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Yamaha F9.92D, Owner'S Manual

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Yamaha F9.92D Owner'S Manual Download Page 3

 

Important manual information

 

EMU25100

 

To the owner

 

Thank you for choosing a Yamaha outboard
motor. This Owner’s Manual contains infor-
mation needed for proper operation, mainte-
nance and care. A thorough understanding
of these simple instructions will help you ob-
tain maximum enjoyment from your new
Yamaha. If you have any question about the
operation or maintenance of your outboard
motor, please consult a Yamaha dealer.
In this Owner’s Manual particularly important
information is distinguished in the following
ways.

 The Safety Alert Symbol means

ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!

WARNING

 

EWM00780 

 

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.

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 discrepancies
between your machine and this manual. If
there is any question concerning this manu-

al, please consult your Yamaha dealer.

NOTE:

 

The F9.9MH, F9.9ER, T9.9ER, T9.9EH,
F15MH, F15EH, F15PR, F15PH and the
standard accessories are used as a base for
the explanations and illustrations in this
manual. Therefore some items may not ap-

 

ply to every model.

 

EMU25110

 

F9.92D, T9.92D,  F15D

OWNER’S MANUAL

©2004 by Yamaha Motor Corporation, USA

1st edition, July 2004

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in Japan

P/N LIT-18626-06-13

Summary of Contents for F9.92D

Page 1: ...F9 92D T9 92D F15D OWNER S MANUAL 66M 28199 1A U S A Edition LIT 18626 06 13 ...

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

Page 3: ... 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 discrepancies between your mach...

Page 4: ... 16 Throttle indicator 16 Throttle friction adjuster 17 Engine stop lanyard switch 17 Engine stop button 18 Choke knob for pull type 18 Manual starter handle 18 Starter button 19 Main switch 19 Power tilt switch 19 Steering friction adjuster 20 Steering friction adjuster 20 Trim tab with anode 20 Trim rod tilt pin 21 Tilt lock mechanism 21 Tilt support knob 21 Tilt support bar 21 Power tilt unit 2...

Page 5: ... additional 57 Greasing 58 Cleaning and adjusting spark plug 60 Checking fuel system 60 Inspecting fuel filter 61 Cleaning fuel filter 61 Inspecting idling speed 62 Changing engine oil 63 Checking wiring and connectors 64 Exhaust leakage 64 Water leakage 65 Engine oil leakage 65 Checking power trim and tilt system 65 Checking propeller 65 Removing the propeller 66 Installing the Propeller 67 Chang...

Page 6: ...a main key switch is equipped with the mo tor the key identification number is stamped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key 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 ...

Page 7: ... Resources Board s 2001 ex haust emission standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke en gines These engines are equivalent to the U S EPA s 2006 standards for marine en gines EMU25290 Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s 2004 ex haust emission standards Engines meeting th...

Page 8: ...or tak ing drugs About 50 of all boating fatali ties involve intoxication Have an approved personal flotation de vice PFD on board for every occupant It is a good idea to wear a PFD whenever boating At a minimum children and non swimmers should always wear PFDs and everyone should wear PFDs when there are potentially hazardous boating condi tions Gasoline is highly flammable and its va pors are fl...

Page 9: ...nformed about boating safety Additional publications and information can be obtained from many organizations including the fol lowing United States Coast Guard Consumer Affairs Staff G BC Office of Boating Public and Consumer Af fairs U S Coast Guard Headquarters Washington D C 20593 0001 Boating Safety Hotline 1 800 368 5647 National Marine Manufacturers Associa tion NMMA 401 N Michigan Ave Chica...

Page 10: ... on vessel The vessel which does not have the right of way is called the give way or burdened 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 de...

Page 11: ...oth of you should alter course to avoid an accident You should keep the other ves sel on your port left side This rule doesn t apply if both of you will clear one another if you continue on your set course and speed Crossing When two power driven vessels are crossing each other s path close enough to run the risk of collision the vessel which has the oth er on the starboard right side must keep ou...

Page 12: ...en 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 driven vessel which can navi gate only in such a channel 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 arra...

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: ...ere are two types of gasohol gasohol con 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 shipp...

Page 15: ...ld adversely affect performance and could also seriously damage the motor Engine speed depends on the propeller size and boat load If engine speed is too high or too low for good engine performance this will have an adverse effect on the engine Yamaha outboard motors are fitted with pro pellers chosen to perform well over a range of applications but there may be uses where a propeller with a diffe...

Page 16: ...tle setting to maintain the engine in the proper operating range For instructions on propeller removal and in stallation see page 65 EMU25770 Start in gear protection Yamaha outboard motors or Yamaha ap proved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is in neutral Always select neutral before starting the en...

Page 17: ...r s 3 Drain screw 4 Anti cavitation plate 5 Propeller 6 Cooling water inlet 7 Trim rod 8 Clamp bracket 9 Steering friction screw 10 Power tilt switch 11 Manual starter handle 12 Choke knob 13 Warning indicator s 14 Gear shift lever 15 Tiller handle 16 Engine stop button Engine stop lanyard switch 17 Transom clamp handle 18 Rope attachment 19 Tilt lock lever 20 Flushing device 21 Starter button 22 ...

Page 18: ...y regula 1 2 3 4 5 6 10 9 8 7 13 11 18 12 17 16 15 14 19 20 21 22 ZMU05129 1 Top cowling 2 Top cowling lock lever s 3 Drain screw 4 Anti cavitation plate 5 Propeller 6 Cooling water inlet 7 Trim rod 8 Steering friction screw 9 Clamp bracket 10 Tiller handle 11 Choke knob 12 Manual starter handle 13 Warning indicator 14 Gear shift lever 15 Throttle friction adjuster 16 Engine stop button Engine sto...

Page 19: ... actuates both the shifter and the throttle The electrical switch es are mounted on the remote control box EMU26190 Remote control lever Moving the lever forward from the neutral po sition engages forward gear Pulling the le ver back from neutral engages reverse The engine will continue to run at idle until the le ver is moved about 35 a detent can be felt Moving the lever farther opens the thrott...

Page 20: ...l lever is in neutral The remote control lever will operate only when the neutral throttle lever is in the closed position EMU26221 Choke switch To activate the choke system press in the main switch while the key is turned to the on or start position The choke system will then supply the rich fuel mixture required to start the engine When the key is released the choke will switch off automatically...

Page 21: ...p is on the tiller handle Turn the grip counterclockwise to increase speed and clockwise to decrease speed EMU25961 Throttle indicator The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position Choose the setting that offers the best performance and fuel economy for the desired operation 1 Forward 2 Neutral 3 Reverse ZMU01997 ZMU04879...

Page 22: ...gine stop switch for the engine to run The lanyard should be attached to a secure place on the operator s clothing or arm or leg Should the operator fall overboard or leave the helm the lanyard will pull out the lock plate stopping ignition to the engine This will prevent the boat from running away un der power WARNING EWM00120 Attach the engine stop switch lanyard to a secure place on your clothi...

Page 23: ...Choke knob for pull type To supply the engine with the rich fuel mix ture required to start pull out this knob EMU26070 Manual starter handle To start the engine first gently pull the han dle out until resistance is felt From that posi tion then pull the handle straight out quickly to crank the engine 1 Lanyard 2 Lock plate 1 Lanyard 2 Lock plate 2 1 ZMU02003 ZMU02083 ZMU02355 ZMU02005 ...

Page 24: ...ts are on and the key cannot be removed start With the main switch in the start po sition the starter motor turns to start the en gine When the key is released it returns automatically to the on position EMU26102 Power tilt switch The power tilt system adjusts the outboard motor angle in relation to the transom Push ing the switch up tilts the outboard mo tor up Pressing the switch down tilts the ...

Page 25: ...r bolt is located on the swivel bracket To increase resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise WARNING EWM00040 Do not overtighten the friction adjuster If there is too much resistance it could be difficult to steer which could result in an accident EMU26241 Trim tab with anode The trim tab should be adjusted so that the steering control can be...

Page 26: ...U26312 Tilt lock mechanism The tilt lock mechanism is used to prevent the outboard motor from lifting out of the wa ter when in reverse gear To lock it set the tilt lock lever in the lock position To release push the tilt lock lever in the release position EMU26320 Tilt support knob To keep the outboard motor in the tilted up position push the tilt support knob under the swivel bracket EMU26330 Ti...

Page 27: ...ling the cowling check to be sure it fits properly in the rubber seal Then lock the cowling again by returning the lever s to the lock position EMU26460 Flushing device This device is used to clean the cooling wa ter passages of the motor using a garden hose and tap water NOTE For details on usage see page 54 EMU26300 Warning indicator If the engine develops a condition which is cause for warning ...

Page 28: ...ill automatically de crease to about 2000 r min The overheat warning indicator will light if equipped on the bottom cowling or the ta chometer The buzzer will sound if equipped on the tiller handle remote control box or main switch panel If the warning system has activated stop the engine and check the cooling water inlet for clogging EMU30164 Low oil pressure warning If the oil pressure drops too...

Page 29: ...tivated stop the engine as soon as it is safe to do so Check the oil level and add oil as needed If the oil level is correct and the warning device does not switch off consult your Yamaha dealer CAUTION ECM00100 Do not continue to run the engine if the low oil pressure warning indicator is on Serious engine damage could occur ZMU02081 ZMU02360 ...

Page 30: ...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 31: ...otor see page 38 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 32: ...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 33: ...ll the fuel tank 3 Securely close the cap after filling the tank Wipe up any spilled fuel EMU27270 Ring Free Fuel Additive Gasoline is a precise blend of many different substances each chosen to give certain characteristics Gasoline blends have been changing in recent years in response to con cerns about pollution and resulting emis sions regulations One of the most obvious changes has been the el...

Page 34: ...s 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 If there is an air vent screw on the fuel tank cap loosen it 2 or 3 turns 2 If there is a fuel joint on the motor firmly connect the fuel line to the joint Then firmly connect the other end of the fuel li...

Page 35: ...to a secure place on your clothing or your arm or leg while operating Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning Avoid accidentally pulling the lanyard during normal operation Loss of en gine power means the loss of most steering control Also without engine power the boat could slow rapidly Th...

Page 36: ...po sition before releasing it 7 Slowly return the throttle grip to the fully closed position NOTE When the engine is cold it needs to be warmed up For further information see page 35 If the engine does not 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 try again Also if the engine is warm and fail...

Page 37: ...oose 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 forward 3 Place the throttle grip in the start position After the ...

Page 38: ...p For further information see page 35 If the engine does not 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 try again Also if the engine is warm and fails to start open the throttle a same amount and try to start the engine again If the engine still fails to start see page 73 EMU27642 Electric sta...

Page 39: ... NOTE On remote controls equipped with a neu tral throttle lever a good starting point is to lift the lever just until you feel resistance then lift slightly more The neutral throttle lever or free accelera tor can only be used when the remote con trol lever is in neutral 5 Press in and hold the main switch to op erate the remote choke system The re mote choke switch automatically returns to its n...

Page 40: ... Be sure the low oil pressure warning in dicator goes off after starting the engine 3 Check for a steady flow of water from the cooling water pilot hole CAUTION ECM00210 If the low oil pressure warning indicator does not go off after the engine starts stop the engine Otherwise serious en gine damage could occur Check the oil level and add oil if necessary Consult your Yamaha dealer if the cause fo...

Page 41: ...lever quickly and firmly from neutral to forward Remote control models 1 Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from neutral to forward EMU27795 Reverse manual tilt and hydro tilt models WARNING EWM00190 When operating in reverse go slowly Do not open the throttle more than half Oth erwise the boat could become unstable which could re...

Page 42: ...mote control models 1 Check that the tilt lock lever is in the lock position 2 Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from neutral to reverse EMU27820 Stopping engine Before stopping the engine first let it cool off for a few minutes at idle or low speed Stop ZMU02030 ZMU02086 ZMU02038 N R N R ZMU04883 ZMU02086 ...

Page 43: ...27861 Trimming outboard motor The trim angle of 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 a...

Page 44: ...ing 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 trim angle can be changed approximately 4 degrees by shifting the trim rod one hole EMU27901 Adjusting trim angle power tilt models WARNING EWM00750 Be sure al...

Page 45: ... effi ciency This is generally when the keel line of the boat is up about 3 to 5 degrees With the bow up the boat may have a greater tenden cy to steer to one side or the other Compen sate for this as you steer The trim tab can also be adjusted to help offset this effect When the bow of the boat is down it is easier to accelerate from a standing start onto plane Bow Up Too much trim out puts the b...

Page 46: ...colli sion with obstructions and also to reduce salt corrosion WARNING EWM00220 Be sure all people are clear of the out board motor when tilting up and down also be careful not to pinch any body parts between the drive unit and engine bracket WARNING EWM00250 Leaking fuel is a fire hazard If there is a fuel joint on the outboard motor discon nect the fuel line or close the fuel cock if the engine ...

Page 47: ... hand and tilt the engine up fully 6 Push the tilt support knob into the clamp bracket Or the tilt support bar will turn to the lock position automatically EMU28005 Procedure for tilting up Power trim and tilt models power tilt models 1 Place the remote control lever the gear shift lever in neutral 2 Disconnect the fuel line from the out board motor or close the fuel cock N ZMU04881 ZMU02042 ZMU02...

Page 48: ... be sure to support it with the tilt support knob or tilt support lever Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit loses pres sure 5 Models equipped with trim rods Once the outboard motor is supported with the tilt support lever press the power trim and tilt switch down to retract the trim rods CAUTION ECM00250 Be sure to retract the trim rods...

Page 49: ...ower trim and tilt models power tilt models 1 Push the power tilt power trim and tilt switch up until the outboard motor is supported by the tilt rod and the tilt support lever tilt support knob becomes free 2 Release the tilt support lever or pull out the tilt support knob 3 Push the power tilt power trim and tilt switch down to lower the outboard motor to the desired position EMU28060 Cruising i...

Page 50: ...otor 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 much reverse thrust can cause the outboard motor to lift out of the water increasing the chance of ac cident and personal injury Return the outboard motor to its normal position as soon as the boat is back in deeper water CAUTION ECM00260 Do not tilt...

Page 51: ... 6 Slowly lower the outboard motor to the normal position EMU28090 Power trim and tilt models power tilt models The outboard motor can be tilted up partially to allow operation in shallow water WARNING EWM00660 Place the gear shift in neutral before setting up for shallow water cruising Return the outboard motor to its normal position as soon as the boat is back in deeper water CAUTION ECM00260 Do...

Page 52: ...er 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 51 Cruising in turbid water Yamaha strongly recommends that you use the optional chromium plated water pump kit if you use the outboard motor in turbid mud dy water con...

Page 53: ...erall height X T9 9EH 1321 mm 52 0 in Transom height S F15EH 440 mm 17 3 in F15MH 440 mm 17 3 in F9 9ER 440 mm 17 3 in F9 9MH 440 mm 17 3 in Transom height L 567 mm 22 3 in Transom height X T9 9EH 635 mm 25 0 in Weight AL S F15EH 48 0 kg 106 lb F15MH 45 0 kg 99 lb F9 9ER 47 0 kg 104 lb F9 9MH 45 0 kg 99 lb Weight AL L F15EH 50 0 kg 110 lb F15MH 47 0 kg 104 lb F15PH 55 0 kg 121 lb F15PR 54 0 kg 119...

Page 54: ...c F9 9MH Manual T9 9EH Electric T9 9ER Electric Starting carburetion system Choke valve Valve clearance cold engine IN 0 15 0 25 mm 0 0059 0 0098 in Valve clearance cold engine EX 0 20 0 30 mm 0 0079 0 0118 in Min cold cranking amps CCA SAE F15EH 245 0 A F15PH 245 0 A F15PR 245 0 A F9 9ER 245 0 A T9 9EH 245 0 A T9 9ER 245 0 A Min marine cranking amps MCA ABYC F15EH 323 0 A F15PH 323 0 A F15PR 323 ...

Page 55: ... 1 0 L 1 06 US qt 0 88 Imp qt Recommended gear oil Hypoid gear oil SAE 90 Gear oil quantity F15EH 250 0 cm3 8 45 US oz 8 82 Imp oz F15MH 250 0 cm3 8 45 US oz 8 82 Imp oz F15PH 250 0 cm3 8 45 US oz 8 82 Imp oz F15PR 250 0 cm3 8 45 US oz 8 82 Imp oz F9 9ER 250 0 cm3 8 45 US oz 8 82 Imp oz F9 9MH 250 0 cm3 8 45 US oz 8 82 Imp oz T9 9EH 370 0 cm3 12 51 US oz 13 05 Imp oz T9 9ER 370 0 cm3 12 51 US oz 1...

Page 56: ...e 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 should be trailered and stored in the normal running position If there is insufficient road clearance in this position then trailer the outboard motor in the tilt po sition using a motor support device such as a transom saver bar Consult your Yamaha deal...

Page 57: ...ditioner and Stabilizer eliminates the need to drain the fuel system Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead 3 Remove the engine top cowling and si lencer cover 4 Install the outboard motor on the test tank 5 Fill the tank with fresh water to above the level of the anti cavitation plate CAUTION ECM00300 Do not run the engine without supply...

Page 58: ... further de tails see page 58 EMU28421 Cleaning and anticorrosion measures 1 Wash down the exterior of the outboard motor with fresh water and dry off com pletely 2 Spray the outboard motor exterior with Yamaha Silicone Protectant Part No LUB SILCNE 13 00 3 Wax the cowling with a non abrasive wax such as Yamaha Silicone Wax Part No ACC 11000 15 02 EMU28430 Battery care WARNING EWM00330 Battery ele...

Page 59: ...0 Flushing power unit Perform this procedure right after operation for the most thorough flushing 1 After shutting off the engine unscrew the garden hose connector from the fit ting on the bottom cowling 2 Screw the garden hose connector onto a garden hose which is connected to a fresh water supply 3 With the engine off turn on the water tap and let the water flush through the cool ing passages fo...

Page 60: ...e 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 individual All warranty repairs however inc...

Page 61: ...r Anode s external Inspection replace ment Anode s internal Inspection replace ment Battery Inspection charging Cooling water pas sages Cleaning Cowling clamp Inspection Fuel filter can be dis assembled Inspection cleaning Fuel system Inspection Fuel tank Yamaha por table tank Inspection cleaning Gear oil Change Greasing points Greasing Idling speed carbure tor models Inspection adjustment Power t...

Page 62: ...igh sulfur gasoline inspecting valve clearance may be required more frequently than every 500 hours Spark plug s Cleaning adjustment replacement Timing belt Inspection replace ment Valve clearance OHC OHV Inspection adjustment Item Actions Initial Every 10 hours 1 month 50 hours 3 months 100 hours 6 months 200 hours 1 year Item Actions Every 500 hours 2 5 years 1000 hours 5 years Timing belt Repla...

Page 63: ...Maintenance 58 EMU28931 Greasing Yamaha marine grease Water resistant grease F9 9ER T9 9ER F15PR ZMU02330 ...

Page 64: ...Maintenance 59 F9 9MH T9 9EH F15MH F15EH F15PH ZMU02331 ...

Page 65: ...de erosion becomes excessive or if carbon and other deposits are excessive you should re place the spark plug with another of the cor rect type Before fitting the spark plug measure the electrode gap with a wire thickness gauge adjust the gap to specification if necessary When fitting the plug always clean the gas ket surface and use a new gasket Wipe off any dirt from the threads and screw in the...

Page 66: ...G EWM00310 Gasoline is highly flammable and its va pors are flammable and explosive If you have any question about properly doing this procedure consult your Yamaha dealer Do not perform this procedure on a hot or running engine Allow the engine to cool There will be fuel in the fuel filter Keep away from sparks cigarettes flames or other sources of ignition This procedure will allow some fuel to ...

Page 67: ...control lever from the start position during warm up The 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 flushin...

Page 68: ...0 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 holding the container under the drain hole Then remove the oil filler cap L...

Page 69: ... Recheck the oil level using the dipstick to be sure the level falls between the up per 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 7 Dispose of used oil according to local regulations NOTE For more information on the disposal of used oil consult your Yamaha dealer Change the oil more often when operating the engine unde...

Page 70: ...heck that all switch es work 3 Tilt the outboard motor up and check that the trim and tilt rod is pushed out completely 4 Check that the trim and tilt rod is free of corrosion or other flaws 5 Tilt the outboard motor down Check that the trim and tilt rod operates smoothly NOTE Consult your Yamaha dealer if any operation is abnormal EMU29171 Checking propeller WARNING EWM00321 You could be seriousl...

Page 71: ... a hard underwater obstacle to help protect the propeller and drive mechanism The propeller will then spin freely on the shaft If this happens the shear pin must be replaced EMU30660 Removing the propeller EMU29194 Spline models 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 EMU29...

Page 72: ... hole Insert a new cotter pin in the hole and bend the cotter pin ends NOTE If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque tighten the nut further to align it with the hole EMU29262 Dual thrust models CAUTION ECM00340 Be sure to install the thrust washer be fore installing the propeller otherwise the lower case and propeller boss could be...

Page 73: ...ls 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 magnetic gear oil drain screw equipped remove all metal particles from the screw before installing it 4 Remove the oil level plug to allow the oil to drain completely CAUTION ECM00710 Inspect the used oil after...

Page 74: ...k carefully Im proper assembly can result in a fuel leak which could result in a fire 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 assembl...

Page 75: ...ground leads attached to external anodes on equipped models Consult a Yamaha dealer for inspection and replace ment of internal anodes attached to the pow er unit EMU29320 Checking battery for electric start models WARNING EWM00330 Battery electrolytic fluid is dangerous it contains sulfuric acid and therefore is poisonous and highly caustic Always follow these preventive mea sures Avoid bodily co...

Page 76: ... will not use the boat for a month or more re move the battery from the boat and store it in a cool dark place Completely re charge the battery before using it 3 If the battery will be stored for longer than a month check the specific gravity of the fluid at least once a month and re charge the battery when it is low NOTE Consult a Yamaha dealer when charging or re charging batteries EMU29331 Conn...

Page 77: ... 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 These paints can cause mo...

Page 78: ...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 30 Q Has fuel pump malfunctioned A Have serviced by a Yamaha deal...

Page 79: ...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 80: ...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 81: ...n emergency EMU29440 Impact damage WARNING EWM00870 The outboard motor can be seriously damaged by a collision while operating or trailering Damage could make the out board motor unsafe to operate If the outboard motor hits an object in the wa ter follow the procedure below 1 Stop the engine immediately 2 Inspect the control system and all com ponents for damage Also inspect the boat for damage 3 ...

Page 82: ... does not oper ate Make sure the remote control lever is in neutral Otherwise the boat could unexpectedly start to move which could result in an accident Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg while operating Do not attach the lanyard to clothing that could tear loose Do not route the cord where it could become entangled preventing it from funct...

Page 83: ... ends of the choke link rod 4 Remove the starter flywheel cover after removing the 3 bolts Disconnect the wire leads from the starter flywheel cov er 5 Prepare the engine for starting For fur ther information see page 30 Be sure the engine is in neutral and that the en gine stop switch lanyard lock plate is at tached to the engine stop switch 6 Pull up the lever on the carburetor to op erate the c...

Page 84: ...elow in order to minimize engine dam age EMU29783 Procedure 1 Thoroughly wash away mud salt sea weed and so on with fresh water 2 Remove the spark plug s then face the spark plug holes downward to allow any water mud or contaminants to drain 3 Drain the fuel from the carburetor fuel filter and fuel line Drain the engine oil completely 4 Fill the sump with the fresh engine oil 5 Feed engine fogging...

Page 85: ...80 Consumer information EMU29811 Important warranty information for U S A and Canada ...

Page 86: ...Consumer information 81 ...

Page 87: ...Consumer information 82 EMU29830 YAMAHA MOTOR CORPORATION U S A FOUR STROKE OUTBOARD MOTOR THREE YEAR LIMITED WARRANTY ...

Page 88: ...Consumer information 83 ...

Page 89: ...Consumer information 84 EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U S A OR CANADA ...

Page 90: ...Printed in Japan July 2004 0 4 1 Printed on raecycled paper ...

Page 91: ...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 92: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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