68V-9-17 Hyoshi 4/21/05 5:33 PM Page 1 F115 LF115 OWNER’S MANUAL U.S.A.
68V-9-17 Hyoshi 4/21/05 5:33 PM Page 2 EMU25060 ZMU01690 Read this owner’s manual carefully before operating your outboard motor.
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.
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............................... 4 Warning labels ..................................
Table of contents Operating engine........................... 34 Feeding fuel .................................... 34 Starting engine ................................ 35 Warming up engine ....................... 38 Manual start and electric start models .......................................... 38 Shifting .......................................... 38 Forward (tiller handle and remote control models) ............................. 38 Reverse (automatic reverse lock and power trim and tilt models).....
Table of contents INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ......................
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.
General information particular label. ZMU05159 ZMU04776 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. EPA’s 2006 standards for marine engines. 1 ZMU04277 1.
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 ● ● ● 3 Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation.
General information the switch, stopping the engine. 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.
General information EMU25413 Label (counter rotation models) EWM01281 WARNING Use only a counterclockwise rotation propeller with this engine. Counterclockwise propellers are marked with a letter “L” after the size indication. The wrong type of propeller could cause the boat to go in an unexpected direction, which could lead to an accident.
General information sel head-on) Crossing: (you are traveling across the other vessel’s path) Overtaking: (you are passing or being passed by another vessel) In the following illustration, your boat is in the center. You should give the right-of-way to any vessels shown in white area (you are the Give-Way vessel). Any vessels in the shaded area must yield to you (they are the GiveWay vessels). Both you and the meeting vessel must alter course to avoid each other.
General information bend that may obstruct the view of other water vessels, the operator should sound a prolonged blast on the whistle (4 to 6 seconds). If another vessel is around the bend, it too should sound the whistle. Even if no reply is heard, however, the vessel should still proceed around the bend with caution. If you navigate such waters with your boat, you will need to carry a portable air horn, available from local marine supply stores.
General information ZMU01708 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. Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. Take care not to spill gasoline.
General information ● ● ● ● ● 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. Change clothing if gasoline spills on it. Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
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. For electric start models, choose a battery which meets the following specifications. ler, as an incorrect choice could adversely affect performance and could also seriously damage the motor.
General information rise above the maximum recommended range, reduce the throttle setting to maintain the engine in the proper operating range. For instructions on propeller removal and installation, see page 63. EMU25770 Start-in-gear protection Yamaha outboard motors or Yamaha-approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is in neutral. Always select neutral before starting the engine.
Basic components EMU25796 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. F115, LF115 1 9 2 2 10 11 12 14 15 16 17 13 3 8 4 7 5 6 18 ZMU04773 1. Top cowling 2. Top cowling lock lever(s) 3. Drain screw 4. Anti-cavitation plate 5. Trim tab (anode) 6. Propeller* 7. Cooling water inlet 8. Anode 9. Flushing device 10. Power trim and tilt switch 11. Remote control box (side mount type)* 12.
Basic components 1. Power trim and tilt switch 2. Remote control lever 3. Neutral interlock trigger 4. Neutral throttle lever 5. Main switch / choke switch 6. Engine stop lanyard switch 7. Throttle friction adjuster 1. Neutral “ ” 2. Forward “ ” 3. Reverse “ ” 4. Shift 5. Fully closed 6. Throttle 7. Fully open 1 2 4 F 2 6 4 5 N 1 R 3 4 6 5 2 7 3 7 ZMU04569 1. Remote control lever 2. Power trim and tilt switch 3. Free accelerator 4.
Basic components erator button and move the remote control lever. 2 3 1 1. Neutral interlock trigger EMU26211 Neutral throttle lever To open the throttle without shifting into either forward or reverse, put the remote control lever in the neutral position and lift the neutral throttle lever. ZMU04575 1. Fully open 2. Fully closed 3. Free accelerator NOTE: ● NOTE: The neutral throttle lever will operate only when the remote control lever is in neutral.
Basic components EMU25922 EMU25961 Gear shift lever Throttle indicator 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. The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation. 1.
Basic components difficult to move throttle lever or grip, which could result in an accident. 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. EWM00120 WARNING ● ● ● ZMU04646 Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating.
Basic components EMU26090 OFF ON START OFF ON START 2 1 ZMU04564 1. Lanyard 2. Lock plate Main switch 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.
Basic components EMU26141 EMU26151 Power trim and tilt switch on remote control or tiller handle Power trim and tilt switch on bottom engine cowling The power trim and tilt system adjusts the outboard motor angle in relation to the transom. Pressing the switch “ ” (up) trims the outboard motor up, then tilts it up. Pressing the switch “ ” (down) tilts the outboard motor down and trims it down. When the switch is released, the outboard motor will stop in its current position.
Basic components UP 1 ● the remote control grip controls both outboard motors at the same time. For instructions on using the power trim and tilt switches, see pages 41 and 43. EMU26241 DN Trim tab with anode ZMU04223 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. EWM00840 1. Power trim and tilt switch WARNING NOTE: For instructions on using the power trim and tilt switch, see page 43.
Basic components 2. Bolt 3. Cap 1 ZMU04225 A 1. Top cowling lock lever(s) B ZMU01863 EMU26340 Tilt support lever for power trim and tilt or hydro tilt model To keep the outboard motor in the tilted up position, lock the tilt support lever to the clamp bracket. 1 1 ZMU04226 1. Top cowling lock lever(s) EMU26460 Flushing device ZMU03979 1. Tilt support lever This device is used to clean the cooling water passages of the motor using a garden hose and tap water.
Basic components 1 1 2 ZMU04578 ZMU04256 1. Flushing device 1. Tachometer 2. Warning indicator(s) EMU26300 Warning indicator If the engine develops a condition which is cause for warning, the indicator lights up. For details on how to read the warning indicator, see page 28. EMU26491 Digital tachometer The tachometer shows the engine speed and has the following functions.
Basic components NOTE: The water separator and engine trouble warning indicators only operate when the engine is equipped with the appropriate functions. EMU26501 ● ous 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 33. Low oil pressure warning indicator If oil pressure drops too low, this indicator will flash. For further information, see page 30.
Basic components EMU26581 Overheat warning indicator (digital type) If the engine temperature rises too high, the warning indicator will start to blink. For further information on reading the indicator, see page 28. NOTE: After the main switch is first turned on, all segments of the display come on as a test. After a few seconds, the gauge will change to normal operation. Watch the gauge when turning on the main switch to make sure all segments come on.
Basic components engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off. ZMU04581 NOTE: Memorize the trim angles that work best for your boat under different conditions. Adjust the trim angle to the desired setting with the power trim and tilt switch. ZMU01741 ● ● EMU26620 Trim meter (digital type) This meter shows the trim angle of your outboard motor.
Basic components NOTE: The clock operates on battery power. Disconnecting the battery will stop the clock. Reset the clock after connecting the battery. EMU26710 Fuel gauge The fuel level is indicated by eight segments. When all segments are showing, the fuel tank is full. ECM00860 NOTE: ● ● The trip distance is shown in kilometers or miles depending upon the unit of measurement selected for the speedometer. The trip distance is kept in memory by battery power.
Basic components 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. EMU26740 Fuel management meter The fuel management meter shows the state of the fuel consumption while the engine is running. 1 3 2 ZMU01748 1. Fuel level warning segment 1. Fuel flow meter 2. Fuel consumption meter / Fuel economy meter / Twin engine speed synchronizer 3.
Basic components ● The fuel consumption meter and fuel economy meter will indicate the same unit of measurement. EMU26760 Fuel consumption meter ZMU01749 Use the “ ” (set) button to rotate the fuel flow display in the following order: ● Press the “ ” (set) button once to display the fuel flow of the starboard engine. An “ ” (for starboard) will also be displayed. ● Press the “ ” (set) button a second time to display the fuel flow of the port engine. A “ ” (for port) will also be displayed.
Basic components NOTE: If twin engines are installed on your boat, the gauge will only display the total fuel economy of both engines. until the indicator on the face of the gauge points to “ ” (synchronizer). NOTE: ● ● ● Fuel consumption varies greatly with boat design, weight, propeller used, engine trim angle, sea conditions (including wind), and throttle position.
Basic components not be located and corrected. EMU30340 Overheat warning (twin engines) This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate. Activation of warning device ● Engine speed will automatically decrease to 2000–3500 r/min. ZMU03025 ON OFF START ON OFF START ZMU04746 ZMU04584 ● If equipped with an overheat warning indicator, it will light.
Basic components on the engine not affected by overheating, turn off the main switch of the engine overheating. EMU30351 Low oil pressure warning If the oil pressure drops too low, the warning device will activate. Activation of warning device ● Engine speed will automatically decrease to 2000–3500 r/min. ZMU02360 ON OFF The low oil pressure warning indicator will light. ON OFF START ZMU04584 ZMU04587 ● START If the warning system has activated, stop the engine as soon as it is safe to do so.
Operation EMU26901 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. NOTE: During water testing check the buoyancy of the boat, at rest, with its maximum load.
Operation ● board motor is affected by the boat/motor combination and the desired use. Test runs at different heights can help determine the optimum mounting height. Consult your Yamaha dealer or boat manufacturer for further information on determining the proper mounting height. For instructions on setting the trim angle of the outboard motor, see page 41. EMU30172 Breaking in engine 1.
Operation not working properly, have it inspected and repaired before operating the outboard motor. Otherwise an accident could occur. ECM00120 CAUTION: Do not start the engine out of water. Overheating and serious engine damage can occur. EMU27111 Fuel ● ● ● ● Check to be sure you have plenty of fuel for your trip. Make sure there are no fuel leaks or gasoline fumes. Check fuel line connections to be sure they are tight (if equipped Yamaha fuel tank or boat tank).
Operation EMU30021 EMU27450 Filling fuel EWM00060 WARNING Gasoline and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition. 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.
Operation ● 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. EMU27490 Starting engine EMU27592 Electric start / prime start models 1. Place the gear shift lever in neutral. 3. Place the throttle grip in the “ ” (start) position.
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.
Operation gine 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. ON OFF ON START OFF ON START START ZMU04590 5. Immediately after the engine starts, release the main switch to return it to “ ” (on). ECM00191 ZMU04589 3. Turn the main switch to “ ” (on).
Operation EMU27670 Warming up engine EMU27710 Manual start and electric start models 1. 2. 3. After starting the engine, allow it to idle for 3 minutes to warm up. Failure to do so will shorten engine life. Be sure the low oil pressure warning indicator goes off after starting the engine. Check for a steady flow of water from the cooling water pilot hole.
Operation firmly from neutral to forward. EMU27784 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. Remote control models 1. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward. Tiller control models 1.
Operation OFF ON OFF ON ZMU04600 N R ZMU04598 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. EMU27844 Procedure 1. Push and hold the engine stop button or turn the main switch to “ ” (off). 2. 3. 4. After stopping the engine, disconnect the fuel line if there is a fuel joint on the outboard motor.
Operation switch to “ ” (off). EMU27861 Trimming outboard motor The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help improve performance and fuel economy while reducing strain on the engine. 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.
Operation Adjust the outboard motor trim angle using the power trim and tilt switch. 1. Power trim and tilt switch To raise the bow (trim-out), press the switch “ ” (up). 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. 1. Power trim and tilt switch 1 DN UP NOTE: ZMU04601 1.
Operation Bow Up Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces performance further, and the boat may “porpoise” (hop in the water), which could throw the operator and passengers overboard.
Operation ● on page 40. 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 (if equipped) because this could break the handle. 2. 3. Disconnect the fuel line from the outboard motor or close the fuel cock. Press the power trim and tilt switch / power tilt switch “ ” (up) until the outboard motor has tilted up completely.
Operation from marine growth and corrosion which could damage the power trim and tilt mechanism. 4. Push the tilt support knob into the clamp bracket or pull the tilt support lever toward you to support the engine. ZMU03452 EMU28053 Procedure for tilting down ZMU03449 Power trim and tilt models / power tilt models 1. Push the power tilt / power trim and tilt switch “ ” (up) until the outboard motor is supported by the tilt rod and the tilt support lever / tilt support knob becomes free. 2.
Operation EMU28060 Cruising in shallow water DN The outboard motor can be tilted up partially to allow operation in shallow water. UP DN EMU28090 Power trim and tilt models / power tilt models The outboard motor can be tilted up partially to allow operation in shallow water. ZMU01936 EWM00660 WARNING ● DN ● Place the gear shift in neutral before setting up for shallow water cruising. Return the outboard motor to its normal position as soon as the boat is back in deeper water.
Operation N UP ZMU04588 ZMU04602 UP ZMU04235 2. Slightly tilt the outboard motor up to the desired position using the power trim / tilt switch. UP UP DN 3. ZMU01935 To return the outboard motor to the normal running position, press the power trim / tilt switch and slowly tilt the outboard motor down.
Operation NOTE: For cooling system flushing instructions, see page 50. Cruising in turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (not available for some models) if you use the outboard motor in turbid (muddy) water conditions.
Maintenance EMU28217 Specifications Dimension: Overall length: 825 mm (32.5 in) Overall width: 498 mm (19.6 in) Overall height L: F115TR 1609 mm (63.3 in) Overall height X: 1736 mm (68.3 in) Transom height L: F115TR 516 mm (20.3 in) Transom height X: 643 mm (25.3 in) Weight (without propeller) L: F115TR 183.0 kg (403 lb) Weight (without propeller) X: 188.0 kg (414 lb) Performance: Full throttle operating range: 5000–6000 r/min Maximum output: 84.
Maintenance 4.3 L (4.55 US qt) (3.78 Imp.qt) Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: F115TR 760.0 cm3 (25.70 US oz) (26.81 Imp.oz) LF115TR 715.0 cm3 (24.17 US oz) (25.22 Imp.oz) Tightening torque for engine: Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) Propeller nut: 55.0 Nm (40.6 ft-lb) (5.61 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 motor accidentally falls.
Maintenance cooling water inlet. lowing procedures. ECM01080 CAUTION: ● ● ● To prevent problems which can be caused by oil entering the cylinder from the sump, keep the outboard motor in the attitude shown when transporting and storing it. If storing or transporting the outboard motor on its side (not upright), put it on a cushion after draining the engine oil.
Maintenance “Yamaha Silicone Protectant” (Part No. LUB-SILCNE-13-00). parts while the engine is running. 6. 7. 8. 9. Run the engine at a fast idle for 10–15 minutes in neutral position while supplying fresh water. Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite Engine Fogging Oil” (Part No. LUB-STRRT-1200) alternately into each carburetor/ each intake manifold. When properly done, the engine will smoke excessively and almost stall.
Maintenance equipment, lighted cigarettes, and so on.) ● DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN. 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.
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 50. EMU28450 Cleaning the outboard motor After use, wash the exterior of the outboard motor with fresh water.
Maintenance EMU30562 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 according to usage conditions. Disassembly or repairs may be necessary depending on the outcome of maintenance checks.
Maintenance Initial Item Actions Shift link / shift cable Inspection / adjustment Thermostat Inspection / replacement Throttle link / throttle cable / throttle pick-up timing Inspection / adjustment Water pump Inspection / replacement Engine oil Inspection / change Oil filter (cartridge) Change Spark plug(s) Timing belt 10 hours (1 month) Every 50 hours (3 months) 100 hours (6 months) 200 hours (1 year) Cleaning / adjustment / replacement Inspection / replacement EMU28874 Maintenance c
Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) F115, LF115 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. The condition of the spark plug can indicate something about the condition of the engine.
Maintenance sources of ignition. 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 I.D. mark (NGK) Spark plug gap: 1.0–1.1 mm (0.039–0.043 in) Check the fuel lines for leaks, crack, or malfunction.
Maintenance 2. EMU28980 Inspecting fuel filter EWM00310 3. WARNING Gasoline is highly flammable, and its vapors are flammable and explosive. ● If you have any question about properly doing this procedure, consult your Yamaha dealer. ● Do not perform this procedure on a hot or running engine. Allow the engine to cool. ● There will be fuel in the fuel filter. Keep away from sparks, cigarettes, flames or other sources of ignition. ● This procedure will allow some fuel to spill. Catch fuel in a rag.
Maintenance parts while the engine is running. 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. Results may vary depending on whether testing is conducted with the flushing attachment, in a test tank, or with the outboard motor in the water. 1. Start the engine and allow it to warm up fully in neutral until it is running smoothly.
Maintenance 1 1 ZMU04271 ZMU04241 1. Drain screw 3. Put a new gasket on the oil drain screw. Apply a light coat of oil to the gasket and install the drain screw. Drain screw tightening torque: 28.0 Nm (20.7 ft-lb) (2.86 kgf-m) NOTE: If a torque wrench is not available when you are installing the drain screw, finger tighten the screw just until the gasket comes into contact with the surface of the drain hole. Then tighten 1/4 to 1/2 turn more.
Maintenance 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. NOTE: ZMU02058 7. Dispose of used oil according to local regulations. NOTE: ● ● If any leaks are found, consult your Yamaha dealer. EMU29153 Checking power trim and tilt system EWM00430 For more information on the disposal of used oil, consult your Yamaha dealer.
Maintenance NOTE: 2. Trim rods 3. Tilt support lever 4. Consult your Yamaha dealer if any operation is abnormal. Use the tilt support lever to lock the motor in the up position. Operate the tilt down switch briefly so the motor is supported by the tilt support lever. 1 ZMU02634 1. Tilt support lever 5. 6. Check that the tilt rod and trim rods are free of corrosion or other flaws. Activate the tilt-down switch until the trim rods have retracted completely into the cylinders.
Maintenance EMU30660 Removing the propeller EMU29194 Spline models 1. Straighten the cotter pin and pull it out using a pair of pliers. 2. Remove the propeller nut, washer, and spacer (if equipped). ZMU01897 Checkpoints 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 nut 3.
Maintenance from that expected. ECM00340 EMU29281 Changing gear oil EWM00800 CAUTION: ● ● Be sure to install the thrust washer before installing the propeller, otherwise the lower case and propeller boss could be damaged. 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. 2. 3. 4. Apply Yamaha marine grease or a corrosion resistant grease to the propeller shaft.
Maintenance to drain completely. EMU29312 Inspecting and replacing anode(s) ECM00710 CAUTION: Inspect the used oil after it has been drained. If the oil is milky, water is getting into the gear case which can cause gear damage. Consult a Yamaha dealer for repair of the lower unit seals. Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes.
Maintenance EMU29320 Checking battery (for electric start models) ● EWM00330 WARNING Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: ● 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.
Maintenance tion in the boat. Install a fully charged battery in the holder. ECM01121 CAUTION: ● ● ● ● Make sure the main switch (on applicable models) is “ ” (off) before working on the battery. Reversal of the battery cables will damage the electrical parts. 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.
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. If the engine trouble warning indicator is flashing, consult your Yamaha dealer. Starter will not operate. Q.
Trouble Recovery Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is fuel filter 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. Is ignition wiring damaged or poorly connected? A.
Trouble Recovery A. Have serviced by a Yamaha dealer. Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. Q. Are weeds or other foreign matter tangled on gear housing? 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.
Trouble Recovery Q. Is fuel joint connection incorrect? A. Connect correctly. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type. damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate. If the outboard motor hits an object in the water, follow the procedure below. Q. Is high pressure fuel pump drive belt broken? A. Have serviced by a Yamaha dealer. Q.
Trouble Recovery 3 4 2 EMU29480 Replacing fuse 2 1 If the fuse has blown on an electric start model, remove the electrical cover, open the fuse holder, and replace the fuse with a new one of the proper amperage. 5 EWM00630 WARNING Be sure to use the specified fuse. An incorrect fuse or a piece of wire could allow excessive current flow. This could cause electric system damage and a fire hazard. NOTE: Consult your Yamaha dealer if the new fuse immediately blows again. ZMU04279 1.
Trouble Recovery the power trim and tilt / the power tilt because of a discharged battery or a failure with the power trim and tilt unit / the power tilt unit, the engine can be tilted manually. 1. Loosen the manual valve screw by turning it counterclockwise until it stops. ● ● ● 1 ZMU03464 ● 1. Manual valve screw 2. Put the engine in the desired position, then tighten the manual valve screw by turning it clockwise.
Trouble Recovery ZMU04250 4. Prepare the engine for starting. For further information, see page 35. Be sure the engine is in neutral and that the engine stop switch lanyard lock plate is attached to the engine stop switch. The main switch must be “ ” (on). 5. 6. 7. 8. 9. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope around the flywheel clockwise. Pull the rope slowly until resistance is felt. Remove the rope from the flywheel temporarily.
Trouble Recovery dure 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. Remove the spark plugs and face the spark plug holes downward to allow any water, mud, or contaminants to drain. Drain the fuel from the vapor separator, fuel filter, and fuel line. Feed fogging oil or engine oil through the intake manifold and spark plug holes while cranking with the emergency starter rope.
Consumer information EMU29811 Important warranty information for U.S.A.
Consumer information 78
Consumer information EMU29830 YAMAHA MOTOR CORPORATION, U.S.A.
Consumer information 80
Consumer information EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA 81
68V-9-17 Hyoshi 4/21/05 5:33 PM Printed in Japan May 2005–2.
Warranty card-04 2/17/03 2:41 PM 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-04 2/17/03 2:41 PM Page 2 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT
