F6D F8D T8D OWNER’S MANUAL YAMAHA MOTOR CORPORATION, USA Printed in France January 2004–0.3 × 1 CR U.S.A.
ZMU01690 Read this owner’s manual carefully before operating your outboard motor.
U60R10E0.book Page 1 Monday, June 21, 2004 9:34 AM Important manual information EMU25100 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.
U60R10E0.book Page 1 Monday, June 21, 2004 9:34 AM Table of contents General information ...................... 1 Identification numbers record ...... 1 Outboard motor serial number ....... 1 Key number .................................... 1 Emission control information ....... 1 North American models.................. 1 Star labels ...................................... 2 Safety information ....................... 3 Important labels........................... 4 Warning labels............................
U60R10E0.book Page 2 Monday, June 21, 2004 9:34 AM Table of contents Forward (tiller handle and remote control models) ......................... 33 Reverse (manual tilt and hydro tilt models) ..................................... 34 Stopping engine ........................ 35 Procedure..................................... 35 Procedure..................................... 35 Trimming outboard motor .......... 36 Adjusting trim angle for manual tilt models ......................................
U60R10E0.book Page 3 Monday, June 21, 2004 9:34 AM Table of contents Treatment of submerged motor ...................................... 72 Procedure..................................... 72 Consumer information................ 74 Important warranty information for U.S.A. and Canada ........... 74 YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY ........... 76 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA ..............
U60R10E0.book Page 1 Monday, June 21, 2004 9:34 AM General information EMU25170 Identification numbers record EMU25182 Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket or the upper part of the swivel bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen.
U60R10E0.book Page 2 Monday, June 21, 2004 9:34 AM General information New Technology; (4-stroke/HPDI) EM Manufactured: ZMU04346 EMU25272 Star labels 1. Approval label location Your outboard motor is labeled with a California Air Resources Board (CARB) star label. See below for a description of your particular label. ZMU01699 EMU25261 Manufactured date label This label is attached to the clamp bracket or the swivel bracket. 1. Star labels location EMU25280 1.
U60R10E0.book Page 3 Monday, June 21, 2004 9:34 AM General information ZMU01702 ZMU01704 EMU25290 EMU25360 Two Stars—Very Low Emission The two-star label identifies engines that meet the Air Resources Board’s 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low-Emission engines.
U60R10E0.book Page 4 Monday, June 21, 2004 9:34 AM General information ● ● ● ● ● ● ● ● 4 everyone should wear PFDs when there are potentially hazardous boating conditions. Gasoline is highly flammable, and its vapors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel before starting the engine. This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled.
U60R10E0.book Page 5 Monday, June 21, 2004 9:34 AM General information ● ● Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from flywheel and other rotating parts while engine is running. EMU25431 Label EWM01300 WARNING ● ● This engine is equipped with a neutral starting device. The engine will not start unless the shift control is in neutral position.
U60R10E0.book Page 6 Monday, June 21, 2004 9:34 AM General information Stand-on vessel The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision. When you maintain your direction and speed, the other vessel will be able to determine how best to avoid you. Give-way vessel The vessel which does not have the right-ofway has the duty to take positive and timely action to stay out of the way of the Stand-On vessel.
U60R10E0.book Page 7 Monday, June 21, 2004 9:34 AM General information Crossing When two power driven vessels are crossing each other’s path close enough to run the risk of collision, the vessel which has the other on the starboard (right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of its way; you are the Give-Way vessel.
U60R10E0.book Page 8 Monday, June 21, 2004 9:34 AM General information proceeding from open water into port, and black buoys are to port (left) side. When navigating out of port, your position with respect to the buoys should be reversed; red buoys should be to port and black buoys to starboard. Many bodies of water used by boaters are entirely within the boundaries of a particular state. The Uniform State Waterway Marking System has been devised for these waters.
U60R10E0.book Page 9 Monday, June 21, 2004 9:34 AM 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.
U60R10E0.book Page 10 Monday, June 21, 2004 9:34 AM General information ● ● ● ● ● ● Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Do not overfill the fuel tank. Tighten the filler cap securely after refueling. If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it.
U60R10E0.book Page 11 Monday, June 21, 2004 9:34 AM General information tric 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): T8PRD 245.0 A T8PHD 245.0 A T8EHD 245.0 A Minimum marine cranking amps (MCA/ABYC): T8PRD 323.0 A T8PHD 323.0 A T8EHD 323.
U60R10E0.book Page 12 Monday, June 21, 2004 9:34 AM General information 1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark) NOTE: Select a propeller which will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat load.
U60R10E0.book Page 13 Monday, June 21, 2004 9:34 AM Basic components EMU25795 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. F6, F8 1. Top cowling 2. Top cowling lock lever 3. Anti-cavitation plate 4. Propeller* 5. Cooling water inlet 6. Drain screw 7. Trim rod 8. Clamp bracket 9. Manual starter handle 10.Warning indicator 11.Engine stop button/Engine stop lanyard switch 12.Gear shift lever 13.Tiller handle 14.Steering friction lever 15.
U60R10E0.book Page 14 Monday, June 21, 2004 9:34 AM Basic components T8 1. Top cowling 2. Top cowling lock lever 3. Anti-cavitation plate 4. Propeller 5. Cooling water inlet 6. Drain screw 7. Trim rod 8. Clamp bracket 9. Power tilt switch* 10.Manual starter handle* 11.Warning indicator 12.Starter button* 13.Engine stop button/Engine stop lanyard switch* 14.Gear shift lever* 15.Tiller handle* 16.Steering friction lever* 17.Tilt lock lever* 18.Clamp screw 19.Rope attachment 20.Flushing device 14 21.
U60R10E0.book Page 15 Monday, June 21, 2004 9:34 AM Basic components 3 4 1 2 ZMU01992 1. 2. 3. 4. Air vent screw Fuel gauge Fuel joint Fuel tank cap 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 Fuel tank cap This cap seals the fuel tank. When removed, the tank can be filled with fuel.
U60R10E0.book Page 16 Monday, June 21, 2004 9:34 AM Basic components EMU26201 EMU26221 Neutral interlock trigger Choke switch To shift out of neutral, first pull the neutral interlock trigger up. To activate the choke system, press in the main switch while the key is turned to the “ ” (on) or “ ” (start) position. The choke system will then supply the rich fuel mixture required to start the engine. When the key is released, the choke will switch off automatically. 1.
U60R10E0.book Page 17 Monday, June 21, 2004 9:34 AM Basic components 1. Forward “ ” 2. Neutral “ ” 3. Reverse “ ” EMU25941 Throttle grip The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed. 1. Throttle indicator EMU25970 Throttle friction adjuster 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.
U60R10E0.book Page 18 Monday, June 21, 2004 9:34 AM Basic components NOTE: The engine cannot be started with the lock plate removed. When constant speed is desired, tighten the adjuster to maintain the desired throttle setting. EMU25990 Engine stop lanyard switch The lock plate must be attached to the engine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg.
U60R10E0.book Page 19 Monday, June 21, 2004 9:34 AM Basic components EMU26011 Choke knob for pull type To supply the engine with the rich fuel mixture required to start, pull out this knob. EMU26090 Main switch 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. The main switch controls the ignition system; its operation is described below.
U60R10E0.book Page 20 Monday, June 21, 2004 9:34 AM Basic components tor up. Pressing the switch “ ” (down) tilts the outboard motor down. When the switch is released, the outboard motor will stop in its current position. EMU26110 Steering friction adjuster A friction device provides adjustable resistance to the steering mechanism, and can be set according to operator preference. An adjuster lever is located on the bottom of the tiller handle bracket. To increase resistance, turn the lever to the left.
U60R10E0.book Page 21 Monday, June 21, 2004 9:34 AM Basic components EMU26312 Tilt lock mechanism The tilt lock mechanism is used to prevent the outboard motor from lifting out of the water when in reverse gear. EMU26360 Power tilt unit This unit tilts the outboard motor up and down and is controlled with the power tilt switch. ECM00630 1. Tilt lock lever To lock it, set the tilt lock lever in the “ ” (lock) position. To release, push the tilt lock lever in the “ ” (release) position.
U60R10E0.book Page 22 Monday, June 21, 2004 9:34 AM Basic components EMU26460 Flushing device This device is used to clean the cooling water passages of the motor using a garden hose and tap water. 1. Warning indicator EMU26501 Low oil pressure warning indicator If oil pressure drops too low, this indicator will flash. For further information, see page 23. ECM00020 NOTE: For details on usage, see page 50. CAUTION: ● ● 1.
U60R10E0.book Page 23 Monday, June 21, 2004 9:34 AM Basic components EMU26801 Warning system ECM00090 CAUTION: Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. 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.
U60R10E0.book Page 24 Monday, June 21, 2004 9:34 AM Operation EMU26901 EWM00830 Installation ECM00110 CAUTION: Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat, or accessories such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operated continuously in the presence of airborne water spray.
U60R10E0.book Page 25 Monday, June 21, 2004 9:34 AM Operation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in.) below it. 0–25mm (0–1in.
U60R10E0.book Page 26 Monday, June 21, 2004 9:34 AM Operation 3. Secure the clamp bracket to the transom using the bolts provided with the outboard (if packed). For details, consult your Yamaha dealer. 1. 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.
U60R10E0.book Page 27 Monday, June 21, 2004 9:34 AM Operation ● ● ● 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. EMU27140 Engine ● ● ● Check the engine and engine mounting. Look for loose or damaged fasteners. Check the propeller for damage. EMU27163 NOTE: Checking the engine oil level 1. 2. 3. 4.
U60R10E0.book Page 28 Monday, June 21, 2004 9:34 AM Operation As gasoline has changed, the amount of additives such as aromatics and oxygenates has increased. These additives are important for the engines in passenger cars, but they can have detrimental effects in marine engines, because of increased deposits in the combustion chamber. When enough deposits collect, piston rings begin sticking. Performance drops and engine wear increases dramatically.
U60R10E0.book Page 29 Monday, June 21, 2004 9:34 AM Operation 3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp. 2. NOTE: During engine operation place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank. 4. Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the engine stop switch.
U60R10E0.book Page 30 Monday, June 21, 2004 9:34 AM Operation 4. Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position. 6. 7. After the engine starts, slowly return the manual starter handle to its original position before releasing it. Slowly return the throttle grip to the fully closed position. NOTE: ● ● It is not necessary to use the choke when starting a warm engine.
U60R10E0.book Page 31 Monday, June 21, 2004 9:34 AM Operation NOTE: 3. The start-in-gear protection device prevents the engine from starting except when in neutral. 2. ON Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the engine stop switch. WARNING ● ● ” (on).
U60R10E0.book Page 32 Monday, June 21, 2004 9:34 AM Operation NOTE: ● ● On remote controls equipped with a neutral throttle lever, a good starting point is to lift the lever just until you feel resistance, then lift slightly more. The neutral throttle lever or free accelerator can only be used when the remote control lever is in neutral. 5. Press in and hold the main switch to operate the remote choke system.
U60R10E0.book Page 33 Monday, June 21, 2004 9:34 AM Operation ● 2. In temperatures of -5°C or less, leave the choke knob pulled out fully for approximately 30 seconds after starting. Check for a steady flow of water from the cooling water pilot hole. ECM00510 CAUTION: ECM00220 CAUTION: To change the boat direction or shifting position from forward to reverse or viceversa, first close the throttle so that the engine idles (or runs at low speeds).
U60R10E0.book Page 34 Monday, June 21, 2004 9:34 AM Operation EMU27795 Reverse (manual tilt and hydro tilt models) 3. Move the gear shift lever quickly and firmly from neutral to reverse. EWM00190 WARNING When operating in reverse, go slowly. Do not open the throttle more than half. Otherwise the boat could become unstable, which could result in loss of control and an accident. Tiller control models 1. Place the throttle grip in the fully closed position. Remote control models 1.
U60R10E0.book Page 35 Monday, June 21, 2004 9:34 AM Operation EMU27820 Stopping engine 3. 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. Disconnect the fuel line if you are using an external fuel tank. EMU27832 Procedure 1. Push and hold the engine stop button until the engine comes to a complete stop.
U60R10E0.book Page 36 Monday, June 21, 2004 9:34 AM Operation 2. 3. 4. After stopping the engine, disconnect the fuel line or close the fuel cock if there is a fuel joint or a fuel cock on the boat. Tighten the air vent screw on the fuel tank cap (if equipped). Remove the key if the boat will be left unattended. NOTE: The engine can also be stopped by pulling the lanyard and removing the clip from the engine stop switch, then turning the main switch to “ ” (off).
U60R10E0.book Page 37 Monday, June 21, 2004 9:34 AM Operation 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. ● Use the power tilt switch located on the bottom engine cowling (if equipped) only when the boat is at a complete stop with the engine off.
U60R10E0.book Page 38 Monday, June 21, 2004 9:34 AM Operation NOTE: Stay within the trim operating angle when trimming the outboard motor using the power tilt system. mance further, and the boat may “porpoise” (hop in the water), which could throw the operator and passengers overboard. To raise the bow (“trim-out”), tilt the engine up. To lower the bow (“trim-in”), tilt the engine down.
U60R10E0.book Page 39 Monday, June 21, 2004 9:34 AM Operation ler and casing from damage by collision with obstructions, and also to reduce salt corrosion. 2. Disconnect the fuel line from the outboard motor. 3. Place the tilt lock lever (if equipped) in the release/up position. 4. Pull up the shallow water lever (if equipped). Hold the rear of the top cowling with one hand and tilt the engine up fully. Push the tilt support knob into the clamp bracket.
U60R10E0.book Page 40 Monday, June 21, 2004 9:34 AM Operation EMU28004 Procedure for tilting up 4. Power trim and tilt models / power tilt models 1. Place the remote control lever / the gear shift lever in neutral. 2. Disconnect the fuel line from the outboard motor or close the fuel cock. 3. Press the power trim and tilt switch / power tilt switch “ ” (up) until the outboard motor has tilted up completely.
U60R10E0.book Page 41 Monday, June 21, 2004 9:34 AM Operation DN UP DN ZMU01936 2. 3. Slightly tilt the engine up until the tilt support bar is automatically released. Slowly tilt the engine down. EMU28052 Procedure for tilting down 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.
U60R10E0.book Page 42 Monday, June 21, 2004 9:34 AM Operation ● ● ● ● Run the boat at the lowest possible speed when using the shallow water cruising system. The tilt lock mechanism does not work while the shallow water cruising system is being used. Hitting an underwater obstacle could cause the outboard motor to lift out of the water, resulting in loss of control. Do not rotate the outboard motor 180° and operate the boat in reverse. Place the gear shift in reverse to operate the boat in reverse.
U60R10E0.book Page 43 Monday, June 21, 2004 9:34 AM Operation 4. To return the outboard motor to the normal running position, place the gear shift lever in neutral, then place the tilt lock lever in the lock/down position. 5. Slightly tilt the outboard motor up until the tilt support bar automatically returns to the free position. Slowly lower the outboard motor to the normal position. 6.
U60R10E0.book Page 44 Monday, June 21, 2004 9:34 AM Operation 3. To return the outboard motor to the normal running position, press the power trim / tilt switch and slowly tilt the outboard motor down. EMU28190 Cruising in other conditions Cruising in salt water After operating in salt water, wash out the cooling water passages with fresh water to prevent them from becoming clogged with salt deposits. NOTE: For cooling system flushing instructions, see page 46.
U60R10E0.book Page 45 Monday, June 21, 2004 9:34 AM Maintenance EMU28213 Specifications Dimension: Overall length: F6MHD 1038 mm (40.9 in) F8MHD 1038 mm (40.9 in) T8PHD 1038 mm (40.9 in) T8PRD 552 mm (21.7 in) T8EHD 1038 mm (40.9 in) Overall width: F6MHD 371 mm (14.6 in) F8MHD 371 mm (14.6 in) T8PRD 312 mm (12.3 in) T8PHD 371 mm (14.6 in) T8EHD 371 mm (14.6 in) Overall height S: F6MHD 998 mm (39.3 in) F8MHD 998 mm (39.3 in) Overall height L: F6MHD 1125 mm (44.3 in) F8MHD 1125 mm (44.
U60R10E0.book Page 46 Monday, June 21, 2004 9:34 AM Maintenance Starting system: F6MHD Manual F8MHD Manual T8PRD Electric T8PHD Electric T8EHD Manual and electric Starting carburetion system: Choke valve Valve clearance (cold engine) IN: 0.15–0.20 mm (0.0059–0.0079 in) Valve clearance (cold engine) EX: 0.20–0.25 mm (0.0079–0.0098 in) Recommended fuel: Unleaded regular gasoline Min.
U60R10E0.book Page 47 Monday, June 21, 2004 9:34 AM Maintenance ● DO NOT fill fuel container to maximum capacity. Gasoline will expand considerably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard. EWM00700 WARNING Never get under the lower unit while it is tilted, even if a motor support bar is used. Severe injury could occur if the outboard motor accidentally falls.
U60R10E0.book Page 48 Monday, June 21, 2004 9:34 AM Maintenance ● ● 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. EMU28301 Procedure EMU28371 Flushing in a test tank 1.
U60R10E0.book Page 49 Monday, June 21, 2004 9:34 AM Maintenance ● Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. 7. Run the engine at a fast idle for 10–15 minutes in neutral position. 8. Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite Engine Fogging Oil” (Part No. LUB-STRRT-12-00) alternately into each carburetor or the fogging hole of the silencer cover, if equipped.
U60R10E0.book Page 50 Monday, June 21, 2004 9:34 AM Maintenance Keep batteries away from fire, sparks, or open flames (for example: welding 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.
U60R10E0.book Page 51 Monday, June 21, 2004 9:34 AM Maintenance 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 46. EMU28450 Cleaning the outboard motor After use, wash the exterior of the outboard motor with fresh water.
U60R10E0.book Page 52 Monday, June 21, 2004 9:34 AM Maintenance EMU28521 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer.
U60R10E0.book Page 53 Monday, June 21, 2004 9:34 AM Maintenance Initial Item Actions Valve clearance (OHC, OHV) Inspection / adjustment Every 10 hours 50 hours 100 hours 200 hours (1 month) (3 months) (6 months) (1 year) 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.
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U60R10E0.book Page 55 Monday, June 21, 2004 9:34 AM Maintenance 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. 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.
U60R10E0.book Page 56 Monday, June 21, 2004 9:34 AM Maintenance ● ● 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. Check the fuel lines for leaks, crack, or malfunction. If a problem is found, your Yamaha dealer or other qualified mechanic should repair it immediately.
U60R10E0.book Page 57 Monday, June 21, 2004 9:34 AM Maintenance NOTE: Correct idling speed inspection is only possible if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechanic. 2. Verify whether the idle speed is set to specification. For idle speed specifications, see page 45. 2.
U60R10E0.book Page 58 Monday, June 21, 2004 9:34 AM Maintenance tighten 1/4 to 1/2 turn more. Tighten the drain screw to the correct torque with a torque wrench as soon as possible. 4. Add the correct amount of oil through the filler hole. Install the filler cap. Recommended engine oil: 4-stroke outboard motor oil Engine oil quantity (excluding oil filter): 0.8 L (0.85 US qt) (0.70 Imp.qt) ZMU02058 7. Dispose of used oil according to local regulations.
U60R10E0.book Page 59 Monday, June 21, 2004 9:34 AM 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. 3. 4. EMU29140 Engine oil leakage Check for oil leaks on the around the engine. 5. Tilt the outboard motor up and check that the trim and tilt rod is pushed out completely. Check that the trim and tilt rod is free of corrosion or other flaws. Tilt the outboard motor down.
U60R10E0.book Page 60 Monday, June 21, 2004 9:34 AM Maintenance 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). 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.
U60R10E0.book Page 61 Monday, June 21, 2004 9:34 AM Maintenance EMU29230 EMU29280 Installing the propeller Changing gear oil ECM00340 EWM00800 CAUTION: ● ● 1. 2. 3. 4. WARNING 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.
U60R10E0.book Page 62 Monday, June 21, 2004 9:34 AM Maintenance 7. 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. NOTE: For disposal of used oil consult your Yamaha dealer. 5. With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole.
U60R10E0.book Page 63 Monday, June 21, 2004 9:34 AM Maintenance ZMU02067 4. 5. Clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allow the filter to dry. Replace the gasket with a new one. Reinstall the fuel joint assembly and tighten the screws firmly. EMU29312 Inspecting and replacing anode(s) Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes.
U60R10E0.book Page 64 Monday, June 21, 2004 9:34 AM Maintenance Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury. ● Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): ● SKIN - Flush with water. ● EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): ● Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil.
U60R10E0.book Page 65 Monday, June 21, 2004 9:34 AM Maintenance ● ● Connect the red battery cable first when installing the battery and disconnect the black battery cable first when removing it. Otherwise, the electrical parts can be damaged. The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine. tom can be coated with an anti-fouling paint approved for your area to inhibit marine growth.
U60R10E0.book Page 66 Monday, June 21, 2004 9:34 AM Trouble Recovery EMU29422 Troubleshooting A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. This section describes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble warning indicator is flashing, consult your Yamaha dealer.
U60R10E0.book Page 67 Monday, June 21, 2004 9:34 AM Trouble Recovery A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer. Q. Has warning system activated? A. Find and correct cause of warning. Q. Is spark plug gap incorrect? A. Inspect and adjust as specified. Q.
U60R10E0.book Page 68 Monday, June 21, 2004 9:34 AM Trouble Recovery Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. A. Remove foreign matter and clean lower unit. Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer. Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is there excess water in fuel filter cup? A. Drain filter cup. Q. Is fuel filter clogged? A.
U60R10E0.book Page 69 Monday, June 21, 2004 9:34 AM Trouble Recovery A. Inspect spark plug and replace it with recommended type. Q. Is high pressure fuel pump drive belt broken? A. Have serviced by a Yamaha dealer. Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer. Engine vibrates excessively. Q. Is propeller damaged? A. Have propeller repaired or replaced. 1. 2. 3. Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer. 4. Q.
U60R10E0.book Page 70 Monday, June 21, 2004 9:34 AM Trouble Recovery 2. Fuse (10 A) 3. Spare fuse (10 A) 4. Fuse puller ● NOTE: Consult your Yamaha dealer if the new fuse immediately blows again. EMU29520 ● Power trim and tilt will not operate If the engine cannot be tilted up or down with 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, the engine can be tilted manually. 1.
U60R10E0.book Page 71 Monday, June 21, 2004 9:34 AM Trouble Recovery 2. Remove the start-in-gear protection cable from the starter, if equipped. ON OFF ZMU01880 5. If equipped the choke knob, pull out it when the engine is cold. After the engine starts, gradually return the choke knob to its home position as the engine warms up. 6. 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.
U60R10E0.book Page 72 Monday, June 21, 2004 9:34 AM Trouble Recovery 1. Yellow cord EMU29670 Engine fails to operate EMU29691 Ignition system malfunction If the battery voltage is low or in the unlikely event of an ignition system malfunction, the engine speed may become erratic or the engine may stop. In such a situation, follow the procedure below. 1. Remove the CDI unit cover or electrical cover, if equipped. 2. Disconnect the yellow cord (emergency circuit) of the CDI unit to return to port.
U60R10E0.book Page 73 Monday, June 21, 2004 9:34 AM Trouble Recovery ZMU02076 3. 4. Drain the fuel from the carburetor, fuel filter, and fuel line. Drain the engine oil completely. Fill the sump with the fresh engine oil. Engine oil capacity: 0.8 L (0.85 US qt) (0.70 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. ZMU02077 6.
U60R10E0.book Page 74 Monday, June 21, 2004 9:34 AM Consumer information EMU29811 Important warranty information for U.S.A.
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U60R10E0.book Page 76 Monday, June 21, 2004 9:34 AM Consumer information EMU29830 YAMAHA MOTOR CORPORATION, U.S.A.
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U60R10E0.book Page 78 Monday, June 21, 2004 9:34 AM Consumer information EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A.
F6D F8D T8D OWNER’S MANUAL YAMAHA MOTOR CORPORATION, USA Printed in France January 2004–0.3 × 1 CR U.S.A.
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