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Table of contents
Instruments and indicators ............ 27

Procedure

Indicators...................................... 27

Trimming outboard motor 47

Low oil pressure-alert indicator ........ 27

Adjusting trim angle for manual tilt

Engine control system................... 28

models 47

Alert system

Low oil pressure alert

Installation

Mounting the outboard motor

Clamping the outboard motor

Operation

First-time operation

Fill engine oil

Breaking in engine.

Getting to know your boat 32
Checks before starting engine

Fuel level

Remove the top cowling 33
Fuel system

Controls 33
Engine shut-off cord (lanyard)

Engine oil

Engine 34
Flushing device 34

Adjusting trim angle (power tilt
models) 48
Adjusting boat trim

Tilting up and down

Procedure for tilting up (manual tilt
models) 50
Procedure for tilting up (power tilt
models) 51
Procedure for tilting down (manual
tilt models)

Procedure for tilting down (power tilt models) 52
Shallow water

Cruising in shallow water (manual
tilt models)

Power tilt models 54
Cruising in other conditions

Maintenance

Transporting and storing outboard motor

Install top cowling ............................. 35

Dismounting the outboard motor

Checking power tilt system.............. 35

Storing outboard motor

Battery .............................................. 36

Procedure

Filling fuel

Operating engine. 37
Sending fuel (portable tank)

Starting engine 38
Checks after starting engine

Cooling water

Warming up engine

Manual start and electric start
models 43
Checks after engine warm up

Shifting 44
Stop switches

Shifting 44
Stopping boat

Stopping engine 46

Lubrication....................................... 59
Flushing power unit

Cleaning the outboard motor

Checking painted surface of
outboard motor 60
Periodic maintenance

Replacement parts

Severe operating conditions

Maintenance chart 1.

Maintenance chart 2.

Greasing.

Cleaning and adjusting spark plug ... 67 Checking
fuel filter 67
Inspecting idle speed.

Changing engine oil

Inspecting wiring and connectors

Procedure........................................ 46

Checking propeller

Removing propeller

Installing propeller

Changing gear oil 72
Cleaning fuel tank

Inspecting and replacing anode(s) ... 74 Checking battery (for electric start
models) 75
Connecting the battery

Disconnecting the battery 76
Trouble Recovery 77

Содержание MOTOR99

Страница 1: ...e contiguous states excluding the states with high altitude areas identified in 40 CFR part 1068 Appendix III To exercise this warranty DO NOT RETURN TO RETAILER Instead call Customer Service toll free at 1 888 287 6981 email address info buffalotools com and you will be instructed on where to take the engine for warranty service Take the engine and proof of purchase your receipt to the repair fac...

Страница 2: ...7 Compression Ratio 9 4 1 Fuel Induction System 1 OHV Intake Carburetor Exhaust Above Propeller Cooling Water Thermostatic Control Ignition System CDI Alternator Output 6A Starting System Manual Lubrication Wet Pump Gear Ratio 27 13 2 08 1 Gear Shift Forward Neutral Reverse Shaft Length 17 9 Tilt Up Angle 71 Degree of Trim 5 Positions Steering Angle 45 Oil Capacity 23 ounces Fuel Capacity 6 3 Gall...

Страница 3: ...15 Emergency equipment 15 Components 16 Components diagram 16 Fuel tank 17 Fuel joint 18 Fuel gauge 18 Fuel tank cap 18 Air vent screw 18 Remote control box 18 Remote control lever 18 Neutral interlock trigger 19 Neutral throttle lever 19 Choke switch 19 Tiller handle 19 Gear shift lever 19 Throttle grip 20 Throttle indicator 20 Throttle friction adjuster 20 Engine shut off cord lanyard and clip21...

Страница 4: ...ing in other conditions 55 Maintenance 56 Transporting and storing outboard motor 56 Install top cowling 35 Dismounting the outboard motor 56 Checking power tilt system 35 Storing outboard motor 58 Battery 36 Procedure 58 Filling fuel 36 Operating engine 37 Sending fuel portable tank 37 Starting engine 38 Checks after starting engine 43 Cooling water 43 Warming up engine 43 Manual start and electr...

Страница 5: ...ction in emergency 80 Impact damage 80 Replacing fuse 80 Power tilt will not operate 81 Starter will not operate 81 Emergency starting engine82 Engine fails to operate 83 Emergency engine operation 83 Treatment of submerged motor 83 ...

Страница 6: ...s overboard or leaves the helm This prevents the boat from running away under power and leaving people stranded or running over people or objects Always attach the engine shut off cord to a secure place on your clothing or your arm or leg while operating Do not remove it to leave the helm while the boat is moving Do not attach the cord to clothing that could tear loose or route the cord where it c...

Страница 7: ...he motor is in neutral Stop the engine when a person is in the water near you Passengers Consult your boat manufacturer s instructions for details about appropriate passenger locations in your boat and be sure all passengers are positioned properly before accelerating and when operating above an idle speed Standing or sitting in non designated locations may result in being thrown either overboard ...

Страница 8: ...he organizations listed in the next section can provide information about courses in your area You may also want to consider an Internet based program for basic boater education The Online Boating Safety Course provided by the Boat U S Foundation is approved by the National Association of State Boating Law Administrators NASBLA and recognized by the United States Coast Guard Most but not all state...

Страница 9: ...4 http www mraa com Basic boating rules Rules of the road Just as there are rules that apply when you are driving on streets and highways there are waterway rules that apply when you are driving your boat These rules are used internationally For U S A and are also enforced by the United States Coast Guard and local agencies You should be aware of these rules and follow them whenever you encounter ...

Страница 10: ...Overtaking you are passing or being passed by another vessel In the following illustration your boat is in the center You should give the right of way to any vessels shown in white area you are the Give Way vessel Any vessels in the shaded area must yield to you they are the Give Way vessels Both you and the meeting vessel must alter course to avoid each other 8 Meeting If you are meeting another ...

Страница 11: ...t considered fishing vessels Fishing vessels have the right of way regardless of position Fishing vessels cannot however impede the passage of other vessels in narrow channels Sailing vessel right of way Sailing vessels should 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 driven vessel has the right of way 2 ...

Страница 12: ...his system uses buoys and signs with distinctive shapes and colors to show regulatory or advisory information These markers are white with black letters and orange boarders They signify speed zones restricted areas danger areas and general information Remember markings may vary by geographic location Always consult local boating authorities before driving your boat in unfamiliar waters 10 ...

Страница 13: ... 11 1 2 3 4 Symbols The following symbols mean as follows Notice Warning Electrical hazard Read Owner s Manual Hazard caused by continuous rotation ...

Страница 14: ...um output F4MHA 2 9 kW 4500 r min 4 HP 4500 r min FP6A 4 4 kW 5000 r min 6 HP 5000 r min Idle speed in neutral 1500 50 r min Type 4 stroke S Displacement 139 0 cm Bore stroke 62 0 46 0 mm 2 44 1 81 in Ignition system CDI Spark plug NGK CR6HSB Spark plug gap 0 6 0 7 mm 0 024 0 028 in Control system Tiller handle Starting system Manual starter Starting carburetion system Choke valve Valve clearance ...

Страница 15: ... perform well over a range of applications but there may be uses where a different propeller would be more appropriate Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boatload Generally select a larger pitch propeller for a smaller operating load and a smaller pitch propeller for a heavier load If you carry lo...

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Страница 17: ... have been changing in recent years in response to concerns about pollution and resulting emissions regulations One of the most obvious changes has been the elimination of lead from most fuels As gasoline has changed the amount of additives such as aromatics and oxygenates has increased These additives are important for the engines in passenger cars but they can have detrimental effects in marine ...

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Страница 23: ...rm or leg while operating Do not attach the cord to clothing that could tear loose Do not route the cord where it could become entangled preventing it from functioning Avoid accidentally pulling the cord during normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause people and objects in the boat to be thr...

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Страница 25: ...hten the steering friction adjuster If there is too much resistance it could be difficult to steer which could result in an accident The steering friction adjuster provides adjust able resistance to the steering mechanism and can be set according to operator prefer ence The steering friction adjuster is located on the port side of the outboard motor 1 Trim rod Tilt lock mechanism The tilt lock mec...

Страница 26: ...cure the top cowling 1 Tilt lock When the gear shift lever is moved to the neutral position or forward position the outboard motor can be tilted up Tilt support bar Use the tilt support bar to keep the outboard motor in the tilted up position or a shallow water cruising position 1 Cowling lock lever Carryinghandle Used to carry the outboard motor 2 1 1 2 3 1 1 1 ...

Страница 27: ... Improper mounting of the outboard motor could result in hazardous conditions such as poor handling loss of control or fire hazards Mounting the outboard motor WARNING Do not hold the top cowling or tiller handle when mounting or dismounting the out board motor Otherwise the outboard motor could fall 1 Be sure to mount the outboard motor while the boat is on land If the boat is on the water move i...

Страница 28: ...ng height is too high cavitation tends to occur thus reducing the propulsion and if the propeller tips cut the air the engine speed will rise abnormally and cause the engine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engine efficiency Mount the outboard motor so that the anti cavitation plate is between the bottom of the boat and a level 25 ...

Страница 29: ...est runs at different heights can help determine the optimum mounting height Clamping the outboard motor 1 Place the outboard motor on the transom so that it is positioned as close to the center as possible Tighten the clamp screws evenly and securely Occasionally check the clamp screws for tightness during operation of the outboard motor because they could become loose due to engine vibration WAR...

Страница 30: ...reaking in engine avoid extended idling rough water and crowded areas For the first hour of operation Run the engine at varying speeds up to 2000 r min or approximately half throttle 1 For the second hour of operation Run the engine at 3000 r min or at approximately three quarter throttle 2 Remaining 8 hours Run the engine at any speed However avoid operating at full throttle for more than 5 minut...

Страница 31: ...qualified mechanic Improper repairs can make the outboard unsafe to operate Check for fuel leaks Check for fuel leaks or gasoline fumes in the boat Check for fuel leakage from the fuel system Check the fuel tank and fuel lines for cracks swellings or other damage Controls Move the tiller handle fully to the left and right to check that operation is smooth Turn the throttle grip from the fully clos...

Страница 32: ...ication check window TIP The oil lubrication check window does not indicate the engine oil level Use the oil lubrication check window to make sure that the engine is being lubricated with oil while it is running 3 Install the oil filler cap and tighten it completely 4 Remove the oil filler cap again and check that the oil level on the dipstick is between the upper and lower marks If the oil level ...

Страница 33: ...the bottom cowling and then make sure that the fuel tank cap and manual starter handle fit properly into their respective holes 1 Hook 4 Check to be sure the rubber seal is seated correctly between the top cowling and the bottom cowling 5 Pull the cowling lock lever down to secure the top cowling 1 Cowling lock lever 6 Check the fitting of the top cowling by pushing it with both hands NOTICE If th...

Страница 34: ... container to store and dispense fuel only use a locally approved GASOLINE container To prevent electrostatic sparks discharge any built up static electricity from your body before refueling Filling fuel for built in fuel tank 1 Remove the fuel tank cap 2 Fill the fuel tank but do not overfill it Fuel can expand and overflow if the temperature increases 3 Tighten the fuel tank cap securely 4 Wipe ...

Страница 35: ...t you can steer clear of any obstructions Be sure there are no swimmers in the water near you When the air vent screw is loosened gasoline vapor will be released Gasoline is highly flammable and its vapors are flammable and explosive Refrain from smoking and keep away from open flames and sparks while loosening the air vent screw This product emits exhaust gases which contain carbon monoxide a col...

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Страница 39: ...on your clothing or your arm or leg Then install the clip on the other end of the cord to the engine shut off switch 3 Align the engine start mark on the throttle grip with the notch in the tiller handle 1 Start mark 2 Notch TIP If the ambient temperature is 15 C or less turn the throttle grip so that the engine start mark is positioned past the notch in the tiller handle 4 Pull out the choke knob...

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Страница 41: ...ng engine Cooling water Check for a steady flow of water from the cooling water pilot hole A continuous flow of water from the pilot hole indicates that the water pump is pumping water through the cooling water passages If the cooling water passages are frozen it may take a while for water to start flowing out of the pilot hole NOTICE If water is not flowing out of the pilot hole at all times whil...

Страница 42: ...he engine stops when the engine stop button is pushed Restart the engine and then check that the engine stops when the clip is pulled from the engine shut off switch Check that the engine cannot be started with the clip removed from the engine shut off switch Before shifting the outboard motor turn the throttle grip to the fully closed position and let the engine speed return to idle speed Otherwi...

Страница 43: ...g on gross weight water surface conditions and wind direction 3 1 2 1 Engine shut off switch 2 Cord 3 Clip 2 Tighten the air vent screw on the fuel tank cap Stoppingengine Before stopping the engine first let it cool off for a few minutes at idle or low speed Stopping the engine immediately after operating at high speed is not recommended Procedure 1 Push and hold the engine stop button until the ...

Страница 44: ...ssibility of an accident If the boat begins to feel unstable or is hard to steer slow down and or readjust the trim angle 38 The trim angle of the outboard motor helps determine the position of the bow of the boat inthe water The correcttrim angle isaffected byvariables such asthe load inthe boat sea conditions and runningspeed 1 Trim operating angle Adjusting Trim Angle For Manual Tilt Models WAR...

Страница 45: ...ur boat and operating conditions Adjusting boat trim Generally a boat is stable when the keel line of the boat is up about 3 to 5 degrees With the bow up the boat may have a greater tendency to steer to one side or the other If this occurs adjust the trim angle Bow Up Too much trim out puts the bow of the boat too high in the water Excessive trim out can also cause the propeller to ventilate which...

Страница 46: ...e hazard When the outboard motor will be tilted up for more than a few minutes tighten the air vent screw and fuel tank cap and align the fuel cock with the closed position Otherwise fuel may leak NOTICE Before tilting the outboard motor up follow the procedure under Stopping engine in this chapter Never tilt the outboard motor up while the engine is running Severe damage from overheating can resu...

Страница 47: ...ted on the clamp bracket 1 Steering friction adjuster 4 Tighten the air vent screw 1 Tilt support bar 2 Holder 1 Air vent screw 5 When using a portable fuel tank disconnect the fuel hose and then install the fuel joint cap WARNING When not using a portable fuel tank make sure to install the fuel joint cap Otherwise injury could result from striking the fuel joint accidentally Procedure for tilting...

Страница 48: ...NOTICE Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when setting up for and cruising in shallow water Otherwise severe damage from overheating can result 1 Cooling water inlet Shallow water Cruising in shallow water Procedure for shallow water cruising 1 Move the gear shift lever to the neutral position WARNING Operate the bo...

Страница 49: ...n other conditions Cruising in salt water After operating in salt water flush the cooling water passages with fresh water to prevent them from becoming clogged Also rinse the outside of the outboard motor with fresh water Cruising in muddy turbid or acidic water Water in some areas can be acidic or with a lot of sediment in it such as muddy or turbid cloudy water After operating in such water flus...

Страница 50: ...port bar when trailering the boat The outboard motor could shake loose from the tilt support and fall The outboard motor should be trailered and stored in the fully tilted down position Dismounting the outboard motor WARNING Do not hold the top cowling or tiller handle when mounting or dismounting the outboard motor Otherwise the outboard motor could fall 1 Stop the engine and land the boat 44 2 T...

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Страница 54: ...and fogging at the same time 1 Wash the outboard motor body using fresh water NOTICE Do not spray water into the air intake 2 Fill the built in fuel tank with fresh fuel and add one ounce of Fuel Conditioner and Stabilizer to each gallon of fuel TIP The use of Fuel Conditioner and Stabilizer eliminates the need to drain the fuelsystem 3 When using a portable fuel tank discon nect the fuel hose ins...

Страница 55: ...ng hole cap and top cowling 13 Align the fuel cock with the closed position and tighten the air vent screw 14 Install the propeller 48 Flushing with the water flush plug optional NOTICE Before starting the engine make sure to supply water to the cooling water passages Otherwise the engine could overheat andbe damaged Cooling system flushing is essential to pre vent the cooling system from clogging...

Страница 56: ...that indicates a leaky seal 3 Grease all grease fittings TIP For long term storage fogging the engine with oil is recommended Cleaning and anticorrosion measures 1 Wash down the exterior of the outboard motor with fresh water and dry off completely NOTICE Do not spray water into the air intake 2 Spray the outboard motor exterior with Silicone Protectant 3 Wax the cowling with a non abrasive wax su...

Страница 57: ...or quality may malfunction and the resulting loss of control could endanger the operator and passengers 50 Maintenance interval guidelines The service intervals provided in the Mainte nance Chart were developed based upon typical use that includes operating at varied speeds with sufficient time for engine warm up and cool down a medium to light load and an average cruising speed near the 3000 to 4...

Страница 58: ... the warranty period When operating in salt water muddy other turbid cloudy acidic water the engine should be flushed with clean water after each use 51 1 year Anode external Inspection or replace ment as necessary O Anode thermostat cover Inspection or replace ment as necessary Cooling water leakage Inspection or replace ment as necessary Cowling lock lever Inspection Engine starting condi tion n...

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Страница 61: ...the insulator A damaged insulator could allow external sparks which could lead to explosion or fire Standard spark plug CR6HSB Be sure to use the specified spark plug otherwise the engine may not operate properly Before fitting the spark plug measure the electrode gap with a wire thickness gauge replace it if out of specification 2 1 1 Spark plug gap 2 Spark plug part number 3 Spark plug l D mark ...

Страница 62: ...ine oil with an oil changer 1 Put the outboard motor in an upright position not tilted NOTICE If the motor is not level the oil level indicated on the dipstick may not be accurate 2 Start the engine Warm it up and keep the idle speed for 5 10 minutes 3 Stop the engine and leave itfor 5 10 minutes 4 Remove the top cowling 5 Remove the oil filler cap 1 Oil filler cap 2 Oil lubrication check window T...

Страница 63: ...upper and lower marks If the oil level is not at the proper level add or extract oil until the oil is between the upper and lower marks 15A Start the engine and make sure that there are no oil leaks NOTICE If there are oil leaks stop the engine and find the cause 1 Drainscrew 2 Washer 8 If the drain screw was removed install a new washer and drain screw and then tighten the drain screen Engine oil...

Страница 64: ...clip from the engine shut off switch Checkpoints Check each of the propeller blades for erosion from cavitation or ventilation or other damage Check the propeller shaft for damage Check the splines for wear or damage Check for fish line tangled around the propeller shaft Check the propeller shaft oil seal for damage 1 Do not use your hand to hold the propeller when loosening or tightening the prop...

Страница 65: ...en the propeller nut until there is no looseness in the propeller 4 Align the propeller nut hole with the propeller shaft hole Insert a new cotter pin in the holes and bend the cotter pin ends NOTICE Do not reuse the cotter pin installed Otherwise the propeller can come off during operation TIP If the propeller nut hole does not align with the propeller shaft hole after tightening the propeller nu...

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Страница 67: ...new gasket on the oil level plug When the oil begins to flow out of the oil level plug hole insert and tighten the oil level plug Tightening torque 9 0 Nm 0 92 kgf m 6 6 ft lb 7 Put a new gasket on the gear oil drain screw Insert and tighten the gear oil drain screw Tightening torque 9 0 Nm 0 92 kgf m 6 6 ft lb Inspecting and replacing anode external Outboard motors are protected from corrosion by...

Страница 68: ...ct Customer Service Q Is clip on engine shut off cord lanyard installed A Install clip to engine shut off switch Q Are engine inner parts damaged A Contact Customer Service Engine idles irregularly or stalls Q Is fuel system obstructed A Check for pinched or kinked fuel line or other obstructions in fuel system Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is fuel filter clog...

Страница 69: ... Clean or replace with recommended type 1 Are weeds or other foreign material tangled on gear housing 61 A Remove foreign material and clean lower unit 1 Is fuel system obstructed A Check for pinched or kinked fuel line or other obstructions in fuel system 1 Is fuel filter clogged A Clean or replace filter 1 Is fuel contaminated or stale A Fill tank with clean fresh fuel 1 Is spark plug gap incorr...

Страница 70: ...ism does not operate the engine cannot be cranked with the starter the engine can be started with an emergency starter rope AWARNING WARNING Use this procedure only for emergency engine starting to return to the nearest port for repairs When the emergency starter rope is used to start the engine the start in gear protection device does not operate Make sure that the shift lever is in the neutral p...

Страница 71: ... starting or operating the outboard motor You could get an electrical shock Emergency engine starting Before performing the following procedure make sure to read the emergency starting label on the manual starter flywheel magnet cover 1 Neutral position 2 Remove the top cowling 3 Loosen the nut and then disconnect the start in gear protection cable 2 1 1 Start in gear protection cable 2 Nut 4 Remo...

Страница 72: ...engine shut off cord to a secure place on your clothing or your arm or leg Then install the clip on the other end of the cord to the engine shut off switch 7 Align the engine start mark on the throttle grip with the notch in the tiller handle 1 Start mark 2 Notch 8 Give a strong pull straight out to crank and start the engine TIP If the engine does not start after several attempts pull out the cho...

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