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Yamaha VX250A, Owner'S Manual

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Yamaha VX250A Owner'S Manual Download Page 65

E

EMU00317

Chapter 4

MAINTENANCE

SPECIFICATION DATA..........................4-1

TRANSPORTING AND STORING 
OUTBOARD MOTOR .............................4-2

Trailering outboard motor.....................4-2
Storing outboard motor ........................4-3

PERIODIC MAINTENANCE....................4-8

Replacement parts ...............................4-8
Maintenance chart................................4-9
Greasing.............................................4-10
Cleaning and adjusting spark plug .....4-11
Checking fuel system .........................4-13
Inspecting fuel filter ............................4-14
Adjusting idling speed ........................4-16
Checking water in engine oil tank ......4-17
Replacing fuse ...................................4-17
Checking wiring and connectors ........4-18
Exhaust leakage.................................4-18
Water leakage ....................................4-18
Checking power trim and tilt
system................................................4-19
Checking propeller .............................4-20
Changing gear oil ...............................4-22
Inspecting and replacing anode(s) .....4-23
Checking battery ................................4-24
Checking bolts and nuts.....................4-27
Cleaning cooling-water passages ......4-28
Motor exterior .....................................4-29
Coating the boat bottom.....................4-29

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 69L-9-11-4  5/10/01 11:42 AM  Page 1

Summary of Contents for VX250A

Page 1: ...LIT 18626 04 65 OWNER S MANUAL U S A Edition VX250A ...

Page 2: ......

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

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: ...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: ...NTIFICATION 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 number 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 YAMAHA MO...

Page 7: ...amp 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 THIS ENGINE CONFORMS TO 2001 CALIFORNIA EMISSION REGULATIONS FOR SI MARINE ENGINES AND IS CERTIFIED TO g kw hr HC NOx ENGINE FAMILY EXHAUST EMISSION STANDARD IN CALIFORNIA REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATI...

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

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

Page 10: ...r during and after operation To avoid burns do not touch finned resistor with bare hands 65L 83625 40 YAMAHA 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: ...dened ves sel These rules determine which vessel has the right of way and what each vessel should do Stand on vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision When you maintain your direction and speed the other vessel will be able to determine how best to avoid you Give way vessel The vessel which does not have the right ...

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

Page 13: ...d normally be given the right of way The exceptions to this are 1 When the sailing vessel is overtaking the power driven vessel the power dri ven vessel has the right of way 2 Sailing vessels should keep clear of any fishing vessel 3 In a narrow channel a sailing vessel should not hamper the safe passage of a power driven vessel which can navi gate only in such a channel Reading buoys and other ma...

Page 14: ...head of naviga MAIN CHANNEL BUOYS 1 3 5 7 tion Leave to port left proceeding upstream LIGHTED BUOY Port Hand White Light Green Light old new old new old new LIGHTED BUOY Starboard Hand 2 4 6 Even number increasing toward head of naviga tion Leave to starboard right proceeding up stream White Light Red Light A LIGHTED SAFE WATER BUOY No number Marks midchannel pass on either side Letter has no late...

Page 15: ...iller 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 electro static sparks cC 8 Use only new clea...

Page 16: ...taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 and the fuel meets minimum octane ratings Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or engine per formance problems EMU00858 ENGINE OIL If the recommended engine oil is not avail able another 2 stroke engine oil with a NMMA...

Page 17: ...mately 9 volts or below during operation or while starting the elec tric fuel pump for the Electronic Fuel Injection system will not operate The engine can not be started if battery voltage is too low Minimum cold crank performance 520 Amps at 17 8 C 0 F Minimum reserve capacity 80 Minutes at 26 7 C 80 F EMU01395 PROPELLER SELECTION The performance of your outboard motor will be critically affecte...

Page 18: ...nstall a propeller on your outboard that is best suit ed 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 SPECIFICATIONS 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 recommen...

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: ...D OTHER FUNCTIONS 2 2 Remote control 2 2 Trim tab 2 6 Power trim tilt switch 2 7 Digital tachometer 2 8 Digital speedometer 2 11 Tilt support lever 2 14 Top cowling release lever 2 14 Flushing device 2 15 WARNING SYSTEM 2 16 Overheat warning 2 16 Oil level warning Oil filter clogging warning 2 17 ...

Page 22: ...opeller 5 Cooling water inlet 6 Anode 7 Clamp bracket 8 Tilt support lever 9 Flushing device 0 Power trim and tilt switch q Cowling release lever w Fuel hose e Battery cable r Cooling water pilot hole t Remote control box Side mount type y Digital tachometer u Digital speedometer i Remote oil tank May not be exactly as shown also may not be included as standard equipment on all models ...

Page 23: ...gine stop lanyard switch 6 Power trim tilt switch 7 Throttle friction adjusting screw R N F q w e r t y u u t r y 701031 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 continue to run at idle until the lever is moved about 35 a detent can be felt Moving the lever farther opens...

Page 24: ...E 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 ON START OFF 701021 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 remove...

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: ... could result in an accident 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 do...

Page 27: ...aced 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 000625 q w e 603014 Boat tends to veer The fin of trim tab To the left Turn to the left port ...

Page 28: ... 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 dis tract 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 thereafter EMU00136 Tachometer This meter shows the engine speed EMU01109 Trim Meter This meter shows the trim angle of your out board motor NOTE 8 Memorize the trim angles that work best for your boat under different conditions Adjust the trim angle to the desired set ting 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: ... indicator will start to blink Refer to OVERHEAT WARNING for details 1 Overheat warning indicator cC Do not continue to operate the engine if a warning device has activated If neces sary refer to the TROUBLESHOOTING section in this manual Consult your dealer if the problem cannot be located and corrected ...

Page 32: ...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 q w e 000330 802034 TRIP TIME BATT Km h knot mph km mile SPEED YAMAHA set mode EMU00141 Speedometer This meter shows the boat speed NOTE The speedometer displays km h mph or knots depending upon operator preference Select the desired unit of me...

Page 33: ...d data will be lost if the battery is disconnected 000332 TRIP TIME BATT Km h knot mph km mile SPEED YAMAHA set mode 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 bu...

Page 34: ... in the fuel tank and the attitude of the boat in the water Operation with bow up trim or continuous turning can give false readings 802031 TRIP TIME BATT Km h knot mph km mile SPEED YAMAHA set mode q w EMU01555 Warning indicators 8 Fuel warning If the fuel level decreases to one segment the fuel level warning segment 1 will begin blinking 8 Low battery voltage warning If battery voltage drops the...

Page 35: ...cowling can be removed by operat ing the cowling release lever Pulling the front lever unlocks the top cowling for removal 403033 EMU00157 TILT SUPPORT LEVER To keep the outboard motor in the tilted up position lock the tilt support lever to the clamp bracket ...

Page 36: ... the top cowling 8 When the release lever is operated both front and rear cowling hooks should be released at the same time If not adjust the cable adjuster for the rear clamps 8 Make sure the cable operates smooth ly and is free of corrosion 8 Check that the cable is properly secured in the holder 8 When reinstalling the cowling insure that both the front and rear locks have operated properly If ...

Page 37: ...is engine has 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 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 indicator 1 wi...

Page 38: ...E The warning for oil filter clogging is similar to the warnings for low oil level and over heating For easy troubleshooting it is advisable to check for engine overheating first then oil level and finally oil filter clog ging 1 Oil filter 001054 701054 213022 q 905012 q Warning device Tiller Remote activation control control model model The engine speed will automatically 1 decrease to about 2 00...

Page 39: ...od of storage 3 8 FILLING FUEL AND ENGINE OIL 3 9 Filling fuel 3 9 Filling oil 3 10 STARTING ENGINE 3 13 WARMING UP ENGINE 3 16 SHIFTING 3 17 Forward 3 17 Reverse 3 17 STOPPING ENGINE 3 18 TRIMMING OUTBOARD MOTOR 3 19 Adjusting trim angle 3 20 TILTING UP DOWN 3 22 CRUISING IN OTHER CONDITIONS 3 24 Cruising in salt water 3 24 Cruising in turbid water 3 24 1 2 3 4 5 6 ...

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

Page 41: ...ry possible boat motor combination Proper mounting depends in part on experi ence and the specific boat motor com bination w Improper mounting of the outboard motor could result in hazardous condi tions such as poor handling loss of con trol or fire hazards Observe the follow ing 8 For permanently mounted models your dealer or other person experi enced in proper rigging should mount the motor If y...

Page 42: ...ounting 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 resis tance will increase and thereby reduce engine efficiency Mount the engine so the anti cavitation plate is about 130 mm 5 in above the bottom of the boat NOTE 8 The optimum mounting height of the out board motor is affected by the boa...

Page 43: ...low the break in running in procedure may result in reduced engine life or even severe engine dam age 8 Premix fuel must be used during break in running in in addition to oil in the Precision Blend System 8 After break in running in use gaso line petrol only If premix fuel is used continuously the oxygen sensor for the Electronic Fuel Injection system could be damaged Break in running in time 10 h...

Page 44: ...celerate at full throttle onto plane then reduce engine speed to three quarter throttle approximately 4 000 r min Vary engine speed occasionally Run at full throttle for one minute then allow about 10 minutes of operation 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 betwee...

Page 45: ...verheating and serious engine damage can occur EMU00206 Fuel 8 Check to be sure you have plenty of fuel for your trip 8 Make sure there are no fuel leaks or gasoline fumes 8 Check fuel line connections to be sure they are tight 8 Be sure the fuel tank is positioned on a secure flat surface and that the fuel hose is not twisted or flattened or likely to contact sharp objects EMU00207 Oil 8 Check to...

Page 46: ...g or unusual free play 8 Look for loose or damaged connections 8 Check operation of the starter and stop switches when the outboard motor is in the water EMU00211 Engine 8 Check the engine and engine mounting 8 Look for loose or damaged fasteners 8 Check the propeller for damage 8 Check that the battery is in good condi tion and battery connections are secure ...

Page 47: ...el 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 the YAMAHA PRE CISION BLEND SYSTEM should sup ply oil normally If no oil has begun flowing after 10 minutes of idling con sult your Yamaha dealer cC 8 When operating the engine after a long period of storage be sure to take the above steps otherwis...

Page 48: ...s gasoline has changed the amount of additives such as aromatics and oxy genates has increased These additives are important for the engines in passenger cars but they can have detrimental effects in marine engines because of increased deposits in the combustion chamber When enough deposits collect piston rings begin sticking Performance drops and engine wear increases dramatically While many addi...

Page 49: ...TOR for details To fill the 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 ON START OFF 701024 ON START OFF 701052 Engine oil tank capacity Refer to SPECIFICATIONS page 4 1 EMU01556 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 oil automatically f...

Page 50: ...ated 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 51: ...S 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 oil filling Check oil filter for clog ging Check battery cable connection Buzzer will sound Engine speed is auto matically reduced ...

Page 52: ...p 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 ...

Page 53: ... of the lanyard in the engine stop switch w 8 Attach the engine stop switch lanyard to a secure place on your clothing your arm or leg while operating 8 Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing from functioning 8 Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss ...

Page 54: ...n 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 55: ...ntinuous 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 dam age could occur Stop the engine and check to see if the water inlet on the lower casing is blocked If the problem cannot be found and c...

Page 56: ...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 57: ...el joint or a fuel cock on the boat disconnect the fuel line or close the fuel cock 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 the mai...

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

Page 59: ...im 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 different angles to find the position that works best for your bo...

Page 60: ...t is pushing the water and there is more air drag Excessive trim up can cause the propeller to ventilate which reduces performance fur ther When trimmed out too much a boat may porpoise hop in the water which could throw the operator and passengers overboard EMU01559 Bow Down When the bow of the boat is down it is eas ier to accelerate from a standing start onto plane Too much trim in causes the b...

Page 61: ... pro cedures under STOPPING ENGINE Never tilt the motor while the engine is running Severe damage from overheat ing 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 t...

Page 62: ...ward 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 DN down to retract the trim rods cC Be sure to retract the trim rods com pletely during moor...

Page 63: ...EMU00316 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 instructions in TRANSPORTING AND STORING OUT BOARD MOTOR CRUISING IN TURBID WATER It is strongly recommended that the optional chromium plated water pump kit ...

Page 64: ...E MEMO ...

Page 65: ...ing fuel system 4 13 Inspecting fuel filter 4 14 Adjusting idling speed 4 16 Checking water in engine oil tank 4 17 Replacing fuse 4 17 Checking wiring and connectors 4 18 Exhaust leakage 4 18 Water leakage 4 18 Checking power trim and tilt system 4 19 Checking propeller 4 20 Changing gear oil 4 22 Inspecting and replacing anode s 4 23 Checking battery 4 24 Checking bolts and nuts 4 27 Cleaning co...

Page 66: ...tery capacity V Ah Minimum cold crank peformance Amps at 17 8 C 0 F Minimum reserve capacity Minutes at 26 7 C 80 F 9 Alternator output V A W 9 Starting carburetion system DRIVE UNIT 9 Gear positions Gear ratio 9 Trim and tilt system 9 Propeller mark FUEL AND OIL TIGHTENING TORQUE EMU00318 SPECIFICATION DATA Model Unit VX250TRA Item 2 stroke 76 V6 3 130 191 0 90 0 82 0 3 54 3 23 C D I system BR9HS...

Page 67: ...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 8 DO NOT fill fuel container to maximum capacity Gasoline will expand consid erably as it warms up and can build up pressure in the fuel container This can ca...

Page 68: ...e any chemical goods con taining Silicon Phosphorus or Lead Otherwise the oxygen sensor for Electronic Fuel Injection system could be damaged For the detail consult your Yamaha dealer to use chemical goods for storage 8 Drain the remaining gasoline from the vapor separator Gasoline left in the vapor separator for a prolonged period of time will break down and possibly cause damage to the fuel line...

Page 69: ...lushing 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 while supplying water 4 Just prior to turning off the en...

Page 70: ...g oil into the piston rings 3 Fill the oil tanks This prevents the for mation of condensation For models with a remote tank it may be necessary to manually override the control unit to completely fill the engine main tank Refer to the section FILLING OIL for details 4 Change the gear case oil Refer to the section CHANGING GEAR OIL for details Inspect the oil for the presence of water which indicat...

Page 71: ...ior with Yamaha Silicone Protectant Part No LUB SILCNE 13 00 cC Do not spray when the engine is run ning Also do not spray near the silencer and oxygen sensor cover or into the engine Otherwise the oxygen sen sor for Electronic Fuel Injection system could be damaged 3 Wax the cowling with a non abrasive wax such as Yamaha Silicone Wax Part No ACC 11000 15 02 ...

Page 72: ...Ventilate when charging or using in a closed space Always wear eye protec tion when working near batteries KEEP OUT OF REACH OF CHILDREN Batteries vary among manufacturers Therefore the following procedures may not always apply Consult your battery manu facturer s instructions 1 Disconnect and remove the battery from the boat Always disconnect the black negative lead first to prevent the risk of s...

Page 73: ... Yamaha dealer for owners who have the mechanical skills tools and other equipment necessary to perform mainte nance not covered by this owner s manual EMU00356 REPLACEMENT PARTS If replacement parts are necessary use only genuine Yamaha parts or equivalents of the same type and of equivalent strength and materials Any part of inferior quality may malfunction and the resulting loss of control coul...

Page 74: ...Inspection 4 29 Cooling water passages 1 Cleaning 4 4 4 28 Propeller Cotter pin Inspection Replacement 4 20 Battery Inspection Charge every 4 24 month Throttle pick up timing Inspection Adjustment 1 Bolts Nuts Retightening 4 27 Oil tank water drain Cleaning 4 17 Oil pump Inspection Adjustment 1 Power trim tilt unit Inspection 4 19 Power trim tilt operation Inspection 4 19 Exhaust leakage Inspectio...

Page 75: ...E 4 10 EMU00366 GREASING Yamaha marine grease Water resistant grease 000596 ...

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 periodical ly 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 ...

Page 77: ...lug a good estimate of the correct torque is 1 4 to 1 2 a turn past finger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench 1 Spark plug gap 2 Spark plug I D mark NGK E 4 12 903022 q w Spark plug gap Refer to SPECIFICATIONS page 4 1 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 ...

Page 78: ...oblem is found it should be repaired immediately by Yamaha dealer or other qualified mechanic Checkpoints 8 Fuel system parts leakage 8 Fuel hose joint leakage 8 Fuel hose cracks or other damage 8 Fuel connector leakage w Leaking fuel can result in fire or explo sion 8 Check for fuel leakage regularly 8 If any fuel leakage is found the fuel system must be repaired by a qualified mechanic Improper ...

Page 79: ...or running engine Allow the engine to cool 8 There will be fuel in the fuel filter Keep away from sparks cigarettes flames or other sources of ignition 8 This procedure will allow some fuel to spill Catch fuel in a rag Wipe up any spilled fuel immediately 8 The fuel filter must be reassembled carefully with O ring filter cup and hoses in place Improper assembly or replacement can result in a fuel ...

Page 80: ...filter element and O ring 5 to make sure they are in good condition Replace them if neces sary 4 Reinstall the filter element Make sure the O ring is in position in the cup Insert the cup and O ring into the filter housing 6 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 ring nut is tight Align one of th...

Page 81: ... to warm up fully in Neutral until it is running smoothly If the outboard is mounted on a boat be sure the boat is tightly moored 2 Adjust the throttle stop screw 1 to set the idling speed to specification see SPECIFICATIONS on page 4 1 by turning the stop screw clockwise to increase the idling speed and turning it counterclockwise to decrease the idling speed NOTE Correct idling speed adjustment ...

Page 82: ...iece of wire may allow excessive current flow This could cause electrical system damage and a fire hazard NOTE If the new fuse blows again immediately consult a Yamaha dealer 1 Electrical cover 2 Fuse holder 3 Fuse 80A 2 30A 1 4 Spare fuse 80A 30A 4 17 EMU00377 CHECKING WATER IN ENGINE OIL TANK There is a trap at the bottom of the engine oil tank If water or foreign matter is visible in this trap ...

Page 83: ...onnector is engaged securely EMU00384 EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and crank case EMU00385 WATER LEAKAGE Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head and crank case 000627 ...

Page 84: ...t up the motor 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 ...

Page 85: ...as 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 86: ... or Corrosion 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 propeller 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 ...

Page 87: ...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 88: ...level plug 7 Insert and tighten the oil drain plug EMU01462 INSPECTING AND REPLACING ANODE S Yamaha outboard motors are protected from corrosion by sacrificial anodes Check the anodes periodically Remove scales from the surfaces of the anodes For inspection and replacement of anodes consult a Yamaha dealer cC Do not paint anodes as this would ren der them ineffective 000626 405022 Gear oil grade c...

Page 89: ...8 EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL 8 Drink large quantities of water or milk followed by milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydro gen gas therefore you should always follow these preventive measures 8 Charge batteries in a well ventilated area 8 Keep batteries away ...

Page 90: ...ways in a good state 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 gravity of the fluid at least once a month and recharge the battery when...

Page 91: ... connect the BLACK lead to the NEGATIVE terminal 8 Using an accessory battery option Use a connecting cable between the ter minals of the starting battery and accessory battery See the illustrations of the wiring connections This cable must be made from wire equivalent to the starting battery cable 3 w Use of smaller wire could lead to a fire 1 Battery for starting 2 Battery for accessories 3 Larg...

Page 92: ...al first Then disconnect the RED lead from the POSITIVE terminal 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 ...

Page 93: ... 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 conne...

Page 94: ...ould be kept as clean of marine growths as possible If necessary 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 corrosion EMU00409 MOTOR EXTERIOR EMU00410 Cleaning the Outboard Motor After use wash the exterior of the outboard with fresh...

Page 95: ...1 TEMPORARY ACTION IN EMERGENCY 5 5 Impact damage 5 5 Power 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 Top cowling does not unlock 5 11 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: ...ttle valve adjustment incorrect 16 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 Ti...

Page 98: ...ed 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 16 Thermostat faulty or clogged 17 Air vent screw closed 18 Fuel pump damaged 1 Have propeller repaired or repla...

Page 99: ...ded 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 propeller 4 Tighten bolt 5 Tighten or have serviced by a Yamaha dealer ...

Page 100: ...e Also inspect the boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and care fully 4 Have a Yamaha dealer inspect the out board motor before operating it again 411025 q EMU00419 POWER TILT WILL NOT OPERATE If the engine cannot be tilted up or down with the power tilt because of a discharged battery or a failure with the power tilt unit the engine can be tilted m...

Page 101: ...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 emergency starter ro...

Page 102: ... the engine is in Neutral and that the lanyard is attached to the engine stop switch 4 Turn the main switch to the ON posi tion OFF 000977 ON 000595 208042 208041 5 Insert the knotted end of the emer gency starter rope into the notch in the flywheel rotor and wind the rope sever al turns clockwise 6 Give a strong pull straight out to crank the engine Repeat if necessary ...

Page 103: ...procedure w When the emergency circuit is used the engine may run faster than normal at idling and low speeds Be prepared for slightly increased speeds when operat ing 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 usin...

Page 104: ...ce circuit of the microcom puter 1 CDI unit 2 Yellow White cord 3 Open the throttle slightly without shift ing using the neutral throttle lever or the free accelerator After the engine starts return the throt tle 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 5 Start the engine N 701014 q w 216016 ON...

Page 105: ...too 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 posi tion 3 Lift the emergency switch to pump reserve oil in remote oil tank into the engi...

Page 106: ...aged or miss adjusted 1 Pull the cowling release lever 1 to unlock the front lock 2 Pull the emergency cowling release wire 2 coming out of the hole on the side of the pilot hole in the bottom cowl ing to release the port side rear lock 3 Lift the port side of the top cowling to pull out the emergency cowling release wire 3 from the port side of the bottom cowling 4 Pull the emergency cowling rele...

Page 107: ...age EMU00449 1 Thoroughly wash away mud salt sea weed 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 separator 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 outb...

Page 108: ...E MEMO ...

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

Page 110: ...ng in salt water 3 24 Cruising in turbid water 3 24 D Digital speedometer 2 11 Digital tachometer 2 8 Disconnecting the battery 4 27 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 18 F Filling fuel 3 9 Filling fuel and engine oil 3 9 Filling fuel tank 4 3 Filling oil 3 10 Flushing cooling...

Page 111: ...se 3 17 Ring free fuel additive 3 9 S Safety information 1 3 Shifting 3 17 Specification data 4 1 Speedometer 2 11 Start in gear protection 1 14 Starter will not operate 5 6 Starting engine 3 13 Stopping engine 3 18 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 14 Tilting up down 3 22 Top cowling does not un...

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 separately or when supplied as original equipment by a boat builder The terms also apply to original equipment packages sold in Canada with coverage provided by Yamaha Motor Canada see Warranty Guide for Ca...

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: ...motor purchased and registered for use in the United States only excluding its territories 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 damages Q What are some examples of abnormal strain...

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

Page 118: ...Printed in Japan April 2001 0 5 1 69L 28199 11 250CETO E Printed on recycled paper ...

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