Yamaha FL150A Page 81 Owner'S Manual Download

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Maintenance

Single engine

Twin engines

EMU29371

Disconnecting the battery

Turn off the battery cut-off switch (if
equipped) and main switch.

NOTICE:

they are left on, the electrical system
can be damaged.

[ECM01930]

Disconnect the negative cable(s) from
the negative (-) terminal.

NOTICE:

Al-

ways disconnect all negative (-) ca-
bles first to avoid a short circuit and
damage to the electrical system.

[ECM01940]

1. Isolator lead with circuit protection

2. Red cable

3. Black cable
4. Fuse

5. Battery for accessories

6. Battery for starting
7. Negative connecting cable

ZMU05939

1. Starboard side engine

2. Port side engine

3. Red cable
4. Black cable

5. Isolator leads with circuit protection

6. Fuse
7. Battery for starting

8. Battery for accessories

9. Negative connecting cable

ZMU05941

U63P7AE0.book Page 75 Thursday, February 25, 2010 1:14 PM

Summary of Contents for FL150A

Page 1: ...Read this manual carefully before operating this outboard motor OWNER S MANUAL F150A FL150A F150A1 FL150A1 63P 28199 7A E0 U63P7AE0 book Page 1 Thursday February 25 2010 1 14 PM ...

Page 2: ...arefully before operating this outboard motor Keep this manual onboard in a waterproof bag when boating This manual should stay with the outboard motor if it is sold U63P7AE0 book Page 1 Thursday February 25 2010 1 14 PM ...

Page 3: ... your machine and this manual If there is any question concerning this manual please con sult your Yamaha dealer To ensure long product life Yamaha recom mends that you use the product and perform the specified periodic inspections and mainte nance by correctly following the instructions in the owner s manual Any damage resulting from neglect of these instructions is not cov ered by warranty Some ...

Page 4: ...le batteries 11 Propeller selection 11 Counter rotation models 11 Start in gear protection 12 Engine oil requirements 12 Fuel requirements 12 Gasoline 12 Muddy or acidic water 13 Anti fouling paint 13 Motor disposal requirements 13 Emergency equipment 13 Emission control information 13 North American models 13 Star labels 14 Components 16 Components diagram 16 Remote control box 17 Remote control ...

Page 5: ...ng to know your boat 41 Checks before starting engine 41 Fuel level 41 Remove cowling 42 Fuel system 42 Controls 42 Engine shut off cord lanyard 43 Engine oil 43 Engine 43 Flushing device 43 Install cowling 44 Checking power trim and tilt system 44 Battery 45 Filling fuel 45 Operating engine 46 Sending fuel 46 Starting engine 46 Checks after starting engine 48 Cooling water 48 Warming up engine 49...

Page 6: ...r 70 Removing propeller 70 Installing propeller 71 Changing gear oil 71 Inspecting and replacing anode s 73 Checking battery for electric start models 73 Connecting the battery 74 Disconnecting the battery 75 Trouble Recovery 77 Troubleshooting 77 Temporary action in emergency 80 Impact damage 80 Running single engine twin engines 80 Replacing fuse 81 Power trim and tilt will not operate 81 Water ...

Page 7: ... times Be sure no one is in this area before operating the power trim and tilt mech anism The power trim and tilt switches operate even when the main switch is off Keep people be away from the switches whenever working around the motor Never get under the lower unit while it is tilted even when the tilt support lever is locked Se vere injury could occur if the outboard motor accidentally falls EMU...

Page 8: ...ous boating condi tions EMU33731 People in the water Always watch carefully for people in the wa ter such as swimmers skiers or divers whenever the engine is running When some one is in the water near the boat shift into neutral and stop the engine Stay away from swimming areas Swimmers can be hard to see The propeller can keep moving even when the motor is in neutral Stop the engine when a person...

Page 9: ...e not sure that you can stop in time before hitting an obstacle apply throttle and turn in anoth er direction EMU33790 Weather Stay informed about the weather Check weather forecasts before boating Avoid boat ing in hazardous weather EMU33880 Passenger training Make sure at least one other passenger is trained to operate the boat in the event of an emergency EMU33890 Boating safety publications Be...

Page 10: ...illustration Record this number in the space provided for reference in case you need a new key EMU37290 EC Declaration of Conformity DoC This outboard motor conforms to certain por tions of the European Parliament directive re lating to machinery Each conformed outboard motor accompa nied with EC DoC EC DoC contains the fol lowing information Name of Engine Manufacture Model name Product code of m...

Page 11: ...General information 5 ZMU06040 U63P7AE0 book Page 5 Thursday February 25 2010 1 14 PM ...

Page 12: ...nuals supplied with the boat Read all labels on the outboard motor and the boat If you need any additional information contact your Yamaha dealer EMU33832 Warning labels If these labels are damaged or missing contact your Yamaha dealer for replacements F150A FL150A F150A1 FL150A1 U63P7AE0 book Page 6 Thursday February 25 2010 1 14 PM ...

Page 13: ...r remove electrical parts when starting or during operation 2 WARNING EWM01671 Read Owner s Manuals and labels Wear an approved personal flotation de vice PFD Attach engine shut off cord lanyard to your PFD arm or leg so the engine stops if you accidentally leave the helm which could prevent a runaway boat EMU33850 Other labels 1 2 ZMU06191 3 ZMU05710 U63P7AE0 book Page 7 Thursday February 25 2010...

Page 14: ...ing Read Owner s Manual Hazard caused by continuous rotation Electrical hazard Remote control lever gear shift lever operat ing direction dual direction Engine start Engine cranking ZMU05696 ZMU05664 ZMU05665 ZMU05666 ZMU05667 ZMU05668 U63P7AE0 book Page 8 Thursday February 25 2010 1 14 PM ...

Page 15: ...ce Full throttle operating range 5000 6000 r min Maximum output 110 3 kW 5500 r min 150 HP 5500 r min Idle speed in neutral 700 50 r min Engine Type 4 stroke L Displacement 2670 0 cm Bore stroke 94 0 96 2 mm 3 70 3 79 in Ignition system TCI Spark plug NGK LFR5A 11 Spark plug gap 1 0 1 1 mm 0 039 0 043 in Control system Remote control Starting system Electric starter Starting carburetion system Ele...

Page 16: ...ts EMU33564 Boat horsepower rating WARNING EWM01560 Overpowering a boat can cause severe in stability Before installing the outboard motor s con firm that the total horsepower of your out board motor s does not exceed the boats maximum horsepower rating See the boat s capacity plate or contact the manufacturer EMU33571 Mounting motor WARNING EWM01570 Improper mounting of the outboard mo tor could ...

Page 17: ...appli cation Your outboard motor came with a Yamaha propeller selected to perform well over a range of applications but there may be uses where a different propeller would be more ap propriate Your Yamaha dealer can help you select the right propeller for your boating needs Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with ...

Page 18: ...tive from the fol lowing chart according to the average temper atures in your area EMU36360 Fuel requirements EMU36802 Gasoline Use a good quality gasoline that meets the minimum octane rating If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel NOTICE ECM01981 Do not use leaded gasoline Leaded gas oline can seriously damage the engine Avoid getting water and co...

Page 19: ...ches including metric sizes and electrical tape Waterproof flashlight with extra batteries An extra engine shut off cord lanyard with clip Spare parts such as an extra set of spark plugs Consult your Yamaha dealer for details EMU39000 Emission control information The following labels are affixed to outboard motors that conform to US regulations EMU25230 North American models This engine conforms t...

Page 20: ...1 exhaust emission standards Engines meet ing these standards have 75 lower emis sions than conventional carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 standards for marine engines EMU40340 Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s Personal Water craft and Outboard marine engine 2004 ex haust emission sta...

Page 21: ...meeting these standards have 65 lower emissions than One Star Low Emission engines EMU33861 Four Stars Super Ultra Low Emission The four star label identifies engines that meet the Air Resources Board s Sterndrive and Inboard marine engine 2009 exhaust emission standards Personal Watercraft and Outboard marine engines may also comply with these standards Engines meeting these standards have 90 low...

Page 22: ...ever s 3 Anti cavitation plate 4 Trim tab anode 5 Propeller 6 Cooling water inlet 7 Clamp bracket 8 Flushing device 9 Water separator 10 Power trim and tilt switch 11 Remote control box side mount type 12 Remote control box binnacle mount type 13 Switch panel for use with binnacle type 14 Digital speedometer 15 Digital tachometer 16 Fuel management meter U63P7AE0 book Page 16 Thursday February 25 ...

Page 23: ...it Square type 2 Tachometer unit Round type 3 Speedometer unit Square type 4 Speed fuel meter unit Square type 5 Speed fuel meter unit Round type 6 Fuel management meter Square type 1 Power trim and tilt switch 2 Remote control lever 3 Neutral interlock trigger 4 Neutral throttle lever 5 Main switch 6 Engine shut off switch 7 Throttle friction adjuster U63P7AE0 book Page 17 Thursday February 25 20...

Page 24: ... the neutral in terlock trigger up EMU26212 Neutral throttle lever To open the throttle without shifting into either forward or reverse put the remote control le ver in the neutral position and lift the neutral throttle lever 1 Remote control lever 2 Power trim and tilt switch 3 Free accelerator 4 Throttle friction adjuster 1 Neutral 2 Forward 3 Reverse 4 Shift 5 Fully closed 6 Throttle 7 Fully op...

Page 25: ...remote control lever to the neutral position The free accelerator button will return auto matically to its set position The remote con trol will then engage forward and reverse normally EMU25976 Throttle friction adjuster A friction device provides adjustable resis tance to movement of the throttle grip or the remote control lever and can be set accord ing to operator preference To increase resist...

Page 26: ...d tear loose Do not route the cord where it could become entangled preventing it from functioning Avoid acci dentally pulling the cord during normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause people and ob jects in the boat to be thrown forward EWM00122 EMU26091 Main switch The main switch controls t...

Page 27: ...rim and tilt switch on bottom cowling The power trim and tilt switch is located on the side of the bottom cowling Pushing the switch up trims the outboard motor up and then tilts it up Pushing the switch down tilts the outboard motor down and trims it down When the switch is released the out board motor will stop in its current position For instructions on using the power trim and tilt switch see ...

Page 28: ...ab could cause difficult steering Always test run af ter the trim tab has been installed or re placed to be sure steering is correct Be sure you have tightened the bolt after ad justing the trim tab The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force If the boat tends to veer to the left port side turn the trim...

Page 29: ... the normal running position use an addi tional support device to secure it in the tilt position EMU26383 Cowling lock lever pull up type To remove the engine top cowling pull up the cowling lock lever s and lift off the cowling When installing the cowling check to be sure it fits properly in the rubber seal Then lock the cowling by moving the cowling lock lever s downward 1 Trim tab 2 Bolt 3 Cap ...

Page 30: ...If wa ter separated from the fuel exceeds a specific volume the alert device of 6Y8 Multifunction Tachometer will activate Activation of alert device The water separator alert indicator of 6Y8 Multifunction Tachometer will blink The buzzer will sound intermittently only when the gear shift is in neutral If the alert system has activated stop the engine and consult a Yamaha dealer imme diately 1 Co...

Page 31: ... the desired using the pow er trim and tilt switch If the trim angle of your motor exceeds the trim operating range the top segment on the trim meter display will blink EMU26651 Hour meter This meter shows the number of hours the en gine 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 To change the d...

Page 32: ...further in formation on reading the indicator see page 37 NOTICE ECM00052 Do not continue to run the engine if the overheat alert indicator is on Serious en gine damage will occur EMU26602 Digital speedometer This gauge shows the boat speed and other information All segments of the display will light momen tarily after the main switch is turned on and will return to normal thereafter EMU36061 Spee...

Page 33: ...the face of the gauge points to trip meter clock or voltmeter EMU26691 Trip meter This gauge displays the distance the boat has traveled since the gauge was last reset The trip distance is shown in kilometers or miles depending upon the unit of measure ment selected for the speedometer To reset the trip meter to zero press the set and mode buttons at the same time The trip distance is kept in memo...

Page 34: ...y will auto matically turn on and blink Get back to the port soon if an alert device has activated For charging the battery consult your Yamaha dealer EMU26741 Fuel management meter The fuel management meter shows the state of the fuel consumption while the engine is running All segments of the display will light momen tarily after the main switch is turned on and will return to normal thereafter ...

Page 35: ...isplays for fuel flow to the starboard en gine only for fuel flow to the port engine only or for total fuel flow both engines EMU36090 Fuel consumption meter Fuel econo my meter Twin engine speed syn chronizer The display shows either the fuel consump tion meter the fuel economy meter or the twin engine synchronizer To change the display press the mode button repeatedly until the indicator on the ...

Page 36: ...ividual engines may slightly vary in their fuel consumption due to manufacturing variations These variations can be even greater if the engines are of different year models In addition variations in propellers even of the same basic dimensions of the same design can also cause a slight varia tion in fuel consumption EMU26782 Twin engine speed synchronizer This gauge displays the difference in engi...

Page 37: ...he tachometer shows the engine revolutions per minute It has functions of trim meter ad justing trolling speed cooling water engine temperature display battery voltage display total hour trip hour display oil pressure dis play water detection alert engine trouble alert and periodic maintenance notification If the cooling water pressure sensor is installed the unit can also show the cooling water p...

Page 38: ...min Stop the engine immediately if the buzzer sounds and the low oil pressure alert indicator blinks Check the engine oil quantity and re plenish oil if necessary If the alert device has activated while the appropriate engine oil quantity is maintained consult your Yamaha dealer NOTICE ECM01601 Do not continue to run the engine if the low oil pressure alert device has activated Serious engine dama...

Page 39: ...ce has activated Consult your Yamaha dealer if the problem can not be located and corrected EMU36150 Water separator alert This indicator will blink if water has accumulat ed in the water separator fuel filter while cruising In such an event stop the engine im mediately and see page 80 of this manual to drain the water from the fuel filter Get back to the port soon and consult a Yamaha dealer imme...

Page 40: ...eed and has the functions of fuel meter to tal fuel consumption display fuel economy display fuel flow display and system voltage display The chosen display is selected by us ing the set and mode buttons as described in this section If the speed sen sor is installed the unit can also show the trip display However even if the speed sensor is not installed the trip display can be shown by connecting...

Page 41: ... chosen display is select ed by using the set and mode buttons as described in this section In addi tion the speedometer can show the desired unit of measurement such as km h mph or knots If the speed sensor is installed the unit can also show the trip display However even if the speed sensor is not installed the trip dis play can be shown by connecting an optional sensor to the unit In addition i...

Page 42: ...s play fuel economy display and remaining fuel display The chosen display is selected by using the set and mode buttons as described in this section For more information see the operation manual origi nally supplied with the meter After the main switch is first turned on all the displays come on as a test After a few sec onds the gauge will change to normal opera tion For more information see the ...

Page 43: ...merged Check the cooling water inlet for clogging Dual engine drive users If the overheat alert system of one engine ac tivates the engine will slow down To switch off the alert activation on the engine not affect ed by overheating turn off the main switch of the engine overheating If the alert system has activated stop the engine and tilt the out board motor up to check the cooling water in let f...

Page 44: ...ot switch off consult your Yamaha dealer Twin engine drive users If the low oil pressure alert system of one en gine activates both engines will slow down and the buzzer will sound To switch off the alert activation on the engine not affected by low oil pressure turn off the main switch of the engine with the low oil pressure ZMU01828 OFF START ON OFF START ON ZMU04584 U63P7AE0 book Page 38 Thursd...

Page 45: ... boats mount the outboard motor on the cen terline keel line of the boat For twin engine boats mount the outboard motors equidistant from the centerline Consult your Yamaha dealer or boat manufacturer for further infor mation on determining the proper mounting location EMU26933 Mounting height boat bottom The mounting height of your outboard motor affects its efficiency and reliability If it is mo...

Page 46: ...tructions to the smooth flow of water such as the design or condition of the boat or ac cessories such as transom ladders or depth finder transducers can create air borne water spray while the boat is cruising If the outboard motor is operat ed continuously in the presence of air borne water spray enough water could enter the engine through the air intake opening in the top cowling to cause se ver...

Page 47: ...ing rough water and crowded areas 1 For the first hour of operation Run the engine at varying speeds up to 2000 r min or approximately half throttle 2 For the second hour of operation Increase engine speed as much as nec essary to put the boat on plane but avoid full throttle operation then back off on the throttle while keeping the boat at a planing speed 3 Remaining 8 hours Run the engine at any...

Page 48: ...ck for fuel leaks or gasoline fumes in the boat Check for fuel leakage from the fuel system Check the fuel tank and fuel lines for cracks swellings or other damages EMU37321 Checking the fuel filter Check that the fuel filter is clean and free of water If any water is found in the fuel or if a significant amount of debris is found the fuel tank should be checked and cleaned by a Yamaha dealer EMU3...

Page 49: ...evel falls between the upper lev el mark and lower level mark Consult your Yamaha dealer if the oil level is out of specified level or if it appears milky or dirty EMU27153 Engine Check the engine and engine mounting Look for loose or damaged fasteners Check the propeller for damage Check for engine oil leaks EMU36492 Flushing device Check that the flushing device s garden hose connector is secure...

Page 50: ...h speeds ECM01991 After installing check the fitting of the top cowling by pushing it with both hands If the top cowling is loose have it repaired by your Yamaha dealer EMU29158 Checking power trim and tilt system WARNING EWM01930 Never get under the lower unit while it is tilted even when the tilt support lever is locked Severe injury could occur if the outboard motor accidentally falls Body part...

Page 51: ...mooth ly EMU36582 Battery Check that the battery is in good condition and fully charged Check that the battery con nections are clean secure and covered by in sulating covers The electrical contacts of the battery and cables must be clean and proper ly connected or the battery will not start the engine Refer to the battery manufacturer s instruc tions for checks for your particular battery EMU3002...

Page 52: ...moored and that you can steer clear of any obstructions Be sure there are no swimmers in the water near you When the air vent screw is loosened gasoline vapor will be released Gaso line is highly flammable and its vapors are flammable and explosive Refrain from smoking and keep away from open flames and sparks while loosening the air vent screw This product emits exhaust gases which contain carbon...

Page 53: ...d dur ing normal operation Loss of engine 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 1 Place the remote control lever in neutral TIP The start in gear protection device prevents the engine from starting except when in neu tral 2 Attach the engine shut off cord to a se cure ...

Page 54: ...onds of cranking return the main switch to on wait 10 sec onds then crank the engine again ECM00192 EMU36510 Checks after starting engine EMU36522 Cooling water Check for a steady flow of water from the cool ing water pilot hole A continuous flow of water from the pilot hole indicates that the water pump is pumping water through the cooling water passages If the cooling water passag es are frozen ...

Page 55: ...se and back to neutral EMU31721 Stop switches Confirm that turning the main switch to the off position stops the engine Confirm that removing the clip from the en gine shut off switch stops the engine Confirm that the engine cannot be started with the clip removed from the engine shut off switch EMU31733 Shifting WARNING EWM00180 Before shifting make sure there are no swimmers or obstacles in the ...

Page 56: ...speed in gear move the remote control lever firmly and crisply to the neutral position EMU31742 Stopping boat WARNING EWM01510 Do not use the reverse function to slow down or stop the boat as it could cause you to lose control be ejected or impact the steering wheel or other parts of the N ZMU04588 U63P7AE0 book Page 50 Thursday February 25 2010 1 14 PM ...

Page 57: ...ere is a fuel joint or a fuel cock on the boat 3 Tighten the air vent screw on the fuel tank cap if equipped 4 Remove the key if the boat will be left un attended TIP The engine can also be stopped by pulling the cord and removing the clip from the engine shut off switch then turning the main switch to off EMU27862 Trimming outboard motor WARNING EWM00740 Excessive trim for the operating condi tio...

Page 58: ...er trim an gle can cause loss of control If equipped with a power trim and tilt switch located on the bottom cowling use the switch only when the boat is at a complete stop with the engine off Do not adjust the trim angle with this switch while the boat is moving Adjust the outboard motor trim angle using the power trim and tilt switch To raise the bow trim out press the switch up To lower the bow...

Page 59: ...engers overboard Bow Down Too much trim in causes the boat to plow through the water decreasing fuel economy and making it hard to increase speed Operat ing with excessive trim in at higher speeds also makes the boat unstable Resistance at the bow is greatly increased heightening the danger of bow steering and making opera tion difficult and dangerous TIP Depending on the type of boat the outboard...

Page 60: ...pushing the tiller handle if equipped because this could break the handle EMU32724 Procedure for tilting up power trim and tilt models 1 Place the remote control lever in neutral 2 Press the power trim and tilt switch up until the outboard motor has tilted up completely 3 Pull the tilt support lever toward you to support the engine WARNING After tilting the outboard motor be sure to support it wit...

Page 61: ... power trim and tilt switch down to retract the trim rods NOTICE Make sure that the trim rods retracts completely during moor ing This protects the rods from ma rine growth and corrosion which could damage the power trim and tilt mechanism ECM00252 EMU33121 Procedure for tilting down power trim and tilt models 1 Push the power trim and tilt switch up until the outboard motor is supported by the ti...

Page 62: ...and tilt models 1 Place the remote control lever in neutral 2 Slightly tilt the outboard motor up to the desired position using the power trim and tilt switch WARNING Using the power trim and tilt switch on the bottom cowling while the boat is moving or engine is on could increase the risk of falling overboard and could distract the operator increasing the risk of collision with another boat or an...

Page 63: ... in muddy turbid or acidic water Yamaha strongly recommends that you use the optional chromium plated water pump kit see page 13 if you use the outboard motor in acidic water or water with a lot of sediment in it such as muddy or turbid cloudy water Af ter operating in such water flush the cooling passages with fresh water to prevent corro sion Also rinse the outside of the outboard motor with fre...

Page 64: ...there is insufficient road clearance in this po sition then trailer the outboard motor in the tilt position using a motor support device such as a transom saver bar Consult your Yamaha dealer for further details When the outboard motor is tilted prolonged time for mooring or trailering the boat close the fuel valve EMU30041 Storing outboard motor When storing your Yamaha outboard motor for prolong...

Page 65: ...the cooling system from clogging up with salt sand or dirt In addition fog ging lubricating the engine is mandatory to prevent excessive engine damage due to rust Perform the flushing and fogging at the same time WARNING Do not touch or remove electrical parts when starting or during operation Keep hands hair and clothes away from the flywheel and other rotating parts while the engine is running E...

Page 66: ...l the spark plug s and torque to proper specification For information on spark plug installation see page 67 2 Change the gear oil For instructions see page 71 Inspect the oil for the presence of water that indicates a leaky seal Seal replacement should be performed by an authorized Yamaha dealer prior to use 3 Grease all grease fittings For further de tails see page 66 TIP For long term storage f...

Page 67: ...ecurely on the fitting after flushing the engine ECM00541 TIP When flushing the engine with the boat in the water tilting up the outboard motor until it is completely out of the water will achieve better results For cooling system flushing instructions see page 58 EMU28451 Cleaning the outboard motor After use wash the exterior of the outboard motor with fresh water Flush the cooling sys tem with ...

Page 68: ...n and quality Any part of inferior quality may malfunction and the resulting loss of control could endanger the operator and pas sengers Yamaha genuine parts and acces sories are available from your Yamaha dealer EMU34151 Severe operating conditions Severe operating conditions involve one or more of the following types of operation on a regular basis Operating continuously at or near maxi mum engi...

Page 69: ... symbol indicates the check ups which you may carry out yourself The symbol indicates work to be carried out by your Yamaha dealer Item Actions Initial Every 20 hours 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years Anode s external Inspection or replace ment as necessary Anode s cylinder head thermostat cov er Inspection or replace ment as necessary Anodes exhaust cover cooling water...

Page 70: ...ssary PCV Pressure Con trol Valve Inspection or replace ment as necessary Shift link shift cable Inspection adjustment or replacement as nec essary Spark plug s Inspection or replace ment as necessary Spark plug caps spark plug wires Inspection or replace ment as necessary Water from the cooling water pilot hole Inspection Throttle link throttle ca ble throttle pick up tim ing Inspection adjustmen...

Page 71: ...r replace ment as necessary Wire harness connec tions wire coupler con nections Inspection or replace ment as necessary Yamaha Meter gauge Inspection Item Actions Every 1000 hours Exhaust guide exhaust manifold Inspection or replace ment as necessary Timing belt Replacement Item Actions Initial Every 20 hours 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years U63P7AE0 book Page 65 Thurs...

Page 72: ...nce 66 EMU28943 Greasing Yamaha grease A water resistant grease Yamaha grease D corrosion resistant grease for propeller shaft F150A FL150A F150A1 FL150A1 U63P7AE0 book Page 66 Thursday February 25 2010 1 14 PM ...

Page 73: ...A damaged insulator could allow exter nal sparks which could lead to explo sion or fire EWM00561 3 Be sure to use the specified spark plug otherwise the engine may not operate properly Before fitting the spark plug measure the electrode gap with a wire thickness gauge replace it if out of spec ification 4 When fitting the plug wipe off any dirt from the threads and then screw it in to the correct ...

Page 74: ...TICE ECM01710 Change the engine oil after the first 20 hours of operation or 3 months and every 100 hours or at 1 year intervals thereafter Otherwise the engine will wear quickly The engine oil should be extracted with an oil changer 1 Put the outboard motor in an upright po sition not tilted NOTICE If the out board motor is not level the oil level indicated on the oil dipstick may not be accurate...

Page 75: ...tinued operation with a problem could cause severe engine damage Consult your Yamaha dealer if the problem cannot be located and corrected ECM01622 12 Dispose of used oil according to local regulations TIP For more information on the disposal of used oil consult your Yamaha dealer Change the oil more often when operating the engine under adverse conditions such as extended trolling EMU29114 Inspec...

Page 76: ...tween the anti cavi tation plate and the propeller to prevent the propeller from turning Checkpoints Check each of the propeller blades for ero sion from cavitation or ventilation or other damage Check the propeller shaft for damage Check the splines for wear or damage Check for fish line tangled around the pro peller shaft Check the propeller shaft oil seal for dam age EMU30662 Removing propeller...

Page 77: ...her before in stalling the propeller Otherwise the lower case and propeller boss could be damaged ECM01881 3 Install the spacer and washer Tighten the propeller nut to the specified torque 4 Align the propeller nut with the propeller shaft hole Insert a new cotter pin in the hole and bend the cotter pin ends NOTICE Do not reuse the cotter pin Otherwise the propeller can come off during operation E...

Page 78: ...et to allow the oil to drain completely NOTICE Check the used gear oil after it has been drained If the gear oil is milky or contains water or a large amount of metal particles the gear case may be damaged Have a Yamaha dealer check and repair the outboard motor ECM00713 TIP For disposal of used oil consult your Yamaha dealer 5 Put the outboard motor in a vertical posi tion Using a flexible or pre...

Page 79: ...s attached to the power unit EMU29323 Checking battery for electric start models WARNING EWM01902 Battery electrolyte is poisonous and caus tic and batteries generate explosive hy drogen gas When working near the battery Wear protective eye gear and rubber gloves Do not smoke or bring any other source of ignition near the battery The procedure for checking the battery varies for different batterie...

Page 80: ... the battery cables Other wise the electrical parts could be dam aged 1 Make sure the main switch on applicable models is off before working on the battery 2 Connect the red battery cable to the POSITIVE terminal first Then con nect the black battery cable to the NEGA TIVE terminal 3 The electrical contacts of the battery and cables must be clean and properly con nected or the battery will not sta...

Page 81: ...st to avoid a short circuit and damage to the electrical system ECM01940 1 Isolator lead with circuit protection 2 Red cable 3 Black cable 4 Fuse 5 Battery for accessories 6 Battery for starting 7 Negative connecting cable 2 1 7 6 5 3 4 ZMU05939 1 Starboard side engine 2 Port side engine 3 Red cable 4 Black cable 5 Isolator leads with circuit protection 6 Fuse 7 Battery for starting 8 Battery for ...

Page 82: ...6 3 Disconnect the positive cable s and re move the battery from the boat 4 Clean maintain and store the battery ac cording to the manufacturer s instruc tions U63P7AE0 book Page 76 Thursday February 25 2010 1 14 PM ...

Page 83: ...ift 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 46 Q Has fuel pump malfunctioned A Have serviced by a Yamaha dealer Q Are spark plug s fouled or of incorre...

Page 84: ...crew 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 a Yamaha dealer Q Is battery cable disconnected A Connect se...

Page 85: ...th 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 oth er obstructions in fuel system Q Is fuel filter clogged A Clean or replace filter Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is spark plug gap incorrect A Inspect and adjust a...

Page 86: ...29441 Impact damage WARNING EWM00870 The outboard motor can be seriously dam aged 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 Check the control system and all compo nents for damage Also check the boat for damage 3 Whether damage is ...

Page 87: ...a fire hazard Consult your Yamaha dealer if the new fuse immediately blows again EMU29524 Power trim and tilt will not operate If the engine cannot be tilted up or down with the power trim and tilt because of a dis charged battery or a failure with the power trim and tilt unit the engine can be tilted man ually 1 Loosen the manual valve screw by turn ing it counterclockwise until it stops 1 Electr...

Page 88: ...rag Wipe up any spilled fuel immediately The fuel filter must be reassembled carefully with the O ring filter cup and hoses in place Improper assembly or replacement could result in a fuel leak which could result in a fire or explosion hazard If the water separator alert indicator on the 6Y8 Multifunction tachometer blinks perform the following procedure 1 Stop the engine 2 Remove the top cowling ...

Page 89: ...tion switch cou pler securely until a click is heard 8 Install the top cowling 9 Start the engine and make sure that the water separator alert indicator remains off Have a Yamaha dealer inspect the outboard motor after returning to port EMU33501 Treatment of submerged motor If the outboard motor is submerged immedi ately take it to a Yamaha dealer Otherwise some corrosion may begin almost immediat...

Page 90: ...YAMAHA MOTOR CO LTD Printed on recycled paper Printed in Japan March 2010 0 3 1 CR U63P7AE0 book Page 1 Thursday February 25 2010 1 14 PM ...

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