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EMK00010

Chapter 4

MAINTENANCE

SPECIFICATION DATA

.............................4-1

TRANSPORTING AND STORING
OUTBOARD MOTOR

...............................4-2

Trailering outboard motor ...................4-2
Storing outboard motor .......................4-3

PERIODIC MAINTENANCE

......................4-6

Replacement parts ................................4-6
Maintenance chart ................................4-7
Cleaning and adjusting spark plug .....4-8
Checking fuel system .........................4-10
Inspecting and replacing fuel filter ...4-11
Adjusting idling speed .......................4-12
Checking wiring and connectors.......4-13
Exhaust leakage ..................................4-13
Water leakage......................................4-13
Greasing...............................................4-14
Checking propeller..............................4-15
Changing gear oil................................4-17
Cleaning fuel tank ...............................4-18
Inspecting and replacing anode ........4-19
Checking bolts and nuts.....................4-20
Motor exterior .....................................4-20
Coating the boat bottom ....................4-20

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Summary of Contents for 8A

Page 1: ...8A LIT 18626 04 50 8A OWNER S MANUAL U S A Edition ...

Page 2: ......

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

Page 4: ......

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

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Page 7: ...N NUMBERS RECORD 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 petrol 1 11 Engine oil 1 11 PROPELLER SELECTION 1 12 START IN GEAR PROTECTION 1 13 1 2 3 4 5 6 E ...

Page 8: ...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 serial number M B K INDUSTRIE PRODUCT ASSEMBLED IN FRANCE PRODUIT ASSEMBLE EN FRANCE ...

Page 9: ...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 IN ...

Page 10: ...king 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 operation before starting the engine 8 Attach the ...

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

Page 12: ...ll not start unless the shift control is in neutral position 6E0 83627 41 WARNING Be sure shift control is in neutral before starting engine except 2HP Do not touch or remove electrical parts when starting or during operation Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 6A1 83625 41 8 8 8 ...

Page 13: ...r 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: ... 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 16: ...ead 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 later...

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: ...g ethanol can be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not recommended by 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 oil YAMALUBE 2 ...

Page 19: ... 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 20: ...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 602013 9 1 4 x8 N 1 2 3 ...

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

Page 22: ...ustment 5 Engine stop button Engine stop lanyard switch 6 Clamp screw 7 Rope attachment 8 Cooling water inlet 9 Anti cavitation plate 0 Trim angle adjusting rod q Shallow water lever w Tilt support knob e Gear shift lever r Top cowling t Fuel tank y Fuel hose May not be exactly as shown also may not be included as standard equipment on all models ...

Page 23: ...se 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 counterclockwise EMC25010 GEAR SHIFT LEVER for Tiller control model Turning the gear shift lever towards you engages the clutch with the ...

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

Page 25: ...is on the tiller handle Turn the grip counterclockwise to increase speed and clockwise to decrease speed EMC42110 CHOKE KNOB Turning this knob to right setting it to ON supplies a rich mixture required to start the engine Throttle indicator The fuel consumption curve on the throt tle indicator shows the relative amount of fuel consumed for each throttle position Choose the setting that offers the ...

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

Page 27: ...To increase the resistance Turn the adjusting screw bolt clockwise To decrease the resistance Turn the adjusting screw bolt counter clockwise w Do not overtighten the friction screw bolt If there is too much resis tance it may be difficult to steer which could result in an accident EMU01297 TRIM ANGLE ADJUSTING ROD The position of the trim angle adjusting rod determines the minimum trim angle of t...

Page 28: ...WLING 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 EMD47010 TILT SUPPORT KNOB To keep the outboard motor in the tilted up position push the tilt support knob under the swivel bracket 412011 ...

Page 29: ...ixing 3 6 PRE OPERATION CHECKS 3 7 BREAKING IN RUNNING IN ENGINE 3 8 STARTING ENGINE 3 10 WARMING UP ENGINE 3 13 SHIFTING 3 14 Forward 3 14 Reverse 3 14 STOPPING ENGINE 3 15 TRIMMING OUTBOARD MOTOR 3 16 Adjusting trim angle 3 17 CRUISING IN SHALLOW WATER 3 19 TILTING UP DOWN 3 21 CRUISING IN OTHER CONDITIONS 3 23 Cruising in salt water 3 23 Cruising in turbid water 3 23 1 2 3 4 5 6 E ...

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

Page 31: ... 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 32: ...g height is too high cavitation tends to occur thus reducing the propulsion and if the pro peller tips cut the air the engine speed will rise abnormally and cause the engine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engine efficiency Mount the engine so that the anti cavita tion plate is between the bottom of the boat and a level 25 mm 1 in...

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

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

Page 35: ...ing ratio is incorrect the following problems could occur Low oil ratio Lack of oil could cause major engine trouble such as piston seizure High oil ratio Too much oil could cause fouled spark plugs smoky exgaust and heavy carbon deposits Oil Gasoline Petrol Break in period 1 25 After break in 1 100 902032 q w Mixing ratio 25 1 Gasoline Petrol 1 L 0 26 US gal 0 22 Imp gal 12 L 3 2 US gal 2 6 Imp g...

Page 36: ...F40012 PRE OPERATION CHECKS w If any item in the pre operation check is not working properly have it inspected and repaired before operating the out board motor Otherwise an accident could occur EMF41110 Fuel 8 Check to be sure you have plenty of fuel for your trip 8 Make sure there are no fuel leaks or gasoline fumes 8 Check fuel line connections to be sure they are tight 8 Be sure the fuel tank ...

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

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

Page 39: ...screw 8 This product emits exhaust gases which contain carbon monoxide a col orless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated 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 conn...

Page 40: ...e 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 it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss...

Page 41: ...ine 8 If the choke knob is left pulled out after the engine starts the engine will stall 8 Pull the starter handle slowly until you feel resistance Then give a strong pull straight out to crank and start the engine Repeat it if neces sary 9 After the engine starts return the starter handle slowly to the original position before releasing it 10 Return the throttle to the fully closed position 30501...

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

Page 43: ...ds EMG22110 FORWARD 1 Place the throttle control grip in the fully closed position 2 Turn the gear shift lever quickly and firmly from Neutral to Forward EMU00267 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 1 Place the throttle control grip in the fully closed pos...

Page 44: ...commended EMU00275 1 Push and hold the engine stop button until the engine comes to a complete stop 2 After stopping the engine disconnect the fuel line from the motor 3 Tighten the air vent screw on the fuel tank cap after stopping the engine if it is equipped NOTE The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop lanyard switch ...

Page 45: ...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 46: ...rd the transom Make test runs with the trim set to differ ent angles to find the position that works best for your boat and operating condi tions w 8 Stop the engine before adjusting the trim angle 8 Use care to avoid being pinched when removing or installing the rod 8 Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any signs of instabili ty or co...

Page 47: ...at is pushing the water and there is more air drag Excessive trim up can cause the propeller to ventilate which reduces performance further When trimmed out too much a boat may porpoise hop in the water which could throw the operator and pas sengers overboard 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 48: ...nism does not work while the shallow water cruising system is being used Hitting an underwater obstacle could cause the engine to lift out of the water resulting in loss of control 8 Use extra care when operating in reverse Too much reverse thrust can cause the engine to lift out of the water increasing the chance of acci dent and personal injury 8 Return the engine to its normal posi tion as soon...

Page 49: ...artially raised position 4 When lowering the engine slightly tilt up the engine and push the shallow water lever down Then slowly lower the engine to the normal position 2 Slightly tilt up the engine Pull up the shallow water lever EMG71110 PROCEDURE 1 Place the gear shift lever in Neutral ...

Page 50: ...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 51: ...he fuel line connection from the motor 3 Hold the rear of the top cowling with one hand and fully tilt the engine up 4 Push the tilt support knob into the clamp bracket PROCEDURE FOR TILTING DOWN 1 Slightly tilt up the engine 2 Pull out the tilt support knob 3 Tilt down the engine slowly to its home position ...

Page 52: ...resh water to prevent them from becoming clogged up with salt deposits NOTE Refer to cooling system flushing instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR CRUISING IN TURBID WATER It is strongly recommended that the optional chromium plated water pump kit be installed if the outboard is to be used in turbid muddy water conditions ...

Page 53: ...7 Cleaning and adjusting spark plug 4 8 Checking fuel system 4 10 Inspecting and replacing fuel filter 4 11 Adjusting idling speed 4 12 Checking wiring and connectors 4 13 Exhaust leakage 4 13 Water leakage 4 13 Greasing 4 14 Checking propeller 4 15 Changing gear oil 4 17 Cleaning fuel tank 4 18 Inspecting and replacing anode 4 19 Checking bolts and nuts 4 20 Motor exterior 4 20 Coating the boat b...

Page 54: ... reserve capacity minutes at 26 7 C 80 F 8Alternator output V A W 8Starting carburetion system 2 stroke L2 165 10 01 50 42 1 97 1 65 C D I B7HS 10 0 9 1 0 0 035 0 039 Tiller control Manual start 12 80 Choke valve start system EMR50302 SPECIFICATION DATA Model Unit 8MHA Item DRIVE UNIT 8Gear positions Gear ratio 8Trim tilt system 8Propeller mark Forward Neutral Reverse 2 08 27 13 Manual N FUEL AND ...

Page 55: ...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 falls 8 USE CARE when transporting fuel tank whether in a boat or car DO NOT fill fuel container to maximum capacity Gasoline will expand considerably as it warms up and can build up pressure in...

Page 56: ...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 Conditioner and Stabilizer eliminates the need to drain the fuel system Consult your Yamaha dealer or other qualified mechanic if the fuel sys tem is to be drained instead NOTE Place a towel or the like under the...

Page 57: ...ng EMU00340 8 Flushing in a Water Tank 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 1 Remove the engine top cowling 2 Install the outboard motor on the water tank 3 Fill the tank with fresh water to above the level of the anti cavitation plate 4 Run the engine at a fast idle for 10 15 minutes 5 Just prio...

Page 58: ... the lower unit oil Refer to the Periodic Maintenance section Changing gear oil Inspect the oil for the presence of water which indi cates a leaky seal Seal replacement should be performed by an autho rized Yamaha dealership prior to use 4 Grease all grease fittings Refer to the Periodic Maintenance section Greasing EMK27010 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the out b...

Page 59: ...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 60: ...4 8 Greasing points Greasing 7 4 14 Gear oil Change 7 7 4 17 Fuel system Inspection 7 4 10 Fuel filter Cleaning Inspection 7 7 7 4 11 Fuel tank 1 Cleaning 7 4 18 Idling speed Adjustment 7 4 12 Anode Inspection Replacement 2 2 4 19 Outboard motor exterior Inspection 7 7 4 20 Cooling water passages Cleaning 7 7 4 4 Propeller and cotter pin Inspection Replacement 7 7 4 15 Carburetor setting Inspectio...

Page 61: ...k 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 spark plu...

Page 62: ...u 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 4 9 E 903022 q w Initial of spark plug Plug wrench I D mark size 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 63: ... found 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 rep...

Page 64: ... cool 8 There will be fuel in the fuel filter Keep away from sparks cigarettes flames or other sources of ignition 8 The procedure will allow some fuel to spill Catch fuel in a rag Wipe up any spilled fuel immediately 8 Improper replacement can result in a fuel leak which could result in a fire or explosion hazard Check the fuel filter periodically The fuel filter is a one piece disposable type If...

Page 65: ... to warm up fully in Neutral until it is running smoothly If the outboard is mounted on a boat be sure the boat is tightly moored 2 Adjust the throttle stop screw 1 to set the idling speed to specification see SPECIFICATIONS on page 4 1 by turning the stop screw clockwise to increase the idling speed and turn ing it counterclockwise to decrease the idling speed NOTE Correct idling speed adjustment...

Page 66: ...aust cover cylinder head and crank case WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head and crank case EMK78010 CHECKING WIRING AND CONNECTORS 1 Check that each grounding wire is properly secured 2 Check that each connector is engaged securely ...

Page 67: ...4 14 E EMU00366 GREASING Yamaha marine grease Water resistant grease 103101 ...

Page 68: ...e key and remove the lanyard from the engine stop switch Turn off the battery cut off switch if your boat has one 8 Do not use your hand to hold the pro peller when loosening or tightening the propeller nut Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning 1 Check each of the propeller blades for wear erosion from cavitation or ven tilation or ot...

Page 69: ...to install the thrust washer before installing propeller otherwise lower case and propeller boss may be damaged 3 Tighten the propeller nut to the speci fied torque 4 Align the propeller nut with the pro peller shaft hole Insert a new cotter pin in the hole and bend the cotter pin ends NOTE When the propeller nut does not align with the propeller shaft hole after tighten ing to the specified torqu...

Page 70: ...injured if the outboard falls on you 2 Place a suitable container under the gearcase 3 Remove the oil drain plug NOTE The oil drain plug is magnetic Remove all metal particles from the plug before rein stalling it 4 Remove the oil level plug to allow the oil to drain completely 1 Oil level plug 2 Oil drain plug cC Inspect the used oil after it has been drained If the oil is milky water is get ting...

Page 71: ... w Gasoline 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...

Page 72: ... To clean the fuel tank 1 Empty the fuel tank into an approved gasoline container 2 Pour a small amount of suitable sol vent in the tank Reinstall the cap and shake the tank Drain the solvent completely To clean the fuel filter 1 Remove the screws holding the fuel meter assembly Pull the assembly out of the tank 2 Clean the filter located on the end of the suction pipe in a suitable clean ing solv...

Page 73: ...ouling 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 EMU00409 MOTOR EXTERIOR EMU00410 Cleaning the Outboard Motor After use wash the exterior of the out board with fresh water Flush the cooling system with fresh water NOTE Refer to Flushing Cooling System instruc tions in TRAN...

Page 74: ...E MEMO ...

Page 75: ...EMN00010 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damege 5 5 Starter will not operate 5 6 Treatment of submerged motor 5 8 1 2 3 4 5 6 E ...

Page 76: ...oad and repair Replace fuse with one of correct amperage 4 Have serviced by a Yamaha dealer 5 Attach lanyard 6 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 damage...

Page 77: ...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 78: ... filter cup 1 Propeller damaged 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...

Page 79: ...serviced by a Yamaha 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 21 Have serviced by a Yamaha dealer 22 Have serviced by a Yamaha dealer E Engine power loss F Engine vibrates excessively 1 Propeller damaged 2 Prop...

Page 80: ... board motor unsafe to operate If the outboard motor hits any object in the water follow the procedure below 1 Stop the engine immediately 2 Inspect control system and all compo nents for damage Also inspect the boat damage 3 However damage is found or not found go back to a nearest harbor slowly and carefully 4 Have a Yamaha dealer inspection of the outboard motor before operating it again ...

Page 81: ...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 82: ...ary Procedure 1 Remove the top cowling 2 Remove the starter flywheel cover by removing the bolts NOTE On a model equipped with the start in gear protection device cable disconnect the cable from the starter 3 Prepare the engine for starting See STARTING ENGINE for procedures Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch On the electric start model the ...

Page 83: ...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 84: ...E MEMO ...

Page 85: ...EMP00010 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 86: ...uel 3 5 Filling fuel and engine oil 3 5 Flushing cooling system and fogging engine 4 4 Forward 3 14 Fuel hose joint 2 2 Fuel meter 2 2 Fuel tank cap 2 2 Fuel tank 2 2 Fueling instructions 1 10 G Gasoline petrol 1 11 Gasoline petrol and oil mixing 3 6 Gear shift lever 2 2 Greasing 4 14 I Identification numbers record 1 1 Impact damage 5 5 Important labels 1 5 Index 6 1 Inspecting and replacing anod...

Page 87: ...iction adjustment 2 5 Throttle indicator 2 4 Tiller handle 2 5 Tilt support knob 2 7 Tilting up down 3 21 Top cowling lock lever 2 7 Trailering outboard motor 4 2 Transporting and storing outboard motor 4 2 Treatment of submerged motor 5 8 Trim angle adjusting rod 2 6 Trimming outboard motor 3 16 Troubleshooting 5 1 W Warning lavels 1 5 Warming up engine 3 13 Water leakage 4 13 Warranty informatio...

Page 88: ...egistration 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 ...

Page 89: ...able 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 North ...

Page 90: ...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 91: ...he 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 strain neglect or abuse A These terms are general and overlap each other in areas Specific examples include Running the machine out of oil operating the machine with a broken or damaged part which causes anoth...

Page 92: ...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 93: ...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 96: ...8A Printed in Belgium January 2001 0 5 1 6M8 F8199 15 8CMH Printed on recycled paper ...

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