Yamaha 9.9D Owner'S Manual Download Page 43 | Manualshive

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Maintenance

38

spark plug because heat and deposits will
cause the spark plug to slowly break down
and erode. If electrode erosion becomes ex-
cessive, or if carbon and other deposits are
excessive, you should replace the spark plug
with another of the correct type.

Before fitting the spark plug, measure the
electrode gap with a wire thickness gauge;
adjust the gap to specification if necessary.

When fitting the plug, always clean the gasket
surface and use a new gasket. Wipe off any
dirt from the threads and screw in the spark
plug to the correct torque.

NOTE:

If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of the
correct torque is 1/4 to 1/2 a turn past finger-

tight. Have the spark plug adjusted to the cor-
rect torque as soon as possible with a torque-
wrench.

EMU28962

Checking fuel system

WARNING

EWM00060

Gasoline and its vapors are highly flam-
mable and explosive. Keep away from
sparks, cigarettes, flames, or other sourc-
es of ignition.

WARNING

EWM00910

Leaking fuel can result in fire or explosion.

●

Check for fuel leakage regularly.

●

If any fuel leakage is found, the fuel sys-
tem must be repaired by a qualified me-
chanic. Improper repairs can make the
outboard unsafe to operate.

Check the fuel lines for leaks, crack, or mal-
function. If a problem is found, your Yamaha
dealer or other qualified mechanic should re-
pair it immediately.

Checkpoints

●

Fuel system parts leakage

●

Fuel line joint leakage

●

Fuel line cracks or other damage

●

Fuel connector leakage

Standard spark plug:

B7HS-10
BR7HS-10

1. Spark plug gap

2. Spark plug I.D. mark (NGK)

Spark plug gap:

0.9–1.0 mm (0.035–0.039 in)

Spark plug torque:

25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

U63V17E0.book Page 38 Thursday, February 26, 2004 11:52 AM

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Summary of Contents for 9.9D

Page 1: ...9 9D ...

Page 2: ...ZMU01690 ...

Page 3: ...rd motor CAUTION ECM00700 A CAUTION indicates 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 advancements 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 discrepa...

Page 4: ... Tilt lock mechanism 14 Tilt support bar 14 Top cowling lock lever s turn type 14 Carrying handle 15 Operation 16 Installation 16 Mounting the outboard motor 16 Clamping the outboard motor 17 Breaking in engine 18 Gasoline and engine oil mixing chart 25 1 18 Procedure for pre mixed models 18 Preoperation checks 19 Fuel 19 Oil 19 Controls 19 Engine 19 Filling fuel and engine oil 19 Filling fuel for...

Page 5: ... 39 Inspecting idling speed 39 Checking wiring and connectors 40 Exhaust leakage 40 Water leakage 40 Checking propeller 40 Removing the propeller 41 Installing the propeller 41 Changing gear oil 42 Cleaning fuel tank 43 Inspecting and replacing anode s 43 Checking top cowling 44 Coating the boat bottom 44 Trouble Recovery 45 Troubleshooting 45 Temporary action in emergency 48 Impact damage 48 Star...

Page 6: ...cy EPA regulations for ma rine SI engines See the label affixed to your engine for details EMU30390 Approval label of emission control certifi cate This label is attached to the bottom cowling Existing Technology N A EMU25261 Manufactured date label This label is attached to the clamp bracket or the swivel bracket 1 Outboard motor serial number location 1 Approval label location 1 Manufactured dat...

Page 7: ...and explosive Handle and store gasoline carefully Make sure there are no gas fumes or leaking fuel be fore starting the engine This product emits exhaust gases which contain carbon monoxide a colorless odorless gas which may cause brain dam age or death when inhaled Symptoms in clude nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilat ed Avoid blocking exhaust outlets Check ...

Page 8: ...s while engine is running EMU25431 Label WARNING EWM01300 This engine is equipped with a neutral starting device The engine will not start unless the shift control is in neutral position EMU25500 Basic boating rules Rules of the road Just as there are rules which apply when you are driving on streets and high ways there are waterway rules which apply when you are driving your boat These rules are ...

Page 9: ...may render a departure from the above rules necessary in order to avoid im mediate danger In other words follow the standard rules ex cept when a collision will occur unless both vessels try to avoid each other If that is the case both vessels become Give Way ves sels EMU25520 Rules when encountering vessels There are three main situations which you may encounter with other vessels which could lea...

Page 10: ...l to do so If the operator of a power driven vessel is preparing to go around a bend that may obstruct the view of other water vessels the operator should sound a pro longed blast on the whistle 4 to 6 seconds If another vessel is around the bend it too should sound the whistle Even if no reply is heard however the vessel should still pro ceed around the bend with caution If you nav igate such wat...

Page 11: ...r into port and black buoys are to port left side When navi gating out of port your position with respect to the buoys should be reversed red buoys should be to port and black buoys to star board Many bodies of water used by boaters are en tirely within the boundaries of a particular state The Uniform State Waterway Marking System has been devised for these waters This system uses buoys and signs ...

Page 12: ...0010 GASOLINE AND ITS VAPORS ARE HIGH LY FLAMMABLE AND EXPLOSIVE Do not smoke when refueling and keep away from sparks flames or other sources of ignition Stop engine before refueling Refuel in a well ventilated area Refuel portable fuel tanks off the boat ZMU01708 ...

Page 13: ...e or engine performance problems EMU25650 Engine oil If the recommended engine oil is not avail able another 2 stroke engine oil with an NMMA certified TC W3 rating may be used EMU25741 Propeller selection The performance of your outboard motor will be critically affected by your choice of propel ler as an incorrect choice could adversely af fect performance and could also seriously damage the mot...

Page 14: ...tle setting to maintain the en gine in the proper operating range For instructions on propeller removal and in stallation see page 40 EMU25770 Start in gear protection Yamaha outboard motors or Yamaha ap proved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is in neutral Always select neutral before starting the e...

Page 15: ...and must not be used as a fuel storage container Com mercial users should conform to relevant licensing or approval authority regula tions 1 Top cowling 2 Top cowling lock lever 3 Cooling water pilot hole 4 Tilt lock lever 5 Manual starter handle 6 Gear shift lever 7 Engine stop button Engine stop lanyard switch 8 Throttle grip 9 Throttle friction adjuster 10 Clamp screw 11 Carrying handle 12 Chok...

Page 16: ...uel tank cap To loosen the screw turn it counterclockwise EMU25911 Tiller handle To change direction move the tiller handle to the left or right as necessary EMU25922 Gear shift lever Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern EMU25941 Throttle gr...

Page 17: ... could result in an accident When constant speed is desired tighten the adjuster to maintain the desired throttle set ting EMU25990 Engine stop lanyard switch The lock plate must be attached to the engine stop switch for the engine to run The lanyard should be attached to a secure place on the operator s clothing or arm or leg Should the operator fall overboard or leave the helm the lanyard will p...

Page 18: ... positions shown in the following illustration EMU26070 Manual starter handle To start the engine first gently pull the handle out until resistance is felt From that position then pull the handle straight out quickly to crank the engine EMU26122 Steering friction adjuster A friction device provides adjustable resis tance to the steering mechanism and can be set according to operator preference An ...

Page 19: ... tilt lock mechanism is used to prevent the outboard motor from lifting out of the water when in reverse gear To tilt the outboard motor up set the tilt lock lever to the up position To tilt the out board motor down set the tilt lock lever to the down position EMU26330 Tilt support bar The tilt support bar keeps the outboard motor in the tilted up position EMU26372 Top cowling lock lever s turn ty...

Page 20: ... set up the carrying handle proceed as fol lows 1 Place the tilt lock lever in the lock posi tion 2 Securely hook the arm on the carrying handle end to the clamp bracket bar CAUTION ECM00080 Place the tilt lock lever in the lock position while using the carrying handle Other wise the lower unit could fall to the ground while carrying the motor 1 Top cowling lock lever s 1 Clamp bracket bar ...

Page 21: ... not possible to provide complete in structions for every possible boat and motor combination Proper mounting depends in part on experience and the specific boat and motor combination WARNING EWM00830 Improper mounting of the outboard motor could result in hazardous conditions such as poor handling loss of control or fire hazards Observe the following For permanently mounted models your dealer or ...

Page 22: ... see page 26 EMU26970 Clamping the outboard motor 1 Place the outboard motor on the transom so that it is positioned as close to the cen ter as possible Tighten the transom clamp screws evenly and securely Oc casionally check the clamp screws for tightness during operation of the out board motor because they could become loose due to engine vibration WARNING EWM00640 Loose clamp screws could allow...

Page 23: ... damaged EMU27073 Procedure for pre mixed models Run the engine under load in gear with a pro peller installed as follows 1 First 10 minutes Run the engine at the lowest possible speed A fast idle in neutral is best 2 Next 50 minutes Do not exceed half throttle approximate ly 3000 r min Vary engine speed occa sionally If you have an easy planing boat accelerate at full throttle onto plane then imm...

Page 24: ...the water EMU27140 Engine Check the engine and engine mounting Look for loose or damaged fasteners Check the propeller for damage EMU27233 Filling fuel and engine oil EMU27242 Filling fuel for portable tank WARNING EWM00060 Gasoline and its vapors are highly flam mable and explosive Keep away from sparks cigarettes flames or other sourc es of ignition 1 Remove the fuel tank cap 2 Fill the fuel tan...

Page 25: ...n fuel tank 1 Pour oil into a clean fuel can and then add gasoline 2 Replace the fuel can cap and close tight ly 3 Shake the fuel can to mix the fuel thor oughly 4 Make sure that the oil and gasoline are mixed 5 Pour the gasoline and oil mixture into the built in fuel tank CAUTION ECM00810 Avoid using any oil other than the spec ified type Use a thoroughly blended fuel oil mix ture If the mixture ...

Page 26: ...olorless odorless gas which could cause brain damage or death when inhaled Symp toms include nausea dizziness and drowsiness Keep cockpit and cabin ar eas well ventilated Avoid blocking ex haust outlets 1 If there is an air vent screw on the fuel tank cap loosen it 2 or 3 turns 2 If there is a fuel joint on the motor firmly connect the fuel line to the joint Then firmly connect the other end of th...

Page 27: ...leg while operating 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 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause people and objects in the boat to be...

Page 28: ...t between 1 8 and 1 4 and try again Also if the engine is warm and fails to start open the throttle a same amount and try to start the engine again If the engine still fails to start see page 45 EMU27670 Warming up engine EMU27680 Choke start models 1 After starting the engine allow it to idle for 3 minutes to warm up Failure to do so will shorten engine life Gradually return the choke knob to its...

Page 29: ...ove the gear shift lever quickly and firm ly from neutral to forward Remote control models Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from neutral to forward EMU27795 Reverse manual tilt and hydro tilt models WARNING EWM00190 When operating in reverse go slowly Do not open the throttle more than half Other wise the boat could become unsta...

Page 30: ...opping engine Before stopping the engine first let it cool off for a few minutes at idle or low speed Stop ping the engine immediately after operating at high speed is not recommended EMU27832 Procedure 1 Push and hold the engine stop button un til the engine comes to a complete stop 2 After stopping the engine tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to ...

Page 31: ...r Correct trim is also af fected by variables such as the load in the boat sea conditions and running speed WARNING EWM00740 Excessive trim for the operating condi tions either trim up or trim down can cause boat instability and can make steer ing 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 readjust ...

Page 32: ... is generally when the keel line of the boat is up about 3 to 5 degrees With the bow up the boat may have a greater tenden cy to steer to one side or the other Compen sate for this as you steer The trim tab can also be adjusted to help offset this effect When the bow of the boat is down it is easier to accelerate from a standing start onto plane Bow Up Too much trim out puts the bow of the boat to...

Page 33: ...t and engine bracket WARNING EWM00250 Leaking fuel is a fire hazard If there is a fuel joint on the outboard motor discon nect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes Otherwise fuel may leak CAUTION ECM00241 Before tilting the outboard motor stop the engine by following the procedure on page 25 Never tilt the outboard mo tor while the engine is...

Page 34: ...lted up partially to allow operation in shallow water EMU28071 Cruising in shallow water manual tilt models WARNING EWM00710 Place the gear shift in neutral before us ing the shallow water cruising system Run the boat at the lowest possible speed when using the shallow water cruising system The tilt lock mecha nism does not work while the shallow water cruising system is being used Hit ting an und...

Page 35: ...m overheat ing can result EMU28123 Procedure 1 Place the gear shift lever in neutral 2 Place the tilt lock lever in the release up position 3 Slightly tilt the outboard motor up The tilt support bar will lock automatically sup porting the outboard motor in a partially raised position NOTE This outboard motor has 2 positions for shal low water cruising 4 To return the outboard motor to the nor mal ...

Page 36: ...ditions Cruising in salt water After operating in salt water wash out the cooling water passages with fresh water to prevent them from becoming clogged with salt deposits NOTE For cooling system flushing instructions see page 32 Cruising in turbid water Yamaha strongly recommends that you use the optional chromium plated water pump kit if you use the outboard motor in turbid mud dy water condition...

Page 37: ... system Manual tilt Propeller mark J Fuel and oil Recommended fuel Regular unleaded gasoline Min pump octane 86 Fuel tank capacity 24 0 L 6 34 US gal 5 28 Imp gal Recommended engine oil YAMALUBE 2 stroke outboard motor oil Fuel oil ratio Regular gasoline 100 1 Lubrication Pre mixed fuel and oil Recommended gear oil Hypoid gear oil SAE 90 Gear oil quantity 250 0 cm 8 45 US oz 8 82 Imp oz Tightening...

Page 38: ... transporting or storing the outboard motor while removed from a boat keep the outboard motor in the attitude shown NOTE Place a towel or something similar under the outboard motor to protect it from damage EMU30272 Storing outboard motor When storing your Yamaha outboard motor for prolonged periods of time 2 months or longer several important procedures must be performed to prevent excessive dama...

Page 39: ...or if the water supply is insufficient engine seizure may occur 6 Cooling system flushing is essential to prevent the cooling system from clogging up with salt sand or dirt In addition fog ging of the engine is mandatory to pre vent excessive engine damage due to rust Perform the flushing and fogging at the same time WARNING EWM00090 Do not touch or remove electrical parts when starting or during ...

Page 40: ... surface of motor Check the motor for scratches nicks or flak ing paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas A touch up paint is available from your Yamaha dealer EMU28483 Periodic maintenance WARNING EWM01070 Be sure to turn off the engine when you perform maintenance unless otherwise specified If you or the owner is not famil iar with machine...

Page 41: ... engine should be flushed with clean water after each use Item Actions Initial Every 10 hours 1 month 50 hours 3 months 100 hours 6 months 200 hours 1 year Anode s external Inspection replacement Anode s internal Inspection replacement Cooling water passages Cleaning Cowling clamp Inspection Fuel filter can be disassembled Inspection cleaning Fuel system Inspection Fuel tank Yamaha portable tank I...

Page 42: ...ld lead to explosion or fire The spark plug is an important engine compo nent and is easy to inspect The condition of the spark plug can indicate something about the condition of the engine For example if the center electrode porcelain is very white this could indicate an intake air leak or carburetion problem in that cylinder Do not attempt to di agnose any problems yourself Instead take the outb...

Page 43: ...justed to the cor rect torque as soon as possible with a torque wrench EMU28962 Checking fuel system WARNING EWM00060 Gasoline and its vapors are highly flam mable and explosive Keep away from sparks cigarettes flames or other sourc es of ignition WARNING EWM00910 Leaking fuel can result in fire or explosion Check for fuel leakage regularly If any fuel leakage is found the fuel sys tem must be rep...

Page 44: ... filter cup catching any spilled fuel in a rag 3 Remove the filter element and wash it in solvent Allow it to dry Inspect the filter el ement and O ring to make sure they are in good condition Replace them if neces sary If any water is found in the fuel the Yamaha portable fuel tank or other fuel tanks should be checked and cleaned 4 Reinstall the filter element in the cup Make sure the O ring is ...

Page 45: ...mechanic 2 Verify whether the idle speed is set to specification For idle speed specifica tions see page 32 EMU29111 Checking wiring and connectors Check that each grounding wire is properly secured Check that each connector is engaged se curely EMU29120 Exhaust leakage Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and body cylinder EMU291...

Page 46: ...en spin freely on the shaft If this happens the shear pin must be replaced EMU29193 Removing the propeller 1 Straighten the cotter pin and pull it out us ing a pair of pliers 2 Remove the propeller nut washer and spacer if equipped 3 Remove the propeller and thrust washer EMU29230 Installing the propeller CAUTION ECM00340 Be sure to install the thrust washer be fore installing the propeller otherw...

Page 47: ... lower unit while it is tilted even when the tilt support lever or knob is locked Severe injury could oc cur if the outboard motor accidentally falls 1 Tilt the outboard motor so that the gear oil drain screw is at the lowest point possi ble 2 Place a suitable container under the gear case 3 Remove the gear oil drain screw NOTE If the magnetic gear oil drain screw equipped remove all metal particl...

Page 48: ...oline according to lo cal regulations 1 Empty the fuel tank into an approved con tainer 2 Pour a small amount of suitable solvent into the tank Install the cap and shake the tank Drain the solvent completely 3 Remove the screws holding the fuel joint assembly Pull the assembly out of the tank 4 Clean the filter located on the end of the suction pipe in a suitable cleaning sol vent Allow the filter...

Page 49: ...ng it with both hands If it is loose have it repaired by your Yamaha dealer EMU29400 Coating the boat bottom A clean hull improves boat performance The boat bottom should be kept as clean of marine growth as possible If necessary the boat bot tom can be coated with an anti fouling paint approved for your area to inhibit marine growth Do not use anti fouling paint which includes copper or graphite ...

Page 50: ...ed by a Yamaha dealer Q Is shift lever in gear A Shift to neutral Engine will not start starter operates Q Is fuel tank empty A Fill tank with clean fresh fuel Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is fuel filter clogged A Clean or replace filter Q Is starting procedure incorrect A See page 22 Q Has fuel pump malfunctioned A Have serviced by a Yamaha dealer Q Are spar...

Page 51: ...Yamaha dealer Q Is air vent screw on fuel tank closed A Open air vent screw Q Is choke knob pulled out A Return to home position Q Is motor angle too high A Return to normal operating position Q Is carburetor clogged A Have serviced by a Yamaha dealer Q Is fuel joint connection incorrect A Connect correctly Q Is throttle valve adjustment incorrect A Have serviced by a Yamaha dealer Q Is battery ca...

Page 52: ...ect spark plug s Clean or replace with recommended type Q Are weeds or other foreign matter tangled on gear housing A Remove foreign matter and clean lower unit Q Is fuel system obstructed A Check for pinched or kinked fuel line or oth er obstructions in fuel system Q Is fuel filter clogged A Clean or replace filter Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is spark plug ...

Page 53: ...rd motor unsafe to operate If the outboard motor hits an object in the wa ter follow the procedure below 1 Stop the engine immediately 2 Inspect the control system and all compo nents for damage Also inspect the boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and careful ly 4 Have a Yamaha dealer inspect the out board motor before operating it again EMU29531 St...

Page 54: ...ter the engine is running Do not touch the ignition coil spark plug wire spark plug cap or other electrical components when starting or operating the motor You could get an electrical shock EMU29561 Emergency starting engine 1 Remove the top cowling 2 Remove the start in gear protection ca ble from the starter if equipped 3 Remove the starter flywheel cover after removing the bolt s 4 Prepare the ...

Page 55: ...away mud salt sea weed and so on 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 fuel fil ter and fuel line 4 Feed fogging oil or engine oil through the carburetor s and spark plug holes while cranking with the manual starter or emer gency starter rope 5 Take the outboard motor to ...

Page 56: ...Consumer information 51 EMU29811 Important warranty information for U S A and Canada ...

Page 57: ...Consumer information 52 ...

Page 58: ...Consumer information 53 EMU29820 YAMAHA MOTOR CORPORATION U S A OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ...

Page 59: ...Consumer information 54 ...

Page 60: ...Consumer information 55 ...

Page 61: ...Consumer information 56 EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U S A OR CANADA ...

Page 62: ...pliquée à l acheteur 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 ADD...

Page 63: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT ...

Page 64: ......

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