U67720E0.
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM Read this owner’s manual carefully before operating your outboard motor.
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM Important manual information EMU25100 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.
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM Table of contents General information ...................... 1 Identification numbers record ...... 1 Outboard motor serial number ....... 1 EC label....................................... 1 Safety information ....................... 1 Important labels........................... 2 Warning labels................................ 2 Fueling instructions ..................... 3 Gasoline ......................................... 3 Engine oil.................
U67720E0.book Page 2 Friday, March 26, 2004 10:36 AM Table of contents Lubrication (except oil injection models)...... 29 Cleaning the outboard motor........ 29 Checking painted surface of motor ........................ 29 Periodic maintenance................ 29 Replacement parts ....................... Maintenance chart........................ Greasing....................................... Cleaning and adjusting spark plug ................................. Checking fuel system ...................
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM General information EMU25170 Identification numbers record EMU25182 Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket or the upper part of the swivel 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.
U67720E0.book Page 2 Friday, March 26, 2004 10:36 AM General information ● ● ● ● ● ● ● ● ● ● Do not modify the outboard. Modifications could make the motor unfit or unsafe to use. Never operate after drinking alcohol or taking drugs. About 50% of all boating fatalities involve intoxication. Have an approved personal flotation device (PFD) on board for every occupant. It is a good idea to wear a PFD whenever boating.
U67720E0.book Page 3 Friday, March 26, 2004 10:36 AM General information EMU25431 EMU30330 Label Gasoline EWM01300 WARNING ● ● This engine is equipped with a neutral starting device. The engine will not start unless the shift control is in neutral position. EMU25540 Fueling instructions EWM00010 WARNING GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! ● Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. ● Stop engine before refueling.
U67720E0.book Page 4 Friday, March 26, 2004 10:36 AM General information 1 x 1 2 3 ZMU04604 1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark) ZMU01713 1. Start-in-gear protection label 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.
U67720E0.book Page 5 Friday, March 26, 2004 10:36 AM Basic components EMU25795 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. 1. 2. 3. 4. Manual starter handle Tiller handle Choke knob Engine stop button/Engine stop lanyard switch 5. Tilt lock lever 6. Clamp screw 7. Trim rod 8. Propeller 9. Cooling water inlet 10.Anti-cavitation plate 11.Clamp bracket 12.Rope attachment 13.Gear shift lever 14.Top cowling 15.
U67720E0.book Page 6 Friday, March 26, 2004 10:36 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. Fuel joint 2. Fuel tank cap 3. Air vent screw EMU25830 Fuel joint This joint is used to connect the fuel line. EMU25850 Fuel tank cap This cap seals the fuel tank.
U67720E0.book Page 7 Friday, March 26, 2004 10:36 AM Basic components 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. 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. 1.
U67720E0.book Page 8 Friday, March 26, 2004 10:36 AM Basic components EMU26001 Engine stop button To open the ignition circuit and stop the engine, push this button. EMU26122 Steering friction adjuster EMU26011 Choke knob for pull type To supply the engine with the rich fuel mixture required to start, pull out this knob. EMU26070 Manual starter handle To start the engine, first gently pull the handle out until resistance is felt.
U67720E0.book Page 9 Friday, March 26, 2004 10:36 AM Basic components EMU30460 EMU26372 Tilt lock mechanism Top cowling lock lever(s) (turn type) The tilt lock mechanism is used to prevent the outboard motor from lifting out of the water when in reverse gear. To remove the engine top cowling, turn the lock lever(s) and lift off the cowling. When installing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by returning the lever(s) to the lock position. 1.
U67720E0.book Page 10 Friday, March 26, 2004 10:36 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.
U67720E0.book Page 11 Friday, March 26, 2004 10:36 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 between the bottom of the boat and a level 25 mm (1 in.) below it. 0–25mm (0–1in.
U67720E0.book Page 12 Friday, March 26, 2004 10:36 AM Operation 3. Secure the clamp bracket to the transom using the bolts provided with the outboard (if packed). For details, consult your Yamaha dealer. ECM00150 CAUTION: Be sure to mix gasoline and oil completely, otherwise the engine may be damaged. EWM00650 WARNING Avoid using bolts, nuts or washers other than those contained in the engine packaging.
U67720E0.book Page 13 Friday, March 26, 2004 10:36 AM Operation EMU27101 EMU27140 Preoperation checks EWM00080 WARNING If any item in the preoperation check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise an accident could occur. Engine ● ● ● Check the engine and engine mounting. Look for loose or damaged fasteners. Check the propeller for damage.
U67720E0.book Page 14 Friday, March 26, 2004 10:36 AM Operation ECM00810 CAUTION: ● ● ● ● Avoid using any oil other than the specified type. Use a thoroughly blended fuel-oil mixture. If the mixture is not thoroughly mixed, or if the mixing ratio is incorrect, the following problems could occur. Low oil ratio: Lack of oil could cause major engine trouble, such as piston seizure. High oil ratio: Too much oil could cause fouled spark plugs, smoky exhaust, and heavy carbon deposits.
U67720E0.book Page 15 Friday, March 26, 2004 10:36 AM Operation drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets. 1. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns. 3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp. NOTE: During engine operation place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank. 4.
U67720E0.book Page 16 Friday, March 26, 2004 10:36 AM Operation 2. Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the engine stop switch. EWM00120 WARNING ● ● ● Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating. Do not attach the lanyard to clothing that could tear loose.
U67720E0.book Page 17 Friday, March 26, 2004 10:36 AM Operation EMU27670 Warming up engine EMU27680 Choke start models 1. 2. 6. After the engine starts, slowly return the manual starter handle to its original position before releasing it. Slowly return the throttle grip to the fully closed position. 7. ZMU02030 NOTE: ● ● When the engine is cold, it needs to be warmed up. For further information, see page 17. If the engine does not start on the first try, repeat the procedure.
U67720E0.book Page 18 Friday, March 26, 2004 10:36 AM Operation EMU27740 Shifting EWM00180 WARNING Before shifting, make sure there are no swimmers or obstacles in the water near you. Remote control models Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward.
U67720E0.book Page 19 Friday, March 26, 2004 10:36 AM Operation ZMU02301 Remote control models 1. Check that the tilt lock lever is in the lock position. 2. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to reverse. 3. Disconnect the fuel line if you are using an external fuel tank. EMU27820 Stopping engine Before stopping the engine, first let it cool off for a few minutes at idle or low speed.
U67720E0.book Page 20 Friday, March 26, 2004 10:36 AM Operation EWM00740 WARNING Excessive trim for the operating conditions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle. 1. Trim rod 3. Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom.
U67720E0.book Page 21 Friday, March 26, 2004 10:36 AM Operation bow up, the boat may have a greater 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. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane. also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making operation difficult and dangerous.
U67720E0.book Page 22 Friday, March 26, 2004 10:36 AM Operation ECM00230 CAUTION: ● ● ● ● Before tilting the outboard motor, follow the procedure under “Stopping engine”in this chapter. Never tilt the outboard motor while the engine is running. Severe damage from overheating can result. Do not tilt up the engine by pushing the tiller handle because this could break the handle. Keep the power unit higher than the propeller at all times. Otherwise water could run into the cylinder and cause damage.
U67720E0.book Page 23 Friday, March 26, 2004 10:36 AM Operation EMU28031 Procedure for tilting down (manual tilt models) 1. 2. Slightly tilt the outboard motor up. If the tilt support bar equipped: Slowly tilt the outboard motor down while pulling the tilt support bar lever up. ● ● ● 3. If the tilt support knob equipped: pull out it, then slowly tilt the engine down.
U67720E0.book Page 24 Friday, March 26, 2004 10:36 AM Operation 2. 3. 4. To return the outboard motor to the normal running position, place the gear shift lever in neutral, then place the tilt lock lever in the lock position. 5. Slightly tilt the outboard motor up. Slowly tilt the outboard motor down while pulling the tilt support bar lever up. 6. Slowly lower the outboard motor to the normal position. Place the tilt lock lever in the release position. Slightly tilt the outboard motor up.
U67720E0.book Page 25 Friday, March 26, 2004 10:36 AM Operation Cruising in turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit if you use the outboard motor in turbid (muddy) water conditions.
U67720E0.book Page 26 Friday, March 26, 2004 10:36 AM Maintenance EMU28215 Specifications Drive unit: Gear positions: Forward-neutral-reverse Gear ratio: 2.08 (27/13) Trim and tilt system: Manual tilt Propeller mark: C Dimension: Overall length: 718 mm (28.3 in) Overall width: 328 mm (12.9 in) Overall height S: 1044 mm (41.1 in) Overall height L: 1184 mm (46.6 in) Transom height S: 442 mm (17.4 in) Transom height L: 582 mm (22.9 in) Weight (AL) S: 28.0 kg (62 lb) Weight (AL) L: 29.
U67720E0.book Page 27 Friday, March 26, 2004 10:36 AM Maintenance EWM00700 WARNING Never get under the lower unit while it is tilted, even if a motor support bar is used. Severe injury could occur if the outboard motor accidentally falls. ECM00660 CAUTION: Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall.
U67720E0.book Page 28 Friday, March 26, 2004 10:36 AM Maintenance 5. EMU28301 Procedure Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging/lubricating of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flushing and fogging at the same time. EMU28332 Flushing in a test tank ECM00300 CAUTION: Do not run the engine without supplying it with cooling water.
U67720E0.book Page 29 Friday, March 26, 2004 10:36 AM Maintenance EMU28460 NOTE: Checking painted surface of motor Store the fuel tank in a dry, well-ventilated place, not in direct sunlight. Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer. EMU28400 Lubrication (except oil injection models) 1. 2. 3.
U67720E0.book Page 30 Friday, March 26, 2004 10:36 AM Maintenance EMU28521 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer.
U67720E0.book Page 31 Friday, March 26, 2004 10:36 AM Maintenance EMU28940 Greasing Yamaha grease A (water resistant grease) Yamaha grease D (corrosion resistant grease; for propeller shaft) EMU28951 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. 31 The spark plug is an important engine component and is easy to inspect.
U67720E0.book Page 32 Friday, March 26, 2004 10:36 AM Maintenance should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type.
U67720E0.book Page 33 Friday, March 26, 2004 10:36 AM Maintenance EMU28980 Inspecting fuel filter 3. Remove the filter element, and wash it in solvent. Allow it to dry. Inspect the filter element and O-ring to make sure they are in good condition. Replace them if necessary. If any water is found in the fuel, the Yamaha portable fuel tank or other fuel tanks should be checked and cleaned. EWM00310 WARNING Gasoline is highly flammable, and its vapors are flammable and explosive.
U67720E0.book Page 34 Friday, March 26, 2004 10:36 AM Maintenance start position during warm-up. The boat could unexpectedly start to move, which could result in an accident. ECM00490 CAUTION: This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used. A diagnostic tachometer should be used for this procedure.
U67720E0.book Page 35 Friday, March 26, 2004 10:36 AM Maintenance ● ● ● ● Check each of the propeller blades for wear, erosion from cavitation or ventilation, or other damage. Check the propeller shaft for damage. Check the splines / shear pin for wear or damage. Check for fish line tangled around the propeller shaft. 1. Cotter pin 2. Propeller 3. Shear pin 2. 3. Remove the propeller nut and washer, if equipped. Remove the shear pin and the propeller.
U67720E0.book Page 36 Friday, March 26, 2004 10:36 AM Maintenance 6. Insert a new cotter pin in the holes, and then bend the cotter pin ends. ZMU02714 NOTE: There is a holder on the bottom cowling for spare shear and cotter pins. Be sure to replace any used pins. EMU29280 1. Gear oil drain screw 2. Oil level plug NOTE: If the magnetic gear oil drain screw equipped: remove all metal particles from the screw before installing it. 4. Changing gear oil EWM00800 WARNING ● ● 1. 2. 3.
U67720E0.book Page 37 Friday, March 26, 2004 10:36 AM Maintenance 2. 3. 6. 7. Pour a small amount of suitable solvent into the tank. Install the cap and shake the tank. Drain the solvent completely. Remove the screws holding the fuel joint assembly. Pull the assembly out of the tank. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. Insert and tighten the gear oil drain screw. ZMU02324 EMU29302 Cleaning fuel tank EWM00920 4.
U67720E0.book Page 38 Friday, March 26, 2004 10:36 AM Maintenance EMU29390 Checking top cowling Check the fitting of the top cowling by pushing it with both hands. If it is loose have it repaired by your Yamaha dealer. EMU29400 Coating the boat bottom A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth.
U67720E0.book Page 39 Friday, March 26, 2004 10:36 AM Trouble Recovery EMU29422 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.
U67720E0.book Page 40 Friday, March 26, 2004 10:36 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.
U67720E0.book Page 41 Friday, March 26, 2004 10:36 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.
U67720E0.book Page 42 Friday, March 26, 2004 10:36 AM Trouble Recovery 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. Engine vibrates excessively. Q. Is propeller damaged? A. Have propeller repaired or replaced. 1. 2. 3. Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer. 4. Q.
U67720E0.book Page 43 Friday, March 26, 2004 10:36 AM Trouble Recovery ● ● ● ● ● Do not attach the lanyard to clothing that could tear loose. Do not route the cord 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.
U67720E0.book Page 44 Friday, March 26, 2004 10:36 AM Trouble Recovery EMU29760 Treatment of submerged motor 4. 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.
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM YAMAHA MOTOR CO., LTD. Printed in Japan April 2004–0.
