Yamaha F40 Owner'S Manual Download Page 64 | Manualshive

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Maintenance

58

EMU28931

Greasing

Yamaha marine grease (Water resistant grease)

F40

EMU28952

Cleaning and adjusting spark plug

WARNING

EWM00560

When removing or installing a spark plug,
be careful not to damage the insulator. A
damaged insulator could allow external
sparks, which could lead to explosion or

fire.

The spark plug is an important engine com-
ponent and is easy to inspect. The condition
of the spark plug can indicate something
about the condition of the engine. For exam-
ple, if the center electrode porcelain is very
white, this could indicate an intake air leak or
carburetion problem in that cylinder. Do not

attempt to diagnose any problems yourself.
Instead, take the outboard motor to a
Yamaha dealer. You should periodically re-
move 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 re-
place the spark plug with another of the cor-
rect type.

Before fitting the spark plug, measure the
electrode gap with a wire thickness gauge;

ZMU04081

Standard spark plug:

DPR6EA-9

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Summary of Contents for F40

Page 1: ...F40 OWNER S MANUAL 67C 28199 18 U S A Edition LIT 18626 07 10 67C 9 18 Hyoshi 06 3 3 10 15 AM ページ 1 ...

Page 2: ...EMU25060 ZMU01690 Read this owner s manual carefully before operating your outboard motor 67C 9 18 Hyoshi 06 3 3 10 15 AM ページ 2 ...

Page 3: ...d motor CAUTION ECM00700 A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current prod uct information available at the time of print ing there may be minor discrep...

Page 4: ...ttle friction adjuster 16 Engine stop lanyard switch 17 Engine stop button 17 Manual starter handle 18 Main switch 18 Steering friction adjuster 18 Steering friction adjuster 19 Power trim and tilt switch on remote control or tiller handle 19 Power trim and tilt switch on bottom engine cowling 20 Trim tab with anode 20 Tilt lock mechanism 21 Tilt support knob 21 Top cowling lock lever s turn type ...

Page 5: ...easures 52 Battery care 52 Flushing power unit 53 Cleaning the outboard motor 54 Checking painted surface of motor 54 Periodic maintenance 54 Replacement parts 54 Maintenance chart 56 Maintenance chart additional 57 Greasing 58 Cleaning and adjusting spark plug 58 Checking fuel system 59 Checking fuel filter 60 Inspecting idling speed 60 Changing engine oil 60 Checking wiring and connectors 62 Exh...

Page 6: ...Table of contents YAMAHA MOTOR CORPORATION U S A FOUR STROKE OUTBOARD MOTOR THREE YEAR LIMITED WARRANTY 79 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA 81 ...

Page 7: ...ped with the mo tor the key identification number is stamped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key EMU25221 Emission control information EMU25230 North American models This engine conforms to U S Environmental Protection Agency EPA regulations for ma rine SI engines See the label affixed to your engine for details...

Page 8: ... Resources Board s 2001 ex haust emission standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke en gines These engines are equivalent to the U S EPA s 2006 standards for marine en gines EMU25290 Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s 2004 ex haust emission standards Engines meeting th...

Page 9: ...e may not only cause engine damage but also adversely affect fuel consumption Consult your dealer for correct use Never operate after drinking alcohol or tak ing drugs About 50 of all boating fatali ties involve intoxication Have an approved personal flotation de vice PFD on board for every occupant It is a good idea to wear a PFD whenever boating At a minimum children and non swimmers should alwa...

Page 10: ...nd shut off the engine Do not illegally discard empty containers used to replace or replenish oil For the correct processing of empty containers consult the dealer where you purchased the oil When replacing oils used to lubricate the product engine or gear oil be sure to wipe away any spilt oil Never pour oil with out using a funnel or similar device If nec essary verify the necessary replacement ...

Page 11: ... your boat These rules are used internationally and are also enforced by the United States Coast Guard and local agen cies You should be aware of these rules and follow them whenever you encounter another vessel on the water Several sets of rules prevail according to geographic location but are all basically the same as the International Rules of the Road The rules presented here in your Owner s M...

Page 12: ...ex cept when a collision will occur unless both vessels try to avoid each other If that is the case both vessels become Give Way ves sels EMU25520 Rules when encountering vessels There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed Meeting you are approaching another ves sel head on Crossing you are travel...

Page 13: ...the vessel should still pro ceed around the bend with caution If you navigate such waters with your boat you will need to carry a portable air horn available from local marine supply stores Fishing vessel right of way All vessels which are fishing with nets lines or trawls are considered to be fishing ves sels under the International Rules Vessels with trolling lines are not considered fishing ves...

Page 14: ...of a particular state The Uniform State Waterway Marking System has been devised for these waters This system uses buoys and signs with dis tinctive shapes and colors to show regulato ry or advisory information These markers are white with black letters and orange boarders They signify speed zones restrict ed areas danger areas and general infor mation Remember markings may vary by geo graphic loc...

Page 15: ... FLAMMABLE AND EXPLOSIVE Do not smoke when refueling and keep away from sparks flames or other sources of ignition Stop engine before refueling Refuel in a well ventilated area Refuel portable fuel tanks off the boat Take care not to spill gasoline If gaso line spills wipe it up immediately with ZMU01708 ...

Page 16: ...n taining ethanol and that containing metha nol Gasohol containing ethanol can be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Yamaha does not recommended gasohol containing methanol because it can cause fuel system damage or engine performance problems EMU31440 Engine oil NOTE If the recommended engine oil grades are not available select an alternative from...

Page 17: ...on installing an optional Rectifier Regulator EMU25742 Propeller selection The performance of your outboard motor will be critically affected by your choice of propel ler as an incorrect choice could adversely affect performance and could also seriously damage the motor Engine speed depends on the propeller size and boat load If engine speed is too high or too low for good engine performance this ...

Page 18: ...tle setting to maintain the engine in the proper operating range For instructions on propeller removal and in stallation see page 63 EMU25770 Start in gear protection Yamaha outboard motors or Yamaha ap proved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is in neutral Always select neutral before starting the en...

Page 19: ...h this engine is 13 1 2 3 4 5 9 8 7 6 16 17 18 13 15 14 10 11 12 19 20 ZMU05026 1 Top cowling 2 Top cowling lock lever 3 Drain screw 4 Anti cavitation plate 5 Trim tab anode 6 Propeller 7 Cooling water inlet 8 Clamp bracket 9 Power trim and tilt switch 10 Manual starter handle 11 Warning indicator s 12 Steering friction adjuster 13 Tilt support knob 14 Flushing device 15 Tiller handle 16 Fuel tank...

Page 20: ...o loosen the screw turn it counterclockwise EMU26180 Remote control The remote control lever actuates both the shifter and the throttle The electrical switch es are mounted on the remote control box EMU26190 Remote control lever Moving the lever forward from the neutral po sition engages forward gear Pulling the le ver back from neutral engages reverse The engine will continue to run at idle until...

Page 21: ...hen the remote control lever is in neutral The remote control lever will operate only when the neutral throttle lever is in the closed position EMU25911 Tiller handle To change direction move the tiller handle to the left or right as necessary EMU25922 Gear shift lever Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead Pushing the lever away from ...

Page 22: ...nomy for the desired operation EMU25971 Throttle friction adjuster A friction device provides adjustable resis tance to movement of the throttle grip or the remote control lever and can be set accord ing to operator preference To increase resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise WARNING EWM00031 Do not overtighten the friction adjuster If the...

Page 23: ...ach the engine stop switch lanyard to a secure place on your clothing or 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 en gine power means the loss of most steering control Also without engine p...

Page 24: ...be removed start With the main switch in the start po sition the starter motor turns to start the en gine When the key is released it returns automatically to the on position EMU31430 Steering friction adjuster A friction device provides adjustable resis tance to the steering mechanism and can be set according to operator preference An ad juster lever is located on the bottom of the tiller handle ...

Page 25: ...resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise WARNING EWM00040 Do not overtighten the friction adjuster If there is too much resistance it could be difficult to steer which could result in an accident EMU26141 Power trim and tilt switch on remote control or tiller handle The power trim and tilt system adjusts the outboard motor angle in relation t...

Page 26: ...er boat or an obsta cle NOTE For instructions on using the power trim and tilt switch see page 42 EMU26241 Trim tab with anode The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force WARNING EWM00840 An improperly adjusted trim tab could cause difficult steering Always test run after the trim tab has been installed...

Page 27: ...ob under the swivel bracket EMU26372 Top cowling lock lever s turn type To remove the engine top cowling turn the lock lever s and lift off the cowling When in stalling the cowling check to be sure it fits properly in the rubber seal Then lock the cowling again by returning the lever s to the lock position EMU26460 Flushing device This device is used to clean the cooling wa ter passages of the mot...

Page 28: ...r shows the engine speed and has the following functions NOTE All segments of the display will light momen tarily after the main switch is turned on and will return to normal thereafter 1 Flushing device 1 Warning indicator 1 ZMU04042 1 ZMU04043 1 Tachometer 2 Warning indicator s 1 Tachometer 2 Trim meter 3 Hour meter 4 Low oil pressure warning indicator 5 Overheat warning indicator 6 Water separa...

Page 29: ...22 Low oil pressure warning indicator If oil pressure drops too low the warning in dicator will start to blink For further informa tion see page 25 CAUTION ECM00020 Do not continue to run the engine if the low oil pressure warning indicator is on and the engine oil level is lower Seri ous engine damage will occur The low oil pressure warning indicator does not indicate the engine oil level Use the...

Page 30: ...angle to the desired setting with the power trim and tilt switch EMU26620 Trim meter digital type This meter shows the trim angle of your out board motor NOTE Memorize the trim angles that work best for your boat under different conditions Adjust the trim angle to the desired using the power trim and tilt switch If the trim angle of your motor exceeds the trim operating range the top segment on th...

Page 31: ...o operate the engine if a warning device has activated Consult your Yamaha dealer if the problem can not be located and corrected EMU26816 Overheat warning This engine has an overheat warning device If the engine temperature rises too high the warning device will activate Activation of warning device The engine speed will automatically de crease to about 2000 r min If equipped with an overheat war...

Page 32: ...ght or blink The buzzer will sound if equipped on the tiller handle remote control box or main switch panel If the warning system has activated stop the engine as soon as it is safe to do so Check the oil level and add oil as needed If the oil level is correct and the warning device does not switch off consult your Yamaha dealer CAUTION ECM00100 Do not continue to run the engine if the low oil pre...

Page 33: ...n is intended as reference only It is not possible to provide complete in structions for every possible boat and motor combination Proper mounting depends in part on experience and the specific boat and motor combination WARNING EWM00830 Improper mounting of the outboard mo tor could result in hazardous conditions such as poor handling loss of control or fire hazards Observe the following For perm...

Page 34: ... surfaces of moving parts to wear in evenly Correct break in will help en sure proper performance and longer engine life CAUTION ECM00800 Failure to follow the break in procedure could result in reduced engine life or even severe engine damage EMU27081 Procedure for 4 stroke models Run the engine under load in gear with a propeller installed for 10 hours as follows 1 First hour Run the engine at 2...

Page 35: ...damaged fasteners Check the propeller for damage EMU27163 Checking the engine oil level 1 Put the outboard motor in an upright po sition not tilted 2 Remove oil dipstick and wipe it clean 3 Completely insert the dipstick and re move 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 ...

Page 36: ...repeatedly proven its ability to clean combustion deposits from inside the engine notably the critical piston ring land area and fuel system components Follow product la beling for use instructions EMU27450 Operating engine EMU27461 Feeding fuel portable tank WARNING EWM00420 Before starting the engine make sure that the boat is tightly moored and that you can steer clear of any obstructions Be su...

Page 37: ...feel it become firm EMU27490 Starting engine EMU27541 Starting engine 1 Place the gear shift lever in neutral NOTE The start in gear protection device prevents the engine from starting except when in neu tral 2 Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg Then install the lock plate on the other end of the lanyard into the en gine stop switch WARNING ...

Page 38: ...t out to crank and start the engine Repeat if necessary 5 After the engine starts slowly return the manual starter handle to its original po sition before releasing it NOTE When the engine is cold it needs to be warmed up For further information see page 35 If the engine is warm and fails to start open the throttle slightly and try to start the engine again If the engine still fails to start see p...

Page 39: ... and objects in the boat to be thrown forward 3 Place the throttle grip in the start position After the engine starts return the throttle to the fully closed po sition 4 Turn the main switch to start and hold it for a maximum of 5 seconds 5 Immediately after the engine starts re lease the main switch and allow it to re turn to on CAUTION ECM00191 Never turn the main switch to start while the engin...

Page 40: ...a secure place on your clothing or 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 en gine power means the loss of most steering control Also without engine power the boat could slow rapidly This ...

Page 41: ...he engine starts stop the engine Otherwise serious en gine damage could occur Check the oil level and add oil if necessary Consult your Yamaha dealer if the cause for the low oil pressure warning indicator can not be found A continuous flow of water from the pi lot 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 time...

Page 42: ...ard EMU27785 Reverse automatic reverse lock and power trim and tilt models WARNING EWM00190 When operating in reverse go slowly Do not open the throttle more than half Oth erwise the boat could become unstable which could result in loss of control and an accident Tiller handle models 1 Place the throttle grip in the fully closed position 2 Move the gear shift lever quickly and firmly from neutral ...

Page 43: ...operating in reverse go slowly Do not open the throttle more than half Oth erwise the boat could become unstable which could result in loss of control and an accident Tiller handle models 1 Place the throttle grip in the fully closed position 2 On models equipped with a tilt lock le ver check that it is in the lock down po sition 3 Move the gear shift lever quickly and firmly from neutral to rever...

Page 44: ...ckly and firmly from neutral to reverse EMU27820 Stopping engine Before stopping the engine first let it cool off for a few minutes at idle or low speed Stop ping the engine immediately after operating at high speed is not recommended EMU27844 Procedure 1 Push and hold the engine stop button or turn the main switch to off ZMU04053 UP DN ZMU03909 N R ZMU03627 ON START OFF ZMU03630 ...

Page 45: ...ine the position of the bow of the boat in the water Correct trim angle will help im prove performance and fuel economy while reducing strain on the engine Correct trim angle depends upon the combination of boat engine and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed WARNING EWM00740 Excessive trim for the operating condi tions ...

Page 46: ...ns of instabil ity or control problems Improper trim angle can cause loss of control If equipped with a power trim and tilt switch located on the bottom cowling use the switch only when the boat is at a complete stop with the engine off Do not adjust the trim angle with this switch while the boat is moving Adjust the outboard motor trim angle using the power trim and tilt switch To raise the bow t...

Page 47: ... engine To raise the bow trim out tilt the engine up To lower the bow trim in tilt the engine down Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions EMU27911 Adjusting boat trim When the boat is on plane a bow up attitude results in less drag greater stability and effi ciency This is generally when the keel line of the ...

Page 48: ... with obstructions and also to reduce salt corrosion WARNING EWM00220 Be sure all people are clear of the out board motor when tilting up and down also be careful not to pinch any body parts between the drive unit and engine bracket WARNING EWM00250 Leaking fuel is a fire hazard If there is a fuel joint on the outboard motor discon nect the fuel line or close the fuel cock if the engine will be ti...

Page 49: ...ort lever toward you or tilt support knob into the clamp bracket and then place the tilt lock lever back into the lock position to support the outboard motor EMU28007 Procedure for tilting up power trim and tilt models power tilt models 1 Place the remote control lever gear shift lever in neutral 2 Disconnect the fuel line from the out board motor or close the fuel cock ZMU04063 ZMU04064 ZMU04065 ...

Page 50: ...support it with the tilt support knob or tilt support lever Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit loses pres sure 5 Models equipped with trim rods Once the outboard motor is supported with the tilt support lever press the power trim and tilt switch power tilt switch down to retract the trim rods CAUTION ECM00250 Be sure to retract the tri...

Page 51: ...wly tilt the outboard motor down 4 Place the tilt lock lever in the lock posi tion EMU28055 Procedure for tilting down power trim and tilt models power tilt models 1 Push the power trim and tilt switch pow er tilt switch up until the outboard motor is supported by the tilt rod and the tilt support lever tilt support knob be comes free 2 Release the tilt support lever or pull out the tilt support k...

Page 52: ...se extra care when operating in re verse Too much reverse thrust can cause the outboard motor to lift out of the water increasing the chance of ac cident and personal injury Return the outboard motor to its normal position as soon as the boat is back in deeper water CAUTION ECM00260 Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the wate...

Page 53: ...outboard motor can be tilted up partially to allow operation in shallow water WARNING EWM00660 Place the gear shift in neutral before setting up for shallow water cruising Return the outboard motor to its normal position as soon as the boat is back in deeper water CAUTION ECM00260 Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water ...

Page 54: ...92 Cruising in other conditions Cruising in salt water After operating in salt water flush the cooling water passages with fresh water to prevent them from becoming clogged with salt de posits NOTE For cooling system flushing instructions see page 50 Cruising in turbid water Yamaha strongly recommends that you use the optional chromium plated water pump kit not available for some models if you use...

Page 55: ...aximum output 29 4 kW 5500 r min 40 HP 5500 r min Idling speed in neutral 850 50 r min Engine Type 4 stroke L Displacement 747 0 cm3 45 58 cu in Bore stroke 65 0 75 0 mm 2 56 2 95 in Ignition system CDI Spark plug with resistor NGK DPR6EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Control system F40MH Tiller F40TR Remote control Starting system F40MH Manual F40TR Electric Starting carburetion syst...

Page 56: ... warms up and can build up pressure in the fuel container This can cause fuel leakage and a potential fire hazard WARNING EWM00700 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 motor accidentally falls CAUTION ECM00660 Do not use the tilt support lever or knob when trailering the boat The outboard motor could shake l...

Page 57: ...Flushing in a test tank 1 Wash the outboard motor body using fresh water For further information see page 54 2 Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer Part No LUB FUELC 12 00 to each gallon of fuel NOTE The use of Yamaha Fuel Conditioner and Stabilizer eliminates the need to drain the fuel system Consult your Yamaha dealer or other qualified m...

Page 58: ...lmost stall 9 Remove the outboard motor from the test tank 10 Drain the cooling water completely out of the motor Clean the body thoroughly 11 Install the silencer cover cap and top cowling EMU28401 Lubrication 1 Grease the spark plug threads and in stall the spark plug s and torque to proper specification For information on spark plug installation see page 58 2 Change the gear oil For instruction...

Page 59: ...ct and remove the battery from the boat Always disconnect the black negative cable first to prevent the risk of shorting 2 Clean the battery casing and terminals Fill each cell to the upper level with dis tilled water 3 Store the battery on a level surface in a cool dry well ventilated place out of di rect sunlight 4 Once a month check the specific gravity of the electrolyte and recharge as re qui...

Page 60: ...e 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 avail able from your Yamaha dealer EMU28486 Periodic maintenance WARNING EWM01070 Be sure to turn off the engine when you perform maintenance unless otherwise specified If you or the owner is not famil iar with machine servi...

Page 61: ...Maintenance 55 Yamaha genuine parts and accessories are available from your Yamaha dealer ...

Page 62: ...ler Item Actions Initial Every 10 hours 1 month 50 hours 3 months 100 hours 6 months 200 hours 1 year Anode s external Inspection replace ment Anode s internal Inspection replace ment Battery Inspection charging Cooling water pas sages Cleaning Cowling clamp Inspection Fuel filter disposable Inspection replace ment Fuel system Inspection Fuel tank Yamaha por table tank Inspection cleaning Gear oil...

Page 63: ...nt Engine oil Inspection change Oil filter cartridge Change Spark plug s Cleaning adjustment replacement Timing belt Inspection replace ment Valve clearance OHC OHV Inspection adjustment Item Actions Every 500 hours 2 5 years 1000 hours 5 years Timing belt Replacement Exhaust guide exhaust manifold Inspection replace ment Item Actions Initial Every 10 hours 1 month 50 hours 3 months 100 hours 6 mo...

Page 64: ...ngine For exam ple if the center electrode porcelain is very white this could indicate an intake air leak or carburetion problem in that cylinder Do not attempt to diagnose any problems yourself Instead take the outboard motor to a Yamaha dealer You should periodically re move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode...

Page 65: ...ly flam mable and explosive Keep away from sparks cigarettes flames or other sources of ignition WARNING EWM00910 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 repairs can make the outboard unsafe to operate Check the fuel lines for leaks crack or mal function If a proble...

Page 66: ...ect idling speed inspection is only possi ble if the engine is fully warmed up If not warmed up fully the idle speed will measure higher than normal If you have difficulty ver ifying the idle speed or the idle speed re quires adjustment consult a Yamaha dealer or other qualified mechanic 2 Verify whether the idle speed is set to specification For idle speed specifica tions see page 49 EMU29073 Cha...

Page 67: ... surface of the drain hole Then tighten 1 4 to 1 2 turn more Tighten the drain screw to the correct torque with a torque wrench as soon as possible 4 Add the correct amount of oil through the filler hole Install the filler cap 5 Start the engine and watch to make sure the low oil pressure warning indicator if equipped turns off Make sure that there are no oil leaks CAUTION ECM00680 If the low oil ...

Page 68: ...or is engaged se curely EMU29120 Exhaust leakage Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and body cylinder EMU29130 Water leakage Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head and body cylinder EMU29140 Engine oil leakage Check for oil leaks on the around the engine NOTE If any...

Page 69: ...ler Before inspecting removing or install ing the propeller remove the spark plug caps from the spark plugs Also place the shift control in neutral turn the main switch to off and re move the key and remove the lanyard from the engine stop switch Turn off the battery cut off switch if your boat has one Do not use your hand to hold the pro peller when loosening or tightening the propeller nut Put a...

Page 70: ...29231 Spline models CAUTION ECM00340 Be sure to install the thrust washer be fore installing the propeller otherwise the lower case and propeller boss could be damaged Be sure to use a new cotter pin and bend the ends over securely Otherwise the propeller could come off during op eration and be lost 1 Apply Yamaha marine grease or a cor rosion resistant grease to the propeller shaft 2 Install the ...

Page 71: ...tic gear oil drain screw is equipped remove all metal particles from the screw before installing it Always use new gaskets Do not reuse the removed gaskets 4 Remove the oil level plug and gasket to allow the oil to drain completely CAUTION ECM00710 Inspect the used oil after it has been drained If the oil is milky water is getting into the gear case which can cause gear damage Consult a Yamaha dea...

Page 72: ...k into an approved container 2 Pour a small amount of suitable solvent into the tank Install the cap and shake the tank Drain the solvent completely 3 Remove the screws holding the fuel joint assembly Pull the assembly out of the tank 4 Clean the filter located on the end of the suction pipe in a suitable cleaning sol vent Allow the filter to dry 5 Replace the gasket with a new one Re install the ...

Page 73: ...t immediate medical attention Batteries also generate explosive hydro gen gas therefore you should always follow these preventive measures Charge batteries in a well ventilated ar ea Keep batteries away from fire sparks or open flames for example welding equipment lighted cigarettes and so on DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CH...

Page 74: ... parts Connect the red battery cable first when installing the battery and discon nect the black battery cable 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 battery cable to the POSI TIVE terminal first Then connect the black battery...

Page 75: ...Maintenance 69 marine growth Do not use anti fouling paint which includes copper or graphite These paints can cause more rapid engine corrosion ZMU01943 ...

Page 76: ...A Have serviced by a Yamaha dealer Q Is shift lever in gear A Shift to neutral Engine will not start starter operates Q Is fuel tank empty A Fill tank with clean fresh fuel Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is fuel filter clogged A Clean or replace filter Q Is starting procedure incorrect A See page 31 Q Has fuel pump malfunctioned A Have serviced by a Yamaha deal...

Page 77: ...p damaged A Have serviced by a Yamaha dealer Q Is air vent screw on fuel tank closed A Open air vent screw Q Is choke knob pulled out A Return to home position Q Is motor angle too high A Return to normal operating position Q Is carburetor clogged A Have serviced by a Yamaha dealer Q Is fuel joint connection incorrect A Connect correctly Q Is throttle valve adjustment incorrect A Have serviced by ...

Page 78: ...ed or of incorrect type A Inspect spark plug s Clean or replace with recommended type Q Are weeds or other foreign matter tangled on gear housing A Remove foreign matter and clean lower unit Q Is fuel system obstructed A Check for pinched or kinked fuel line or other obstructions in fuel system Q Is fuel filter clogged A Clean or replace filter Q Is fuel contaminated or stale A Fill tank with clea...

Page 79: ...damage WARNING EWM00870 The outboard motor can be seriously damaged by a collision while operating or trailering Damage could make the out board motor unsafe to operate If the outboard motor hits an object in the wa ter follow the procedure below 1 Stop the engine immediately 2 Inspect the control system and all com ponents for damage Also inspect the boat for damage 3 Whether damage is found or n...

Page 80: ...ith the start er the engine can be started with an emer gency starter rope WARNING EWM01021 Use this procedure only in an emergen cy to return to the nearest port for re pairs When the emergency starter rope is used to start the engine the start in gear protection device does not oper ate Make sure the remote control lever is in neutral Otherwise the boat could unexpectedly start to move which cou...

Page 81: ...Do not touch the fly wheel or other moving parts when the engine is running Do not install the starter mechanism or top cowling after the engine is running Do not touch the ignition coil spark plug wire spark plug cap or other elec trical components when starting or op erating the motor You could get an electrical shock EMU30361 Emergency starting engine 1 Remove the top cowling 2 Disconnect the s...

Page 82: ...er to minimize engine dam age EMU29783 Procedure 1 Thoroughly wash away mud salt sea weed and so on with fresh water 2 Remove the spark plug s then face the spark plug holes downward to allow any water mud or contaminants 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 5 Feed engine fogging oil or eng...

Page 83: ...77 Consumer information EMU29811 Important warranty information for U S A and Canada ...

Page 84: ...Consumer information 78 ...

Page 85: ...Consumer information 79 EMU29830 YAMAHA MOTOR CORPORATION U S A FOUR STROKE OUTBOARD MOTOR THREE YEAR LIMITED WARRANTY ...

Page 86: ...Consumer information 80 ...

Page 87: ...Consumer information 81 EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ...

Page 88: ......

Page 89: ...67C 9 18 Hyoshi 06 3 3 10 15 AM ページ 3 ...

Page 90: ...Printed in Japan April 2006 0 6 1 Printed on recycled paper 67C 9 18 Hyoshi 06 3 3 10 15 AM ページ 4 ...

Page 91: ... 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 N...

Page 92: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 04 2 17 03 2 41 PM Page 2 ...

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