6G8-9-1N-Hyoshi 7/2/04 4:09 PM Page 1 F9.9D T9.9D OWNER’S MANUAL Printed in Japan April 2004–0.4 × 1 ! Printed on recycled paper U.S.A.
6G8-9-1N-Hyoshi 7/2/04 4:09 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 Procedure for tilting down (manual tilt models) .................................... 37 Cruising in shallow water .............. 37 Cruising in shallow water (manual tilt models) .................................... 37 Cruising in other conditions........... 39 Maintenance..................................... 40 Specifications ................................ 40 Transporting and storing outboard motor ........................................... 42 Clamp screw mounting models .......
General information EMU25170 Identification numbers record EMU25182 Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket or the upper part of the swivel bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen. 1.
General information particular label. 1 ZMU01699 ZMU04354 EMU25262 Manufactured date label This label is attached to the clamp bracket or the swivel bracket. 1 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. Reading it should give you an understanding of the motor and its operation.
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 EMU25464 EMU25510 Caution labels Steering and sailing rules and sound signals ZMU04357 EMU25472 Label ECM01190 CAUTION: Transport and 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.
General information sels. EMU25520 Rules when encountering vessels There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed: Meeting: (you are approaching another vessel head-on) Crossing: (you are traveling across the other vessel’s path) Overtaking: (you are passing or being passed by another vessel) In the following illustration, your boat is in the center.
General information EMU25530 Other special situations There are three other rules you should be aware of when driving your boat around other vessels. Narrow channels and bends When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a powerdriven vessel is preparing to go around a bend that may obstruct the view of other water vessels, the operator should sound a prolonged blast on the whistle (4 to 6 seconds).
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 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): F9.9ER 245.0 A T9.9EH 245.0 A T9.9ER 245.0 A Minimum marine cranking amps (MCA/ ABYC): F9.9ER 323.0 A T9.9EH 323.0 A T9.9ER 323.0 A Minimum reserve capacity (RC/SAE): F9.9ER 52 minutes T9.9EH 52 minutes T9.
General information x 1 2 3 ZMU04604 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. 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.
Basic components EMU25795 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. F9.9D, T9.9D 1 2 3 4 13 21 15 14 19 16 17 20 12 11 10 9 18 21 18 22 15 19 23 5 6 7 8 24 25 26 ZMU04360 1. Top cowling 2. Top cowling lock lever(s) 3. Cooling water pilot hole 4. Drain screw 5. Anti-cavitation plate 6. Anode 7. Propeller 8. Cooling water inlet 9. Shallow water lever* 10. Trim rod 11. Tilt support lever 12. Clamp bracket 13.
Basic components EMU25802 EMU25860 Fuel tank Air vent screw If your model was equipped with a portable fuel tank, its function is as follows. This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise. EWM00020 EMU26180 Remote control WARNING The fuel tank supplied with this engine is 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.
Basic components when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position. 1. Neutral “ ” 2. Forward “ ” 3. Reverse “ ” 4. Shift 5. Fully closed 6. Throttle 7. Fully open 1. Fully open 2. Fully closed EMU25911 EMU26201 Neutral interlock trigger To shift out of neutral, first pull the neutral interlock trigger up. Tiller handle To change direction, move the tiller handle to the left or right as necessary.
Basic components EMU25922 Gear shift lever Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead. Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern. R 3 N 2 F 1 ZMU04363 ZMU02902 1. Forward “ ” 2. Neutral “ ” ZMU04448 3. Reverse “ ” EMU25961 R 3 N 2 Throttle indicator F 1 The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position.
Basic components 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. To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. gine 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 2 tion, then pull the handle straight out quickly to crank the engine. 1 ZMU04365 1. Lanyard 2. Lock plate EMU26080 Starter button EMU26001 Engine stop button To open the ignition circuit and stop the engine, push this button. To start the engine with the electric starter, push the starter button. ZMU04368 ZMU04366 EMU26090 Main switch ZMU04367 EMU26070 Manual starter handle To start the engine, first gently pull the handle out until resistance is felt.
Basic components gine. When the key is released, it returns automatically to the “ ” (on) position. EMU26170 Steering Lock Device A boat with a rudder (such as a sailboat) can be steered with the boat’s rudder if the engine is locked in the straight-ahead position. Lock the steering lock lever to the steering lock plate. 1 EMU26122 Steering friction adjuster A friction device provides adjustable resistance to the steering mechanism, and can be set according to operator preference.
Basic components To lock it, set the tilt lock lever in the “ ” (lock) position. To release, push the tilt lock lever in the “ ” (release) position. EMU26350 Tilt support lever for manual tilt model To keep the outboard motor in the tilted up position, lock the tilt support lever to the swivel bracket. ZMU04371 EMU26270 Shallow water lever Lifting this lever will tilt the motor up partially to provide more clearance when operating in shallow water.
Basic components EMU26511 Low oil pressure warning indicator The oil pressure lamp is on when the engine is running and oil pressure is normal. If oil pressure drops too low, the lamp goes off. As an additional alert of the low oil pressure condition, the engine runs roughly and will not exceed about 2000 rpm. If the oil lamp goes out or does not come on when the engine is running, stop the engine as soon as it is safe to do so. Check oil level and add oil as needed.
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.
Operation come loose due to engine vibration. EWM00640 WARNING board (if packed). For details, consult your Yamaha dealer. EWM00650 Loose clamp screws could allow the outboard motor to fall off or move on the transom. This could cause loss of control and serious injury. Make sure the transom screws are tightened securely. Occasionally check the screws for tightness during operation. WARNING Avoid using bolts, nuts or washers other than those contained in the engine packaging.
Operation 2. 3. 4. Run the engine at 2000 r/min or at approximately half throttle. For the second hour of operation: Run the engine at 3000 r/min or at approximately three-quarter throttle. For the next eight hours of operation: Avoid continuous operation at full throttle for more than five minutes at a time. After the first 10 hours: Operate the engine normally.
Operation 1 3 2 ZMU02082 1. Lower level mark 2. Oil dipstick 3. Upper level mark NOTE: Be sure to completely insert the dipstick into the dipstick guide. EMU27433 Filling fuel EWM00060 WARNING Gasoline and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition. 1. 2. 3. Remove the fuel tank cap. Carefully fill the fuel tank. Securely close the cap after filling the tank. Wipe up any spilled fuel.
Operation line to the joint on the fuel tank. EMU27450 Operating engine EMU27461 Feeding fuel (portable tank) EWM00420 WARNING ● ● ● 1. Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the 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.
Operation EMU27490 Starting engine EMU27541 Starting engine 1. Place the gear shift lever in neutral. N ZMU04381 3. Place the throttle grip in the “ (start) position. ” ZMU04380 NOTE: The start-in-gear protection device prevents the engine from starting except when in neutral. 2. Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the engine stop switch. ZMU04382 4.
Operation 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. NOTE: ● ● When the engine is cold, it needs to be warmed up. For further information, see page 30. If the engine is warm and fails to start, open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 61.
Operation ZMU04387 5. Immediately after the engine starts, release the starter button and allow it to return to its original position. ECM00160 CAUTION: ● ● Never push the starter button while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged.
Operation again. NOTE: ● ● 3. 4. Turn the main switch to “ ” (on). Turn the main switch to “ ” (start), and hold it for a maximum of 5 seconds. When the engine is cold, it needs to be warmed up. For further information, see page 30. If the engine is warm and fails to start, open the throttle slightly and try to start the engine again. If the engine still fails to start, see page 61. EMU27670 Warming up engine EMU27721 Oil pressure indicator models 1. 2. 3.
Operation firmly from neutral to forward. N F ZMU04393 ZMU02866 EMU27740 Shifting N EWM00180 WARNING Before shifting, make sure there are no swimmers or obstacles in the water near you. F 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). EMU27763 Forward (tiller handle and remote control models) Tiller control models 1.
Operation EMU27795 Reverse (manual tilt and hydro tilt models) N R 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. ZMU02867 Tiller control models 1. Place the throttle grip in the fully closed position. N R ZMU04396 ZMU02030 2. Remote control models 1. Check that the tilt lock lever is in the lock position.
Operation 2. EMU27820 Stopping engine Before stopping the engine, first let it cool off for a few minutes at idle or low speed. Stopping the engine immediately after operating at high speed is not recommended. After stopping the engine, disconnect the fuel line if there is a fuel joint on the outboard motor. EMU27844 Procedure 1. Push and hold the engine stop button or turn the main switch to “ ” (off). ZMU04400 3. Tighten the air vent screw on the fuel tank cap (if equipped).
Operation the engine stop switch, then turning the main switch to “ ” (off). EMU27861 Trimming outboard motor The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help improve performance and fuel economy while reducing strain on the engine. Correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.
Operation 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. 1 ZMU04401 1. Trim rod 3. Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom.
Operation and making it hard to increase speed. Operating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of “bow steering” and making operation difficult and dangerous. the engine will be tilted for more than a few minutes. Otherwise fuel may leak. ECM00241 CAUTION: ● ● Before tilting the outboard motor, stop the engine by following the procedure on page 33.
Operation N ZMU04384 2. Disconnect the fuel line if a fuel joint is provided on the outboard motor. ZMU04404 EMU28013 Procedure for tilting down (manual tilt models) 1. 2. Slightly tilt the engine up. On models equipped with a tilt support knob, pull it out. ZMU04402 3. Place the tilt lock lever in the release position. ZMU04405 3. Slowly tilt the engine down. EMU28060 Cruising in shallow water The outboard motor can be tilted up partially to allow operation in shallow water.
Operation ● ● ● nism 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. Use extra care when operating in reverse.
Operation 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: ZMU04403 3. Slightly tilt the outboard motor up and pull the shallow water lever toward the transom. ZMU04409 4. To return the outboard motor to the normal position, place the gear shift lever in neutral, then slightly tilt the outboard motor up. Push the shallow water lever down.
Maintenance EMU28216 Specifications Dimension: Overall length: F9.9ER 575 mm (22.6 in) F9.9MH 863 mm (34.0 in) T9.9EH 993 mm (39.1 in) T9.9ER 575 mm (22.6 in) Overall width: F9.9ER 325 mm (12.8 in) F9.9MH 392 mm (15.4 in) T9.9EH 430 mm (16.9 in) T9.9ER 325 mm (12.8 in) Overall height S: F9.9MH 1004 mm (39.5 in) Overall height L: F9.9ER 1131 mm (44.5 in) F9.9MH 1131 mm (44.5 in) T9.9EH 1178 mm (46.4 in) T9.9ER 1178 mm (46.4 in) Overall height X: T9.9EH 1254 mm (49.4 in) Transom height S: F9.9MH 432 mm (17.
Maintenance 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) Min. cold cranking amps (CCA/SAE): F9.9ER 245.0 A T9.9EH 245.0 A T9.9ER 245.0 A Min. marine cranking amps (MCA/ABYC): F9.9ER 323.0 A T9.9EH 323.0 A T9.9ER 323.0 A Min. reserve capacity (RC/SAE): F9.9ER 52 minutes T9.9EH 52 minutes T9.9ER 52 minutes Alternator output: F9.9MH 80 W Alternator output for battery DC: F9.9ER 6.0 A T9.9EH 10.0 A T9.9ER 10.
Maintenance EMU28222 Transporting and storing outboard motor EWM00690 WARNING ● ● ● EMU28235 Clamp screw mounting models When transporting or storing the outboard motor while removed from a boat, keep the outboard motor in the attitude shown. 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. USE CARE when transporting fuel tank, whether in a boat or car. DO NOT fill fuel container to maximum capacity.
Maintenance lowing procedures. ECM01080 CAUTION: ● ● ● To prevent problems which can be caused by oil entering the cylinder from the sump, keep the outboard motor in the attitude shown when transporting and storing it. If storing or transporting the outboard motor on its side (not upright), put it on a cushion after draining the engine oil.
Maintenance ● when starting or during operation. 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-1200) alternately into each carburetor or the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke excessively and almost stall.
Maintenance FLUID OUT OF REACH OF CHILDREN. Batteries vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery manufacturer’s instructions. Procedure 1. Disconnect and remove the battery from the boat. Always disconnect the black negative cable first to prevent the risk of shorting. 2. Clean the battery casing and terminals. Fill each cell to the upper level with distilled water. 3.
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 Actions Timing belt Inspection / replacement Valve clearance (OHC, OHV) Inspection / adjustment 10 hours (1 month) Every 50 hours (3 months) 100 hours (6 months) 200 hours (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.
Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) F9.9D, T9.9D ZMU04413 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 The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine.
Maintenance 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. The boat could unexpectedly start to move, which could result in an accident.
Maintenance while holding the container under the drain hole. Then remove the oil filler cap. Let the oil drain completely. Wipe up any spilled oil immediately. or other qualified mechanic. 2. Verify whether the idle speed is set to specification. For idle speed specifications, see page 40. EMU29093 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.
Maintenance ● outboard motor is upright (not tilted) when checking and changing the engine oil. If the oil level is above the upper level mark, drain until the level meets the specified capacity. Overfilling the oil could cause leakage or damage. 5. Start the engine and watch to make sure the oil pressure indicator turns on. Make sure that there are no oil leaks. ZMU02058 7.
Maintenance EMU29130 Water leakage Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head, and body cylinder. EMU29140 Engine oil leakage Check for oil leaks on the around the engine. NOTE: If any leaks are found, consult your Yamaha dealer. ZMU02876 EMU29171 Checking propeller EWM00321 WARNING You could be seriously injured if the engine accidentally starts when you are near the propeller.
Maintenance NOTE: 1 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. 2 3 6 EMU29193 5 Removing the propeller 1. 2. ZMU04420 Straighten the cotter pin and pull it out using a pair of pliers. Remove the propeller nut, washer, and spacer (if equipped). 1 32 5 4 1. Cotter pin 2. Propeller nut 3.
Maintenance 4. hole and bend the cotter pin ends. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends. ZMU02063 ZMU02063 NOTE: If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to align it with the hole.
Maintenance the gear oil drain screw hole. 2 Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: F9.9ER 185.0 cm3 (6.25 US oz) (6.52 Imp.oz) F9.9MH 185.0 cm3 (6.25 US oz) (6.52 Imp.oz) T9.9EH 320.0 cm3 (10.82 US oz) (11.29 Imp.oz) T9.9ER 320.0 cm3 (10.82 US oz) (11.29 Imp.oz) 1 ZMU04421 1. Gear oil drain screw 2. Oil level plug NOTE: If the magnetic gear oil drain screw equipped: remove all metal particles from the screw before installing it. 4.
Maintenance ● ● ● fore cleaning it. Work only outdoors in an area with good ventilation. Wipe up any spilled fuel immediately. Reassemble the fuel tank carefully. Improper assembly can result in a fuel leak, which could result in a fire or explosion hazard. Dispose of old gasoline according to local regulations. 1. 2. 3. 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.
Maintenance 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. Batteries also generate explosive hydrogen gas; therefore, you should always follow these preventive measures: ● Charge batteries in a well-ventilated area. ● Keep batteries away from fire, sparks, or open flames (for example: welding equipment, lighted cigarettes, and so on.
Maintenance ● 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. Connect the red battery cable to the POSITIVE (+) terminal first. Then connect the black battery cable to the NEGATIVE (-) terminal. 1 ZMU04424 1. Fuse holder 2.
Maintenance page 57 for the correct procedure. 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. 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.
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 2 1 ● ZMU04428 ● 1. Fuse holder 2. Fuse (20 A) NOTE: Consult your Yamaha dealer if the new fuse immediately blows again. 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 ● ● ● ● ● Use this procedure only in an emergency and only to return to port for repairs.
Trouble Recovery the engine is in neutral and that the engine stop switch lanyard lock plate is attached to the engine stop switch. The main switch must be “ ” (on), if equipped. 6. 7. 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. ZMU04445 ZMU04430 EMU29670 Engine fails to operate EMU29711 Cold engine fails to start 1.
Trouble Recovery EMU29783 Procedure N 1. Thoroughly wash away mud, salt, seaweed, and so on, with fresh water. ZMU04451 N ZMU02075 2. Remove the spark plug(s), then face the spark plug holes downward to allow any water, mud, or contaminants to drain. ZMU03087 2. 3. 4. 5. Open the throttle halfway. On models with a neutral throttle limiter, open the throttle as far as it will go. Start the engine.
Trouble Recovery dealer as soon as possible. ECM00400 CAUTION: Do not attempt to run the outboard motor until it has been completely inspected.
Consumer information EMU29811 Important warranty information for U.S.A.
Consumer information 70
Consumer information EMU29830 YAMAHA MOTOR CORPORATION, U.S.A.
Consumer information 72
Consumer information EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A.
6G8-9-1N-Hyoshi 7/2/04 4:09 PM Page 1 F9.9D T9.9D OWNER’S MANUAL Printed in Japan April 2004–0.4 × 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
