VZ150A VZ175A VZ200A OWNER’S MANUAL U.S.A.
CAUTION USE STRAIGHT GASOLINE ONLY • Do not use fuel mixed with oil both during break-in and during normal use. • Oil can damage fuel injectors.
E EMU01448 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. In this Owner’s Manual particularly important information is distinguished in the following ways.
EMU00003 CONTENTS E GENERAL INFORMATION 1 BASIC COMPONENTS 2 OPERATION 3 MAINTENANCE 4 TROUBLE RECOVERY 5 INDEX 6 READ THIS OWNER’S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR.
E EMU00004 Chapter 1 GENERAL INFORMATION IDENTIFICATION NUMBERS RECORD ..1-1 Outboard motor serial number...........1-1 Key number...........................................1-1 EMISSION CONTROL INFORMATION...1-2 Star labels..............................................1-3 SAFETY INFORMATION..........................1-4 IMPORTANT LABELS ..............................1-6 1 2 3 BASIC BOATING RULES .........................1-7 FUELING INSTRUCTIONS.....................1-11 Gasoline ..........................
E EMU00005 IDENTIFICATION NUMBERS RECORD EMU00007 OUTBOARD MOTOR SERIAL NUMBER YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON q 401016 The outboard motor serial number is stamped on the label attached to the port side of the clamp-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.
E EMU01385 EMISSION CONTROL INFORMATION q EMU01444 NORTH AMERICAN MODELS w 000517 This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details. Approval label of Emission control certificate This label is attached to the bottom cowling. 1 Emission control information label EMISSION CONTROL INFORMATION EM ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.
E EMU01389 STAR LABELS Your outboard motor is labeled with a California Air Resources Board (CARB) star label. See below for a description of your particular label. q 1 Star label 000854 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.
E EMU00917 Q SAFETY INFORMATION 8 Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation. 8 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. 8 Do not overpower the boat with this outboard motor. Overpowering the boat could result in loss of control.
E 8 When a swimmer is in the water near you shift into neutral and shut off the engine. 8 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. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647 National Marine Manufacturers Association (NMMA) 401 N. Michigan Ave.
E q EMU00014 IMPORTANT LABELS w WARNING LABELS e 1 WARNING 6 Be sure shift control is in neutral 6before starting engine. (except 2HP) 6 Do not touch or remove electrical parts 6 when starting or during operation. 6 Keep hands,hair,and clothes away from flywheel 6and other rotating parts while engine is running. t 6A1-83625-41 202036 2 WARNING Use only a counterclockwise rotation propeller with this engine. Counterclockwise propellers are marked with a letter "L" after the size indication.
E EMU00015 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. You should be aware of these rules, and follow them whenever you encounter another vessel on the water.
E 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.
E of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you. 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.
E Remember, markings may vary by geographic location. Always consult local boating authorities before driving your boat in unfamiliar waters. N EL MAIN CHANNEL BUOYS A N " 6" A C H C " 1" M N O AN N White Light C H D A R Odd number. increasing toward head of navigation.Leave to port (left) proceeding upstream.
E EMU01550 FUELING INSTRUCTIONS w GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! 8 Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. 8 Stop engine before refueling. 8 Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. 8 Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. 8 Do not overfill the fuel tank. 8 Tighten the filler cap securely after refueling.
E EMU00019 GASOLINE (PETROL) Recommended gasoline: Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2 If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. EMU00027 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings.
E EMU01551 BATTERY REQUIREMENT cC Do not use a battery that does not meet the specified capacity. If a battery which differs from the specification is used, the electrical system may perform poorly or be overloaded, causing electrical system damage. Choose a battery which meets the following specifications. Minimum cold crank performance 512 Amps at -17.8°C (0°F) Minimum reserve capacity 182 Minutes at 26.7°C (80°F) If any electrical accessories are used, use a second battery to power them.
E 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. Conversely, a larger-pitch propeller is more suitable for a smaller operating load.
E EMU01209 START-IN-GEAR PROTECTION Yamaha outboard motors or Yamaha approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is Neutral. Always select Neutral before starting the engine.
E EMU00037 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-2 Remote control .....................................2-2 Trim tab .................................................2-6 Power trim/tilt switch ...........................2-7 Digital tachometer................................2-8 Digital speedometer...........................2-10 Tilt support lever ................................
E EMU01206 MAIN COMPONENTS q !0 o w w 000511 !1 i u !3 !2 YAMAHA SPEED y Km/h knot mph km mile TRIP TIME BATT set t mode e !4 r 000510 1 2 3 *4 5 6 7 8 Top cowling Top cowling lock levers Trim tab (Anode) Propeller Cooling water inlet Anti-cavitation plate Anode Tilt support lever * * * * 9 0 q w e r Flushing device Power trim and tilt switch Remote control box Digital tachometer Digital speedometer Remote oil tank * May not be exactly as shown; also may not be included as standard e
E EMU00039 y q OPERATIONS OF CONTROLS AND OTHER FUNCTIONS w e r t u EMU00096 REMOTE CONTROL 000608 Both the shifter and the throttle are actuated by the remote control lever. In addition, this control also has the electrical switches.
E EMU00099 Neutral Interlock Trigger To shift out of Neutral, the neutral interlock trigger of the remote control lever must first be pulled up. EMU00100 701034* N q w 701033 Neutral Throttle Lever To open the throttle without shifting into either Forward or Reverse, place the remote control lever in the Neutral position and lift the neutral throttle lever. NOTE: The neutral throttle lever will operate only when the remote control lever is in Neutral.
E EMU00934 q w 000569 Engine Stop Lanyard Switch The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 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.
E EMU01331 UP DN UP DN 701034 Power Trim/Tilt Switch The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the remote control lever grip. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.
E EMU01552 TRIM TAB The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force. w An improperly adjusted trim tab may cause difficult steering. Always test run after the trim tab has been installed or replaced to be sure steering is correct. Be sure you have tightened the bolt after adjusting the trim tab.
E EMU01563 POWER TRIM/TILT SWITCH UP DN 302022 The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the side of the bottom engine cowling. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down. When the switch button is released, the motor will stop in its current position.
E EMU01614 DIGITAL TACHOMETER q w e t y r u 001078 This gauge contains the tachometer, trim meter, hour meter, oil level indicator, and the overheat warning indicator. 1 2 3 4 5 6 7 Tachometer Trim meter Hour meter Oil level indicator Overheat warning indicator Set button Mode button NOTE: All segments of the display will light momentarily after the main switch is turned on and will return to normal thereafter. 001082 EMU00136 Tachometer This meter shows the engine speed.
E EMU01620 001087 Hour Meter This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off.
E EMU01553 Overheat Warning Indicator If the engine temperature rises too high, the warning indicator will start to blink. Refer to “OVERHEAT WARNING” for details. q 1 Overheat warning indicator 001052 cC Do not continue to operate the engine if a warning device has activated. If necessary, refer to the “TROUBLESHOOTING” section in this manual. Consult your dealer if the problem cannot be located and corrected.
E EMU00141 YAMAHA SPEED Km/h knot mph km mile TRIP TIME set BATT mode 802034 Speedometer This meter shows the boat speed. NOTE: The speedometer displays km/h, mph, or knots, depending upon operator preference. Select the desired unit of measurement by setting the selector switch on the back of the meter. See the illustration for settings.
E EMU01275 YAMAHA SPEED Km/h knot mph km mile TRIP TIME set BATT mode 802025* Clock This meter shows the current time. Repeatedly push and release the “mode” button until the indicator on the face of the meter points to “TIME.” To set the clock, be sure the meter is in the “TIME” mode. Press the “set” button; the hour display will begin blinking. Press the “mode” button until the desired hour is displayed. Press the “set” button again, the minute display will begin blinking.
E EMU01555 YAMAHA SPEED Km/h knot mph w km mile TRIP TIME set q BATT mode 802031 Warning indicators 8 Fuel warning If the fuel level decreases to one segment the fuel level warning segment 1 will begin blinking. 8 Low battery voltage warning If battery voltage drops, the display 2 will automatically turn on and begin blinking. cC Do not continue to operate the engine if a warning device has activated. Refer to the “TROUBLESHOOTING” section in this manual.
E EMU01180 TOP COWLING LOCK LEVERS To remove the engine top cowling, pull up the front and rear lock levers. Then lift off the cowling. When replacing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by moving the levers downward. 301052 cC The air intake grills 1 on the top cowling are not designed as handles and may break if used as such.
E EMU00169 WARNING SYSTEM cC Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. 001053 EMU01476 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate. (1) ; Included (—); N/A Activation of warning device 701054 Tiller control model The engine speed will automatically decrease to about 2,000 r/min.
E EMU00172 OIL LEVEL WARNING / OIL FILTER CLOGGING WARNING This engine has an oil level warning system. If oil level falls below lower limit, the warning device will activate. (1); Included (—); N/A Warning device activation 001094 q 213032 q 905012 Tiller control model Remote control model The engine speed will automatically decrease to about 2,000 r/min. 1 The oil level warning indicator will come on. 1 The buzzer will sound.
E – MEMO –
E EMU00174 Chapter 3 OPERATION 1 INSTALLATION ........................................3-1 Mounting the outboard motor............3-2 BREAKING IN (RUNNING IN) ENGINE ..3-4 2 PRE-OPERATION CHECKS ......................3-5 Operation after a long period of storage...................................................3-7 FILLING FUEL AND ENGINE OIL ............3-8 Filling fuel..............................................3-8 Filling oil ................................................3-9 STARTING ENGINE .....
E EMU00175 INSTALLATION cC Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat or accessories such as transom ladders/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.
E EMU01478 MOUNTING THE OUTBOARD MOTOR w 8 Overpowering a boat may cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer. 8 The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat/motor combination.
E Mount the outboard motor on the center line (keel line) of the boat, and ensure that the boat itself is well balanced. Otherwise, the boat will be hard to steer. For boats without a keel or which are asymmetrical, consult your dealer. 1 Center line (keel line) q 104016 EMU01566 Mounting Height To run your boat at optimum efficiency, the water-resistance (drag) of the boat and outboard motor must be made as little as possible.
E EMU01494 BREAKING IN (RUNNING IN) ENGINE Your new engine requires a period of break-in (running-in) to allow mating surfaces of moving parts to wear-in evenly. Correct break-in (running-in) will help ensure proper performance and longer engine life. cC Do not use fuel mixed with oil during break-in or under any circumstances. 000106 8 Failure to follow the break-in (runningin) procedure may result in reduced engine life or even severe engine damage.
E 2) 3) 4) 5) Next 50 minutes: Do not exceed half throttle (approximately 3,000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 r/min or less. Second hour: Accelerate at full throttle onto plane, then reduce engine speed to threequarter throttle (approximately 4,000 r/min). Vary engine speed occasionally.
E EMU00206 Fuel 8 Check to be sure you have plenty of fuel for your trip. 8 Make sure there are no fuel leaks or gasoline fumes. 8 Check fuel line connections to be sure they are tight. 8 Be sure the fuel tank is positioned on a secure, flat surface, and that the fuel hose is not twisted or flattened, or likely to contact sharp objects. EMU00207 Oil 8 Check to be sure you have plenty of oil for your trip.
E EMU01184 OPERATION AFTER A LONG PERIOD OF STORAGE (for Yamaha oil injection system model) When operating the engine after a long period (12 months) of storage, proceed as follows: 1) Start the engine. Leave it idling. w 8 Do not touch or remove electrical parts when starting or during operation. 8 Keep hands, hair, and clothes away from flywheel and other rotating parts while engine is running. 2) 212023 Watch for oil flowing through the oil feed pipes.
E EMU00186 FILLING FUEL AND ENGINE OIL EMU01031 FILLING FUEL 1) 2) 3) Remove the fuel tank cap. Fill the fuel tank carefully. Close the cap securely after refueling. Wipe up any spilled fuel. EMU01019 Ring Free Fuel Additive Gasoline is a precise blend of many different substances, each chosen to give certain characteristics. Gasoline blends have been changing in recent years in response to concerns about pollution and resulting emissions regulations.
E EMU01185 FILLING OIL (for Yamaha oil injection system model) This engine uses the Yamaha oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operating conditions. No fuel pre-mixing is needed. Simply pour gasoline into the fuel tank and oil into the oil tank. Convenient indicators show the status of the oil supply. Refer to the section “OIL LEVEL INDICATOR” for details.
E EMU01543¯ Oil Level Indicator The various oil level system functions are as follows: Oil level Oil level indicator (Digital indicator (Analog tachometer) tachometer) Green Yellow Red Red Green Engine oil tank Remote oil tank Remarks More than 300 cm3 (0.32 US qt, 0.26 Imp qt) More than 1,500 cm3 (1.6 US qt, 1.31 Imp qt) • No refilling necessary. More than 300 cm3 (0.32 US qt, 0.26 Imp qt) 1,500 cm3 (1.6 US qt, 1.31 Imp qt) or less • Add oil, refer to “FILLING OIL.” 300 cm3 (0.32 US qt, 0.
E EMU01197 STARTING ENGINE w 8 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. 8 When the air vent screw is loosened, gasoline (petrol) vapor will be released. Gasoline (petrol) 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.
E EMU00248 PROCEDURE FOR REMOTE CONTROL MODEL N 4) 701015 Place the remote control lever in the Neutral position. NOTE: The start-in-gear protection device permits the engine to be started only when it is in Neutral. 5) 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 in the engine stop switch.
E EMU00949 OFF ON Electric Start Model 7) Turn the main switch to “START”, and hold it for a maximum of 5 seconds. 8) Immediately after the engine starts, release the main switch to return it to “ON”. START 701022 cC 8 Do not turn the main switch to “START” when the engine is running. 8 Do not keep the starter-motor turning for more than 5 seconds. The battery will rapidly become exhausted and it will be impossible for it to start the engine.
E EMU00261 SHIFTING w Before shifting, make sure there are no swimmers or obstacles in the water near you. cC To change the shifting position from forward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speeds). N F EMU00264 FORWARD 701043 Pull up the neutral interlock trigger (If equipped) and move the remote control lever quickly and firmly from Neutral to Forward. EMU00269 REVERSE w When operating in Reverse, go slowly.
E EMU00273 STOPPING ENGINE Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended. EMU01199 1) 2) ON OFF START 701023 Turn the main switch to “OFF”. If there is a fuel joint or a fuel cock on the boat, disconnect the fuel line or close the fuel cock after stopping the engine. 3) Tighten the air vent screw on the fuel tank cap after stopping the engine, if it is equipped.
E EMU01412 TRIMMING OUTBOARD MOTOR The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The 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.
E ADJUSTING TRIM ANGLE EMU01401 Power Trim/Tilt Model w 8 Be sure all people are clear of the outboard motor when adjusting the trim/tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket. 8 Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems.
E EMU01558 Bow Up When the boat is on plane, a bow-up attitude results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. When trimmed out, the boat may have more 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. q 105011 w Too much trim-out puts the bow of the boat too high in the water.
E EMU01200 TILTING UP/DOWN 000516 If the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion. cC Before tilting the motor, follow the procedures under “STOPPING ENGINE”. Never tilt the motor while the engine is running. Severe damage from overheating can result.
E EMU01548 UP PROCEDURE FOR TILTING UP Power trim/tilt models UP DN 1) 2) DN 702014 3) If there is a fuel joint or a fuel cock on the boat, disconnect the fuel line or close the fuel cock. Push the power trim/tilt switch “UP” until the outboard has tilted up completely. Turn the tilt-support lever toward you and support the engine. w After tilting the engine, be sure to support it with the tilt-support lever.
E EMU00316 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 cloggedup with salt deposits. NOTE: Refer to cooling system flushing instructions in “TRANSPORTING AND STORING OUTBOARD MOTOR”. CRUISING IN TURBID WATER It is strongly recommended that the optional chromium-plated water-pump kit be installed if the outboard is to be used in turbid (muddy) water conditions.
E EMU00317 Chapter 4 MAINTENANCE SPECIFICATION DATA.............................4-1 TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-3 Trailering outboard motor...................4-3 Storing outboard motor ......................4-4 PERIODIC MAINTENANCE......................4-8 Replacement parts ...............................4-8 Maintenance chart................................4-9 Greasing ..............................................4-10 Cleaning and adjusting spark plug...
E EMU00318* SPECIFICATION DATA Model Item Unit VZ150TRA DIMENSIONS Overall Length Overall Width Overall Height Transom height Weight L L L mm (in.) mm (in.) mm (in.) mm (in.) kg (lb.) 792 (31.2) 554 (21.8) 1,693 (66.6) 516 (20.3) 217 (478) PERFORMANCE Full throttle operating range Maximum output Idling speed (Neutral) r/min kW (HP) @ r/min r/min 4,500 - 5,500 110.
E VZ175TRA VZ200TRA 792 (31.2) 554 (21.8) 1,693 (66.6) 516 (20.3) 217 (478) 792 (31.2) 554 (21.8) 1,693 (66.6) 516 (20.3) 217 (478) 4,500 - 5,500 128.7 (175) @ 5,000 670 - 730 4,500 - 5,500 147.1 (200) @ 5,000 670 - 730 2-stroke, 76°V6 2,596 (158.4) 90.0 × 68.0 (3.54 × 2.68) TCI BKR7EKU 1.5 - 1.6 (0.059 - 0.062) Remote control Electric start 12-100 - 120 512 182 12-45 Electronic Fuel Injection 2-stroke, 76°V6 2,596 (158.4) 90.0 × 68.0 (3.54 × 2.68) TCI BKR7EKU 1.5 - 1.6 (0.059 - 0.
E EMU01369 TRANSPORTING AND STORING OUTBOARD MOTOR w 000515 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. EMU00326 TRAILERING OUTBOARD MOTOR 102074 The motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the motor in the tilt position using a motor support device such as a transom saver bar.
E EMU01187 STORING OUTBOARD MOTOR When storing your Yamaha outboard for prolonged periods of time, (2 months or longer), several important procedures must be performed to prevent expensive damage. This is especially important for your Yamaha oil injection systemequipped outboard due to the lean oil ratios used at idle prior to shutting the engine off for the season. It is advisable to have your outboard serviced by an authorized Yamaha dealer prior to storage.
E EMU00338 903021 Flushing Cooling System and Fogging Engine Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging of the engine is mandatory to prevent expensive engine damage due to rust. Perform the flushing and fogging at the same time. w 8 Do not touch or remove electrical parts when starting or during operation. 8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running.
E EMU01568 Lubrication 1) Remove the spark plug(s). Spray “Yamaha Stor-Rite Engine Fogging Oil” into each cylinder for 5 seconds. Grease the spark plug threads and reinstall the spark plug(s) and torque to proper specification. (Refer to the section “CLEANING AND ADJUSTING SPARK PLUG” for details). 2) Turn the engine over with the stop lanyard disconnected to work the fogging oil into the piston rings. 3) Fill the oil tanks. This prevents the formation of condensation.
E 3) Wax the cowling with a non-abrasive wax such as “Yamaha Silicone Wax” (Part No. ACC-11000-15-02). EMU01545 Battery Care w Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.
E 2) 3) EL LEV EL ER V UPP ER LE LOW 4) 901015 Clean the battery casing and terminals. Fill each cell to the upper level with distilled water. Store the battery on a level surface in a cool, dry, well-ventilated place out of direct sunlight. Once a month, check the specific gravity of the electrolyte and recharge as required to prolong battery life. EMU01569 PERIODIC MAINTENANCE w Be sure to turn off the engine when you perform maintenance unless otherwise specified.
E EMU00362* MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. The mark (6) indicates the check-ups which you may carry out yourself. The mark (1) indicates work to be carried out by your Yamaha dealer.
E EMU00366 GREASING Yamaha marine grease (Water resistant grease) 000523 4-10
E EMU01202 CLEANING AND ADJUSTING SPARK PLUG w 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.
E Spark plug gap: Refer to “SPECIFICATIONS”, page 4-1. When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque. Spark plug torque: Refer to “SPECIFICATIONS”, page 4-1. NOTE: If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past finger-tight.
E EMU01509 CHECKING FUEL SYSTEM w Gasoline (petrol) and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition. Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by Yamaha dealer or other qualified mechanic. 106092 Checkpoints 8 Fuel system parts leakage. 8 Fuel hose joint leakage. 8 Fuel hose cracks or other damage. 8 Fuel connector leakage.
E EMU00370 INSPECTING FUEL FILTER w Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly doing this procedure, consult your Yamaha dealer. 8 Do not perform this procedure on a hot or running engine. Allow the engine to cool. 8 There will be fuel in the fuel filter. Keep away from sparks, cigarettes, flames or other sources of ignition. 8 This procedure will allow some fuel to spill. Catch fuel in a rag.
E 4) 5) 6) Reinstall the filter element. Make sure the O-ring is in position in the cup. Insert the cup and O-ring into the filter housing 6. Screw the ring nut onto the filter housing until the ring is lightly seated. Tighten the ring nut approximately an additional 1/4 turn until ring nut is tight. Align one of the four larger ring nut tabs into the slot of the locking tab. Install the locking tab bolt and tighten. Run the engine and check the filter and lines for leaks.
E q 204063 A diagnostic tachometer should be used for this procedure. 1) Start the engine and allow it to warm up fully in Neutral until it is running smoothly. If the outboard is mounted on a boat, be sure the boat is tightly moored. 2) Adjust the throttle stop-screw 1 to set the idling speed to specification (see “SPECIFICATIONS” on page 4-1) by turning the stop-screw clockwise to increase the idling speed, and turning it counterclockwise to decrease the idling speed.
E EMU01189 CHECKING HIGH PRESSURE FUEL PUMP DRIVE BELT 206016 Inspect the high pressure fuel pump drive belt and replace it if any of the following signs is observed: 8 Cracks in the back of the belt or in the base of belt teeth. 8 Excessive wear at the roots of cogs. 8 Rubber portion swollen by oil. 8 Belt surfaces roughened. 8 Signs of wear on edges or outer surface of belt. cC Consult your Yamaha dealer when replacing or adjusting the high pressure fuel pump drive belt.
E EMU01330 r e e w t q r 000500 t REPLACING FUSE If a fuse has blown, remove the electrical cover, open the fuse holder and remove the fuse with a fuse puller. Replace it with a spare one of proper amperage. w Be sure to use the specified fuse. An incorrect fuse or a piece of wire may allow excessive current flow. This could cause electrical system damage and a fire hazard. NOTE: If the new fuse blows again immediately, consult a Yamaha dealer.
E EMU00993 CHECKING POWER TRIM AND TILT SYSTEM w 8 Never get under the lower unit while it is tilted, even when the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls. 8 Make sure no one is under the outboard before performing this test. 1) q w 411046 e 411044 Check the power trim and tilt unit for any sign of oil leaks. 2) Operate each of the power trim and tilt switches on remote control and engine bottom cowling (If equipped) to check that all switches work.
E EMU00388 CHECKING PROPELLER w 210012 602051 You could be seriously injured if the engine accidentally starts while you are near the propeller. 8 Before inspecting, removing or installing the propeller, remove the spark plug caps from the spark plugs. Also, put the shift control in Neutral, put the main switch in the “OFF” position and remove the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one.
E EMU01560 Installing the Propeller cC 8 Be sure to install the thrust washer before installing propeller, otherwise the lower case and propeller boss may be damaged. 8 Be sure to use a new cotter pin and bend the ends over securely. Otherwise, the propeller could come off during operation and be lost. 1) 2) 3) Apply Yamaha Marine grease or Corrosion resistant grease to the propeller shaft. Install the thrust washer and propeller on the propeller shaft. Install the spacer and washer.
E EMU01460 CHANGING GEAR OIL w 8 Be sure the outboard is securely fastened to the transom or a stable stand. You could be severely injured if the outboard falls on you. 8 Never get under the lower unit while it is tilted, even when the tilt-support lever/knob is locked. Severe injury could occur if the outboard accidentally falls. 1) Tilt the outboard motor so that the oil drain plug is at the lowest point possible. 2) Place a suitable container under the gear-case. 3) Remove the oil drain plug 1.
E 5) With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the oil drain plug hole. Gear oil grade/capacity: Refer to “SPECIFICATIONS,” page 4-1. 6) 601033 7) When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. Insert and tighten the oil drain plug. EMU01462 INSPECTING AND REPLACING ANODE(S) 603024 Yamaha outboard motors are protected from corrosion by sacrificial anodes.
E EMU00404 CHECKING BATTERY (for Electric start models) w Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: 8 Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury. 8 Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): 8 SKIN - Flush with water. 8 EYES - Flush with water for 15 minutes and get immediate medical attention.
E cC 8 A poorly maintained battery will quickly deteriorate. 8 Ordinary tap-water contains minerals harmful to a battery, and should not be used for topping-up. 1) 2) 3) Check the electrolyte level at least once a month. Fill to the manufacturer’s recommended level when necessary. Top up only with distilled water (or pure de-ionized water suitable to use in batteries). Keep the battery always in a good state of charge. Installing a voltmeter will help you monitor your battery.
E cC 8 Make sure the main switch (on applicable models) is “OFF” before working on the battery. 8 Reversal of the battery leads will damage the rectifier. 8 Connect the RED lead first when installing the battery and disconnect the RED lead last when removing it. Otherwise, the electrical system can be damaged. 8 The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine.
E EMU01280 Disconnecting the Battery Disconnect the BLACK lead from the NEGATIVE (-) terminal first. Then disconnect the RED lead from the POSITIVE (+) terminal. EMU00408 CHECKING BOLTS AND NUTS 1) 2) 4-27 Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torque. Check the tightening torque of other bolts and nuts.
E EMU01172 CLEANING COOLING-WATER PASSAGES Flushing device equipped model Perform this procedure right after operation for the most thorough flushing. 1) After shutting off the engine, unscrew the garden-hose connector 2 from the fitting 1 on the bottom cowling. 2) Screw the garden-hose connector 2 onto a garden hose 3 which is connected to a fresh-water supply. 3) With the engine off, turn on the water tap and let the water flush through the cooling passages for about 15 minutes.
E EMU00409 MOTOR EXTERIOR EMU00410 Cleaning the Outboard Motor After use, wash the exterior of the outboard with fresh water. Flush the cooling system with fresh water. NOTE: Refer to Flushing Cooling System instructions in “TRANSPORTING AND STORING OUTBOARD MOTOR”. EMU00412 Checking Painted Surface of Motor Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas.
E EMU00414 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING ..............................5-1 TEMPORARY ACTION IN EMERGENCY ............................................5-5 Impact damage.....................................5-5 Power trim/tilt will not operate ...........5-5 Starter will not operate ........................5-6 Low oil level warning activates...........5-8 Treatment of submerged motor.......
E EMU01204 TROUBLESHOOTING A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.) If your outboard motor requires repair, bring it to a Yamaha dealer. Trouble Possible Cause 1. Battery capacity weak or low. 2. Battery connections loose or corroded. 3.
E Trouble Possible Cause 1. Spark plug(s) fouled or incorrect type. 2. Fuel system obstructed. 3. Fuel contaminated or stale. 4. Fuel filter clogged. 5. Failed ignition parts. 6. Warning system activated. 7. Spark plug gap incorrect. 8. Poor connections or damaged ignition wiring. C. Engine idles irregularly or stalls. 9. Specified engine oil not used. 10. Thermostat faulty or clogged. 11. Fuel pump damaged. 12. Air vent screw on the fuel tank closed. 13. Choke knob pulled out. 14. Motor angle too high.
E Trouble Possible Cause 1. Cooling system clogged. 2. Engine oil level low. 3. Heat range of spark plug incorrect. 4. Specified engine oil not used. D. Warning buzzer sounds or indicator lamp lights. 5. Engine oil contaminated or deteriorated. 6. Oil filter clogged. 7. Oil feed/injection pump malfunctions. 8. Load on boat improperly distributed. 9. Water pump/thermostat faulty. 1. Propeller damaged. 2. Propeller pitch or diameter incorrect. 3. Trim angle incorrect. E. Engine power loss. 4.
E Trouble Possible Cause 13. Poor connections or damaged ignition wiring. 14. Failed ignition parts. 15. Specified engine oil not used. 16. Thermostat faulty or clogged. E. Engine power loss. 17. Air vent screw closed. 18. Fuel pump damaged. 19. Fuel joint connection incorrect. 20. Heat range of spark plug incorrect. 21. High pressure fuel pump drive belt broken. 22. Engine not responding properly to shift lever position. 1. Propeller damaged. 2. Propeller shaft damaged. F. Engine vibrates excessively.
E EMU00416 TEMPORARY ACTION IN EMERGENCY EMU01492 IMPACT DAMAGE w The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate. 607011 If the outboard motor hits any object in the water, follow the procedure below. 1) Stop the engine immediately. 2) Inspect the control system and all components for damage. Also, inspect the boat for damage.
E EMU01561 STARTER WILL NOT OPERATE If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be manually started with an emergency starter rope. However, the engine can not be manually started if the battery voltage is low. If the battery is discharged to 9 volts or below, the electrical fuel pump will not operate. w 8 Use this procedure only in an emergency and only to return to port for repairs.
E EMU01309 Emergency Starting Engine 1) Remove the top cowling. 301052 2) 3) Remove the flywheel cover. Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch. 4) Turn the main switch to the ON position. 5) Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise. Give a strong pull straight out to crank the engine.
E EMU01565 LOW OIL LEVEL WARNING ACTIVATES q 218013 If the oil level is allowed to drop too low, the red segment will appear on the oil level indicator, the buzzer will sound, and engine speed will be limited to about 2,000 r/min. If this happens, a reserve amount of oil can be pumped from the remote oil tank 3 to the engine oil tank 2 using the emergency switch 1. w Be sure to stop the engine before performing this procedure.
E NOTE: 8 Reserve oil capacity is maximum 1,500 cm3 (1.6 US qt, 1.31 Imp qt). 8 The oil feed pump will not operate if the engine is tilted more than 35°. Put the engine in the down position before operating the emergency switch.
E EMU01511 TREATMENT OF SUBMERGED MOTOR 107012 If the outboard motor is submerged, immediately take it a Yamaha dealer. Otherwise, some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure below in order to minimize engine damage. EMU00449 1) 2) 3) 107013 4) 5) Thoroughly wash away mud, salt, seaweed, etc. with fresh water.
E – MEMO –
E EMU00450 Chapter 6 INDEX INDEX........................................................
E EMU00451 INDEX A Adjusting idling speed ..........................4-15 Adjusting trim angle..............................3-17 B Basic boating rules ..................................1-7 Battery care...............................................4-7 Battery requirement ..............................1-13 Bow down...............................................3-18 Bow up ....................................................3-18 Breaking in (running in) engine..............3-4 C Changing gear oil.............
E Mounting the outboard motor ...............3-2 N Neutral interlock trigger ..........................2-3 Neutral throttle lever ...............................2-3 O Oil level indicator............................2-9, 3-10 Oil level warning/ oil filter clogging warning.....................2-16 Operation after a long period of storage ......................................................3-7 Operations of controls and other functions ...................................................
EMU01599 IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha. Yamaha is ready to stand behind your purchase with strong warranty coverage.
5. Your warranty applies specifically to repairs made in the country of purchase. If your U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian purchased Yamaha needs service while in the United States, Yamaha will assist the local dealer whenever possible. However, some products available in one country may not be sold or serviced in the other. 6.
EMU00912* YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. is proud of its heritage and reputation for producing products with high standards of quality and workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Outboard Limited Warranty is your assurance of this commitment.
SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs, shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes are not covered by warranty. Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yamaha outboard dealer are excluded from warranty coverage.
CUSTOMER SERVICE If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you.
EMU01178 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is committed to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfaction with your Yamaha. This model was manufactured as a U.S.A.
Printed in Japan April 2001—0.
