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EMK00010

Chapter 4

MAINTENANCE

SPECIFICATION DATA

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

TRANSPORTING AND STORING
OUTBOARD MOTOR

...............................4-3

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

PERIODIC MAINTENANCE

......................4-9

Replacement parts ...............................4-9
Maintenance chart..............................4-10
Greasing ..............................................4-11
Cleaning and adjusting spark plug...4-12
Checking fuel system .........................4-14
Cleaning fuel filter ..............................4-15
Adjusting idling speed .......................4-16
Replacing fuse ....................................4-17
Checking wiring and connectors ......4-17
Exhaust leakage..................................4-17
Water leakage .....................................4-17
Checking power trim and
tilt system ............................................4-18
Checking propeller .............................4-19
Changing gear oil ...............................4-21
Cleaning fuel tank...............................4-22
Inspecting and replacing anode .......4-23
Checking battery.................................4-24
Checking bolts and nuts ....................4-26
Motor exterior.....................................4-27
Coating the boat bottom ...................4-27

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Summary of Contents for C40A

Page 1: ...C40A C50A LIT 18626 04 75 C40A C50A OWNER S MANUAL U S A Edition ...

Page 2: ......

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

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

Page 6: ......

Page 7: ...board motor serial number 1 1 Key number 1 1 EMISSION CONTROL INFORMATION 1 2 SAFETY INFORMATION 1 3 IMPORTANT LABELS 1 5 BASIC BOATING RULES 1 6 FUELING INSTRUCTIONS 1 10 Gasoline Petrol 1 10 Engine oil 1 11 BATTERY REQUIREMENT 1 12 PROPELLER SELECTION 1 12 START IN GEAR PROTECTION 1 14 1 ...

Page 8: ... 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 EMU00008 KEY NUMBER If a main key switch is equipped with the motor the key identification number is stamped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key 1 ...

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: ... obstacles and other traffic 8 Always watch carefully for swimmers during the engine operation 8 Stay away from swimming areas EMU00917 SAFETY INFORMATION 8 Before mounting or operating the out board motor read this entire manual Reading it should give you an under standing of the motor and its operation 8 Before operating the boat read any owner s or operator s manuals supplied with it and all la...

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

Page 12: ...NG 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 CAUTION Use premix fuel only ...

Page 13: ... 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: ... the passage of other vessels in narrow channels E Sailing vessel right of 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 pas...

Page 16: ...ing 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 lateral significance used for No number Topmost band red preferred Top Mark White Light White Light OR OR LIGHTED PREFERRED CHANNEL TO RB L RG L PORT BUOY identification and location purposes channel is to left of ...

Page 17: ...ler 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 funnel to help prevent electrosta tic sparks cC Use only new clean ga...

Page 18: ...ntaining methanol Gasohol containing 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 Yama ha because it can cause fuel system dam age or engine performance problems EMU00858 ENGINE OIL If the recommended engine oil is not available another 2 stroke engine oil with a NMMA certified TC W3 rating may...

Page 19: ...h or too low for good engine performance this will have an adverse effect on the engine E Minimum cold crank performance 380 Amps at 17 8 C 0 F Minimum reserve capacity 124 minutes at 26 7 C 80 F EMU00031 BATTERY REQUIREMENT cC Do not use the battery that does not meet the specified capacity If different battery from the specification is used the electric system may perform poorly or be overloaded...

Page 20: ...r outboard that is best suited to your application NOTE At full throttle and under a maximum boat load the engine s rpm should be within the upper half of the full throttle operating range as listed in SPECIFICA TIONS on page 4 1 Select a propeller which fulfills this requirement If operating under conditions which allow the engine s rpm to rise above the maxi mum recommended range such as light b...

Page 21: ...TION 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 ...

Page 22: ...E MEMO ...

Page 23: ... COMPONENTS 2 1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS 2 2 Fuel tank 2 2 Remote control 2 3 Trim tab 2 7 Trim angle adjusting rod 2 7 Tilt support lever 2 8 Top cowling lock lever 2 8 WARNING SYSTEM 2 9 Overheat warning 2 9 1 2 3 4 5 6 E ...

Page 24: ...bracket 2 Anode 3 Battery lead 4 Cooling water inlet 5 Trim tab 6 Anti cavitation plate 7 Anode 8 Trim angle adjusting rod 9 Tilt support lever 0 Top cowling q Fuel hose May not be exactly as shown also may not be included as standard equipment on all models 902063 1 ...

Page 25: ...nk cap 4 Air vent screw If equipped Fuel hose joint This connector is provided for connecting or disconnecting fuel hose Fuel meter This meter is on the fuel tank cap It shows current fuel quantity in the fuel tank approximately Fuel tank cap This cap is for filling fuel To remove it turn it counterclockwise Air Vent screw This screw is on the fuel tank cap To loosen it turn it counterclockwise q ...

Page 26: ...rew Remote control lever Moving the lever forward from the Neu tral position engages Forward gear Pulling the lever back from Neutral engages Reverse The engine will contin ue to run at idle until the lever is moved about 35 a detent can be felt Moving the lever farther opens the throttle and the engine will begin to accelerate 1 Neutral 2 Forward 3 Reverse 4 Shift 5 Fully closed 6 Throttle 7 Full...

Page 27: ...l The remote control lever will operate only when the neutral throttle lever is in the closed position 1 Fully open 2 Fully closed Main switch The main switch controls the ignition sys tem its operation is described below 8 OFF Electrical circuits switched off The key can be removed 8 ON Electrical circuits switched on The key cannot be removed 8 START Starter motor will turn and start engine When...

Page 28: ...er w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control...

Page 29: ...ctions ADJUSTING TRIM ANGLE and TILTING UP DOWN in Chapter 3 for instructions on usage EMU01155 Throttle Friction Adjusting Screw A friction device in the remote control box provides adjustable resistance to move ment of the remote control lever and can be set according to operator preference An adjusting screw is located on the front of the remote control box w Do not overtighten the friction adj...

Page 30: ...djusted trim tab may cause difficult steering Always test run after the trim tab has been installed or replaced to be sure steering is correct Be sure you have tightened the bolt after adjusting the trim tab 1 Trim tab 2 Bolt cC The trim tab also serves as an anode to protect the engine from electroche mical corrosion Never paint the trim tab as it will become ineffective as an anode Boat tends to...

Page 31: ... lever to the clamp bracket E 2 8 403011 EMD62010 TOP COWLING LOCK LEVER To remove the engine top cowling push the lock lever downward Then lift off the cowling When replacing the cowling check to be sure it fits properly in the rub ber seal Then lock the cowling again by moving the lever upward 301014 ...

Page 32: ...engine has an overheat warning device If the engine temperature rises too high the warning device will activate 2 Included N A If the warning system has been activated stop the engine and check the water inlet for clogging Activation of warning device The engine speed will automatically decrease to about 2 000 r min The overheat warning indicator will come on The buzzer will sound Tiller control m...

Page 33: ...xing 3 5 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 TILTING UP DOWN 3 19 CRUISING IN OTHER CONDITIONS 3 21 Cruising in salt water 3 21 Cruising in turbid water 3 21 1 2 3 4 5 6 E ...

Page 34: ...rne water spray while the boat is cruising Severe engine damage may result if the motor is operat ed continuously in the presence of air borne water spray NOTE During water testing check the buoyancy of the boat at rest with its maximum load Check that the static water level on the exhaust housing is low enough to pre vent water entry into the powerhead when water rises due to waves when the outbo...

Page 35: ... 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 the center...

Page 36: ...ng 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 i...

Page 37: ... changed the amount of additives 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 E 902055 EMU00186 FILLING F...

Page 38: ...3 5 While many additives available may reduce deposits Yamaha recommends the use of Ring Free Fuel Additive avail able from your Yamaha dealer Ring Free has repeatedly proven its ability to clean combustion deposits from inside the engine notably the critical piston ring land area and fuel system components Follow product labeling for use instruc tions Engine oil Gasoline Petrol Break in period 1 ...

Page 39: ... installed tank pour the oil gradually as the fuel is being added to the tank Mixing ratio 25 1 Gasoline Petrol Engine oil 0 04 L 0 48 L 0 56 L 0 96 L 0 04 US qt 0 51 US qt 0 59 US qt 1 01 US qt 0 04 Imp qt 0 42 Imp qt 0 49 Imp qt 0 84 Imp qt 1 L 12 L 14 L 24 L 0 26 US gal 3 2 US gal 3 7 US gal 6 3 US gal 0 22 Imp gal 2 6 Imp gal 3 1 Imp gal 5 3 Imp gal Mixing ratio 50 1 Gasoline Petrol Engine oil...

Page 40: ...d that there are no sharp objects near it Oil 8 Check to be sure you have plenty of oil for your trip Controls 8 Check throttle shift and steering for proper operation before starting the engine 8 The controls should work smoothly without binding or unusual free play 8 Look for loose or damaged connec tions 8 Check operation of the starter and stop switches when the outboard moter is in the water ...

Page 41: ...ven severe engine damage EMU00226 Run the engine under load in gear with a propeller installed as follows 1 First 10 minutes Run the engine at the lowest possi ble speed A fast idle in neutral is best 2 Next 50 minutes Do not exceed half throttle approxi mately 3 000 r min Vary engine speed occasionally If you have an easy planing boat accelerate at full throttle onto plane then immediately reduce...

Page 42: ...n 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 engine speed occasionally 5 After the first 10 hours Operate the engine normally Use the standard premix ratio of gasoline Oil Refer to Gasoline Petrol and O...

Page 43: ...the air vent 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 moto...

Page 44: ...stall the lock plate on the other end of the lanyard in the engine stop switch w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing from functioning 8 Avoid accidentally pulling the lanyard during normal operation...

Page 45: ...the engine is running 8 Do not keep the starter motor turning for more than 5 seconds with the main switch in the START position If the starter motor is run continuously for more than 5 seconds the battery will rapidly become exhausted and it will be impossible for it to start the engine If the engine does not start within 5 sec onds return the main switch to ON wait 10 seconds and then crank the ...

Page 46: ...ter through the cooling pas sages If water is not flowing out of the pilot hole at all times while the engine is running do not continue to run the engine Overheating and serious damage could occur Stop the engine and check to see if the water inlet on the lower cas ing is blocked If the problem cannot be found and corrected consult your Yama ha dealer NOTE After the engine starts warm up opera ti...

Page 47: ...WARD Pull up the neutral interlock trigger If equipped and move the remote control lever quickly and firmly from Neutral to Forward REVERSE Pull up the neutral interlock trigger If equipped and move the remote control lever quickly and firmly from Neutral to Reverse w When operating in Reverse go slowly Do not open the throttle more than half Oth erwise the boat may become unstable which could res...

Page 48: ...ch to OFF NOTE The engine can also be stopped by pulling the lanyard from the engine stop switch then turning the main switch to OFF 2 If the fuel joints are provided discon nect the fuel line from the motor after stopping the engine 3 Tighten the air vent screw on the fuel tank cap after stopping the engine if it is equipped 4 Remove the key if the boat will be left unattended 304015 ON START OFF...

Page 49: ... 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 readjust the ...

Page 50: ... Use the power trim tilt switch located on the bottom engine cowling if equipped only when the boat is at a complete stop with the engine off The outboard motor trim angle can be adjusted operating the power trim tilt switch 1 To raise the bow trim out push the switch UP To lower the bow trim in push the switch DN Make test runs with the trim set to differ ent angles to find the position that work...

Page 51: ... 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 105011 q 105013 w 105015 e EMU00283 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 52: ...dures under STOPPING ENGINE Never tilt the motor while the engine is running Severe damage from overheating can result w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinch any body parts between the drive unit and engine bracket w Leaking fuel is a fire hazard Disconnect the fuel line or close the fuel cock if the engine will be tilted fo...

Page 53: ...fter tilting the engine be sure to sup port it with the tilt support lever Other wise the engine could fall back down suddenly if oil in the power trim tilt unit should lose pressure EMU00303 PROCEDURE FOR TILTING DOWN Power trim tilt model 1 Push the power trim tilt switch UP until the engine is supported by the tilt rod 2 Release the tilt support lever 3 Push the power trim tilt switch DN Down t...

Page 54: ...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 55: ...ting spark plug 4 12 Checking fuel system 4 14 Cleaning fuel filter 4 15 Adjusting idling speed 4 16 Replacing fuse 4 17 Checking wiring and connectors 4 17 Exhaust leakage 4 17 Water leakage 4 17 Checking power trim and tilt system 4 18 Checking propeller 4 19 Changing gear oil 4 21 Cleaning fuel tank 4 22 Inspecting and replacing anode 4 23 Checking battery 4 24 Checking bolts and nuts 4 26 Moto...

Page 56: ... Minimum cold crank performance Amps at 17 8 C 0 F Minimum reserve capacity minutes at 26 7 C 80 F 8Alternator output V A W 8Starting carburetion system 2 stroke L 3 698 42 60 67 0 66 0 2 64 2 60 C D I system B7HS 10 0 9 1 0 0 035 0 039 Remote control Electric start 12 70 100 380 124 12 6 Prime start system DRIVE UNIT 8Gear positions Gear ratio 8Trim tilt system 8 Propeller mark Forward Neutral Re...

Page 57: ... 0 2 64 2 60 C D I system B8HS 10 0 9 1 0 0 035 0 039 Remote control Electric start 12 70 100 380 124 12 6 Prime start system Forward Neutral Reverse 1 85 24 13 Power trim tilt G Regular unleaded gasoline P O N minimum 86 YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC W3 certified outboard oil Remote Engine 50 1 Hypoid gear oil SAE 90 430 14 5 15 1 ...

Page 58: ...Do not use the tilt support lever knob when trailering the boat The outboard motor could shake loose from the tilt support and fall If the motor can not be trailered in the down position use 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 fal...

Page 59: ...u the owner with a minimum of tools EMK21010 Filling Fuel Tank Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer Part No LUB FUELC 12 00 to each gallon of fuel NOTE The use of Yamaha Fuel Conditioner and Stabilizer eliminates the need to drain the fuel system Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained inst...

Page 60: ...ur 1 Remove the engine top cowling and silencer cover 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 prior to turning off the engine quickly spray Yamaha Stor Rite Engine Fogging Oil Part No LUB STRRT 12 00 alternately into each carburetor When properly done the...

Page 61: ...trical parts when starting or during operation 8 Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 3 Run the engine at a fast idle for 10 15 minutes 4 Just prior to turning off the engine quickly spray Yamaha Stor Rite Engine Fogging Oil Part No LUB STRRT 12 00 alternately into each carburetor When properly done the engine will smoke excessively and al...

Page 62: ...n rings 3 Change the lower unit oil Refer to CHANGING GEAR OIL Inspect the oil for the presence of water which indicates a leaky seal Seal replace ment should be performed by an authorized Yamaha dealership prior to use 4 Grease all grease fittings Refer to the GREASING EMK27011 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the out board with fresh water and dry off completely 2 ...

Page 63: ...g in a closed space Always wear eye protection when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE Batteries vary among manufacturers Therefore the following procedures may not always apply Consult your battery manufacturer s instructions 1 Disconnect and remove the battery from the boat Always disconnect the black negative lead first to prevent the risk of shorting 2 Clean the battery ...

Page 64: ...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 65: ...nspection Anode Inspection 4 23 Propeller Inspection 4 19 Motor exterior Inspection 4 27 Cooling water passages 3 Cleaning 4 5 Battery Inspection every 4 24 month Interval Item Initial Every Refer page 10 hours 50 hours 3 months 100 hours 6 months 200 hours 1 year EMK30114 MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating con ditions but the following...

Page 66: ...4 11 E EMU00366 GREASING Yamaha marine grease Water resistant grease ...

Page 67: ...air leak or carburetion problem in that cylinder Do not attempt to diagnose any problems yourself Instead take the outboard motor to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the sp...

Page 68: ...en you 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 E 903022 q w Spark plug torque Refer to SPECIFICATIONS page 4 1 Initial of spark plug Plug wrench size I D mark B 21 mm 13 16 in C BK 16 mm 5 8 in D 18 3 m...

Page 69: ...und it should be repaired immediately by Yama ha dealer or other qualified mechanic Checking points 8 Fuel system parts leakage 8 Fuel hose joint leakage 8 Fuel hose cracks or other damage 8 Fuel connector leakage w Leaking fuel can result in fire or explo sion 8 Check for fuel leakage regularly 8 If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper repair...

Page 70: ... place Improper assembly can result in a fuel leak which could result in a fire or explosion hazard To clean the fuel filter 1 Remove the nut holding the fuel filter assembly if equipped 2 Unscrew the 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 ele ment and O ring to make sure they are in good condition Replace...

Page 71: ... it 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 to set the idling speed to specification see SPECIFICATIONS by turning the stop screw clockwise to increase the idling speed and turning it counter clockwise to decrease the idling speed NOTE Correct idling speed adjustment is only po...

Page 72: ...ard NOTE If the new fuse blows again immediately consult a Yamaha dealer 1 Fuse holder 2 Fuse 20A EMK78010 CHECKING WIRING AND CONNECTORS 1 Check that each grounding wire is properly secured 2 Check that each connector is engaged securely EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and crank case WATER LEAKAGE Start the e...

Page 73: ...l leaks 2 Operate each of the power trim and tilt switches on remote control and engine bottom cowling If equipped to check that all switches work 3 Tilt up the motor and check that the trim and tilt rod is pushed out com pletely 4 Check that the trim and tilt rod is free of corrosion or other flaws 5 Operate the motor to trim and tilt down Check that the trim and tilt rod operates smoothly 1 Trim...

Page 74: ...nd to hold the pro peller when loosening or tightening the propeller nut Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning 1 Check each of the propeller blades for wear erosion from cavitation or ven tilation or other damage 2 Check the splines for wear and dam age 3 Check for fish line winding around the propeller shaft Check the propeller shaft...

Page 75: ...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 torque then tighten it more to align the hole cC Be sure to use a new cotter pin and bend the ends over securely Otherwise the propeller could co...

Page 76: ...board 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 into the gearcase...

Page 77: ...soline 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...

Page 78: ... the filter located on the end of the suction pipe in a suitable clean ing solvent Allow the filter to dry 3 Replace the gasket with a new one Reinstall the fuel hose joint assembly and tighten the screws firmly 902054 405011 604012 EML24010 INSPECTING AND REPLACING ANODE Yamaha outboard motor is protected from corrosion by a sacrificial anode s Check the anode periodically Remove the scales from ...

Page 79: ... with water for 15 minutes and get immediate medical attention Antidote INTERNAL 8 Drink large quantities of water or milk followed by milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventive mea sures 8 Charge batteries in a well ventilated area 8 Keep batteries away from fire sp...

Page 80: ...voltmeter will help you monitor your battery If you will not use the boat for a month or more remove the battery from the boat and store it in a cool dark place Completely recharge the battery before using it 3 If the battery will be stored for longer than a month check the specific grav ity of the fluid at least once a month and recharge the battery when it is low 901015 UPPER LEVEL LOWER LEVEL E...

Page 81: ...r the battery will not start the engine Connect the RED lead to the POSITIVE terminal first Then connect the BLACK lead to the NEG ATIVE terminal 1 Red lead 2 Black lead 3 Battery EMU01280 Disconnecting the Battery Disconnect the BLACK lead from the NEG ATIVE terminal first Then disconnect the RED lead from the POSITIVE termi nal UPPER LEVEL LOWER LEVEL 901012 q w e EML40010 CHECKING BOLTS AND NUT...

Page 82: ...otor 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 EML44010 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clean of marine growths as possible If neces sary the boat bottom can be coated with an anti fouling paint approved fo...

Page 83: ...LE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Power trim tilt will not operate 5 5 Starter will not operate 5 6 Engine fails to operate 5 8 Treatment of submerged motor 5 10 1 2 3 4 5 6 E ...

Page 84: ...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 85: ...lve adjustment incorrect 18 Battery lead disconnected 1 Inspect spark plug s Clean or replace with recommended type 2 Check for pinched or kinked fuel line or other obstructions in fuel system 3 Fill tank with clean fresh fuel 4 Clean or replace filter 5 Have serviced by a Yamaha dealer 6 Find and correct cause of warning 7 Inspect and adjust as specified 8 Check wires for wear or breaks Tighten a...

Page 86: ...ged 2 Propeller pitch or diameter incorrect 3 Trim angle incorrect 4 Motor mounted at incorrect height on transom 5 Warning system activated 6 Boat bottom fouled with marine growth 7 Spark plug s fouled or incorrect type 8 Weeds or other foreign matter tangled on gear housing 9 Fuel system obstructed 10 Fuel filter clogged 11 Fuel contaminated or stale 12 Spark plug gap incorrect 1 Have propeller ...

Page 87: ...iced 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 E Engine power loss F Engine vibrates excessively 1 Propeller damaged 2 Propeller shaft damaged 3 Weeds or other for...

Page 88: ...amage 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 EMG65210 POWER TRIM TILT WILL NOT OPER ATE If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit the engine can be tilted manual...

Page 89: ...ectedly 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 eng...

Page 90: ...tch must be on if the main switch is equipped on the elec tric start model NOTE Prime start model If the engine will not start with this proce dure refer to ENGINE FAILS TO OPER ATE 4 To start the engine with emergency starter rope insert the knotted end of the rope into the notch in the flywheel rotor and wind the rope several turns clockwise Then give a strong pull straight out to crank the engi...

Page 91: ... when starting it with an emergency starter rope An unguarded rotating flywheel is very dangerous Do not attempt to replace the top cowling when the engine is running Proceed at once to the nearest port to get the engine repaired Take care to prevent water splashing onto the flywheel 1 Adjust the trim angle so that the drive shaft is at right angles to the water surface or is trimmed in 2 Open the...

Page 92: ...turn the main switch to START when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds The battery will rapidly become exhausted and it will be impossible for the starter motor to start the engine If the engine does not start within 5 seconds return the main switch to ON wait 10 seconds and then crank the engine again 7 After the engine starts return the emergency...

Page 93: ...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 to a Yamaha dealer as s...

Page 94: ... MEMO E ...

Page 95: ...EMP00010 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 96: ... 3 21 Cruising in salt water 3 21 Cruising in turbid water 3 21 D Disconnecting the battery 4 26 E Emission control information 1 2 Engine fails to operate 5 8 Engine oil 1 11 Engine stop lanyard switch 2 5 Exhaust leakage 4 17 F Filling fuel 3 4 Filling fuel and engine oil 3 4 Filling fuel tank 4 4 Flushing cooling system and fogging engine 4 4 Forward 3 14 Fuel hose joint 2 2 Fuel meter 2 2 Fuel...

Page 97: ...tion data 4 1 Start in gear protection 1 14 Starter will not operate 5 6 Starting engine 3 10 Stopping engine 3 15 Storing outboard motor 4 4 T Temporary action in emergency 5 5 Throttle friction adjusting screw 2 6 Tilt support lever 2 8 Tilting up down 3 19 Top cowling lock lever 2 8 Trailering outboard motor 4 3 Transporting and storing outboard motor 4 3 Treatment of submerged motor 5 10 Trim ...

Page 98: ...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 99: ...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 100: ...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 Cor poration U S A A warranty registration form is provided in the Owner s Manual...

Page 101: ...LSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A Post Office Box 6555 Cypress California 90630 WARRANTY QUESTIONS AND ANSWERS Q What costs are my responsibility during the warranty period A The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision dam ages Q What are some examples of abnormal strai...

Page 102: ...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 103: ...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 106: ...C40A C50A Printed in Japan April 2001 0 5 1 63D 28199 15 40VET 50HET E Printed on recycled paper ...

Page 107: ...C40A C50A OWNER S MANUAL ...

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