Yamaha E8D Page 41 Owner'S Manual Download | Manualshive

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Maintenance

36

6.

Insert a new cotter pin in the holes, and
then bend the cotter pin ends.

NOTE:

There is a holder on the bottom cowling for
spare shear and cotter pins. Be sure to re-
place any used pins.

EMU29280

Changing gear oil

WARNING

EWM00800

●

Be sure the outboard motor is securely
fastened to the transom or a stable
stand. You could be severely injured if
the outboard motor falls on you.

●

Never get under the 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 particles from the screw be-
fore installing it.

4.

Remove the oil level plug to allow the oil
to drain completely.

CAUTION:

ECM00710

Inspect the used oil after it has been
drained. If the oil is milky, water is getting
into the gear case which can cause gear
damage. Consult a Yamaha dealer for re-
pair of the lower unit seals.

NOTE:

For disposal of used oil consult your Yamaha
dealer.

5.

With the outboard motor in a vertical po-
sition, and using a flexible or pressurized
filling device, inject the gear oil into the
gear oil drain screw hole.

ZMU02714

1. Gear oil drain screw

2. Oil level plug

Recommended gear oil:

Hypoid gear oil SAE#90

Gear oil quantity:

230.0 cm³ (7.78 US oz) (8.11 Imp.oz)

U67720E0.book Page 36 Friday, March 26, 2004 10:36 AM

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Summary of Contents for E8D

Page 1: ...OWNER S MANUAL E8D 677 28199 20 E0 U67720E0 book Page 1 Friday March 26 2004 10 36 AM ...

Page 2: ...Read this owner s manual carefully before operating your outboard motor U67720E0 book Page 1 Friday March 26 2004 10 36 AM ...

Page 3: ...d 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 discrepan...

Page 4: ... Gasoline and engine oil mixing chart 25 1 12 Procedure for pre mixed models 12 Preoperation checks 13 Fuel 13 Oil 13 Controls 13 Engine 13 Filling fuel and engine oil 13 Filling fuel for portable tank 13 Gasoline and oil mixing 13 Operating engine 14 Feeding fuel portable tank 14 Starting engine 15 Warming up engine 17 Choke start models 17 Shifting 18 Forward tiller handle and remote control mod...

Page 5: ...dling speed 33 Checking wiring and connectors 34 Exhaust leakage 34 Water leakage 34 Checking propeller 34 Removing the propeller 35 Installing the Propeller 35 Changing gear oil 36 Cleaning fuel tank 37 Inspecting and replacing anode s 37 Checking top cowling 38 Coating the boat bottom 38 Trouble Recovery 39 Troubleshooting 39 Temporary action in emergency 42 Impact damage 42 Starter will not ope...

Page 6: ... Declaration of Conformity for more details EMU25370 Safety information Before mounting or operating the outboard motor read this entire manual Reading it should give you an understanding of the motor and its operation Before operating the boat read any own er s or operator s manuals supplied with it and all labels Be sure you understand each item before operating Do not overpower the boat with th...

Page 7: ...r your arm or leg while operating If you accidentally leave the helm the lanyard will pull from the switch stopping the engine Know the marine laws and regulations where you will be boating and obey them Stay informed about the weather Check weather forecasts before boating Avoid boating in hazardous weather Tell someone where you are going leave a Float Plan with a responsible person Be sure to c...

Page 8: ... use a different brand of gasoline or premium unleaded fuel If unleaded gasoline is not available then pre mium gasoline can be used 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 le...

Page 9: ... For instructions on propeller removal and in stallation see page 34 EMU25760 Start in gear protection Yamaha outboard motors affixed with the pic tured label or Yamaha approved remote con trol 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 en gine 1 Propeller diameter in i...

Page 10: ... dedicated fuel reservoir and must not be used as a fuel storage container Com mercial users should conform to relevant licensing or approval authority regula tions 1 Manual starter handle 2 Tiller handle 3 Choke knob 4 Engine stop button Engine stop lanyard switch 5 Tilt lock lever 6 Clamp screw 7 Trim rod 8 Propeller 9 Cooling water inlet 10 Anti cavitation plate 11 Clamp bracket 12 Rope attachm...

Page 11: ...owards 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 grip The throttle grip is on the tiller handle Turn the grip counterclockwise to increase speed and clockwise to decrease speed EMU25961 Throttle indicator The fuel consumption curve on the throttle in dicator shows ...

Page 12: ...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 pull out the lock plate stopping ig nition to the engine This will prevent the boat from running away under power WARNING EWM00120 Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg while operating Do not attach the la...

Page 13: ...n adjuster A friction device provides adjustable resis tance to the steering mechanism and can be set according to operator preference An ad justing screw or bolt is located on the swivel bracket To increase resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise WARNING EWM00040 Do not overtighten the friction adjuster If there is too much resistance it co...

Page 14: ...on EMU26330 Tilt support bar The tilt support bar keeps the outboard motor in the tilted up position EMU26372 Top cowling lock lever s turn type To remove the engine top cowling turn the lock lever s and lift off the cowling When in stalling the cowling check to be sure it fits properly in the rubber seal Then lock the cowling again by returning the lever s to the lock position 1 Tilt lock lever 1...

Page 15: ...omplete 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 other person experienced i...

Page 16: ...ping 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 the out board motor to fa...

Page 17: ...e 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 immediately reduce the thrott...

Page 18: ...ng for proper operation before starting the engine The controls should work smoothly without binding or unusual free play Look for loose or damaged connections Check operation of the starter and stop switches when the outboard motor is in 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 engin...

Page 19: ...eizure High oil ratio Too much oil could cause fouled spark plugs smoky exhaust and heavy carbon deposits NOTE If using a permanently installed tank pour the oil gradually as the gasoline is being added to the tank EMU27450 Operating engine EMU27461 Feeding fuel portable tank WARNING EWM00420 Before starting the engine make sure that the boat is tightly moored and that you can steer clear of any o...

Page 20: ...djuster is provided on your outboard motor securely attach the fuel line to the fuel line clamp NOTE During engine operation place the tank hori zontally otherwise fuel cannot be drawn from the fuel tank 4 Squeeze the primer pump with the outlet end up until you feel it become firm EMU27490 Starting engine EMU27505 Manual start models tiller control 1 Place the gear shift lever in neutral NOTE The...

Page 21: ...ion 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 thrown forward 3 Place the throttle grip in the start position 4 Pull out turn the choke knob fully After the engine starts replace return the knob to the home position NOTE It is not necessary to use the choke when starting a ...

Page 22: ...0 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 home position as the engine warms up 2 Check for a steady flow of water from the cooling water pilot hole CAUTION ECM00510 A flow of water from the hole on the ex haust cover shows that the water pump ...

Page 23: ...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 unstable which could result in loss of control and an accident ...

Page 24: ...et the fuel cock lever or knob to the closed position if equipped 3 Disconnect the fuel line if you are using an external fuel tank NOTE If the outboard motor is equipped with an en gine stop switch lanyard the engine can also be stopped by pulling the lanyard and remov ing the lock plate from the engine stop switch EMU27861 Trimming outboard motor The trim angle of the outboard motor helps determ...

Page 25: ...move the rod to ward the transom Make test runs with the trim set to different an gles to find the position that works best for your boat and operating conditions WARNING EWM00400 Stop the engine before adjusting the trim angle Use care to avoid being pinched when removing or installing the rod Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any s...

Page 26: ...ve trim in at higher speeds also makes the boat unstable Resistance at the bow is greatly increased heightening the danger of bow steering and making opera tion difficult and dangerous NOTE Depending on the type of boat the outboard motor trim angle may have little effect on the trim of the boat when operating EMU27920 Tilting up and down If the engine will be stopped for some time or if the boat ...

Page 27: ...use damage The outboard motor cannot be tilted when in reverse or when the outboard motor is turned 180 facing the rear EMU27975 Procedure for tilting up manual tilt models 1 Place the gear shift lever in neutral 2 Disconnect the fuel line from the out board motor 3 Place the tilt lock lever if equipped in the release up position 4 Pull up the shallow water lever if equipped 5 Hold the rear of the...

Page 28: ... 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 underwater obstacle could cause the outboard motor to lift out of the water resulting in loss of control Do not rotate the outboard motor 180 and operate the boat in reverse Place the gear shift in reverse to operate the...

Page 29: ...e gear shift lever in neutral then place the tilt lock le ver in the lock position 5 Slightly tilt the outboard motor up Slowly tilt the outboard motor down while pulling the tilt support bar lever up 6 Slowly lower the outboard motor to the normal position EMU28190 Cruising in other conditions Cruising in salt water After operating in salt water wash out the cooling water passages with fresh wate...

Page 30: ...ing 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 conditions U67720E0 book Page 25 Friday March 26 2004 10 36 AM ...

Page 31: ...tio 2 08 27 13 Trim and tilt system Manual tilt Propeller mark C Fuel and oil Recommended fuel Unleaded regular gasoline 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 50 1 Lubrication Pre mixed fuel and oil Recommended gear oil Hypoid gear oil SAE 90 Gear oil quantity 230 0 cm 7 78 US oz 8 11 Imp oz Ti...

Page 32: ... EMU28235 Clamp screw mounting models When 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 m...

Page 33: ...vent excessive engine damage due to rust Perform the flushing and fog ging at the same time WARNING EWM00090 Do not touch or remove electrical parts when starting or during operation Keep hands hair and clothes away from the flywheel and other rotating parts while the engine is running 6 Run the engine at a fast idle for a few minutes in neutral position 7 Just prior to turning off the engine quic...

Page 34: ...structions see page 26 EMU28460 Checking painted 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 EMU28474 Periodic maintenance WARNING EWM01070 Be sure to turn off the engine when you perform maintenance unless otherwise specified I...

Page 35: ...s 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 Inspection cleaning Gear oil Change Greasing points Greasing Idling sp...

Page 36: ...xternal sparks which could 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 yourse...

Page 37: ...ed 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 repaire...

Page 38: ...pilled 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 in position in the cup Fir...

Page 39: ...le speed is set to specification For idle speed specifica tions see page 26 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 EMU29130 Water leakage Start the engin...

Page 40: ...eller nut and washer if equipped 3 Remove the shear pin and the propeller EMU30381 Installing the Propeller CAUTION ECM00500 Be sure to use a new cotter pin and bend the ends over securely Otherwise the pro peller could come off during operation and be lost 1 Apply Yamaha Marine grease or Corro sion resistant grease to the propeller shaft 2 Insert the shear pin into the hole in the propeller shaft...

Page 41: ...table container under the gear case 3 Remove the gear oil drain screw NOTE If the magnetic gear oil drain screw equipped remove all metal particles from the screw be fore installing it 4 Remove the oil level plug to allow the oil to drain completely CAUTION ECM00710 Inspect the used oil after it has been drained If the oil is milky water is getting into the gear case which can cause gear damage Co...

Page 42: ...o 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 to dry 5 Replace the gasket with a new one Re install the fuel...

Page 43: ... 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 These paints can cause more rapid engine corrosion ZMU01943 U67720E0 book Page 38 Friday March 26 2004 10 36 A...

Page 44: ... 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 15 Q Has fuel pump malfunctioned A Have serviced by a Yamaha dealer Q Are spark plug s fouled or of inco...

Page 45: ...t 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 cable disconnected A Connect...

Page 46: ...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 gap incorrect A Inspect an...

Page 47: ... 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 Starter will not operate If ...

Page 48: ...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 engine for starting For fu...

Page 49: ... 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 a Yamaha dealer as soon as...

Page 50: ...YAMAHA MOTOR CO LTD Printed on recycled paper Printed in Japan April 2004 0 1 1 CR U67720E0 book Page 1 Friday March 26 2004 10 36 AM ...

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