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4-21

E

EML40010

CHECKING BOLTS AND NUTS

1)

Check that bolts securing the cylinder
head and engine and the nut securing
the flywheel are tightened with their
specified tightening torques.

2)

Check the tightening torques of other
bolts and nuts.

102031

102025

EML44010

COATING THE BOAT BOTTOM

A clean hull improves boat performance.
The boat bottom should be kept as clean
of marine growths as possible.
If necessary, the boat bottom can be coat-
ed 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.

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 “TRANSPORTING AND STORING
OUTBOARD MOTOR”.

Checking Painted Surface of Motor

Check the motor for scratches, nicks, or
flaking paint. Areas with damaged paint
are more likely to corrode.
If necessary, clean and paint the areas.
Consult a Yamaha dealer for touch-up
paint.

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Summary of Contents for 8C

Page 1: ...8C OWNER S MANUAL U S A Edition LIT 18626 05 30 ...

Page 2: ......

Page 3: ...tes 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 manua...

Page 4: ...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 ...

Page 5: ...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 6: ...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 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: ...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 9: ...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 10: ...ill not start unless the shift control is in neutral position 6E0 83627 41 WARNING 6Be sure shift control is in neutral before starting engine except 2HP 6Do not touch or remove electrical parts when starting or during operation 6Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 6A1 83625 41 ...

Page 11: ...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 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: ...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 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: ...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 17: ... 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 18: ...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 19: ...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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...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 28: ...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 29: ... 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 30: ...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 31: ...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 32: ...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 33: ...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 Gasoline Petrol Oil Break in period 25 1 After break in 100 1 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 34: ...qt 024 L 0 25 US qt 0 21 Imp qt EMF40012 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 ...

Page 35: ...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 36: ...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 37: ...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 38: ...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 of engine power means the loss of most steering con...

Page 39: ...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 40: ...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 41: ...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 42: ...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 43: ...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 44: ...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 45: ... 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 46: ...ng 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 as the boat is back in deeper water cC Place the gear shift in t...

Page 47: ...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 48: ...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 49: ...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 50: ...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 51: ...djusting spark plug 4 8 Checking fuel system 4 10 Inspecting and replacing fuel filter 4 11 Inspecting idling speed 4 12 Checking wiring and connectors 4 13 Exhaust leakage 4 13 Water leakage 4 13 Checking top cowling 4 13 Greasing 4 14 Checking propeller 4 15 Changing gear oil 4 18 Cleaning fuel tank 4 19 Inspecting and replacing anode 4 20 Checking bolts and nuts 4 21 Motor exterior 4 21 Coating...

Page 52: ...ropeller mark FUEL AND OIL Recommended fuel P O N Fuel tank capacity L US gal Imp gal Recommended engine oil Lubrication Fuel oil ratio Fuel Oil Recommended gear oil Gear oil capacity cm3 US oz Imp oz TIGHTENING TORQUE Spark plug N m kgf m lb ft Propeller nut N m kgf m lb ft 802 31 6 343 13 5 977 38 5 436 17 2 27 59 4 4 500 5 500 5 9 8 5 000 850 950 2 stroke L2 165 10 01 50 42 1 97 1 65 CDI system...

Page 53: ...onsult 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 consider ably as it warms up and can build up pressure in the fuel container This can cau...

Page 54: ...lizer 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 EMU00327 Clamp handle mounting model When transporting or storing the out board motor while removed from a boat fold the tiller handle and lean the...

Page 55: ...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 56: ... 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 57: ...the emission control system must be performed by an authorized Yamaha marine dealership A service manual is available for purchase through a Yamaha dealer for owners who have the mechanical skills tools and other equipment necessary to perform maintenance not covered by this owner s manual EMK33011 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equiva lents o...

Page 58: ...rs 200 hours 1 month 3 months 6 months 1 year Spark plug s Cleaning adjustment replacement Greasing points Greasing Gear oil Change Fuel system Inspection Fuel filter disposable Inspection replacement 1 1 1 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...

Page 59: ...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 60: ...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 61: ... 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 62: ... 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 63: ...th the flushing attachment in a test tank or with the outboard motor in the water 1 Start the engine and allow it to warm up fully in neutral until it is running smoothly If the outboard motor is mounted on a boat be sure the boat is tightly moored 2 Verify whether the idle speed is set to specification For idle speed specifica tions see Specifications in this chapter NOTE Correct idling speed ins...

Page 64: ...k 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 EMU16350 CHECKING TOP COWLING Check the fitting of the top cowling by pushing it with both hands If the fitting is loose have it repaired by a Yamaha dealer ...

Page 65: ...4 14 E EMU00366 GREASING Yamaha marine grease Water resistant grease 103101 ...

Page 66: ...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 EMU00390 Propeller Checking Point 8 Check each of the propeller blades for wear erosion from cavitation or v...

Page 67: ...02052 000607 r e w q t EMU00977 Removing the Propeller 1 Straighten the cotter pin 1 and pull it out using a pair of pliers 2 Remove the propeller nut 2 and washer 3 3 Remove the propeller 4 and thrust washer 5 ...

Page 68: ...ase or a corrosion resistant grease to the pro peller shaft 2 Install the thrust washer and propeller on the propeller shaft 3 Install the washer and tighten the pro peller 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 When the propeller nut does not align with the propeller shaft hole afte...

Page 69: ... if the outboard accidentally falls 1 Tilt the outboard 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 4 Remove the oil level plug 2 to allow the oil to drain completely cC Inspect the used oil after it has been drained If the oil is milky water is get ting into the gear case which can cause gear dama...

Page 70: ...ine petrol is highly flammable and its vapors are flammable and explosive 8 If you have any question about properly doing this procedure consult your Yamaha dealer 8 Keep away from sparks cigarettes flames or other sources of ignition when cleaning the fuel tank 8 Remove the fuel tank from the boat before cleaning it Work only outdoors in an area with good ventilation 8 Wipe up any spilled fuel im...

Page 71: ...ult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit 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...

Page 72: ...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 73: ...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 74: ...ngine 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 ignition wiring 9 Ignition parts faulty 10 Engine stop switch lanyard not attached 11 Engine inner parts damaged 1 Fill tank with...

Page 75: ...ion incorrect 17 Throttle valve adjustment incorrect 1 Inspect spark plug s Clean or replace with recommended type 2 Check for pinched or kinked fuel line or other obstructions in fuel system 3 Fill tank with clean fresh fuel 4 Clean or replace filter 5 Have serviced by a Yamaha dealer 6 Inspect and adjust as specified 7 Check wires for wear or breaks Tighten all loose connections Replace worn or ...

Page 76: ...repaired or replaced 2 Install correct propeller to operate outboard at its recommended speed r min range 3 Adjust trim angle to achieve most efficient operation 4 Have motor adjusted to proper transom height 5 Clean boat bottom 6 Inspect spark plug s Clean or replace with recommended type 7 Remove foreign matter and clean lower unit 8 Check for pinched or kinked fuel line or other obstructions in...

Page 77: ...ler shaft damaged 3 Weeds or other foreign matter tangled on propeller 4 Motor mounting bolt loose 5 Steering pivot loose or damaged 1 Have propeller repaired or replaced 2 Have serviced by a Yamaha dealer 3 Remove and clean propeller 4 Tighten bolt 5 Tighten or have serviced by a Yamaha dealer ...

Page 78: ... 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 79: ...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 80: ...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 81: ...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 82: ...E MEMO ...

Page 83: ...EMP00010 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 84: ...ling fuel 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 Inspecting and replacing anode 4 ...

Page 85: ... 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 Trim angle settings and boat handling 3 18 Trimming outboard motor 3 16 Troubleshooting 5 1 W Warning labels 1 5 Warming up engine 3 13 W...

Page 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...Printed in France January 2003 0 5 1 6M8 F8199 17 8CMH E Printed on recycled paper ...

Page 93: ...Warranty card 12 6 01 7 40 PM Page 1 ...

Page 94: ...Warranty card 12 6 01 7 40 PM Page 2 ...

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