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4-9

E

EMU19500

MAINTENANCE CHART

Frequency of maintenance operations may be adjusted according to the operating con-
ditions, but the following table gives general guidelines. Refer to the sections in this
chapter for explanations of each owner-specific action.
The mark (

●

) indicates the check-ups which you may carry out yourself.

The mark (

1

) indicates work to be carried out by your Yamaha dealer.

NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushed
with clean water after each use.

10 hours

50 hours

100 hours

200 hours

(1 month)

(3 months)

(6 months)

(1 year)

Spark plug(s)

Cleaning / adjustment /
replacement

●

●

●

Greasing points

Greasing

●

Gear oil

Change

●

●

Fuel system

Inspection

●

●

●

Fuel filter (can be
disassembled)

Inspection / cleaning

●

●

●

Fuel tank (Yamaha
portable tank)

Inspection / cleaning

●

High pressure fuel pump
drive belt

Inspection / replacement

1

1

High pressure fuel pump
oil level

Inspection / filling

1

Idling speed (EFI, HPDI
models)

Inspection / adjustment

1

Anode(s) (external)

Inspection / replacement

●

/

1

●

/

1

Anode(s) (internal)

Inspection / replacement

1

Cooling water passages

Cleaning

●

●

Propeller and cotter pin

Inspection / replacement

●

●

Battery

Inspection / charging

●

/

1

Throttle link / throttle cable
/ throttle pick-up timing

Inspection / adjustment

1

Shift link / shift cable

Inspection / adjustment

1

Throttle position sensor

Inspection / adjustment

1

Oil tank water drain

Inspection / cleaning

●

/

1

●

/

1

●

/

1

Oil pump

Inspection / adjustment

1

Thermostat

Inspection

1

PCV (Pressure Control
Valve)

Inspection

1

Power trim and tilt unit

Inspection

1

Water pump

Inspection

1

Cowling clamp

Inspection

●

Item

Actions

Initial

Every

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Summary of Contents for VZ150C

Page 1: ...VZ150C VZ175C VZ200C OWNER S MANUAL U S A Edition LIT 18626 05 40 ...

Page 2: ...OLINE ONLY CAUTION Gasoline containing lead can cause performance loss and Do not use gasoline mixed with oil during the break in period engine damage 001629 or any time afterwards YAMALUBE 2 STROKE OUTBOARD OIL IS RECOMMENDED ...

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

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

Page 5: ...l number 1 1 Key number 1 1 EMISSION CONTROL INFORMATION 1 2 Star labels 1 3 SAFETY INFORMATION 1 4 IMPORTANT LABELS 1 6 BASIC BOATING RULES 1 7 FUELING INSTRUCTIONS 1 11 Gasoline 1 12 Engine oil 1 12 BATTERY REQUIREMENT 1 13 PROPELLER SELECTION 1 14 START IN GEAR PROTECTION 1 15 1 2 3 4 5 6 E ...

Page 6: ... ordering spare parts from your Yamaha dealer or for reference in case your out board motor is stolen 1 Outboard motor serial number EMU00008 KEY NUMBER If a main key switch is equipped with the motor the key identification number is stamped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key 1 Key number 1 1 q 401016 904011 12...

Page 7: ...label New Technology 4 stroke HPDI EM Manufactured date label This label is attached to the clamp brack et 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 REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTME...

Page 8: ...nal carbureted two stroke engines These engines are equivalent to the U S EPA s 2006 stan dards for marine engines Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low Emission The three star label identifi...

Page 9: ...lly 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 operati...

Page 10: ...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 11: ...ith 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 qt 9 2 IMP qt USE UNLEADED STRAIGHT GASOLINE ONLY CAUTION Gasoline containi...

Page 12: ...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 13: ...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 14: ...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 15: ...ew 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 16: ...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 electrosta tic sparks cC 8 Use only new clea...

Page 17: ...and of gasoline or premium unlead ed fuel Recommended gasoline Regular unleaded gasoline with a minimum octane rating of 86 Pump Octane Number R M 2 EMU19570 ENGINE OIL Use Yamalube 2 M outboard oil If Yamalube 2 M is not available use only another outboard motor manufacturer s factory brand oil with TC W3 rating cC Serious engine damage can result from the use of lower quality oil including some ...

Page 18: ...rform poorly or be overloaded causing electric system damage For electric start models choose a battery which meets the following specifications EMU01861 EMU01787 NOTE The engine cannot be started if battery voltage is too low Minimum cold cranking amps CCA SAE 512 amps at 18 C 0 4 F Minimum marine cranking amps MCA ABYC 675 amps at 0 C 32 F Minimum reserve capacity RC SAE 182 minutes ...

Page 19: ... For a greater operating load a smaller pitch propeller is more suitable as it enables the correct engine speed to be main tained Conversely a larger pitch pro peller is more suitable for a smaller oper ating load Yamaha dealers stock a range of pro pellers and can advise you and install a propeller on your outboard that is best suited to your application NOTE At full throttle and under a maximum ...

Page 20: ...ion device s This feature permits the engine to be started only when it is Neutral Always select Neutral before starting the engine 1 Propeller diameter in inches 2 Propeller pitch in inches 3 Type of propeller propeller mark Refer to the section CHECKING PRO PELLER for instructions on propeller removal and installation 602022 14 1 2x17 M 1 23 ...

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

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

Page 23: ...itch 6 Power trim tilt switch 7 Throttle friction adjusting screw 000608 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: ... EMU00099 Neutral Interlock Trigger To shift out of Neutral the neutral inter lock trigger of the remote control lever must first be pulled up EMU00100 Neutral Throttle Lever To open the throttle without shifting into either Forward or Reverse place the remote control lever in the Neutral posi tion and lift the neutral throttle lever NOTE The neutral throttle lever will operate only when the remot...

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: ...h 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 d...

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

Page 28: ... 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 co...

Page 29: ...fter the main switch is turned on and will return to normal there after q t w u y e r 001078 EMU00136 Tachometer This meter shows the engine speed 001050 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: ...if the problem cannot be located and corrected 802016 TRIP TIME BATT Km h knot mph km mile SPEED YAMAHA set mode q w e r 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 mete...

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

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

Page 34: ...turn on and begin blinking cC Do not continue to operate the engine if a warning device has activated Refer to the TROUBLESHOOTING section in this manual Consult your Yamaha dealer if the problem cannot be located and cor rected 802031 TRIP TIME BATT Km h knot mph km mile SPEED YAMAHA set mode q w EMU00157 TILT SUPPORT LEVER To keep the outboard motor in the tilted up position lock the tilt suppor...

Page 35: ...er seal Then lock the cowling again by moving the levers downward cC The air intake grills 1 on the top cowling are not designed as handles and may break if used as such 301052 q q 000519 313024 q EMU01546 FLUSHING DEVICE This device 1 is used to clean the cooling water passages of the motor using a gar den hose and tap water NOTE Refer to CLEANING COOLING WATER PASSAGES in Chapter 4 for instructi...

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

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

Page 38: ...E MEMO ...

Page 39: ... of storage 3 7 FILLING FUEL AND ENGINE OIL 3 8 Filling fuel 3 8 Filling oil 3 9 STARTING ENGINE 3 12 WARMING UP ENGINE 3 14 SHIFTING 3 15 Forward 3 15 Reverse 3 15 STOPPING ENGINE 3 16 TRIMMING OUTBOARD MOTOR 3 17 Adjusting trim angle 3 18 TILTING UP DOWN 3 20 CRUISING IN OTHER CONDITIONS 3 22 Cruising in salt water 3 22 Cruising in turbid water 3 22 1 2 3 4 5 6 E ...

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

Page 41: ...sible 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 you are...

Page 42: ...eight 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 motor c...

Page 43: ...his engine as it may cause carbon deposits on the fuel injector thereby causing engine trouble 8 Follow the instructions for breaking in running in carefully NOTE The label pictured at left is to be left on the top cowling until the break in run ning in procedure has been completed and may be removed afterwards Break in running in time 10 hours EMU01195 Run the engine under load in gear with a pro...

Page 44: ...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 occasionally 5 After the first 10 hours Operate the engine normally EMU00204 PRE OPERATION CHECKS w If any item in the pre ope...

Page 45: ... be sure you have plenty of oil for your trip EMU00209 Controls 8 Check throttle shift and steering for proper operation before starting the engine 8 The 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 EMU00211 Engine 8 Check the engine and engine m...

Page 46: ...d other rotating parts while the engine is running 2 Watch for oil flowing through the oil feed pipes After any air in the oil lines has been expelled the oil injec tion system should supply oil normal ly If no oil is flowing after 10 minutes of idling consult your Yamaha dealer cC 8 Be sure to take the above steps when operating the engine after a long period of storage Otherwise engine seizure c...

Page 47: ... 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 48: ...ed Simply pour gasoline into the fuel tank and oil into the oil tank Convenient indicator segments indicate the status of the oil supply For details on reading the indicator segments see Oil level indica tor in this chapter To fill the engine oil tank proceed as fol lows w Do not add gasoline into the oil tank Fire or explosion could result Engine oil tank capacity See Chapter 4 Specifications ...

Page 49: ... and the bottom oil level line indicates approxi mately 3 8 L 1 US gal 0 8 Imp gal can be added 2 Turn on the main switch The oil injection system will automatically feed oil from the remote oil tank to the engine oil tank 3 Operate the engine normally cC When the engine is operated 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 ...

Page 50: ...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 FILLING OIL Check oil filter for clogging Check battery cable con nection Buzzer will sound Engine speed is automati cally reduced ...

Page 51: ... 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 or 3...

Page 52: ...our 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 people and objects in...

Page 53: ...uld occur Stop the engine and check to see if the water inlet on the lower cas ing is blocked If the problem cannot be found and corrected consult your Yamaha dealer ON START OFF 701022 EMU00949 Electric Start Model 7 Turn the main switch to START and hold it for a maximum of 5 sec onds 8 Immediately after the engine starts release the main switch to return it to ON cC 8 Do not turn the main switc...

Page 54: ...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 55: ... 2 If there is a fuel 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 t...

Page 56: ...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 57: ... 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 and...

Page 58: ...nd economy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces performance further and the boat may porpoise hop in the water which could throw the operator and passengers overboard Bow Down When the bow of the boat is down it is easier to accelerate from a standing start onto plane To...

Page 59: ...e engine is running Severe damage from overheating can result w Be sure all people are clear of the out board motor when adjusting the tilt angle also be careful not to pinch any body parts between the drive unit and engine bracket w Leaking fuel is a fire hazard Disconnect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes Otherwise fuel may leak If the ...

Page 60: ...all 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 complete ly during mooring This protects the rods from marine growths and corrosion which could damage the power trim tilt mechanism 411043 EMU00303 PROCEDURE FO...

Page 61: ...resh 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 installed if the outboard is to be used in turbid muddy water conditions ...

Page 62: ...E MEMO ...

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

Page 64: ... Type Displacement cm3 cu in Bore stroke mm in Ignition system Spark plug NGK Spark plug gap mm in Control system Starting system Battery Min cold cranking amps CCA SAE amps at 18 C 0 4 F Min marine cranking amps MCA ABYC amps at 0 C 32 F Min reserve capacity RC SAE minutes Alternator output V A W Starting carburetion system 2 stroke 76 V6 2 596 158 4 90 0 68 0 3 54 2 68 TCI BKR6EKU 1 5 1 6 0 059 ...

Page 65: ...l SAE90 980 33 1 34 5 Forward Neutral Reverse 2 00 28 14 Power trim tilt M 25 2 5 18 55 5 5 40 792 31 2 554 21 8 1 693 66 6 516 20 3 213 470 4 500 5 500 147 1 200 5 000 670 730 2 stroke 76 V6 2 596 158 4 90 0 68 0 3 54 2 68 TCI BKR7EKU 1 5 1 6 0 059 0 062 Remote control Electric start 512 675 182 12 45 Electronic Fuel Injection Regular unleaded gasoline Minimum 86 Yamalube 2 M outboard oil or anot...

Page 66: ...ls 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...

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

Page 68: ...h the Flushing 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...

Page 69: ...e 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 pres ence of water which indicates a leaky seal Seal replacement should be per formed by an authorized Yamaha dealership prior to use 5 Grease all grease fittings Refer to the section GREASING for details EMU00352 Cleaning and Anti corrosion...

Page 70: ...t medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away 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 batt...

Page 71: ...nd passengers Yamaha genuine parts and accessories are available from a Yamaha dealer EMU01569 PERIODIC MAINTENANCE w Be sure to turn off the engine when you perform maintenance unless otherwise specified If the owner is not familiar with machine servicing this work should be done by a Yamaha dealer or other quali fied mechanic Maintenance replacement or repair of the emission control devices and ...

Page 72: ...filter can be disassembled Inspection cleaning Fuel tank Yamaha portable tank Inspection cleaning High pressure fuel pump drive belt Inspection replacement 1 1 High pressure fuel pump oil level Inspection filling 1 Idling speed EFI HPDI models Inspection adjustment 1 Anode s external Inspection replacement 1 1 Anode s internal Inspection replacement 1 Cooling water passages Cleaning Propeller and ...

Page 73: ...4 10 E EMU00366 GREASING Yamaha marine grease Water resistant grease 000523 500 hours 1000 hours 2 5 years 5 years High pressure fuel pump drive belt Replacement 1 Every Actions Item ...

Page 74: ...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 75: ...r 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 q q w 000790 Spark plug torque Refer to SPECIFICATIONS page 4 1 Spark plug gap Refer to SPECIFICATIONS page 4 1 Initial of spark Plug wrench size plug I D mark B 21 mm 13 16 in C BK 16 mm 5 8 in D 18 3 mm 23 32 in EMU16350 CHECKING TOP COWLING Check the fit...

Page 76: ...lem is found it should be repaired immediately by Yamaha dealer or other qualified mechan ic 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 r...

Page 77: ...he fuel filter must be reassembled carefully with O ring filter cup and hoses in place Improper assembly or replacement can result in a fuel leak which could result in a fire or explosion hazard 001811 u q EMU19920 NOTE If any water is in the fuel the float 7 will rise If so remove the cup and drain the water 1 Lift up and hold the spring 1 to loosen the filter cup ring nut 2 2 Remove the filter c...

Page 78: ...ng nut is tight Align one of the four larger ring nut tabs with the spring and release it to lock the ring nut in position 6 Run the engine and check the filter and lines for leaks EMU09912 INSPECTING 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 pr...

Page 79: ...e speed is set to specification For idle speed specifica tions see Specifications in this chapter NOTE Correct idling speed inspection is only possible if the engine is fully warmed up If not warmed up fully the idle speed will measure higher than normal If you have difficulty verifying the idle speed or the idle speed requires adjustment consult a Yamaha dealer or other qualified mechan ic 213033...

Page 80: ...use blows again immediately consult a Yamaha dealer 1 Electrical cover 2 Fuse holder 3 Fuse 20A 3 30A 1 80A 2 4 Spare fuse 20A 30A 80A 5 Fuse puller 000501 t 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...

Page 81: ...ottom cowling If equipped to check that all switches work 3 Tilt 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...

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

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

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

Page 85: ...efer to SPECIFICATIONS page 4 1 EMU14622 INSPECTING AND REPLACING ANODE S Yamaha outboard motors are protected from corrosion by sacrificial anodes Inspect the external anodes periodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes cC Do not paint anodes as this would ren der them ineffective NOTE Inspect ground leads attached to extern...

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

Page 87: ...ter will help you monitor your battery If you will not use the boat for a month or more remove the battery from the boat and store it in a cool dark place Completely recharge the battery before using it 3 If the battery will be stored for longer than a month check the specific grav ity of the fluid at least once a month and recharge the battery when it is low NOTE Consult a Yamaha dealer when char...

Page 88: ...connect the BLACK lead to the NEGATIVE terminal UPPER LEVEL LOWER LEVEL 000359 8 Using an accessory battery option Use a connecting cable between the terminals of the starting battery and accessory battery See the illustrations of the wiring connections This cable must be made from wire equivalent to the start ing battery cable 3 w Use of smaller wire could lead to a fire 1 Battery for starting 2 ...

Page 89: ...ne and the nut securing the flywheel are tightened with their specified tightening torque 2 Check the tightening torque of other bolts and nuts EMU01280 Disconnecting the Battery Disconnect the BLACK lead from the NEG ATIVE terminal first Then disconnect the RED lead from the POSITIVE termi nal ...

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

Page 91: ...e paints can cause more rapid engine corrosion EMU00409 MOTOR EXTERIOR EMU00410 Cleaning the Outboard Motor After use wash the exterior of the out board with fresh water Flush the cooling system with fresh water NOTE Refer to Flushing Cooling System instruc tions in TRANSPORTING AND STORING OUTBOARD MOTOR EMU00412 Checking Painted Surface of Motor Check the motor for scratches nicks or flaking pai...

Page 92: ...E MEMO ...

Page 93: ...ECOVERY TROUBLESHOOTING 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 Low oil level warning activates 5 8 Treatment of submerged motor 5 10 1 2 3 4 5 6 E ...

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

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

Page 96: ...ged 2 Propeller pitch or diameter incorrect 3 Trim angle incorrect 4 Motor mounted at incorrect height on transom 5 Warning system activated 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 1 Have propeller ...

Page 97: ...serviced by a Yamaha dealer 15 Check and replace oil with specified type 16 Have serviced by a Yamaha dealer 17 Open the air vent screw 18 Have 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 22 Have serviced by a Yamaha dealer E Engine power loss F Engine vibrates excessively 1 Propeller damaged 2 Prop...

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

Page 99: ... 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 r...

Page 100: ...STARTING ENGINE for procedures Be sure 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 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 ...

Page 101: ...l will be pumped into the engine tank overflowing it Release the switch when oil reaches the upper level line on the engine oil tank 8 Do not use this emergency procedure unless the oil level warning lamps are installed and working 1 Remove the top cowling 2 Turn the main switch to the ON position 3 Lift the emergency switch to pump reserve oil in remote oil tank into the engine oil tank 4 After u...

Page 102: ...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 103: ...14 EMU00449 1 Thoroughly 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 outbo...

Page 104: ...E MEMO ...

Page 105: ...EMU00450 Chapter 6 INDEX INDEX 6 1 1 2 3 4 5 6 E ...

Page 106: ...r 3 22 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 oil 1 12 Engine stop lanyard switch 2 4 Exhaust leakage 4 17 F Filling fuel 3 8 Filling fuel and engine oil 3 8 Filling fuel tank 4 4 Filling oil 3 9 Flushing cooling system and fogging engine 4 5 Flushing device 2 15 Flushing with the flus...

Page 107: ...lacing fuse 4 17 Reverse 3 15 Ring free fuel additive 3 8 S Safety information 1 4 Shifting 3 15 Specifications 4 1 Speedometer 2 11 Star labels 1 3 Start in gear protection 1 15 Starter will not operate 5 6 Starting engine 3 12 Stopping engine 3 16 Storing outboard motor 4 4 T Tachometer 2 8 Temporary action in emergency 5 5 Throttle friction adjusting screw 2 5 Tilt support lever 2 13 Tilting up...

Page 108: ...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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...Printed in Japan March 2003 0 5 1 68J 28199 15 Z150QETO Z175HETO Z200PETO E Printed on recycled paper ...

Page 115: ...r au détail OUTBOARD MOTOR MODEL AND SERIAL NUMBER From I D label on clamp bracket MODÉLE ET NO DE SÉRIE DU MOTEUR HORS BORD sur l étiquette d identification de la presse de fixation For Dealer Use Only A l usage du concessionnaire YAMAHA DEALER NUMBER NO DU CONCESSIONNAIRE YAMAHA DEALER NAME NOM DU CONCESSIONNAIRE DATE SOLD DATE DE LIVRAISON OWNER S NAME NOM DU PROPRIÉTAIRE ADDRESS ADRESSE PHONE ...

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

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