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EMU03170

Chapter 4

MAINTENANCE

SPECIFICATIONS

...................................4-1

TRANSPORTING AND STORING
OUTBOARD MOTOR

.............................4-3

Trailering outboard motor .....................4-3
Storing outboard motor .........................4-4

PERIODIC MAINTENANCE

....................4-9

Replacement parts................................4-9
Maintenance chart ..............................4-10
Greasing .............................................4-11
Cleaning and adjusting spark plug......4-12
Checking fuel system..........................4-14
Inspecting fuel filter.............................4-15
Inspecting idling speed .......................4-16
Changing engine oil ............................4-17
Checking wiring and connectors.........4-19
Exhaust leakage .................................4-19
Water leakage.....................................4-19
Checking propeller..............................4-20
Changing gear oil................................4-22
Cleaning fuel tank ...............................4-24
Inspecting and replacing anode(s)......4-25
Checking battery.................................4-26
Checking bolts and nuts .....................4-28
Checking top cowling..........................4-29
Motor exterior......................................4-29
Coating the boat bottom .....................4-29

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Summary of Contents for F9.9C

Page 1: ...F9 9C T9 9C OWNER S MANUAL U S A Edition LIT 18626 05 49 ...

Page 2: ......

Page 3: ...TION indicates special precau tions that must be taken to avoid dam age 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 cur rent product information available at the time of printing there may be minor dis crepancies between your machine ...

Page 4: ...E EMU00030 CONTENTS 1 2 3 4 5 6 GENERAL INFORMATION BASIC COMPONENTS OPERATION MAINTENANCE TROUBLE RECOVERY INDEX READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR ...

Page 5: ...rd motor serial number 1 1 Key number 1 1 EMISSION CONTROL INFORMATION 1 2 Star labels 1 3 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 15 START IN GEAR PROTECTION 1 16 ...

Page 6: ...u in ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor serial number EMU00080 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 illus tration Record this number in the space provided for reference in case you need a new key 1 Key number YAMAHA MOTOR CO L...

Page 7: ... mm FUEL GASOLINE VALVE LASH mm IN EX cm kw g kw hr rpm IN NEUTRAL 3 EM Manufactured EMU13850 EMISSION CONTROL INFORMATION EMU14440 NORTH AMERICAN MODELS This engine conforms to U S Environmental Protection Agency EPA regulations for marine SI engines See the label affixed to your engine for details Approval label of Emission control cer tificate This label is attached to the bottom cowling 1 Emis...

Page 8: ...onventional 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 meet ing these standards have 20 lower emis sions than One Star Low Emission engines Three Stars Ultra Low Emission The three star labe...

Page 9: ...ing fuel before starting the engine 8 This product emits exhaust gases which contain carbon monoxide a colorless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 8 Check throttle shift and steering for proper operation before starting the engine 8 Attach the e...

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

Page 11: ...neutral before starting engine except 2HP 7Do not touch or remove electrical parts when starting or during operation 7Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 6A1 83625 41 6G8 13444 41 CAUTION Transport and store the engine only as shown Otherwise engine damage could result from leaking oil EMU00140 IMPORTANT LABELS q w e WARNING LABELS CAUTIO...

Page 12: ...dened ves sel 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 13: ... the risk of collision neither of you has the right of way Both of you should alter course to avoid an accident You should keep the other vessel on your port left side This rule doesn t apply if both of you will clear one another if you continue on your set course and speed Crossing When two power driven vessels are cross ing each other s path close enough to run the risk of collision the vessel w...

Page 14: ...rs This system uses buoys and signs with dis tinctive shapes and colors to show regulato ry or advisory information These markers are white with black letters and orange boarders They signify speed zones restricted areas danger areas and general information way until you are clear of it Likewise if another vessel is passing you you should maintain your speed and direction so that the other vessel ...

Page 15: ...head of naviga MAIN CHANNEL BUOYS 1 3 5 7 tion Leave to port left proceeding upstream LIGHTED BUOY Port Hand White Light Green Light old new old new old new LIGHTED BUOY Starboard Hand 2 4 6 Even number increasing toward head of naviga tion Leave to starboard right proceeding up stream White Light Red Light A LIGHTED SAFE WATER BUOY No number Marks midchannel pass on either side Letter has no late...

Page 16: ...ately 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 ...

Page 17: ...ting of 86 Pump Octane Number R M 2 EMU00270 Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or engine per formance problems ...

Page 18: ... stroke motor oil with a combination of cor responding SAE and API as shown in the chart cC All 4 stroke engines are shipped from the factory without engine oil SAE API SE SF SG SH SJ 10W 30 10W 40 Engine oil quantity See Chapter 4 Specifications 001162 ...

Page 19: ...ose a battery which meets the following specifications EMU18590 EMU17830 cC A battery cannot be connected to mod els that do not have a rectifier or Rectifier Regulator Models without a rectifier or Rectifier Regulator F9 9MH 8 If you wish to use a battery with the above models install an optional Rectifier Regulator Minimum cold cranking amps CCA SAE 245 amps at 18 C 0 4 F Minimum marine cranking...

Page 20: ...te For a greater operating load a smaller pitch propeller is more suitable as it enables the correct engine speed to be maintained Conversely a larger pitch propeller is more suitable for a smaller operating load Yamaha dealers stock a range of pro pellers and can advise you and install a propeller on your outboard that is best suit ed to your application NOTE At full throttle and under a maximum ...

Page 21: ... propeller removal and installation 9 1 4 x 9 3 4 J 602021 q w e 11 3 4 x 9 1 4 R 602031 w q e EMU12090 START IN GEAR PROTECTION 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 22: ...E MEMO ...

Page 23: ... Gear shift lever 2 3 Engine stop lanyard switch 2 3 Recoil starter handle 2 4 Starter button 2 4 Tiller handle 2 4 Remote control 2 6 Steering friction adjusting screw 2 9 Trim angle adjusting rod 2 10 Shallow water lever 2 11 Tilt lock mechanism 2 12 Tilt support lever 2 12 Top cowling lock lever 2 12 E 1 2 3 4 5 6 ...

Page 24: ... 0 Trim angle adjusting rod q Tilt support lever w Clamp bracket e Starter button r Engine stop lanyard switch t Gear shift lever y Engine stop button u Clamp screw i Throttle control grip o Tiller handle p Recoil starter handle a Oil pressure indicator s Engine stop button Engine stop lanyard switch d Tilt lock lever f Remote control box g Oil pressure indicator panel May not be exactly as shown ...

Page 25: ... screw if equipped EMU00420 Fuel Hose Joint This connector is provided for connecting or disconnecting fuel hose EMU15310 Fuel Meter This meter is on the fuel tank cap It shows the approximate amount of fuel remaining in the tank EMU00450 Fuel Tank Cap This cap is for filling fuel To remove it turn it counterclockwise EMU00460 Air Vent Screw This screw is on the fuel tank cap To loosen it turn it ...

Page 26: ...eg Should the operator fall over board or leave the helm the lanyard will pull out the lock plate stopping ignition to the engine This will prevent the boat from run ning 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 ...

Page 27: ...ngine to start it q w t r 001532 e EMU09430 TILLER HANDLE for Tiller control model T9 9EH Moving the tiller handle sideways to adjust the steering direction In addition this han dle contains the functions as follows 1 Throttle control grip 2 Throttle indicator 3 Throttle friction adjusting knob screw 4 Engine stop button 5 Gear shift lever 503024 EMU00650 Throttle Control Grip The throttle control...

Page 28: ...r EMU12930 Throttle friction adjusting screw knob A friction device in the tiller handle provide resistance to movement of the throttle grip This is adjustable for operator preference An adjusting screw knob is located within the tiller handle When constant speed is desired tighten the adjusting screw bolt to maintain the desired throttle setting w Do not over tighten the friction adjusting screw ...

Page 29: ...l lever In addition this control also has the electrical switches 1 Remote control lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Main switch 5 Engine stop lanyard switch 6 Throttle friction adjusting screw EMU00980 Remote Control Lever Moving the lever forward from the Neutral position engages Forward gear Pulling the lever back from Neutral engages Reverse The engine will continue ...

Page 30: ...he neutral throttle lever will operate only when the remote control lever is in Neutral The remote control lever will operate only when the neutral throttle lever is in the closed position 1 Fully open 2 Fully closed ON START OFF 701021 EMU01010 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...

Page 31: ...om run ning 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 ...

Page 32: ...move the lever which could result in an accident Resistance Screw Increase Turn clockwise Decrease Turn counterclockwise 408014 EMU01080 STEERING FRICTION ADJUSTING SCREW for Tiller control model A friction device provides resistance to steering movement This is adjustable for operator preference An adjusting screw bolt is located on the swivel bracket EMU12960 Adjustment w Do not over tighten the...

Page 33: ...ock lever and the boat s rudder is set straight readjust the outboard s steering handle angle with the adjustment bolts If the engine is forced to turn right or left when the steering is locked the steering plate is designed to break to protect the out board motor If the plate breaks remove the screw and replace the plate NOTE A spare plate is contained in the outboard s original packing 001540 q ...

Page 34: ... As an additional alert of the low oil pressure condition the engine runs roughly and will not exceed about 2 000 rpm If the oil lamp goes out or does not come on when the engine is running stop the engine as soon as it is safe to do so Check oil level and add oil as needed If the lamp goes off when the oil level is correct con sult your Yamaha dealer cC Do not continue to run the engine if the oi...

Page 35: ...ever down 1 Tilt lock lever EMU01580 TILT SUPPORT LEVER To keep the outboard motor in the tilted up position push the tilt support lever so the pin locks in the upper slot 001527 q 001530 001524 q EMU01620 TOP COWLING LOCK LEVER To remove the engine top cowling turn the lock lever Then lift off the cowling When replacing the cowling check to be sure it fits properly in the rubber seal Then lock th...

Page 36: ...E MEMO ...

Page 37: ... the engine oil level 3 9 FILLING FUEL 3 10 STARTING ENGINE 3 11 WARMING UP ENGINE 3 16 CHECKPOINTS AFTER STARTING ENGINE 3 17 SHIFTING 3 18 Forward 3 18 Reverse 3 19 STOPPING ENGINE 3 20 TRIMMING OUTBOARD MOTOR 3 21 Adjusting trim angle 3 22 TILTING UP DOWN 3 24 CRUISING IN SHALLOW WATER 3 26 CRUISING IN OTHER CONDITIONS 3 28 Cruising in salt water 3 28 Cruising in turbid water 3 28 E 1 2 3 4 5 6...

Page 38: ...borne water spray while the boat is cruising Severe engine damage may result if the motor is operated continuously in the presence of airborne 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 prevent water entry into the powerhead when water rises due to waves when the outboa...

Page 39: ...ry possible boat motor combination Proper mounting depends in part on experi ence and the specific boat motor com bination w Improper mounting of the outboard motor could result in hazardous condi tions such as poor handling loss of con trol or fire hazards Observe the follow ing 8 For permanently mounted models your dealer or other person experi enced in proper rigging should mount the motor If y...

Page 40: ...is too high cavitation tends to occur thus reducing the propul sion and if the propeller tips cut the air the engine speed will rise abnormally and cause the engine to overheat If the mount ing height is too low the water resistance will increase and thereby reduce engine efficiency Mount the engine so that the anti cavitation plate is between the bottom of the boat and a level 25 mm 1 in below it...

Page 41: ...tboard motor should be able to be tilted up out of the water so the propeller does not contact the water spray Disconnect the fuel line connec tion 8 Check that the outboard motor does not interfere with the rudder 8 Check that the engine can be easily start ed and stopped 8 Check the ease of operating the gear shift and throttle control 8 If mounting the outboard motor on a well type boat exhaust...

Page 42: ...lly check the screws for tight ness during operation 2 An engine restraint cable or chain should be used Attach one end to the engine restraint cable attachment point and the other to a secure mounting point on the boat Otherwise the engine could be completely lost if it accidentally falls off the transom Secure the clamp bracket to the tran som with the bolts provided with the outboard For detail...

Page 43: ...erminal fixed with the red lead from the rectifier regulator 1 Fuse holder 3 Reinstall the CDI unit cover and fit the fuse holder onto the top side of the cover 4 Connect the other fuse holder terminal to the red terminal of the charge lead Secure the black terminal ground of the charge lead to the engine together with the CDI unit ground terminal 2 Charge lead 5 Pull out the charge lead through t...

Page 44: ... life or even severe engine damage EMU13670 Run 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 3 For the next eight hours of operation Avoid continuous operation at full thr...

Page 45: ...mage can occur EMU02060 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 objects EMU02080 Oil 8 Check the level of the oil in the sump w...

Page 46: ...unting 8 Look for loose or damaged fasteners 8 Check the propeller for damage EMU14360 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 47: ...tives such as aromatics and oxy genates has increased These additives are important for the engines in passenger cars but they can have detrimental effects in marine engines because of increased deposits in the combustion chamber When enough deposits collect piston rings begin sticking Performance drops and engine wear increases dramatically While many additives available may reduce deposits Yamah...

Page 48: ...ew 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 2 If there is a fuel joint on the motor firm ly connec...

Page 49: ...engine stop switch w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering con...

Page 50: ...button to start the starting motor 8 Immediately after the engine starts release the starter switch to return it to its home position cC 8 Do not push the starter switch when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds If the starter motor is run continuously for more than 5 seconds the battery will rapidly become exhausted and it will be impossible for it...

Page 51: ...d in the engine stop switch w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steeri...

Page 52: ...rn 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 ON 000978 START ...

Page 53: ...ine Otherwise serious engine damage could occur Check the oil level and add oil if necessary Consult your Yamaha dealer if the cause can not be found 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 overheating and serious damage could occur...

Page 54: ...ter 2 Oil pressure indicator 8 Check that the engine idle speed is stable after the engine has warmed up cC If water is not flowing out of the pilot hole at all times while the engine is run ning overheating and serious damage could occur Stop the engine and check whether the cooling water inlet on the lower case is blocked Consult your Yamaha dealer if the problem cannot be located and corrected ...

Page 55: ...t so that the engine idles or runs at low speeds EMU02650 FORWARD Tiller control model 1 Place the throttle control grip in the fully closed position 2 Turn the gear shift lever quickly and firmly from Neutral to Forward 503012 N F 310013 507012 N F 701043 N F Remote control model Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from Neutral to...

Page 56: ...dent 1 Place the throttle control grip in the fully closed position for Tiller control model 2 Check that the tilt lock lever for Manual tilt Hydro tilt model is in the locked position Tiller control model 3 Turn the gear shift lever quickly and firmly from Neutral to Reverse Remote control model 3 Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firm...

Page 57: ...ne stop button or turn the main switch to OFF 2 If the 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 sto...

Page 58: ...oat engine and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed w Excessive trim for the operating condi tions either trim up or trim down can cause boat instability and can make steering the boat more difficult This increases the possibility of an accident If the boat begins to feel unstable or is hard to steer slow down and or rea...

Page 59: ... the rod toward the transom Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions w 8 Stop the engine before adjusting the trim angle 8 Use care to avoid being pinched when removing or installing the rod 8 Use caution when trying a trim posi tion for the first time Increase speed gradually and watch for any signs of instabi...

Page 60: ... economy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces performance further and the boat may porpoise hop in the water which could throw the operator and passengers overboard Bow Down When the bow of the boat is down it is eas ier to accelerate from a standing start onto plane Too...

Page 61: ... from over heating can result 8 Do not tilt up the engine by pushing the steering handle as this could break the handle 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 if the engine will be tilted for more than a few minu...

Page 62: ...tor is pro vided on the motor 2 Place the tilt lock lever in Release 3 Hold the rear of the top cowling with one hand tilt the engine up and turn the tilt support lever to the locked posi tion and support the engine EMU02970 PROCEDURE FOR TILTING DOWN Manual tilt model 1 Return the tilt support lever tilting up the engine slightly 2 Tilt down the engine ...

Page 63: ...m is being used Hitting an underwater obstacle could cause the engine to lift out of the water resulting in loss of control 8 Do not rotate the engine 180 and operate the boat in reverse Place the gear shift in the Reverse position to operate the boat in reverse 8 Use extra care when operating in reverse Too much reverse thrust can cause the engine to lift out of the water increasing the chance of...

Page 64: ...er down to the release position 3 Slightly tilt up the engine and pull the shallow water lever toward the transom 4 To return the engine to the normal posi tion put the engine in Neutral then slightly tilt up the engine Push the shal low water lever down Set the tilt lock lever to the lock position and slowly tilt the engine down ...

Page 65: ...resh water to prevent them from becoming clogged up with salt deposits NOTE Refer to cooling system flushing instructions in TRANSPORTING AND STORING OUT BOARD MOTOR CRUISING IN TURBID WATER It is strongly recommended that the optional chromium plated water pump kit be installed if the outboard is to be used in tur bid muddy water conditions ...

Page 66: ...E MEMO ...

Page 67: ...sting spark plug 4 12 Checking fuel system 4 14 Inspecting fuel filter 4 15 Inspecting idling speed 4 16 Changing engine oil 4 17 Checking wiring and connectors 4 19 Exhaust leakage 4 19 Water leakage 4 19 Checking propeller 4 20 Changing gear oil 4 22 Cleaning fuel tank 4 24 Inspecting and replacing anode s 4 25 Checking battery 4 26 Checking bolts and nuts 4 28 Checking top cowling 4 29 Motor ex...

Page 68: ...ear ratio Trim and tilt system Propeller mark FUEL AND OIL Recommended fuel Fuel tank capacity L US gal Imp gal Recommended engine oil API SAE Engine oil capacity L US qt Imp qt Recommended gear oil Gear oil capacity cm3 US oz Imp oz TIGHTENING TORQUE Spark plug N m kgf m lb ft Propeller nut N m kgf m lb ft Engine oil drain bolt N m kgf m lb ft Engine oil filter N m kgf m lb ft 863 33 98 392 15 43...

Page 69: ...32 1 67 CDI system CR6HS 0 6 0 7 0 02 0 03 Tiller control Electric start 0 15 0 20 0 0059 0 0079 0 20 0 25 0 0079 0 0098 245 323 52 12 10 Prime start Forward Neutral Reverse 2 92 38 13 Manual tilt R Regular unleaded gasoline 25 6 60 5 50 4 stroke motor oil SE SF SG SH SJ 10W 30 10W 40 1 0 1 06 0 88 Hypoid gear oil SAE90 320 10 8 11 3 13 1 3 9 4 21 2 1 15 8 0 8 5 8 8 0 8 5 8 575 22 64 325 12 8 1 17...

Page 70: ...t your Yamaha dealer w 8 Never get under the lower unit while it is tilted even if a motor support bar is used Severe injury could occur if the outboard accidentally falls 8 USE CARE when transporting fuel tank whether in a boat or car 8 DO NOT fill fuel container to maximum capacity Gasoline will expand consid erably as it warms up and can build up pressure in the fuel container This can cause fu...

Page 71: ...attitude shown when transporting and storing it 8 Do not place the engine on its side before the cooling water has drained from it completely or water may enter the cylinder through the exhaust port and cause problems 8 Store the engine in a dry well ventilat ed place not in direct sunlight 1 Vertical position 2 Horizontal position 3 Upright EMU03350 Filling Fuel Tank Fill the fuel tank with fresh...

Page 72: ...nd other rotating parts while engine is running EMU03400 8 Flushing in a Water Tank cC If the fresh water level is below the level of the anti cavitation plate or if the water supply is insufficient engine seizure may occur 1 Remove the engine top cowling 2 Install the outboard motor on the water tank 3 Fill the tank with fresh water to above the level of the anti cavitation plate 4 Run the engine...

Page 73: ...ler 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 spray Yamaha Stor Rite Engine Fogging Oil Part No LUB STRRT 12 00 alternately into the silencer cover When properly done the engine will smoke excessively and almost stall 5 Remove the flushing attachment and wipe of...

Page 74: ...rings 3 Change the gear case oil Refer to CHANGING GEAR OIL Inspect the oil for the presence of water which indi cates a leaky seal Seal replacement should be performed by an authorized Yamaha dealership prior to use 4 Grease all grease fittings Refer to the GREASING EMU03510 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the outboard with fresh water and dry off completely 2 Spra...

Page 75: ...g in a closed space Always wear eye protec tion 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 manu facturer 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 the battery cas...

Page 76: ...the emission control system must be performed by an autho rized 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 mainte nance not covered by this owner s manual EMU03560 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equivalents ...

Page 77: ...t replacement Greasing points Greasing Gear oil Change Fuel system Inspection Fuel filter disposable Inspection replacement 1 1 1 Fuel tank Yamaha portable tank Cleaning Idling speed carburetor models Inspection adjustment 1 1 Anode s Inspection replacement 1 1 1 Cooling water passages Cleaning Propeller and cotter pin Inspection replacement Timing belt Inspection replacement 1 1 Battery Inspectio...

Page 78: ...E 4 11 EMU03660 GREASING Yamaha marine grease Water resistant grease 001563 500 hours 1000 hours 2 5 years 5 years Timing belt Replacement 1 Item Actions Every ...

Page 79: ...ir 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 elec trode erosion becomes excessive or if car bon and other deposits are excessive you should replace the s...

Page 80: ... when you are fitting a spark plug a good estimate 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 Spark plug torque Refer to SPECIFICATIONS page 4 1 Initial of spark plug Plug wrench size I D mark B 21 mm 13 16 in C BK 16 mm 5 8 in D 18 3 mm 23 32 in ...

Page 81: ...oblem is found it should be repaired immediately by Yamaha dealer or other qualified mechanic Checkpoints 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 ...

Page 82: ... 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 which could result in a fire or explo sion hazard EMU03740 Check the fuel filter periodicall...

Page 83: ... the flushing attachment in a test tank or with the outboard motor in the water 1 Start the engine and allow it to warm up fully in neutral until it is running smooth ly If the outboard motor is mounted on a boat be sure the boat is tightly moored 2 Verify whether the idle speed is set to specification For idle speed specifica tions see Specifications in this chap ter NOTE Correct idling speed ins...

Page 84: ...t tilted 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 could cause leakage or damage 1 Put the outboard motor in an upright position not tilted 2 Prepare a suitable container that holds a larger amount than the engine oil capacity Loosen and remove the drain screw 1 while holding the...

Page 85: ...or turns on Make sure that there are no oil leaks cC If the oil pressure indicator does not turn on or if there are oil leaks stop the engine and find the cause Continued operation with a problem could cause severe engine damage Consult your Yamaha dealer if the problem cannot be located and corrected 6 Turn off the engine and wait 3 minutes Recheck the oil level using the dipstick to be sure the ...

Page 86: ...NG WIRING AND CONNEC TORS 1 Check that each grounding wire is properly secured 2 Check that each connector is engaged securely EMU03840 EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and crank case EMU03850 WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head an...

Page 87: ...he 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 EMU03900 Propeller Checking Point 8 Check each of the propeller blades for wear erosion from cavitation or ve...

Page 88: ...nstall the thrust washer before installing propeller otherwise lower case and propeller boss may be damaged 8 Be sure to use a new cotter pin and bend the ends over securely Otherwise the propeller could come off during operation and be lost 1 Apply Yamaha Marine grease or a cor rosion resistant grease to the propeller shaft 2 Install the thrust washer and propeller on the propeller shaft Install ...

Page 89: ...L w 8 Be sure the outboard motor is secure ly fastened to the transom or a stable stand You could be severely injured if the outboard motor falls on you 8 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 accidentally falls 1 Tilt the outboard motor so that the gear oil drain screw is at the lowest p...

Page 90: ...or repair of the lower unit seals NOTE For disposal of used oil consult your Yamaha dealer 5 With the outboard motor in a vertical position and using a flexible or pres surized filling device inject the gear oil into the gear oil drain screw hole 6 When the oil begins to flow out of the oil level plug hole insert and tighten the oil level plug 7 Insert and tighten the gear oil drain screw Gear oil...

Page 91: ... tank carefully Improper assembly can result in a fuel leak which could result in a fire or explosion hazard 8 Dispose of old gasoline petrol according to local regulations 1 Empty the fuel tank into an approved container 2 Pour a small amount of suitable solvent in the tank Reinstall the cap and shake the tank Drain the solvent completely EMU04020 Cleaning the Fuel Filter 1 Remove the screws hold...

Page 92: ...es periodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes cC Do not paint anodes as this would ren der them ineffective NOTE Inspect ground leads attached to external anodes on equipped models Consult a Yamaha dealer for inspection and replace ment of internal anodes attached to the power unit ...

Page 93: ...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 hydro gen gas therefore you should always follow these preventive measures 8 Charge batteries in a well ventilated area 8 Keep batteries away ...

Page 94: ...eter 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 gravity of the fluid at least once a month and recharge the battery when it is low NOTE Consult a Yamaha dealer when char...

Page 95: ... 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 EMU12800 Disconnecting the Battery Disconnect the BLACK lead from the NEG ATIVE terminal first Then disconnect the RED lead from the POSITIVE terminal UPPER LEVEL LOWER LEVEL 901012 q w e EMU04080 CHECKING BOLTS AND NU...

Page 96: ...EMU04120 Checking Painted Surface of Motor Check the motor for scratches nicks or flaking paint Areas with damaged paint are more likely to corrode If necessary clean and paint the areas A touch up paint is available from a Yamaha dealer EMU04130 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clean of marine growths as possible If necessary the boa...

Page 97: ...er 5 TROUBLE RECOVERY TROUBLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 4 Impact damage 5 4 Replacing fuse 5 4 Starter will not operate 5 5 Engine fails to operate 5 7 Treatment of submerged motor 5 8 E 1 2 3 4 5 6 ...

Page 98: ...Starting procedure incorrect 5 Fuel pump malfunctions 6 Spark plug s fouled or incorrect type 7 Spark plug cap s fitted incorrectly 8 Poor connections or damaged ignition wiring 9 Ignition parts faulty 10 Engine stop switch lanyard not attached 11 Engine inner parts damaged 1 Fill tank with clean fresh fuel 2 Fill tank with clean fresh fuel 3 Clean or replace filter 4 Read STARTING ENGINE section ...

Page 99: ...ngled on gear housing 9 Fuel system obstructed 10 Fuel filter clogged 11 Fuel contaminated or stale 12 Spark plug gap incorrect 13 Poor connections or damaged ignition wiring 14 Failed ignition parts 15 Specified engine oil not used 16 Thermostat faulty or clogged 17 Air vent screw closed 18 Fuel pump damaged 19 Fuel joint connection incorrect 20 Heat range of spark plug incorrect 1 Have propeller...

Page 100: ...s or other foreign matter tangled on propeller 4 Motor mounting bolt loose 5 Clamp screw is loose 6 Steering pivot loose or damaged 1 Have propeller repaired or replaced 2 Have serviced by a Yamaha dealer 3 Remove and clean propeller 4 Tighten bolt 5 Tighten the clamp screw 6 Tighten or have serviced by a Yamaha dealer ...

Page 101: ... the boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and care fully 4 Have a Yamaha dealer inspect the out board motor before operating it again EMU13290 REPLACING FUSE If the fuse has blown on an Electric start model open the fuse holder and replace the fuse with a new one of proper amper age w Be sure to use the specified fuse An incorrect fuse or a piece of ...

Page 102: ...oat could unexpected ly 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 flywheel or other moving par...

Page 103: ...arting See STARTING ENGINE for procedures Be sure the engine is in neutral and that the lanyard is attached to the engine stop switch The main switch must be on if the main switch is equipped on the electric start model NOTE Refer to ENGINE FAILS TO OPERATE for cold engine starting procedures 5 To start the engine with the emergency starter rope insert the knotted end of the rope into the notch in...

Page 104: ... 2 Open the throttle halfway on models with neutral throttle limiter open throttle as far as it will go 3 Start the engine 4 If the engine still will not start open and close the throttle two or three times to feed additional fuel to the intake mani fold by the accelerator pump of the car buretor 5 Then open the throttle halfway and start the engine ...

Page 105: ... 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 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 or ...

Page 106: ...E MEMO ...

Page 107: ...EMU04500 Chapter 6 INDEX INDEX 6 1 E 1 2 3 4 5 6 ...

Page 108: ...tom 4 29 Cold engine fails to start 5 7 Connecting the battery 4 27 Cruising in other conditions 3 28 Cruising in salt water 3 26 Cruising in shallow water 3 28 Cruising in turbid water 3 28 D Disconnecting the battery 4 28 E Emission control information 1 2 Engine fails to operate 5 7 Engine oil 1 13 Engine stop button 2 5 Engine stop lanyard switch 2 3 2 8 Exhaust leakage 4 19 F Filling fuel 3 1...

Page 109: ... Starter button 2 4 Starter will not operate 5 5 Starting engine 3 11 Start in gear protection 1 16 Steering friction adjusting screw 2 9 Steering Lock Device 2 10 Stopping engine 3 20 Storing outboard motor 4 4 T Temporary action in emergency 5 4 Three Stars Ultra Low Emission 1 3 Throttle control grip 2 4 Throttle friction adjusting screw 2 9 Throttle friction adjusting screw knob 2 5 Throttle i...

Page 110: ...istration 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 separately 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 Can...

Page 111: ...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 112: ...m 8 Power Trim and Tilt Assembly WARRANTY REGISTRATION To be eligible for warranty coverage the outboard motor must be registered with Yamaha Motor Corporation U S A Warranty registration can be accomplished by any authorized Yamaha Outboard Motor Dealer Upon receipt of the registration an Owner s Warranty Card will be sent by Yamaha to the registered purchaser OBTAINING REPAIRS UNDER WARRANTY To ...

Page 113: ...ed Yamaha Outboard Motor Dealer and requesting the dealer to submit a change of registration to Yamaha Motor Corporation U S A within ten 10 days of the transfer YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGA TIONS AND TIME LIMITS STATED IN THIS WARRANTY A...

Page 114: ... receive service If you need more information about your warranty cov erage or your Yamaha outside the U S A or Canada please contact an authorized 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 pur chase which is important evidence the repairing dealer w...

Page 115: ...Printed in Japan April 2003 0 5 1 6G8 28199 1M F9 9BMH F9 9BE FT9 9AEH FT9 9AE E Printed on recycled paper ...

Page 116: ...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 117: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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