F75 F90 OWNER’S MANUAL U.S.A.
U6D613E0.book Page 1 Thursday, March 2, 2006 11:28 AM ZMU01690 Read this owner’s manual carefully before operating your outboard motor.
U6D613E0.book Page 1 Thursday, March 2, 2006 11:28 AM Important manual information EMU31280 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.
U6D613E0.book Page 1 Thursday, March 2, 2006 11:28 AM Table of contents General information .......................... 1 Identification numbers record .......... 1 Outboard motor serial number ........... 1 Key number ........................................ 1 Emission control information ........... 1 North American models...................... 1 Star labels .......................................... 2 Safety information ........................... 3 Important labels...............................
U6D613E0.book Page 2 Thursday, March 2, 2006 11:28 AM Table of contents Starting engine ................................. 36 Warming up engine ....................... 38 Electric start models ......................... 38 Shifting .......................................... 39 Forward (tiller handle and remote control models) ............................. 39 Reverse (automatic reverse lock and power trim and tilt models)..... 40 Trolling ..........................................
U6D613E0.book Page 3 Thursday, March 2, 2006 11:28 AM Table of contents Consumer information.................... 75 Important warranty information for U.S.A. and Canada .................... 75 YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY ............... 77 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA .............
U6D613E0.book Page 1 Thursday, March 2, 2006 11:28 AM General information EMU25170 Identification numbers record EMU25183 Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen. 1.
U6D613E0.book Page 2 Thursday, March 2, 2006 11:28 AM General information 1. Star labels location EMU25262 Manufactured date label This label is attached to the clamp bracket or the swivel bracket. EMU25280 One Star—Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S.
U6D613E0.book Page 3 Thursday, March 2, 2006 11:28 AM General information ● ● ZMU01703 EMU25300 Three Stars—Ultra Low Emission The three-star label identifies engines that meet the Air Resources Board’s 2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low-Emission engines. ● ● ● ZMU01704 ● EMU25362 Safety information ● ● ● Before mounting or operating the outboard motor, read this entire manual.
U6D613E0.book Page 4 Thursday, March 2, 2006 11:28 AM General information Know the marine laws and regulations where you will be boating—and obey them. For basic boating rules, see “Rules of the road” on page 5. ● Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather. ● Tell someone where you are going: leave a Float Plan with a responsible person. Be sure to cancel the Float Plan when you return. ● Use common sense and good judgment when boating.
U6D613E0.book Page 5 Thursday, March 2, 2006 11:28 AM General information EMU25500 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.
U6D613E0.book Page 6 Thursday, March 2, 2006 11:28 AM General information area must yield to you (they are the Give-Way vessels). Both you and the meeting vessel must alter course to avoid each other. should maintain course and direction, provided the other vessel gives you the right-of-way as it should. Meeting If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of-way! Both of you should alter course to avoid an accident.
U6D613E0.book Page 7 Thursday, March 2, 2006 11:28 AM General information Fishing vessel right-of-way All vessels which are fishing with nets, lines or trawls are considered to be “fishing vessels” under the International Rules. Vessels with trolling lines are not 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.
U6D613E0.book Page 8 Thursday, March 2, 2006 11:28 AM General information ZMU01708 EMU25540 Fueling instructions ● EWM00010 WARNING 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. Stop engine before refueling. Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat.
U6D613E0.book Page 9 Thursday, March 2, 2006 11:28 AM General information ● ● ● ● ● ● Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Do not overfill the fuel tank. Tighten the filler cap securely after refueling. If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. If any gasoline spills onto your skin, immediately wash with soap and water.
U6D613E0.book Page 10 Thursday, March 2, 2006 11:28 AM General information ZMU01710 EMU25700 Battery requirement ECM01060 CAUTION: 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. damage the motor. Engine speed depends on the propeller size and boat load.
U6D613E0.book Page 11 Thursday, March 2, 2006 11:28 AM General information x 1 2 3 ZMU04607 1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark) NOTE: Select a propeller which will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat load.
U6D613E0.book Page 12 Thursday, March 2, 2006 11:28 AM Basic components EMU25799 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. 1. Top cowling 2. Top cowling lock lever(s) 3. Anti-cavitation plate 4. Trim tab (anode) 5. Propeller* 6. Cooling water inlet 7. Clamp bracket 8. Flushing device 9. Water separator 10.Power trim and tilt switch 11.Remote control box (side mount type)* 12.Digital speedometer* 13.
U6D613E0.book Page 13 Thursday, March 2, 2006 11:28 AM Basic components 1 2 3 4 5 6 ZMU05429 1. 2. 3. 4. 5. 6. Tachometer unit (Square type)* Tachometer unit (Round type)* Speedometer unit (Square type)* Speed & fuel meter unit (Square type)* Speed & fuel meter unit (Round type)* Fuel management meter (Square type)* EMU26180 Remote control The remote control lever actuates both the shifter and the throttle. The electrical switches are mounted on the remote control box. 1. 2. 3. 4. 5. 6. 7.
U6D613E0.book Page 14 Thursday, March 2, 2006 11:28 AM Basic components EMU26190 EMU26211 Remote control lever Neutral throttle lever Moving the lever forward from the neutral position engages forward gear. Pulling the lever back from neutral engages reverse. The engine will continue to run at idle until the lever is moved about 35° (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate.
U6D613E0.book Page 15 Thursday, March 2, 2006 11:28 AM Basic components EMU25922 Gear shift lever Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead. Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern. 1. Throttle indicator EMU25971 Throttle friction adjuster 1. Forward “ ” 2. Neutral “ ” 3. Reverse “ ” EMU25941 Throttle grip The throttle grip is on the tiller handle.
U6D613E0.book Page 16 Thursday, March 2, 2006 11:28 AM Basic components NOTE: The engine cannot be started with the lock plate removed. When constant speed is desired, tighten the adjuster to maintain the desired throttle setting. EMU25990 Engine stop lanyard switch The lock plate 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.
U6D613E0.book Page 17 Thursday, March 2, 2006 11:28 AM Basic components EMU26090 EMU26141 Main switch Power trim and tilt switch on remote control or tiller handle The main switch controls the ignition system; its operation is described below. ● “ ” (off) With the main switch in the “ ” (off) position, the electrical circuits are off, and the key can be removed. ● “ ” (on) With the main switch in the “ ” (on) position, the electrical circuits are on, and the key cannot be removed.
U6D613E0.book Page 18 Thursday, March 2, 2006 11:28 AM Basic components (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current position. ● EWM01030 WARNING ● Use the power trim and tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the engine off.
U6D613E0.book Page 19 Thursday, March 2, 2006 11:28 AM Basic components ECM00840 CAUTION: 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. 3 2 1 1. Tilt support lever B EMU26382 Top cowling lock lever (pull up type) A ZMU02525 1. Trim tab 2. Bolt 3. Cap To remove the engine top cowling, pull up the lock lever(s) and lift off the cowling.
U6D613E0.book Page 20 Thursday, March 2, 2006 11:28 AM Basic components EMU26460 Flushing device This device is used to clean the cooling water passages of the motor using a garden hose and tap water. NOTE: For details on usage, see page 52. ● If the warning system has activated, stop the engine and consult a Yamaha dealer immediately. EMU31410 Digital tachometer The tachometer shows the engine speed and has the following functions.
U6D613E0.book Page 21 Thursday, March 2, 2006 11:28 AM Basic components ECM00020 CAUTION: ● ● Do not continue to run the engine if the low oil pressure warning indicator is on and the engine oil level is lower. Serious engine damage will occur. The low oil pressure warning indicator does not indicate the engine oil level. Use the oil dipstick to check the remaining oil quantity. For further information, see page 34. 1 ZMU01737 1.
U6D613E0.book Page 22 Thursday, March 2, 2006 11:28 AM Basic components NOTE: The speedometer displays km/h, mph, or knots, according to operator preference. Select the desired unit of measurement by setting the selector switch on the back of the gauge. See the illustration for settings. ZMU01740 EMU26650 Hour meter (digital type) This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip.
U6D613E0.book Page 23 Thursday, March 2, 2006 11:28 AM Basic components EMU26690 Trip meter This gauge displays the distance the boat has traveled since the gauge was last reset. Press the “ ” (mode) button repeatedly until the indicator on the face of the gauge points to “ ” (trip). To reset the trip meter to zero, press the “ ” (set) and “ ” (mode) buttons at the same time. NOTE: The clock operates on battery power. Disconnecting the battery will stop the clock.
U6D613E0.book Page 24 Thursday, March 2, 2006 11:28 AM Basic components ZMU01745 EMU26720 Fuel warning indicator If the fuel level decreases to one segment, the fuel level warning segment will begin to blink. ECM00880 CAUTION: Do not continue to operate the engine with full throttle if a warning device has activated. Get back to the port within trolling engine speed. 1.
U6D613E0.book Page 25 Thursday, March 2, 2006 11:28 AM Basic components 1 4 5 2 3 2 1 6 ZMU05415 1. Set button 2. Mode button 1. 2. 3. 4. 5. 1 5 4 2 7 3 6 8 9 ZMU05418 Tachometer Trim meter Multifunction display Water detection warning indicator Engine trouble warning/maintenance indicator Cooling water pressure Oil pressure (4-stroke models) Cooling water/engine temperature Battery voltage NOTE: 8 1. 2. 3. 4. 5. 6. 7. 8. 6. 7. 8. 9.
U6D613E0.book Page 26 Thursday, March 2, 2006 11:28 AM Basic components Low oil pressure warning When the engine oil pressure drops too low, the low oil pressure warning indicator will start to blink, and the engine speed will automatically decrease to about 2000 r/min. Overheat warning If the engine temperature rises too high while cruising, the overheat warning indicator will start to blink. The engine speed will automatically decrease to about 2000 r/min.
U6D613E0.book Page 27 Thursday, March 2, 2006 11:28 AM Basic components Water separator warning This indicator will blink when water has accumulated in the water separator (fuel filter) while cruising. In such an event, stop the engine immediately and see page 69 of this manual to drain the water from the fuel filter. Get back to the port soon and consult a Yamaha dealer immediately. ZMU05425 ZMU05423 ZMU05426 ECM00920 CAUTION: In such an event, the engine will not operate properly.
U6D613E0.book Page 28 Thursday, March 2, 2006 11:28 AM Basic components 1 ZMU05427 2 ZMU05432 1. Set button 2. Mode button 1 3 2 ZMU05428 EMU31610 ZMU05433 Speed & fuel meter unit This unit shows the boat speed and has the functions of fuel meter, total fuel consumption display, fuel economy display, fuel flow display, and system voltage display. If optional sensors are connected to the unit, trip display, water surface temperature display, depth display, and clock will be available.
U6D613E0.book Page 29 Thursday, March 2, 2006 11:28 AM Basic components 1 2 1 3 ZMU05435 1. Speedometer 2. Fuel meter 3. Multifunction display NOTE: After the main switch is first turned on, all the displays come on as a test. After a few seconds, the gauge will change to normal operation. 2 ZMU05436 1. Set button 2. Mode button 1 3 2 NOTE: The speed & fuel meter unit shows various kinds of information according to the setting made with the “ ” (set) and “ ” (mode) buttons.
U6D613E0.book Page 30 Thursday, March 2, 2006 11:28 AM Basic components EMU31630 EMU26801 Warning system Fuel management meter This meter has functions of fuel flow meter, total consumption display, fuel economy display, and remaining fuel display. ECM00090 CAUTION: Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU26816 Overheat warning 2 1 ZMU05438 1. Set button 2.
U6D613E0.book Page 31 Thursday, March 2, 2006 11:28 AM Basic components ● The buzzer will sound. If the warning system has activated, stop the engine and check the cooling water inlet for clogging. ZMU02630 EMU26855 Low oil pressure warning If the oil pressure drops too low, the warning device will activate. Activation of warning device ● The engine speed will automatically decrease to about 2000 r/min. ● The low oil pressure warning indicator will light or blink.
U6D613E0.book Page 32 Thursday, March 2, 2006 11:28 AM Operation EMU26901 EWM00830 Installation ECM00110 CAUTION: Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat, or accessories such as transom ladders or 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.
U6D613E0.book Page 33 Thursday, March 2, 2006 11:28 AM Operation 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 in alignment with the bottom of the boat.
U6D613E0.book Page 34 Thursday, March 2, 2006 11:28 AM Operation ● ● ● Check fuel line connections to be sure they are tight (if equipped Yamaha fuel tank or boat tank). Be sure the fuel tank is positioned on a secure, flat surface, and that the fuel line is not twisted or flattened, or likely to contact sharp objects (if equipped Yamaha fuel tank or boat tank). Check the water in the fuel filter with the water separator warning device.
U6D613E0.book Page 35 Thursday, March 2, 2006 11:28 AM Operation 1. 2. 3. Remove the fuel tank cap. Carefully fill the fuel tank. Securely close the cap after filling the tank. Wipe up any spilled fuel. EMU27450 Operating engine EMU27482 Feeding fuel EWM00420 WARNING EMU27270 Ring Free Fuel Additive Gasoline is a precise blend of many different substances, each chosen to give certain characteristics.
U6D613E0.book Page 36 Thursday, March 2, 2006 11:28 AM Operation ● ● 1. Arrow Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard where it could become entangled, preventing it from functioning. 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 the boat to be thrown forward.
U6D613E0.book Page 37 Thursday, March 2, 2006 11:28 AM Operation NOTE: The start-in-gear protection device prevents the engine from starting except when in neutral. 5. Immediately after the engine starts, release the main switch and allow it to return to “ ” (on). ECM00191 CAUTION: ● ● Never turn the main switch to “ ” (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds.
U6D613E0.book Page 38 Thursday, March 2, 2006 11:28 AM Operation 5. Immediately after the engine starts, release the main switch to return it to “ ” (on). ECM00191 CAUTION: ● ● 3. Turn the main switch to “ ” (on). NOTE: Dual engine users: When the main switch is turned on, the buzzer operates for a few seconds then stops automatically. The buzzer also operates if one of the engines stalls. Never turn the main switch to “ ” (start) while the engine is running.
U6D613E0.book Page 39 Thursday, March 2, 2006 11:28 AM Operation ● sages. If water is not flowing out of the pilot hole at all times while the engine is running, overheating and serious damage could occur. Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and corrected. If the cooling passage is frozen, it may take awhile for water to start flowing out of the pilot hole.
U6D613E0.book Page 40 Thursday, March 2, 2006 11:28 AM Operation EMU27785 Reverse (automatic reverse lock and power trim and tilt models) EWM00190 WARNING When operating in reverse, go slowly. Do not open the throttle more than half. Otherwise the boat could become unstable, which could result in loss of control and an accident. Tiller handle models 1. Place the throttle grip in the fully closed position.
U6D613E0.book Page 41 Thursday, March 2, 2006 11:28 AM Operation ● If the trolling speed has been adjusted, the engine returns to the normal trolling speed when the engine is stopped and restarted or when the engine speed exceeds approximately 3000 r/min. EMU27820 Stopping engine 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. 2. EMU27844 Procedure 1.
U6D613E0.book Page 42 Thursday, March 2, 2006 11:28 AM Operation the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle. complete stop with the engine off. Do not adjust the trim angle with this switch while the boat is moving. Adjust the outboard motor trim angle using the power trim and tilt switch. 1. Power trim and tilt switch 1 ZMU04258 1.
U6D613E0.book Page 43 Thursday, March 2, 2006 11:28 AM Operation To lower the bow (trim-in), press the switch “ ” (down). Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions. EMU27911 Adjusting boat trim When the boat is on plane, a bow-up attitude results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees.
U6D613E0.book Page 44 Thursday, March 2, 2006 11:28 AM Operation EWM00220 WARNING Be sure all people are clear of the outboard motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket. EWM00250 WARNING Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, 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.
U6D613E0.book Page 45 Thursday, March 2, 2006 11:28 AM Operation ECM00250 UP CAUTION: Be sure to retract the trim rods completely during mooring. This protects the rods from marine growth and corrosion which could damage the power trim and tilt mechanism. EMU28055 ZMU04232 4. Push the tilt support knob into the clamp bracket or pull the tilt support lever toward you to support the engine. Procedure for tilting down (power trim and tilt models / power tilt models) 1. 2.
U6D613E0.book Page 46 Thursday, March 2, 2006 11:28 AM Operation ting up for and cruising in shallow water. Otherwise severe damage from overheating can result. EMU28185 Procedure for power trim and tilt / power tilt models 1. Place the remote control lever / gear shift lever in neutral. DN ZMU04255 EMU28060 Cruising in shallow water The outboard motor can be tilted up partially to allow operation in shallow water.
U6D613E0.book Page 47 Thursday, March 2, 2006 11:28 AM Operation 3. To return the outboard motor to the normal running position, press the power trim and tilt switch / power tilt switch and slowly tilt the outboard motor down. EMU28192 Cruising in 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 with salt deposits. NOTE: For cooling system flushing instructions, see page 49.
U6D613E0.book Page 48 Thursday, March 2, 2006 11:28 AM Maintenance EMU31480 Specifications NOTE: “(AL)” stated in the specification data below represents the numerical value for the aluminum propeller installed. Likewise, “(SUS)” represents the value for stainless steel propeller installed and “(PL)” for plastic propeller installed. EMU28218 Dimension: Overall length: 817 mm (32.2 in) Overall width: 479 mm (18.9 in) Overall height L: 1582 mm (62.3 in) Overall height X: 1710 mm (67.
U6D613E0.book Page 49 Thursday, March 2, 2006 11:28 AM Maintenance Gear oil quantity: 670.0 cm³ (22.65 US oz) (23.63 Imp.oz) Tightening torque for engine: Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) Propeller nut: 35.0 Nm (25.8 ft-lb) (3.57 kgf-m) Engine oil drain bolt: 28.0 Nm (20.7 ft-lb) (2.86 kgf-m) Engine oil filter: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m) EMU28222 Transporting and storing outboard motor EWM00690 WARNING ● ● ● Leaking fuel is a fire hazard.
U6D613E0.book Page 50 Thursday, March 2, 2006 11:28 AM Maintenance ECM00310 CAUTION: Avoid running the outboard motor at high speed while on the flushing attachment, otherwise overheating could occur. ZMU03659 EMU28303 Procedure EMU30001 Flushing with the flushing attachment 1. Wash the outboard motor body using fresh water. For further information, see page 53. 2. Fill the fuel tank with fresh fuel and add one ounce of “Yamaha Fuel Conditioner and Stabilizer” (Part No.
U6D613E0.book Page 51 Thursday, March 2, 2006 11:28 AM Maintenance 6. Run the engine at a fast idle for a few minutes in neutral position while supplying fresh water. 7. Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite Engine Fogging Oil” (Part No. LUB-STRRT-12-00) alternately into the intake silencer or the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke excessively and almost stall. 8.
U6D613E0.book Page 52 Thursday, March 2, 2006 11:28 AM Maintenance Batteries vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery manufacturer’s instructions. Procedure 1. Disconnect and remove the battery from the boat. Always disconnect the black negative cable first to prevent the risk of shorting. 2. Clean the battery casing and terminals. Fill each cell to the upper level with distilled water. 3.
U6D613E0.book Page 53 Thursday, March 2, 2006 11:28 AM Maintenance instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fitting after flushing the engine. NOTE: ● ● When flushing the engine with the boat in the water, tilting up the outboard motor until it is completely out of the water will achieve better results. For cooling system flushing instructions, see page 49.
U6D613E0.book Page 54 Thursday, March 2, 2006 11:28 AM Maintenance EMU30563 Maintenance chart NOTE: ● ● ● ● ● Refer to the sections in this chapter for explanations of each owner-specific action. The maintenance cycle on these charts assume usage of 200 hours per year and regular flushing of the cooling water passages. Maintenance frequency should be adjusted when operating the engine under adverse conditions such as extended trolling.
U6D613E0.
U6D613E0.book Page 56 Thursday, March 2, 2006 11:28 AM Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) ZMU04266 EMU28952 Cleaning and adjusting spark plug EWM00560 WARNING 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.
U6D613E0.book Page 57 Thursday, March 2, 2006 11:28 AM Maintenance EWM00910 WARNING Leaking fuel can result in fire or explosion. ● Check for fuel leakage regularly. ● If any fuel leakage is found, the fuel system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate. 1. Spark plug gap 2. Spark plug part number 3. Spark plug I.D. mark (NGK) Check the fuel lines for leaks, crack, or malfunction.
U6D613E0.book Page 58 Thursday, March 2, 2006 11:28 AM Maintenance EMU29073 Changing engine oil EWM00760 WARNING ● ● Avoid draining the engine oil immediately after stopping the engine. The oil is hot and should be handled with care to avoid burns. Be sure the outboard motor is securely fastened to the transom or a stable stand. ZMU04270 2. ECM00970 CAUTION: ● ● Do not overfill the oil, and be sure the outboard motor is upright (not tilted) when checking and changing the engine oil.
U6D613E0.book Page 59 Thursday, March 2, 2006 11:28 AM Maintenance tighten 1/4 to 1/2 turn more. Tighten the drain screw to the correct torque with a torque wrench as soon as possible. 4. Add the correct amount of oil through the filler hole. Install the filler cap. Recommended engine oil: 4-stroke outboard motor oil Engine oil quantity (excluding oil filter): 4.3 L (4.55 US qt) (3.78 Imp.qt) 1. Lower level mark 2. Oil dipstick 3. Upper level mark 7.
U6D613E0.book Page 60 Thursday, March 2, 2006 11:28 AM Maintenance 2. EMU29120 Exhaust leakage Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head, and body cylinder. 3. EMU29130 Water leakage Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head, and body cylinder. EMU29140 Engine oil leakage Check for oil leaks on the around the engine. 4. 5.
U6D613E0.book Page 61 Thursday, March 2, 2006 11:28 AM Maintenance NOTE: If the shear pin equipped: it is designed to break if the propeller hits a hard underwater obstacle to help protect the propeller and drive mechanism. The propeller will then spin freely on the shaft. If this happens, the shear pin must be replaced. EMU30660 ZMU04262 Removing the propeller EMU29194 Spline models 1. Straighten the cotter pin and pull it out using a pair of pliers. 2.
U6D613E0.book Page 62 Thursday, March 2, 2006 11:28 AM Maintenance ● Be sure to use a new cotter pin and bend the ends over securely. Otherwise the propeller could come off during operation and be lost. 1. Apply Yamaha marine grease or a corrosion resistant grease to the propeller shaft. Install the spacer (if equipped), thrust washer, and propeller on the propeller shaft. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque.
U6D613E0.book Page 63 Thursday, March 2, 2006 11:28 AM Maintenance ECM00720 NOTE: For disposal of used oil, consult your Yamaha dealer. 5. With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole. Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: 670.0 cm³ (22.65 US oz) (23.63 Imp.oz) CAUTION: Do not paint anodes, as this would render them ineffective.
U6D613E0.book Page 64 Thursday, March 2, 2006 11:28 AM Maintenance Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury. ● Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): ● SKIN - Flush with water. ● EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): ● Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil.
U6D613E0.book Page 65 Thursday, March 2, 2006 11:28 AM Maintenance ● ● Connect the red battery cable first when installing the battery and disconnect the black battery cable first when removing it. Otherwise, the electrical parts can be damaged. The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine. Connect the red battery cable to the POSITIVE (+) terminal first. Then connect the black battery cable to the NEGATIVE (-) terminal.
U6D613E0.book Page 66 Thursday, March 2, 2006 11:28 AM Trouble Recovery EMU29424 Troubleshooting A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. This section describes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer.
U6D613E0.book Page 67 Thursday, March 2, 2006 11:28 AM Trouble Recovery 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 clogged? A. Clean or replace filter. Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer. Q. Has warning system activated? A. Find and correct cause of warning. Q. Is spark plug gap incorrect? A. Inspect and adjust as specified. Q.
U6D613E0.book Page 68 Thursday, March 2, 2006 11:28 AM Trouble Recovery Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. A. Remove foreign matter and clean lower unit. Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer. Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is there excess water in fuel filter cup? A. Drain filter cup. Q. Is fuel filter clogged? A.
U6D613E0.book Page 69 Thursday, March 2, 2006 11:28 AM Trouble Recovery A. Connect correctly. If the outboard motor hits an object in the water, follow the procedure below. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type. Q. Is high pressure fuel pump drive belt broken? A. Have serviced by a Yamaha dealer. Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer. 1. 2. Engine vibrates excessively. Q.
U6D613E0.book Page 70 Thursday, March 2, 2006 11:28 AM Trouble Recovery 1 ZMU04249 1. Manual valve screw 2. Put the engine in the desired position, then tighten the manual valve screw by turning it clockwise. EMU31601 Water separator warning indicator blinks while cruising EWM01500 WARNING 1. 2. 3. 4. 5. 6. 7.
U6D613E0.book Page 71 Thursday, March 2, 2006 11:28 AM Trouble Recovery 1. Water separator warning indicator 1. 2. 3. Stop the engine. Remove the top cowling. Remove the plastic tie. 1. Water detection switch coupler 5. Unscrew the filter cup from the filter housing. NOTE: Be careful not to twist the water detection switch lead when unscrewing the filter cup. 1. Plastic tie 4. Disconnect the water detection switch coupler.
U6D613E0.book Page 72 Thursday, March 2, 2006 11:28 AM Trouble Recovery NOTE: NOTE: Properly dispose of the rag. Have a Yamaha dealer inspect the outboard motor after returning to port. 7. Firmly screw the filter cup onto the filter housing. NOTE: Be careful not to twist the water detection switch lead when screwing the filter cup onto the filter housing. 8. Connect the water detection switch coupler securely until a click is heard.
U6D613E0.book Page 73 Thursday, March 2, 2006 11:28 AM Trouble Recovery ● ● ● Make sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure someone. An unguarded, rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the flywheel or other moving parts when the engine is running.
U6D613E0.book Page 74 Thursday, March 2, 2006 11:28 AM Trouble Recovery ZMU04272 EMU29760 Treatment of submerged motor If the outboard motor is submerged, immediately take it to 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 below in order to minimize engine damage. EMU29790 Procedure 1. 2. 3. 4. 5. Thoroughly wash away mud, salt, seaweed, and so on, with fresh water.
U6D613E0.book Page 75 Thursday, March 2, 2006 11:28 AM Consumer information EMU29811 Important warranty information for U.S.A.
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U6D613E0.book Page 77 Thursday, March 2, 2006 11:28 AM Consumer information EMU29830 YAMAHA MOTOR CORPORATION, U.S.A.
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YAMAHA MOTOR CORPORATION, USA Printed in Japan March 2006–3.
MONTH MOIS PHONE NUMBER ( ) NUMÉRO DE TÉLÉPHONE ADDRESS ADRESSE OWNER’S NAME NOM DU PROPRIÉTAIRE DATE SOLD DATE DE LIVRAISON CITY VILLE YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON DAY JOUR FIRST PRÉNOM STATE/PROVINCE PROVINCE STREET RUE YEAR ANNÉE PLEASURE LOISIR COMMERCIAL COMMERCIAL ZIP CODE POSTAL LAST NOM DE FAMILLE USAGE (Check One) UTILISATION (En cocher un.) DEALER NAME NOM DU CONCESSIONNAIRE YAMAHA DEALER NUMBER NO.
Warranty card 2/27/02 11:47 AM Page 2 ATTN: WARRANTY DEPARTMENT PLACE POSTAGE HERE
