Yamaha F200C Owner'S Manual Download | Manualshive

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4-14

E

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

NOTE:

@

If a torque-wrench is not available when you
are fitting a spark plug, a good estimate of
the correct torque is 1/4 to 1/2 a turn past
finger-tight. Have the spark plug adjusted to
the correct torque as soon as possible with a
torque-wrench.

@

1

Spark plug gap

2

Spark plug I.D. mark (NGK)

Spark plug torque:
Refer to “SPECIFICATIONS”, page 4-1.

Initial of spark
plug I.D. mark

Plug wrench size

B

21 mm (13/16 in.)

C, L

16 mm (5/8 in.)

D

18.3 mm (23/32 in.)

U69J13.book Page 14 Thursday, March 20, 2003 10:48 AM

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Summary of Contents for F200C

Page 1: ...F200C LF200C ...

Page 2: ......

Page 3: ...ON indicates special precau tions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current prod uct information available at the time of print ing there may be minor discrepancies between your machine and...

Page 4: ...E EMU00003 CONTENTS READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR GENERAL INFORMATION 1 BASIC COMPONENTS 2 OPERATION 3 MAINTENANCE 4 TROUBLE RECOVERY 5 INDEX 6 ...

Page 5: ...els 1 2 Star labels 1 3 SAFETY INFORMATION 1 4 IMPORTANT LABELS 1 6 Warning labels 1 6 BASIC BOATING RULES Rules of the road 1 7 Steering and sailing rules and sound signals 1 7 Rules when encountering vessels 1 8 Other special situations 1 9 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 ...

Page 6: ...number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen 1 Outboard motor serial number EMU00008 KEY NUMBER If a main key switch is equipped with the motor the key identification number is stamped on your key as shown in the illus tration Record this number in the space provided for reference in case you need...

Page 7: ... regulations for marine SI engines See the label affixed to your engine for details Approval label of Emission control certif icate This label is attached to the bottom cowling 1 Emission control information label New Technology 4 stroke HPDI EM Manufactured date label This label is attached to the clamp bracket 2 Manufactured date label ...

Page 8: ...ntional carbureted two stroke engines These engines are equiva lent to the U S EPA s 2006 standards 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 meet ing these standards have 20 lower emis sions than One Star Low Emission engines Three Stars Ultra Low Emission The three star label id...

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

Page 10: ...organizations includ ing 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 Associa tion NMMA 401 N Michigan Ave Chicago Il 60611 Marine Retailers Association of America 155 N Michigan Ave Chicago Il 60601 ...

Page 11: ...1 6 E EMU00014 IMPORTANT LABELS WARNING LABELS 1 ...

Page 12: ...dened ves sel 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: ...her power vessel head on and 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 clo...

Page 14: ... 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 driven vessel which can navi gate only in ...

Page 15: ...1 10 E Remember markings may vary by geo graphic location Always consult local boat ing authorities before driving your boat in unfamiliar waters ...

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

Page 17: ...ing of 86 Pump Octane Number R M 2 EMU00027 Gasohol There are two types of gasohol gasohol containing ethanol and that containing meth anol 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 perfor mance problems ...

Page 18: ...mended engine oil 4 stroke motor oil with a combination of cor responding SAE and API as shown in the chart CAUTION All 4 stroke engines are shipped from the factory without engine oil Engine oil quantity See Chapter 4 Specifications ...

Page 19: ...perform poorly or be overloaded causing electric system damage For electric start models choose a battery which meets the following specifications EMU01861 EMU01787 NOTE The engine cannot be started if battery volt age is too low Minimum cold cranking amps CCA SAE 512 amps at 18 C 0 4 F Minimum marine cranking amps MCA ABYC 675 amps at 0 C 32 F Minimum reserve capacity RC SAE 182 minutes ...

Page 20: ...te For a greater operat ing load a smaller pitch propeller is more suitable as it enables the correct engine speed to be maintained Conversely a larger pitch propeller is more suitable for a smaller operating load Yamaha dealers stock a range of propellers and can advise you and install a propeller on your outboard that is best suited to your application NOTE At full throttle and under a maximum b...

Page 21: ...PROPEL LER for instructions on propeller removal and installation EMU01209 START IN GEAR PROTECTION Yamaha outboard motors or Yamaha approved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is Neutral Always select Neutral before starting the engine ...

Page 22: ...1 17 E MEMO ...

Page 23: ...FUNCTIONS 2 2 Remote control 2 2 Trim tab 2 8 Power trim tilt switch 2 9 Digital tachometer 2 10 Digital speedometer 2 13 Fuel management meter 2 16 Tilt support lever 2 19 Top cowling lock levers 2 20 Flushing device 2 20 WARNING SYSTEM 2 21 Overheat warning 2 21 Low oil pressure warning 2 22 ...

Page 24: ...7 Top cowling lock levers 8 Power trim and tilt switch 9 Flushing device 0 Remote control box Side mount type A Remote control box Binnacle mount type B Switch panel For use with A C Digital speedometer D Digital tachometer E Fuel management meter May not be exactly as shown also may not be in cluded as standard equipment on all models ...

Page 25: ...addition the electrical switches are mounted on the remote control box È Side mount remote control box É Binnacle mount remote control box Ê Switch panel for use with É 1 Remote control lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Free accelerator 5 Main switch 6 Engine stop lanyard switch 7 Power trim tilt switch 8 Throttle friction adjusting screw ...

Page 26: ...ntinue 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 acceler ate 1 Neutral 2 Forward 3 Reverse 4 Shift 5 Fully closed 6 Throttle 7 Fully open EMU00099 Neutral Interlock Trigger To shift out of Neutral the neutral interlock trigger of the remote control lever must first be pulled up ...

Page 27: ...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 OFF Electrical circuits switched off The key can be removed ON Electrical circuits switched on The key cannot be removed START Starter motor will turn ...

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

Page 29: ...efer to the sections Adjusting Trim Angle and Tilting Up Down in Chapter 3 for instructions on usage EMU00106 Free Accelerator To open the throttle without shifting into either Forward or Reverse push the free accelerator button and turn the remote con trol lever NOTE The free accelerator button can be oper ated only when the remote control lever is in the Neutral position After the button is push...

Page 30: ...ol lever and can be set according to operator preference An adjusting screw is located on the front of the remote control box WARNING Do not overtighten the friction adjusting screw If there is too much resistance it may be difficult to move the lever which could result in an accident Resistance Screw Increase Turn clockwise Decrease Turn counterclockwise ...

Page 31: ...n installed or replaced to be sure steering is correct Be sure you have tightened the bolt after adjusting the trim tab 1 Trim tab 2 Bolt 3 Cap if equipped CAUTION 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 Boat tends to veer The fin of trim tab To the left port side Turn to the left A...

Page 32: ...switch button is released the motor will stop in its current position WARNING Use the power trim tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the engine off Attempting to use the cowl ing mounted power trim tilt switch while the boat is moving could increase the risk of falling overboard and could dis tract the operator increasing the risk of colli...

Page 33: ...rheat warning indica tor 1 Tachometer 2 Trim meter 3 Hour meter 4 Low oil pressure warning indicator 5 Overheat warning indicator 6 Set button 7 Mode button NOTE All segments of the display will light momen tarily after the main switch is turned on and will return to normal thereafter EMU00136 Tachometer This meter shows the engine speed ...

Page 34: ...7 Hour Meter This meter shows the number of hours the engine has been run It can be set to show the total number of hours or the number of hours for the current trip The display can also be turned on and off Changing the display format Pressing the MODE button changes the display format in the following circular pat tern Total hours Trip hours Display off Resetting the trip hours Simultaneously pr...

Page 35: ...ate the oil level in the engine Use the Oil Level Gauge to check the remaining oil quantity Refer to the section CHECKING THE ENGINE OIL LEVEL for details EMU01553 Overheat Warning Indicator If the engine temperature rises too high the warning indicator will start to blink Refer to OVERHEAT WARNING for details 1 Overheat warning indicator CAUTION Do not continue to operate the engine if a warning ...

Page 36: ...n as a check After a few seconds the meters will change to normal operation Watch the meter when turning on the main switch to make sure all segments come on EMU00141 Speedometer This meter shows the boat speed NOTE The speedometer displays km h mph or knots depending upon operator preference Select the desired unit of measurement by setting the selector switch on the back of the meter See the ill...

Page 37: ...ata will be lost if the battery is disconnected EMU01275 Clock This meter shows the current time Repeatedly push and release the mode button until the indicator on the face of the meter points to TIME To set the clock be sure the meter is in the TIME mode Press the set button the hour display will begin blinking Press the mode button until the desired hour is displayed Press the set button again t...

Page 38: ...of the sensor in the fuel tank and the attitude of the boat in the water Operation with bow up trim or continuous turning can give false readings EMU01555 Warning indicators Fuel warning If the fuel level decreases to one segment the fuel level warning segment 1 will begin blinking Low battery voltage warning If battery voltage drops the display 2 will automatically turn on and begin blinking CAUT...

Page 39: ...ow meter 2 Fuel consumption Fuel economy meter Twin engine speed synchronizer 3 Water separator warning indicator Operates only if the sensor has been installed NOTE After the main switch is first turned on all portions of the meter come on as a check After a few seconds the meters will change to normal operation Watch the meter when turning on the main switch to make sure all segments come on ...

Page 40: ...indication By pressing set button again the meter will display total fuel flow NOTE The meter displays gallon hour and liter depending upon operator preference Select the desired unit of measurement by setting the selector switch 1 on the back of the meter during installation Fuel consumption meter and Fuel econ omy meter will indicate same unit of mea surement EMU01276 Fuel Consumption Meter This...

Page 41: ...umidity cleanli ness of the boat bottom engine mounting height skill of the operator and individual gasoline formulation winter or summer fuel and amount of additives The Yamaha digital speedometer and fuel management meter calculates speed miles traveled and fuel economy by water movement at the stern of the boat This distance can vary greatly from the actual distance traveled because of water cu...

Page 42: ...Starboard side engines 4 Starboard side engine speed is slightly higher 5 Starboard side engine speed is higher NOTE If the two engines speeds are not synchro nized while cruising they can be synchro nized by adjusting trim angle or throttle EMU01207 Water Separator Warning Indicator If the water which has been separated from fuel in the water trap exceeds a specific vol ume the indicator will bli...

Page 43: ...eplacing the cowling check to be sure it fits properly in the rubber seal Then lock the cowling again by moving the levers downward EMU01701 FLUSHING DEVICE This device 1 is used to clean the cooling water passages of the motor using a garden hose and tap water NOTE Refer to CLEANING COOLING WATER PASSAGES in Chapter 4 for instructions on usage ...

Page 44: ... warning device The engine speed will automatically decrease to about 2 000 r min The overheat warning indicator will come on The buzzer will sound If the warning system has been activated stop the engine and check the water inlet for clogging NOTE In case of dual engine drive Should the overheat warning system of one engine operate it slows down and the buzzer sounds This will cause the other eng...

Page 45: ...to about 2 000 r min The low oil pressure warning indicator will come on The buzzer will sound If the warning system has been activated stop the engine as soon as it is safe to do so Check oil level and add oil as needed If the oil level is correct consult your Yamaha dealer CAUTION Do not continue to run the engine if the low oil pressure lamp is ON Serious engine damage may occur ...

Page 46: ...2 23 E MEMO ...

Page 47: ...ENGINE 3 5 Procedure for remote control model 3 6 WARMING UP ENGINE 3 8 CHECKING POINTS AFTER STARTING ENGINE 3 8 SHIFTING 3 9 Forward 3 9 Reverse 3 9 STOPPING ENGINE 3 10 TRIMMING OUTBOARD MOTOR 3 11 Adjusting trim angle 3 12 TILTING UP DOWN 3 14 Procedure for tilting up 3 15 Procedure for tilting down 3 16 CRUISING IN OTHER CONDITIONS 3 17 Cruising in salt water 3 17 ...

Page 48: ...irborne water spray while the boat is cruising Severe engine damage may result if the motor is operated continuously in the presence of airborne 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 prevent water entry into the powerhead when water rises due to waves when the outb...

Page 49: ...ine life or even severe engine damage Break in running in time 10 hours EMU01367 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 3 For the next eight hours of operation A...

Page 50: ... leaks or gas oline fumes Check fuel line connections to be sure they are tight Be sure that the fuel hose is not twisted or flattened or likely to contact sharp objects EMU00208 Oil Check the level of the oil in the sump with the dipstick If necessary add oil to bring the level up to the upper mark EMU00209 Controls Check throttle shift and steering for proper operation before starting the engine...

Page 51: ...ull 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 marks Fill with oil if it is below the lower mark or drain to the specified level if it is above the upper mark 1 Oil dipstick 2 Lower level mark 3 Upper level mark EMU01031 FILLING FUEL 1 Remove the fue...

Page 52: ... from open flames and sparks while loosening the air vent screw This product emits exhaust gases which contain carbon monoxide a col orless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 1 If there is an air vent screw on the fuel tank cap loosen it 2 or 3 t...

Page 53: ...of the lanyard in the engine stop switch WARNING Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the los...

Page 54: ...ch to START and hold it for a maximum of 5 seconds 8 Immediately after the engine starts release the main switch to return it to ON CAUTION Do not turn the main switch to START when the engine is running 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 s...

Page 55: ...r light is off Refer to WARNING SYSTEM section Check for a steady flow of water from the cooling water pilot hole CAUTION If water is not flowing out of the pilot hole at all times while the engine is running do not continue to run the engine Overheating and serious dam age could occur Stop the engine and check if the water inlet on the lower casing is blocked If the problem can not be found and c...

Page 56: ... EMU00264 FORWARD Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from Neutral to For ward EMU00269 REVERSE WARNING When operating in Reverse go slowly Do not open the throttle more than half Otherwise the boat may become unsta ble which could result in loss of control and an accident Pull up the neutral interlock trigger if equipped and move ...

Page 57: ...e is a fuel joint or a fuel cock on the boat disconnect the fuel line or close the fuel cock 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 turnin...

Page 58: ...ine and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed WARNING 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 read...

Page 59: ...problems Use the power trim tilt switch located on the bottom engine cowling if equipped only when the boat is at a complete stop with the engine off The outboard motor trim angle can be adjusted operating the power trim tilt switch 1 To raise the bow trim out push the switch UP To lower the bow trim in push the switch DN Make test runs with the trim set to different angles to find the position th...

Page 60: ...t 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 When the bow of the boat is down it is eas ier to accelerate from a standing start onto plane Too much trim in causes the boat to plow through th...

Page 61: ...rts between the drive unit and engine bracket Leaking fuel is a fire hazard Discon nect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes Otherwise fuel may leak If the fuel connector is provided on the motor CAUTION Before tilting the motor follow the pro cedures under STOPPING ENGINE Never tilt the motor while the engine is running Severe damage from o...

Page 62: ...e outboard has tilted up com pletely 3 Turn the tilt support lever toward you to support the engine WARNING After tilting the engine be sure to sup port it with the tilt support lever Other wise the engine could fall back down suddenly if oil in the power trim and tilt unit should lose pressure Never operate the engine while it is supported by the tilt support lever ...

Page 63: ...letely during mooring This protects the rods from marine growths and corrosion which could damage the power trim and tilt mechanism EMU00303 PROCEDURE FOR TILTING DOWN Power trim tilt model 1 Push the power trim tilt switch UP until the engine is supported by the tilt rod 2 Release the tilt support lever 3 Push the power trim tilt switch DN Down to lower the engine to the desired position ...

Page 64: ...G IN SALT WATER After operating in salt water wash out the cooling water passages with fresh water to prevent them from becoming clogged up with salt deposits NOTE Refer to cooling system flushing instructions in TRANSPORTING AND STORING OUT BOARD MOTOR ...

Page 65: ...stem 4 15 Inspecting fuel filter 4 16 Changing engine oil 4 18 Replacing fuse 4 21 Checking wiring and connectors 4 22 Exhaust leakage 4 22 Water leakage 4 22 Engine oil leakage 4 22 Checking power trim and tilt system 4 23 Checking propeller 4 24 Changing gear oil 4 26 Inspecting and replacing anode s 4 27 Checking battery for electric start models 4 28 Checking bolts and nuts 4 31 Cleaning cooli...

Page 66: ...C 0 4 F 512 Min marine cranking amps MCA ABYC amps at 0 C 32 F 675 Min reserve capacity RC SAE minutes 182 Alternator output V A W 12 45 Starting carburetion system Electronic fuel injection DRIVE UNIT Gear positions Forward Neutral Reverse Gear ratio 2 00 30 15 Trim and tilt system Power trim and tilt Propeller mark T M FUEL AND OIL Recommended fuel Regular unleaded gasoline P O N Minimum 86 Fuel...

Page 67: ... 009 0 31 0 37 0 012 0 015 0 31 0 37 0 012 0 015 0 31 0 37 0 012 0 015 512 512 512 675 675 675 182 182 182 12 45 12 45 12 45 Electronic fuel injection Electronic fuel injection Electronic fuel injection Forward Neutral Reverse Forward Neutral Reverse Forward Neutral Reverse 2 00 30 15 2 00 30 15 2 00 30 15 Power trim and tilt Power trim and tilt Power trim and tilt TL LM T M TL ML Regular unleaded...

Page 68: ...ver bar For further details consult your Yamaha dealer WARNING 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 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 leakage and a potential f...

Page 69: ...Yamaha dealer prior to storage However the following pro cedures can be performed by the owner with a minimum of tools CAUTION To prevent problems which can be caused by oil entering the cylinder from the sump keep the outboard motor upright when transporting and storing it If storing or transporting the outboard motor on its side not upright put it on a cushion after draining the engine oil Store...

Page 70: ...ntial to pre vent the cooling system from clogging up with salt sand or dirt In addition fogging of the engine is mandatory to prevent expen sive engine damage due to rust Perform the flushing and fogging at the same time WARNING 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 ...

Page 71: ...a Yamaha dealer EMU00349 Lubrication 1 Remove the spark plug s Spray a Yamaha Stor Rite Engine Fogging Oil into each cylinder for 10 seconds Grease the spark plug threads and rein stall the spark plug s and torque to proper specification Refer to the CLEANING AND ADJUSTING SPARK PLUG 2 Turn the engine over with the stop lan yard disconnected to work the fogging oil into the piston rings 3 Change t...

Page 72: ...r with Yamaha Silicone Protectant Part No LUB SILCNE 13 00 CAUTION Do not spray when the engine is running Also do not spray near the silencer and oxygen sensor cover or into the engine Otherwise the oxygen sensor for Elec tronic Fuel Injection system could be damaged 3 Wax the cowling with a non abrasive wax such as Yamaha Silicone Wax Part No ACC 11000 15 02 ...

Page 73: ...hen charging or using in a closed space Always wear eye protection when working near batteries KEEP OUT OF REACH OF CHILDREN Batteries vary among manufacturers There fore the following procedures may not always apply Consult your battery manufac turer 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 C...

Page 74: ...4 9 E MEMO ...

Page 75: ...e to the emission 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 mainte nance not covered by this owner s manual EMU00356 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equivale...

Page 76: ...ing points Greasing Gear oil Change Fuel system Inspection Fuel filter can be disassembled Inspection cleaning Fuel tank Yamaha portable tank Cleaning Idling speed EFI models Inspection adjustment Anode s Inspection replacement Cooling water passages Cleaning Propeller and cotter pin Inspection replacement Timing belt Inspection replacement Battery Inspection charging Throttle link throttle cable ...

Page 77: ...4 12 E EMU00366 GREASING Yamaha marine grease Water resistant grease ...

Page 78: ...ke air leak or carburetion problem in that cylinder Do not attempt to diagnose any problems your self 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 th...

Page 79: ...ilable when you are fitting a spark plug a good estimate of the correct torque is 1 4 to 1 2 a turn past finger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench 1 Spark plug gap 2 Spark plug I D mark NGK Spark plug torque Refer to SPECIFICATIONS page 4 1 Initial of spark plug I D mark Plug wrench size B 21 mm 13 16 in C L 16 mm 5 8 in D 18 3 mm 23 3...

Page 80: ...problem is found it should be repaired immediately by Yamaha dealer or other qualified mechanic Checkpoints Fuel system parts leakage Fuel hose joint leakage Fuel hose cracks or other damage Fuel connector leakage WARNING Leaking fuel can result in fire or explo sion Check for fuel leakage regularly If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper repa...

Page 81: ...hot or running engine Allow the engine to cool There will be fuel in the fuel filter Keep away from sparks cigarettes flames or other sources of ignition This procedure will allow some fuel to spill Catch fuel in a rag Wipe up any spilled fuel immediately 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 le...

Page 82: ...el tank or other fuel tanks should be checked and cleaned 7 Reinstall the filter element in the filter housing 6 8 Reinsert the O ring in its proper posi tion screw the ring nut onto the filler housing until the filter housing is lightly seated 9 Tighten the ring nut approximately an additional 1 4 turn until the ring nut is tight Align one of the eight large ring nut tabs into the slot of the loc...

Page 83: ... stand CAUTION Change the engine oil after the first 10 hours of operation and every 100 hours or at 6 month intervals thereafter Other wise the engine will wear quickly The engine oil can be extracted with an oil changer recommended or drained by removing the oil drain plug Extracting the oil with an oil changer normal oil change 1 Put the outboard motor in an upright position not tilted 2 Pull o...

Page 84: ...essure warning indicator 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 cor rected consult your Yamaha dealer 5 Turn off the engine and wait 3 minutes Recheck the oil level using the dipstick to be sure the level falls between the upper and lower marks Fill with oi...

Page 85: ...the drain hole Let the oil drain completely Wipe up any spilled oil immediately 4 Put a new gasket on the oil drain bolt Apply a light coat of oil to the gasket and reinstall the drain bolt NOTE If a torque wrench is not available when you are installing the drain plug finger tighten the bolt just until the gasket comes into contact with the surface of the drain hole Then tighten 1 4 1 2 turn Have...

Page 86: ...ain fuse has blown be sure to also check the other main fuse If the outboard motor is operated after a main fuse has blown charging capa bility will be insufficient and the engine will not start NOTE If the new fuse blows again immediately consult a Yamaha dealer 1 Fuse box 2 Fuse 5A 1 20A 2 30A 5 3 Spare fuse 5A 20A 30A 4 Fuse puller 5 Starter relay 6 Main fuse 2 7 Main fuse 1 8 Fuel feed pump 9 ...

Page 87: ...e engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and crank case EMU00385 WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head and crank case EMU01634 ENGINE OIL LEAKAGE Check that no oil leaks from the engine oil system NOTE If any leaks are found consult a Yamaha dealer ...

Page 88: ... and check that the tilt rod 1 and trim rods 2 are pushed out completely 4 Use the tilt support lever 3 to lock the motor in the UP position Operate the tilt down switch briefly so the motor is sup ported the tilt support lever 5 Check that the tilt rod and trim rods are free of corrosion or other flaws 6 Activate the tilt down switch until the trim rods have gone completely into the cylinders 7 A...

Page 89: ...ween the cavitation plate and the propeller to pre vent the propeller from turning EMU00390 Propeller Checking Point Check each of the propeller blades for wear erosion from cavitation or ventila tion or other damage Check the splines for wear and damage Check for fish line winding around the propeller shaft Check the propeller shaft oil seal for dam age ...

Page 90: ...e the propeller could come off dur ing operation and be lost 1 Apply Yamaha Marine grease or Corro sion resistant grease to the propeller shaft 2 Install the spacer washer and propeller on the propeller shaft 3 Install the spacer washer and the pro peller nut and then tighten the nut to the specified torque 4 Align the propeller nut with the propeller shaft hole Insert a new cotter pin in the hole...

Page 91: ...r case 3 Remove the oil drain plug 1 NOTE The oil drain plug is magnetic Remove all metal particles from the plug before rein stalling it 4 Remove the oil level plug 2 to allow the oil to drain completely CAUTION Inspect the used oil after it has been drained If the oil is milky water is getting into the gear case which can cause gear damage Consult a Yamaha dealer for repair of the lower unit sea...

Page 92: ... 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 CAUTION Do not paint anodes as this would ren der them ineffective NOTE Inspect ground leads attached to external anodes on equipped models Consult a Yamaha dealer for inspection and replace ment of internal anodes a...

Page 93: ...KIN Flush with water EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL 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 follow these preventive measures Charge batteries in a well ventilated area Keep ba...

Page 94: ...ter suitable to use in batter ies 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 will be stored for longer than a month check the specific gravity of the fl...

Page 95: ... Reversal of the battery leads will dam age the electrical parts Connect the RED lead first when installing the battery and disconnect the BLACK lead first when removing it Otherwise the electrical parts can be damaged The electrical contacts of the battery and cables must be clean and properly connected or the battery will not start the engine Connect the RED lead to the POSITIVE terminal first T...

Page 96: ...rting 3 Battery for accessories 4 Large red lead for starting battery 5 Small red lead for accessory battery charging optional part 6 Large black lead 7 Negative connecting cable optional part 8 Power for accessories NOTE If a battery selector switch is desired con sult your YAMAHA dealer about correct wir ing EMU01280 Disconnecting the Battery Disconnect the BLACK lead from the NEGA TIVE terminal...

Page 97: ...ct 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 CAUTION 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 sur...

Page 98: ...MOTOR EMU00412 Checking Painted Surface of Motor Check the motor for scratches nicks or flak ing paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas A touch up paint is available from a Yamaha dealer EMU00413 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clean of marine growths as possible If necessary ...

Page 99: ... EMU00414 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 4 IMpact damage 5 4 Running single engine 5 4 Power trim tilt will not operate 5 5 Treatment of submerged motor 5 6 ...

Page 100: ...orrect amperage 4 Starter components faulty 4 Have serviced by a Yamaha dealer 5 Shift lever in gear 5 Shift to neutral B Engine will not start Starter operates 1 Fuel tank empty 1 Fill tank with clean fresh fuel 2 Fuel contaminated or stale 2 Fill tank with clean fresh fuel 3 Fuel filter clogged 3 Clean or replace filter 4 Starting procedure incorrect 4 Read STARTING ENGINE section 5 Fuel pump ma...

Page 101: ...fied 10 Thermostat faulty or clogged 10 Have serviced by a Yamaha dealer 11 Fuel pump damaged 11 Have serviced by a Yamaha dealer 12 Motor angle too high 12 Return to normal operating position 13 Fuel joint connection incorrect 13 Connect correctly 14 Battery lead disconnected 14 Connect securely D Warning buzzer sounds or indicator lamp lights 1 Cooling system clogged 1 Check water intake for res...

Page 102: ... Fuel contaminated or stale 11 Fill tank with clean fresh fuel 12 Spark plug gap incorrect 12 Inspect and adjust as specified 13 Poor connections or damaged ignition wiring 13 Check wires for wear or breaks Tighten all loose connections Replace worn or broken wires 14 Failed ignition parts 14 Have serviced by a Yamaha dealer 15 Specified engine oil not used 15 Check and replace oil with specified ...

Page 103: ...ether damage is found or not return to the nearest harbor slowly and care fully 4 Have a Yamaha dealer inspect the out board motor before operating it again EMU00418 RUNNING SINGLE ENGINE Using only one of the engines in case of an emergency be sure to keep the unused one tilted up and operate the other engine at low speed CAUTION If the boat is operated with one engine in the water but not runnin...

Page 104: ...rim and tilt because of a dis charged battery or a failure with the power trim and tilt unit the engine can be tilted manually 1 Manual valve screw EMU00421 1 Loosen the manual valve screw counter clockwise until it stops 2 Put the engine in the desired position then tighten the manual valve screw clockwise ...

Page 105: ...he proce dure below in order to minimize engine dam age EMU00449 1 Thoroughly wash away mud salt sea weed etc with fresh water 2 Remove the spark plugs and face the spark plug holes downward to allow any water mud or contaminants to drain 3 Drain the fuel from the vapor separator fuel filter and fuel line 4 Take the outboard motor to a Yamaha dealer as soon as possible CAUTION Do not attempt to ru...

Page 106: ...5 7 E MEMO ...

Page 107: ...E 6 EMU00450 Chapter 6 INDEX INDEX 6 1 ...

Page 108: ...0 Disconnecting the battery 4 31 Draining the oil by removing the oil drain plug 4 20 E Electric start model 3 7 Emission control information 1 2 Engine 3 4 Engine oil 1 13 Engine oil leakage 4 22 Engine stop lanyard switch 2 5 Exhaust leakage 4 22 Extracting the oil with an oil changer normal oil change 4 18 F Filling fuel 3 4 Filling fuel tank 4 5 Fishing vessel right of way 1 9 Flushing cooling...

Page 109: ...s 1 8 Running single engine 5 4 S Safety information 1 4 Sailing vessel right of way 1 9 Shifting 3 9 Specifications 4 1 Speedometer 2 13 Stand on vessel 1 7 Star labels 1 3 Start in gear protection 1 16 Starting engine 3 5 Steering and sailing rules and sound signals 1 7 Stopping engine 3 10 Storing outboard motor 4 4 T Tachometer 2 10 Temporary action in emergency 5 4 The general prudential rule...

Page 110: ...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 111: ...lable 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 Toron...

Page 112: ...im and Tilt Assembly WARRANTY REGISTRATION To be eligible for warranty coverage the outboard motor must be registered with Yamaha Motor Corpora tion U S A Warranty registration can be accomplished by any authorized Yamaha Outboard Motor Dealer Upon receipt of the registra tion an Owner s Warranty Card will be sent by Yamaha to the registered purchaser OBTAINING REPAIRS UNDER WARRANTY To receive re...

Page 113: ...Yamaha Outboard Motor Dealer and requesting the dealer to submit a change of registration to Yamaha Motor Corporation U S A within ten 10 days of the transfer YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGA TIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE ...

Page 114: ...l receive service If you need more information about your warranty coverage or your Yamaha outside the U S A or Canada please contact an authorized 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 pur chase which is important evidence the repairing dealer w...

Page 115: ......

Page 116: ...pliquée à l acheteur au détail OUTBOARD MOTOR MODEL AND SERIAL NUMBER From I D label on clamp bracket MODÉLE ET NO DE SÉRIE DU MOTEUR HORS BORD sur l étiquette d identification de la presse de fixation For Dealer Use Only A l usage du concessionnaire YAMAHA DEALER NUMBER NO DU CONCESSIONNAIRE YAMAHA DEALER NAME NOM DU CONCESSIONNAIRE DATE SOLD DATE DE LIVRAISON OWNER S NAME NOM DU PROPRIÉTAIRE ADD...

Page 117: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT ...

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