F4D OWNER’S MANUAL U.S.A.
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 type) .............................................. 17 Carrying handle ............................... 17 Outboard motor serial number .......... 1 Emission control information ........... 1 Operation ......................................... 18 Installation..................................... 18 North American models..................... 1 Star labels .........................................
Table of contents Lubrication (except oil injection models) ......................................... 37 Cleaning and anticorrosion measures ...................................... 37 Cleaning the outboard motor .......... 38 Checking painted surface of motor............................................. 38 Periodic maintenance.................... 38 Replacement parts .......................... 38 Maintenance chart .......................... 39 Greasing .........................................
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. engine for details.
General information EMU25280 1 ZMU02651 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.
General information these standards have 65% lower emissions than One Star-Low-Emission engines. ● ● ZMU01704 EMU25360 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 Before operating the boat, read any owner’s or operator’s manuals supplied with it and all labels. Be sure you understand each item before operating. Do not overpower the boat with this outboard motor.
General information watch for obstacles and other traffic. ● Always watch carefully for swimmers during the engine operation. ● Stay away from swimming areas. ● When a swimmer is in the water near you shift into neutral and shut off the engine. Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the following: United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S.
General information EMU25481 Label ECM01200 CAUTION: Store the engine only as shown. Otherwise, engine damage could result from Leaking oil. 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.
General information 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 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. 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.
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 on the propeller size and boat load. If engine speed is too high or too low for good engine performance, this will have an adverse effect on the engine. Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct engine speed to be maintained.
Basic components EMU25795 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. F4D 11 12 13 2 1 2 10 9 8 3 4 19 14 18 17 16 15 20 7 5 6 1. Top cowling 2. Top cowling lock lever 3. Carrying handle 4. Steering friction screw 5. Anti-cavitation plate 6. Propeller 7. Cooling water inlet 8. Trim rod 9. Clamp bracket 10. Tiller handle 11. Air vent screw 12. Fuel tank cap 13. Manual starter handle 14.
Basic components its dedicated fuel reservoir and must not be used as a fuel storage container. Commercial users should conform to relevant licensing or approval authority regulations. 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 3 4 1 2 Fuel tank cap This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise.
Basic components 1 1 ZMU02652 ZMU02659 1. “OPEN” position for the portable tank 1. Close position EMU25901 EMU25911 Open Tiller handle The fuel cock has two open positions, one for selecting fuel flow from the built-in fuel tank, and one for an external tank. Fuel flows to the carburetor with the lever or knob in either open position. These are the normal running positions. To change direction, move the tiller handle to the left or right as necessary.
Basic components R 3 N 2 1 F 1 ZMU02665 ZMU02663 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 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.
Basic components difficult to steer, which could result in an accident. EMU26070 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. EMU26261 Trim rod (tilt pin) The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.
Basic components EMU26450 Carrying handle A carrying handle is provided on the rear of the outboard motor. It enables you to carry the outboard motor easily with one hand. 1 ZMU02674 EMU26382 Top cowling lock lever (pull up type) To remove the engine top cowling, pull up 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 by moving the lever(s) downward. 1 ZMU02675 1.
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 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 between the bottom of the boat and a level 25 mm (1 in.) below it. 0–25mm (0–1in.
Operation board (if packed). For details, consult your Yamaha dealer. 2. EWM00650 WARNING Avoid using bolts, nuts or washers other than those contained in the engine packaging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tightening, test run the engine and check their tightness. 3. 4. Run the engine at 2000 r/min or at approximately half throttle.
Operation ● ● ● er operation before starting the engine. The controls should work smoothly, without binding or unusual free play. Look for loose or damaged connections. Check operation of the starter and stop switches when the outboard motor is in the water. 2 3 1 EMU27140 Engine ● ● ● Check the engine and engine mounting. Look for loose or damaged fasteners. Check the propeller for damage. EMU27163 Checking the engine oil level 1. 2. 3. 4.
Operation ● ZMU04484 3. ● Securely close the cap after filling the tank. Wipe up any spilled fuel. Fuel tank capacity: 1.10 L (0.291 US gal) (0.2420 Imp.gal) NOTE: The upper fuel level mark is indicated on the built-in fuel tank. water near you. When the air vent screw is loosened, gasoline vapor will be released. Gasoline is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw.
Operation ZMU02894 ZMU02681 EMU27490 Starting engine EMU27505 Manual start models (tiller control) 1. Place the gear shift lever in neutral. N ZMU02680 3. If you are using an external fuel tank, connect the fuel joints securely and squeeze the primer pump with the outlet end up until you feel it become firm (if equipped the fuel joint). ZMU02682 NOTE: The start-in-gear protection device prevents the engine from starting except when in neutral. 2.
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. ZMU02669 NOTE: ● ● 5. ZMU02683 3. Place the throttle grip in the “ (start) position. ” It is not necessary to use the choke when starting a warm engine.
Operation 2. Check for a steady flow of water from the cooling water pilot hole. ECM00510 CAUTION: ZMU02685 NOTE: ● ● When the engine is cold, it needs to be warmed up. For further information, see page 25. If the engine does not start on the first try, repeat the procedure. If the engine fails to start after 4 or 5 tries, open the throttle a small amount (between 1/8 and 1/4) and try again.
Operation EMU27763 Forward (tiller handle and remote control models) an accident. 1. Tiller control models 1. Place the throttle grip in the fully closed position. Place the throttle grip in the fully closed position. ZMU02685 2. ZMU02685 2. Move the gear shift lever quickly and firmly from neutral to reverse. Move the gear shift lever quickly and firmly from neutral to forward. R N N F ZMU02688 NOTE: ZMU02687 Remote control models 1.
Operation until the engine comes to a complete stop. ZMU02689 ZMU02668 2. After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to the closed position, if equipped. NOTE: If the outboard motor is equipped with an engine stop switch lanyard, the engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop switch.
Operation 1 ZMU02691 1. Trim rod 1 ZMU02690 1. Trim operating angle 3. Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom. To lower the bow (“trim-in”), move the rod toward the transom. Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.
Operation 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. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane. and making it hard to increase speed. Operating with excessive trim-in at higher speeds also makes the boat unstable.
Operation when in reverse or when the outboard motor is turned 180° (facing the rear). EMU27964 Procedure for tilting up (manual tilt models) 1. ZMU02692 Place the gear shift lever in neutral (if equipped) and face the outboard motor forward. N 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. ZMU02682 EWM00230 WARNING 2. Leaking fuel is a fire hazard.
Operation ZMU02694 6. 7. ZMU02689 4. Tilt support knob equipped models: Hold the rear of the top cowling with one hand, fully tilt the outboard motor up, and push the tilt support knob into the clamp bracket. Tilt support lever equipped models: Hold the rear handle and tilt the engine up fully until the tilt support lever automatically locks. NOTE: Tilt support lever/bar equipped models: If the motor is not facing forward, the tilt support lever/bar cannot automatically turn to the locked position.
Operation ● ZMU02673 3. 4. If the tilt support knob equipped: pull out it, then slowly tilt the engine down. Loosen the steering friction adjuster by turning it counterclockwise, and adjust the steering friction according to operator preference. ● ● EWM00720 WARNING If there is too much resistance it could be difficult to steer, which could result in an accident. ● ing the shallow water cruising system. Run the boat at the lowest possible speed when using the shallow water cruising system.
Operation EMU28101 Procedure 1. Place the gear shift lever in neutral and face the outboard motor forward. N ZMU02673 NOTE: ZMU02682 2. Slightly tilt the outboard motor up until the tilt support bar automatically turns to the lock position to support the engine. The outboard motor is equipped with 2 or 3 positions for shallow water cruising.
Maintenance EMU28213 Specifications Dimension: Overall length: 717 mm (28.2 in) Overall width: 361 mm (14.2 in) Overall height S: 1029 mm (40.5 in) Overall height L: 1156 mm (45.5 in) Transom height S: 435 mm (17.1 in) Transom height L: 562 mm (22.1 in) Weight (AL) S: 22.0 kg (49 lb) Weight (AL) L: 23.0 kg (51 lb) Performance: Full throttle operating range: 4000–5000 r/min Maximum output: 2.
Maintenance Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) Engine oil drain bolt: 20.0 Nm (15.0 ft-lb) (2.0 kgf-m) sition using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details. EMU28222 Transporting and storing outboard motor EWM00690 WARNING ● ● ● Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking.
Maintenance ● ZMU02701 ● 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. Do not place the outboard motor on its side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trouble. Store the outboard motor in a dry, wellventilated place, not in direct sunlight.
Maintenance ● when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. 7. 1. Water surface 2. Lowest water level 5. Fill the tank with fresh water to above the level of the anti-cavitation plate. ECM00300 CAUTION: Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the engine will be damaged from overheating.
Maintenance 2. Spray the outboard motor exterior with “Yamaha Silicone Protectant” (Part No. LUB-SILCNE-13-00). ECM01330 CAUTION: If equipped Electronic Fuel Injection: Do not spray when the engine is running. Also, do not spray near the silencer and oxygen sensor cover or into the engine. Otherwise the oxygen sensor for Electronic Fuel Injection system could be damaged. 3. Wax the cowling with a non-abrasive wax such as “Yamaha Silicone Wax” (Part No. ACC-11000-15-02).
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 NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. EMU28931 Greasing Yamaha marine grease (Water resistant grease) F4D ZMU02706 EMU28950 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.
Maintenance 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. For example, 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.
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. The boat could unexpectedly start to move, which could result in an accident.
Maintenance or other qualified mechanic. 2. Verify whether the idle speed is set to specification. For idle speed specifications, see page 34. EMU29103 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. ZMU02699 2.
Maintenance en 1/4 - 1/2 turn. Have the drain plug torqued to the correct value with a torque wrench as soon as possible. 4. Add the correct amount of oil through the filler hole. Install the filler cap. curely. EMU29120 Exhaust leakage Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head, and body cylinder.
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. EMU29193 ZMU02710 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 occur if the outboard motor accidentally falls. 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. 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 until there is no forward-and-backward movement. Align the propeller nut with the propeller shaft hole.
Maintenance ized filling device, inject the gear oil into the gear oil drain screw hole. Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: 100.0 cm3 (3.38 US oz) (3.53 Imp.oz) ● 1. 2. 3. plosion hazard. Dispose of old gasoline according to local regulations. Empty the fuel tank into an approved container. 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.
Maintenance more rapid engine corrosion. 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. ZMU01943 ZMU02717 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. ZMU04477 EMU29400 Coating the boat bottom A clean hull improves boat performance.
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. 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 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. Have propeller repaired or replaced.
Trouble Recovery ● ● ● ● ● your arm or leg while operating. 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.
Trouble Recovery 9. Give a strong pull straight out to crank and start the engine. Repeat if necessary. ZMU02721 6. Prepare the engine for starting. For further information, see page 23. Be sure the engine is in neutral and that the engine stop switch lanyard lock plate is attached to the engine stop switch. ZMU02722 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.
Trouble Recovery filter, and fuel line. Drain the engine oil completely. ZMU02724 4. Fill the sump with the fresh engine oil. Engine oil capacity: 0.5 L (0.53 US qt) (0.44 Imp.qt) 5. Feed engine fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking the engine with the manual starter or emergency starter rope. ZMU02725 6. Take the outboard motor to a Yamaha dealer as soon as possible.
Consumer information EMU29811 Important warranty information for U.S.A.
Consumer information 57
Consumer information EMU29830 YAMAHA MOTOR CORPORATION, U.S.A.
Consumer information 59
Consumer information EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A.
Printed in France April 2004–0.
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