63B-9-1A hyoshi 4/12/02 3:31 PM Page 1 (2,1) 40B 50B OWNER’S MANUAL U.S.A.
63B-9-1A hyoshi 4/12/02 3:31 PM Page 2 (1,1)
63B-9-1A-1 2/28/02 5:11 PM Page 1 E EMU01449 TO THE OWNER Thank you for choosing a Yamaha outboard motor. This Owner’s manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.
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63B-9-1A-1 2/28/02 5:11 PM Page 3 EMA20010 CONTENTS E GENERAL INFORMATION 1 BASIC COMPONENTS 2 OPERATION 3 MAINTENANCE 4 TROUBLE RECOVERY 5 INDEX 6 READ THIS OWNER’S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR.
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63B-9-1A-1 3/1/02 11:04 AM Page 5 E EMB00010 Chapter 1 GENERAL INFORMATION 1 IDENTIFICATION NUMBERS RECORD ....................................................1-1 Outboard motor serial number...........1-1 Key number...........................................1-1 EMISSION CONTROL INFORMATION...1-2 2 SAFETY INFORMATION..........................1-3 3 IMPORTANT LABELS ..............................1-5 BASIC BOATING RULES .........................1-6 FUELING INSTRUCTIONS.....................
63B-9-1A-1 2/28/02 5:11 PM Page 6 E EMU00005 IDENTIFICATION NUMBERS RECORD EMU00007 OUTBOARD MOTOR SERIAL NUMBER YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON 1 401012 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 outboard motor is stolen.
63B-9-1A-1 2/28/02 5:11 PM Page 7 E EMU01385 EMISSION CONTROL INFORMATION q EMU01386 NORTH AMERICAN MODELS w 000909 This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details. Approval label of Emission control certificate This label is attached to the bottom cowling. 1 Emission control information label EMISSION CONTROL INFORMATION ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S.
63B-9-1A-1 2/28/02 5:11 PM Page 8 E EMU00917 Q SAFETY INFORMATION 8 Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation. 8 Before operating the boat, read any owner’s or operator’s manuals supplied with it and all labels. Be sure you understand each item before operating. 8 Do not overpower the boat with this outboard motor. Overpowering the boat could result in loss of control.
63B-9-1A-1 2/28/02 5:11 PM Page 9 E 8 When a swimmer is in the water near you shift into neutral and shut off the engine. 8 Be informed about boating safety. Additional publications and information can be obtained from many organizations, 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.
63B-9-1A-1 2/28/02 5:11 PM Page 10 E EMB30011 IMPORTANT LABELS q WARNING LABELS 1 WARNING ●Be sure shift control is in neutral before starting engine. (except 2HP) ●Do not touch or remove electrical parts when starting or during operation. ●Keep hands,hair,and clothes away from flywheel and other rotating parts while engine is running.
63B-9-1A-1 2/28/02 5:11 PM Page 11 E EMB40010 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 local agencies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water.
63B-9-1A-1 2/28/02 5:11 PM Page 12 E will clear one another if you continue on your set course and speed.
63B-9-1A-1 2/28/02 5:11 PM Page 13 E its course and speed. You must stay out 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. Narrow channels and bends When navigating in narrow channels, you should keep to the right when it is safe and practical to do so.
63B-9-1A-1 2/28/02 5:11 PM Page 14 E tion. 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. N A A C H C " 1" M N O AN N White Light C H D A R Odd number. increasing toward head of navigation.Leave to port (left) proceeding upstream.
63B-9-1A-1 2/28/02 5:11 PM Page 15 E EMU00016 FUELING INSTRUCTIONS w GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! 8 Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. 8 Stop engine before refueling. 8 Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. 8 Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. 8 Do not overfill the fuel tank. 8 Tighten the filler cap securely after refueling.
63B-9-1A-1 2/28/02 5:11 PM Page 16 E EMU01804 GASOLINE Recommended gasoline: Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2 If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. EMU00027 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings.
63B-9-1A-1 3/1/02 11:05 AM Page 17 E EMU01775 BATTERY REQUIREMENT cC Do not use a battery that does not meet the specified capacity. If a battery which does not meet specifications is used, the electric system could perform poorly or be overloaded, causing electric system damage. For electric start models, choose a battery which meets the following specifications. EMU01859 Minimum cold cranking amps (CCA/SAE): 245 amps at -18°C (-0.
63B-9-1A-1 2/28/02 5:11 PM Page 18 E EMU01395 PROPELLER SELECTION The performance of your outboard motor will be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine.
63B-9-1A-1 2/28/02 5:11 PM Page 19 E 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 maximum recommended range (such as light boat loads), reduce the throttle setting to maintain the rpm in the proper operating range.
63B-9-1A-1 2/28/02 5:11 PM Page 20 E -MEMO-
63B-9-1A-2 3/7/02 3:33 PM Page 1 E EMC00010 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-2 Fuel tank ................................................2-2 Remote control .....................................2-3 Power trim/tilt switch ...........................2-7 Warning indicator.................................2-8 Digital tachometer................................2-9 Trim tab ....................
63B-9-1A-2 2/28/02 5:12 PM Page 2 E EMU01206 MAIN COMPONENTS q !3 w !2 !4 e r !1 !5 !0 o t i y u 1 2 3 4 5 6 7 8 9 0 q w e *r *t Oil filler access cap Warning indicator lamp Clamp bracket Battery lead Anode Cooling water inlet Propeller Trim tab (Anode) Anti-cavitation plate Anode Trim angle adjusting rod Tilt support lever Top cowling Remote control box Digital tachometer * May not be exactly as shown; also may not be included as standard equipment on all models.
63B-9-1A-2 2/28/02 5:12 PM Page 3 E EMC20010 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS EMC21012 FUEL TANK If your model was equipped with a portable fuel tank, its function is as follows. q e r w 1 2 3 4 Fuel hose joint Fuel meter(If equipped) Fuel tank cap Air vent screw(If equipped) EMC31010 Fuel hose joint This connector is provided for connecting or disconnecting fuel hose. 902051* EMC41110 Fuel meter This meter is on the fuel tank cap.
63B-9-1A-2 2/28/02 5:12 PM Page 4 E EMU00096* REMOTE CONTROL y q w Both the shifter and the throttle are actuated by the remote control lever. Additionally, the remote control also has the electrical switches.
63B-9-1A-2 2/28/02 5:12 PM Page 5 E EMC50110 Neutral interlock trigger To shift out of Neutral, the neutral interlock trigger of the remote control lever must first be pulled up. EMC50210 701036 N q w 701033* Neutral throttle lever To open the throttle without shifting into either Forward or Reverse, place the remote control lever in the Neutral position and lift the neutral throttle lever. NOTE: The neutral throttle lever will operate only when the remote control lever is in Neutral.
63B-9-1A-2 2/28/02 5:12 PM Page 6 E EMU01331 UP DN UP DN 701034 Power Trim/Tilt Switch The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the remote control lever grip. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.
63B-9-1A-2 2/28/02 5:12 PM Page 7 E EMC28210 Engine stop lanyard switch The lock-plate on the end of the lanyard must be attached to the engine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine. This will prevent the boat from running away under power.
63B-9-1A-2 2/28/02 5:12 PM Page 8 E EMC87011 Throttle friction adjusting screw A friction device in the remote control box provides resistance to movement of the remote control lever. This is adjustable for operator preference. An adjusting screw is located at the front of the remote control box. 701035 Resistance Screw Increase Turn clockwise Decrease Turn counterclockwise w Do not overtighten the friction adjusting screw.
63B-9-1A-2 2/28/02 5:12 PM Page 9 E 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 cowling-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 collision with another boat or an obstacle. NOTE: Refer to the section “Adjusting Trim Angle” and “Tilting Up/Down” for instructions on usage.
63B-9-1A-2 2/28/02 5:12 PM Page 10 E EMU01614 DIGITAL TACHOMETER q w e t y r u 001078 This gauge contains the tachometer, trim meter, hour meter, oil level indicator, and the overheat warning indicator. 1 2 3 4 5 6 7 Tachometer Trim meter Hour meter Oil level indicator Overheat warning indicator Set button Mode button NOTE: All segments of the display will light momentarily after the main switch is turned on and will return to normal thereafter.
63B-9-1A-2 2/28/02 5:12 PM Page 11 E EMU01109 001050 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 conditions. Adjust the trim angle to the desired setting by operating the power trim and tilt switch. 8 If the trim angle of your motor exceeds the trim operating range, the top segment on the trim meter display will start to blink.
63B-9-1A-2 2/28/02 5:12 PM Page 12 E EMU00138 Oil-Level Indicator This indicator shows the engine oil level. If the oil level falls below the lower limit, the warning indicator will start to blink. Refer to the sections “FILLING OIL” and “OIL LEVEL WARNING” for details. q 001051 1 Oil-level indicator cC Do not operate the engine without oil. Serious engine damage will occur. EMU01553 Overheat Warning Indicator If the engine temperature rises too high, the warning indicator will start to blink.
63B-9-1A-2 2/28/02 5:12 PM Page 13 E EMD04011* TRIM TAB The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force. w An improperly adjusted trim tab may cause difficult steering. Always test run after the trim tab has been installed or replaced to be sure steering is correct. Be sure you have tightened the bolt after adjusting the trim tab.
63B-9-1A-2 2/28/02 5:12 PM Page 14 E EMD60010 TILT SUPPORT LEVER Power trim & tilt/Hydro tilt model To keep the outboard motor in the tiltedup position, lock the tilt support lever to the clamp bracket. 403011 EMD62011 TOP COWLING LOCK LEVER q 301013* To remove the engine top cowling, turn the lock lever. Then lift off the cowling. When replacing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by moving the lever upward.
63B-9-1A-2 2/28/02 5:12 PM Page 15 E EMD80010 WARNING SYSTEM cC Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. 303012 EMD82012* OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate.
63B-9-1A-2 2/28/02 5:12 PM Page 16 E EMD84012* OIL LEVEL WARNING / OIL FILTER CLOGGING WARNING This engine has an oil level warning system. If oil level falls below lower limit, the warning device will activate. 303012 (2); Included (—); N/A Warning device activation 303022 Tiller control model Remote control model The engine speed will automatically decrease to about 2,000 r/min. 2 The oil level warning indicator will come on. 2 The buzzer will sound.
63B-9-1A-3 3/7/02 3:39 PM Page 1 E EMF00010 Chapter 3 OPERATION INSTALLATION ........................................3-1 Mounting the outboard motor............3-2 FILLING FUEL AND ENGINE OIL ............3-4 Filling fuel..............................................3-4 Filling oil ................................................3-5 PRE-OPERATION CHECKS ......................3-8 Operation after a long period of storage...................................................3-9 BREAKING IN ENGINE .............
63B-9-1A-3 2/28/02 5:13 PM Page 2 E EMF10010 INSTALLATION cC Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat or accessories such as transom ladders/depth finder transducers) can create airborne 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.
63B-9-1A-3 2/28/02 5:13 PM Page 3 E EMF12012 MOUNTING THE OUTBOARD MOTOR w Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Observe the following: 8 The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat/motor combination. Proper mounting depends in part on experience and the specific boat/motor combination.
63B-9-1A-3 2/28/02 5:13 PM Page 4 E w Overpowering a boat may cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer. EMU01299 104014 Mounting Height To run your boat at optimum efficiency, the water-resistance (drag) of the boat and outboard motor must be made as little as possible.
63B-9-1A-3 2/28/02 5:13 PM Page 5 E EMF20010 FILLING FUEL AND ENGINE OIL EMF30011 FILLING FUEL 1) 2) 3) 902055 Remove the fuel tank cap. Fill the fuel tank carefully. Close the cap securely after refueling. Wipe up any spilled fuel. Fuel tank capacity: Refer to SPECIFICATIONS, page 4-1. EMU01019 Ring Free Fuel Additive Gasoline is a precise blend of many different substances, each chosen to give certain characteristics.
63B-9-1A-3 2/28/02 5:13 PM Page 6 E EMU01800 FILLING OIL This engine uses the oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operating conditions. No fuel premixing is needed (except during break-in). 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 indicator” in this chapter.
63B-9-1A-3 2/28/02 5:13 PM Page 7 E EMF34110 Procedure Electric start model 1) Turn the oil filler access cap on top of the top cowling counterclockwise and open it. 2) Open the oil tank filler cap by pulling a tab on the cap. 3) Slowly fill the engine oil into the engine oil tank. After filling, replace the all caps securely.
63B-9-1A-3 2/28/02 5:13 PM Page 8 E EMD33110 Oil level indicator Electric start model The various oil-level system functions are as follows: Oil level warning indicator (Digital tachometer) Oil level warning indicator lamp (Analog tachometer/Bottom cowling) Engine oil tank Green Yellow Red 3-7 Remarks more than 4 50 cm3 (0.48 US qt, 0.40 Imp qt) No refilling necessary. from 450 cm3 (0.48 US qt, 0.40 Imp qt) down to 200 cm3 (0.21 US qt, 0.18 Imp qt) Add oil, refer to oil filling. 200 cm3 (0.
63B-9-1A-3 2/28/02 5:13 PM Page 9 E EMF40012 PRE-OPERATION CHECKS w If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur. EMF41110 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.
63B-9-1A-3 2/28/02 5:13 PM Page 10 E EMF43510 Engine 8 Check the engine and engine mounting. 8 Look for loose or damaged fasteners. 8 Check the propeller for damage. cC Do not start the engine out of water. Overheating and serious engine damage can occur. EMU01790 OPERATION AFTER A LONG PERIOD OF STORAGE When operating the engine after a long period (12 months) of storage, proceed as follows: 1) Use a 50:1 gasoline-oil mixture to start the engine. 2) Start the engine. Leave it idling.
63B-9-1A-3 2/28/02 5:13 PM Page 11 E EMU01776 BREAKING IN ENGINE Your new engine requires a period of break-in to allow mating surfaces of moving parts to wear in evenly. Correct breakin will help ensure proper performance and longer engine life. cC 8 Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage. 8 Premix fuel must be used during breakin, in addition to oil in the oil injection system.
63B-9-1A-3 2/28/02 5:13 PM Page 12 E EMU01784 Run the engine under load (in gear with a propeller installed) as follows. 1) First 10 minutes: Run the engine at the lowest possible-speed. A fast idle in neutral is best. 2) Next 50 minutes: Do not exceed half throttle (approximately 3,000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 r/min or less.
63B-9-1A-3 2/28/02 5:13 PM Page 13 E EMU01147 STARTING ENGINE w 902053 304034 8 Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you. 8 When the air vent screw is loosened, gasoline (petrol) vapor will be released. Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive.
63B-9-1A-3 2/28/02 5:13 PM Page 14 E EMF65010 PROCEDURE FOR REMOTE CONTROL MODEL N 4) 701015 Place the remote control lever in the Neutral position. NOTE: 8 The start-in-gear protection device prevents the engine from starting except when in Neutral. 8 It is not necessary to open the free accelerator lever or Neutral throttle lever while starting. 5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg.
63B-9-1A-3 2/28/02 5:13 PM Page 15 E EMF63910 OFF ON Electric start model 7) Turn the main switch to “START”, and hold it for a maximum of 5 seconds. 8) Immediately the engine starts, release the main switch to return it to “ON”. START cC 701022 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 with the main switch in the “START” position.
63B-9-1A-3 2/28/02 5:13 PM Page 16 E EMG00210 WARMING UP ENGINE 1) 2) 309014 Before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (Failure to do this will shorten engine life.) Check for a steady flow of water from the cooling-water pilot hole. cC A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages.
63B-9-1A-3 3/1/02 11:06 AM Page 17 E EMG20111 SHIFTING w Before shifting, make sure there are no swimmers or obstacles in the water near you. cC F To change the shifting position from forward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speeds). N EMU00264 FORWARD 701043 Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from Neutral to Forward.
63B-9-1A-3 2/28/02 5:13 PM Page 18 E EMG38010 STOPPING ENGINE Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended. EMG35310 ON OFF PROCEDURE START Main switch equipped model 701023 1) Turn the main switch to “OFF”. NOTE: The engine can also be stopped by pulling the lanyard from the engine stop switch (then turning the main switch to “OFF”).
63B-9-1A-3 2/28/02 5:13 PM Page 19 E EMU01412 TRIMMING OUTBOARD MOTOR The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.
63B-9-1A-3 2/28/02 5:13 PM Page 20 E ADJUSTING TRIM ANGLE EMU01401 Power Trim/Tilt Model w UP DN 8 Be sure all people are clear of the outboard motor when adjusting the trim/tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket. 8 Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems.
63B-9-1A-3 2/28/02 5:13 PM Page 21 E EMG62010 Bow up When the boat is on plane, a bow-up attitude result in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. When trimmed out, the boat may have more tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adjusted to help offset this effect. q 105011 w Too much trim-out puts the bow of the boat too high in the water.
63B-9-1A-3 2/28/02 5:13 PM Page 22 E EMH10110 TILTING UP/DOWN If the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion. 000817 cC 8 Before tilting the motor, follow the procedures under “STOPPING ENGINE”. Never tilt the motor while the engine is running. Severe damage from overheating can result.
63B-9-1A-3 2/28/02 5:13 PM Page 23 E EMG63210 PROCEDURE FOR TILTING UP Power trim and tilt model 1) Remove the fuel-line connection from the motor. 2) Push the power trim and tilt switch “UP” until the outboard has tilted up completely. 3) Turn the tilt-support lever toward engine bracket and support the engine. 304036 UP DN UP DN 701034 UP DN 302013* w 403011 After tilting the engine, be sure to support it with the tilt-support lever.
63B-9-1A-3 2/28/02 5:13 PM Page 24 E EMG64110 PROCEDURE FOR TILTING DOWN Power trim and tilt model 1) 2) 3) 411035 Push the power trim and tilt switch “UP” until the engine is supported by the tilt rod. Release the tilt-support lever. Push the power trim and tilt switch “DN” (Down) to lower the engine to the desired position.
B-9-1A-4 3/7/02 3:45 PM Page 1 E EMK00010 Chapter 4 MAINTENANCE SPECIFICATIONS .....................................4-1 TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-3 Trailering outboard motor...................4-3 Storing outboard motor ......................4-4 PERIODIC MAINTENANCE......................4-9 Replacement parts ...............................4-9 Maintenance chart..............................4-10 Greasing ..............................................
63B-9-1A-4 3/7/02 3:45 PM Page 2 E EMK10011* SPECIFICATIONS Model Unit 40TRB Item DIMENSIONS 8Overall Length 8Overall Width 8Overall Height 8Transom height 8Weight* L L L mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.) 646 (25.4) 360 (14.2) 1,319 (51.9) 533 (21.0) 86 (190) 8Full throttle operating range 8Maximum output 8Idling speed r/min kW (HP) r/min 4,500–5,500 29.
63B-9-1A-4 3/7/02 3:45 PM Page 3 E 50TRB — 670 (26.4) 360 (14.2) 1,319 (51.9) 533 (21.0) 86 (190) 4,500–5,500 36.8 (50) at 5,000 r/min 750–850 2-stroke, L 3 698 (42.6) 67.0 × 66.0 (2.6 × 2.6) C.D.I system B8HS-10 0.9–1.0 (0.035–0.039) Remote control Electric start 245 323 52 12-6 Prime start system Forward-Neutral-Reverse 1.85 (24/13) Power trim and tilt G Regular-unleaded gasoline (P.O.N.
63B-9-1A-4 2/28/02 5:14 PM Page 4 E EMU01369* TRANSPORTING AND STORING OUTBOARD MOTOR w Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. TRAILERING OUTBOARD MOTOR The motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the motor in the tilt position using a motor support device such as a transom saver bar.
63B-9-1A-4 2/28/02 5:14 PM Page 5 E EMU01796 STORING OUTBOARD MOTOR When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. This is especially important for your oil injection-equipped outboard motor due to the lean oil ratios used at idle prior to shutting the engine off for the season. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage.
63B-9-1A-4 2/28/02 5:14 PM Page 6 E EMK22511 Flushing Cooling System and Fogging Engine Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging of the engine is mandatory to prevent expensive engine damage due to rust. Perform the flushing and fogging at the same time. q w 605024 8 Flushing in a water tank 1) Remove the engine top cowling and silencer cover.
63B-9-1A-4 2/28/02 5:14 PM Page 7 E 4) Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite Engine Fogging Oil” (Part No. LUBSTRRT-12-00) alternately into each carburetor. When properly done, the engine will smoke excessively and almost stall. 8 Flushing with the flushing attachment 1) Remove the top cowling and silencer cover. Remove the propeller. 2) Install a flushing attachment to the lower unit. (Flushing attachment available from your Yamaha dealer).
63B-9-1A-4 2/28/02 5:14 PM Page 8 E EMK26112 Lubrication 1) Remove the spark plugs, and spray a 10 second spray of “Yamaha StorRite Engine Fogging Oil” into each cylinder. Grease the spark plug threads and reinstall the spark plugs and torque to proper specification. (Refer to “CLEANING AND ADJUSTING SPARK PLUG”.) 2) Turn the engine over with the stop lanyard disconnected to work the fogging oil into the piston rings. 3) Fill the oil tanks. This prevents the formation of condensation.
63B-9-1A-4 2/28/02 5:14 PM Page 9 E EMK29010 Battery Care w Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL; Flush with water. INTERNAL; Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. EYES; Flush with water for 15 minutes and get prompt medical attention.
63B-9-1A-4 2/28/02 5:14 PM Page 10 E 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 qualified mechanic. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any marine engine repair establishment or individual.
63B-9-1A-4 2/28/02 5:14 PM Page 11 E EMK30114* MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. 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.
63B-9-1A-4 2/28/02 5:14 PM Page 12 E EMU00366 GREASING Yamaha marine grease (Water resistant grease) 4-11
63B-9-1A-4 2/28/02 5:14 PM Page 13 E EMU01202 CLEANING AND ADJUSTING SPARK PLUG w When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire. The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine.
63B-9-1A-4 2/28/02 5:14 PM Page 14 E When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque. Spark plug torque: Refer to “SPECIFICATIONS”, page 4-1. NOTE: If a torque-wrench is not available when you are fitting a spark plug, 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.
63B-9-1A-4 2/28/02 5:14 PM Page 15 E EMK38010 CHECKING FUEL SYSTEM w Gasoline (petrol) and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition. Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by Yamaha dealer or other qualified mechanic. Checking points 8 Fuel system parts leakage. 8 Fuel hose joint leakage. 8 Fuel hose cracks or other damage. 8 Fuel connector leakage.
63B-9-1A-4 2/28/02 5:14 PM Page 16 E EMK50011 CLEANING FUEL FILTER w Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly doing this procedure, consult your Yamaha dealer. 8 Do not perform this procedure on a hot 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.
63B-9-1A-4 2/28/02 5:14 PM Page 17 E 5) q w 6) r e 207013 1 2 3 4 Attach the filter assembly to the bracket with that the fuel hoses are attached to the filter assembly. Run the engine and check the filter and lines for leaks. Filter element O-ring Filter cup Filter housing EMK54110 ADJUSTING IDLING SPEED w 8 Do not touch or remove electrical parts when starting or during operation. 8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running.
63B-9-1A-4 2/28/02 5:14 PM Page 18 E 2) Adjust the throttle stop-screw to set the idling speed to specification (see “SPECIFICATIONS”) 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 is only possible if the engine is fully warmed-up. If not warmed up fully, the speed setting will tend to be too high.
63B-9-1A-4 2/28/02 5:14 PM Page 19 E EMU01329 REPLACING FUSE If the fuse has blown on an Electric start model, open the fuse holder and replace the fuse with a new one of proper amperage. w Be sure to use the specified fuse. An incorrect fuse or a piece of wire may allow excessive current flow. This could cause electrical system damage and a fire hazard. q w 205015* NOTE: If the new fuse blows again immediately, consult a Yamaha dealer.
63B-9-1A-4 2/28/02 5:14 PM Page 20 E EMU00992 CHECKING POWER TRIM AND TILT SYSTEM w 8 Never get under the lower unit while it is tilted, even when the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls. 8 Make sure no one is under the outboard before performing this test. 1) q Check the power trim and tilt unit for any sign of oil leaks.
63B-9-1A-4 2/28/02 5:14 PM Page 21 E EML08011* CHECKING PROPELLER w 210012 602051 You could be seriously injured if the engine accidentally starts while you are near the propeller. 8 Before inspecting, removing or installing the propeller, remove the spark plug caps from the spark plugs. Also, put the shift control in Neutral, put the main switch in the “OFF” position and remove the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one.
63B-9-1A-4 2/28/02 5:14 PM Page 22 E 6 4 3 1 5 2 602041 1 2 3 4 5 6 Thrust washer Propeller Spacer Washer Propeller nut Cotter pin Installation 1) Apply Yamaha Marine grease (waterresistant grease) to the propellershaft. 2) Slide the propeller over the propellershaft. cC Be sure to install the thrust washer before installing propeller, otherwise, lower case and propeller boss may be damaged. 3) Tighten the propeller nut to the specified torque.
63B-9-1A-4 2/28/02 5:14 PM Page 23 E EMU01460 CHANGING GEAR OIL w 8 Be sure the outboard is securely fastened to the transom or a stable stand. You could be severely injured if the outboard falls on you. 8 Never get under the lower unit while it is tilted, even when the tilt-support lever/knob is locked. Severe injury could occur if the outboard accidentally falls. 1) Tilt the outboard motor so that the oil drain plug is at the lowest point possible. 2) Place a suitable container under the gear-case.
63B-9-1A-4 2/28/02 5:14 PM Page 24 E 5) With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the oil drain plug hole. Gear oil grade/capacity: Refer to “SPECIFICATIONS,” page 4-1. 601015 6) 7) When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. Insert and tighten the oil drain plug.
63B-9-1A-4 2/28/02 5:14 PM Page 25 E To clean the fuel tank 1) Empty the fuel tank into an approved gasoline (petrol) container. 2) Pour a small amount of suitable solvent in the tank. Reinstall the cap and shake the tank. Drain the solvent completely. To clean the fuel filter 1) Remove the screws holding the fuel hose joint assembly . Pull the assembly out of the tank. 2) Clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allow the filter to dry.
63B-9-1A-4 2/28/02 5:14 PM Page 26 E EML26010 CHECKING BATTERY (for Electric start model) w Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: 8 Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury. 8 Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): 8 SKIN—Flush with water.
63B-9-1A-4 2/28/02 5:14 PM Page 27 E 1) Check the electrolyte level at least once a month. Fill to the manufacturer’s recommended level when necessary. Top up only with distilled water (or pure de-ionized water suitable to use in batteries). cC Ordinary tap-water contains minerals harmhul to a battery, and should not be used for topping-up. 2) 3) 4-26 Keep the battery always in a good state of charge. Installing a voltmeter will help you monitor your battery.
63B-9-1A-4 2/28/02 5:14 PM Page 28 E EMU01279 Connecting the Battery w Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder. cC q EL L E V EL ER V U P P ER LE LOW 8 Make sure the main switch (on applicable models) is “OFF” before working on the battery. 8 Reversal of the battery leads will damage the rectifier.
63B-9-1A-4 2/28/02 5:14 PM Page 29 E EML40010 CHECKING BOLTS AND NUTS 1) 2) Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torques. Check the tightening torques of other bolts and nuts. EML42011 MOTOR EXTERIOR Cleaning the Outboard Motor After use, wash the exterior of the outboard with fresh water. Flush the cooling system with fresh water.
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63B-9-1A-5 2/28/02 5:14 PM Page 1 E EMN00010 Chapter 5 TROUBLE RECOVERY 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 Engine fails to operate .........................5-8 Treatment of submerged motor.......
63B-9-1A-5 2/28/02 5:14 PM Page 2 E EMU01204¯ TROUBLESHOOTING A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.) If your outboard motor requires repair, bring it to a Yamaha dealer. Trouble Possible Cause 1. Battery capacity weak or low. A. Starter will not operate. 5.
63B-9-1A-5 2/28/02 5:14 PM Page 3 E Trouble Possible Cause 1. Spark plug(s) fouled or incorrect type. 2. Fuel system obstructed. 3. Fuel contaminated or stale. 4. Fuel filter clogged. 5. Failed ignition parts. 6. Warning system activated. 7. Spark plug gap incorrect. 8. Poor connections or damaged ignition wiring. C. Engine idles irregularly or stalls. 9. Specified engine oil not used. 10. Thermostat faulty or clogged. 11. Carburetor adjustments incorrect. 12. Fuel pump damaged. 13.
63B-9-1A-5 2/28/02 5:14 PM Page 4 E Trouble Possible Cause 1. Cooling system clogged. 2. Engine oil level low. 3. Heat range of spark plug incorrect. 4. Specified engine oil not used. D. Warning buzzer sounds or indicator lamp lights. 5. Engine oil contaminated or deteriorated. 6. Oil filter clogged. 7. Oil feed/injection pump malfunctions. 8. Load on boat improperly distributed. 9. Water pump/thermostat faulty. 1. Propeller damaged. 2. Propeller pitch or diameter incorrect. 3. Trim angle incorrect.
63B-9-1A-5 2/28/02 5:14 PM Page 5 E Trouble Possible Cause 13. Poor connections or damaged ignition wiring. 14. Failed ignition parts. 15. Specified engine oil not used. E. Engine power loss. 16. Thermostat faulty or clogged. 17. Air vent screw closed. 18. Fuel pump damaged. 19. Fuel joint connection incorrect. 20. Heat range of spark plug incorrect. 1. Propeller damaged. 2. Propeller shaft damaged. F. Engine vibrates excessively. 3. Weeds or other foreign matter tangled on propeller. 4.
63B-9-1A-5 2/28/02 6:25 PM Page 6 E EMN20010 TEMPORARY ACTION IN EMERGENCY EMU01492 IMPACT DAMAGE w The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate. 607011 If the outboard motor hits any object in the water, follow the procedure below. 1) Stop the engine immediately. 2) Inspect the control system and all components for damage. Also, inspect the boat for damage.
63B-9-1A-5 2/28/02 5:15 PM Page 7 E EMN30310 STARTER WILL NOT OPERATE If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be started with an emergency starter rope. w 8 Use this procedure only in an emergency and only to return to port for repairs. 8 When the emergency starter rope is used to start the engine, the start-ingear protection device does not operate. Make sure the transmission is in neutral.
63B-9-1A-5 2/28/02 5:15 PM Page 8 E Procedure 1) Remove the top cowling. 2) Remove the starter/flywheel cover by removing the bolts. NOTE: On a model equipped with the start-ingear protection device (cable), disconnect the cable from the starter. 208026 3) OFF ON START 701024 Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch.
63B-9-1A-5 2/28/02 5:15 PM Page 9 E EMN32411 ENGINE FAILS TO OPERATE Cold engine fails to start (for Prime start model) If a cold engine fails to start, use the following procedure. 1) Adjust the trim angle so that the drive shaft is at right angles to the water surface or is trimmed in. 2) Open the emergency starter valve located behind the silencer cover on the front side. 3) Squeeze the priming pump two or three times to feed fuel.
63B-9-1A-5 2/28/02 5:15 PM Page 10 E OFF ON 5) Set the MAIN SWITCH to “ON”. 6) Set the MAIN SWITCH to “START”. NOTE: When the starter mechanism malfunctions, refer to “STARTER WILL NOT OPERATE”. START cC 701022 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 with the main switch in the “START” position.
63B-9-1A-5 2/28/02 5:15 PM Page 11 E EMN50011 TREATMENT OF SUBMERGED MOTOR 107012 107013 If the outboard motor is submerged, immediately take it a Yamaha dealer. Otherwise, some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure bellow for taking care to minimize engine damage. 1) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.
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63B-9-1A-6 2/28/02 5:15 PM Page 1 E EMP00010 Chapter 6 INDEX INDEX........................................................
63B-9-1A-6 3/7/02 4:06 PM Page 2 E EMP10010 INDEX A Adjusting idling speed ..........................4-16 Adjusting trim angle..............................3-19 Air vent screw...........................................2-2 B Basic boating rules ..................................1-6 Battery care...............................................4-8 Battery requirement ..............................1-12 Bow down...............................................3-20 Bow up ...........................................
63B-9-1A-6 3/7/02 4:06 PM Page 3 E Mounting the outboard motor ...............3-2 N Neutral interlock trigger ..........................2-4 Neutral throttle lever ...............................2-4 O Oil level indicator............................2-11, 3-7 Oil level warning/oil filter clogging warning ...................................................2-15 Operation after a long period of storage ......................................................3-9 Operations of controls and other functions ..........
63B-9-1A-6 2/28/02 5:15 PM Page 4 EMU01599 IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha. Yamaha is ready to stand behind your purchase with strong warranty coverage.
63B-9-1A-6 2/28/02 5:15 PM Page 5 5. Your warranty applies specifically to repairs made in the country of purchase. If your U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian purchased Yamaha needs service while in the United States, Yamaha will assist the local dealer whenever possible. However, some products available in one country may not be sold or serviced in the other. 6.
63B-9-1A-6 2/28/02 5:15 PM Page 6 EMU00912* YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. is proud of its heritage and reputation for producing products with high standards of quality and workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Outboard Limited Warranty is your assurance of this commitment.
63B-9-1A-6 2/28/02 5:15 PM Page 7 SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs, shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes are not covered by warranty. Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yamaha outboard dealer are excluded from warranty coverage.
63B-9-1A-6 2/28/02 5:15 PM Page 8 CUSTOMER SERVICE If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you.
63B-9-1A-6 2/28/02 5:15 PM Page 9 EMU01178 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha. This model was manufactured as a U.S.A.
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63B-9-1A hyoshi 4/12/02 3:31 PM Page 2 (2,1)
63B-9-1A hyoshi 4/12/02 3:31 PM Page 1 (1,1) OWN Printed in Japan March 2002-0.
Warranty card 2/27/02 11:47 AM Page 1 OUTBOARD MOTOR WARRANTY REGISTRATION ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD Please complete and mail this card. This information is necessary to accurately register your unit for warranty. Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.
Warranty card 2/27/02 11:47 AM Page 2 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT
