Yamaha F75B Page 93 Ower'S Manual Download

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EMN00010

Chapter 5

TROUBLE RECOVERY

TROUBLESHOOTING

..............................5-1

TEMPORARY ACTION IN
EMERGENCY

............................................5-5

Impact damage.....................................5-5
Power trim/tilt will not operate ...........5-5
Starter will not operate ........................5-6
Engine fails to operate .........................5-8
Treatment of submerged motor .........5-9

67F-9-16-5 3/3/02 10:56 AM Page 1

Summary of Contents for F75B

Page 1: ...F75B F80B F90B OWNER S MANUAL U S A Edition LIT 18626 05 09 ...

Page 2: ......

Page 3: ...ecial 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 advance ments in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your machine and this manual If t...

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Page 5: ...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 ...

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Page 7: ...Outboard motor serial number 1 1 Key number 1 1 EMISSION CONTROL INFORMATION 1 2 SAFETY INFORMATION 1 4 IMPORTANT LABELS 1 6 BASIC BOATING RULES 1 7 FUELING INSTRUCTIONS 1 11 Gasoline 1 12 ENGINE OIL 1 13 BATTERY REQUIREMENT 1 14 PROPELLER SELECTION 1 14 START IN GEAR PROTECTION 1 16 1 ...

Page 8: ...ou in ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor serial number EMU00008 KEY NUMBER If a main key switch is equipped with the motor 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 1 Key number q F1001 904011 12...

Page 9: ...ew 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 FELs SPA...

Page 10: ...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 11: ...bstacles and other traffic 8 Always watch carefully for swimmers during the engine operation 8 Stay away from swimming areas EMU00917 SAFETY INFORMATION 8 Before mounting or operating the out board motor read this entire manual Reading it should give you an under standing of the motor and its operation 8 Before operating the boat read any owner s or operator s manuals supplied with it and all labe...

Page 12: ...ny 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 13: ...RNING 8Be sure shift control is in neutral before starting engine except 2HP 8Do not touch or remove electrical parts when starting or during operation 8Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 6A1 83625 41 ...

Page 14: ... dened vessel These rules determine which vessel has the right of way and what each vessel should do Stand on vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision When you maintain your direction and speed the other vessel will be able to determine how best to avoid you Give way vessel The vessel which does not have the right ...

Page 15: ...hree main situations which you may encounter with other vessels which could lead to a collision unless the Steer ing Rules are followed Meeting you are approaching another vessel head on Crossing you are traveling across the other vessel s path Overtaking you are passing or being passed by another vessel In the following illustration your boat is in the center You should give the right of way to a...

Page 16: ...de the passage of other vessels in narrow channels Sailing vessel right of way Sailing vessels should normally be given the right of way The exceptions to this are 1 When the sailing vessel is overtaking the power driven vessel the power driven vessel has the right of way 2 Sailing vessels should keep clear of any fishing vessel 3 In a narrow channel a sailing vessel should not hamper the safe pas...

Page 17: ...g toward head of naviga tion Leave to starboard right proceeding up stream White Light Red Light A LIGHTED SAFE WATER BUOY No number Marks midchannel pass on either side Letter has no lateral significance used for No number Topmost band red preferred Top Mark White Light White Light OR OR LIGHTED PREFERRED CHANNEL TO RB L RG L PORT BUOY identification and location purposes channel is to left of bu...

Page 18: ...ly 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 fun...

Page 19: ...nol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not recommended by Yama ha because it can cause fuel system dam age or engine performance problems Recommended gasoline Regular unleaded gasoline with a minimum octane rating of 86 Pump Octane Number R M 2 ...

Page 20: ...troke 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 Engine oil quantity See Chapter 4 Specifications 001162 SAE API SE SF SG SH SJ 10W 30 10W 40 ...

Page 21: ... cold cranking amps CCA SAE 380 amps at 18 C 0 4 F Minimum marine cranking amps MCA ABYC 502 amps at 0 C 32 F Minimum reserve capacity RC SAE 124 minutes EMU01395 PROPELLER SELECTION The performance of your outboard motor will be critically affected by your choice of propeller as an incorrect choice could adversely affect performance and could also seriously damage the motor Engine speed depends o...

Page 22: ...ard that is best suited to your application NOTE At full throttle and under a maximum boat load the engine s rpm should be within the upper half of the full throttle operating range as listed in SPECIFICA TIONS on page 4 1 Select a propeller which fulfills this requirement If operating under conditions which allow the engine s rpm to rise above the maxi mum recommended range such as light boat loa...

Page 23: ...TION Yamaha outboard motors or Yamaha approved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is Neutral Always select Neutral before starting the engine ...

Page 24: ...E MEMO ...

Page 25: ...ONTROLS AND OTHER FUNCTIONS 2 2 Remote control 2 2 Trim tab 2 6 Power trim tilt switch 2 7 Digital tachometer 2 8 Tilt support lever 2 11 Top cowling lock levers 2 11 Flushing device 2 11 WARNING SYSTEM 2 12 Overheat warning 2 12 Low oil pressure warning 2 13 1 2 3 4 5 6 E ...

Page 26: ... drain bolt 4 Anti cavitation plate 5 Trim tab Anode 6 Propeller 7 Cooling water inlet 8 Clamp bracket 9 Tilt support lever 0 Flushing device q Power trim and tilt switch w Remote control box e Digital tachometer May not be exactly as shown also may not be included as standard equipment on all models ...

Page 27: ...Remote Control Lever Moving the lever forward from the Neu tral position engages Forward gear Pulling the lever back from Neutral engages Reverse The engine will contin ue to run at idle until the lever is moved about 35 a detent can be felt Moving the lever farther opens the throttle and the engine will begin to accelerate 1 Neutral 5 Fully closed 2 Forward 6 Throttle 3 Reverse 7 Fully open 4 Shi...

Page 28: ...emote control lever is in Neu tral The remote control lever will operate only when the neutral throttle lever is in the closed position 1 Fully open 2 Fully closed EMU00101 Main switch The main switch controls the ignition sys tem its operation is described below 8 OFF Electrical circuits switched off The key can be removed 8 ON Electrical circuits switched on The key cannot be removed 8 START Sta...

Page 29: ... away under power w 8 Attach the lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control Als...

Page 30: ...ition NOTE Refer to the sections ADJUSTING TRIM ANGLE and TILTING UP DOWN in Chapter 3 for instructions on usage EMU01155 Throttle Friction Adjusting Screw A friction device in the remote control box provides adjustable resistance to move ment of the remote control lever and can be set according to operator preference An adjusting screw is located on the front of the remote control box w Do not ov...

Page 31: ...r replaced to be sure steering is correct Be sure you have tightened the bolt after adjusting the trim tab 1 Trim tab 2 Bolt 3 Cap If equipped q w e 603014 q F1010 A B cC The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode Boat tends to veer The fin of trim tab To the left Turn to the left port...

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

Page 33: ...er trim meter hour meter low oil pressure warn ing indicator and the overheat warning indicator 1 Tachometer 2 Trim meter 3 Hour meter 4 Low oil pressure warning indicator 5 Overheat warning indicator 6 Set button 7 Mode button NOTE All segments of the display will light momentarily after the main switch is turned on and will return to normal there after ...

Page 34: ...Meter This meter shows the number of hours the engine has been run It can be set to show the total number of hours or the number of hours for the current trip The display can also be turned on and off 8 Changing the display format Pressing the MODE button changes the display format in the following circular pattern Total hours Trip hours Display off 8 Resetting the trip hours Simultaneously pressi...

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

Page 36: ...er seal Then lock the cowling again by moving the levers downward F1009 EMU00157 TILT SUPPORT LEVER To keep the outboard motor in the tilted up position lock the tilt support lever to the clamp bracket 000365 q EMU01146 FLUSHING DEVICE This device 1 is used to clean the cooling water passages of the motor using a gar den hose and tap water NOTE Refer to Cleaning Cooling water Pas sages in Chapter ...

Page 37: ...verheat warning device If the engine temperature rises too high the warning device will activate 1 Included N A If the warning system has been activated stop the engine and check the water inlet for clogging 605015 Activation of Tiller Remote warning device control control model modell The engine speed will automatically 1 decrease to about 3 000 r min The overheat warning indicator 1 will come on...

Page 38: ...k oil level and add oil as needed If the oil level is correct consult your Yamaha dealer cC Do not continue to run the engine if the low oil pressure lamp is ON Serious engine damage may occur Activation of Tiller Remote warning device control control model model Engine speed will automatically 1 decrease to about 3 000 r min The low oil pressure warning indicator 1 will come on The buzzer will so...

Page 39: ...hecking the engine oil level 3 6 BREAKING IN RUNNING IN ENGINE 3 7 STARTING ENGINE 3 8 WARMING UP ENGINE 3 11 SHIFTING 3 12 Forward 3 12 Reverse 3 12 STOPPING ENGINE 3 13 TRIMMING OUTBOARD MOTOR 3 14 Adjusting trim angle 3 15 TILTING UP DOWN 3 17 CRUISING IN OTHER CONDITIONS 3 19 Cruising in salt water 3 19 1 2 3 4 5 6 E ...

Page 40: ... 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 outboard...

Page 41: ... 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 42: ... resistance will increase and thereby reduce engine efficiency Mount the engine so that the anti cavita tion plate is in alignment with the bottom of the boat NOTE 8 The optimum mounting height of the outboard motor is affected by the boat motor combination Test runs at different heights can help determine the optimum mounting height 8 Refer to the section TRIMMING OUT BOARD MOTOR for instructions...

Page 43: ...d the amount of additives such as aromatics and oxy genates has increased These additives are important for the engines in passen ger cars but they can have detrimental effects in marine engines because of increased deposits in the combustion chamber When enough deposits collect piston rings begin sticking Performance drops and engine wear increases dramati cally While many additives available may...

Page 44: ...mage can occur EMU00206 Fuel 8 Check to be sure you have plenty of fuel for your trip 8 Make sure there are no fuel leaks or gasoline fumes 8 Check fuel line connections to be sure they are tight 8 Be sure the fuel tank is positioned on a secure flat surface and that the fuel hose is not twisted or flattened or likely to contact sharp objectss EMU00208 Oil 8 Check the level of the oil in the sump ...

Page 45: ...unting 8 Look for loose or damaged fasteners 8 Check the propeller for damage EMU01436 CHECKING THE ENGINE OIL LEVEL 1 Put the outboard motor in an upright position not tilted 2 Pull out the oil dipstick and wipe it clean 3 Completely re insert the dipstick and pull out it again 4 Check the oil level using the dipstick to be sure the level falls between the upper and lower marks Fill with oil if i...

Page 46: ... the engine under load in gear with a propeller installed as follows 1 For the first hour of operation Run the engine at 2 000 r min or at approximately half throttle 2 For the second hour of operation Run the engine at 3 000 r min or at approximately three quarter throttle and during this period run it at full throttle for approximately one minute every ten minutes 3 For the next eight hours of o...

Page 47: ...pen flames and sparks while 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 If there is an air vent screw on the fuel tank cap loosen it 2 or 3 turns ...

Page 48: ...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 from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slo...

Page 49: ...main switch to return it to ON cC 8 Do not turn the main switch to START when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds The battery will rapidly become exhausted and it will be impossible for it to start the engine If the engine does not start within 5 seconds return the main switch to ON wait 10 seconds and then crank the engine again ...

Page 50: ...serious engine damage could occur Check the oil level and add oil if necessary If the cause for the low oil pressure warning indicator cannot be found consult your Yamaha dealer 8 A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages If water is not flowing out of the pilot hole at all times while the engine is running do not continu...

Page 51: ...the neutral interlock trigger If equipped and move the remote control lever quickly and firmly from Neutral to Forward 701034 UP DN 701043 N F EMU00269 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 Pull up the neutral interlock trigger If equipped and move the remot...

Page 52: ...he fuel joints are provided discon nect the fuel line from the motor after stopping the engine 3 Tighten the air vent screw on the fuel tank cap after stopping the engine if it is equipped 4 Remove the key if the boat will be left unattended NOTE The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop lanyard switch then turning the main switch to OFF...

Page 53: ... and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed w Excessive trim for the operating condi tions either trim up or trim down can cause boat instability and can make steering the boat more difficult This increases the possibility of an accident If the boat begins to feel unstable or is hard to steer slow down and or readjust the ...

Page 54: ...ilt switch located on the bottom engine cowling if equipped only when the boat is at a complete stop with the engine off The outboard motor trim angle can be adjusted operating the power trim tilt switch 1 To raise the bow trim out push the switch UP To lower the bow trim in push the switch DN Make test runs with the trim set to differ ent angles to find the position that works best for your boat ...

Page 55: ... there is more air drag Excessive trim up can cause the propeller to ventilate which reduces performance further When trimmed out too much a boat may porpoise hop in the water which could throw the operator and pas sengers overboard EMU00283 Bow Down When the bow of the boat is down it is easier to accelerate from a standing start onto plane Too much trim in causes the boat to plow through the wat...

Page 56: ...dures under STOPPING ENGINE Never tilt the motor while the engine is running Severe damage from overheating can result w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinch any body parts between the drive unit and engine bracket w Leaking fuel is a fire hazard Disconnect the fuel line or close the fuel cock if the engine will be tilted fo...

Page 57: ...utboard has tilted up com pletely UP DN F1006 UP DN 701034 UP DN F1009 3 Turn the tilt support lever toward engine bracket and support the engine w 8 After tilting the engine be sure to sup port it with the tilt support lever Oth erwise the engine could fall back down suddenly if oil in the power trim tilt unit should lose pressure 8 Never operate the engine while it is supported by the tilt suppo...

Page 58: ...sh the power trim tilt switch DN Down to lower the engine to the desired position 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 F1015 ...

Page 59: ...ystem 4 13 Inspecting fuel filter 4 14 Adjusting idling speed 4 16 Changing engine oil 4 17 Checking timing belt 4 19 Replacing fuse 4 20 Checking wiring and connectors 4 21 Exhaust leakage 4 21 Water leakage 4 21 Checking power trim and tilt system 4 22 Checking propeller 4 23 Changing gear oil 4 25 Inspecting and replacing anodes 4 26 Checking battery 4 27 Checking bolts and nuts 4 30 Cleaning c...

Page 60: ...king amps MCA ABYC Min reserve capacity RC SAE 8Alternator output 8Starting carburetion system cm3 cu in mm in NGK mm in mm in mm in amps at 18 C 0 4 F amps at 0 C 32 F minutes V A W 4 stroke DOHC L4 1 596 97 39 79 0 81 4 3 11 3 20 CDI system LFR5A 11 1 1 0 043 Remote control Electric start 0 17 0 23 0 007 0 009 0 31 0 37 0 012 0 015 380 502 124 12 20 Prime start DRIVE UNIT 8Gear positions Gear ra...

Page 61: ... 4 stroke motor oil SE SF SG SH SJ 10W 30 10W 40 4 5 4 8 4 0 4 7 5 0 4 1 Hypoid gear oil SAE90 670 22 64 23 58 25 2 5 18 35 3 5 25 27 2 7 20 18 1 8 13 817 32 2 479 18 9 1 582 62 3 1 710 67 3 536 21 1 664 26 1 168 370 172 379 5 000 6 000 66 2 90 0 5 500 800 900 4 stroke DOHC L4 1 596 97 39 79 0 81 4 3 11 3 20 CDI system LFR5A 11 1 1 0 043 Remote control Electric start 0 17 0 23 0 007 0 009 0 31 0 3...

Page 62: ...our 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 DO NOT fill fuel container to maximum capacity Gasoline will expand consid erably as it warms up and can build up pressure in the fuel container This can cause fuel le...

Page 63: ... with a minimum of tools cC 8 To prevent problems which can be caused by oil entering the cylinder from the sump keep the engine in the verti cal position when transporting and storing it If storing or transporting the outboard motor in a horizontal position put it on a cushion after draining the engine oil 8 Do not place the engine on its side before the cooling water has drained from it complete...

Page 64: ...while engine is running EMU00342 8 Flushing with the Flushing Attachment cC Avoid running the outboard at high speed while on the flushing attachment or overheating could occur 1 Remove the top cowling and the pro peller 2 Install a flushing attachment 1 to the cooling water inlet 3 Run the engine at a fast idle for 10 15 minutes supplying fresh water 4 Just prior to turning off the engine quickly...

Page 65: ... fog ging oil into the piston rings 3 Change the gear case oil Refer to CHANGING GEAR OIL Inspect the oil for the presence of water which indicates a leaky seal Seal replace ment should be performed by an authorized Yamaha dealership prior to use 4 Grease all grease fittings Refer to the GREASING EMU00351 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the out board with fresh wate...

Page 66: ...n charging or using in a closed space Always wear eye protection when working near batteries KEEP OUT OF REACH OF CHILDREN Batteries vary among manufacturers Therefore the following procedures may not always apply Consult your battery manufacturer s instructions 1 Disconnect and remove the battery from the boat Always disconnect the black negative lead first to prevent the risk of shorting 2 Clean...

Page 67: ...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 68: ...m Initial Every Refer page 10 hours 50 hours 3 months 100 hours 6 months 200 hours 1 year EMU00361 MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating con ditions but the following table gives general guidelines The mark 7 indicates the check ups which you may carry out yourself The mark 2 indicates work to be carried out by your Yamaha dealer 1 If a po...

Page 69: ...E 4 10 EMU00366 GREASING Yamaha marine grease Water resistant grease F1017 ...

Page 70: ...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 71: ...you are fitting a spark plug a good esti mate of the correct torque is 1 4 to 1 2 a turn past finger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench 1 Spark plug gap 2 Spark plug I D mark NGK 4 12 Spark plug torque Refer to SPECIFICATIONS page 4 1 Initial of spark Plug wrench size plug I D mark B 21 mm 13 16 in C L 16 mm 5 8 in D 18 3 mm 23 32 in 9...

Page 72: ...ound it should be repaired immediately by Yama ha dealer or other qualified mechanic Checking points 8 Fuel system parts leakage 8 Fuel hose joint leakage 8 Fuel hose cracks or other damage 8 Fuel connector leakage w Leaking fuel can result in fire or explo sion 8 Check for fuel leakage regularly 8 If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper repai...

Page 73: ...nning 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 result in a fuel leak ...

Page 74: ...it in solvent Allow it to dry Inspect the filter element and O ring 3 to make sure they are in good con dition Replace them if necessary 4 Reinsert the float in the filter cup making sure the indentations in the float ring match the ribs inside the fil ter cup Reinstall the filter element in the cup Make sure the O ring is in proper position in the cup Firmly screw the cup onto the filter housing ...

Page 75: ... to warm up fully in Neutral until it is running smoothly If the outboard is mounted on a boat be sure the boat is tightly moored 2 Adjust the throttle stop screw 1 to set the idling speed to specification see SPECIFICATIONS on page 4 1 by turning the stop screw clockwise to increase the idling speed and turn ing it counterclockwise to decrease the idling speed NOTE Correct idling speed adjustment...

Page 76: ...ition not tilt ed when checking and changing the engine oil 8 If the oil level is above the upper level mark drain until the level meets the specified capacity Overfilling the oil may cause leakage or damage 1 Put the outboard motor in an upright position not tilted 2 Prepare a suitable container which can hold a larger amount than the engine oil capacity Loosen and remove the drain bolt 1 while h...

Page 77: ...filler cap 2 Add the correct amount of oil through the filler hole Reinstall the filler cap 5 Start the engine and watch to make sure the low oil pressure warning lamp turns off Make sure that there are no oil leaks cC If the oil lamp does not turn off or if there are oil leaks stop the engine and find the cause Continued operation with a problem could cause severe engine damage If the problem can...

Page 78: ...il should be changed more often when the engine is operated under adverse conditions such as extended trolling 000815 EMU00380 CHECKING TIMING BELT Inspect the timing belt and replace it if any to the following signs is observed 8 Cracks in the back of the belt or in the base of belt teeth 8 Excessive wear at the roots of cogs 8 Rubber portion swollen by oil 8 Belt surfaces roughened 8 Signs of we...

Page 79: ...Replace it with a spare one of proper amperage w Be sure to use the specified fuse An incorrect fuse or a piece of wire may allow excessive current flow This could cause electrical system damage and a fire hazard NOTE If the new fuse blows again immediately consult a Yamaha dealer 1 Electrical cover 2 Fuse holder 3 Fuse 30A 1 20A 1 4 Spare fuse 30A 20A 5 Fuse puller ...

Page 80: ...onnector 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 F1030 ...

Page 81: ... of oil leaks 2 Operate each of the power trim and tilt switches on remote control and engine bottom cowling If equipped to check that all switches work 3 Tilt up the motor and check that the trim and tilt rod 1 is pushed out com pletely 4 Check that the trim and tilt rod is free of corrosion or other flaws 5 Operate the motor to trim and tilt down Check that the trim and tilt rod operates smoothl...

Page 82: ...the key and remove the lanyard from the engine stop switch Turn off the battery cut off switch if your boat has one 8 Do not use your 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 f...

Page 83: ...peller could come off dur ing operation and be lost 1 Apply Yamaha Marine grease or Cor rosion resistant grease to the pro peller shaft 2 Install the thrust washer and propeller on the propeller shaft 3 Install the spacer and washer Tighten the propeller nut to the specified torque 4 Align the propeller nut with the pro peller shaft hole Insert a new cotter pin in the hole and bend the cotter pin ...

Page 84: ...able container under the gear case 3 Remove the oil drain plug 1 NOTE The oil drain plug is magnetic Remove all metal particles from the plug before rein stalling it 4 Remove the oil level plug 2 to allow the oil to drain completely cC Inspect the used oil after it has been drained If the oil is milky water is get ting into the gear case which can cause gear damage Consult a Yamaha dealer for repa...

Page 85: ...D REPLACING ANODE S Yamaha outboard motor is protected from corrosion by a sacrificial anode s Check the anode s periodically Remove the scales from surfaces of the anode s For the inspection and replacement of the anode s consult a Yamaha dealer cC Do not paint the anode s for this would render it ineffective NOTE Remove the cover with anode after removing the bolts 1 when checking the anode cond...

Page 86: ...lush with water 8 EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL 8 Drink large quantities of water or milk followed by milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventive mea sures 8 Charge batteries in a well ventilated area 8 Keep...

Page 87: ... pure de ionized water suitable to use in batteries 2 Keep the battery always in a good state of charge Installing a voltmeter will help you monitor your battery If you will not use the boat for a month or more remove the battery from the boat and store it in a cool dark place Completely recharge the battery before using it 3 If the battery will be stored for longer than a month check the specific...

Page 88: ...lling the battery and disconnect the RED lead last when removing it Otherwise the electrical system can be damaged 8 The electrical contacts of the battery and cables must be clean and properly connected or the battery will not start the engine Connect the RED lead to the POSITIVE terminal first Then connect the BLACK lead to the NEG ATIVE terminal 1 Red lead 2 Black lead 3 Battery EMU01280 Discon...

Page 89: ...ctor 2 onto a garden hose 3 which is con nected to a fresh water supply 3 With the engine off turn on the water tap and let the water flush through the cooling passages for about 15 minutes Turn off the water and dis connect the garden hose 3 4 When flushing is complete reinstall the garden hose connector 2 on the fitting 1 on the bottom cowling Tighten the connector securely cC Do not leave the g...

Page 90: ...00410 Cleaning the Outboard Motor After use wash the exterior of the out board with fresh water Flush the cooling system with fresh water NOTE Refer to Flushing Cooling System instruc tions 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 ...

Page 91: ...m should be kept as clean of marine growths as possible If neces sary the boat bottom can be coated with an anti fouling paint approved for your area to inhibit marine growth Do not use anti fouling paint which includes copper or graphite These paints can cause more rapid engine corrosion F1021 ...

Page 92: ...E MEMO ...

Page 93: ...BLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Power trim tilt will not operate 5 5 Starter will not operate 5 6 Engine fails to operate 5 8 Treatment of submerged motor 5 9 1 2 3 4 5 6 E ...

Page 94: ...ric overload and repair Replace fuse with one of correct amperage 4 Have serviced by a Yamaha dealer 5 Shift to neutral B Engine will not start Starter operates 1 Fuel tank empty 2 Fuel contaminated or stale 3 Fuel filter clogged 4 Starting procedure incorrect 5 Fuel pump malfunctions 6 Spark plug s fouled or incorrect type 7 Spark plug cap s fitted incorrectly 8 Poor connections or damaged igniti...

Page 95: ...ve adjustment incorrect 19 Battery lead disconnected 1 Inspect spark plug s Clean or replace with recommended type 2 Check for pinched or kinked fuel line or other obstructions in fuel system 3 Fill tank with clean fresh fuel 4 Clean or replace filter 5 Have serviced by a Yamaha dealer 6 Find and correct cause of warning 7 Inspect and adjust as specified 8 Check wires for wear or breaks Tighten al...

Page 96: ...ged 2 Propeller pitch or diameter incorrect 3 Trim angle incorrect 4 Motor mounted at incorrect height on transom 5 Warning system activated 6 Boat bottom fouled with marine growth 7 Spark plug s fouled or incorrect type 8 Weeds or other foreign matter tangled on gear housing 9 Fuel system obstructed 10 Fuel filter clogged 11 Fuel contaminated or stale 12 Spark plug gap incorrect 1 Have propeller ...

Page 97: ...amaha dealer 15 Check and replace oil with specified type 16 Have serviced by a Yamaha dealer 17 Open the air vent screw 18 Have serviced by a Yamaha dealer 19 Connect correctly 20 Inspect spark plug and replace it with recommended type E Engine power loss F Engine vibrates excessively 1 Propeller damaged 2 Propeller shaft damaged 3 Weeds or other foreign matter tangled on propeller 4 Motor mounti...

Page 98: ...boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and carefully 4 Have a Yamaha dealer inspect the outboard motor before operating it again E 607011 EMU00419 POWER TRIM TILT WILL NOT OPERATE If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit the engine can be tilted...

Page 99: ...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 100: ...in Neutral and that the lock plate is attached to the engine stop lanyard switch The main switch must be ON 5 Insert the knotted end of the emer gency starter rope into the notch in the flywheel rotor and wind the rope clockwise 6 Pull the rope slowly until resistance is felt 7 Remove the rope from the flywheel temporarily 8 Rewind the rope approximatery 3 4 of a turn clockwise 9 Give a strong pul...

Page 101: ...ocedure below 1 Remove the electric cover 1 2 Disconnect the connection of the yel low cord 2 emergency circuit to return to the nearest port w When the connection is disconnected the idling and low speeds are slightly higher than normal Use care when starting off or stopping cC Follow this procedure only in an emer gency and just long enough to return to port for repairs F1025A q w F1046 ...

Page 102: ...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 103: ...EMU00450 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 104: ...Disconnecting the battery 4 29 E Emission control information 1 2 Engine fails to operate 5 8 Engine stop lanyard switch 2 4 Engine oil 1 13 Exhaust leakage 4 21 F Filling fuel 3 4 Flushing cooling system and fogging engine 4 5 Flushing device 2 11 Forward 3 12 Fueling instructions 1 11 G Gasoline 1 12 Greasing 4 10 I Identification numbers record 1 1 Impact damage 5 5 Important labels 1 6 Inspect...

Page 105: ... 5 6 Starting engine 3 8 Stopping engine 3 13 Storing outboard motor 4 4 T Tachometer 2 8 Temporary action in emergency 5 5 Throttle friction adjusting screw 2 5 Tilting up down 3 17 Tilt support lever 2 11 Top cowling lock levers 2 11 Trailering outboard motor 4 3 Transporting and storing outboard motor 4 3 Treatment of submerged motor 5 9 Trim meter 2 9 Trim tab 2 6 Trimming outboard motor 3 14 ...

Page 106: ...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 107: ...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 108: ...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 109: ...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 110: ...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 111: ...ll receive service If you need more information about your warranty coverage or your Yamaha outside the U S A or Canada please contact an autho rized Yamaha dealer in your country 2 Keep a copy of your sales contract or invoice for the purchase of your Yamaha and present it if you need warranty repairs This document should show the date of purchase which is important evidence the repairing dealer ...

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Page 114: ...Printed in Japan March 2002 0 2 1 67F 28199 16 F75AET F80AET F90AET E Printed on recycled paper ...

Page 115: ...r au détail OUTBOARD MOTOR MODEL AND SERIAL NUMBER From I D label on clamp bracket MODÉLE ET NO DE SÉRIE DU MOTEUR HORS BORD sur l étiquette d identification de la presse de fixation For Dealer Use Only A l usage du concessionnaire YAMAHA DEALER NUMBER NO DU CONCESSIONNAIRE YAMAHA DEALER NAME NOM DU CONCESSIONNAIRE DATE SOLD DATE DE LIVRAISON OWNER S NAME NOM DU PROPRIÉTAIRE ADDRESS ADRESSE PHONE ...

Page 116: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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