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EMK00010

Chapter 4

MAINTENANCE

SPECIFICATIONS

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

TRANSPORTING AND STORING
OUTBOARD MOTOR

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

Trailering outboard motor ...................4-3
Storing outboard motor .......................4-5

PERIODIC MAINTENANCE

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

Replacement parts ................................4-9
Maintenance chart ..............................4-10
Greasing...............................................4-12
Cleaning and adjusting spark plug ...4-13
Checking top cowling .........................4-14
Checking fuel system .........................4-15
Inspecting fuel filter ............................4-16
Inspecting idling speed ......................4-17
Changing engine oil............................4-18
Replacing fuse .....................................4-20
Checking wiring and connectors.......4-21
Exhaust leakage ..................................4-21
Water leakage......................................4-21
Checking power tilt system................4-22
Checking propeller..............................4-23
Changing gear oil................................4-25
Cleaning fuel tank ...............................4-26
Inspecting and replacing anode(s)....4-27
Checking battery .................................4-28
Checking bolts and nuts.....................4-30
Cleaning cooling-water passages .....4-31
Motor exterior .....................................4-32
Coating the boat bottom ....................4-32

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Summary of Contents for F15C

Page 1: ...F15C OWNER S MANUAL U S A Edition LIT 18626 05 47 ...

Page 2: ......

Page 3: ...pecial 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 ...

Page 4: ...E GENERAL INFORMATION BASIC COMPONENTS OPERATION MAINTENANCE TROUBLE RECOVERY INDEX READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR 1 2 3 4 5 6 EMA20010 CONTENTS ...

Page 5: ...or serial number 1 1 EMISSION CONTROL INFORMATION 1 2 Star labels 1 3 SAFETY INFORMATION 1 4 IMPORTANT LABELS 1 6 BASIC BOATING RULES 1 7 FUELING INSTRUCTIONS 1 11 Gasoline 1 12 ENGINE OIL 1 13 BATTERY REQUIREMENT 1 14 PROPELLER SELECTION 1 15 START IN GEAR PROTECTION 1 16 1 2 3 4 5 6 E ...

Page 6: ... label attached to the port side of the clamp bracket Record your outboard motor serial num ber in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor serial number E 1 401012 YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON ...

Page 7: ...n label New Technology 4 stroke EM Manufactured date label This label is attached to the clamp brack et 2 Manufactured date label EMISSION CONTROL INFORMATION ENGINE FAMILY THIS ENGINE CONFORMS TO 2001 U S EPA REGULATIONS FOR MARINE SI ENGINES THIS ENGINE CONFORMS TO 2001 CALIFORNIA EMISSION REGULATIONS FOR SI MARINE ENGINES REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS...

Page 8: ...nal carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 stan dards for marine engines Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low Emission The three star label identifi...

Page 9: ...fully Make sure there are no gas fumes or leaking fuel before starting the engine 8 This product emits exhaust gases which contain carbon monoxide a colorless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 8 Check throttle shift and steering for proper opera...

Page 10: ...y organiza tions 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 11: ...ral position 6E0 83627 41 WARNING 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 6G8 13444 41 CAUTION Transport and store the engine only as shown Otherwise engine damage could result from leaki...

Page 12: ...r dened vessel These rules determine which vessel has the right of way and what each vessel should do Stand on vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision When you maintain your direction and speed the other vessel will be able to determine how best to avoid you Give way vessel The vessel which does not have the right...

Page 13: ...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 14: ...er vessels in narrow channels 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 passage of a power drive...

Page 15: ...E L old new 2 2 2 A L L Odd number increasing toward head of naviga MAIN CHANNEL BUOYS 1 3 5 7 tion Leave to port left proceeding upstream LIGHTED BUOY Port Hand White Light Green Light old new old new old new LIGHTED BUOY Starboard Hand 2 4 6 Even number increasing toward head of naviga tion Leave to starboard right proceeding up stream White Light Red Light A LIGHTED SAFE WATER BUOY No number Ma...

Page 16: ...tely with dry rags 8 Do not overfill the fuel tank 8 Tighten the filler cap securely after refueling 8 If you should swallow some gasoline inhale a lot of gasoline vapor or get gasoline in your eyes get immediate medical attention 8 If any gasoline spills onto your skin immediately wash with soap and water Change clothing if gasoline spills on it 8 Touch the fuel nozzle to the filler open ing or f...

Page 17: ...ating of 86 Pump Octane Number R M 2 EMB50610 Gasohol There are two types of gasohol gasohol containing ethanol and that containing 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 Yamaha because it can cause fuel system damage or engine performance prob lems ...

Page 18: ... motor oil with a combination of corresponding SAE and API as shown in the chart cC All 4 stroke engines are shipped from the factory without engine oil E 1 13 Engine oil quantity See Chapter 4 Specifications 001162 SAE API SE SF SG SH SJ 10W 30 10W 40 ...

Page 19: ...which does not meet specifications is used the electric system could perform poorly or be overloaded causing electric system damage For electric start models choose a battery which meets the following specifications EMU01859 EMU01783 cC A battery cannot be connected to models that do not have a rectifier or Rectifier Regulator Models without a rectifier or Rectifier Regulator F15MH 8 If you wish t...

Page 20: ...dverse effect on the engine Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications but there may be uses where a propeller with a different pitch would be more appropriate For a greater operating load a smaller pitch propeller is more suitable as it enables the correct engine speed to be main tained Conversely a larger pitch pro peller is more suitabl...

Page 21: ...e 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 boat loads reduce the throttle setting to maintain the rpm in the proper operating range 1 Propeller diameter in ...

Page 22: ...E MEMO ...

Page 23: ... 3 Starter button 2 3 Tiller handle 2 4 Remote control 2 7 Steering friction adjusting lever 2 11 Trim angle adjusting rod 2 11 Warning indicator s 2 11 Tilt lock mechanism 2 12 Tilt support knob 2 12 Tilt support bar 2 12 Power tilt unit 2 12 Top cowling lock lever 2 13 Flushing device 2 13 WARNING SYSTEM 2 14 Overheat warning 2 14 Low oil pressure warning 2 14 1 2 3 4 5 6 E ...

Page 24: ...let 7 Trim angle adjusting rod 8 Clamp bracket 9 Recoil starter handle 0 Choke knob q Warning indicator w Gear shift lever e Tiller handle r Steering friction adjusting lever t Transom clamp handle y Rope attachment u Tilt lock lever i Flushing device o Starter button p Power tilt switch a Tilt support knob s Remote control May not be exactly as shown also may not be included as standard equipment...

Page 25: ...screw If equipped EMC31010 Fuel hose joint This connector is provided for connecting or disconnecting fuel hose EMC41110 Fuel meter This meter is on the fuel tank cap It shows current fuel quantity in the fuel tank approximately EMC51010 Fuel tank cap This cap is for filling fuel To remove it turn it counterclockwise EMC61010 Air vent screw This screw is on the fuel tank cap To loosen it turn it c...

Page 26: ...ward 3 Reverse E 406023 w q e 226011 209014 225011 EMC42210 CHOKE KNOB Pulling out this knob setting it to ON supplies a rich mixture required to start the engine EMC44010 RECOIL STARTER HANDLE If equipped Pull the handle gently until resistance is felt Then vigorously pull the handle straight out to crank the engine to start it EMC46010 STARTER BUTTON for Tiller control model When you push the st...

Page 27: ...d switch 5 Power tilt switch if equipped q w e r 508015 000613 t 503034 508013 q EMC40210 Throttle indicator The fuel consumption curve on the throt tle indicator shows the relative amount of fuel consumed for each throttle position Choose the setting that offers the best performance and fuel economy for the desired operation 1 Throttle indicator EMC40011 Throttle control grip The throttle control...

Page 28: ... result in an accident E 502016 Resistance Knob Increase Turn clockwise Decrease Turn counterclockwise 506021 EMC27110 Engine stop button Pushing this button opens the ignition cir cuit and stops the engine EMC28210 Engine stop lanyard switch The lock plate on the end of the lanyard must be attached to the engine stop switch for the engine to run The lanyard should be attached to a secure place on...

Page 29: ...so without engine power the boat could slow rapidly This could cause people and objects in the boat to be thrown forward NOTE The engine cannot be started with the lock plate removed 1 Lock plate 2 Lanyard q w 000647 000610 DN UP EMU01323 Power Tilt Switch The power tilt adjusts the motor angle in relation to the transom The power tilt switch is located on the tiller handle Pushing the switch UP t...

Page 30: ...tilt switch 7 Throttle friction adjusting screw 000608 w q e r t y u EMU00098 Remote Control Lever Moving the lever forward from the Neutral 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 accelera...

Page 31: ...The neutral throttle lever will operate only when the remote control lever is in Neutral The remote control lever will operate only when the neutral throttle lever is in the closed position 1 Fully open 2 Fully closed EMU00101 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 circ...

Page 32: ...h 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 Also without engine power the boat could slow rapidly This could cause people and objects in the boat to be thrown forward NO...

Page 33: ...G UP DOWN 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 adjusting screw If there is too much resistance it may...

Page 34: ...h could result in an accident E 408033 001776 223013 q EMU01297 TRIM ANGLE ADJUSTING ROD The position of the trim angle adjusting rod determines the minimum trim angle of the outboard motor in relation to the transom EMU01128 WARNING INDICATOR S If the engine develops a condition moni tored by the warning system an indicator will come on Refer to the WARNING SYSTEM sec tion for details 1 Warning i...

Page 35: ...ilt lock lever EMD48010 TILT SUPPORT BAR The tilt support bar 1 keeps the outboard motor in the tilted up position 000603 EMU00155 TILT SUPPORT KNOB To keep the outboard motor in the tilted up position push the tilt support knob under the swivel bracket q w 000615 EMU01348 POWER TILT UNIT This unit tilts the motor up and down and is controlled via the power tilt switch 1 Power tilt unit 2 Power ti...

Page 36: ...e sure it fits properly in the rubber seal Then lock the cowling again by moving the lever upward 1 Top cowling lock lever 301045 q q 000935 EMU01146 FLUSHING DEVICE This device 1 is used to clean the cooling water passages of the motor using a gar den hose and tap water NOTE Refer to Cleaning Cooling water Passages in Chapter 4 for instructions on usage ...

Page 37: ...verheat warning device If the engine temperature rises too high the warning device will activate 1 Included N A If the warning system has been activated stop the engine and check the water inlet for clogging 605021 Activation of Tiller Remote warning device control control model model The engine speed will automatically decrease 1 1 to about 2 000 r min The overheat warning indicator will come on ...

Page 38: ...l level and add oil as needed If the oil level is correct consult your Yamaha dealer cC Do not continue to run the engine if the low oil pressure lamp is ON Serious engine damage may occur E 223013 Activation of Tiller Remote warning device control control model model Engine speed will automatically decrease 1 1 to about 2 000 r min The low oil pressure warning indicator 1 1 will come on The buzze...

Page 39: ...6 Checking the engine oil level 3 7 FILLING FUEL 3 8 STARTING ENGINE 3 9 WARMING UP ENGINE 3 16 SHIFTING 3 17 Forward 3 17 Reverse 3 18 STOPPING ENGINE 3 19 TRIMMING OUTBOARD MOTOR 3 20 Adjusting trim angle 3 21 TILTING UP DOWN 3 24 CRUISING IN SHALLOW WATER 3 28 CRUISING IN OTHER CONDITIONS 3 31 Cruising in salt water 3 31 Cruising in turbid water 3 31 1 2 3 4 5 6 E ...

Page 40: ...e 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 outboar...

Page 41: ...he 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 l...

Page 42: ...thereby reduce engine efficiency Mount the engine so that the anti cavita tion plate is between the bottom of the boat and a level 25 mm 1 in below it NOTE 8 The optimum mounting height of the outboard motor is affected by the boat motor combination and the desired use Test runs at different heights can help determine the opti mum mounting height 8 Refer to the section TRIMMING OUT BOARD MOTOR for...

Page 43: ...ly check the screws for tight ness during operation 2 An engine restraint cable or chain should be used Attach one end to the engine restraint cable attachment point and the other to a secure mounting point on the boat Otherwise the engine could be com pletely lost if it accidentally falls off the transom Secure the clamp bracket to the tran som with the bolts provided with the outboard For detail...

Page 44: ...ning in time 10 hours EMF53711 Run the engine under load in gear with a propeller installed as follows 1 For the first hour of operation Run the engine at 2 000 r min or at approximately half throttle 2 For the second hour of operation Run the engine at 3 000 r min or at approximately three quarter throttle and during this period run it at full throttle for approximately one minute every ten minut...

Page 45: ...ge can occur EMF41110 Fuel 8 Check to be sure you have plenty of fuel for your trip 8 Make sure there are no fuel leaks or gasoline fumes 8 Check fuel line connections to be sure they are tight 8 Be sure the fuel tank is positioned on a secure flat surface and that the fuel hose is not twisted or flattened or likely to contact sharp objects EMF42210 Oil 8 Check the level of the oil in the sump wit...

Page 46: ...ting 8 Look for loose or damaged fasteners 8 Check the propeller for damage E 201016 q 201012 w e q EMU01436 CHECKING THE ENGINE OIL LEVEL 1 Put the outboard motor in an upright position not tilted 2 Pull out the oil dipstick and wipe it clean 3 Completely re insert the dipstick and pull out it again 4 Check the oil level using the dipstick to be sure the level falls between the upper and lower ma...

Page 47: ...ives such as aromatics and oxy genates has increased These additives are important for the engines in passen ger cars but they can have detrimental effects in marine engines because of increased deposits in the combustion chamber When enough deposits collect piston rings begin sticking Performance drops and engine wear increases dramati cally While many additives available may reduce deposits Yama...

Page 48: ...t gases which contain carbon monoxide a col orless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 1 If there is an air vent screw on the fuel tank cap loosen it 2 or 3 turns 2 If there is a fuel joint on the motor firmly connect the fuel line to the joint Th...

Page 49: ...he engine stop switch w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering ...

Page 50: ...e 8 If the choke knob is left pulled out after the engine starts the engine will stall 8 Pull the starter handle slowly until you feel resistance Then give a strong pull straight out to crank and start the engine Repeat it if neces sary 9 After the engine starts return the starter handle slowly to the original position before releasing it 10 Return the throttle to the fully closed position E 22601...

Page 51: ... return it to the original position 10 Return the throttle control grip slowly to the fully closed position so that the engine does not stall cC 8 Never push the starter switch while the engine is running 8 Do not keep the starter motor turning for more than 5 seconds If the starter motor is turned continuously for more than 5 seconds the battery will be quickly discharged thus making it impossibl...

Page 52: ... 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 Loss of engine power means the loss of most...

Page 53: ...tle lever is possible only when the remote control lever is in N 8 Press in and hold the main switch to operate the remote choke system The remote choke switch returns to its home position when you release your hand Therefore keep the switch pressed in NOTE 8 It is not necessary to use the choke when the engine is warm 8 Set the choke knob to the home posi tion or the remote choke system will not ...

Page 54: ...Do not keep the starter motor turning 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 seconds return the main switch to ON wait 10 seconds and then crank the engine again ...

Page 55: ...erious engine damage could occur Check the oil level and add oil if necessary If the cause for the low oil pressure warning indicator cannot be found consult your Yamaha dealer 8 A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages If water is not flowing out of the pilot hole at all times while the engine is running do not continue...

Page 56: ...e first so that the engine idles or runs at low speeds 503012 406024 N F 701043 N F EMU00265 FORWARD Tiller control model 1 Place the throttle control grip in the fully closed position 2 Turn the gear shift lever quickly and firmly from Neutral to Forward Remote control model Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from Neutral to Forw...

Page 57: ...4 1 Place the throttle control grip in the fully closed position for Tiller control model 2 Check that the tilt lock lever for Manual tilt Hydro tilt model is in the locked position Tiller control model 3 Turn the gear shift lever quickly and firmly from Neutral to Reverse Remote control model 3 Pull up the neutral interlock trigger if equipped and move the remote con trol lever quickly and firmly...

Page 58: ...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 NOTE The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop lanyard switch then turning the main switch to OFF EMU00277 1 Push and hold th...

Page 59: ... 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 60: ...ake test runs with the trim set to differ ent angles to find the position that works best for your boat and operating condi tions w 8 Stop the engine before adjusting the trim angle 8 Use care to avoid being pinched when removing or installing the rod 8 Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any signs of instabili ty or control problems I...

Page 61: ...n cause loss of control 8 Use the power tilt switch located on the bottom engine cowling if equipped only when the boat is at a complete stop with the engine off 1 Place the gear shift lever in the neu tral position 2 Tilt the engine to the desired angle using the power tilt switch NOTE Stay within the trim operating angle when trimming the outboard motor using the power tilt system To raise the b...

Page 62: ...nd economy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces performance further and the boat may porpoise hop in the water which could throw the operator and passengers overboard Bow Down When the bow of the boat is down it is easier to accelerate from a standing start onto plane To...

Page 63: ...er heating can result 8 Do not tilt up the engine by pushing the steering handle as this could break the handle 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 if the engine will be tilted for more than a few minutes Othe...

Page 64: ... position 4 Hold the rear of the top cowling with one hand and fully tilt the engine up 5 The tilt support bar turns to the locked position automatically 402016 403 3 403055 EMU00300 PROCEDURE FOR TILTING DOWN Manual tilt model 1 Place the tilt lock lever in the lock position 2 Slightly tilt up the engine until the tilt support bar is released automatically 3 Tilt down the engine 406023 N ...

Page 65: ...om the motor 2 Push the power tilt switch UP until the outboard has tilted up completely 3 Push the tilt support knob into the clamp bracket to support the engine w After tilting the engine be sure to sup port it with the tilt support knob Otherwise the engine could fall back down suddenly if oil in the power tilt unit should lose pressure ...

Page 66: ... FOR TILTING DOWN Power tilt model 1 Push the power tilt switch UP until the engine is supported by the tilt rod 2 Pull out the tilt support knob 3 Push the power tilt switch DN Down to lower the engine to the desired position ...

Page 67: ...echa nism does not work while the shallow water cruising system is being used Hitting an underwater obstacle could cause the engine to lift out of the water resulting in loss of control 8 Use extra care when operating in reverse Too much reverse thrust can cause the engine to lift out of the water increasing the chance of acci dent and personal injury 8 Return the engine to its normal posi tion as...

Page 68: ...the engine The tilt support bar will lock automatically supporting the engine in a partially raised position NOTE This motor has 2 positions for shallow water cruising RETURNING TO ORIGINAL POSITION 1 Place the tilt lock lever in the lock position 2 Slightly tilt up the engine until the tilt support bar automatically returns to the free position 3 Then slowly lower the engine to the normal positio...

Page 69: ...its normal posi tion as soon as the boat is back in deeper water cC Do not tilt up the outboard motor so that the cooling water inlet of the lower unit is above the surface of the water when setting for and cruising in shallow water Otherwise severe damage from overheat ing can result N 701015 UP DN 701034 UP DN 000610 DN UP EMU01320 PROCEDURE 1 Place the gear shift lever in the neu tral position ...

Page 70: ...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 3 31 ...

Page 71: ...14 Checking fuel system 4 15 Inspecting fuel filter 4 16 Inspecting idling speed 4 17 Changing engine oil 4 18 Replacing fuse 4 20 Checking wiring and connectors 4 21 Exhaust leakage 4 21 Water leakage 4 21 Checking power tilt system 4 22 Checking propeller 4 23 Changing gear oil 4 25 Cleaning fuel tank 4 26 Inspecting and replacing anode s 4 27 Checking battery 4 28 Checking bolts and nuts 4 30 C...

Page 72: ...EX mm in Battery Min cold cranking amps CCA SAE amps at 18 C 0 4 F Min marine cranking amps MCA ABYC amps at 0 C 32 F Min reserve capacity RC SAE minutes Alternator output V A W Starting carburetion system 4 stroke OHC L2 323 19 71 59 0 59 0 2 32 2 32 CDI system DPR6EA 9 0 8 0 9 0 031 0 035 Tiller control Manual start 0 15 0 25 0 006 0 010 0 20 0 30 0 008 0 012 12 80 Choke valve DRIVE UNIT Gear po...

Page 73: ...system DPR6EA 9 0 8 0 9 0 031 0 035 Remote control Electric start 0 15 0 25 0 006 0 010 0 20 0 30 0 008 0 012 245 323 52 12 10 Choke valve Forward Neutral Reverse 2 08 27 13 Power tilt J Regular unleaded gasoline Minimum 86 25 6 60 5 50 4 stroke motor oil SE SF SG SH SJ 10W 30 10W 40 1 0 1 06 0 88 1 2 1 27 1 06 Hypoid gear oil SAE90 250 8 45 8 80 18 1 8 13 16 1 6 11 27 2 7 20 18 1 8 13 1 001 39 4 ...

Page 74: ...your Yamaha dealer w 8 Never get under the lower unit while it is tilted even if a motor support bar is used Severe injury could occur if the outboard accidentally falls 8 USE CARE when transporting fuel tank whether in a boat or car DO NOT fill fuel container to maximum capacity Gasoline will expand consid erably as it warms up and can build up pressure in the fuel container This can cause fuel l...

Page 75: ...fold the tiller handle and lean the motor on the tiller handle to keep in a horizontal position cC Keep the power unit higher than the pro peller at all times Otherwise cooling water can run into the cylinder which could result in damage NOTE Place a towel or the like under the out board motor to protect it from damage ...

Page 76: ...transporting and storing it 8 Do not place the engine on its side before the cooling water has drained from it completely or water may enter the cylinder through the exhaust port and cause problems 8 Store the engine in a dry well ventilat ed place not in direct sunlight 1 Vertical position 2 Horizontal position on the port side 000923 102065 EMK21010 Filling Fuel Tank Fill the fuel tank with fres...

Page 77: ...nd other rotating parts while engine is running EMK25510 8 Flushing in a Water Tank cC If the fresh water level is below the level of the anti cavitation plate or if the water supply is insufficient engine seizure may occur 1 Remove the engine top cowling 2 Install the outboard motor on the water tank 3 Fill the tank with fresh water to above the level of the anti cavitation plate 4 Run the engine...

Page 78: ...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 605024 q w 4 7 E EMK27011 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the out board with fresh water and dry off completely 2 Spray the engine s exterior with Yamaha Silicone Protectan...

Page 79: ...ing in a closed space Always wear eye protection when working near batteries KEEP OUT OF REACH OF CHILDREN 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 cas...

Page 80: ...ission control system must be performed by an authorized Yamaha marine dealership A service manual is available for purchase through a Yamaha dealer for owners who have the mechanical skills tools and other equipment necessary to perform maintenance not covered by this owner s manual EMK33011 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equiva lents of the ...

Page 81: ...ning adjustment replacement Greasing points Greasing Gear oil Change Fuel system Inspection Fuel filter disposable Inspection replacement 1 1 1 Fuel tank Yamaha portable tank Cleaning Idling speed carburetor models Inspection adjustment 1 1 Anode s Inspection replacement 1 1 1 Cooling water passages Cleaning Propeller and cotter pin Inspection replacement Timing belt Inspection replacement 1 1 Bat...

Page 82: ...4 11 E 500 hours 1000 hours 2 5 years 5 years Timing belt Replacement 1 Item Actions Every ...

Page 83: ...4 12 E 103192 EML00011 GREASING Yamaha marine grease Water resistant grease ...

Page 84: ...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 85: ... 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 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 mm 23 32 in EMU16350 CHECKING TOP COWLING Check the fitting of the top cowling b...

Page 86: ...und it should be repaired immediately by Yamaha dealer or other qualified mechan ic Checking points 8 Fuel system parts leakage 8 Fuel hose joint leakage 8 Fuel hose cracks or other damage 8 Fuel connector leakage w Leaking fuel can result in fire or explo sion 8 Check for fuel leakage regularly 8 If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper repair...

Page 87: ...cigarettes flames or other sources of ignition 8 This procedure will allow some fuel to spill Catch fuel in a rag Wipe up any spilled fuel immediately 8 The fuel filter must be reassembled carefully with O ring filter cup and hoses in place Improper assembly or replacement can result in a fuel leak which could result in a fire or explosion hazard 207054 EMK50310 Check the fuel filter periodically ...

Page 88: ...th the flushing attachment in a test tank or with the outboard motor in the water 1 Start the engine and allow it to warm up fully in neutral until it is running smoothly If the outboard motor is mounted on a boat be sure the boat is tightly moored 2 Verify whether the idle speed is set to specification For idle speed specifica tions see Specifications in this chapter NOTE Correct idling speed ins...

Page 89: ...ition not tilt ed when checking and changing the engine oil 8 If the oil level is above the upper level mark drain until the level meets the specified capacity Overfilling the oil may cause leakage or damage 1 Put the outboard motor in an upright position not tilted 2 Prepare a suitable container which can hold a larger amount than the engine oil capacity Loosen and remove the drain bolt 1 while h...

Page 90: ...re warning lamp turns off Make sure that there are no oil leaks cC If the oil lamp does not turn off or if there are oil leaks stop the engine and find the cause Continued operation with a problem could cause severe engine damage If the problem cannot be found and corrected consult your Yamaha deal er 6 Turn off the engine and wait 3 min utes Recheck the oil level using the dipstick to be sure the...

Page 91: ...correct fuse or a piece of wire may allow excessive current flow This could cause electrical system damage and a fire hazard NOTE If the new fuse blows again immediately consult a Yamaha dealer 1 Fuse holder 2 Fuse 20A 3 Spare fuse 20A NOTE 8 For disposal of used oil consult your Yamaha dealer 8 The oil should be changed more often when the engine is operated under adverse conditions such as exten...

Page 92: ...onnector is engaged securely EMK78110 EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and crank case EMK78210 WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head and crank case 606011 ...

Page 93: ...lt unit for any sign of oil leaks 2 Operate each of the power tilt switch es on remote control and engine bot tom cowling if equipped to check that all switches work 3 Tilt up the motor and check that the tilt rod 1 is pushed out completely 4 Check that the tilt rod is free of corro sion or other flaws 5 Operate the motor to tilt down Check that the tilt rod operates smoothly NOTE If any operation...

Page 94: ...your hand to hold the pro peller when loosening or tightening the propeller nut Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning EML09010 Propeller checking Point 8 Check each of the propeller blades for wear erosion from cavitation or ventila tion or other damage 8 Check the splines for wear and damage 8 Check for fish line winding around the p...

Page 95: ...rosion resistant grease to the pro peller shaft 2 Install the thrust washer and propeller on the propeller shaft 3 Install the washer and tighten the pro peller nut to the specified torque 4 Align the propeller nut with the pro peller shaft hole Insert a new cotter pin in the hole and bend the cotter pin ends NOTE When the propeller nut does not align with the propeller shaft hole after tighten in...

Page 96: ...motor acci dentally falls 1 Tilt the outboard motor so that the gear oil drain screw is at the lowest point possible 2 Place a suitable container under the gear case 3 Remove the gear oil drain screw 1 4 Remove the oil level plug 2 to allow the oil to drain completely cC Inspect the used oil after it has been drained If the oil is milky water is get ting into the gear case which can cause gear dam...

Page 97: ...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 immediately 8 Reassemble the fuel tank carefully Improper assembly can result in a fuel le...

Page 98: ...screws firmly 902054 604011 224012 000606 EMU14622 INSPECTING AND REPLACING ANODE S Yamaha outboard motors are protected from corrosion by sacrificial anodes Inspect the external anodes periodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes cC Do not paint anodes as this would ren der them ineffective NOTE Inspect ground leads attached...

Page 99: ...lush with water 8 EYES Flush 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 hydro gen gas therefore you should always fol low these preventive measures 8 Charge batteries in a well ventilated area 8 Kee...

Page 100: ...el when neces sary Top up only with distilled water or pure de ionized water suitable to use in batteries 2 Always keep the battery in a good state of charge Installing a 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 wil...

Page 101: ...or 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 EML40011 CHECKING BOLTS AND NUTS 1 Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torque 2 Check the tightening torque of other bol...

Page 102: ...is connect the garden hose 3 4 When flushing is complete reinstall the garden hose connector 2 on the fitting 1 on the bottom cowling Tighten the connector securely cC Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal opera tion Water will leak out of the connector instead of cooling the engine which can cause serious overheating Be ...

Page 103: ...ratches nicks or flaking paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas A touch up paint is available from a Yamaha dealer 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 for y...

Page 104: ...E MEMO ...

Page 105: ...0 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Power tilt will not operate 5 5 Starter will not operate 5 6 Treatment of submerged motor 5 9 1 2 3 4 5 6 E ...

Page 106: ...ric overload and repair Replace fuse with one of correct amperage 4 Have serviced by a Yamaha dealer 5 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 damaged igniti...

Page 107: ...ve adjustment incorrect 19 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 al...

Page 108: ...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 109: ...amaha 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 E Engine power loss F Engine vibrates excessively 1 Propeller damaged 2 Propeller shaft damaged 3 Weeds or other foreign matter tangled on propeller 4 Motor mounti...

Page 110: ...spect the boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and carefully 4 Have a Yamaha dealer inspect the outboard motor before operating it again E 607011 q 000605 EMU01321 POWER TILT WILL NOT OPERATE If the engine cannot be tilted up or down with the power tilt because of a dis charged battery or a failure with the power tilt unit the engine can be tilted ma...

Page 111: ... could unexpected ly 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...

Page 112: ...n the carburetor to operate the choke system when the engine is cold After the engine starts return the lever to the original position 4 Remove the starter flywheel cover after removing 3 bolts Disconnect the wire leads connected the starter flywheel cover 5 Prepare the engine for starting See STARTING ENGINE for procedures Be sure the engine is in Neutral and that the lanyard lock plate is attach...

Page 113: ...f the emer gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise 8 Pull the rope slowly until resistance is felt 9 Give a strong pull straight out to crank and start the engine Repeat if necessary ...

Page 114: ...he spark plug holes downward to allow any water mud or contami nants to drain 3 Drain the fuel from the carburetor fuel filter and fuel line Drain the engine oil completely 4 Fill the sump with the fresh engine oil as the same quantity as the engine oil capacity 5 Feed engine fogging oil or engine oil through the carburetor s and spark plug hole s while cranking the engine with the manual starter ...

Page 115: ...EMP00010 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 116: ...tom 4 32 Connecting the battery 4 29 Cruising in other conditions 3 31 Cruising in salt water 3 31 Cruising in shallow water 3 28 Cruising in turbid water 3 31 D Disconnecting the battery 4 30 E Emergency starting engine 5 7 Emission control information 1 2 Engine oil 1 13 Engine stop button 2 5 Engine stop lanyard switch 2 5 2 9 Exhaust leakage 4 21 F Filling fuel 3 8 Filling fuel tank 4 5 Flushi...

Page 117: ...ecifications 4 1 Star labels 1 3 Start in gear protection 1 16 Starter button 2 3 Starter will not operate 5 6 Starting engine 3 9 Steering friction adjusting lever 2 11 Stopping engine 3 19 Storing outboard motor 4 5 T Temporary action in emergency 5 5 Throttle control grip 2 4 Throttle friction adjusting knob 2 5 Throttle friction adjusting screw 2 10 Throttle indicator 2 4 Tiller handle 2 4 Til...

Page 118: ...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 119: ...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 120: ...em 8 Power Trim and Tilt Assembly WARRANTY REGISTRATION To be eligible for warranty coverage the outboard motor must be registered with Yamaha Motor Corporation U S A Warranty registration can be accomplished by any authorized Yamaha Outboard Motor Dealer Upon receipt of the registration an Owner s Warranty Card will be sent by Yamaha to the registered purchaser OBTAINING REPAIRS UNDER WARRANTY To...

Page 121: ...he warranty period A The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision dam ages Q What are some examples of abnormal strain neglect or abuse A These terms are general and overlap each other in areas Specific examples include Running the machine out of oil operating the machine with a broken or damaged part which causes anoth...

Page 122: ...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 123: ...ll receive service If you need more information about your warranty coverage or your Yamaha outside the U S A or Canada please contact an autho rized Yamaha dealer in your country 2 Keep a copy of your sales contract or invoice for the purchase of your Yamaha and present it if you need warranty repairs This document should show the date of purchase which is important evidence the repairing dealer ...

Page 124: ...Printed in Japan April 2003 0 5 1 66M 28199 17 F15AMH F15AEH F15AEP F15AEHP E Printed on recycled paper ...

Page 125: ...r au détail OUTBOARD MOTOR MODEL AND SERIAL NUMBER From I D label on clamp bracket MODÉLE ET NO DE SÉRIE DU MOTEUR HORS BORD sur l étiquette d identification de la presse de fixation For Dealer Use Only A l usage du concessionnaire YAMAHA DEALER NUMBER NO DU CONCESSIONNAIRE YAMAHA DEALER NAME NOM DU CONCESSIONNAIRE DATE SOLD DATE DE LIVRAISON OWNER S NAME NOM DU PROPRIÉTAIRE ADDRESS ADRESSE PHONE ...

Page 126: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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