Yamaha SX150C Owner'S Manual Download

Page: 1 / 118

Printed in Japan
March 2003-0.5

67K-28199-15

(150JETO, 200JETO)

(E)

Printed on recycled paper

SX150C
SX200C

OWNER’S MANUAL

U.S.A.Edition

LIT-18626-05-37

67K-9-15 Hyoshi 1/30/03 13:39 Page 1

Summary of Contents for SX150C

Page 1: ...SX150C SX200C OWNER S MANUAL U S A Edition LIT 18626 05 37 ...

Page 2: ......

Page 3: ... precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer Yamaha continually seeks advance ments in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your machine and this manual If there ...

Page 4: ...E CONTENTS GENERAL INFORMATION BASIC COMPONENTS OPERATION MAINTENANCE TROUBLE RECOVERY INDEX 1 2 3 4 5 6 READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR EMU00003 ...

Page 5: ...otor serial number 1 1 Key number 1 1 EMISSION CONTROL INFORMATION 1 2 SAFETY INFORMATION 1 3 IMPORTANT LABELS 1 5 BASIC BOATING RULES 1 6 FUELING INSTRUCTIONS 1 10 Gasoline 1 11 Engine oil 1 11 BATTERY REQUIREMENT 1 12 PROPELLER SELECTION 1 13 START IN GEAR PROTECTION 1 14 1 2 3 4 5 6 ...

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 EMU00008 KEY NUMBER If a main key switch is equipped with the motor the key identification number is stamped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key 1 Key number 1 401012 904011 12...

Page 7: ...of Emission control certificate This label is attached to the bottom cowl ing 1 Emission control information label Existing Technology N A Manufactured date label This label is attached to the clamp bracket or the swivel bracket 2 Manufactured date label EMISSION CONTROL INFORMATION ENGINE FAMILY THIS ENGINE CONFORMS TO 2001 U S EPA REGULATIONS FOR MARINE SI ENGINES FELs SPARK PLUG IDLE SPEED rpm ...

Page 8: ...fully Make sure there are no gas fumes or leaking 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 opera...

Page 9: ...y organiza tions including the following United States Coast Guard Consumer Affairs Staff G BC Office of Boating Public and Consumer Affairs U S Coast Guard Headquarters Washington D C 20593 0001 Boating Safety Hotline 1 800 368 5647 National Marine Manufacturers Association NMMA 401 N Michigan Ave Chicago Il 60611 Marine Retailers Association of America 155 N Michigan Ave Chicago Il 60601 ...

Page 10: ...is cover during and after operation To avoid burns do not touch finned resistor with bare hands 65L 83625 40 3 ENGINE OIL ONLY WARNING 6E5 13437 43 Pour the engine oil into this oil tank not gasoline RECOMMENDED OIL YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC W3 certified outborad oil Do not add gasoline to the oil tank Fire or explosion could result OIL TANK CAPACITY 10 5 LITERS 11 1 U S q...

Page 11: ...ccur unless both vessels try to avoid each other If that is the case both vessels become Give Way vessels EMU00015 BASIC BOATING RULES Rules of the road Just as there are rules which apply when you are driving on streets and high ways there are waterway rules which apply when you are driving your boat These rules are used internationally and are also enforced by the United States Coast Guard and l...

Page 12: ...run 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 102045 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...

Page 13: ...nd orange boarders They signify speed zones restricted areas danger areas and general information of its 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 can steer itself around you OTHER SPECIAL SITUATIONS There are three other rules you should be aware of when driving your boat around other vessels Narro...

Page 14: ...w 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 lateral significance used for No number Topmost band red preferred Top Mark White Light White Light OR OR LIGHTED PREFERRED CHANNEL TO RB L RG ...

Page 15: ... 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 funnel to help prevent electrosta tic sparks cC 8 Use only new cl...

Page 16: ... EMU01804 GASOLINE If knocking or pinging occurs use a differ ent brand of gasoline or premium unlead ed fuel EMU00027 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...

Page 17: ...rform poorly or be overloaded causing electric system damage For electric start models choose a battery which meets the following specifications EMU01860 EMU01787 NOTE The engine cannot be started if battery voltage is too low Minimum cold cranking amps CCA SAE 380 amps at 18 C 0 4 F Minimum marine cranking amps MCA ABYC 502 amps at 0 C 32 F Minimum reserve capacity RC SAE 124 minutes ...

Page 18: ... For a greater operating load a smaller pitch propeller is more suitable as it enables the correct engine speed to be main tained Conversely a larger pitch pro peller is more suitable for a smaller oper ating load Yamaha dealers stock a range of pro pellers and can advise you and install a propeller on your outboard that is best suited to your application NOTE At full throttle and under a maximum ...

Page 19: ...ion device s This feature permits the engine to be started only when it is Neutral Always select Neutral before starting the engine 602022 14 1 2x17 M 1 23 1 Propeller diameter in inches 2 Propeller pitch in inches 3 Type of propeller propeller mark Refer to the section CHECKING PRO PELLER for instructions on propeller removal and installation ...

Page 20: ...E MEMO ...

Page 21: ...CTIONS 2 2 Remote control 2 2 Trim tab 2 6 Power trim tilt switch 2 7 Digital tachometer 2 8 Digital speedometer 2 10 Tilt support lever 2 13 Top cowling lock levers 2 14 Flushing device 2 14 WARNING SYSTEM 2 15 Overheat warning 2 15 Oil level warning Oil filter clogging warning 2 16 1 2 3 4 5 6 ...

Page 22: ...vers 3 Anti cavitation plate 4 Trim tab Anode 5 Propeller 6 Cooling water inlet 7 Clamp bracket 8 Tilt support lever 9 Flushing device 0 Power trim and tilt switch q Remote control box Side mount type w Digital tachometer e Digital speedometer r Remote oil tank May not be exactly as shown also may not be included as standard equipment on all models 2 1 ...

Page 23: ... 6 Power trim tilt switch 7 Throttle friction adjusting screw 2 2 000200 w q e r t y u EMU00098 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 contin ue to run at idle until the lever is moved about 35 a detent can be felt Moving the lever farther opens the throttle and the engine will...

Page 24: ...2 3 EMU00099 Neutral Interlock Trigger To shift out of Neutral the neutral inter lock trigger of the remote control lever must first be pulled up EMU00100 Neutral Throttle Lever To open the throttle without shifting into either Forward or Reverse place the remote control lever in the Neutral posi tion and lift the neutral throttle lever NOTE The neutral throttle lever will operate only when the re...

Page 25: ... away under power w 8 Attach the lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard in such a way that it could become entangled preventing it from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of most steering control Als...

Page 26: ...uld result in an accident Resistance Screw Increase Turn clockwise Decrease Turn counterclockwise 2 5 EMU01331 Power Trim Tilt Switch The power trim tilt adjusts the motor angle in relation to the transom The power trim tilt switch is located on the remote control lever grip Pushing the switch UP trims the motor up then tilts the motor up Pressing the switch DN tilts the motor down and trims the m...

Page 27: ...or replaced to be sure steering is correct Be sure you have tightened the bolt after adjusting the trim tab 1 Trim tab 2 Bolt 3 Cap If equipped cC The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode A B 603012 q w e 603014 Boat tends to veer To the left port side To the right starboard side The...

Page 28: ...n When the switch button is released the motor will stop in its current position w Use the power trim tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the engine off Attempting to use the cowl ing mounted power trim tilt switch while the boat is moving could increase the risk of falling overboard and could distract the operator increasing the risk of c...

Page 29: ...lay will light momentarily after the main switch is turned on and will return to normal there after EMU00136 Tachometer This meter shows the engine speed EMU01109 Trim Meter This meter shows the trim angle of your outboard motor NOTE 8 Memorize the trim angles that work best for your boat under different condi tions Adjust the trim angle to the desired setting by operating the power trim and tilt ...

Page 30: ...rs Display off 8 Resetting the trip hours Simultaneously pressing the SET and MODE buttons for more than 1 second while the trip hours are displayed resets the trip counter to 0 zero NOTE The total number of hours the engine has been run cannot be reset EMU00138 Oil Level Indicator This indicator shows the engine oil level If the oil level falls below the lower limit the warning indicator will sta...

Page 31: ...me on as a check After a few seconds the meters will change to normal operation Watch the meter when turning on the main switch to make sure all segments come on 001052 q EMU01553 Overheat Warning Indicator If the engine temperature rises too high the warning indicator will start to blink Refer to OVERHEAT WARNING for details 1 Overheat warning indicator cC Do not continue to operate the engine if...

Page 32: ... SPEED YAMAHA set mode EMU01274 Trip Meter This meter displays the distance the boat has traveled since the meter was last reset Repeatedly push and release the mode button until the indicator on the face of the meter points to TRIP To reset the trip meter to 0 press the set and mode button together NOTE 8 The trip distance is shown in kilometers or miles depending upon the unit of measurement sel...

Page 33: ... up trim or continu ous turning can give false readings 802032 TRIP TIME BATT Km h knot mph km mile SPEED EMU01275 Clock This meter shows the current time Repeatedly push and release the mode button until the indicator on the face of the meter points to TIME To set the clock be sure the meter is in the TIME mode Press the set button the hour display will begin blinking Press the mode button until ...

Page 34: ...uel level warning segment 1 begins blinking 8 Low battery voltage warning If battery voltage drops the display 2 will be automatically turned on and it begins blinking cC Do not continue to operate the engine if a warning device has activated Refer to the TROUBLESHOOTING section in this manual Consult a Yamaha dealer if the problem cannot be located and corrected 802031 TRIP TIME BATT Km h knot mp...

Page 35: ...cowl ing check to be sure it fits properly in the rubber seal Then lock the cowling again by moving the levers downward 301021 301022 q 000825 EMU01146 FLUSHING DEVICE This device 1 is used to clean the cooling water passages of the motor using a gar den hose and tap water NOTE Refer to Cleaning Cooling water Passages in Chapter 4 for instructions on usage ...

Page 36: ...an overheat warning device If the engine temperature rises too high the warning device will activate 1 Included N A If the warning system has been activated stop the engine and check the water inlet for clogging Not equipped on all models Activation of Tiller Remote warning device control control model model The engine speed will automatically 1 decrease to about 2 000 r min The overheat warning i...

Page 37: ... and check for the cause NOTE The warning for oil filter clogging is simi lar to the warnings for low oil level and overheating For easy troubleshooting it is advisable to check for engine overheat ing first then oil level and finally oil filter clogging 1 Oil filter Warning device Tiller Remote activation control control model model The engine speed will automatically 1 decrease to about 2 000 r ...

Page 38: ...E MEMO ...

Page 39: ...ECKS 3 8 Operation after a long period of storage 3 9 BREAKING IN ENGINE 3 10 STARTING ENGINE 3 12 WARMING UP ENGINE 3 15 SHIFTING 3 16 Forward 3 16 Reverse 3 16 STOPPING ENGINE 3 17 TRIMMING OUTBOARD MOTOR 3 18 Adjusting trim angle 3 19 TILTING UP DOWN 3 21 CRUISING IN OTHER CONDITIONS 3 23 Cruising in salt water 3 23 Cruising in turbid water 3 23 1 2 3 4 5 6 ...

Page 40: ...water spray while the boat is cruising Severe engine damage may result if the motor is operat ed continuously in the presence of air borne water spray NOTE During water testing check the buoyancy of the boat at rest with its maximum load Check that the static water level on the exhaust housing is low enough to pre vent water entry into the powerhead when water rises due to waves when the outboard ...

Page 41: ... specific boat motor com bination 8 Your dealer or other person experi enced in proper rigging should mount the motor If you are mounting the motor yourself you should be trained by an experienced person permanent mounted type 8 Your dealer or other person experi enced in proper outboard motor mounting should show you how to mount your motor portable type Mount the outboard motor on the center lin...

Page 42: ...nting height is too high cavitation tends to occur thus reducing the propulsion and if the pro peller tips cut the air the engine speed will rise abnormally and cause the engine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engine efficiency Mount the engine so that the anti cavita tion plate is in alignment with the bottom of the boat NOTE 8 T...

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

Page 44: ...w Do not add gasoline into the oil tank Fire or explosion could result 001475 ON START OFF 701024 3 5 Engine oil tank capacity See Chapter 4 Specifications EMU01825 Using remote oil tank 1 Pour engine oil into the remote oil tank NOTE The oil level lines on the remote oil tank indicate the amount of additional oil that can be added to the tank The top oil level line indicates approximately 1 9 L 0...

Page 45: ...ted for the first time or stored for a period of time a min imum of 5 liters 5 3 US qt 4 4 Imp qt of oil should be kept in the remote oil tank Otherwise the oil feed pump chamber will not be filled with oil and no oil will be supplied ...

Page 46: ... qt 0 26 Imp qt or less More than 300 cm3 0 32 US qt 0 26 Imp qt 300 cm3 0 32 US qt 0 26 Imp qt or less More than 1 500 cm3 1 6 US qt 1 31 Imp qt More than 1 500 cm3 1 6 US qt 1 31 Imp qt 1 500 cm3 1 6 US qt 1 31 Imp qt or less No refilling necessary Add oil refer to FILLING OIL Check oil filter for clog ging Check battery cable con nection Buzzer will sound Engine speed is automati cally reduced ...

Page 47: ... 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 EMU00207 Oil 8 Check to be sure you have plenty of oil for your trip EMU00209 Controls 8 Check throttle shift and steering for proper operation before starting the engine 8 The...

Page 48: ...rical parts when starting or during operation 8 Keep hands hair and clothes away from the flywheel and other rotating parts while the engine is running 3 Watch for oil flowing through the oil feed pipes After any air in the oil lines has been expelled the oil injec tion system should supply oil normal ly If no oil is flowing after 10 minutes of idling consult your Yamaha dealer cC 8 Be sure to tak...

Page 49: ...line only If pre mix fuel is used continuously the oxy gen sensor for the Electronic Fuel Injection system could be damaged EMU00225 Gasoline Petrol Engine oil mixing chart cC Make sure to mix gasoline petrol and oil completely otherwise your outboard motor may be damaged Mixing ratio E 3 10 50 1 Gasoline Petrol 1 L 0 26 US gal 0 22 Imp gal 12 L 3 2 US gal 2 6 Imp gal 14 L 3 7 US gal 3 1 Imp gal 2...

Page 50: ...then reduce engine speed to three quarter throttle approximately 4 000 r min Vary engine speed occasional ly Run at full throttle for one minute then allow about 10 minutes of opera tion at three quarter throttle or less to let the engine cool 4 Third through tenth hours Avoid operating at full throttle for more than 5 minutes at a time Let the engine cool between full throttle runs Vary engine sp...

Page 51: ...away from open flames and sparks while loosening the air vent screw 8 This product emits exhaust gases which contain carbon monoxide a col orless odorless gas which may cause brain damage or death when inhaled Symptoms include nausea dizziness and drowsiness Keep cockpit and cabin areas well ventilated Avoid blocking exhaust outlets 1 If there is an air vent screw on the fuel tank cap loosen it 2 ...

Page 52: ...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 steering contro...

Page 53: ...main switch to return it to ON cC 8 Do not turn the main switch to START when the engine is running 8 Do not keep the starter motor turning for more than 5 seconds The battery will rapidly become exhausted and it will be impossible for it to start the engine If the engine does not start within 5 seconds return the main switch to ON wait 10 seconds and then crank the engine again ...

Page 54: ...cC A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling pas sages If water is not flowing out of the pilot hole at all times while the engine is running do not continue to run the engine Overheating and serious damage could occur Stop the engine and check to see if the water inlet on the lower cas ing is blocked If the problem cannot be foun...

Page 55: ...ow speeds EMU00264 FORWARD Pull up the neutral interlock trigger If equipped and move the remote control lever quickly and firmly from Neutral to Forward EMU00269 REVERSE w When operating in Reverse go slowly Do not open the throttle more than half Otherwise the boat may become unsta ble which could result in loss of control and an accident Pull up the neutral interlock trigger If equipped and mov...

Page 56: ...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 stop lanyard switch then turning th...

Page 57: ...at 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 read...

Page 58: ...e the power trim tilt switch located on the bottom engine cowling if equipped only when the boat is at a complete stop with the engine off The outboard motor trim angle can be adjusted operating the power trim tilt switch 1 To raise the bow trim out push the switch UP To lower the bow trim in push the switch DN Make test runs with the trim set to differ ent angles to find the position that works b...

Page 59: ... in the water Performance and 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 easier to accelerate from a s...

Page 60: ...e engine is running Severe damage from overheating can result w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinch any body parts between the drive unit and engine bracket w Leaking fuel is a fire hazard Disconnect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes Otherwise fuel may leak If the ...

Page 61: ...oward you and support the engine w After tilting the engine be sure to sup port it with the tilt support lever Otherwise the engine could fall back down suddenly if oil in the power trim tilt unit should lose pressure 4 Once the engine is supported with the tilt support lever push the power trim tilt switch DOWN to retract the trim rods cC Be sure to retract the trim rods complete ly during moorin...

Page 62: ...G AND STORING OUTBOARD 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 turbid muddy water conditions E 3 23 EMU00303 PROCEDURE FOR TILTING DOWN Power trim tilt model 1 Push the power trim tilt switch UP until the engine is supported by the tilt rod 2 Release the tilt support lever 3 Push the po...

Page 63: ...4 12 Checking fuel system 4 13 Inspecting fuel filter 4 14 Inspecting idling speed 4 15 Checking water in engine oil tank 4 16 Replacing fuse 4 17 Checking wiring and connectors 4 17 Exhaust leakage 4 17 Water leakage 4 17 Checking power trim and tilt system 4 18 Checking propeller 4 19 Changing gear oil 4 21 Inspecting and replacing anode s 4 22 Checking battery 4 23 Checking bolts and nuts 4 26 ...

Page 64: ...E Type Displacement cm3 cu in Bore stroke mm in Ignition system Spark plug NGK Spark plug gap mm in Control system Starting system Battery Min cold cranking amps CCA SAE amps at 18 C 0 4 F Min marine cranking amps MCA ABYC amps at 0 C 32 F Min reserve capacity RC SAE minutes Alternator output V A W Starting carburetion system 2 stroke 90 V6 2 596 158 4 90 0 68 0 3 54 2 68 C D I system BR7HS 10 0 9...

Page 65: ...ote control Electric start 380 502 124 12 35 Electronic Fuel Injection Regular unleaded gasoline Minimum 86 Yamalube 2 M outboard oil or another outboard motor manufacturer s factory brand oil with TC W3 rating oil injection system 0 9 0 95 0 79 10 5 11 1 9 24 18 0 19 1 15 9 Hypoid gear oil SAE90 980 Forward Neutral Reverse 1 86 26 14 Power trim tilt M 25 2 5 18 55 5 5 40 SX200TRC ...

Page 66: ... consult 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 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 cau...

Page 67: ...ollowing procedures can be performed by you the owner with a minimum of tools cC Do not use any chemical goods contain ing Silicon Phosphorus or Lead Otherwise the oxygen sensor for the Electronic Fuel Injection system could be damaged Consult your Yamaha dealer for details on the use of chemical goods for storage EMU00335 Filling Fuel Tank Fill the fuel tank with fresh fuel and add one ounce of Y...

Page 68: ...ushing Attachment cC Avoid running the outboard at high speed while on the flushing attachment or overheating could occur 1 Remove the top cowling and silencer cover Remove the propeller 2 Install a flushing attachment to the lower unit A flushing attachment is available from a Yamaha dealer 3 Run the engine at a fast idle for 10 15 minutes supplying water 4 Just prior to turning off the engine qu...

Page 69: ...ng Oil section 4 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 5 Grease all grease fittings Refer to GREASING EMU00352 Cleaning and Anti corrosion Measure 1 Wash down the exterior of the out board with fresh water and dry off completely ...

Page 70: ...y Ventilate when charging or using in a closed space Always wear eye protection when working near batteries KEEP OUT OF REACH OF CHILDREN Batteries vary among manufacturers Therefore the following procedures may not always apply Consult your battery manufacturer s instructions 1 Disconnect and remove the battery from the boat Always disconnect the black negative lead first to prevent the risk of s...

Page 71: ...the emission control system must be performed by an authorized Yamaha marine dealership A service manual is available for purchase through a Yamaha dealer for owners who have the mechanical skills tools and other equipment necessary to perform maintenance not covered by this owner s manual EMU00356 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equiva lents o...

Page 72: ...ints Greasing Gear oil Change Fuel system Inspection Fuel filter can be disassembled Inspection cleaning Fuel tank Yamaha portable tank Inspection cleaning Idling speed EFI HPDI models Inspection adjustment 1 Anode s external Inspection replacement 1 1 Anode s internal Inspection replacement 1 Cooling water passages Cleaning Propeller and cotter pin Inspection replacement Battery Inspection chargi...

Page 73: ...E 4 10 EMU00366 GREASING Yamaha marine grease Water resistant grease ...

Page 74: ...air leak or carburetion problem in that cylinder Do not attempt to diagnose any problems yourself Instead take the outboard motor to a Yamaha dealer You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should replace the sp...

Page 75: ... 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 903022 q w Spark plug torque Refer to SPECIFICATIONS page 4 1 Initial of spark Plug wrench size plug I D mark B 21 mm 13 16 in C BK 16 mm 5 8 in D 18 3 mm 23 32 in EMU16350 CHECKING TOP COWLING Check the fitting of the top cowling b...

Page 76: ...s found it should be repaired immediately by Yamaha dealer or other qualified mechan ic Checking points 8 Fuel system parts leakage 8 Fuel hose joint leakage 8 Fuel hose cracks or other damage 8 Fuel connector leakage w Leaking fuel can result in fire or explo sion 8 Check for fuel leakage regularly 8 If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper re...

Page 77: ...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 explosion hazard 001813 q EMU19910 1 Lift up and hold the spring 1 to loosen the filter cup ring nut 2 2 Remove the filter cup 3 catching any spilled fuel in a rag 3 Remove ...

Page 78: ...cup Make sure the O ring is in position in the cup Insert the cup and O ring into the filter housing 6 Lift up and hold the spring to screw the ring nut onto the filter housing until the ring is lightly seated 5 Tighten the ring nut approximately an additional 1 4 turn until the ring nut is tight Align one of the four larger ring nut tabs with the spring and release it to lock the ring nut in posi...

Page 79: ...e speed is set to specification For idle speed specifica tions see Specifications in this chapter NOTE Correct idling speed inspection is only possible if the engine is fully warmed up If not warmed up fully the idle speed will measure higher than normal If you have difficulty verifying the idle speed or the idle speed requires adjustment consult a Yamaha dealer or other qualified mechan ic 213021...

Page 80: ...OTE If the new fuse blows again immediately consult a Yamaha dealer 1 Electrical cover 2 Fuse holder 3 Fuse 30A 80A 2 4 Spare fuse 30A 80A 2 5 Fuse puller EMU00383 CHECKING WIRING AND CONNECTORS 1 Check that each grounding wire is properly secured 2 Check that each connector is engaged securely EMU00384 EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the ex...

Page 81: ...r and check that the tilt rod 1 and trim rods 2 are pushed out completely 4 Use the tilt support lever 3 to lock the motor in the UP position Operate the tilt down switch briefly so the motor is supported the tilt support lever 5 Check that the tilt rod and trim rods are free of corrosion or other flaws 6 Activate the tilt down switch until the trim rods have gone completely into the cylinders 7 A...

Page 82: ...has one 8 Do not use your hand to hold the pro peller when loosening or tightening the propeller nut Put a wood block between the cavitation plate and the propeller to prevent the propeller from turning EMU00390 Propeller Checking Point 8 Check each of the propeller blades for wear erosion from cavitation or ventila tion or other damage 8 Check the splines for wear and damage 8 Check for fish line...

Page 83: ...ion resistant grease to the pro peller shaft 2 Install the thrust washer and propeller on the propeller shaft 3 Install the spacer and washer Tighten the propeller nut to the specified torque 4 Align the propeller nut with the pro peller shaft hole Insert a new cotter pin in the hole and bend the cotter pin ends NOTE If the propeller nut does not align with the propeller shaft hole after tightenin...

Page 84: ...d motor so that the oil drain plug is at the lowest point possi ble 2 Place a suitable container under the gear case 3 Remove the oil drain plug 1 NOTE The oil drain plug is magnetic Remove all metal particles from the plug before rein stalling it 4 Remove the oil level plug 2 to allow the oil to drain completely cC Inspect the used oil after it has been drained If the oil is milky water is get ti...

Page 85: ...r to SPECIFICATIONS page 4 1 EMU14622 INSPECTING AND REPLACING ANODE S Yamaha outboard motors are protected from corrosion by sacrificial anodes Inspect the external anodes 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 ...

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

Page 87: ...ter 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 grav ity of the fluid at least once a month and recharge the battery when it is low NOTE Consult a Yamaha dealer when char...

Page 88: ...hen connect the BLACK lead to the NEGATIVE terminal 8 Using a single battery Connect both red cables 1 and 2 to the terminal w Do not leave cable 2 unconnected If it accidentally contacts the NEGATIVE terminal of the battery there will be a short circuit Electrical system damage and a fire could result 1 Large red lead for starting battery 2 Small red lead for accessory battery charg ing optional ...

Page 89: ...OTOR EXTERIOR EMU00410 Cleaning the Outboard Motor After use wash the exterior of the out board with fresh water Flush the cooling system with fresh water NOTE Refer to Flushing Cooling System instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR w Use of smaller wire could lead to a fire 1 Battery for starting 2 Battery for accessories 3 Large red lead for starting battery 4 Small red lead for...

Page 90: ...is connect the garden hose 3 4 When flushing is complete reinstall the garden hose connector 2 on the fitting 1 on the bottom cowling Tighten the connector securely cC Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal opera tion Water will leak out of the connector instead of cooling the engine which can cause serious overheating Be ...

Page 91: ... available from a Yamaha dealer 102025 EMU00413 COATING THE BOAT BOTTOM A clean hull improves boat performance The boat bottom should be kept as clean of marine growths as possible If neces sary the boat bottom can be coated with an anti fouling paint approved for your area to inhibit marine growth Do not use anti fouling paint which includes copper or graphite These paints can cause more rapid en...

Page 92: ...E MEMO ...

Page 93: ...BLESHOOTING 5 1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Power trim tilt will not operate 5 5 Starter will not operate 5 6 Engine fails to operate 5 8 Low oil level warning activates 5 10 Treatment of submerged motor 5 12 1 2 3 4 5 6 ...

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

Page 95: ...tle valve adjustment incorrect 17 Battery lead disconnected 1 Inspect spark plug s Clean or replace with recommended type 2 Check for pinched or kinked fuel line or other obstructions in fuel system 3 Fill tank with clean fresh fuel 4 Clean or replace filter 5 Have serviced by a Yamaha dealer 6 Find and correct cause of warning 7 Inspect and adjust as specified 8 Check wires for wear or breaks Tig...

Page 96: ...d 6 Boat bottom fouled with marine growth 7 Spark plug s fouled or incorrect type 8 Weeds or other foreign matter tangled on gear housing 9 Fuel system obstructed 10 Fuel filter clogged 11 Fuel contaminated or stale 12 Spark plug gap incorrect 13 Poor connections or damaged ignition wiring 14 Failed ignition parts 15 Specified engine oil not used 1 Have propeller repaired or replaced 2 Install cor...

Page 97: ... a Yamaha dealer 19 Connect correctly 20 Inspect spark plug and replace it with recommended type E Engine power loss F Engine vibrates excessively 1 Propeller damaged 2 Propeller shaft damaged 3 Weeds or other foreign matter tangled on propeller 4 Motor mounting bolt loose 5 Steering pivot loose or damaged 1 Have propeller repaired or replaced 2 Have serviced by a Yamaha dealer 3 Remove and clean ...

Page 98: ...t for damage 3 Whether damage is found or not return to the nearest harbor slowly and carefully 4 Have a Yamaha dealer inspect the outboard motor before operating it again 607011 411025 q 5 5 EMU00419 POWER TRIM TILT WILL NOT OPERATE If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit the engine can b...

Page 99: ...oes 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 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 emergen...

Page 100: ...ngine stop switch 4 Turn the main switch to START and back to OFF several times to inject some fuel into the combustion cham bers then put the switch in the ON position 5 Insert the knotted end of the emer gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise 6 Give a strong pull straight out to crank the engine Repeat if necessary NOTE If the engine wil...

Page 101: ...s procedure w When the emergency circuit is used the engine may run faster than normal at idling and low speeds Be prepared slightly increased speeds when operating at low throttle settings cC 8 This emergency circuit should only be used long enough to return to port for repairs Do not continue to operate the engine without getting repairs 8 Do not operate the engine over 3 500 r min while using t...

Page 102: ...nector The ignition timing advance circuit of the microcomputer is bypassed 1 CDI unit 2 Yellow White cord 3 Open the throttle slightly without shifting using the neutral throttle lever or the free accelerator After the engine starts return the throttle to the original position 4 Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch The main switch must be on ...

Page 103: ...h oil will be pumped into the engine tank overflowing it Release the switch when oil reaches the upper level line on the engine oil tank 8 Do not use this emergency procedure unless the oil level warning lamps are installed and working 1 Remove the top cowling 2 Turn the main switch to the ON position 3 Lift the emergency switch to pump reserve oil in remote oil tank into the engine oil tank 4 Aft...

Page 104: ...8 Reserve oil capacity is maximum 1 500 cm3 1 6 US qt 1 31 Imp qt 8 The oil feed pump will not operate if the engine is tilted more than 35 Put the engine in the down position before operating the emergency switch ...

Page 105: ...roughly wash away mud salt seaweed etc with fresh water 2 Remove the spark plugs and face the spark plug holes downward to allow any water mud or contaminants to drain 3 Drain the fuel from the vapor separa tor fuel filter and fuel line 4 Feed fogging oil or engine oil through the intake manifold and spark plug holes while cranking with the emer gency starter rope 5 Take the outboard motor to a Ya...

Page 106: ...E MEMO ...

Page 107: ...E EMU00450 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 ...

Page 108: ...edometer 2 10 Digital tachometer 2 8 Disconnecting the battery 4 26 E Emergency starting engine 5 7 Emission control information 1 2 Engine fails to operate 5 8 Engine oil 1 11 Engine stop lanyard switch 2 4 Exhaust leakage 4 17 F Filling fuel 3 4 Filling fuel and engine oil 3 4 Filling fuel tank 4 4 Filling oil 3 5 Flushing cooling system and fogging engine 4 5 Flushing device 2 14 Forward 3 16 F...

Page 109: ...e 3 16 Ring free fuel additive 3 4 S Safety information 1 3 Shifting 3 16 Specifications 4 1 Speedometer 2 11 Start in gear protection 1 14 Starter will not operate 5 6 Starting engine 3 12 Stopping engine 3 17 Storing outboard motor 4 4 T Tachometer 2 8 Temporary action in emergency 5 5 Throttle friction adjusting screw 2 5 Tilt support lever 2 13 Tilting up down 3 21 Top cowling lock levers 2 14...

Page 110: ...gistration records are checked 2 Read the Limited Warranty statement which follows these instructions This warranty applies to Yamaha outboard motors sold in the United States whether purchased sepa rately or when supplied as original equipment by a boat builder The terms also apply to original equipment packages sold in Canada with coverage provided by Yamaha Motor Canada see Warranty Guide for C...

Page 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: ...tor purchased and registered for use in the United States only excluding its territo ries For warranty provisions outside the United States contact the particular country s local Yamaha distributor WARRANTY REGISTRATION To be eligible for warranty coverage the outboard motor must first be registered with Yamaha Motor Corporation U S A A warranty registration form is provided in the Owner s Manual ...

Page 113: ...LSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A Post Office Box 6555 Cypress California 90630 WARRANTY QUESTIONS AND ANSWERS Q What costs are my responsibility during the warranty period A The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision dam ages Q What are some examples of abnormal strai...

Page 114: ...ation such as names addresses model engine serial number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is complied from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling deal...

Page 115: ...ll receive service If you need more information about your warranty coverage or your Yamaha outside the U S A or Canada please contact an autho rized Yamaha dealer in your country 2 Keep a copy of your sales contract or invoice for the purchase of your Yamaha and present it if you need warranty repairs This document should show the date of purchase which is important evidence the repairing dealer ...

Page 116: ...Printed in Japan March 2003 0 5 1 67K 28199 15 150JETO 200JETO E Printed on recycled paper ...

Page 117: ...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 118: ...PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT Warranty card 2 27 02 11 47 AM Page 2 ...

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