Yamaha F4C Owner'S Manual Download | Manualshive

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E

5-1

EMU01663¯

TROUBLESHOOTING

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of
power, or other problems. The troubleshooting chart describes basic checks and possi-
ble remedies. (This chart covers all Yamaha outboard motors. Therefore, some items
may not apply to your model.)
If your outboard motor requires repair, bring it to a Yamaha dealer.
If the engine warning indicator is flashing, consult your Yamaha dealer.

A. Starter will not

operate.

Trouble

Possible Cause

Remedy

1. Starter components faulty.

2. Shift lever in gear.

1. Have serviced by a Yamaha

dealer.

2. 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

ignition wiring.

9. Ignition parts faulty.

10. Engine stop switch lanyard not

attached.

11. Engine inner parts damaged.

1. Fill tank with clean, fresh fuel.

2. Fill tank with clean, fresh fuel.

3. Clean or replace filter.

4. Read “STARTING ENGINE”

section.

5. Have serviced by a Yamaha

dealer.

6. Inspect spark plug(s). Clean or

replace with recommended type.

7. Check and re-fit cap(s).

8. Check wires for wear or breaks.

Tighten all loose connections.

Replace worn or broken wires.

9. Have serviced by a Yamaha

dealer.

10. Attach lanyard.

11. Have serviced by a Yamaha

dealer.

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Summary of Contents for F4C

Page 1: ...F4C OWNER S MANUAL U S A Edition LIT 18626 05 29 ...

Page 2: ......

Page 3: ... The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED w Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the out board motor cC A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make proce...

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: ... 1 1 Outboard motor serial 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 petrol 1 12 ENGINE OIL 1 13 PROPELLER SELECTION 1 14 START IN GEAR PROTECTION 1 15 1 2 3 4 5 6 E ...

Page 6: ...ttached to the port side of the clamp bracket Record your outboard motor serial num ber in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor serial number E 1 401012 M B K INDUSTRIE PRODUCT ASSEMBLED IN FRANCE PRODUIT ASSEMBLE EN FRANCE ...

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

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: ...ully Make sure there are no gas fumes or leaking fuel before starting the engine 8 This product emits exhaust gases which contain carbon monoxide a colorless odorless gas which may cause brain damage or death when inhaled 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 opera...

Page 10: ...any organizations including the following United States Coast Guard Consumer Affairs Staff G BC Office of Boating Public and Consumer Affairs U S Coast Guard Headquarters Washington D C 20593 0001 Boating Safety Hotline 1 800 368 5647 National Marine Manufacturers Association NMMA 401 N Michigan Ave Chicago Il 60611 Marine Retailers Association of America 155 N Michigan Ave Chicago Il 60601 ...

Page 11: ... 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 67D 13444 40 Store the engine only as shown Otherwise engine damage could result from leaking oil CAUTION WARNING LEAKING FUEL COULD CAUSE A FIRE Before tilting up the engine or laying it on its side Turn ...

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 o...

Page 13: ...wer 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 close eno...

Page 14: ...er vessels in narrow channels Sailing vessel right of way Sailing vessels should normally be given the right of way The exceptions to this are 1 When the sailing vessel is overtaking the power driven vessel the power driven vessel has the right of way 2 Sailing vessels should keep clear of any fishing vessel 3 In a narrow channel a sailing vessel should not hamper the safe passage of a power drive...

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

Page 16: ...ely 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 fu...

Page 17: ...ter every 100 hours of opera tion E Recommended gasoline Regular unleaded gasoline with a minimum octane rating of 86 Pump octane number R M 2 EMU00027 Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not...

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

Page 19: ...adverse effect on the engine Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications but there may be uses where a propeller with a different pitch would be more appropriate For a greater operating load a smaller pitch propeller is more suitable as it enables the correct engine speed to be main tained Conversely a larger pitch pro peller is more suitab...

Page 20: ... reduce the throttle setting to maintain the rpm in the proper operating range 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 E 602025 7 1 4 x7 1 4 BA 1 2 3 EMU01209 START IN GEAR PROTECTION Yamaha outboard motors or Yamaha approved remote control units are...

Page 21: ...CTIONS 2 2 Fuel tank 2 2 Fuel cock 2 3 Gear shift lever 2 3 Engine stop button 2 4 Engine stop lanyard switch 2 4 Choke knob 2 5 Recoil starter handle 2 5 Tiller handle 2 5 Steering friction adjusting screw 2 7 Trim angle adjusting rod 2 7 Tilt support bar 2 7 Top cowling lock lever 2 8 Carrying handle 2 8 ...

Page 22: ...tion plate 6 Propeller 7 Cooling water inlet 8 Trim angle adjusting rod 9 Clamp bracket 0 Tiller handle q Air vent screw w Fuel tank cap e Recoil starter handle r Engine stop button Engine stop lanyard switch t Clamp screw y Rope attachment u Fuel hose joint i Choke knob o Gear shift lever May not be exactly as shown also may not be included as standard equipment on all models ...

Page 23: ...cap 4 Air vent screw If equipped EMU00042 Fuel Hose Joint This connector is provided for connecting or disconnecting fuel hose EMU00044 Fuel Meter This meter is on the fuel tank cap It shows current fuel quantity in the fuel tank approximately EMU00045 Fuel Tank Cap This cap is for filling fuel To remove it turn it counterclockwise EMU00046 Air Vent Screw This screw is on the fuel tank cap To loos...

Page 24: ...r stop fuel from the fuel tank to the engine EMU00930 CLOSE With the lever knob in this position shown in the illustration A fuel does not flow Always turn the knob to this position when the engine is not running EMU00970 OPEN There are two OPEN positions on the fuel cock for selecting the fuel flow from the built in tank or the portable tank With the knob in both positions fuel flows to the carbu...

Page 25: ...e stopping igni tion to the engine This will prevent the boat from 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 ...

Page 26: ... the steering direction In addition this handle contains the functions as fol lows 1 Throttle control grip 2 Throttle indicator 3 Throttle friction adjusting knob screw E 2 5 EMU00879 CHOKE KNOB Pulling out this knob setting it to ON supplies a rich mixture required to start the engine EMU00059 RECOIL STARTER HANDLE If equipped Pull the handle gently until resistance is felt Then vigorously pull t...

Page 27: ... device in the tiller handle pro vide resistance to movement of the throt tle grip This is adjustable for operator preference An adjusting screw knob is located within the tiller handle When constant speed is desired tighten the adjusting screw bolt to maintain the desired throttle setting w Do not over tighten the friction adjusting screw knob If there is too much resistance it may be difficult t...

Page 28: ...reference An adjusting screw bolt is located on the swivel brack et EMU01296 Adjustment w Do not over tighten the friction screw bolt If there is too much resis tance it may be difficult to steer which could result in an accident EMU01297 TRIM ANGLE ADJUSTING ROD The position of the trim angle adjusting rod determines the minimum trim angle of the outboard motor in relation to the transom Resistan...

Page 29: ...wl ing When replacing the cowling check to be sure it fits properly Then lock the cowl ing again by moving the lever downward EMU01240 CARRYING HANDLE A carrying handle is provided on the rear of the motor The carrying handle is designed to balance the weight of the motor to make it easier to carry one hand ed 415 1 ...

Page 30: ...E MEMO ...

Page 31: ...ecking the engine oil level 3 8 BREAKING IN RUNNING IN ENGINE 3 8 STARTING ENGINE 3 10 WARMING UP ENGINE 3 13 SHIFTING 3 14 Forward 3 14 Reverse 3 14 STOPPING ENGINE 3 15 TRIMMING OUTBOARD MOTOR 3 16 Adjusting trim angle 3 17 TILTING UP DOWN 3 19 CRUISING IN SHALLOW WATER 3 22 CRUISING IN OTHER CONDITIONS 3 23 Cruising in salt water 3 23 Cruising in turbid water 3 23 ...

Page 32: ...rne 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 outbo...

Page 33: ... 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 the center...

Page 34: ...eby reduce engine efficiency Mount the engine so that the anti cavita tion plate is between the bottom of the boat and a level 25 mm 1 in below it NOTE 8 The optimum mounting height of the outboard motor is affected by the boat motor combination and the desired use Test runs at different heights can help determine the opti mum mounting height 8 Refer to the section TRIMMING OUT BOARD MOTOR for ins...

Page 35: ... Loose clamp screws could allow the motor to move on the transom or fall off the transom This could cause loss of control and serious injury Make sure the transom screws are tightened securely Occasionally check the screws for tight ness during operation 2 An engine restraint cable or chain should be used Attach one end to the engine restraint cable attachment point and the other to a secure mount...

Page 36: ...bvious changes has been the elimination of lead from most fuels As gasoline has changed the amount of additives such as aromatics and oxy genates has increased These additives are important for the engines in passenger 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 Perform...

Page 37: ...not twisted or flattened or likely to contact sharp objects EMU00208 Oil 8 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 EMU00204 PRE OPERATION CHECKS w If any item in the pre operation check is not working properly have it inspected and repaired before operating the out board motor Otherwise an accident could occur cC Do not ...

Page 38: ...rols should work smoothly without binding or unusual free play 8 Look for loose or damaged connec tions 8 Check operation of the starter and stop switches when the outboard motor is in the water EMU00210 Engine 8 Check the engine and engine mounting 8 Look for loose or damaged fasteners 8 Check the propeller for damage ...

Page 39: ...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 EMU00224 BREAKING IN RUNNING IN ENGINE Your new engine requires a period of break in running in to allow mating sur faces of moving parts to wear in evenly Correct break in running in will help ensure proper performance and longer engine life cC Failure t...

Page 40: ...he 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 operation Avoid continuous operation at full throttle for more than five minutes at a time 4 After these first 10 hours Operate the engine normally 000826 000827 000828 ...

Page 41: ... loosening the air vent screw 8 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 Loosen the air vent screw attached to the both fuel tank caps on the built in and portable fuel tanks...

Page 42: ... stop switch w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control A...

Page 43: ...at if necessary 9 After the engine starts return the starter handle slowly to the original position before releasing it NOTE 8 When starting a cold engine the engine needs to be warmed up Refer to Warming Up Engine for details 8 If the engine doesn t start on the first try repeat the procedure If the engine fails to start after 4 or 5 tries open the throttle a small amount between 1 8 and 1 4 and ...

Page 44: ...ss leave the choke knob completely pulled out for approximately 30 seconds after starting Then follow the standard instructions for warming up the engine 2 Check for a steady flow of water from the cooling water pilot hole cC A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling pas sages If water is not flowing out of the pilot hole at all t...

Page 45: ... and firmly from Neutral to Forward EMU00849 REVERSE w When operating in Reverse go slowly Do not open the throttle more than half Oth erwise the boat may become unstable which could result in loss of control and an accident 1 Place the throttle control grip in the fully closed position 2 Turn the gear shift lever quickly and firmly from Neutral to Reverse NOTE The outboard motor will make a full ...

Page 46: ...nd hold the engine stop button until the engine comes to a complete stop 2 After stopping the engine disconnect the fuel line from the motor if a portable fuel tank is used 3 Tighten the air vent screw s on the fuel tank cap s 4 Set the fuel cock in the closed posi tion NOTE The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop lanyard switch ...

Page 47: ...at engine 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 read...

Page 48: ...he transom 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 w 8 Stop the engine before adjusting the trim angle 8 Use care to avoid being pinched when removing or installing the rod 8 Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any signs of instabili ty or contro...

Page 49: ...nd economy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces performance further and the boat may porpoise hop in the water which could throw the operator and passengers overboard Bow Down When the bow of the boat is down it is easier to accelerate from a standing start onto plane To...

Page 50: ... result 8 Do not tilt up the engine by pushing the steering handle as this could break the handle 8 Keep the power unit higher than the propeller at all times Otherwise water can run into the cylinder causing dam age 8 The outboard cannot be tilted when in Reverse or when the outboard is turned 180 facing to the rear w Be sure all people are clear of the out board motor when adjusting the tilt ang...

Page 51: ...ion 3 Place the gear shift lever in Neutral and face the motor forward 4 Tighten the steering friction adjusting screw by turning it clockwise to pre vent the motor from turning freely N 408 2 w Leaking fuel is a fire hazard Tighten the air vent screw and place the fuel cock in the closed position if the engine will be tilted for more than a few minutes Oth erwise fuel may leak ...

Page 52: ...n the steering friction adjusting screw by turning it counterclockwise and adjust the steering friction according to operator preference w If there is too much resistance it may be difficult to steer which could result in an accident 5 Hold the rear handle and tilt the engine up fully until the tilt support bar automatically turns to the locked position ...

Page 53: ...itting an underwater obstacle could cause the engine to lift out of the water resulting in loss of control 8 Do not rotate the engine 180 and oper ate the boat in reverse Place the gear shift in the Reverse position to operate the boat in reverse 8 Use extra care when operating in reverse Too much reverse thrust can cause the engine to lift out of the water increasing the chance of acci dent and p...

Page 54: ...s provided 2 or 3 positions for shallow water cruising EMU00316 CRUISING IN OTHER CONDITIONS CRUISING 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 instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR CRUISING IN TURBID WATER It is strongly recomm...

Page 55: ...Greasing 4 9 Cleaning and adjusting spark plug 4 10 Checking fuel system 4 11 Inspecting fuel filter 4 12 Inspecting idling speed 4 13 Changing engine oil 4 14 Checking wiring and connectors 4 16 Exhaust leakage 4 16 Water leakage 4 16 Checking propeller 4 17 Changing gear oil 4 19 Cleaning fuel tank 4 20 Inspecting and replacing anode s 4 21 Checking bolts and nuts 4 22 Motor exterior 4 22 Coatin...

Page 56: ... OIL Recommended fuel P O N Fuel tank capacity L US gal Imp gal Recommended engine oil API SAE Engine oil capacity L US qt Imp qt Recommended gear oil Gear oil capacity cm3 US oz Imp oz TIGHTENING TORQUE Spark plug N m kgf m lb ft Engine oil drain bolt N m kgf m lb ft 717 28 2 361 14 2 1 029 40 5 1 156 45 5 435 17 1 562 22 1 22 49 23 51 4 000 5 000 2 9 4 4 500 1 450 1 550 4 stroke OHV Single 112 6...

Page 57: ...on then trailer the motor in the tilt position using a motor support device such as a transom saver bar For further details consult 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 ma...

Page 58: ...the tilt support and fall If the motor can not be trailered in the down position use an additional support device to secure it in the up position EMU01362 TRANSPORTING OUTBOARD WHEN UNMOUNTED Transport in an upright position to pre vent engine oil from entering the cylinder head and causing damage to the motor 415 2 ...

Page 59: ...hanical damage or leakage 8 Drain cooling water completely before placing the engine on its side Other wise water may enter the engine through the exhaust manifold and cause corrosion or other mechanical damage 8 Store the engine in a dry well ventilat ed place not in direct sunlight 1 Vertical position 2 Horizontal position On the tiller handle q 102 1 w EMU00335 Filling Fuel Tank Fill the fuel t...

Page 60: ...le engine is running EMU00994 8 Flushing in a Water Tank cC If the fresh water level is below the level of the anti cavitation plate or if the water supply is insufficient engine seizure may occur 1 Remove the engine top cowling 2 Install the outboard motor on the water tank 3 Fill the tank with fresh water to above the level of the anti cavitation plate 4 Remove the cap 1 for fogging on the silen...

Page 61: ...pect 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 605016 q w EMU00351 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the out board with fresh water and dry off completely 2 Spray the engine s exterior with Yamaha Silicone Protec...

Page 62: ...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 63: ...ours 200 hours 1 month 3 months 6 months 1 year Spark plug s Cleaning adjustment replacement Greasing points Greasing Gear oil Change Fuel system Inspection Fuel filter disposable Inspection replacement 1 1 1 Fuel tank built in tank Inspection cleaning 1 Idling speed carburetor models Inspection adjustment 1 1 Anode s Inspection replacement 1 1 1 Cooling water passages Cleaning Propeller and cotte...

Page 64: ...E 4 9 EMU00366 GREASING Yamaha marine grease Water resistant grease ...

Page 65: ...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 66: ...k plug I D mark NGK 903022 q w Initial of spark plug I D mark Plug wrench size B 21 mm 13 16 in C BK 16 mm 5 8 in D 18 3 mm 23 32 in EMU00369 CHECKING FUEL SYSTEM w Gasoline petrol and its vapors are highly flammable and explosive Keep away from sparks cigarettes flames or other sources of ignition Check the fuel line for leaks cracks or malfunctions If any problem is found it should be repaired i...

Page 67: ...re on a hot or running engine Allow the engine to cool 8 There will be fuel in the fuel filter Keep away from 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 resul...

Page 68: ...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 69: ...an upright position 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 ...

Page 70: ...ller hole Reinstall the filler cap dipstick 5 Start the engine and make sure that there are no oil leaks 6 Turn off the engine and wait 3 min utes Recheck 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 NOTE 8 For disposal of used oil consult your ...

Page 71: ...h connector is engaged securely EMU00384 EXHAUST LEAKAGE Start the 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 ...

Page 72: ...r hand to hold the pro peller when loosening or tightening the propeller nut Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning 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 prop...

Page 73: ...eration and be lost 1 Apply Yamaha Marine grease or a corrosion resistant grease to the pro peller shaft 2 Install the thrust washer and propeller on the propeller shaft 3 Install the washer and tighten the pro peller nut 4 Align the propeller nut with the pro peller shaft hole Insert a new cotter pin in the hole and bend the cotter pin ends NOTE When the propeller nut does not align with the prop...

Page 74: ...sition not tilted 2 Place a suitable container under the gear case 3 Remove the oil drain plug 1 4 Remove the oil level plug 2 to allow the oil to drain completely cC Inspect the used oil after it has been drained If the oil is milky water is get ting into the gear case which can cause gear damage Consult a Yamaha dealer for repair of the lower unit seals NOTE For disposal of used oil consult your...

Page 75: ... when cleaning the fuel tank 8 Remove the fuel tank from the boat before cleaning it Work only outdoors in an area with good ventilation 8 Wipe up any spilled fuel immediately 8 Reassemble the fuel tank carefully Improper assembly can result in a fuel leak which could result in a fire or explosion hazard 8 Dispose of old gasoline petrol accord ing to local regulations 1 Empty the fuel tank into an...

Page 76: ...ive NOTE Inspect ground leads attached to external anodes on equipped models Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit EMU00402 Cleaning the Fuel Filter 1 Remove the screws holding the fuel hose joint assembly Pull the assem bly out of the tank 2 Clean the filter located on the end of the suction pipe in a suitable clean ing solvent Allow ...

Page 77: ...ons in TRANSPORTING AND STORING OUTBOARD MOTOR EMU00412 Checking Painted Surface of Motor Check the motor for scratches nicks or flaking paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas A touch up paint is available from a Yamaha dealer EMU00413 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clean of ...

Page 78: ...E 4 23 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 ...

Page 79: ...E EMU00414 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Starter will not operate 5 6 Treatment of submerged motor 5 9 1 2 3 4 5 6 ...

Page 80: ...ngine 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 ignition wiring 9 Ignition parts faulty 10 Engine stop switch lanyard not attached 11 Engine inner parts damaged 1 Fill tank with...

Page 81: ...ion incorrect 17 Throttle valve adjustment incorrect 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 Inspect and adjust as specified 7 Check wires for wear or breaks Tighten all loose connections Replace worn or ...

Page 82: ...repaired or replaced 2 Install correct propeller to operate outboard at its recommended speed r min range 3 Adjust trim angle to achieve most efficient operation 4 Have motor adjusted to proper transom height 5 Clean boat bottom 6 Inspect spark plug s Clean or replace with recommended type 7 Remove foreign matter and clean lower unit 8 Check for pinched or kinked fuel line or other obstructions in...

Page 83: ...ler shaft damaged 3 Weeds or other foreign matter tangled on propeller 4 Motor mounting bolt loose 5 Steering pivot loose or damaged 1 Have propeller repaired or replaced 2 Have serviced by a Yamaha dealer 3 Remove and clean propeller 4 Tighten bolt 5 Tighten or have serviced by a Yamaha dealer ...

Page 84: ...motor unsafe to operate If the outboard motor hits any object in the water follow the procedure below 1 Stop the engine immediately 2 Inspect control system and all compo nents for damage Also inspect the boat damage 3 However damage is found or not found go back to a nearest harbor slowly and carefully 4 Have a Yamaha dealer inspection of the outboard motor before operating it again 607011 ...

Page 85: ...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 86: ...on the starter After removing the choke cable con firm that the cable end is contacted with the silencer by pushing it inside 3 Remove the start in gear protection cable end by pulling it out from the lever of the starter after loosening the nut 3 4 Remove the starter after removing the three bolts e q w 5 Reinstall two bolts to secure the fuel tank ...

Page 87: ...anyard lock plate is attached to the engine stop lanyard switch 7 Insert the knotted end of the emer gency starter rope into the notch in the rotor and wind the rope several turns clockwise 8 Pull the rope slowly until resistance is felt 9 Give a strong pull straight out to crank and start the engine Repeat if necessary N ...

Page 88: ...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 89: ...EMU00450 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 90: ...5 7 Emission control information 1 2 Engine oil 1 13 Engine stop button 2 4 Engine stop lanyard switch 2 4 Exhaust leakage 4 16 F Filling fuel 3 5 Flushing cooling system and fogging engine 4 5 Forward 3 14 Fuel cock 2 3 Fuel hose joint 2 2 Fuel meter 2 2 Fuel tank 2 2 4 4 Fuel tank cap 2 2 Fueling instructions 1 11 G Gasohol 1 12 Gasoline petrol 1 12 Gear shift lever 2 3 Greasing 4 9 I Identifica...

Page 91: ...rottle control grip 2 5 Throttle friction adjusting screw knob 2 6 Throttle indicator 2 6 Tiller handle 2 5 Tilt support bar 2 7 Tilting up down 3 19 Top cowling lock lever 2 8 Trailering outboard motor 4 2 Transporting and storing outboard motor 4 2 Transporting outboard when unmounted 4 3 Treatment of submerged motor 5 9 Trim angle adjusting rod 2 7 Trim angle settings and boat handling 3 18 Tri...

Page 92: ...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 93: ...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 94: ...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 95: ...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 96: ...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 97: ...will 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 deale...

Page 98: ...Printed in France January 2003 0 5 1 68D F8199 13 F4AMH E Printed on recycled paper ...

Page 99: ...Warranty card 12 6 01 7 40 PM Page 1 ...

Page 100: ...Warranty card 12 6 01 7 40 PM Page 2 ...

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