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EMU00414

Chapter 5

TROUBLE RECOVERY

TROUBLESHOOTING

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TEMPORARY ACTION IN
EMERGENCY

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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

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Summary of Contents for VX150A

Page 1: ...LIT 18626 04 58 VX150A OWNER S MANUAL U S A Edition ...

Page 2: ......

Page 3: ...es special precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer Yamaha continually seeks 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...

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

Page 5: ...r 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 petrol 1 11 Engine oil 1 11 BATTERY REQUIREMENT 1 12 PROPELLER SELECTION 1 12 START IN GEAR PROTECTION 1 14 1 2 3 4 5 6 ...

Page 6: ...TIFICATION NUMBERS RECORD EMU00007 OUTBOARD MOTOR SERIAL NUMBER The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket Record your outboard motor serial num ber in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor serial number 1 401012 904011 12...

Page 7: ...sion 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 IN NEUT...

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: ...p hands hair and clothes away from flywheel 6and other rotating parts while engine is running 6A1 83625 41 WARNING Hot surface under this cover during and after operation To avoid burns do not touch finned resistor with bare hands 65L 83625 40 YAMAHA 4 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 equiv...

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: ...YAMALUBE 2 STROKE OUTBOARD OIL Recommended gasoline Regular unleaded gasoline with a minimum octane rating of 86 Pump Octane Number R M 2 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 reco...

Page 17: ...igh or too low for good engine performance this will have an adverse effect on the engine EMU00031 BATTERY REQUIREMENT cC Do not use the battery that does not meet the specified capacity If different battery from the specification is used the electric system may perform poorly or be overloaded causing electrical system damage Choose battery which meets the following specifications for Electric sta...

Page 18: ...install a propeller on your outboard that is best suited to your application NOTE At full throttle and under a maximum boat load the engine s rpm should be within the upper half of the full throttle operating range as listed in SPECIFICA TIONS on page 4 1 Select a propeller which fulfills this requirement If operating under conditions which allow the engine s rpm to rise above the maxi mum recomme...

Page 19: ...TION Yamaha outboard motors or Yamaha approved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is Neutral Always select Neutral before starting the engine ...

Page 20: ...E MEMO ...

Page 21: ...ote control 2 2 Trim tab 2 6 Power trim tilt switch 2 7 Digital tachometer 2 8 Digital speedometer 2 10 Fuel management meter 2 13 Tilt support lever 2 17 Top cowling lock levers 2 17 Flushing device 2 17 WARNING SYSTEM 2 18 Overheat warning 2 18 Oil level warning Oil filter clogging warning 2 19 1 2 3 4 5 6 ...

Page 22: ... support lever 4 Anti cavitation plate 5 Trim tab Anode 6 Propeller 7 Cooling water inlet 8 Anode 9 Clamp bracket 0 Power trim and tilt unit q Cowling release lever w Top cowling e Cooling water pilot hole r Remote control box Side mount type t Digital tachometer y Digital speedometer u Remote oil tank May not be exactly as shown also may not be included as standard equipment on all models ...

Page 23: ...itch 6 Power trim tilt switch 7 Throttle friction adjusting screw 701011 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: ...TE The 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 EMU00101 Main switch The main switch controls the ignition sys tem its operation is described below 8 OFF Electrical circuits switched off The key can be removed 8 ON Electrical c...

Page 25: ...rom running 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 26: ...t in an accident E 2 5 701035 Resistance Screw Increase Turn clockwise Decrease Turn counterclockwise UP DN 701034 UP DN 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 d...

Page 27: ...laced 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 E 2 6 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: ...tion in this manual Consult your deal er if the problem cannot be located and corrected EMU00140 DIGITAL SPEEDOMETER This meter contains the speedometer fuel meter with warning trip meter clock and voltmeter with warning 1 Speedometer 2 Fuel meter 3 Trip meter clock voltmeter 4 Warning indicator NOTE After the main switch is first turned on all portions of the meter come on as a check After a few ...

Page 32: ...switch For speed unit 3 Selector switch For fuel sender 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...

Page 33: ...on until the desired minute is displayed Press the set but ton again to start the clock NOTE The clock operates on battery power Disconnecting the battery will stop the clock Reset the clock after connecting the battery EMU00144 Fuel meter The fuel level is displayed by eight seg ments When all segments are showing the fuel is full cC The Yamaha fuel tank sensor is different from a conventional ty...

Page 34: ...vated Refer to the TROUBLESHOOTING section in this manual Consult a Yamaha dealer if the problem cannot be located and corrected EMU00146 FUEL MANAGEMENT METER Optional equipment The meter contains the fuel flow meter fuel consumption meter fuel economy meter twin engine speed synchronizer water separator warning indicator 1 Fuel flow meter 2 Fuel consumption Fuel economy meter Twin engine speed s...

Page 35: ...button again the meter will display fuel flow of port side engine and P indication By pressing set button again the meter will display total fuel flow NOTE 8 The meter displays gallon hour and liter depending upon operator preference Select the desired unit of measurement by setting the selector switch 1 on the back of the meter during installation 8 Fuel consumption meter and Fuel econ omy meter ...

Page 36: ...ls air temperature and humidity cleanliness of the boat bottom engine mounting height skill of the operator and individual gasoline formulation winter or summer fuel and amount of additives 8 The Yamaha digital speedometer and fuel management meter calculates speed miles traveled and fuel econo my by water movement at the stern of the boat This distance can vary greatly from the actual distance tr...

Page 37: ...points to SYNC 1 Port side engine speed is higher 2 Port side engine speed is slightly higher 3 Engine speed is synchronized evenly between Port and Starboard side engines 4 Starboard side engine speed is slightly higher 5 Starboard side engine speed is higher NOTE If the two engines speeds are not syn chronized while cruising they can be syn chronized by adjusting trim angle or throttle EMU01207 ...

Page 38: ...ull up the front and rear lock levers Then lift off the cowling When replacing the cowl ing check to be sure it fits properly in the rubber seal Then lock the cowling again by moving the levers downward 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 ...

Page 39: ...ater inlet for clogging EMU00169 WARNING SYSTEM cC Do not continue to operate the engine if the warning device has activated Consult your Yamaha dealer if the problem can not be located and corrected 2 18 001053 701054 605015 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 1 indicator wi...

Page 40: ... 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 2 19 001054 213022 q 905012 q Warning device Tiller Remote activation control control model model The engine speed will automatically 1 decrease to about 2 000 r min...

Page 41: ...3 8 Operation after a long period of storage 3 9 BREAKING IN RUNNING 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 42: ...rne 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 outbo...

Page 43: ... ence and the specific boat motor com bination 8 Your dealer or other person experi enced in proper rigging should mount the motor If you are mounting the motor yourself you should be trained by an experienced person permanent mounted type 8 Your dealer or other person experi enced in proper outboard motor mounting should show you how to mount your motor portable type Mount the outboard motor on t...

Page 44: ...nting height is too high cavitation tends to occur thus reducing the propulsion and causing the engine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engine effi ciency Mount the engine so the anti cavi tation plate is about 130 mm 5 in above the bottom of the boat NOTE 8 The optimum mounting height of the outboard motor is affected by the boat ...

Page 45: ... gasoline 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 add...

Page 46: ...e engine oil into the engine oil tank proceed as follows w Do not add gasoline Petrol into the oil tank Fire or explosion could result E 3 5 905015 ON START OFF 701024 ON START OFF 701052 Engine oil tank capacity Refer to SPECIFICATION page 4 1 EMU00194 When remote oil tank is used 1 Pour the engine oil into the remote oil tank 2 Turn the main switch to ON to feed the oil automatically from the re...

Page 47: ...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 48: ... 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 oil filling Check oil filter for clog ging Check battery cable connection Buzzer will sound Engine speed is auto matically reduced to a...

Page 49: ...ur trip EMU00209 Controls 8 Check throttle shift and steering for proper operation before starting the engine 8 The controls should work smoothly without binding or unusual free play 8 Look for loose or damaged connec tions 8 Check operation of the starter and stop switches when the outboard motor is in the water EMU00204 PRE OPERATION CHECKS w If any item in the pre operation check is not working...

Page 50: ...r remove electrical parts when starting or during operation 8 Keep hands hair and clothes away from flywheel and other rotating parts while engine is running 3 Watch for oil flowing through the oil feed pipes After any air in the oil lines has been expelled YAMAHA PRECISION BLEND SYSTEM should supply oil normally If no oil has begun flowing after 10 minutes of idling consult your Yamaha dealer cC ...

Page 51: ...er break in running in use gaso line petrol only If premix fuel is used continually the oxygen sensor for Electronic Fuel Injection system could be damaged Break in running in time 10 hours Break in running in premix ratio Gasoline petrol Engine oil 50 1 EMU00225 Gasoline Petrol Engine oil mixing chart cC Make sure to mix gasoline petrol and oil completely otherwise your outboard motor may be dama...

Page 52: ...n 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 speed...

Page 53: ...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 54: ... 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 control Also without engine power the boat could slow rapidly This could cause peopl...

Page 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...ilt switch located on the bottom engine cowling if equipped only when the boat is at a complete stop with the engine off The outboard motor trim angle can be adjusted operating the power trim tilt switch 1 To raise the bow trim out push the switch UP To lower the bow trim in push the switch DN Make test runs with the trim set to differ ent angles to find the position that works best for your boat ...

Page 61: ...e boat is on plane a bow up atti tude result in less drag greater stability and efficiency This is generally when the keel line of the boat is up about 3 to 5 degrees When trimmed out the boat may have more tendency to steer to one side or the other Compensate for this as you steer The trim tab can also be adjust ed to help offset this effect Too much trim out puts the bow of the boat too high in ...

Page 62: ... proce dures under STOPPING ENGINE Never tilt the motor while the engine is running Severe damage from overheating can result w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinch any body parts between the drive unit and engine bracket w Leaking fuel is a fire hazard Disconnect the fuel line or close the fuel cock if the engine will be ti...

Page 63: ...lever toward 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...

Page 64: ...00316 CRUISING IN OTHER CONDITIONS CRUISING IN SALT WATER After operating in salt water wash out the cooling water passages with fresh water to prevent them from becoming clogged up with salt deposits NOTE Refer to cooling system flushing instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR CRUISING IN TURBID WATER It is strongly recommended that the optional chromium plated water pump kit be ...

Page 65: ...ing fuel system 4 13 Inspecting fuel filter 4 14 Adjusting 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 Motor exter...

Page 66: ...in 4 500 5 500 110 3 150 0 5 000 700 760 ENGINE Type Displacement cm3 cu in Bore stroke mm in Ignition system Spark plug NGK Spark plug gap mm in Control system Starting system Battery capacity V AH Minimum cold crank performance Amps at 17 8 C 0 F Minimum reserve capacity Minutes at 26 7 C 80 F 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 ...

Page 67: ...sition then trailer the motor in the tilt position using a motor support device such as a transom saver bar For further details 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 ...

Page 68: ...performed to prevent expensive damage This is especially important for your Precision Blend equipped outboard due to the lean oil ratios used at idle prior to shutting the engine off for the season It is advisable to have your outboard ser viced by an authorized Yamaha dealer prior to storage However the following procedures can be performed by you the owner with a minimum of tools cC Do not use a...

Page 69: ...nic if the fuel system is to be drained instead EMU00338 Flushing Cooling System and Fogging Engine Cooling system flushing is essential to prevent the cooling system from clogging up with salt sand or dirt In addition fog ging of the engine is mandatory to pre vent expensive engine damage due to rust Perform the flushing and fogging at the same time w 8 Do not touch or remove electrical parts whe...

Page 70: ...er 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 quickly spray Yamaha Stor Rite Engine Fogging Oil Part No LUB STRRT 12 00 alternately into each intake manifold When properly done the engine will smoke excessively and almost stall 5 Remove the flushing attachment and wipe off any...

Page 71: ...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 72: ...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 73: ...aha 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 of the same type and of equivalent strength and materials Any part of inferi or quality may malfunction and the resulting loss of control could e...

Page 74: ...rior Inspection 4 26 Cooling water passage 1 Cleaning 4 27 Propeller Cotter pin Inspection Replacement 4 19 Battery Inspection Charge every 4 23 month Throttle pick up timing Inspection Adjustment 1 Bolts Nuts Retightening 4 26 Oil tank water drain Cleaning 4 16 Oil pump Inspection Adjustment 1 Power trim tilt unit Inspection 4 18 Power trim tilt operation Inspection 4 18 Exhaust leakage Inspectio...

Page 75: ...E 4 10 EMU00366 GREASING Yamaha marine grease Water resistant grease ...

Page 76: ...ould indicate an intake 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 y...

Page 77: ...ug a good esti mate of the correct torque is 1 4 to 1 2 a turn past finger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench 1 Spark plug gap 2 Spark plug I D mark NGK E 4 12 Spark plug gap Refer to SPECIFICATIONS page 4 1 Spark plug torque Refer to SPECIFICATIONS page 4 1 903022 q w Initial of spark Plug wrench size plug I D mark B 21 mm 13 16 in C ...

Page 78: ...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 79: ...embled 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 207052 r t e w y q EMU00979 1 Loosen and remove the locking tab bolt and tab 1 Slightly loosen the fil ter cup ring nut 2 2 Remove the filter cup 3 catching any spilled fuel in a rag 3 Remove the filter element 4 and wash it in solve...

Page 80: ... leaks NOTE If any water is in the fuel the red ring in the fuel filter unit will float If so remove the cup and drain the water EMU00991 ADJUSTING IDLING SPEED w 8 Do not touch or remove electrical parts when starting or during operation 8 Keep hands hair and clothes away from flywheel and other rotating parts while engine is running cC This procedure must be performed while the outboard motor is...

Page 81: ...kwise to increase the idling speed and turn ing it counterclockwise to decrease the idling speed NOTE Correct idling speed adjustment is only possible if the engine is fully warmed up If not warmed up fully the speed setting will tend to be too high If you have diffi culty obtaining the specified idle consult a Yamaha dealer or other qualified mechanic q 213021 q w EMU00377 CHECKING WATER IN ENGIN...

Page 82: ...ard NOTE 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 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 exhaust...

Page 83: ... 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 Activate the...

Page 84: ...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 85: ...istant 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 tightening to th...

Page 86: ... in a vertical position not tilted 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 ting into the gear case which can c...

Page 87: ...lug 7 Insert and tighten the oil drain plug 603024 Gear oil grade capacity Refer to SPECIFICATIONS on page 4 1 601033 EMU00831 INSPECTING AND REPLACING ANODE S Yamaha outboard motor is protected from corrosion by a sacrificial anode s Check the anode s periodically Remove the scales from surfaces of the anode s For the inspection and replacement of the anode s consult a Yamaha dealer cC Do not pai...

Page 88: ...lush with water 8 EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL 8 Drink large quantities of water or milk followed by milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should always follow these preventive mea sures 8 Charge batteries in a well ventilated area 8 Keep...

Page 89: ...tate of charge Installing a voltmeter will help you monitor your battery If you will not use the boat for a month or more remove the battery from the boat and store it in a cool dark place Completely recharge the battery before using it 3 If the battery will be stored for longer than a month check the specific grav ity of the fluid at least once a month and recharge the battery when it is low EMU0...

Page 90: ...Then 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 charging optional ...

Page 91: ...nect the BLACK lead from the NEG ATIVE terminal first Then disconnect the RED lead from the POSITIVE termi nal EMU00408 CHECKING BOLTS AND NUTS 1 Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torque 2 Check the tightening torque of other bolts and nuts EMU00409 MOTOR EXTERIOR EMU00410 Cleaning the Outboard Mot...

Page 92: ...e 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 sure the conn...

Page 93: ... available from a Yamaha dealer 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 engine co...

Page 94: ...E MEMO ...

Page 95: ...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 96: ...oad and repair Replace fuse with one of correct amperage 4 Have serviced by a Yamaha dealer 5 Attach lanyard 6 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 damage...

Page 97: ...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 98: ...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 99: ...serviced by a Yamaha dealer 19 Connect correctly 20 Inspect spark plug and replace it with recommended type 21 Have serviced by a Yamaha dealer 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 ...

Page 100: ...inspect the boat damage 3 However damage is found or not found go back to a nearest harbor slowly and carefully 4 Have a Yamaha dealer inspection of the outboard motor before operating it again 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...

Page 101: ...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 102: ...o the engine 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 eng...

Page 103: ...is 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 ...

Page 104: ...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 105: ... long too much 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 o...

Page 106: ...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 107: ...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 108: ...E MEMO ...

Page 109: ...E EMU00450 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 ...

Page 110: ...ter 3 23 D Digital speedometer 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 4 Flushing devi...

Page 111: ... additive 3 4 S Safety information 1 3 Shifting 3 16 Specification data 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 3 T Tachometer 2 8 Temporary action in emergency 5 5 Throttle friction adjusting screw 2 5 Tilt support lever 2 17 Tilting up down 3 21 Top cowling lock levers 2 17 Trailering outbo...

Page 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...Printed in Japan March 2001 0 5 1 67M 28199 13 150LETO E Printed on recycled paper ...

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