67C-9-15 Hyoushi 3/31/04 9:06 PM Page 1 F30D F40D OWNER’S MANUAL Printed in Japan April 2004–0.1 × 1 ! Printed on recycled paper U.S.A.
67C-9-15 Hyoushi 3/31/04 9:06 PM Page 2 EMU25060 ZMU01690 Read this owner’s manual carefully before operating your outboard motor.
✩✪✰ ✬ ✤ ✤ 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.
✩✪✰ ✬ ✤ ✤ 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 tilt models) .................................... 34 Stopping engine ............................ 35 Procedure ....................................... 35 Trimming outboard motor.............. 36 Adjusting trim angle ........................ 36 Adjusting trim angle for hydro tilt models .......................................... 37 Adjusting boat trim .......................... 38 Tilting up and down .......................
✩✪✰ ✬ ✤ ✤ General information EMU25170 Identification numbers record reference in case you need a new key. 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. 1 ZMU01699 ZMU04977 EMU25261 Manufactured date label This label is attached to the clamp bracket or the swivel bracket. 1. Star labels location 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.
✩✪✰ ✬ ✤ ✦ 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 EMU25361 Safety information ● ● ● 3 Before mounting or operating the outboard motor, read this entire manual.
✩✪✰ ✬ ✤ ✧ General information 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. Know your abilities, and be sure you understand how your boat handles under the different boating conditions you may encounter.
✩✪✰ ✬ ✤ General information and follow them whenever you encounter another vessel on the water. Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the Road. The rules presented here in your Owner’s Manual are condensed, and have been provided for your convenience only. Consult your local U.S.
✩✪✰ ✬ ✤ ✩ General information “The general prudential rule” This rule is called Rule 2 in the International Rules and says, “In obeying and construing these rules due regard shall be had to all dangers of navigation and collision, and to any special circumstances, which may render a departure from the above rules necessary in order to avoid immediate danger.” In other words, follow the standard rules except when a collision will occur unless both vessels try to avoid each other.
✩✪✰ ✬ ✤ ✪ General information Overtaking If you are passing another vessel, you are the “Give-Way” vessel. This means that the other vessel is expected to maintain its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you.
✩✪✰ ✬ ✤ ✫ General information This system uses buoys and signs with distinctive shapes and colors to show regulatory or advisory information. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geographic location. Always consult local boating authorities before driving your boat in unfamiliar waters.
✩✪✰ ✬ ✤ ✬ General information ZMU01708 EMU25540 Fueling instructions EWM00010 WARNING GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! ● Do not smoke when refueling, and keep 9 ● ● ● 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 electric system could perform poorly or be overloaded, causing electric system damage. For electric start models, choose a battery which meets the following specifications. EMU25711 Battery specifications Minimum cold cranking amps (CCA/ SAE): F30TR 380.0 A F40TR 380.0 A Minimum marine cranking amps (MCA/ ABYC): F30TR 502.0 A F40TR 502.
✩✪✰ ✬ ✤ ✤✥ General information to reach the middle or upper half of the operating range at full throttle with the maximum boat load. If operating conditions such as light boat loads then allow the engine r/min to 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 58.
✩✪✰ ✬ ✤ ✤✦ Basic components EMU25795 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. F30TR, F40MH, F40TR 10 11 1 9 2 12 14 13 8 13 15 3 16 7 17 4 5 6 ZMU05026 1. Top cowling 2. Top cowling lock lever 3. Drain screw 4. Anti-cavitation plate 5. Trim tab (anode) 6. Propeller* 7. Cooling water inlet 8. Clamp bracket 9. Power trim and tilt switch* 10. Manual starter handle* 11. Warning indicator(s)* 12.
✩✪✰ ✬ ✤ ✤✧ Basic components licensing or approval authority regulations. 2 1 4 3 ZMU02284 1. Fuel joint 2. Fuel gauge 3. Fuel tank cap 4. Air vent screw EMU25830 Fuel joint This joint is used to connect the fuel line. EMU25841 Fuel gauge This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the approximate amount of fuel remaining in the tank. EMU25850 1. Power trim and tilt switch 2. Remote control lever 3. Neutral interlock trigger 4.
✩✪✰ ✬ ✤ ✤ Basic components 6. Throttle 7. Fully open EMU26201 Neutral interlock trigger To shift out of neutral, first pull the neutral interlock trigger up. 1. Fully open 2. Fully closed EMU25911 Tiller handle To change direction, move the tiller handle to the left or right as necessary. 1.
✩✪✰ ✬ ✤ ✤✩ Basic components R 3 N 2 1 F 1 ZMU04036 ZMU04103 1. Throttle indicator 1. Forward “ ” 2. Neutral “ ” EMU25970 3. Reverse “ ” Throttle friction adjuster EMU25941 Throttle grip The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed. A friction device provides adjustable resistance to movement of the throttle grip or the remote control lever, and can be set according to operator preference.
✩✪✰ ✬ ✤ ✤✪ Basic components NOTE: The engine cannot be started with the lock plate removed. 1 ZMU03169 When constant speed is desired, tighten the adjuster to maintain the desired throttle setting. 2 ZMU03353 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.
✩✪✰ ✬ ✤ ✤✫ Basic components gine. When the key is released, it returns automatically to the “ ” (on) position. OFF ON START ZMU03354 EMU26070 ZMU03590 Manual starter handle To start the engine, first gently pull the handle out until resistance is felt. From that position, then pull the handle straight out quickly to crank the engine.
✩✪✰ ✬ ✤ ✤✬ Basic components EMU26141 Power trim and tilt switch on remote control or tiller handle 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 protect the engine from electrochemical corrosion. Never paint the trim tab as it will become ineffective as an anode. A 1 ZMU04040 B EMU26372 2 Top cowling lock lever(s) (turn type) ZMU02822 1. Trim tab 2. Bolt EMU26312 Tilt lock mechanism 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.
✩✪✰ ✬ ✤ ✥✤ Basic components 1 1 2 ZMU04578 ZMU04042 1. Flushing device 1. Tachometer 2. Warning indicator(s) EMU26300 Warning indicator EMU26501 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 22. Low oil pressure warning indicator If oil pressure drops too low, this indicator will flash. For further information, see page 23.
✩✪✰ ✬ ✤ ✥✥ Basic components indicator will flash. For further information on reading the indicator, see page 22. EMU26801 ECM00050 ECM00090 Warning system CAUTION: CAUTION: Do not continue to run the engine if the overheat warning indicator is on. Serious engine damage will occur. 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.
✩✪✰ ✬ ✤ ✥✦ Basic components switch panel). ZMU04587 If the warning system has activated, stop the engine and check the cooling water inlet for clogging. ZMU04105 ● The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel). EMU30164 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.
✩✪✰ ✬ ✤ ✥✧ Basic components low oil pressure warning indicator is on. Serious engine damage could occur.
✩✪✰ ✬ ✤ ✥ 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.
✩✪✰ ✬ ✤ ✥✩ Operation motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is in alignment with the bottom of the boat.
✩✪✰ ✬ ✤ ✥✪ 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). 1 EMU27130 ZMU04046 Controls ● ● ● ● Check throttle, shift, and steering for proper operation before starting the engine.
✩✪✰ ✬ ✤ ✥✫ Operation fuel system components. Follow product labeling for use instructions. tank. Wipe up any spilled fuel. Fuel tank capacity: 24 L EMU27450 Operating engine EMU27461 Feeding fuel (portable tank) EWM00420 WARNING ● ZMU02834 ● EMU27270 Ring Free Fuel Additive Gasoline is a precise blend of many different substances, each chosen to give certain characteristics.
✩✪✰ ✬ ✤ ✥✬ Operation connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank. ZMU02025 EMU27490 Starting engine ZMU04048 EMU27541 Starting engine 1. Place the gear shift lever in neutral. N R F ZMU02024 3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp.
✩✪✰ ✬ ✤ ✦✣ 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. ZMU04050 5. After the engine starts, slowly return the manual starter handle to its original position before releasing it.
✩✪✰ ✬ ✤ ✦✤ Operation 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. Do not route the lanyard where it could become entangled, preventing it from functioning. Avoid accidentally pulling the lanyard during normal operation.
✩✪✰ ✬ ✤ ✦✥ 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) N EWM00190 F 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. ZMU03619 Remote control models 1.
✩✪✰ ✬ ✤ ✦✧ Operation UP DN ZMU03909 ZMU04055 2. N R On models equipped with a tilt lock lever, check that it is in the lock/down position. ZMU03407 EMU27795 Reverse (manual tilt and hydro 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. ZMU04054 3.
✩✪✰ ✬ ✤ ✦ Operation EMU27844 Procedure 1. Push and hold the engine stop button or turn the main switch to “ ” (off). ZMU04053 2. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to reverse. ZMU03401 ON OFF START UP DN ZMU03630 ZMU03909 2. N R After stopping the engine, disconnect the fuel line if there is a fuel joint on the outboard motor.
✩✪✰ ✬ ✤ ✦✩ Operation ZMU02301 4. Remove the key if the boat will be left unattended. NOTE: The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop switch, then turning the main switch to “ ” (off). 1 EMU27861 ZMU04059 Trimming outboard motor The trim angle of the outboard motor helps determine the position of the bow of the boat in the water.
✩✪✰ ✬ ✤ ✦✪ Operation Adjust the outboard motor trim angle using the power trim and tilt switch. EMU27891 Adjusting trim angle for hydro tilt models EWM00490 WARNING ● ● ● 1. Power trim and tilt switch UP 1. 2. DN Stop the engine before adjusting the trim angle. Be sure all people are clear of the outboard motor when adjusting the tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket.
✩✪✰ ✬ ✤ ✦✫ Operation 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. With the 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.
✩✪✰ ✬ ✤ ✦✬ Operation salt corrosion. N EWM00220 WARNING R 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 F ZMU04062 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. 2.
✩✪✰ ✬ ✤ ✧✣ Operation UP UP DN ZMU01935 ZMU04065 EMU28005 Procedure for tilting up Power trim and tilt models / power tilt models 1. Place the remote control lever / the gear shift lever in neutral. UP N ZMU04067 4. Push the tilt support knob into the clamp bracket or pull the tilt support lever toward you to support the engine. ZMU03196 2. Disconnect the fuel line from the outboard motor or close the fuel cock. ZMU04068 EWM00260 WARNING ZMU04066 3.
✩✪✰ ✬ ✤ ✧✤ Operation sure. 5. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim and tilt switch “ ” (down) to retract the trim rods. ECM00250 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. ZMU04070 3. 4. Slowly tilt the outboard motor down.
✩✪✰ ✬ ✤ ✧✥ Operation to allow operation in shallow water. EWM00270 WARNING ● ● ● ZMU04072 3. Push the power tilt / power trim and tilt switch “ ” (down) to lower the outboard motor to the desired position. ● DN UP DN Place the gear shift in neutral before using the shallow water cruising system. Run the boat at the lowest possible speed when using the shallow water cruising system. Use extra care when operating in reverse.
✩✪✰ ✬ ✤ ✧✦ Operation position. N ZMU03087 ZMU04076 N R EMU28090 F Power trim and tilt models / power tilt models The outboard motor can be tilted up partially to allow operation in shallow water. EWM00660 WARNING ● ZMU03649 2. Pull the tilt lock lever up to the release position. ● 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 cooling water passages with fresh water to prevent them from becoming clogged with salt deposits. N NOTE: For cooling system flushing instructions, see page 46. ZMU03525 2. Slightly tilt the outboard motor up to the desired position using the power trim / tilt switch. UP 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.
✩✪✰ ✬ ✤ ✧ Maintenance EMU28216 Specifications Dimension: Overall length: F30TR 700 mm (27.6 in) F40MH 1332 mm (52.4 in) F40TR 700 mm (27.6 in) Overall width: 378 mm (14.9 in) Overall height S: 1217 mm (47.9 in) Overall height L: 1340 mm (52.8 in) Transom height S: 410 mm (16.1 in) Transom height L: 533 mm (21.0 in) Weight (AL) L: F30TR 90.4 kg (199 lb) Weight (without propeller) S: F40MH 83.0 kg (183 lb) Weight (without propeller) L: F40MH 87.0 kg (192 lb) F40TR 89.
✩✪✰ ✬ ✤ ✧✩ Maintenance F40TR Power trim and tilt Propeller mark: G Fuel and oil: Recommended fuel: Regular unleaded gasoline Min. pump octane: 86 Recommended engine oil: 4-stroke outboard motor oil Engine oil grade API: API SE, SF, SG, SH, SJ Engine oil type SAE: SAE10W30 or SAE10W40 Lubrication: Wet sump Engine oil quantity (excluding oil filter): 2.0 L (2.11 US qt) (1.76 Imp.qt) Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: 430.0 cm3 (14.54 US oz) (15.17 Imp.
✩✪✰ ✬ ✤ ✧✪ Maintenance with a minimum of tools, can perform the following procedures. CAUTION: ● ● Procedure EMU28372 ECM01080 ● EMU28301 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 gine will be damaged from overheating. Before starting the engine, be sure to supply water to the cooling water passages. EMU28400 Lubrication (except oil injection models) 1. ECM00290 CAUTION: If the fresh water level is below the level of the anti-cavitation plate, or if the water supply is insufficient, engine seizure may occur. 6. Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt.
✩✪✰ ✬ ✤ ✧✬ Maintenance dling 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. Get immediate medical attention.
✩✪✰ ✬ ✤ ✣ Maintenance tor securely. more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer. ECM00540 CAUTION: Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal operation. Water will leak out of the connector instead of cooling the engine, which can cause serious overheating.
✩✪✰ ✬ ✤ ✤ 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.
✩✪✰ ✬ ✤ ✥ Maintenance Initial Item Spark plug(s) Timing belt Valve clearance (OHC, OHV) Actions 10 hours (1 month) Every 50 hours (3 months) 100 hours (6 months) 200 hours (1 year) Cleaning / adjustment / replacement Inspection / replacement Inspection / adjustment NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. EMU28871 Maintenance chart (additional) Every Item Actions 500 hours (2.
✩✪✰ ✬ ✤ ✦ Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) F30TR, F40MH, F40TR ZMU04081 EMU28951 Cleaning and adjusting spark plug sparks, which could lead to explosion or fire. EWM00560 WARNING When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external 53 The spark plug is an important engine component and is easy to inspect.
✩✪✰ ✬ ✤ ✧ Maintenance ple, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode.
✩✪✰ ✬ ✤ Maintenance EMU29040 Inspecting idling speed EWM00450 WARNING ● ● ● Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. 2-hp models: The propeller rotates whenever the engine is running. Do not move the throttle control lever from the start position during warm-up.
✩✪✰ ✬ ✤ ✩ Maintenance or other qualified mechanic. 2. Verify whether the idle speed is set to specification. For idle speed specifications, see page 45. 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. ZMU04084 2.
✩✪✰ ✬ ✤ ✪ Maintenance specified level if it is above the upper mark. Then 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): 2.0 L (2.11 US qt) (1.76 Imp.qt) ZMU02058 7. 1 Dispose of used oil according to local regulations.
✩✪✰ ✬ ✤ ✫ Maintenance 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. NOTE: If any leaks are found, consult your Yamaha dealer. 4. 5. Tilt the outboard motor up and check that the trim and tilt rod is pushed out completely.
✩✪✰ ✬ ✤ ✬ Maintenance age. 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. ZMU04089 EMU29193 Removing the propeller 1. 2. Straighten the cotter pin and pull it out using a pair of pliers. Remove the propeller nut, washer, and spacer (if equipped).
✩✪✰ ✬ ✤ ✩✣ Maintenance ● 1. 2. 3. 4. 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. 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.
✩✪✰ ✬ ✤ ✩✤ Maintenance 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: 430.0 cm3 (14.54 US oz) (15.17 Imp.oz) ● ● ● 1. 2. 3. an area with good ventilation. Wipe up any spilled fuel immediately. Reassemble the fuel tank carefully.
✩✪✰ ✬ ✤ ✩✥ Maintenance anodes. ECM00720 CAUTION: Do not paint anodes, as this would render them ineffective. NOTE: Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit. ZMU02820 sures: ● 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.
✩✪✰ ✬ ✤ ✩✦ Maintenance ies). ● ● 2. Always keep the battery in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month or more, remove the battery from the boat and store it in a cool, dark place. Completely recharge the battery before using it. If the battery will be stored for longer than a month, check the specific gravity of the fluid at least once a month and recharge the battery when it is low. 3.
✩✪✰ ✬ ✤ ✩✧ Maintenance ZMU02068 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. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
✩✪✰ ✬ ✤ ✩ 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. If the engine trouble warning indicator is flashing, consult your Yamaha dealer.
✩✪✰ ✬ ✤ ✩✩ 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.
✩✪✰ ✬ ✤ ✩✪ 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.
✩✪✰ ✬ ✤ ✩✫ Trouble Recovery board motor unsafe to operate. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type. 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. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer. Engine vibrates excessively. Q. Is propeller damaged? A.
✩✪✰ ✬ ✤ ✩✬ Trouble Recovery 4 3 1 2 1 ZMU04094 1. Fuse box 2. Fuse (20 A) 3. Spare fuse (20 A) 4. Fuse puller ZMU04095 1. Manual valve screw 2. Put the engine in the desired position, then tighten the manual valve screw by turning it counterclockwise. EMU29531 Starter will not operate If the starter mechanism does not operate (the engine cannot be cranked with the starter), the engine can be started with an emergency starter rope. EWM01020 WARNING 1 ● ZMU04093 1.
✩✪✰ ✬ ✤ ✪✣ Trouble Recovery ● ● ● 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. Be 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.
✩✪✰ ✬ ✤ ✪✤ Trouble Recovery dure below in order to minimize engine damage. EMU29783 Procedure 1. 2. ZMU03387 5. 6. 7. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise. Pull the rope slowly until resistance is felt. Give a strong pull straight out to crank and start the engine. Repeat if necessary. 3. 4. Thoroughly wash away mud, salt, seaweed, and so on, with fresh water.
✩✪✰ ✬ ✤ ✪✥ Consumer information EMU29811 Important warranty information for U.S.A.
✩✪✰ ✬ ✤ ✪✦ Consumer information 73
✩✪✰ ✬ ✤ ✪✧ Consumer information EMU29830 YAMAHA MOTOR CORPORATION, U.S.A.
✩✪✰ ✬ ✤ ✪ Consumer information 75
✩✪✰ ✬ ✤ ✪✩ Consumer information EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A.
67C-9-15 Hyoushi 3/31/04 9:06 PM Page 1 F30D F40D OWNER’S MANUAL Printed in Japan April 2004–0.1 × 1 ! Printed on recycled paper U.S.A.
Warranty card 2/27/02 11:47 AM Page 1 OUTBOARD MOTOR WARRANTY REGISTRATION ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD Please complete and mail this card. This information is necessary to accurately register your unit for warranty. Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.
Warranty card 2/27/02 11:47 AM Page 2 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT
