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4-13

E

When fitting the plug, always clean the
gasket 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 esti-
mate of the correct torque is 1/4 to 1/2 a
turn past finger-tight. Have the spark plug
adjusted to the correct torque as soon as
possible with a torque-wrench.

1

Spark plug gap

2

Spark plug I.D. mark (NGK)

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

16 mm (5/8 in.)

D

18.3 mm (23/32 in.)

903022

q

w

EMU16350

CHECKING TOP COWLING

Check the fitting of the top cowling by
pushing it with both hands.
If the fitting is loose have it repaired by a
Yamaha dealer.

67C-9-14-4 3/25/03 10:36 Page 14

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Summary of Contents for F30C

Page 1: ...F30C F40C OWNER S MANUAL U S A Edition LIT 18626 05 48 ...

Page 2: ......

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

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 EMU00003 CONTENTS ...

Page 5: ...or serial number 1 1 Key number 1 1 EMISSION CONTROL INFORMATION 1 2 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: ...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 EMU00008 KEY NUMBER If main key switch is equipped your key identification number is stamped on your key as shown in the illustration Record this number in the space provided for ref erence if you need a new key 1 Key number...

Page 7: ...on 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 ADJUSTMENT...

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: ...eaking 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 Symp toms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 8 Check throttle shift and steering for proper operation before starting the engine 8 Attach t...

Page 10: ...ited 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: ...n neutral 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 CAUTION 62Y 13444 40 Transport and store the engine only as shown Otherwise engine damage could result from...

Page 12: ... 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: ...de the passage of other 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 pas...

Page 15: ...L M A I N C H A N N 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 WAT...

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: ...nol 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 Yama ha because it can cause fuel system dam age or engine performance problems Recommended gasoline Regular unleaded gasoline with a minimum octane rating of 86 Pump Octane Number R M 2 ...

Page 18: ... stroke 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 Engine oil quantity See Chapter 4 Specifications 001162 SAE API SE SF SG SH SJ 10W 30 10W 40 ...

Page 19: ...ose a battery which meets the following specifications EMU01860 Minimum cold cranking amps CCA SAE 380 amps at 18 C 0 4 F Minimum marine cranking amps MCA ABYC 502 amps at 0 C 32 F Minimum reserve capacity RC SAE 124 minutes 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 F40MH 8 If you wish t...

Page 20: ... 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 suitable for a smaller oper ating load Yamaha dealers stock a range of pro pellers 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 ...

Page 21: ...n device s This feature permits the engine to be started only when it is Neutral Always select Neutral before starting the engine 602011 10 3 4 x 17 G q w e 1 Propeller diameter in inches 2 Propeller pitch in inches 3 Type of propeller propeller mark Refer to the section CHECKING PRO PELLER for instructions on propeller removal and installation ...

Page 22: ...E MEMO ...

Page 23: ...ultifunction tiller handle 2 2 Remote control 2 5 Trim tab 2 10 Power trim tilt switch 2 11 Warning indicator s 2 11 Tachometer 2 12 Trim meter 2 12 Tilt lock mechanism 2 13 Tilt support knob 2 13 Top cowling lock lever 2 13 Flushing device 2 14 WARNING SYSTEM 2 15 Overheat warning 2 15 Low oil pressure warning 2 16 1 2 3 4 5 6 E ...

Page 24: ... bolt 4 Anti cavitation plate 5 Trim tab 6 Propeller 7 Cooling water inlet 8 Clamp bracket 9 Power trim and tilt switch 0 Recoil starter handle q Warning indicators w Multifunction tiller handle e Steering friction adjusting lever r Tilt support knob t Flushing device y Remote control box u Trim meter i Tachometer May not be exactly as shown also may not be included as standard equipment on all mo...

Page 25: ...r the outboard motor operation 1 Tiller handle 2 Gear shift lever 3 Throttle control grip 4 Throttle indicator 5 Throttle friction adjusting knob 6 Engine stop lanyard switch Engine stop button If equipped EMU00079 Tiller handle Moving the tiller handle sideways to adjust the steering direction EMU00080 Gear shift lever Turning the gear shift lever forward bow side engages the clutch with the forw...

Page 26: ...nce and fuel economy for the desired operation 1 Throttle indicator EMU01157 Throttle Friction Adjusting Knob A friction device in the tiller handle pro vides adjustable resistance to movement of the throttle grip and can be set accord ing to operator preference When constant speed is desired tighten the adjusting knob to maintain the desired throttle setting w Do not overtighten the friction adju...

Page 27: ...rom running away under power w 8 Attach the lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering ...

Page 28: ...ndle bracket w Do not overtighten the friction adjusting lever If there is too much resistance it may be difficult to steer which could result in an accident EMU00096 REMOTE CONTROL Both the shifter and the throttle are actu ated by the remote control lever In addi tion this control also has the electrical switches 1 Remote control lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Main ...

Page 29: ...verse The engine will contin ue to run at idle until the lever is moved about 35 a detent can be felt Moving the lever farther opens the throttle and the engine will begin to accelerate 1 Neutral 2 Forward 3 Reverse 4 Shift 5 Fully closed 6 Throttle 7 Fully open EMU00099 Neutral Interlock Trigger To shift out of Neutral the neutral inter lock trigger of the remote control lever must first be pulle...

Page 30: ...emote control lever is in Neu tral 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 circuits switched on The key cannot be removed 8 START Sta...

Page 31: ...rom running away under power w 8 Attach the lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering ...

Page 32: ...ition NOTE Refer to the sections ADJUSTING TRIM ANGLE and TILTING UP DOWN in Chapter 3 for instructions on usage EMU01155 Throttle Friction Adjusting Screw A friction device in the remote control box provides adjustable resistance to move ment of the remote control lever and can be set according to operator preference An adjusting screw is located on the front of the remote control box w Do not ov...

Page 33: ...trim tab has been installed or replaced to be sure steering is correct Be sure you have tightened the bolt after adjusting the trim tab 1 Trim tab 2 Bolt cC The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode Boat tends to veer To the left port side To the right starboard side The fin of trim t...

Page 34: ...ower 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 distract the operator increasing the risk of colli sion with another boat or an obstacle NOTE Refer to the section Adjusting Trim Angle an...

Page 35: ...o low this lamp will flash EMU01365 Overheat Warning Lamp If the engine temperature rises too high this lamp will flash cC Do not continue to run the engine if the low oil pressure lamp or the overheat warning lamp is ON Serious engine damage may occur EMU00132 TRIM METER for Power trim tilt model This meter shows the trim angle of your outboard NOTE Memorize the trim angles that work best for you...

Page 36: ...dro tilt model can be used to keep the outboard motor at a slightly tilted angle for shallow water cruising Refer to CRUISING IN SHALLOW WATER for the correct opera tion EMU00155 TILT SUPPORT KNOB To keep the outboard motor in the tilted up position push the tilt support knob under the swivel bracket EMU00162 TOP COWLING LOCK LEVER To remove the engine top cowling turn the lock lever Then lift off...

Page 37: ... 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 Pas sages in Chapter 4 for instructions on usage ...

Page 38: ... WARNING This engine has an overheat 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 Activation of warning device The engine speed will automatically decrease to about 2 000 r min The overheat warning indicator will come on The buzzer will sound Ti...

Page 39: ... is safe to do so Check oil 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 Activation of warning device Engine speed will automatically decrease to about 2 000 r min The low oil pressure warning indicator will come on The buzzer will sound Tiller Remote contro...

Page 40: ...E MEMO ...

Page 41: ...NGINE OIL LEVEL 3 6 FILLING FUEL 3 7 STARTING ENGINE 3 8 WARMING UP ENGINE 3 12 SHIFTING 3 13 Forward 3 13 Reverse 3 14 STOPPING ENGINE 3 15 TRIMMING OUTBOARD MOTOR 3 16 Adjusting trim angle 3 17 TILTING UP DOWN 3 20 CRUISING IN SHALLOW WATER 3 23 CRUISING IN OTHER CONDITIONS 3 24 Cruising in salt water 3 24 Cruising in turbid water 3 24 1 2 3 4 5 6 E ...

Page 42: ...irborne 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 o...

Page 43: ... ence and the specific boat motor com bination 8 Your dealer or other person experi enced in proper rigging should mount the motor If you are mounting the motor yourself you should be trained by an experienced person permanent mounted type 8 Your dealer or other person experi enced in proper outboard motor mounting should show you how to mount your motor portable type Mount the outboard motor on t...

Page 44: ... mounting height is too high cavitation tends to occur thus reducing the propulsion and if the pro peller tips cut the air the engine speed will rise abnormally and cause the engine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engine efficiency Mount the engine so that the anti cavita tion plate is in alignment with the bottom of the boat NOTE...

Page 45: ... 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 minutes 3 For the next eight hours of o...

Page 46: ...mage can occur EMU00206 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 EMU00208 Oil 8 Check the level of the oil in the sump w...

Page 47: ...unting 8 Look for loose or damaged fasteners 8 Check the propeller for damage 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 marks Fill with oil if i...

Page 48: ...ged the amount of additives such as aromatics and oxy genates has increased These additives are important for the engines in passen ger cars but they can have detrimental effects in marine engines because of increased deposits in the combustion chamber When enough deposits collect piston rings begin sticking Performance drops and engine wear increases dramati cally While many additives available m...

Page 49: ...ts exhaust gases which contain carbon monoxide a col orless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 1 If there is an air vent screw on the fuel tank cap loosen it 2 or 3 turns 2 If there is a fuel joint on the motor firmly connect the fuel line to the...

Page 50: ... 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 control Also without engi...

Page 51: ...he engine 8 After the engine starts return the starter handle slowly to the original position before releasing it EMU00247 PROCEDURE FOR REMOTE CONTROL MODEL 4 Place the remote control lever in the Neutral position NOTE The start in gear protection device pre vents the engine from starting except when in Neutral 5 Attach the engine stop switch lanyard to a secure place on your clothing or your arm...

Page 52: ...use people and objects in the boat to be thrown forward 6 Turn the main switch to ON ON START OFF 701045 ON START OFF 701022 EMU00949 Electric Start Model 7 Turn the main switch to START and hold it for a maximum of 5 sec onds 8 Immediately after the engine starts release the main switch to return it to ON cC 8 Do not turn the main switch to START when the engine is running 8 Do not keep the start...

Page 53: ...rwise serious 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 c...

Page 54: ...rst so that the engine idles or runs at low speeds EMU00265 FORWARD Tiller control model 1 Place the throttle control grip in the fully closed position Remote control model Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from Neutral to Forward 2 Turn the gear shift lever quickly and firmly from Neutral to Forward 501012 501061 N F 7 UP DN 701...

Page 55: ...dent 1 Place the throttle control grip in the fully closed position for Tiller control model 2 Check that the tilt lock lever for Man ual 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 fi...

Page 56: ...to OFF 2 If the fuel joints are provided discon nect the fuel line from the motor after stopping the engine 3 Tighten the air vent screw on the fuel tank cap after stopping the engine if it is equipped 4 Remove the key if the boat will be left unattended 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 ...

Page 57: ... 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 58: ...signs of instabili ty or control problems Improper trim angle can cause loss of control 1 Stop the engine 2 Place the tilt lock lever in the release position 3 Hold the rear of the top cowling with one hand and tilt the engine to the desired angle 4 Place the tilt lock lever back into the lock position to support the engine To raise the bow trim out tilt the engine up To lower the bow trim in tilt...

Page 59: ...ns of instabili ty or control problems The outboard motor trim angle can be adjusted operating the power trim tilt switch 1 To raise the bow trim out push the switch UP To lower the bow trim in push the switch DN Make test runs with the trim set to differ ent angles to find the position that works best for your boat and operating condi tions NOTE To adjust the trim angle while the boat is moving u...

Page 60: ... in the water Performance and 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 s...

Page 61: ...from over 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 minut...

Page 62: ... lock lever in the release position 3 Hold the rear of the top cowling with one hand tilt the engine up push the tilt support knob into the clamp brack et and place the tilt lock lever back into the lock position to support the engine 304053 EMU01327 PROCEDURE FOR TILTING UP Power trim tilt model 1 Remove the fuel line connection from the motor ...

Page 63: ...nit should lose pressure EMU01151 PROCEDURE FOR TILTING DOWN Hydro tilt model 1 Release the tilt lock lever 2 Hold the rear of the top cowling with one hand tilt the engine up slightly and pull out the tilt support knob 3 Slowly tilt the engine down 4 Place the tilt lock lever back into the lock position EMU01328 PROCEDURE FOR TILTING DOWN Power trim tilt model 1 Push the power trim tilt switch UP...

Page 64: ...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 501055 N F R 402065 EMU00315 PROCEDURE 1 Place the gear in the neutral position 2 Pull the tilt lock lever up to the Tilt position 3 Slightly tilt up the engine to the desired position and push the tilt lock lever down to the Lock posit...

Page 65: ...resh water to prevent them from becoming clogged up with salt deposits NOTE Refer to cooling system flushing instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR CRUISING IN TURBID WATER It is strongly recommended that the optional chromium plated water pump kit be installed if the outboard is to be used in turbid muddy water conditions ...

Page 66: ...E MEMO ...

Page 67: ...wling 4 13 Checking fuel system 4 14 Inspecting fuel filter 4 15 Inspecting idling speed 4 16 Changing engine oil 4 17 Replacing fuse 4 20 Checking wiring and connectors 4 20 Exhaust leakage 4 20 Water leakage 4 20 Checking power trim and tilt system 4 21 Checking propeller 4 22 Changing gear oil 4 24 Inspecting and replacing anode s 4 25 Checking battery 4 26 Checking bolts and nuts 4 29 Cleaning...

Page 68: ... CCA SAE Min marine cranking amps MCA ABYC Min reserve capacity RC SAE Alternator output Starting carburetion system cm3 cu in mm in NGK mm in mm in mm in amps at 18 C 0 4 F amps at 0 C 32 F minutes V A W DRIVE UNIT Gear positions Gear ratio Trim tilt system Propeller mark FUEL AND OIL TIGHTENING TORQUE Recommended fuel Fuel tank capacity Recommended engine oil Engine oil capacity without oil filt...

Page 69: ...5 0 25 0 006 0 010 0 25 0 35 0 010 0 014 12 80 Prime start Forward Neutral Reverse 2 0 26 13 Hydro tilt G Regular unleaded gasoline Minimum 86 4 stroke motor oil SE SF SG SH SJ 10W 30 10W 40 2 0 2 11 1 76 2 2 2 33 1 94 Hypoid gear oil SAE90 430 14 54 15 14 14 7 19 6 1 5 2 0 11 14 29 4 49 0 3 0 5 0 22 36 14 7 19 6 1 5 2 0 11 14 15 0 20 0 1 5 2 0 11 14 700 27 6 378 14 9 1 217 47 9 410 16 1 82 181 14...

Page 70: ...ult 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 8 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 ...

Page 71: ...own when 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 000701 102071 q w EMU03350 Filling Fuel Tank Fill the fuel tank with fresh fu...

Page 72: ...ing parts while engine is running EMU00339 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 and silencer cover 2 Install the outboard motor on the water tank 3 Fill the tank with fresh water to above the level of the anti cavitation plate 4 Run the e...

Page 73: ... the pro peller 2 Install a flushing attachment 1 to the cooling water inlet 3 Run the engine at a fast idle for 10 15 minutes supplying fresh water 4 Just prior to turning off the engine quickly spray Yamaha Stor Rite Engine Fogging Oil Part No LUB STRRT 12 00 alternately into the silencer cover When properly done the engine will smoke excessively and almost stall 5 Remove the flushing attachment...

Page 74: ...rings 3 Change the gear case oil Refer to CHANGING GEAR OIL Inspect the oil for the presence of water which indicates a leaky seal Seal replace ment should be performed by an authorized Yamaha dealership prior to use 4 Grease all grease fittings Refer to the GREASING EMU00351 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the out board with fresh water and dry off completely 2 Spr...

Page 75: ...sing 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 ca...

Page 76: ...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 maintenance not covered by this owner s manual EMU00356 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equiva lents o...

Page 77: ...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 78: ...4 11 E EMU00366 GREASING Yamaha marine grease Water resistant grease 103211 500 hours 1000 hours 2 5 years 5 years Timing belt Replacement 1 Item Actions Every ...

Page 79: ...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 80: ... 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 Plug wrench size I D mark B 21 mm 13 16 in C 16 mm 5 8 in D 18 3 mm 23 32 in 903022 q w EMU16350 CHECKING TOP COWLING Check the fitting of the top cowling by...

Page 81: ...m is found it should be repaired immediately by Yama ha dealer or other qualified mechanic Checking points 8 Fuel system parts leakage 8 Fuel hose joint leakage 8 Fuel hose cracks or other damage 8 Fuel connector leakage w Leaking fuel can result in fire or explo sion 8 Check for fuel leakage regularly 8 If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper...

Page 82: ...sparks 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 EMU00374 Check the fuel filter periodically ...

Page 83: ...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 84: ...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 85: ...nd 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 Engine oil grade capacity Refer to SPECIFICATIONS page 4 1 203033 w 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 drai...

Page 86: ...arks Fill with oil if it is below the lower mark or drain to the specified level if it is above the upper mark 7 Dispose of used oil according to local regulations 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 extended trolling 201012 ...

Page 87: ...e haz ard NOTE If the new fuse blows again immediately consult a Yamaha dealer 1 Fuse box 2 Fuse 20A 3 Spare fuse 20A 4 Fuse puller EMU00383 CHECKING WIRING AND CONNECTORS 1 Check that each grounding wire is properly secured 2 Check that each connector is engaged securely EMU00384 EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder he...

Page 88: ...of oil leaks 2 Operate each of the power trim and tilt switches on remote control and engine bottom cowling If equipped to check that all switches work 3 Tilt up the motor and check that the trim and tilt rod 1 is pushed out com pletely 4 Check that the trim and tilt rod is free of corrosion or other flaws 5 Operate the motor to trim and tilt down Check that the trim and tilt rod operates smoothly...

Page 89: ...he 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 EMU00390 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 propeller shaft 8 Ch...

Page 90: ...osion resistant grease to the pro peller shaft 2 Install the thrust washer and propeller on the propeller shaft 3 Install the spacer and washer Tighten the propeller 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 If the propeller nut does not align with the propeller shaft hole after tighten...

Page 91: ...d motor so that the oil drain plug is at the lowest point possi ble 2 Place a suitable container under the gear 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 cC Inspect the used oil after it has been drained If the oil is milky water is get ti...

Page 92: ... 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 to external anodes on equipped models Consult a Yamaha dealer for inspection and...

Page 93: ...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 94: ... 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 will be stored for longer than a month check the specific grav ity of the fluid at least on...

Page 95: ...lling the battery and disconnect the RED lead last when removing it Otherwise the electrical system can be damaged 8 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 Then connect the BLACK lead to the NEG ATIVE terminal 1 Red lead 2 Black lead 3 Battery EMU01280 Discon...

Page 96: ... the garden hose connector 2 onto a garden hose 3 which is con nected to a fresh water supply 3 With the engine off turn on the water tap and let the water flush through the cooling passages for about 15 minutes Turn off the water and dis 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...

Page 97: ...om 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 neces sary the boat bottom can be coated with an anti fouling paint approved for your area to inhibit marine growth Do not use anti fouling paint which includes copper or graphite These paints can cause more rapid engine corrosion 10202...

Page 98: ...E MEMO ...

Page 99: ...Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Power trim tilt will not operate 5 5 Starter will not operate 5 6 Treatment of submerged motor 5 9 1 2 3 4 5 6 E ...

Page 100: ...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 101: ...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 102: ...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 103: ...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 104: ... 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 EMU00419 POWER TRIM TILT WILL NOT OPERATE If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit the engine can be tilted manuall...

Page 105: ...oat could unexpectedly 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 par...

Page 106: ...t from the starter 3 Remove the starter flywheel cover by removing the 4 bolts 4 Prepare the engine for starting See STARTING ENGINE for procedures Be sure the engine is in Neutral and that the lanyard lock plate is attached to the engine stop lanyard switch If the engine is equipped with a main switch it must be on 208075 q 208076 208081 ON START OFF MH ER TR ...

Page 107: ...mer gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise 6 Pull the rope slowly until resistance is felt 7 Give a strong pull straight out to crank and start the engine Repeat if necessary 208082 ...

Page 108: ...the 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 109: ...EMU00450 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 110: ... water 3 24 D Disconnecting the battery 4 28 E Emergency starting engine 5 7 Emission control information 1 2 Engine stop button 2 5 Engine stop lanyard switch 2 4 2 8 Engine oil 1 13 Exhaust leakage 4 20 F Filling fuel 3 7 Flushing cooling system and fogging engine 4 5 Flushing device 2 14 Forward 3 13 Fueling instructions 1 11 G Gasoline 1 12 Gear shift lever 2 2 Greasing 4 11 I Identification n...

Page 111: ...adjusting lever 2 5 Stopping engine 3 15 Storing outboard motor 4 4 T Tachometer 2 12 Temporary action in emergency 5 5 Throttle control grip 2 3 Throttle friction adjusting knob 2 3 Throttle friction adjusting screw 2 9 Throttle indicator 2 3 Tiller handle 2 2 Tilting up down 3 20 Tilt lock mechanism 2 13 Tilt support knob 2 13 Top cowling lock lever 2 13 Trailering outboard motor 4 3 Transportin...

Page 112: ...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 113: ...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 114: ...m 8 Power Trim 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 T...

Page 115: ...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 116: ...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 117: ...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 118: ...Printed in Japan April 2003 0 7 1 67C 28199 14 F30AET F40BMHD F40BED F40BET E Printed on recycled paper ...

Page 119: ...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 120: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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