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Trouble Recovery

86

EMU41861

Troubleshooting

This section describes the likely causes and
remedies for problems, such as those in the
fuel, compression, and ignition systems, poor
starting, and loss of power. Please note that
all of the items in this section may not apply
to your model.
If your outboard motor requires repair, bring
it to a Yamaha dealer.
If the engine trouble-alert indicator is blinking,
consult your Yamaha dealer.

Starter will not operate.

Q. Does the Digital electronic control-alert in-
dicator come on?
A. Have serviced by a Yamaha dealer.

Q. Is control lever in gear?
A. Shift to neutral.

Q. Is battery capacity low or weak?
A. Check battery condition. Use battery of
recommended capacity.

Q. Are battery connections corroded or
loose?
A. Tighten battery cables and clean battery
terminals.

Q. Is fuse for starter relay or electric circuit
blown?
A. Check for cause of electric overload and
repair. Replace fuse with one of correct am-
perage.

Q. Are starter components malfunctioning?
A. Have serviced by a Yamaha dealer.

Engine will not start (starter operates).

Q. Is clip on engine shut-off cord (lanyard) in-
stalled?

A. Install clip to engine shut-off switch.

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 fuel filter.

Q. Is fuel pump malfunctioning?
A. Have serviced by a Yamaha dealer.

Q. Are spark plugs fouled or of incorrect ty-
pe?
A. Inspect spark plugs. Clean or replace with
recommended type.

Q. Are ignition parts malfunctioning?
A. Have serviced by a Yamaha dealer.

Q. Is ignition wiring damaged or poorly con-
nected?
A. Inspect wires for breaks and wear. Have
connections tightened and broken or worn
wires replaced by a Yamaha dealer.

Q. Are engine inner parts damaged?
A. Have serviced by a Yamaha dealer.

Engine idles irregularly or stalls.

Q. Are spark plugs fouled or of incorrect ty-
pe?
A. Inspect spark plugs. Clean or replace with
recommended type.

Q. Is fuel system clogged?
A. Inspect for pinched or kinked fuel line or
other obstructions in fuel system.

U6DV75E0.book Page 86 Tuesday, February 21, 2017 8:33 AM

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Summary of Contents for F150G

Page 1: ...Read this manual carefully before operating this outboard motor OWNER S MANUAL F150G FL150G F175C FL175C F200G FL200G 6DV 28199 75 E0 U6DV75E0 book Page 1 Tuesday February 21 2017 8 33 AM ...

Page 2: ...arefully before operating this outboard motor Keep this manual onboard in a waterproof bag when boating This manual should stay with the outboard motor if it is sold U6DV75E0 book Page 1 Tuesday February 21 2017 8 33 AM ...

Page 3: ...ontains the most current prod uct information available at the time of print ing there may be minor discrepancies between your machine and this manual If there is any question concerning this manual please consult your Yamaha dealer To ensure long product life Yamaha recom mends that you use the product and perform the specified periodic inspections and main tenance by correctly following the inst...

Page 4: ...0G OWNER S MANUAL 2017 by Yamaha Motor Co Ltd 1st Edition February 2017 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U6DV75E0 book Page 2 Tuesday February 21 2017 8 33 AM ...

Page 5: ... rating 11 Mounting outboard motor 11 Digital electronic control requirements 12 Battery requirements 12 Battery specifications 12 Propeller selection 13 Counter rotation models 13 Start in gear protection 13 Engine oil requirements 14 Fuel requirements 14 Gasoline 14 Muddy or acidic water 15 Anti fouling paint 15 Outboard motor disposal requirements 15 Emergency equipment 15 Emission control info...

Page 6: ... cowling 46 Fuel system 46 Controls 47 Engine shut off cord lanyard 47 Engine oil 47 Outboard motor 48 Flushing device 48 Installing top cowling 48 Checking power trim and tilt system 49 Battery 50 Filling fuel 51 Operating engine 51 Sending fuel 51 Starting engine 52 Checks after starting engine 54 Cooling water 54 Warming up engine 54 Electric start models 54 Checks after engine warm up 54 Shift...

Page 7: ...oving propeller 79 Installing propeller 79 Changing gear oil 80 Inspecting and replacing anode s 82 Checking battery for electric start models 82 Connecting the battery 83 Disconnecting the battery 84 Trouble Recovery 86 Troubleshooting 86 Temporary action in emergency 89 Impact damage 89 Running single engine twin engines 89 Replacing fuse 89 Power trim and tilt unit will not operate 90 Water sep...

Page 8: ...ocution EMU33661 Power trim and tilt Body parts can be crushed between the mo tor and the clamp bracket when the motor is trimmed or tilted Keep body parts out of this area at all times Be sure no one is in this area before operating the power trim and tilt mechanism The power trim and tilt switches operate even when the main switch is off Keep people be away from the switches whenever working aro...

Page 9: ...oating fatalities EMU40281 Personal flotation devices PFDs Have an approved PFD on board for every occupant Yamaha recommends that you must wear a PFD whenever boating At a mi nimum children and non swimmers should always wear PFDs and everyone should wear PFDs when there are potentially hazard ous boating conditions EMU33732 People in the water Always watch carefully for people in the wa ter such...

Page 10: ...ction to avoid collisions Re member boats do not have brakes and stopping the engine or reducing throttle can reduce the ability to steer If you are not sure that you can stop in time before hitting an obstacle apply throttle and turn in an other direction EMU33791 Weather Stay informed about the weather Check weather forecasts before boating Avoid boating in hazardous weather EMU33881 Passenger t...

Page 11: ...umber is stamped on the label attached to the digital electronic control box Record your digital electronic control serial number in the spaces provided to assist you in newly connecting the digital electronic control to the outboard motor TIP Consult your Yamaha dealer if you have any questions concerning the digital electronic control serial number 1 Outboard motor serial number location 1 Seria...

Page 12: ...ve re lating to machinery Each conformed outboard motor accompa nied with EC DoC EC DoC contains the fol lowing information Name of Engine Manufacture Model name Product code of model Approved model code Code of conformed directives EMU38995 CE Marking This label is affixed to outboard motors that conform to European regulations Outboard motors affixed with this CE mark ing conform with the direct...

Page 13: ...his mark meet all re quirements of the Canadian Interference Causing Equipment Regulations Manufactured date The manufactured date is stamped on the la bel for the engines that conform to the regu lations for U S Environmental Protection Agency EPA The models that manufac tured exclusively for the Oceanian countries may not have manufactured date on the la bel 1 Compliance mark and manufactured da...

Page 14: ... any manuals supplied with the boat Read all labels on the outboard motor and the boat If you need any additional information contact your Yamaha dealer EMU33836 Warning labels If these labels are damaged or missing contact your Yamaha dealer for replacements 2 1 3 ZMU08832 U6DV75E0 book Page 7 Tuesday February 21 2017 8 33 AM ...

Page 15: ...when starting or during operation 2 WARNING EWM01672 Read Owner s Manuals and labels Wear an approved personal flotation de vice PFD Attach engine shut off cord lanyard to your PFD arm or leg so the engine stops if you accidentally leave the helm which could prevent a runaway boat EMU33851 Other labels 6EE G2794 40 6EE H1994 40 1 2 6EE G2794 50 6EE H1994 50 ZMU06191 3 ZMU05710 U6DV75E0 book Page 8...

Page 16: ...133 Symbols The following symbols mean as follows Notice Warning Read Owner s Manual Hazard caused by continuous rotation Electrical hazard ZMU05696 ZMU05664 ZMU05665 ZMU05666 U6DV75E0 book Page 9 Tuesday February 21 2017 8 33 AM ...

Page 17: ...ted power 110 3 kW 150 HP F150GET FL150GET 128 7 kW 175 HP F175CET FL175CET 147 1 kW 200 HP F200GET FL200GET Idle speed in neutral 650 750 r min Power unit Type 4 stroke DOHC L4 16 valves Total displacement 2785 cm 169 9 c i Bore stroke 96 0 96 2 mm 3 78 3 79 in Ignition system TCI Spark plug NGK LFR6A 11 Spark plug gap 1 0 1 1 mm 0 039 0 043 in Steering system Remote steering Starting system Elec...

Page 18: ... oil Recommended gear oil grade SAE 90 API GL 4 SAE 80W API GL 5 SAE 90 API GL 5 Gear oil quantity 0 980 L 1 036 US qt 0 862 Imp qt Tightening torque Spark plug 28 N m 2 86 kgf m 20 7 lb ft Propeller nut 54 N m 5 51 kgf m 39 8 lb ft Engine oil drain bolt 27 N m 2 75 kgf m 19 9 lb ft Engine oil filter 18 N m 1 84 kgf m 13 3 lb ft Noise and vibration level Operator sound pressure level ICOMIA 39 94 ...

Page 19: ...in the follow ing cases If a used outboard motor is installed If the digital electronic control unit is re placed If the ECM Electronic control module of the used outboard motor is replaced If the ECM Electronic control module of the digital electronic control unit is re placed Consult your Yamaha dealer for setting EMU25695 Battery requirements EMU46560 Battery specifications For U S insular area...

Page 20: ...etting to stay within the recommended engine speed range when carrying lighter loads Yamaha recommends to use a propeller suit able for the Shift Dampener System SDS For further information consult your Yamaha dealer To check the propeller see page 78 EMU36313 Counter rotation models Standard outboard motors rotate clockwise Counter rotation models rotate counterclock wise and are typically used i...

Page 21: ... types of gasohol gasohol con taining ethanol E10 and that containing methanol Ethanol can be used if the ethanol Recommended engine oil YAMALUBE 4 or 4 stroke outboard motor oil Recommended engine oil grade 1 SAE 10W 30 10W 40 5W 30 API SE SF SG SH SJ SL Recommended engine oil grade 2 SAE 15W 40 20W 40 20W 50 API SH SJ SL Engine oil quantity without oil filter replacement 4 3 L 4 55 US qt 3 78 Im...

Page 22: ...t A clean hull improves boat performance The boat bottom should be kept as clean of mari ne growth as possible If necessary the boat bottom 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 EMU40302 Outboard motor disposal re quirements Never ill...

Page 23: ...s for marine engines EMU40341 Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2004 exhaust emission standards Engines meet ing these standards have 20 lower emis sions than One Star Low Emission engines 1 Approval label location 1 Star labels location 1 ZMU07871 EMISSION CONTROL INFORMATION THIS EN...

Page 24: ... meeting these standards have 65 lower emissions than One Star Low Emission engines EMU33862 Four Stars Super Ultra Low Emission The four star label identifies engines that meet the Air Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 lo...

Page 25: ...d equipment on all models order from dealer 6 4 3 10 2 1 7 9 2 5 8 ZMU07738 1 Top cowling 2 Cowling lock lever 3 Clamp bracket 4 Power trim and tilt unit 5 Anode 6 Flushing device 7 Anti cavitation plate 8 Trim tab anode 9 Propeller 10 Cooling water inlet U6DV75E0 book Page 18 Tuesday February 21 2017 8 33 AM ...

Page 26: ...33 1 Ignition coil 2 Oil dipstick 3 Cowling lock lever 4 Power trim and tilt switch 5 Oil level plug 6 Oil filler cap 7 Fuse box 8 Fuel filter 9 Cooling water inlet 10 Gear oil drain screw U6DV75E0 book Page 19 Tuesday February 21 2017 8 33 AM ...

Page 27: ...U08525 1 Digital electronic control single type 2 Switch panel for use with single type 3 Digital electronic control twin type 4 Switch panel for use with twin type 5 Start Stop switch panel for use with twin ty pe 6 All Start Stop switch panel for use with twin type 7 Yamaha Security System Y COP U6DV75E0 book Page 20 Tuesday February 21 2017 8 33 AM ...

Page 28: ...it is used in For details consult your Yamaha dealer The Yamaha Security System which pro tects against theft consists of the receiver and remote control transmitters The Yamaha Security System is available from your Yamaha dealer For details consult your Yamaha dealer SET MODE SET MODE SET MENU CANCEL ZMU08526 4 3 1 2 1 6Y8 Multifunction tachometer 2 6Y8 Multifunction speed fuel meter 3 6YC Multi...

Page 29: ...gital electronic control system is in the operating state Lights Operation of both shift and throttle possible Blinks when the gear shift is in neutral only Shift not operable Only throttle op eration available Off Shift and throttle not operable 1 Control lever 2 Digital electronic control active indicator 3 Digital electronic control alert indicator 4 Free throttle switch 5 Throttle friction adj...

Page 30: ...elerate Digital electronic control for twin type has the function of automatically synchronizing the engine speeds of both engines of the port and starboard sides EMU35003 Free throttle switch In neutral keep this switch pressed move the control lever forward and release the switch after the digital electronic control ac tive indicator starts blinking While the indica tor blinks you can open or cl...

Page 31: ...control will then engage forward and reverse normally EMU35252 Throttle friction adjuster A friction device provides adjustable resis tance to movement of the control lever and can be set according to operator preference To increase resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise WARNING EWM01771 If the friction is too small the control le ver could...

Page 32: ...d become entan gled preventing it from functioning Avoid accidentally pulling the cord during nor mal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause peo ple and objects in the boat to be thrown forward EWM00123 EMU41552 Main switch The main switch controls the ignition system its operation is described b...

Page 33: ...e Start Stop button allows all engines to start or turn off EMU35154 Power trim and tilt switch on digital electronic control The power trim and tilt system adjusts the outboard motor angle in relation to the tran som Pressing the switch up trims the outboard motor up and then tilts it up Press ing the switch down tilts the outboard motor down and trims it down When the switch is released the outb...

Page 34: ... the risk of falling overboard and could distract the operator increasing the risk of collision with another boat or an obstacle EMU35161 Power trim and tilt switches twin ty pe The power trim and tilt system adjusts the outboard motor angle in relation to the tran som Pushing the switch up trims the outboard motor up and then tilts it up Press ing the switch down tilts the outboard motor down and...

Page 35: ...rim tab rear end to the port side A in the figure If the boat tends to veer to the right starboard side turn the trim tab end to the starboard side B in the figure NOTICE ECM00841 The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode EMU26342 Tilt support lever for power trim and tilt model To ke...

Page 36: ...ng device The flushing device is used to clean the cool ing water passages of the outboard motor using a garden hose and tap water For in structions on using the flushing device see page 65 EMU41312 Fuel filter The fuel filter functions to remove foreign ma terial and separate water from the fuel If wa ter separated from the fuel exceeds a specific volume the alert system will activate For fur the...

Page 37: ...ngine is be ing warmed up and goes off when warming up is finished EMU41661 Engine synchronization indicator In twin types this display appears while the engines are under engine synchronization control It goes off when engine synchroniza tion control is released 1 Directional keypad 2 Set button 3 Cancel button 4 Menu button 5 Display 1 Shift position display 2 Yamaha Security System indicator op...

Page 38: ... NOTICE ECM01594 Do not continue to run the engine if the overheat alert indicator blinks Serious engine damage will occur Do not continue to operate the engine if an alert device has activated Consult your Yamaha dealer if the problem can not be located and corrected EMU41692 Low oil pressure alert If the engine oil pressure drops too low the pop up window will appear Press the set button to chan...

Page 39: ...he set button to change to normal display and the water sep arator alert indicator will start to blink Stop the engine immediately and see page 89 of this manual to drain the water from the fuel filter Get back to the port soon and con sult a Yamaha dealer immediately NOTICE ECM00911 Gasoline mixed with water could cause damage to the engine EMU41721 Low battery voltage alert The pop up window wil...

Page 40: ...splay TIP The optional items displayed on the multi function display can be changed For infor mation on other settings or changing the displayed optional items see the operation manual included with the 6YC Multifunction meter This manual mainly covers the alert display of the 6YC Multifunction meter See the follow ing sections for information about the display and indicators ZMU07253 ZMU07254 1 M...

Page 41: ...or will start to blink NOTICE ECM00921 In such an event the engine will not oper ate properly Consult a Yamaha dealer im mediately Low battery voltage alert If the battery voltage drops the pop up win dow will appear 1 Yamaha Security System indicator optional 2 Engine trouble alert indicator 3 Low battery voltage alert indicator 4 Water separator alert indicator 5 Low oil pressure alert indicator...

Page 42: ... and the water separator alert indicator will start to blink Stop the engine immediately and see page 89 of this manual to drain the water from the fuel filter Get back to the port soon and con sult a Yamaha dealer immediately NOTICE ECM00911 Gasoline mixed with water could cause damage to the engine Low oil pressure alert If the engine oil pressure drops too low the pop up window will appear The ...

Page 43: ...ile cruising the pop up window will appear The engine speed will automatically decrease to about 2000 3500 r min To return to the normal display Push the SET set button and the over heat alert indicator will start to blink Stop the engine immediately if the buzzer sounds and the overheat device has activat ed Check the cooling water inlet for clog ging NOTICE ECM01594 Do not continue to run the en...

Page 44: ...tings or changing the displayed information see the operation manual includ ed with the 6Y8 Multifunction meter This manual mainly covers the alert display of the 6Y8 Multifunction tachometer See the following sections for information about the alert indicators 1 Set button 2 Mode button 1 Tachometer 2 Trim meter 3 Multifunction display SET MODE 2 1 ZMU08407 1 2 3 ZMU08408 1 Set button 2 Mode butt...

Page 45: ...h water could cause damage to the engine Engine trouble alert indicator If the engine malfunctions while cruising the engine trouble alert indicator will start to blink Get back to the port soon and consult a Yamaha dealer immediately NOTICE ECM00921 In such an event the engine will not oper ate properly Consult a Yamaha dealer im mediately 1 Yamaha Security System indicator optional 2 Water separ...

Page 46: ... not continue to operate the engine if an alert device has activated Consult your Yamaha dealer if the problem can not be located and corrected Low oil pressure alert indicator If the engine oil pressure drops too low the low oil pressure alert indicator will start to blink and the engine speed will automatically decrease to about 2000 3500 r min Stop the engine immediately if the buzzer sounds an...

Page 47: ... of trouble on shifting or throttle get back to the port soon and have a Yamaha dealer inspect or repair the outboard motor EMU41926 Overheat alert This engine has an overheat alert device If the engine temperature rises too high the alert device will activate The engine speed will automatically de crease to about 2000 3500 r min The overheat alert indicator will light or blink The pop up window w...

Page 48: ...e engine overheating If the alert system has activated stop the engine and tilt the outboard motor up to check the cooling water inlet for clogging If the alert system has still activated tilt the overheated outboard motor up and return to the port EMU41936 Low oil pressure alert If the oil pressure drops too low the alert de vice will activate The engine speed will automatically de crease to abou...

Page 49: ...r separator alert system If water separated from the fuel exceeds a specific volume the alert system will activate The water separator alert indicator will come on or blink The pop up window will appear on the Multi Display The buzzer will sound intermittently when the control lever is in the neutral position If the alert system has activated stop the en gine immediately and see page 89 of this ma...

Page 50: ...engine boats mount the outboard motor on the cen terline keel line of the boat For twin engine boats mount the outboard motors equidis tant from the centerline Consult your Yamaha dealer or boat manufacturer for fur ther information on determining the proper mounting location EMU26936 Mounting height boat bottom The mounting height of your outboard motor affects its efficiency and reliability If i...

Page 51: ...bstructions to the smooth flow of water such as the design or condition of the boat or ac cessories such as transom ladders or depth finder transducers can create air borne water spray while the boat is cruising If the outboard motor is oper ated continuously in the presence of air borne water spray enough water could enter the engine through the air intake opening in the top cowling to cause se v...

Page 52: ...severe engine damage ECM00802 EMU41223 Procedure for breaking in engine Your new engine requires a period of 10 hours break in so that mating surfaces of moving parts wear in evenly Operate the engine in the water under load in gear with a propeller installed for 10 hours as follows When breaking in the engine avoid extended idling rough water and crowded areas 1 For the 1st hour of operation Oper...

Page 53: ...ove the top cowling from the bottom cowling To remove the top cowling pull the cowling lock levers and lift up the top cowling EMU36443 Fuel system WARNING EWM00061 Gasoline and its vapors are highly flamma ble and explosive Keep away from sparks cigarettes flames or other sources of ig nition WARNING EWM00911 Leaking fuel can result in fire or explosion Check for fuel leakage regularly If any fue...

Page 54: ...the complete range of motion and each le ver should return completely to the idle po sition EMU40363 Engine shut off cord lanyard Check the engine shut off cord and clip for damage such as cuts breaks and wear EMU40994 Engine oil 1 Place the outboard motor in a vertical position not tilted NOTICE If the out board motor is not level the oil level indicated on the oil dipstick may not be accurate EC...

Page 55: ...lling top cowling 1 Check the rubber seal for damage If the rubber seal is damaged have it replaced by a Yamaha dealer 2 Check that the rubber seal is seated all the way around the bottom cowling 3 Check that all of the cowling lock levers are pulled outward 4 Align the 3 protrusions on the top cowl ing with the corresponding holders on the bottom cowling and then place the top cowling on the bott...

Page 56: ...r accidentally falls Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted Be sure no one is near the outboard mo tor before performing this check 1 Check the power trim and tilt unit for any sign of oil leaks 2 Operate each of the power trim and tilt switches on the digital electronic control and engine bottom cowling if equipped to check that all s...

Page 57: ...d and trim rods operate smoothly EMU36585 Battery Check the battery s charge If your boat is equipped with a Yamaha digital speedome ter the voltmeter and low battery alert func tions will help you monitor the battery s charge A battery in good condition will pro vide a minimum of 12 volts Check that the battery connections are clean secure and covered by insulating covers The electrical connectio...

Page 58: ...rces of ignition 5 If you use a portable container to store and dispense fuel only use a locally ap proved GASOLINE container 6 Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks 7 Fill the fuel tank but do not overfill WARNING Do not overfill Otherwise fuel can expand and overflow if the temperature increases EWM02611 8 Tighten the fuel tank cap securely 9 ...

Page 59: ... cord to clothing that could tear loose Do not route the cord where it could become entangled preventing it from functioning Avoid accidentally pulling the cord dur ing normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cau se people and objects in the boat to be thrown forward 1 Place the control lever in ...

Page 60: ...gine using the Start Stop button press the button to start the engine The indicator for the starting engine will come on When starting the engine using the Start Stop button on the All Start Stop switch panel press the button to start the all engines TIP When the main switch is turned to start with the clip removed from the en gine shut off switch the buzzer will sound For twin type if the clip is...

Page 61: ...2 Shifting While the boat is tightly moored and without applying throttle confirm that the engine shifts smoothly into forward and reverse and back to neutral EMU41821 Stop switches Perform the following procedure to check that the main switch and engine shut off switch operate properly Check that the engine stops when the main switch is turned to the off position or press the Start Stop button Ch...

Page 62: ...ious injury It could also damage the shift mechanism Do not shift into reverse while traveling at planing speeds Loss of control boat swamping or damage to the boat could occur The boat is not equipped with a separate braking system Water resistance stops it af ter the throttle lever is moved back to idle The stopping distance varies depending on gross weight water surface conditions and wind dire...

Page 63: ...en warming up a cold engine the troll ing speed cannot be decreased below the specified engine idle speed EMU27822 Stopping 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 EMU41913 Procedure for stopping engine 1 The engine can be turned off either by pressing the Start ...

Page 64: ...ds upon the combination of boat engine and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed EMU27889 Adjusting trim angle Power trim and tilt WARNING EWM00754 Be sure all people are clear of the out board motor when adjusting the trim an gle Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed ...

Page 65: ...much trim out puts the bow of the boat too high in the water Performance and econ omy 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 per formance further and the boat may por poise hop in the water which could throw the operator and passengers overboard Bow Down Too much trim in c...

Page 66: ...etween the outboard motor and the clamp bracket when the outboard mo tor is trimmed or tilted NOTICE ECM00993 Before tilting the outboard motor follow the procedure under Stopping engine in this chapter Never tilt the outboard motor while the engine is running Se vere damage from overheating can re sult To prevent the cooling water passages from becoming frozen when the ambi ent temperature is 5 C...

Page 67: ... the motor cannot be trailered in the normal running position use an addi tional support device to secure it in the tilt position For more detailed in formation see page 63 ECM01642 4 Once the outboard motor is supported with the tilt support lever press the pow er trim and tilt switch down to re tract the trim rods NOTICE Make sure that the trim rods retracts completely during mooring This protec...

Page 68: ... motor can be tilted up partially to allow operation in shallow water NOTICE ECM02361 Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set ting up for and cruising in shallow water Otherwise severe damage from overheat ing can result EMU35237 Procedure for power trim and tilt models 1 Place the control lever in neutral 1 Til...

Page 69: ...8196 Cruising in other conditions Cruising in salt water After operating in salt water flush the cooling water passages with fresh water to prevent them from becoming clogged Also rinse the outside of the outboard motor with fresh wa ter Cruising in muddy turbid or acidic water Yamaha strongly recommends that you use the optional chromium plated water pump kit see page 15 if you use the outboard m...

Page 70: ...clog the fuel line causing engine start difficulty or malfunction Leaking fuel is a fire hazard When trailering the boat close the fuel valve to prevent fuel from leaking The outboard motor should be transported and stored in the normal running position If there is insufficient road clearance in this po sition then trailer the outboard motor in the tilt position using a motor support device such a...

Page 71: ...e air intake ECM01841 For further information see page 66 3 Remove the top cowling and propeller 4 Install the flushing attachment over the cooling water inlet and then turn on the water supply NOTICE Do not run the engine without supplying it with cool ing water Either the engine water pump will be damaged or the engine will be damaged from overheating Before starting the engine be sure to supply...

Page 72: ...oard motor thoroughly EMU41072 Lubrication 1 Change the gear oil For instructions see page 80 Check the gear oil for the pres ence of water that indicates a leaky seal Seal replacement should be performed by an authorized Yamaha dealer prior to use 2 Lubricate all grease fittings For further details see page 71 TIP For long term storage fogging the engine with fogging oil is recommended Contact yo...

Page 73: ...841 2 Drain the cooling water completely out of the outboard motor Clean the body thoroughly EMU28463 Checking painted surface of outboard motor Check the outboard motor for scratches nicks or flaking paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas Touch up paint is available from your Yamaha dealer EMU2850D Periodic maintenance WARNING EWM01872 The...

Page 74: ...part of inferior quality may malfunction and the resulting loss of control could endanger the operator and pas sengers Yamaha genuine parts and acces sories are available from your Yamaha dealer EMU34152 Severe operating conditions Severe operating conditions involve one or more of the following types of operation on a regular basis Operating continuously at or near maxi mum engine speed rpm for m...

Page 75: ...e engine should be flushed with clean water after each use The symbol indicates the check ups which you may carry out yourself The symbol indicates work to be carried out by your Yamaha dealer Item Actions Initial Every Page 20 hours 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years Anode s external Inspection or re placement as nec essary 82 Anode s internal 1 Inspection or re placeme...

Page 76: ...g 71 Clamp bracket bolt through tube Inspection and greasing Impeller water pump housing Inspection or re placement as nec essary Impeller water pump housing Replacement OCV Oil Control Valve filter F200G FL200G Replacement Power trim and tilt unit Inspection 49 Propeller propeller nut cotter pin Inspection or re placement as nec essary 78 PCV Pressure Control Valve Inspection or re placement as n...

Page 77: ...ming belt Inspection or re placement as nec essary Valve clearance Inspection and ad justment Cooling water inlet Inspection 18 Main switch stop switch Inspection or re placement as nec essary Wire harness con nections wire cou pler connections Inspection or re placement as nec essary Yamaha Me ter gauge Inspection Item Actions Every Page 1000 hours Exhaust guide ex haust manifold Inspection or re...

Page 78: ...enance 71 EMU46110 Greasing Yamaha grease A water resistant grease Yamaha grease D corrosion resistant grease for propeller shaft and trim rods ZMU08001 U6DV75E0 book Page 71 Tuesday February 21 2017 8 33 AM ...

Page 79: ...on coil cover 2 Remove the bolt that is securing the igni tion coil and then remove the ignition coil NOTICE Do not use any tools to remove or install the ignition coil Oth erwise the ignition coil coupler could be damaged ECM02331 3 Remove the spark plug WARNING When removing or installing a spark plug be careful not to damage the in sulator A damaged insulator could al low external sparks which ...

Page 80: ...esting is con ducted 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 2 Inspect the engine idle speed If the en gine idle speed is out of specification consult a Yamaha dealer or other quali fied mechanic EMU44472 Changing engine oil WARNING EWM00761 Avoid draining the engine oil immediate ly after stopping the engine The...

Page 81: ...e filler cap and the dipstick NOTICE Overfilling the oil could cause leakage or damage If the oil level is above the upper level mark drain until the level meets the speci fied capacity ECM01851 7 Leave the outboard motor for 5 10 minu tes 8 Remove the oil dipstick and wipe it clean 9 Insert the dipstick and remove it again Be sure to completely insert the dipstick into the dipstick guide otherwis...

Page 82: ...nge the oil more often when operating the engine under adverse conditions such as extended trolling Changing the engine oil by draining the oil The location of the drain screw is different for L transom models and X transom models For L transom models skip steps 5 and 14 because the apron does not have to be re moved L transom models X transom models 1 Put the outboard motor in an upright po sitio...

Page 83: ...odels TIP If the oil does not drain easily change the tilt angle or turn the outboard motor to port and starboard to drain the oil 7 Put a new gasket on the drain screw Ap ply a light coat of oil to the gasket and in stall the drain screw TIP If a torque wrench is not available when you are installing the drain screw finger tighten the screw just until the gasket comes into contact with the surfac...

Page 84: ... oil pressure alert indicator remains off Also make sure that there are no oil leaks NOTICE If the low oil pressure alert indicator comes on or if there are oil leaks stop the engine and find the cause Continued operation with a problem could cause severe engine damage Consult your Yamaha dealer if the problem cannot be located and corrected ECM01623 14 Apply LOCTITE 572 to the threads of the bolt...

Page 85: ...remove the key and remove the clip from the engine shut off switch Turn off the battery cut off switch if your boat has one Do not use your hand to hold the propeller when loosening or tightening the propeller nut Place a block of wood between the anti cavitation plate and the propeller to prevent the propeller from turning Checkpoints Check each of the propeller blades for ero sion from cavitatio...

Page 86: ...e size indication on the propeller Otherwise the boat could move in the opposite direction from that expected NOTICE ECM00502 Make sure to use a new cotter pin and bend the ends over securely Otherwise the propeller could come off during oper ation and be lost 1 Apply Yamalube Marine Grease to the propeller shaft 2 Install the thrust washer and propeller on the propeller shaft NOTICE Make sure to ...

Page 87: ...r tightening the pro peller nut to the specified torque tighten the nut further to align the slot with the hole EMU47100 Changing gear oil WARNING EWM00801 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 lock...

Page 88: ... the gear oil is milky or contains water or a large amount of metal particles the gear case may be damaged Have a Yamaha dealer check and repair the outboard motor ECM00714 TIP For disposal of used oil consult your Yamaha dealer 5 Put the outboard motor in a vertical posi tion Using a flexible or pressurized filling device inject the gear oil into the gear oil drain screw hole 6 Put a new gasket o...

Page 89: ... for replacement of external anodes NOTICE ECM00721 Do not paint anodes as this would render them ineffective TIP Inspect ground leads attached to external an odes on equipped models Consult a Yamaha dealer for inspection and replace ment of internal anodes attached to the pow er unit EMU29324 Checking battery for electric start models WARNING EWM01903 Battery electrolyte is poisonous and caus tic...

Page 90: ...ery holder securely in a dry well ventilated vibration free location in the boat Install a fully charged battery in the holder NOTICE ECM01125 Do not reverse the battery cables Other wise the electrical parts could be dam aged 1 Make sure the main switch on applica ble models is off before working on the battery 2 Connect the red battery cable to the POSITIVE terminal first Then connect the black ...

Page 91: ...age to the electrical system ECM01941 3 Disconnect the positive cable s and re move the battery from the boat 1 Isolator lead with circuit protection 2 Red cable 3 Black cable 4 Fuse 5 Battery for accessories 6 Battery for starting 7 Negative connecting cable 2 1 7 6 5 3 4 ZMU05939 1 Starboard side engine 2 Port side engine 3 Red cable 4 Black cable 5 Isolator leads with circuit protection 6 Fuse ...

Page 92: ...Maintenance 85 4 Clean maintain and store the battery according to the manufacturer s instruc tions U6DV75E0 book Page 85 Tuesday February 21 2017 8 33 AM ...

Page 93: ...components malfunctioning A Have serviced by a Yamaha dealer Engine will not start starter operates Q Is clip on engine shut off cord lanyard in stalled A Install clip to engine shut off switch 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 fuel filter Q Is fuel pump malfunctioning...

Page 94: ...connection incorrect A Connect correctly Q Is battery cable disconnected A Connect securely Alert buzzer sounds or indicator lights Q Is cooling system clogged A Inspect cooling water inlet for obstruc tions Q Is low oil pressure alert indicator on or blinking A Have serviced by a Yamaha dealer Q Is heat range of spark plugs incorrect A Inspect spark plugs and replace with rec ommended type Q Is s...

Page 95: ...ignition wiring damaged or poorly con nected A Inspect wires for breaks and wear Have connections tightened and broken or worn wires replaced by a Yamaha dealer Q Are electrical parts malfunctioning A Have serviced by a Yamaha dealer Q Is specified fuel not being used A Replace fuel with specified type Q Is specified engine oil not being used A Replace engine oil with specified type Q Is thermosta...

Page 96: ...slowly and careful ly 4 Have a Yamaha dealer check the out board motor before operating it again EMU29454 Running single engine twin engines When using only one engine in an emergen cy be sure to keep the unused one tilted up and operate the other engine at low speed NOTICE ECM00371 If the boat is operated with one engine in the water but not running water may run into the exhaust pipe due to wave...

Page 97: ...annot be tilted up or down using the power trim and tilt unit be cause of a discharged battery or a failure with the power trim and tilt unit the outboard mo tor can be tilted manually 1 Stop the engine 2 Loosen the manual valve screw by turn ing it counterclockwise until it stops 1 Fuse box cover 2 Spare fuse 10 A 15 A 20 A 30 A 60 A 3 Fuse puller 1 Fuel feed pump fuse 10 A 2 Main switch PTT swit...

Page 98: ...eak which could result in a fire or explosion hazard If the water separator alert indicator blinks perform the following procedure 1 Stop the engine 2 Remove the top cowling 3 Disconnect the water detection switch coupler NOTICE Be careful not to get any water on the water detection switch coupler otherwise a malfunc tion could occur ECM01951 4 Remove the filter cup from the filter housing and the...

Page 99: ...ave your Yamaha dealer check the outboard motor NOTICE Although the buzzer will stop when the engine is started and the control lever is moved to the forward or reverse position do not use the outboard motor Other wise serious engine damage could occur ECM02481 EMU33502 Treatment of submerged motor If the outboard motor is submerged immedi ately take it to a Yamaha dealer Otherwise some corrosion ...

Page 100: ...gital Electronic Control alert 40 Digital Electronic Control box 22 Digital electronic control requirements 12 Digital electronic control serial number 4 Digital electronic control active indicator 22 Digital electronic control alert indicator 23 E EC Declaration of Conformity DoC 5 Electric shock 1 Emergency equipment 15 Emergency running single engine in an 89 Emergency temporary action in 89 Em...

Page 101: ...rloading 2 P Passenger training 3 Passengers 2 People in the water 2 Periodic maintenance 66 Personal flotation devices PFDs 2 Power trim and tilt 1 Power trim and tilt switch bottom cowling 27 Power trim and tilt switch digital electronic control 26 Power trim and tilt switches twin type 27 Power trim and tilt system checking 49 Power trim and tilt unit will not operate 90 Propeller 1 Propeller c...

Page 102: ...ving 46 Transporting and storing outboard motor 63 Trim tab with anode 28 Trimming outboard motor 57 Trolling 55 Troubleshooting 86 W Warming up engine 54 Warning labels 7 Water separator alert 32 42 Water separator alert indicator blinks while cruising 91 Weather 3 Wiring and connectors inspecting 78 Y Yamaha Security System indicator optional 30 Yamaha Security System Y COP 21 U6DV75E0 book Page...

Page 103: ...U6DV75E0 book Page 96 Tuesday February 21 2017 8 33 AM ...

Page 104: ...Printed on recycled paper Printed in Japan March 2017 0 2 1 CR U6DV75E0 book Page 1 Tuesday February 21 2017 8 33 AM ...

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