Yamaha F4D Owner'S Manual Download Page 45 | Manualshive

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Maintenance

40

NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushed with clean

water after each use.

EMU28931

Greasing

Yamaha marine grease (Water resistant grease)

F4D

EMU28950

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.

ZMU02706

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Summary of Contents for F4D

Page 1: ...F4D OWNER S MANUAL 68D F8199 14 U S A Edition LIT 18626 05 97 ...

Page 2: ...EMU25060 ZMU01690 Read this owner s manual carefully before operating your outboard motor ...

Page 3: ... board 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 di...

Page 4: ...iction adjuster 16 Trim rod tilt pin 16 Tilt lock mechanism 16 Tilt support bar 16 Top cowling lock lever pull up type 17 Carrying handle 17 Operation 18 Installation 18 Mounting the outboard motor 18 Clamping the outboard motor 19 Breaking in engine 20 Procedure for 4 stroke models 20 Preoperation checks 20 Fuel 20 Controls 20 Engine 21 Checking the engine oil level 21 Filling fuel 21 Operating e...

Page 5: ...oil leakage 44 Checking propeller 44 Removing the propeller 45 Installing the propeller 45 Changing gear oil 46 Cleaning fuel tank 47 Inspecting and replacing anode s 47 Checking top cowling 48 Coating the boat bottom 48 Trouble Recovery 49 Troubleshooting 49 Temporary action in emergency 52 Impact damage 52 Starter will not operate 52 Emergency starting engine 53 Treatment of submerged motor 54 P...

Page 6: ...erence in case your outboard motor is sto len EMU25220 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 EMU25241 Approval label of emission control certif icate This label is attached to the bottom cowling New Technology 4 stroke HPDI EM EMU...

Page 7: ...roke 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 these standards have 20 lower emissions than One Star Low Emission engines EMU25300 Three Stars Ultra Low Emission The three star label identifie...

Page 8: ...ns Gasoline is highly flammable and its va pors are flammable and explosive Handle and store gasoline carefully Make sure there are no gas fumes or leaking fuel be fore starting the engine This product emits exhaust gases which contain carbon monoxide a colorless odorless gas which may cause brain dam age or death when inhaled Symptoms in clude nausea dizziness and drowsiness Keep cockpit and cabi...

Page 9: ...n Ave Chicago Il 60611 Marine Retailers Association of America 155 N Michigan Ave Chicago Il 60601 EMU25380 Important labels EMU25395 Warning labels EMU25401 Label WARNING EWM01260 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 whi...

Page 10: ...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 of way has the duty to take positive and timely action to stay out of the way o...

Page 11: ...t side must keep out of the way of the other If the other vessel is on your right you must keep out of its way you are the Give Way vessel If the other vessel is on your port left side remember that you should maintain course and direc tion provided the other vessel gives you the right of way as it should Overtaking If you are passing another vessel you are the Give Way vessel This means that the ...

Page 12: ... Reading buoys and other markers The waters of the United states are marked for safe navigation by the lateral system of buoyage Simply put buoys and markers have an arrangement of shapes colors numbers and lights to show which side of the buoy a boater should pass on when navigat ing in a particular direction The markings on these buoys are oriented from the perspec tive of being entered from sea...

Page 13: ... 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 14: ...on 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 EMU25680 Engine oil CAUTION ECM01050 All 4 stroke engines are shipped from the factory without engine oil...

Page 15: ... outboard that is best suited to your ap plication NOTE Select a propeller which will allow the engine to reach the middle or upper half of the oper ating range at full throttle with the maximum boat load If operating conditions such as light boat loads then allow the engine r min to rise above the maximum recommended range reduce the throttle setting to maintain the engine in the proper operating...

Page 16: ...pplied with this engine is 1 2 4 8 7 6 9 3 5 10 2 11 14 18 17 16 13 12 15 19 ZMU04483 20 1 Top cowling 2 Top cowling lock lever 3 Carrying handle 4 Steering friction screw 5 Anti cavitation plate 6 Propeller 7 Cooling water inlet 8 Trim rod 9 Clamp bracket 10 Tiller handle 11 Air vent screw 12 Fuel tank cap 13 Manual starter handle 14 Engine stop button Engine stop lanyard switch 15 Clamp screw 16...

Page 17: ...in the tank EMU25850 Fuel tank cap This cap seals the fuel tank When removed the tank can be filled with fuel To remove the cap turn it counterclockwise EMU25860 Air vent screw This screw is on the fuel tank cap To loosen the screw turn it counterclockwise EMU25872 Fuel cock The fuel cock turns on and off the supply of fuel from the fuel tank to the engine EMU25881 Close To stop fuel flow to the e...

Page 18: ...sitions EMU25911 Tiller handle To change direction move the tiller handle to the left or right as necessary EMU25921 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 you puts the engine in reverse gear so that the boat moves astern 1 Close position 1 OPEN position for the built in tank ZMU02659 1 ZMU0...

Page 19: ...ster 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 EWM00030 Do not overtighten the friction adjuster If there is too much resistance it could be difficult to move thrott...

Page 20: ...ting 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 could cause people and objects in the boat to be thrown forwar...

Page 21: ...r 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 EMU26261 Trim rod tilt pin The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom EMU26312 Tilt lock mechanism The tilt lock mechanism is used to prevent the outboard mo...

Page 22: ...g check to be sure it fits properly in the rubber seal Then lock the cowling by moving the lever s down ward EMU26450 Carrying handle A carrying handle is provided on the rear of the outboard motor It enables you to carry the outboard motor easily with one hand 1 Top cowling lock lever s 1 Top cowling lock lever s ZMU02674 ZMU02675 1 ZMU04522 1 1 Carrying handle ZMU02676 1 ...

Page 23: ...ec tion 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 Fo...

Page 24: ...otor see page 27 EMU26970 Clamping the outboard motor 1 Place the outboard motor on the tran som so that it is positioned as close to the center as possible Tighten the tran som clamp screws evenly and securely Occasionally check the clamp screws for tightness during operation of the out board motor because they could be come loose due to engine vibration WARNING EWM00640 Loose clamp screws could ...

Page 25: ...2 For the second hour of operation Run the engine at 3000 r min or at ap proximately three quarter throttle 3 For the next eight hours of operation Avoid continuous operation at full throt tle for more than five minutes at a time 4 After the first 10 hours Operate the engine normally EMU27101 Preoperation checks WARNING EWM00080 If any item in the preoperation check is not working properly have it...

Page 26: ...ipstick 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 the specified level if it is above the upper mark NOTE Be sure to completely insert the dipstick into the dipstick guide EMU30540 Filling fuel WARNING EWM00060 Ga...

Page 27: ...e flammable and explosive Refrain from smoking and keep away from open flames and sparks while loosen ing the air vent screw This product emits exhaust gases which contain carbon monoxide a col orless odorless gas which could cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cab in areas well ventilated Avoid blocking exhaust outlets 1 For t...

Page 28: ...rt 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 EWM00120 Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg while operating Do no...

Page 29: ...y After the engine starts replace return the knob to the home position NOTE It is not necessary to use the choke when starting a warm engine If the choke knob is left in the start position while the engine is running the engine will run poorly or stall 5 Pull the manual starter handle slowly un til you feel resistance Then give a strong pull straight out to crank and start the engine Repeat if nec...

Page 30: ... left pulled out after the engine starts the engine will stall In temperatures of 5 C or less leave the choke knob pulled out fully for approxi mately 30 seconds after starting 2 Check for a steady flow of water from the cooling water pilot hole CAUTION ECM00510 A flow of water from the hole on the ex haust cover shows that the water pump is pumping water through the cooling pas sages If water is ...

Page 31: ...boat could become unstable which could result in loss of control and an accident 1 Place the throttle grip in the fully closed position 2 Move the gear shift lever quickly and firmly from neutral to reverse NOTE The outboard motor can turn 360 in its bracket full pivot system The boat can also be backed up by simply turning the outboard motor around 180 with the steering handle facing toward you E...

Page 32: ...f the outboard motor helps determine 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 tr...

Page 33: ...t works best for your boat and operating conditions WARNING EWM00400 Stop the engine before adjusting the trim angle Use care to avoid being pinched when removing or installing the rod Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any signs of instabil ity or control problems Improper trim angle can cause loss of control NOTE The outboard motor ...

Page 34: ...boat may por poise hop in the water which could throw the operator and passengers overboard Bow Down Too much trim in causes the boat to plow through the water decreasing fuel economy and making it hard to increase speed Oper ating with excessive trim in at higher speeds also makes the boat unstable Resistance at the bow is greatly increased heightening the danger of bow steering and making opera ...

Page 35: ...vere damage from overheating can result Do not tilt up the engine by pushing the tiller handle because this could break the handle Keep the power unit higher than the propeller at all times Otherwise water could run into the cylinder and cause damage The outboard motor cannot be tilted when in reverse or when the outboard motor is turned 180 facing the rear EMU27964 Procedure for tilting up manual...

Page 36: ... lever equipped models Hold the rear handle and tilt the engine up ful ly until the tilt support lever automatically locks NOTE Tilt support lever bar equipped models If the motor is not facing forward the tilt support le ver bar cannot automatically turn to the locked position If the tilt support lever bar does not automatically lock swing the motor a little to the left and right EMU28031 Procedu...

Page 37: ...uising system The tilt lock mecha nism does not work while the shallow water cruising system is being used Hitting an underwater obstacle could cause the outboard motor to lift out of the water resulting in loss of control Do not rotate the outboard motor 180 and operate the boat in reverse Place the gear shift in reverse to operate the boat in reverse Use extra care when operating in re verse Too...

Page 38: ...r and slowly tilt the en gine down NOTE The outboard motor is equipped with 2 or 3 positions for shallow water cruising EMU28190 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 with salt deposits NOTE For cooling system flushing instructions see page 35 Cruising in turbid wa...

Page 39: ... in Control system Tiller Starting system Manual Starting carburetion system Choke valve Valve clearance cold engine IN 0 08 0 12 mm 0 0032 0 0047 in Valve clearance cold engine EX 0 08 0 12 mm 0 0032 0 0047 in Drive unit Gear positions Forward neutral reverse Gear ratio 2 08 27 13 Trim and tilt system Manual tilt Propeller mark BA Fuel and oil Recommended fuel Unleaded regular gasoline Min pump o...

Page 40: ...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 loose from the tilt sup port and fall If the motor cannot be trail ered in the normal running position use an additional support device to secure it in the tilt position The outboard motor s...

Page 41: ...ot up right put it on a cushion after draining the engine oil Do not place the outboard motor on its side before the cooling water has drained from it completely otherwise water may enter the cylinder through the exhaust port and cause engine trou ble Store the outboard motor in a dry well ventilated place not in direct sunlight EMU28301 Procedure EMU28372 Flushing in a test tank 1 Wash the outboa...

Page 42: ...7 Run the engine at a fast idle for 10 15 minutes in neutral position 8 Just prior to turning off the engine quick ly spray Yamaha Stor Rite Engine Fogging Oil Part No LUB STRRT 12 00 alternately into each carburetor or the fogging hole of the silencer cover if equipped When properly done the en gine will smoke excessively and almost stall 9 Remove the outboard motor from the test tank 10 Drain th...

Page 43: ...eriodic 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 servicing this work should be done by your Yamaha dealer or other qualified mechanic Maintenance replacement or repair of the emission control devices and sys tems may be performed by any marine engine repair establishment or ...

Page 44: ... Inspection replace ment Anode s internal Inspection replace ment Cooling water pas sages Cleaning Cowling clamp Inspection Fuel filter disposable Inspection replace ment Fuel system Inspection Fuel tank built in tank Inspection cleaning Fuel tank Yamaha por table tank Inspection cleaning Gear oil Change Greasing points Greasing Idling speed carbure tor models Inspection adjustment Propeller and c...

Page 45: ...r after each use EMU28931 Greasing Yamaha marine grease Water resistant grease F4D EMU28950 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 ZMU02706 ...

Page 46: ...et surface and use a new gasket Wipe off any dirt from the threads and screw in the spark plug to the correct torque NOTE If a torque wrench is not available when you are fitting a spark plug a good estimate of the correct torque is 1 4 to 1 2 a turn past fin ger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench EMU28961 Checking fuel system WARNING ...

Page 47: ... boat could unexpectedly start to move which could result in an accident CAUTION ECM00490 This procedure must be performed while the outboard motor is in the water A flushing attachment or test tank can be used A diagnostic tachometer should be used for this procedure Results may vary depending on whether testing is conducted with the flushing attachment in a test tank or with the outboard motor i...

Page 48: ...0 Change the engine oil after the first 10 hours of operation and every 100 hours or at 6 month intervals thereafter Other wise the engine will wear quickly NOTE Change the engine oil when the oil is still warm 1 Put the outboard motor in an upright po sition not tilted 2 Prepare a suitable container that holds a larger amount than the engine oil capac ity Loosen and remove the drain screw while h...

Page 49: ... 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 leaks are found consult your Yamaha dealer EMU29171 Checking propeller WAR...

Page 50: ...ism The propeller will then spin freely on the shaft If this happens the shear pin must be replaced EMU29193 Removing the propeller 1 Straighten the cotter pin and pull it out using a pair of pliers 2 Remove the propeller nut washer and spacer if equipped 3 Remove the propeller and thrust wash er EMU30370 Installing the propeller CAUTION ECM00340 Be sure to install the thrust washer be fore instal...

Page 51: ...jured if the outboard motor falls on you Never get under the lower unit while it is tilted even when the tilt support lever or knob is locked Severe injury could occur if the outboard motor accidental ly falls 1 Tilt the outboard motor so that the gear oil drain screw is at the lowest point pos sible 2 Place a suitable container under the gear case 3 Remove the gear oil drain screw NOTE If the mag...

Page 52: ...re or ex plosion hazard Dispose of old gasoline according to lo cal regulations 1 Empty the fuel tank 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 su...

Page 53: ... with both hands If it is loose have it re paired by your Yamaha dealer EMU29400 Coating the boat bottom A clean hull improves boat performance The boat bottom should be kept as clean of ma rine growth as possible If necessary the boat bottom can be coated with an anti foul ing paint approved for your area to inhibit marine growth Do not use anti fouling paint which includes copper or graphite The...

Page 54: ...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 23 Q Has fuel pump malfunctioned A Have serviced by a Yamaha deal...

Page 55: ...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 56: ...g s fouled 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 w...

Page 57: ...lering 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 not return to the nearest harbor slowly and careful ly 4 Have a Yamaha dealer inspect the out board motor b...

Page 58: ... only as instructed 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 EMU29621 Emergency starting engine 1 Remove the top cowlin...

Page 59: ...t out to crank and start the engine Repeat if neces sary EMU29760 Treatment of submerged motor If the outboard motor is submerged immedi ately take it to a Yamaha dealer Otherwise some corrosion may begin almost immedi ately If you cannot immediately take the outboard motor to a Yamaha dealer follow the proce dure below in order to minimize engine dam age EMU29783 Procedure 1 Thoroughly wash away ...

Page 60: ...il through the carburetor s and spark plug holes while cranking the engine with the manual starter or emergency starter rope 6 Take the outboard motor to a Yamaha dealer as soon as possible CAUTION ECM00400 Do not attempt to run the outboard motor until it has been completely inspected Engine oil capacity 0 5 L 0 53 US qt 0 44 Imp qt ZMU02724 ZMU02725 ...

Page 61: ...56 Consumer information EMU29811 Important warranty information for U S A and Canada ...

Page 62: ...Consumer information 57 ...

Page 63: ...Consumer information 58 EMU29830 YAMAHA MOTOR CORPORATION U S A FOUR STROKE OUTBOARD MOTOR THREE YEAR LIMITED WARRANTY ...

Page 64: ...Consumer information 59 ...

Page 65: ...Consumer information 60 EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U S A OR CANADA ...

Page 66: ...Printed in France April 2004 0 5 1 ...

Page 67: ...Warranty card 12 6 01 7 40 PM Page 1 ...

Page 68: ...Warranty card 12 6 01 7 40 PM Page 2 ...

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