filling Red 280 cm3 0 30 US qt 0 25 Imp qt or less 90 Oil level warning indicator Digital tachometer No refilling necessary more than 1 130 cm3 1 19 US qt 0 99 Imp qt 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 Oil le...

Page 37: ...HECKS 3 6 Operation after a long period of storage 3 7 BREAKING IN ENGINE 3 8 STARTING ENGINE 3 10 WARMING UP ENGINE 3 13 SHIFTING 3 14 Forward 3 14 Reverse 3 14 STOPPING ENGINE 3 15 TRIMMING OUTBOARD MOTOR 3 16 Adjusting trim angle 3 17 TILTING UP DOWN 3 19 CRUISING IN OTHER CONDITIONS 3 21 Cruising in salt water 3 21 Cruising in turbid water 3 21 1 2 3 4 5 6 ...

Page 38: ...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 39: ... 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 t...

Page 40: ... 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 41: ...s 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 particularly 2 cycle outboards because of increased deposits in the combustion chamber When enough deposits collect piston rings begin sticking Performance drops and engine wear increases dramatically EMU00186 FILLING FUEL AND ENGINE OIL EMU00188 ...

Page 42: ...l tank proceed as fol lows w Do not add gasoline into the oil tank Fire or explosion could result 1 Turn the 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 While many additives available may reduce deposits Yamaha recommends the use of Ring Free Fuel Additive avail able from your Yamaha dealer Ring Free has re...

Page 43: ...d or kinked by objects in the boat and that there are no sharp objects near it Oil Check to be sure you have plenty of oil for your trip Controls Check throttle shift and steering for proper operation before starting the engine The controls should work smoothly with out binding or unusual free play Look for loose or damaged connections Check operation of the starter and stop switches when the outb...

Page 44: ...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 45: ...break in in addition to oil in the oil injection system EMF52010 Gasoline Petrol Engine oil mixing chart cC Make sure to mix gasoline petrol and oil completely otherwise your outboard motor may be damaged Mixing ratio 50 1 Gasoline Petrol 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 02 L 0 02 US qt 0 02 Imp ql 0 24 L 0 25 US qt ...

Page 46: ...r 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 47: ...duct 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 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 lin...

Page 48: ...ll the 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 Lo...

Page 49: ...n it to ON cC 8 Do not turn the main switch to START when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds The battery will rapidly become exhausted and it will be impossible for it to start the engine If the engine does not start within 5 seconds return the main switch to ON wait 10 seconds and then crank the engine again ON START OFF 701022 ...

Page 50: ...ater through the cooling pas sages If water is not flowing out of the pilot hole at all times while the engine is running do not continue to run the engine Overheating and serious damage could occur Stop the engine and check to see if the water inlet on the lower cas ing is blocked If the problem cannot be found and corrected consult your Yamaha dealer NOTE After the engine starts warm up opera ti...

Page 51: ... R 701044 EMU00264 FORWARD Pull up the neutral interlock trigger If equipped and move the remote control lever quickly and firmly from Neutral to Forward EMU00269 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 Pull up the neutral interlock trigger If equipped and mov...

Page 52: ...211 PROCEDURE 1 Turn 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 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 boat will be l...

Page 53: ...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 54: ...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 55: ... in the water Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces performance further and the boat may porpoise hop in the water which could throw the operator and passengers overboard Bow Down When the bow of the boat is down it is easier to accelerate from a s...

Page 56: ...e engine is running Severe damage from overheating can result w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinch any body parts between the drive unit and engine bracket w Leaking fuel is a fire hazard Disconnect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes Otherwise fuel may leak If the ...

Page 57: ...itch UP until the outboard has tilted up completely 3 Turn the tilt support lever toward you and support the engine w After tilting the engine be sure to sup port it with the tilt support lever Otherwise the engine could fall back down suddenly if oil in the power tilt power trim tilt unit should lose pressure Power trim tilt model 4 Once the engine is supported with the tilt support lever push th...

Page 58: ...lt 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 EMU00304 PROCEDURE FOR TILTING DOWN Power tilt Power trim tilt model 1 Push the power tilt power trim tilt switch UP...

Page 59: ... fuel system 4 12 Cleaning fuel filter 4 13 Inspecting idling speed 4 14 Checking water in engine oil tank 4 15 Replacing fuse 4 16 Checking wiring and connectors 4 16 Exhaust leakage 4 16 Water leakage 4 16 Greasing 4 17 Checking power trim and tilt system 4 18 Checking propeller 4 19 Changing gear oil 4 21 Inspecting and replacing anode s 4 22 Checking battery 4 23 Checking bolts and nuts 4 26 M...

Page 60: ...F Min marine cranking amps MCA ABYC amps at 0 C 32 F Min reserve capacity RC SAE minutes 8Alternator output V Amp W 8Starting carburetion system 2 stroke L3 849 51 8 72 0 69 5 2 8 2 7 C D I system B8HS 10 0 9 1 0 0 035 0 039 Remote control Electric start 380 502 124 12 6 Prime start system DRIVE UNIT 8Gear positions Gear ratio 8Trim tilt system 8Propeller mark Forward Neutral Reverse 2 33 28 12 Po...

Page 61: ...ified outboard oil oil injection system 2 8 3 0 2 5 Hypoid gear oil SAE 90 610 20 6 21 5 25 2 5 18 35 3 5 25 726 28 6 374 14 7 1 413 55 6 520 20 5 119 262 4 500 5 500 66 2 90 at 5 000 r min 750 850 2 stroke L3 1 140 69 6 82 0 72 0 3 2 2 8 C D I system B8HS 10 0 9 1 0 0 035 0 039 Remote control Electric start 380 502 124 12 10 Prime start system Forward Neutral Reverse 2 00 26 13 Power trim tilt K ...

Page 62: ...consult your Yamaha dealer 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 8 DO NOT fill fuel container to maximum capacity Gasoline will expand consid erably as it warms up and can build up pressure in the fuel container This can ca...

Page 63: ...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 64: ...dealer cC Avoid running the outboard 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 Sto...

Page 65: ...ces sary to manually override the control unit to completely fill the engine main tank Refer to TEMPORARY ACTION IN EMERGENCY 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 Cleani...

Page 66: ...harging or using 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 Cle...

Page 67: ...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 68: ...replacement Greasing points Greasing Gear oil Change Fuel system Inspection Fuel filter can be disassembled Inspection cleaning Fuel tank Yamaha portable tank Inspection cleaning Idling speed carburetor models Inspection adjustment 1 1 Anode s external Inspection replacement 1 1 Anode s internal Inspection replacement 1 Cooling water passages Cleaning Propeller and cotter pin Inspection replacemen...

Page 69: ...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 70: ...rque 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 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 mm 23 32 in Spark plug torque Refer to SPECIFICATIONS page 4 1 EMU16350 CHECKING TOP COWLING Check the fitting of the top cowling b...

Page 71: ...und it should be repaired immediately by Yamaha dealer or other qualified mechan ic 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 72: ...pill Catch fuel in a rag Wipe 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 EMU09782 1 Remove the nut holding the fuel filter assembly if equipped 2 Unscrew the filter cup 1 catching any spilled fuel in a rag 3 Remove the filter el...

Page 73: ... 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 also be used A diagnostic tachometer should be used for this procedure Results may vary depending on whether testing is conduct ed with the flushing attachment in a test tank ...

Page 74: ...d up fully the idle speed will measure higher than normal If you have difficulty verifying the idle speed or the idle speed requires adjustment consult a Yamaha dealer or other qualified mechan ic EMU03782 CHECKING WATER IN 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 in this hose consult a Yama...

Page 75: ...e and a fire hazard NOTE If the new fuse blows again immediately consult a Yamaha dealer 1 Fuse holder 2 Fuse 20A 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 LEA...

Page 76: ...E 4 17 EMU00366 GREASING Yamaha marine grease Water resistant grease 103031 ...

Page 77: ... the motor and check that the tilt rod and trim rods are pushed out completely 4 Use the tilt support lever to lock the motor in the UP position Operate the tilt down switch briefly so the motor is supported the tilt support lever 5 Check that the tilt rod and trim rods are free of corrosion or other flaws 6 Activate the tilt down switch until the trim rods have gone completely into the cylinders ...

Page 78: ...s 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 winding around the propeller shaft...

Page 79: ... Corrosion resistant grease to the pro peller shaft 2 Install the thrust washer and propeller on the propeller shaft 3 Install the spacer and washer Tighten the propeller nut to the specified 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 If the propeller nut does not align with the propeller shaft hole after ti...

Page 80: ...d motor so 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 ti...

Page 81: ...acity Refer to SPECIFICATIONS page 4 1 EMU14622 INSPECTING AND REPLACING ANODE S Yamaha outboard motors are protected from corrosion by sacrificial anodes Inspect the external anodes periodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes cC Do not paint anodes as this would ren der them ineffective NOTE Inspect ground leads attached to...

Page 82: ...lush with water 8 EYES Flush 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 hydro gen gas therefore you should always fol low these preventive measures 8 Charge batteries in a well ventilated area 8 Kee...

Page 83: ...talling 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 the fluid at least once a month and recharge the battery when it is low NOTE Consult a Yamaha ...

Page 84: ...ll 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 battery will not start the engine Connect the RED lead to the POSITIVE terminal first Then connect the BLACK lead to the NEG ...

Page 85: ...RING OUTBOARD MOTOR 102024 90 EMU01172 CLEANING COOLING WATER PASSAGES Flushing device equipped model Perform this procedure right after opera tion for the most thorough flushing 1 After shutting off the engine unscrew the garden hose connector 2 from the fitting 1 on the bottom cowling 2 Screw the garden hose connector 2 onto a garden hose 3 which is con nected to a fresh water supply 3 With the ...

Page 86: ...cooling system flushing instructions in TRANSPORTING AND STORING OUTBOARD MOTOR 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 grap...

Page 87: ...ROUBLESHOOTING 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 Cold engine fails to start 5 8 Treatment of submerged motor 5 11 1 2 3 4 5 6 ...

Page 88: ...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 89: ...lve adjustment incorrect 18 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 a...

Page 90: ...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 91: ...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 92: ...amage Also inspect 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 EMG65010 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...

Page 93: ...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 94: ... 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 rotor and wind the rope several turns clockwise Then give a str...

Page 95: ... to return to port for repairs 1 CDI unit 2 Yellow cord EMU00955 COLD ENGINE FAILS TO START If a cold engine fails to start for prime start model use the following procedure 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 and other objects away from the engine when starting...

Page 96: ... tor It is necessary to change the throttle opening slightly depending on the engine temperature After the engine starts return the throttle to the original position 5 Set the MAIN SWITCH to ON 6 Set the MAIN SWITCH to START cC 8 Do not turn the main switch to START when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds The battery will rapidly become exhausted ...

Page 97: ...E 5 10 OPEN CLOSE 214014 7 After the engine starts return the emergency starter valve if used to CLOSE NOTE When the starter mechanism malfunc tions refer to STARTER WILL NOT OPERATE ...

Page 98: ...nimize 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 ...

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

Page 100: ...le 3 17 Air vent screw 2 2 B Basic boating rules 1 6 Battery care 4 7 Battery requirement 1 12 Breaking in engine 3 8 C Changing gear oil 4 21 Checking battery 4 23 Checking bolts and nuts 4 26 Checking fuel system 4 12 Checking painted surface of motor 4 27 Checking power trim and tilt system 4 18 Checking propeller 4 19 Checking top cowling 4 11 Checking water in engine oil tank 4 15 Checking wi...

Page 101: ...ing the propeller 4 19 Replacement parts 4 8 Replacing fuse 4 16 Reverse 3 14 S Safety information 1 3 Shifting 3 14 Specifications 4 1 Start in gear protection 1 14 Starter will not operate 5 6 Starting engine 3 10 Stopping engine 3 15 Storing outboard motor 4 4 T Tachometer 2 9 Temporary action in emergency 5 5 Throttle friction adjusting screw 2 6 Tilting up down 3 19 Tilt support lever 2 12 To...

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 Corporation 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 ...

Page 108: ...Printed in Japan March 2003 0 6 1 6H3 28199 1N 60FETO 70BETO 90AETO E Printed on recycled paper ...

Page 109: ...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 110: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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