· pdf filef4 f6 owner’s manual lit-18626-08-90 6bv-f8199-11 u.s.a.edition read this...

F4F6

OWNER’S MANUAL

LIT-18626-08-906BV-F8199-11

U.S.A.Edition Read this manual carefully before operating this outboard motor.

DIC183

ZMU01690

Read this manual carefully before operating this outboard motor. Keep thismanual onboard in a waterproof bag when boating. This manual should staywith the outboard motor if it is sold.

U6BV10E0.book Page 1 Friday, July 17, 2009 2:29 PM

Important manual informationEMU31284

To the ownerThank you for selecting a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understanding ofthese simple instructions will help you obtainmaximum enjoyment from your new Yamaha.If you have any question about the operationor maintenance of your outboard motor,please consult a Yamaha dealer.In this Owner’s Manual particularly importantinformation is distinguished in the followingways.

: This is the safety alert symbol. It is usedto alert you to potential personal injury haz-ards. Obey all safety messages that followthis symbol to avoid possible injury or death.

WARNINGEWM00781

A WARNING indicates a hazardous situa-tion which, if not avoided, could result indeath or serious injury.

NOTICEECM00701

A NOTICE indicates special precautionsthat must be taken to avoid damage to theoutboard motor or other property.

TIP:A TIP provides key information to make pro-cedures easier or clearer.

Information about the owner’s manualYamaha continually seeks advancements inproduct design and quality. Therefore, whilethis manual contains the most current productinformation available at the time of printing,there may be minor discrepancies between

your machine and this manual. If there is anyquestion concerning this manual, please con-sult your Yamaha dealer.

TIP:The F4MHA, F6MHA and the standard acces-sories are used as a base for the explanationsand illustrations in this manual. Thereforesome items may not apply to every model.EMU25132

F4, F6OWNER’S MANUAL

©2009 by Yamaha Motor Corporation, U.S.A.

1st Edition, December 2009All rights reserved.

Any reprinting or unauthorized usewithout the written permission ofYamaha Motor Corporation, U.S.A.

is expressly prohibited.Printed in France

P/N LIT-18626-08-90

info1 Page 1 Wednesday, December 9, 2009 11:39 AM

Table of contents

Safety information.............................1Outboard motor safety .................... 1

Propeller ............................................. 1Rotating parts ..................................... 1Hot parts............................................. 1Electric shock ..................................... 1Engine shut-off cord (lanyard) ............ 1Gasoline ............................................. 1Gasoline exposure and spills ............. 1Carbon monoxide ............................... 1Modifications ...................................... 2

Boating safety ................................. 2Alcohol and drugs............................... 2Personal flotation devices .................. 2People in the water............................. 2Passengers ........................................ 2Overloading ........................................ 2Avoid collisions................................... 2Weather.............................................. 3Accident reporting .............................. 3Boat education and training................ 3Passenger training ............................. 3Boating safety publications................. 3Laws and regulations ......................... 3

Boating organizations...................... 4Basic boating rules

(Rules of the road) ....................... 4Steering and sailing rules and sound

signals............................................. 4Rules when encountering vessels...... 5Other special situations ...................... 6

General information ..........................8Identification numbers record.......... 8

Outboard motor serial number ........... 8Read manuals and labels................ 9

Warning labels.................................... 9Specifications and requirements... 12

Specifications ................................ 12Installation requirements ............... 13

Boat horsepower rating .................... 13Mounting the outboard motor ........... 13

Propeller selection ........................ 13Start-in-gear protection ................. 14Engine oil requirements ................ 14Fuel requirements ......................... 14

Gasoline ........................................... 14Ring Free Fuel Additive.................... 15

Anti-fouling paint ........................... 15Motor disposal requirements......... 15Emergency equipment .................. 15Emission control information......... 16

North American models .................... 16Star labels ........................................ 16

Components .................................... 18Components diagram.................... 18

Fuel tank (built-in fuel tank) .............. 18Fuel tank (portable fuel tank)............ 19Fuel cock .......................................... 19Tiller handle...................................... 20Gear shift lever ................................. 20Throttle grip ...................................... 20Throttle indicator............................... 21Throttle friction adjuster .................... 21Engine shut-off cord (lanyard) and

clip................................................. 22Engine stop button ........................... 22Choke knob for pull type................... 22Fuel joint cap .................................... 22Manual starter handle....................... 23Steering friction adjuster................... 23Trim rod (tilt pin) ............................... 23Tilt lock mechanism.......................... 23Tilt support bar ................................. 24Cowling lock lever ............................ 24Carrying handle ................................ 24

Installation ....................................... 26Installation..................................... 26

Mounting the outboard motor ........... 26Clamping the outboard motor ........... 28

Operation ......................................... 29First-time operation ....................... 29

Fill engine oil .................................... 29Breaking in engine............................ 29Getting to know your boat ................ 29


Table of contents

Checks before starting engine ...... 29Fuel level .......................................... 29Removing top cowling ...................... 30Fuel system...................................... 30Controls ............................................ 30Engine shut-off cord (lanyard) .......... 31Engine oil.......................................... 31Engine .............................................. 32Installing top cowling ........................ 32

Filling fuel ...................................... 32Operating engine........................... 34

Sending fuel ..................................... 34Starting engine ................................. 36

Checks after starting engine ......... 38Cooling water ................................... 38

Warming up engine ....................... 38Warming up ...................................... 38

Checks after engine warm up ....... 39Shifting ............................................. 39Stop switches ................................... 39

Shifting .......................................... 39Stopping boat ................................ 40Stopping engine ............................ 40

Procedure......................................... 40Trimming outboard motor.............. 41

Adjusting trim angle for manual tilt models .......................................... 41

Adjusting boat trim............................ 42Tilting up and down ....................... 43

Procedure for tilting up ..................... 43Procedure for tilting down................. 44

Shallow water................................ 45Cruising in shallow water.................. 45

Cruising in other conditions........... 46Maintenance..................................... 47

Transporting and storing outboard motor .......................................... 47Dismounting the outboard motor ...... 47Storing outboard motor..................... 49Procedure......................................... 50Lubrication........................................ 52Cleaning and anticorrosion

measures ...................................... 52

Cleaning the outboard motor ............ 52Checking painted surface of motor... 52

Periodic maintenance ................... 53Replacement parts ........................... 53Maintenance interval guidelines ....... 53Maintenance chart 1......................... 54Maintenance chart 2......................... 56Greasing........................................... 57Cleaning and adjusting spark plug ... 58Checking fuel filter ............................ 58Inspecting idle speed........................ 59Changing engine oil.......................... 59Checking connector and lead........... 61Checking propeller ........................... 61Removing propeller .......................... 61Installing propeller ............................ 62Changing gear oil ............................. 62Inspecting and replacing anode

(external) ....................................... 63Trouble Recovery............................ 64

Troubleshooting ............................ 64Temporary action in emergency ... 66

Impact damage................................. 66Starter will not operate ..................... 66Emergency engine starting............... 67

Treatment of submerged motor .... 69Consumer information ................... 70

YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY ............... 70

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA............. 72


1

Safety informationEMU33622

Outboard motor safetyObserve these precautions at all times.EMU36501

PropellerPeople can be injured or killed if they come incontact with the propeller. The propeller cankeep moving even when the motor is in neu-tral, and sharp edges of the propeller can cuteven when stationary.� Stop the engine when a person is in the wa-

ter near you.� Keep people out of reach of the propeller,

even when the engine is off.EMU33630

Rotating partsHands, feet, hair, jewelry, clothing, PFDstraps, etc. can become entangled with inter-nal rotating parts of the engine, resulting in se-rious injury or death.Keep the top cowling in place whenever pos-sible. Do not remove or replace the cowlingwith the engine running.Only operate the engine with the cowling re-moved according to the specific instructions inthe manual. Keep hands, feet, hair, jewelry,clothing, PFD straps, etc. away from any ex-posed moving parts.EMU33640

Hot partsDuring and after operation, engine parts arehot enough to cause burns. Avoid touchingany parts under the top cowling until the en-gine has cooled.EMU33650

Electric shockDo not touch any electrical parts while startingor operating the engine. They can causeshock or electrocution.EMU33671

Engine shut-off cord (lanyard)Attach the engine shut-off cord so that the en-gine stops if the operator falls overboard orleaves the helm. This prevents the boat from

running away under power and leaving peo-ple stranded, or running over people or ob-jects.Always attach the engine shut-off cord to asecure place on your clothing or your arm orleg while operating. Do not remove it to leavethe helm while the boat is moving. Do not at-tach the cord to clothing that could tear loose,or route the cord where it could become en-tangled, preventing it from functioning.Do not route the cord where it is likely to beaccidentally pulled out. If the cord is pulledduring operation, the engine will shut off andyou will lose most steering control. The boatcould slow rapidly, throwing people and ob-jects forward.EMU33810

GasolineGasoline and its vapors are highly flam-mable and explosive. Always, refuel accord-ing to the procedure on page 34 to reduce therisk of fire and explosion.EMU33820

Gasoline exposure and spillsTake care not to spill gasoline. If gasolinespills, wipe it up immediately with dry rags.Dispose of rags properly.If any gasoline spills onto your skin, immedi-ately wash with soap and water. Changeclothing if gasoline spills on it.If you swallow gasoline, inhale a lot of gaso-line vapor, or get gasoline in your eyes, getimmediate medical attention. Never siphonfuel by mouth.EMU33900

Carbon monoxideThis product emits exhaust gases which con-tain carbon monoxide, a colorless, odorlessgas which may cause brain damage or deathwhen inhaled. Symptoms include nausea,dizziness, and drowsiness. Keep cockpit andcabin areas well ventilated. Avoid blocking ex-haust outlets.


Safety information

2

EMU33780

ModificationsDo not attempt to modify this outboard motor.Modifications to your outboard motor may re-duce safety and reliability, and render the out-board unsafe or illegal to use.EMU33740

Boating safetyThis section includes a few of the many im-portant safety precautions that you should fol-low when boating.EMU33710

Alcohol and drugsNever operate after drinking alcohol or takingdrugs. Intoxication is one of the most commonfactors contributing to boating fatalities.EMU33720

Personal flotation devicesHave an approved personal flotation device(PFD) on board for every occupant. Yamaharecommends that you must wear a PFDwhenever boating. At a minimum, childrenand non-swimmers should always wearPFDs, and everyone should wear PFDs whenthere are potentially hazardous boating condi-tions.EMU33731

People in the waterAlways watch carefully for people in the wa-ter, such as swimmers, skiers, or divers,whenever the engine is running. When some-one is in the water near the boat, shift intoneutral and stop the engine.Stay away from swimming areas. Swimmerscan be hard to see.The propeller can keep moving even whenthe motor is in neutral. Stop the engine whena person is in the water near you.EMU33751

PassengersConsult your boat manufacturer’s instructionsfor details about appropriate passenger loca-tions in your boat and be sure all passengersare positioned properly before accelerating

and when operating above an idle speed.Standing or sitting in non-designated loca-tions may result in being thrown either over-board or within the boat due to waves, wakes,or sudden changes in speed or direction.Even when people are positioned properly,alert your passengers if you must make anyunusual maneuver. Always avoid jumpingwaves or wakes.EMU33760

OverloadingDo not overload the boat. Consult the boat ca-pacity plate or boat manufacturer for maxi-mum weight and number of passengers. Besure that weight is properly distributed ac-cording to the boat manufacturers instruc-tions. Overloading or incorrect weightdistribution can compromise the boats han-dling and lead to an accident, capsizing orswamping.EMU33772

Avoid collisionsScan constantly for people, objects, and otherboats. Be alert for conditions that limit yourvisibility or block your vision of others.

Operate defensively at safe speeds and keepa safe distance away from people, objects,and other boats.� Do not follow directly behind other boats or

waterskiers.

ZMU06025


Safety information

3

� Avoid sharp turns or other maneuvers thatmake it hard for others to avoid you or un-derstand where you are going.

� Avoid areas with submerged objects orshallow water.

� Ride within your limits and avoid aggressivemaneuvers to reduce the risk of loss of con-trol, ejection, and collision.

� Take early action to avoid collisions. Re-member, boats do not have brakes, andstopping the engine or reducing throttle canreduce the ability to steer. If you are notsure that you can stop in time before hittingan obstacle, apply throttle and turn in anoth-er direction.

EMU33790

WeatherStay informed about the weather. Checkweather forecasts before boating. Avoid boat-ing in hazardous weather.EMU33800

Accident reportingBoat operators are required by law to file aBoating Accident Report with their state boat-ing law enforcement agency if their boat is in-volved in any of the following accidents:1. There is loss of life or probable loss of life.2. There is personal injury that requires

medical attention beyond first aid.3. There is property damage to boats or oth-

er property over a certain amount.4. There is complete loss of a boat.Contact local law enforcement personnel if areport is necessary.EMU33870

Boat education and trainingOperators should take a boating safetycourse. This may be required in your state.Many of the organizations listed in the nextsection can provide information about cours-es in your area.

You may also want to consider an Internet-based program for basic boater education.The Online Boating Safety Course providedby the BoatU.S. Foundation, is approved bythe National Association of State Boating LawAdministrators (NASBLA) and recognized bythe United States Coast Guard. Most, but notall, states accept this course to meet theirminimum requirements. While it cannot re-place an in-depth course such as one offeredby the U.S. Coast Guard, U.S. Power Squad-ron, or other organization, this online coursedoes provide a general overview of the basicsin boating safety, requirements, navigation,and operation. Upon successful completion ofthe course, the user can download a certifi-cate of completion immediately or, for a smallcharge, request one by mail. To take this freecourse, go to boatus.org.EMU33880

Passenger trainingMake sure at least one other passenger istrained to operate the boat in the event of anemergency.EMU33890

Boating safety publicationsBe informed about boating safety. Additionalpublications and information can be obtainedfrom many boating organizations.EMU33590

Laws and regulationsKnow the marine laws and regulations whereyou will be boating- and obey them. Severalsets of rules prevail according to geographiclocation, but all are basically the same as theInternational Rules of the Road. The rulespresented in the following section are con-densed- and have been provided for yourconvenience only.


Safety information

4

Contact the U.S. Coast Guard, the NationalAssociation of State Boating Law Administra-tors, or your local Power Squadron for a com-plete set of rules governing the waters inwhich you will be using your boat.EMU33682

Boating organizationsThe following organizations provide boatingsafety training and information about boatingsafety and laws.

United States Coast GuardConsumer Affairs Staff (G-BC)Office of Boating, Public, and Consumer Af-fairsU.S. Coast Guard HeadquartersWashington, D.C. 20593-0001http://www.uscgboating.org/

United States Power Squadrons1-888-FOR-USPS (1-888-367-8777)http://www.usps.org/

Boat Owners Association of The UnitedStates1-800-336-BOAT (1-800-336-2628)http://www.boatus.com/

National Association of State Boating LawAdministrators (NASBLA)1500 Leestown Road, Suite 330Lexington, KY 40511 859-225-9497http://www.nasbla.org/

National Marine Manufacturers Associa-tion (NMMA)200 East Randolph DriveSuite 5100Chicago, IL 60601http://www.nmma.org/

Marine Retailers Association of America155 N. Michigan Ave. Chicago,IL 60304http://www.mraa.com/

EMU33691

Basic boating rules (Rules of the road)

Just as there are rules that apply when youare driving on streets and highways, there arewaterway rules that apply when you are driv-ing your boat. These rules are used interna-tionally. (For U.S.A.: and are also enforced bythe United States Coast Guard and localagencies.) You should be aware of theserules, and follow them whenever you encoun-ter another vessel on the water.EMU33700

Steering and sailing rules and sound signalsWhenever two vessels on the water meet oneanother, one vessel has the right-of-way; it iscalled the “stand-on” vessel. The vessel thatdoes not have the right-of-way is called the“give-way” or “burdened”vessel. These rulesdetermine which vessel has the right-of-way,and what each vessel should do.

Stand-on vesselThe vessel with the right-of-way has the dutyto continue its course and speed, except toavoid an immediate collision. When you main-tain your direction and speed, the other vesselwill be able to determine how best to avoidyou.

Give-way vesselThe vessel that does not have the right-of-way has the duty to take positive and timelyaction to stay out of the way of the Stand-Onvessel. Normally, you should not cross in frontof the vessel with the right-of-way. You should


Safety information

5

slow down or change directions briefly andpass behind the other vessel. You should al-ways move in such a way that the operator ofthe other vessel can see what you are doing.“ The general prudential rule ”This rule is called Rule 2 in the InternationalRules and says,“ In obeying and construing these rules dueregard shall be had to all dangers of naviga-tion and collision, and to any special circum-stances, which may render a departure fromthe above rules necessary in order to avoidimmediate danger.”In other words, follow the standard rules ex-cept when a collision will occur unless bothvessels try to avoid each other. If that is thecase, both vessels become “ Give-Way ” ves-sels.EMU25521

Rules when encountering vesselsThere are three main situations that you mayencounter with other vessels which could leadto a collision unless the Steering Rules are fol-lowed:Meeting: (you are approaching another ves-sel head-on)Crossing: (you are traveling across the othervessel’s path)Overtaking: (you are passing or beingpassed by another vessel)In the following illustration, your boat is in thecenter. You should give the right-of-way toany vessels shown in white area (you are theGive-Way vessel). Any vessels in the shadedarea must yield to you (they are the Give-Wayvessels). Both you and the meeting vesselmust alter course to avoid each other.

MeetingIf you are meeting another power vessel headon, and are close enough to run the risk of col-lision, neither of you has the right-of-way Bothof you should alter course to avoid an acci-dent. You should keep the other vessel onyour port (left) side. This rule doesn’t apply ifboth of you will clear one another if you con-tinue on your set course and speed.

CrossingWhen two power driven vessels are crossingeach other’s path close enough to run the riskof collision, the vessel which has the other onthe starboard (right) side must keep out of theway of the other. If the other vessel is on yourright, you must keep out of its way; you are theGive-Way vessel. If the other vessel is onyour port (left) side, remember that youshould maintain course and direction, provid-ed the other vessel gives you the right-of-wayas it should.


Safety information

6

OvertakingIf you are passing another vessel, you are the“Give-Way” vessel. This means that the othervessel is expected to maintain its course andspeed. You must stay out of its way until youare clear of it. Likewise, if another vessel ispassing you, you should maintain your speedand direction so that the other vessel cansteer itself around you.EMU25531

Other special situationsThere are three other rules you should beaware of when driving your boat around othervessels.Narrow channels and bendsWhen navigating in narrow channels, youshould keep to the right when it is safe andpractical to do so. If the operator of a power-driven vessel is preparing to go around abend that may obstruct the view of other watervessels, the operator should sound a pro-longed blast on the whistle (4 to 6 seconds). Ifanother vessel is around the bend, it tooshould sound the whistle. Even if no reply isheard, however, the vessel should still pro-ceed around the bend with caution. If you nav-igate such waters with your boat, you willneed to carry a portable air horn, availablefrom local marine supply stores.

Fishing vessel right-of-wayAll vessels that are fishing with nets, lines ortrawls are considered to be “fishing vessels”under the International Rules. Vessels withtrolling lines are not considered fishing ves-sels. Fishing vessels have the right-of-way re-gardless of position. Fishing vessels cannot,however, impede the passage of other ves-sels in narrow channels.Sailing vessel right-of-waySailing vessels should normally be given theright-of-way. The exceptions to this are:1. When the sailing vessel is overtaking the

power-driven vessel, the power-drivenvessel has the right-of-way.

2. Sailing vessels should keep clear of anyfishing vessel.

3. In a narrow channel, a sailing vesselshould not hamper the safe passage of apower-driven vessel that can navigateonly in such a channel.

Reading buoys and other markersThe waters of the United States are markedfor safe navigation by the lateral system ofbuoyage. Simply put, buoys and markershave an arrangement of shapes, colors, num-bers and lights to show which side of the buoya boater should pass on when navigating in aparticular direction. The markings on thesebuoys are oriented from the perspective of be-ing entered from seaward (the boater is goingtowards the port). This means that red buoysare passed on the starboard (right) side whenproceeding from open water into port, andblack buoys are to port (left) side. When navi-gating out of port, your position with respect tothe buoys should be reversed; red buoysshould be to port and black buoys to star-board.


Safety information

7

Many bodies of water used by boaters are en-tirely within the boundaries of a particularstate. The Uniform State Waterway MarkingSystem has been devised for these waters.This system uses buoys and signs with dis-tinctive shapes and colors to show regulatoryor advisory information. These markers are

white with black letters and orange boarders.They signify speed zones, restricted areas,danger areas, and general information.Remember, markings may vary by geograph-ic location. Always consult local boating au-thorities before driving your boat in unfamiliarwaters.

ZMU01708


General information

8

EMU25171

Identification numbers recordEMU25183

Outboard motor serial numberThe outboard motor serial number is stampedon the label attached to the port side of theclamp bracket.Record your outboard motor serial number inthe spaces provided to assist you in orderingspare parts from your Yamaha dealer or forreference in case your outboard motor is sto-len.

1. Outboard motor serial number location

ZMU06705

1


General information

9

EMU33520

Read manuals and labelsBefore operating or working on this motor:� Read this manual.� Read any manuals supplied with the boat.� Read all labels on the outboard motor and the boat.If you need any additional information, contact your Yamaha dealer.EMU33831

Warning labelsIf these labels are damaged or missing, contact your Yamaha dealer for replacements.F4, F6

4

12

3

ZMU06709


General information

10

ZMU06860

1 2

3 4


General information

11

EMU35132

SymbolsThe following symbols mean as follows.

Notice/Warning

Read Owner’s Manual

Hazard caused by continuous rotation

Electrical hazard

ZMU05696

ZMU05664

ZMU05665

ZMU05666


Specifications and requirements

12

EMU38090

SpecificationsTIP:“(AL)” stated in the specification data belowrepresents the numerical value for the alumi-num propeller installed.

TIP:“*” means, select the engine oil referring to thechart of engine oil paragraph. For further infor-mation, see page 14.EMU2821G

Dimension:Overall length:

557 mm (21.9 in)Overall width:

329 mm (13.0 in)Overall height S:

1039 mm (40.9 in)Overall height L:

1166 mm (45.9 in)Transom height S:

435 mm (17.1 in)Transom height L:

562 mm (22.1 in)Weight (AL) S:

27.0 kg (60 lb)Weight (AL) L:

28.0 kg (62 lb)Performance:

Full throttle operating range:F4MHA 4000–5000 r/minF6MHA 4500–5500 r/min

Maximum output:F4MHA 2.9 kW@4500 r/min (4 HP@4500 r/min)F6MHA 4.4 kW@5000 r/min (6 HP@5000 r/min)

Idle speed (in neutral):1500 ±50 r/min

Engine:Type:

4-stroke SDisplacement:

139.0 cm³Bore × stroke:

62.0 × 46.0 mm (2.44 × 1.81 in)Ignition system:

CDISpark plug (NGK):

CR6HSBSpark plug gap:

0.6–0.7 mm (0.024–0.028 in)Control system:

Tiller handleStarting system:

Manual starterStarting carburetion system:

Choke valveValve clearance (cold engine) IN:

0.08–0.12 mm (0.0032–0.0047 in)Valve clearance (cold engine) EX:

0.08–0.12 mm (0.0032–0.0047 in)Drive unit:

Gear positions:Forward-neutral-reverse

Gear ratio:2.08(27/13)

Trim and tilt system:Manual tilt

Propeller mark:BA

Fuel and oil:Recommended fuel:

Regular gasolineMin. pump octane:

86Fuel tank capacity (built in type):

1.1 L (0.29 US gal, 0.24 Imp.gal)Recommended engine oil:

4-stroke outboard motor oil



13

Recommended engine oil group 1*:SAE 10W-30/10W-40/5W-30 API SE/SF/SG/SH/SJ/SL

Recommended engine oil group 2*:SAE 15W-40/20W-40/20W-50 API SH/SJ/SL

Engine oil quantity:0.6 L (0.63 US qt, 0.53 Imp.qt)

Lubrication:Wet sump

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:0.100 L (0.106 US qt, 0.088 Imp.qt)

Tightening torque for engine:Spark plug:

13.0 Nm (1.33 kgf-m, 9.6 ft-lb)Engine oil drain bolt:

18.0 Nm (1.84 kgf-m, 13.3 ft-lb)EMU33554

Installation requirementsEMU33563

Boat horsepower rating

WARNINGEWM01560

Overpowering a boat can cause severe in-stability.

Before installing the outboard motor(s), con-firm that the total horsepower of your motor(s)does not exceed the boats maximum horse-power rating. See the boat’s capacity plate orcontact the manufacturer.EMU40170

Mounting the outboard motor

WARNINGEWM02430

Improper mounting of the outboard motorcould result in hazardous conditions,such as poor handling, loss of control, orfire hazards. If you are not able to mountthe outboard motor properly, consult aYamaha dealer.

To lift and mount the outboard motor, twopeople are necessary. For further information,see page 26.EMU34194

Propeller selectionNext to selecting an outboard motor, selectingthe right propeller is one of the most importantpurchasing decisions a boater can make. Thetype, size, and design of your propeller havea direct impact on acceleration, top speed,fuel economy, and even engine life. Yamahadesigns and manufactures propellers for ev-ery Yamaha outboard motor and every appli-cation.Your outboard motor came with a Yamahapropeller selected to perform well over arange of applications, but there may be useswhere a different propeller would be more ap-propriate.Your Yamaha dealer can help you select theright propeller for your boating needs. Selecta propeller that will allow the engine to reachthe middle or upper half of the operatingrange at full throttle with the maximum boat-load. Generally, select a larger pitch propellerfor a smaller operating load and a smallerpitch propeller for a heavier load. If you carryloads that vary widely, select the propeller thatlets the engine run in the proper range for yourmaximum load but remember that you mayneed to reduce your throttle setting to staywithin the recommended engine speed rangewhen carrying lighter loads.To check the propeller, see page 61.



14

EMU39190

Start-in-gear protectionYamaha outboard motors are equipped withstart-in-gear protection device. This featurepermits the engine to be started only when itis in neutral. Always select neutral beforestarting the engine.EMU39691

Engine oil requirementsSelect an oil grade according to the averagetemperatures in the area where the outboardmotor will be used.

If oil grades in recommended engine oil group1 are not available, select an alternative oilgrade from recommended engine oil group 2.

Recommended engine oil group 1

Recommended engine oil group 2

EMU36360

Fuel requirementsEMU40180

GasolineUse a good quality gasoline that meets theminimum octane rating. If knocking or pingingoccurs, use a different brand of gasoline orpremium unleaded fuel. Yamaha recomendsthat you use alcohol-free (see Gasohol) gas-oline whenever possible.

NOTICEECM01981

� Do not use leaded gasoline. Leaded gas-oline can seriously damage the engine.

1. Propeller diameter in inches2. Propeller pitch in inches3. Type of propeller (propeller mark)

Recommended engine oil:4-stroke outboard motor oil

Recommended engine oil group 1*:SAE 10W-30/10W-40/5W-30 API SE/SF/SG/SH/SJ/SL

Recommended engine oil group 2*:SAE 15W-40/20W-40/20W-50 API SH/SJ/SL


ZMU06853

-x1 2 3

Recommended fuel:Regular gasoline

Min. pump octane:86

ZMU06854

ZMU06855



15

� Avoid getting water and contaminants inthe fuel tank. Contaminated fuel cancause poor performance or engine dam-age. Use only fresh gasoline that hasbeen stored in clean containers.

GasoholThere are two types of gasohol: gasohol con-taining ethanol (E10) and that containingmethanol. Ethanol can be used if the ethanolcontent does not exceed 10% and the fuelmeets the minimum octane ratings. E85 is afuel containing 85% ethanol and must not beused in your outboard motor. All ethanolblends containing more than 10% ethanol cancause fuel system damage or cause enginestarting and running problems. Yamaha doesnot recommend gasohol containing methanolbecause it can cause fuel system damage orengine performance problems.It is recommended that you install a water-separating marine fuel filter assembly (10 mi-cron minimum) between your boat’s fuel tankand outboard motor when using ethanol. Eth-anol is known to allow moisture to be ab-sorbed into boat fuel tanks and systems.Moisture in the fuel can cause corrosion ofmetallic fuel system components, starting andrunning complaints and require additional fuelsystem maintenance.EMU27270

Ring Free Fuel AdditiveGasoline is a precise blend of many differentsubstances, each chosen to give certain char-acteristics. Gasoline blends have beenchanging in recent years in response to con-cerns about pollution and resulting emissionsregulations. One of the most obvious changeshas been the elimination of lead from most fu-els.

As gasoline has changed, the amount of addi-tives such as aromatics and oxygenates hasincreased. These additives are important forthe engines in passenger cars, but they canhave detrimental effects in marine engines,because of increased deposits in the combus-tion chamber. When enough deposits collect,piston rings begin sticking. Performancedrops and engine wear increases dramatical-ly.While many additives available may reducedeposits, Yamaha recommends the use ofRing Free Fuel Additive, available from yourYamaha dealer. Ring Free Fuel Additivehas repeatedly proven its ability to clean com-bustion deposits from inside the engine, nota-bly the critical piston-ring-land area, and fuelsystem components. Follow product labelingfor use instructions.EMU36330

Anti-fouling paintA clean hull improves boat performance. Theboat bottom should be kept as clean of marinegrowth as possible. If necessary, the boat bot-tom can be coated with an anti-fouling paintapproved for your area to inhibit marinegrowth.Do not use anti-fouling paint which includescopper or graphite. These paints can causemore rapid engine corrosion.EMU36341

Motor disposal requirementsNever illegally discard (dump) the motor.Yamaha recommends consulting the dealerabout discarding the motor.EMU36351

Emergency equipmentKeep the following items onboard in casethere is trouble with the motor.� A tool kit with assorted screwdrivers, pliers,

wrenches (including metric sizes), andelectrical tape.



16

� Waterproof flashlight with extra batteries.� An extra engine shut-off cord (lanyard) with

clip.� Spare parts, such as an extra set of spark

plugs.Consult your Yamaha dealer for details.EMU25221

Emission control informationEMU25230

North American modelsThis engine conforms to U.S. EnvironmentalProtection Agency (EPA) regulations for ma-rine SI engines. See the label affixed to yourengine for details.EMU25242

Approval label of emission control certifi-cateThis label is attached to the bottom cowling.New Technology; (4-stroke/HPDI) EM

EMU39200

Manufactured date labelThis label is attached to the clamp bracket.

EMU25273

Star labelsYour outboard motor is labeled with a Califor-nia Air Resources Board (CARB) star label.See below for a description of your particularlabel.

1. Approval label location

ZMU06711

1

ZMU07059

EMISSION CONTROL INFORMATION EMTHIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EXHAUSTREGULATIONS FOR SI MARINE ENGINES. REFER TO THE OWNER'SMANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.MEETS U.S. EPA EVAP STANDARDS USING CERTIFIED COMPONENTS.FAMILY:DISPLACEMENT: litersSPARK PLUG:FUEL: GASOLINE

FELs(HC+NOx / CO): / g/kW-hr MAX POWER: kWIDLE SPEED: ± rpm IN NETRALSPARK PLUG GAP (mm):VALVE LASH (mm) IN: EX:

YAMAHA MOTOR CO.,LTD.

1. Manufactured date label location

1. Star labels location

ZMU06712

1

Manufactured:

ZMU04346

ZMU06713

1

chapter3 Page 16 Wednesday, December 9, 2009 11:40 AM


17

EMU25280

One Star—Low EmissionThe one-star label identifies engines thatmeet the Air Resources Board’s 2001 ex-haust emission standards. Engines meetingthese standards have 75% lower emissionsthan conventional carbureted two-stroke en-gines. These engines are equivalent to theU.S. EPA’s 2006 standards for marine en-gines.

EMU25290

Two Stars—Very Low EmissionThe two-star label identifies engines that meetthe Air Resources Board’s 2004 exhaustemission standards. Engines meeting thesestandards have 20% lower emissions thanOne Star-Low-Emission engines.

EMU25300

Three Stars—Ultra Low EmissionThe three-star label identifies engines thatmeet the Air Resources Board’s 2008 ex-haust emission standards. Engines meetingthese standards have 65% lower emissionsthan One Star-Low-Emission engines.

EMU33861

Four Stars—Super Ultra Low EmissionThe four-star label identifies engines thatmeet the Air Resources Board’s Sterndriveand Inboard marine engine 2009 exhaustemission standards. Personal Watercraft andOutboard marine engines may also complywith these standards. Engines meeting thesestandards have 90% lower emissions thanOne Star-Low-Emission engines.

ZMU01702

ZMU01703

ZMU01704

ZMU05663


Components

18

EMU2579R

Components diagramTIP:* May not be exactly as shown; also may not be included as standard equipment on all models.F4, F6

EMU39542

Fuel tank (built-in fuel tank)This outboard motor is equipped with a built-in fuel tank and its parts are as follows.

ZMU06715

12

311

12

13

1514

21 19 18

20 16

17

222324

254

5

6

8

7

910

1. Top cowling2. Cowling lock lever3. Carrying handle4. Anti-cavitation plate5. Propeller*6. Cooling water inlet7. Trim rod8. Clamp bracket9. Steering friction adjuster10.Fuel tank cap11.Air vent screw12.Manual starter handle13.Throttle friction adjuster14.Tiller handle15.Throttle grip16.Fuel joint

17.Fuel joint cap18.Fuel cock19.Engine shut-off cord (lanyard)20.Engine stop button21.Choke knob22.Clamp screw23.Restraint cable attachment24.Tilt support bar25.Gear shift lever


Components

19

Fuel tank capThis cap seals the fuel tank. When removed,the tank can be filled with fuel. To remove thecap, turn it counterclockwise.Air vent screwThis screw is on the fuel tank cap. To loosenthe screw, turn it counterclockwise.

EMU39353

Fuel tank (portable fuel tank)This model can be equipped with an optionalportable fuel tank. The parts of the fuel tankare as follows.Fuel tank capThis cap seals the fuel tank. When removed,the tank can be filled with fuel. To remove thecap, turn it counterclockwise.Air vent screwThis screw is on the fuel tank cap. To loosenthe screw, turn it counterclockwise.Fuel jointThis joint is used to connect the fuel line.Fuel gaugeThis gauge is located on either the fuel tankcap or on the fuel joint base. It shows the ap-proximate amount of fuel remaining in thetank.

WARNINGEWM02380

Do not use the portable fuel tank as a fuelstorage container. Commercial usersshould conform to relevant licensing orapproval authority regulations.

EMU40090

Fuel cockThe fuel cock turns on and off the supply offuel from the fuel tank to the engine.The fuel cock has 3 positions: the closed po-sition, built-in fuel tank position, and portablefuel tank position. Depending on how the out-board motor will be used, align the fuel cockwith the appropriate position indicated on thelabel that is affixed to the outboard motor.

1. Air vent screw2. Fuel tank cap3. Built-in fuel tank

ZMU06717

12

3

1. Air vent screw2. Fuel gauge3. Fuel joint4. Fuel tank cap

1. Fuel cock2. Closed position

ZMU01992

3 24 1

ZMU06880

13

24


Components

20

EMU39210

CloseTo stop the fuel flow from the fuel tank to thecarburetor, align the fuel cock with the closedposition.When the engine is not running, always alignthe fuel cock with the closed position.

EMU39222

OpenTo send fuel from the fuel tank to the carbure-tor, align the fuel cock with the position for thebuilt-in fuel tank or portable fuel tank accord-ing to which fuel tank is being used.When using the built-in fuel tank, align the fuelcock with the built-in fuel tank position.When using a portable fuel tank, align the fuelcock with the portable fuel tank position.

EMU25912

Tiller handleTo change direction, move the tiller handle tothe left or right as necessary.

EMU25923

Gear shift leverMove the gear shift lever forward to engagethe forward gear or rearward to engage thereverse gear.

EMU39700

Throttle gripThe throttle grip is on the tiller handle. Turnthe grip “A” to increase speed and “B” to de-crease speed.

3. Built-in fuel tank position4. Portable fuel tank position

1. Fuel cock2. Closed position

1. Fuel cock

ZMU068831

2

ZMU06882

12

3

2. Built-in fuel tank position3. Portable fuel tank position

1. Tiller handle

1. Forward position2. Neutral position3. Reverse position

ZMU06721

1

123

ZMU06864


Components

21

EMU39711

Throttle indicatorThe throttle indicator shows the throttle posi-tion. When the 100% position of the throttle in-dicator is aligned with the notch in the tillerhandle, the throttle is fully open. When the 0%position of the throttle indicator is aligned withthe notch in the tiller handle, the throttle is fullyclosed.

The engine start mark “ ” on the throttle indi-cator shows the throttle position for startingthe engine.

EMU39242

Throttle friction adjusterThe throttle friction adjuster provides adjust-able resistance when the throttle grip isturned, and can be set according to operatorpreference.To increase resistance, turn the throttle fric-tion adjuster clockwise.To decrease resistance, turn the throttle fric-tion adjuster counterclockwise. When con-stant speed is desired, tighten the throttlefriction adjuster to maintain the desired throt-tle setting. WARNING! Do not overtightenthe throttle friction adjuster. If there is toomuch resistance, it could be difficult toturn the throttle grip, which could result inan accident. [EWM02261]

1. Throttle grip

1. Fully open2. Fully closed3. Throttle indicator4. Notch

ZMU06723

1

A

B

ZMU06877

0 % 100

1 2

3

4 4

3

1. Start mark “ ”2. Notch

1. Throttle friction adjuster

ZMU06808

12

ZMU06724

1


Components

22

EMU25994

Engine shut-off cord (lanyard) and clipThe clip must be attached to the engine shut-off switch for the engine to run. The cordshould be attached to a secure place on theoperator’s clothing, or arm or leg. Should theoperator fall overboard or leave the helm, thecord will pull out the clip, stopping ignition tothe engine. This will prevent the boat fromrunning away under power. WARNING! At-tach the engine shut-off cord to a secureplace on your clothing, or your arm or legwhile operating. Do not attach the cord toclothing that could tear loose. Do not routethe cord where it could become entangled,preventing it from functioning. Avoid acci-dentally pulling the cord during normaloperation. Loss of engine power meansthe loss of most steering control. Also,without engine power, the boat could slowrapidly. This could cause people and ob-jects in the boat to be thrown forward.[EWM00122]

EMU26002

Engine stop buttonThe engine stop button stops the enginewhen the button is pushed.

EMU26012

Choke knob for pull typeTo supply the engine with the rich fuel mixturerequired to start, pull out this knob.

EMU39722

Fuel joint capThe fuel joint is equipped with the fuel jointcap. WARNING! When not using a portablefuel tank, make sure to install the fuel jointcap. Otherwise, injury could result fromstriking the fuel joint accidentally. [EWM02411]

1. Engine shut-off switch2. Cord3. Clip

ZMU06725

1

3

2

1. Engine stop button

1. Choke knob

ZMU06726

1

ZMU06784

1


Components

23

EMU26073

Manual starter handleThe manual starter handle is used to crankand start the engine.

EMU39252

Steering friction adjuster

WARNINGEWM02270

Do not overtighten the steering friction ad-juster. If there is too much resistance, itcould be difficult to steer, which could re-sult in an accident.

The steering friction adjuster provides adjust-able resistance to the steering mechanism,and can be set according to operator prefer-ence. The steering friction adjuster is locatedon the port side of the outboard motor.

To increase resistance, turn the steering fric-tion adjuster clockwise.To decrease resistance, turn the steering fric-tion adjuster counterclockwise.EMU40100

Trim rod (tilt pin)The trim rod (tilt pin) is used to adjust the trimangle of the outboard motor in relation to theangle of the boat transom.

EMU39362

Tilt lock mechanismThe tilt lock mechanism is used to prevent theoutboard motor from lifting out of the waterwhen the gear shift lever is in the reverse po-sition.When the gear shift lever is moved to the re-verse position, the tilt lock mechanism oper-ates to prevent the outboard motor from beingtilted up.

1. Fuel joint cap

1. Manual starter handle

ZMU06868

1

ZMU06728

1

1. Steering friction adjuster

1. Trim rod

ZMU067291

ZMU068431


Components

24

When the gear shift lever is moved to the neu-tral position or forward position, the outboardmotor can be tilted up.EMU39831

Tilt support barUse the tilt support bar to keep the outboardmotor in the tilted up position or a shallow wa-ter cruising position.

EMU39261

Cowling lock leverThe cowling lock lever is used to secure thetop cowling.

EMU39372

Carrying handleThe carrying handle is used to carry the out-board motor. For information on carrying andtransporting the outboard motor, see page 47.

1. Gear shift lever2. Reverse position

1. Tilt lock

ZMU06838

12

1

1

ZMU06839

1. Tilt support bar2. Tilted up position3. Shallow water cruising position

1. Cowling lock lever

ZMU06731

1

2

3

ZMU06850

1


Components

25

1. Carrying handle

ZMU06787

1


Installation

26

EMU39731

InstallationThe information presented in this section is in-tended as reference only. It is not possible toprovide complete instructions for every possi-ble boat and motor combination. Propermounting depends in part on experience andthe specific boat and motor combination.

WARNINGEWM02341

� Overpowering a boat could cause se-vere instability. Do not mount an out-board motor with more horsepower thanthe maximum rating on the capacityplate of the boat. If the boat does nothave a capacity plate, consult the boatmanufacturer.

� Improper mounting of the outboard mo-tor could result in hazardous conditions,such as poor handling, loss of control,or fire hazards. If you are not able tomount the outboard motor properly,consult a Yamaha dealer.

EMU39562

Mounting the outboard motor

WARNINGEWM02300

Do not hold the top cowling or tiller handlewhen mounting or dismounting the out-board motor. Otherwise, the outboard mo-tor could fall.

1. Be sure to mount the outboard motorwhile the boat is on land. If the boat is onthe water, move it to an area on land.

2. To prevent steering movement, turn thesteering friction adjuster clockwise.

3. Turn the tiller handle 180° so that it ispointing rearward.

4. Hold the carrying handle and the hand-grip on the front side of the bottom cowl-ing and lift up the outboard motor usingtwo people.


1. Carrying handle2. Handgrip

ZMU06827

1

ZMU06836

ZMU0682112


Installation

27

5. Mount the outboard motor on the centerline (keel line) of the boat, and ensurethat the boat itself is well balanced. Oth-erwise the boat will be hard to steer. Forboats without a keel or which are asym-metrical, consult your dealer.

6. Turn the steering friction adjuster coun-terclockwise to set the steering frictionaccording to operator preference.WARNING! If there is too much resis-tance it could be difficult to steer,which could result in an accident.[EWM00721]

EMU39740

Mounting heightTo run your boat at optimum efficiency, thewater resistance (drag) of the boat and out-board motor must be made as little as possi-ble. The mounting height of the outboardmotor greatly affects the water resistance. Ifthe mounting height is too high, cavitationtends to occur, thus reducing the propulsion;and if the propeller tips cut the air, the enginespeed will rise abnormally and cause the en-gine to overheat. If the mounting height is toolow, the water resistance will increase andthereby reduce engine efficiency. Mount theoutboard motor so that the anti-cavitationplate is between the bottom of the boat and alevel 25 mm (1 in) below it.

1. Center line (keel line)

ZMU06835

ZMU017601


1. Idle hole2. Anti-cavitation plate

ZMU06834

1

ZMU06796

0-25 mm(0-1 in) 2

1


Installation

28

NOTICEECM02170

� Check that the idle hole stays highenough to keep out water getting insideengine even if the boat is in stationarywith maximum load.

� Incorrect engine height or obstructionsto the smooth flow of water (such as thedesign or condition of the boat) can cre-ate airborne water spray while the boatis cruising. If the motor is operated con-tinuously in the presence of airbornewater spray, enough water could enterthe engine through the intake openingon the top cowling to cause severe en-gine damage. Eliminate the cause of theairborne water spray.

TIP:� The optimum mounting height of the out-

board motor is affected by the boat and mo-tor combination and the desired use. Testruns at different heights can help determinethe optimum mounting height. Consult yourYamaha dealer or boat manufacturer forfurther information on determining the prop-er mounting height.

� For instructions on setting the trim angle ofthe outboard motor, see page 41.

EMU39751

Clamping the outboard motor1. Place the outboard motor on the transom

so that it is positioned as close to the cen-ter as possible. Tighten the clamp screwsevenly and securely. Occasionally checkthe clamp screws for tightness during op-eration of the outboard motor becausethey could become loose due to enginevibration. WARNING! Loose clampscrews could allow the outboard mo-tor to fall off or move on the transom.This could cause loss of control and

serious injury. Make sure the clampscrews are tightened securely. Occa-sionally check the screws for tight-ness during operation. [EWM00642]

2. Attach one end to the restraint cable at-tachment and the other to a securemounting point on the boat. Otherwisethe engine could be completely lost if itaccidentally falls off the transom.

1. Clamp screw

1. Restraint cable attachment

ZMU068111

ZMU06812

1


Operation

29

EMU36381

First-time operationEMU36391

Fill engine oilThe engine is shipped from the factory withoutengine oil. If your dealer did not fill the oil, youmust fill it before starting the engine. NOTICE:Check that the engine is filled with oil be-fore first-time operation to avoid severeengine damage. [ECM01781]

The engine is shipped with the following stick-er, which should be removed after engine oilis filled for the first time. For more informationon checking the engine oil level, see page 31.

EMU30174

Breaking in engineYour new engine requires a period of break-into allow mating surfaces of moving parts towear in evenly. Correct break-in will help en-sure proper performance and longer enginelife. NOTICE: Failure to follow the break-inprocedure could result in reduced enginelife or even severe engine damage. [ECM00801]

EMU40060

Procedure for 4-stroke modelsYour new engine requires a period of 10hours break-in to allow mating surfaces ofmoving parts to wear in evenly.

TIP:Run the engine in the water, under load (ingear with a propeller installed) as follows. For10 hours for breaking in engine avoid extend-ed idling, rough water and crowded areas.

1. For the first hour of operation:Run the engine at varying speeds up to2000 r/min or approximately half throttle.

2. For the second hour of operation:Run the engine at 3000 r/min or at ap-proximately three-quarter throttle.

3. Remaining 8 hours:Run the engine at any speed. However,avoid operating at full throttle for morethan 5 minutes at a time.

4. After the first 10 hours:Operate the engine normally.

EMU36400

Getting to know your boatDifferent boats handle differently. Operatecautiously while you learn how your boat han-dles under different conditions and with differ-ent trim angles (see page 41).EMU36412

Checks before starting engine

WARNINGEWM01920

If any item in the checks before startingengine is not working properly, have it in-spected and repaired before operating theoutboard motor. Otherwise an accidentcould occur.

NOTICEECM00120

Do not start the engine out of water. Over-heating and serious engine damage canoccur.

EMU36560

Fuel levelBe sure you have plenty of fuel for your trip. Agood rule is to use 1/3 of your fuel to get to thedestination, 1/3 to return, and to keep 1/3 asan emergency reserve. With the boat level ona trailer or in the water, check the fuel level.For fuel filling instructions, see page 32.

ZMU01710


Operation

30

EMU39840

Removing top cowlingFor the following checks, remove the topcowling from the bottom cowling.To remove the top cowling, pull the cowlinglock lever up and lift up the top cowling.

EMU36442

Fuel system

WARNINGEWM00060

Gasoline and its vapors are highly flam-mable and explosive. Keep away fromsparks, cigarettes, flames, or other sourc-es of ignition.

WARNINGEWM00910

Leaking fuel can result in fire or explosion.� Check for fuel leakage regularly.� If any fuel leakage is found, the fuel sys-

tem must be repaired by a qualified me-chanic. Improper repairs can make theoutboard unsafe to operate.

EMU36451

Check for fuel leaks� Check for fuel leaks or gasoline fumes in

the boat.� Check for fuel leakage from the fuel system.� Check the fuel tank and fuel lines for

cracks, swellings, or other damages.

EMU39851

Controls� Move the tiller handle fully to the left and

right to check that operation is smooth.� Turn the throttle grip from the fully closed

position to the fully open position. Checkthat the throttle grip turns smoothly and thatit completely returns to the fully closed posi-tion.

� Check the throttle cable and throttle link forloose or damaged connections.

� Check the shift link and start-in-gear protec-tion cable for loose or damaged connec-tions.


ZMU06732

1

ZMU06851

ZMU06852


Operation

31

EMU36483

Engine shut-off cord (lanyard)Inspect the engine shut-off cord and clip fordamage, such as cuts, breaks, and wear.

EMU39383

Engine oil1. Place the outboard motor in an upright

position (not tilted). NOTICE: If the mo-tor is not level, the oil level indicatedon the dipstick may not be accurate.[ECM01790]

2. Remove the oil filler cap and wipe the at-tached oil dipstick clean.

TIP:The oil lubrication check window does not in-dicate the engine oil level. Use the oil lubrica-tion check window to make sure that theengine is being lubricated with oil while it isrunning.3. Install the oil filler cap and tighten it com-

pletely.4. Remove the oil filler cap again and check

that the oil level on the dipstick is be-tween the upper and lower marks. If theoil level is not at the proper level, add orextract oil until the oil is between the up-per and lower marks.

5. Install the oil filler cap and tighten it com-pletely.

1. Clip2. Cord

ZMU06874

ZMU06873

1

2

1. Oil filler cap2. Oil lubrication check window

1. Oil dipstick2. Upper mark3. Lower mark

ZMU06769

1 2

1

23

ZMU06737


Operation

32

EMU27153

Engine� Check the engine and engine mounting.� Look for loose or damaged fasteners.� Check the propeller for damage.� Check for engine oil leaks.EMU39861

Installing top cowling1. Check the rubber seal for damage. If the

rubber seal is damaged, have it replacedby a Yamaha dealer.

2. Align the fuel tank cap and manual starterhandle with their respective holes in thetop cowling.

3. Hook the top cowling hook onto the bot-tom cowling, and then make sure that thefuel tank cap and manual starter handlefit properly into their respective holes.

4. Check to be sure the rubber seal is seat-ed correctly between the top cowling andthe bottom cowling.

5. Pull the cowling lock lever down to securethe top cowling.

6. Check the fitting of the top cowling bypushing it with both hands. NOTICE: Ifthe top cowling is not installed cor-rectly, water spray under the top cowl-ing can damage the engine, or the topcowling can blow off at high speeds.[ECM01991]

EMU39871

Filling fuel

WARNINGEWM01950

Be sure the outboard motor is securelyfastened to the transom or a stable stand.

1. Fuel tank cap2. Manual starter handle3. Rubber seal

1. Hook

ZMU06856

1

2

3

ZMU06857

1


ZMU06738

1

ZMU06739


Operation

33

WARNINGEWM01830

� Gasoline and its vapors are highly flam-mable and explosive. Always refuel ac-cording to this procedure to reduce therisk of fire and explosion.

� Gasoline is poisonous and can cause in-jury or death. Handle gasoline with care.Never siphon gasoline by mouth. If youshould swallow some gasoline or inhalea lot of gasoline vapor, or get some gas-oline in your eyes, see your doctor im-mediately. If gasoline spills on yourskin, wash with soap and water. If gaso-line spills on your clothing, change yourclothes.

Before refueling, check the following points:� Securely moor the boat in a well-ventilated

area and stop the engine. If the boat is trail-ered, make sure that it is stable.

� Do not smoke and keep away from sparks,flames, static electric discharge, or othersources of ignition.

� If you use a portable container to store anddispense fuel, only use a locally approvedGASOLINE container.

� To prevent electrostatic sparks, dischargeany built-up static electricity from your bodybefore refueling.

Filling fuel for built-in fuel tank1. Remove the fuel tank cap.

2. Fill the fuel tank, but do not overfill it. Fuelcan expand and overflow if the tempera-ture increases.

3. Tighten the fuel tank cap securely.4. Wipe up any spilled gasoline immediately

with dry rags. Dispose of rags properlyaccording to local laws or regulations. Ifyou use a portable container to store anddispense fuel, only use a locally ap-proved GASOLINE container.

Filling fuel for portable fuel tank (optional)1. Disconnect the fuel hose, and then install

the fuel joint cap. WARNING! When notusing a portable fuel tank, make sureto install the fuel joint cap. Otherwise,injury could result from striking thefuel joint accidentally. [EWM02411]

1. Fuel tank cap

Fuel tank capacity (built in type):1.1 L (0.29 US gal, 0.24 Imp.gal)

ZMU06875

1

ZMU06810


Operation

34

2. Remove the portable fuel tank from theboat.

3. Remove the fuel tank cap.

4. Fill the fuel tank, but do not overfill it. Fuelcan expand and overflow if the tempera-ture increases.

5. Tighten the fuel tank cap securely.

6. Wipe up any spilled gasoline immediatelywith dry rags. Dispose of rags properlyaccording to local laws or regulations. Ifyou use a portable container to store anddispense fuel, only use a locally ap-proved GASOLINE container.

EMU27452

Operating engine

WARNINGEWM00420

� Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in thewater near you.

� When the air vent screw is loosened,gasoline vapor will be released. Gaso-line is highly flammable, and its vaporsare flammable and explosive. Refrainfrom smoking, and keep away fromopen flames and sparks while looseningthe air vent screw.

� This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which could cause braindamage or death when inhaled. Symp-toms include nausea, dizziness, anddrowsiness. Keep cockpit and cabin ar-eas well ventilated. Avoid blocking ex-haust outlets.

EMU39394

Sending fuelSending fuel for built-in fuel tank1. Loosen the air vent screw by 1 or 2 turns.

1. Fuel hose2. Fuel joint cap

1. Fuel tank cap

ZMU06753

2

1

ZMU06832


Operation

35

2. Align the fuel cock with the built-in fueltank position.

3. Remove the top cowling, and thensqueeze the primer pump in the bottomcowling repeatedly until you feel it be-come slightly firm.

4. Install the top cowling.

Sending fuel for portable fuel tank (optional)1. Loosen the air vent screw on the portable

fuel tank by 2 or 3 turns.

2. If there is fuel in the built-in fuel tank, loos-en the air vent screw by 1 or 2 turns toprevent pressure from increasing insidethe tank due to fuel expansion.

3. Remove the fuel joint cap. Connect thefuel hose securely between the tank andthe outboard motor so that the primerpump arrow is pointing toward the out-board motor.

1. Air vent screw

1. Built-in fuel tank position

1. Primer pump

ZMU06740

1

ZMU06720

11

ZMU068261

1. Air vent screw

1. Air vent screw

ZMU06740

1


Operation

36

4. Align the fuel cock with the portable fueltank position.

5. Send fuel to the carburetor by squeezingthe primer pump repeatedly, with the ar-row pointing up, until you feel it becomefirm. While the engine is running, make

sure to keep the portable fuel tank hori-zontal. Otherwise, fuel cannot be drawnfrom the fuel tank.

EMU27493

Starting engine

WARNINGEWM01600

Before starting the engine, make sure thatthe boat is tightly moored and that you cansteer clear of any obstructions. Be surethere are no swimmers in the water nearyou.

EMU39403

Manual start

WARNINGEWM01840

� Failure to attached engine shut-off cordcould result in a runaway boat if opera-tor is ejected. Attach the engine shut-offcord to a secure place on your clothing,or your arm or leg while operating. Donot attach the cord to clothing that couldtear loose. Do not route the cord whereit could become entangled, preventing itfrom functioning.

� Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power, the


1. Arrow

1. Portable fuel tank position

ZMU06743

2

1

ZMU06802

1

1

1. Arrow


Operation

37

boat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

1. Move the gear shift lever to the neutralposition.

2. Attach the engine shut-off cord to a se-cure place on your clothing, or your armor leg. Then, install the clip on the otherend of the cord to the engine shut-offswitch.

3. Align the engine start mark “ ” on thethrottle grip with the notch in the tiller han-dle.

TIP:If the ambient temperature is -15°C or less,turn the throttle grip so that the engine startmark “ ” is positioned past the notch in thetiller handle.

4. Pull out the choke knob fully.

1. Neutral position

1

ZMU06749

ZMU06744


1. Choke knob

ZMU06808

12

ZMU06865

ZMU06784

1


Operation

38

TIP:It is not necessary to use the choke whenstarting a warm engine, such as immediatelyafter the outboard motor has been operatedunder a load.5. Pull the manual starter handle slowly until

you feel resistance. Then give a strongpull straight out to crank and start the en-gine. If the engine does not start on thefirst try, repeat the procedure.

6. After the engine starts, slowly return themanual starter handle to its original posi-tion before releasing it.

7. Warm up the engine. For further informa-tion, see page 38.

8. Return the choke knob to its original posi-tion gradually.

9. Slowly return the throttle grip to the fullyclosed position.

EMU36510

Checks after starting engineEMU36522

Cooling waterCheck for a steady flow of water from the cool-ing water pilot hole. A continuous flow of waterfrom the pilot hole indicates that the waterpump is pumping water through the coolingwater passages. If the cooling water passag-es are frozen, it may take a while for water tostart flowing out of the pilot hole.

NOTICEECM01810

If water is not flowing out of the pilot holeat all times while the engine is running,overheating and serious damage couldoccur. Stop the engine and check whetherthe cooling water inlet on the lower case orthe cooling water pilot hole is blocked.Consult your Yamaha dealer if the prob-lem cannot be located and corrected.

EMU27670

Warming up engineEMU40070

Warming upAfter starting the engine, return the chokeknob to the halfway position. For approxi-mately the first 5 minutes after starting, warmup the engine by operating at one fifth throttle

ZMU06746

ZMU06818

1. Cooling water pilot hole

ZMU06747

1


Operation

39

or less. After the engine has warmed up, pushthe choke knob in fully. Failure to do so willshorten engine life.

TIP:� If the choke knob is left pulled out after the

engine starts, the engine will stall.� In temperatures of -5°C or less, leave the

choke knob pulled out fully for approximate-ly 30 seconds after starting.

EMU36531

Checks after engine warm upEMU36540

ShiftingWhile tightly moored, and without applyingthrottle, confirm that the engine shifts smooth-ly into forward and reverse, and back to neu-tral.EMU36971

Stop switchesPerform the following procedure to check thatthe engine stop switch and engine shut-offswitch operate properly.� Start the engine, and then check that the

engine stops when the engine stop buttonis pushed.

� Restart the engine, and then check that theengine stops when the clip is pulled fromthe engine shut-off switch.

� Check that the engine cannot be startedwith the clip removed from the engine shut-off switch.

EMU39342

Shifting

WARNINGEWM00180

Before shifting, make sure there are noswimmers or obstacles in the water nearyou.

NOTICEECM02220

Before shifting the outboard motor, turnthe throttle grip to the fully closed positionand let the engine speed return to idlespeed. Otherwise, the shift mechanismcould be damaged.

To shift to forward or reverseMove the gear shift lever to the forward posi-tion or reverse position.

To shift to neutral1. Close the throttle so that the engine

slows to idle speed.2. Move the gear shift lever to the neutral

position.

1. Forward position2. Neutral position3. Reverse position

1. Neutral position

123

ZMU06864

1

ZMU06749


Operation

40

EMU39881

Stopping boat

WARNINGEWM02321

Do not use the reverse function to slowdown or stop the boat as it could causeyou to lose control, be ejected, or impactthe load or other parts of the boat. Thiscould increase the risk of serious injury. Itcould also damage the shift mechanism.

The boat is not equipped with a separatebraking system. Water resistance stops it af-ter the throttle lever is moved back to idle. Thestopping distance varies depending on grossweight, water surface conditions, and wind di-rection.EMU27821

Stopping engineBefore stopping the engine, first let it cool offfor a few minutes at idle or low speed. Stop-ping the engine immediately after operating athigh speed is not recommended.EMU39412

Procedure1. Push and hold the engine stop button un-

til the engine stops completely. The en-gine can also be stopped by pulling theengine shut-off cord and removing theclip from the engine shut-off switch.

2. Tighten the air vent screw on the fuel tankcap.

3. Align the fuel cock with the closed posi-tion.1. Engine stop button

ZMU06726

1

1. Engine shut-off switch2. Cord3. Clip

1. Air vent screw

1. Air vent screw

ZMU06867

132

ZMU06751

1


Operation

41

4. When using a portable fuel tank, discon-nect the fuel hose, and then install thefuel joint cap. WARNING! When not us-ing a portable fuel tank, make sure toinstall the fuel joint cap. Otherwise, in-jury could result from striking the fueljoint accidentally. [EWM02411]

EMU40110

Trimming outboard motor

WARNINGEWM00740

Excessive trim for the operating condi-tions (either trim up or trim down) cancause boat instability and can make steer-ing the boat more difficult. This increasesthe possibility of an accident. If the boatbegins to feel unstable or is hard to steer,slow down and/or readjust the trim angle.

The trim angle of the outboard motor helpsdetermine the position of the bow of the boatin the water. The correct trim angle is affectedby variables, such as the load in the boat, seaconditions, and running speed.

EMU39272

Adjusting trim angle for manual tilt models

WARNINGEWM00400

� Stop the engine before adjusting thetrim angle.

� Use care to avoid being pinched whenremoving or installing the rod.

� Use caution when trying a trim positionfor the first time. Increase speed gradu-ally and watch for any signs of instabilityor control problems. Improper trim an-gle can cause loss of control.

1. Closed position


ZMU068711

1

ZMU06753

2

1

1. Trim operating angle

ZMU06754

1


Operation

42

There are 5 holes provided in the clampbracket to adjust the outboard motor trim an-gle.1. Stop the engine.2. Tilt the outboard motor up, and then re-

move the trim rod from the clamp bracket.

3. Change the position of the trim rod in di-rection “A” to raise the bow (“trim-out”).Change the position of the trim rod in di-rection “B” to lower the bow (“trim-in”).

TIP:The outboard motor trim angle changes ap-proximately 4 degrees when the trim rod posi-tion is changed by 1 hole.4. Make test runs with the outboard motor

set at different trim angles to find the po-sition that works best for your boat andoperating conditions.

EMU40121

Adjusting boat trimGenerally, a boat is stable when the keel lineof the boat is up about 3 to 5 degrees. Withthe bow up, the boat may have a greater ten-dency to steer to one side or the other. If thisoccurs, adjust the trim angle.

Bow UpToo much trim-out puts the bow of the boattoo high in the water. Excessive trim-out canalso cause the propeller to ventilate, which re-duces performance further, and the boat may“porpoise” (hop in the water), which couldthrow the operator and passengers over-board.

Bow DownToo much trim-in causes the boat to “plow”through the water, decreasing fuel economyand making it hard to increase speed. Resis-tance at the bow is greatly increased, height-ening the danger of “bow steering” andmaking operation difficult and dangerous.

1. Trim rod

ZMU06755

1

A

B


Operation

43

EMU39592

Tilting up and downIf the engine will be stopped for some time orif the boat is moored in shallows, the outboardmotor should be tilted up to protect the propel-ler and lower case from damage due to colli-sions with obstructions, and also to reducesalt corrosion.

WARNINGEWM00222

Make sure that no one is near the outboardmotor when tilting the outboard motor upor down. Otherwise, body parts could becrushed between the outboard motor andthe clamp bracket.

WARNINGEWM02312

Leaking fuel is a fire hazard. When the out-board motor will be tilted up for more thana few minutes, tighten the air vent screw

and fuel tank cap and align the fuel cockwith the closed position. Otherwise, fuelmay leak.

NOTICEECM02161

� Before tilting the outboard motor up, fol-low the procedure under “Stopping en-gine” in this chapter. Never tilt theoutboard motor up while the engine isrunning. Severe damage from overheat-ing can result.

� Do not tilt the outboard motor up bypushing the tiller handle because thiscould break the handle.

� The outboard motor cannot be tiltedwhen in reverse.

EMU39552

Procedure for tilting up1. Align the fuel cock with the closed posi-

tion.


ZMU06840

1. Closed position

ZMU068711

1


Operation

44


4. Tighten the air vent screw.

5. When using a portable fuel tank, discon-nect the fuel hose, and then install thefuel joint cap. WARNING! When not us-ing a portable fuel tank, make sure to

install the fuel joint cap. Otherwise, in-jury could result from striking the fueljoint accidentally. [EWM02411]

6. Hold the rear of the top cowling and fullytilt the outboard motor up. Slightly lowerthe outboard motor from the fully tilted upposition and fit the tilt support bar secure-ly into the holder located on the clampbracket.

EMU39571

Procedure for tilting down1. Slightly tilt the outboard motor up.2. Slowly tilt the outboard motor down while

pulling the tilt support bar up.

1. Neutral position


1. Air vent screw

1

ZMU06749

ZMU06827

1

ZMU06751

1


1. Tilt support bar2. Holder

ZMU06753

2

1

ZMU06829

1

2


Operation

45

3. Turn the steering friction adjuster coun-terclockwise to set the steering frictionaccording to operator preference.WARNING! If there is too much resis-tance it could be difficult to steer,which could result in an accident.[EWM00721]

EMU28061

Shallow waterEMU39891

Cruising in shallow water

WARNINGEWM02391

� Operate the boat at the lowest possiblespeed when cruising in shallow water.Hitting an underwater obstacle couldcause the outboard motor to lift out ofthe water, resulting in loss of control.

� When cruising in shallow water, do notoperate in reverse. Reverse thrust cancause the outboard motor to lift out ofthe water, increasing the chance of anaccident and personal injury.

NOTICEECM00260

Do not tilt the outboard motor up so thatthe cooling water inlet on the lower unit isabove the surface of the water when set-ting up for and cruising in shallow water.Otherwise severe damage from overheat-ing can result.

EMU39583

Procedure for shallow water cruising1. Move the gear shift lever to the neutral

position.

1. Tilt support bar


ZMU06833

1

ZMU06834

11. Cooling water inlet

1. Neutral position

ZMU068191

1

ZMU06749


Operation

46

2. Hold the rear of the top cowling andslightly tilt the outboard motor up until thetilt support bar automatically locks. Theoutboard motor can be operated in thisposition for shallow water cruising. Theoutboard motor is equipped with 3 shal-low water cruising positions.

EMU40041

Procedure for returning to normal cruising1. To tilt the outboard motor down to the

normal running position, move the gearshift lever to the neutral position.

2. Slightly tilt the outboard motor up, andthen slowly tilt the outboard motor downwhile pulling the tilt support bar up.

EMU35391

Cruising in other conditionsCruising in salt waterAfter operating in salt water, flush the coolingwater passages with fresh water to preventthem from becoming clogged. Also rinse theoutside of the outboard motor with fresh wa-ter.Cruising in muddy, turbid, or acidic waterWater in some areas can be acidic or with alot of sediment in it, such as muddy or turbid(cloudy) water. After operating in such water,flush the cooling passages with fresh water toprevent corrosion. Also rinse the outside ofthe outboard motor with fresh water.

1. Shallow water cruising position2. Tilt support bar

1. Neutral position

ZMU06760

2

1

1

ZMU06749

1. Tilt support bar

ZMU06881

1


Maintenance

47

EMU39901

Transporting and storing out-board motor

WARNINGEWM00695

� USE CARE when transporting a fuelcontainer, whether in a boat or car.

� DO NOT exceed the specified capacityof a fuel container. Gasoline will expandconsiderably as it warms up and canbuild up pressure in the fuel container.This can cause fuel leakage and a poten-tial fire hazard.

� Leaking fuel is a fire hazard. When trans-porting and storing the outboard motor,close the fuel cock to prevent fuel fromleaking.

WARNINGEWM02330

Never get under the engine while it is tilt-ed. Severe injury could occur if the out-board motor accidentally falls.

NOTICEECM02190

Do not use the tilt support bar when traile-ring the boat. The outboard motor couldshake loose from the tilt support and fall.

The outboard motor should be trailered andstored in the fully tilted down position. If theoutboard motor cannot be trailered in the fullytilted down position, consult a Yamaha dealer.EMU39422

Dismounting the outboard motor

WARNINGEWM02300

Do not hold the top cowling or tiller handlewhen mounting or dismounting the out-board motor. Otherwise, the outboard mo-tor could fall.

1. Stop the engine and land the boat.

2. Tighten the fuel tank cap and air ventscrew securely.

3. Align the fuel cock with the closed posi-tion.

4. When using a portable fuel tank, discon-nect the fuel hose from the fuel joint, andthen install the fuel joint cap. WARNING!When not using a portable fuel tank,make sure to install the fuel joint cap.Otherwise, injury could result fromstriking the fuel joint accidentally.[EWM02411]

1. Air vent screw2. Fuel tank cap

1. Closed position

ZMU06844

12

ZMU068711

1


Maintenance

48


6. Turn the tiller handle 180° so that it ispointing rearward.

7. Loosen the clamp screws.

8. Hold the carrying handle and the hand-grip on the front side of the bottom cowl-ing and lift up the outboard motor usingtwo people to dismount it from the boat.

9. When transporting or storing the out-board motor while removed from a boat,use an outboard motor stand.



ZMU06753

2

1

ZMU06827

1

ZMU06836

1. Carrying handle2. Handgrip

ZMU0682112

ZMU06835


Maintenance

49

10. If transporting or storing the outboard mo-tor horizontally cannot be avoided, tight-en the clamp screws completely, place atowel or something similar under the out-board motor to protect it from damage,and then place the outboard motor in theattitude shown. If the front side of the out-board motor is facing down, turn theclamp bracket 90° so that it does not con-tact the ground, and then turn the steer-ing friction adjuster clockwise to securethe bracket.

EMU39912

Storing outboard motorWhen storing your Yamaha outboard motorfor prolonged periods of time (2 months orlonger), several important procedures mustbe performed to prevent excessive damage.It is advisable to have your outboard motorserviced by an authorized Yamaha dealer pri-or to storage. However, the following proce-dures can be performed by the owner.

NOTICEECM02212

� Do not place the outboard motor on itsside before the cooling water hasdrained from it completely. Otherwise,water may enter the cylinder through theexhaust valve and cause engine trouble.

� Transport and store the outboard motoras specified in “Dismounting the out-board motor”.

ZMU06761

ZMU06806

ZMU06762

ZMU06807


Maintenance

50

� Store the outboard motor in a dry, well-ventilated place, not in direct sunlight.

EMU28305

ProcedureEMU39602

Flushing in a test tank

NOTICEECM00301

Before starting the engine, make sure tosupply water to the cooling water passag-es. Otherwise, the engine could overheatand be damaged.

Cooling system flushing is essential to pre-vent the cooling system from clogging up withsalt, sand, or dirt. In addition, fogging of theengine is mandatory to prevent excessive en-gine damage due to rust. Perform the flushingand fogging at the same time.1. Wash the outboard motor body using

fresh water. NOTICE: Do not spray wa-ter into the air intake. [ECM01840] For furtherinformation, see page 52.

2. Fill the built-in fuel tank with fresh fuel andadd one ounce of “Yamaha Fuel Condi-tioner and Stabilizer” to each gallon of fu-el.

TIP:The use of “Yamaha Fuel Conditioner andStabilizer” eliminates the need to drain thefuel system. Consult a Yamaha dealer or oth-er qualified mechanic if the fuel system is tobe drained instead.3. When using a portable fuel tank, discon-

nect the fuel hose, install the fuel jointcap, and then align the fuel cock with thebuilt-in fuel tank position.

4. Remove the top cowling and fogging holecap.

5. Remove the propeller. For further infor-mation, see page 61.

6. Install the outboard motor on the testtank.

1. Closed position

1. Cap

1. Water surface2. Lowest water level3. Cooling water inlet

ZMU068711

1

1

ZMU06822

3

ZMU06862


Maintenance

51

7. Fill the test tank with fresh water to abovethe level of the anti-cavitation plate.NOTICE: If the fresh water level is be-low the level of the anti-cavitationplate, or if the water supply is insuffi-cient, engine seizure may occur.[ECM00291]

8. Start the engine, operate it for 10–15 min-utes at engine idle speed. WARNING!Do not touch or remove electricalparts when starting or during opera-tion. Keep hands, hair, and clothesaway from the flywheel and other ro-tating parts while the engine is run-ning. [EWM00091]

9. Quickly spray “Yamaha Stor-Rite EngineFogging Oil” into the fogging hole of thesilencer. When properly done, the enginewill smoke excessively and stop.

10. Remove the outboard motor from the testtank.

11. Drain the cooling water completely out ofthe outboard motor. Clean the body thor-oughly.

12. Install the fogging hole cap and top cowl-ing.

13. Align the fuel cock with the closed posi-tion and tighten the air vent screw.

14. Install the propeller. For further informa-tion, see page 62.

EMU39632

Flushing with the water flush plug (option-al)

NOTICEECM00301

Before starting the engine, make sure tosupply water to the cooling water passag-es. Otherwise, the engine could overheatand be damaged.

Cooling system flushing is essential to pre-vent the cooling system from clogging up withsalt, sand, or dirt. In addition, fogging of theengine is mandatory to prevent excessive en-gine damage due to rust. Perform the flushingand fogging at the same time.1. Wash the outboard motor body using

fresh water. NOTICE: Do not spray wa-ter into the air intake. [ECM01840] For furtherinformation, see page 52.

2. Fill the built-in fuel tank with fresh fuel andadd “Yamaha Fuel Conditioner and Sta-bilizer”. Remove the top cowling and fog-ging hole cap. For further information,see steps 2-4 in “Flushing in a test tank”.

3. Remove the propeller. For further infor-mation, see page 61.

4. Remove the screw located beside the“ ” (wash) mark on the lower case.Install the water flush plug and connect itto a fresh water tap.

5. Cover the cooling water inlet with tape.

ZMU06823


Maintenance

52

6. Turn on the water supply to the outboardmotor.

7. Start the engine, operate it for 10–15 min-utes at engine idle speed, and then spray“Yamaha Stor-Rite Engine Fogging Oil”into the fogging hole of the silencer. Forfurther information, see steps 8-9 in“Flushing in a test tank”.

8. Turn off the water supply to the outboardmotor, and then remove the water flushplug and tape.

9. Install the fogging hole cap and top cowl-ing. Align the fuel cock with the closed po-sition and tighten the air vent screw.

10. Install the propeller. For further informa-tion, see page 62.

EMU39280

Lubrication1. Install the spark plug and torque to proper

specification. For information on sparkplug installation, see page 58.

2. Change the gear oil. For instructions, seepage 62. Inspect the oil for the presenceof water that indicates a leaky seal. Sealreplacement should be performed by anauthorized Yamaha dealer prior to use.

3. Grease all grease fittings. For further de-tails, see page 57.

TIP:For long-term storage, fogging the enginewith oil is recommended. Contact yourYamaha dealer for information about foggingoil and procedures for your engine.EMU28423

Cleaning and anticorrosion measures1. Wash down the exterior of the outboard

motor with fresh water and dry off com-pletely. NOTICE: Do not spray waterinto the air intake. [ECM01840]

2. Spray the outboard motor exterior with“Yamaha Silicone Protectant”.

3. Wax the cowling with a non-abrasive waxsuch as “Yamaha Silicone Wax”.

EMU28451

Cleaning the outboard motorAfter use, wash the exterior of the outboardmotor with fresh water. Flush the cooling sys-tem with fresh water.

EMU28460

Checking painted surface of motorCheck the motor for scratches, nicks, or flak-ing paint. Areas with damaged paint are morelikely to corrode. If necessary, clean and paintthe areas. A touch-up paint is available fromyour Yamaha dealer.

1. Water flush plug

1

ZMU02509

ZMU06763


Maintenance

53

EMU37081

Periodic maintenance

WARNINGEWM01981

These procedures require mechanicalskills, tools, and supplies. If you do nothave the proper skills, tools, or supplies toperform a maintenance procedure, have aYamaha dealer or other qualified mechan-ic do the work.The procedures involve disassemblingthe motor and exposing dangerous parts.To reduce the risk of injury from moving,hot, or electrical parts:� Turn off the engine and keep engine

shut-off cord (lanyard) with you whenyou perform maintenance unless other-wise specified.

� Allow the engine to cool before handlinghot parts or fluids.

� Always completely reassemble the mo-tor before operation.

Maintenance, replacement, or repair of theemission control devices and systemsmay be performed by any marine enginerepair establishment or individual. All war-ranty repairs, however, including those tothe emission control system, must be per-formed by an authorized Yamaha marinedealership.A service manual is available for purchasethrough your Yamaha dealer for owners whohave the mechanical skills, tools, and otherequipment necessary to perform mainte-nance not covered by this owner’s manual.EMU28511

Replacement partsIf replacement parts are necessary, use onlygenuine Yamaha parts or parts of equivalentdesign and quality. Any part of inferior qualitymay malfunction, and the resulting loss ofcontrol could endanger the operator and pas-

sengers. Yamaha genuine parts and acces-sories are available from your Yamahadealer.EMU35520

Maintenance interval guidelinesThe service intervals provided in the Mainte-nance Chart were developed based upon“typical” use that includes operating at variedspeeds, with sufficient time for engine warmup and cool-down, a medium to light load, andan average cruising speed near the 3000 to4000 rpm range. As with any engine, howev-er, if your normal operating conditions are dif-ferent, you should consider service moreoften than shown, especially how often youchange your engine and gear oil. Examplesmight include extended wide-open-throttleuse or long periods of trolling or idling, carry-ing heavy loads, or frequent starting and stop-ping or shifting. More frequent maintenancewill often pay off many times over in increasedengine life and greater owner satisfaction.Consult your Yamaha dealer for additionalmaintenance recommendations.


Maintenance

54

EMU34446

Maintenance chart 1TIP:� Refer to the sections in this chapter for explanations of each owner-specific action.� The maintenance cycle on these charts assume usage of 100 hours per year and regular

flushing of the cooling water passages. Maintenance frequency should be adjusted when op-erating the engine under adverse conditions such as extended trolling.

� Disassembly or repairs may be necessary depending on the outcome of maintenancechecks.

� Expendable or consumable parts and lubricants will lose their effectiveness over time andthrough normal usage regardless of the warranty period.

� When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine shouldbe flushed with clean water after each use.

The “ ” symbol indicates the check-ups which you may carry out yourself.The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

20 hours (3 months)

100 hours (1 year)

300 hours (3 years)

500 hours (5 years)

Anode (external) Inspection or replace-ment as necessary

Anode (thermostat cover)

Inspection or replace-ment as necessary

Cooling water leakage Inspection or replace-ment as necessary

Cowling lock lever Inspection

Engine starting condi-tion/noise Inspection

Engine idle speed/noise Inspection

Engine oil Replacement

Engine oil filter (crank-case)

Inspection, cleaning or replacement as neces-sary

Fuel filter (disposal type) Replacement

Fuel filter (inside built-in fuel tank)

Inspection and clean-ing as necessary

Fuel line Inspection

Fuel line Inspection or replace-ment as necessary

Fuel pump Inspection or replace-ment as necessary


Maintenance

55

Fuel/engine oil leakage Inspection

Gear oil Replacement

Greasing points Greasing

Impeller/water pump housing


Impeller/water pump housing Replacement

Propeller/propeller nut/cotter pin


Shift linkInspection, adjustment or replacement as nec-essary

Spark plug Inspection or replace-ment as necessary

Spark plug cap/spark plug wire


Water from the cooling water pilot hole Inspection

Throttle link/throttle ca-ble

Inspection, adjustment or replacement as nec-essary

Thermostat Inspection or replace-ment as necessary

Valve clearance Inspection and adjust-ment

Water inlet Inspection

Stop switch Inspection or replace-ment as necessary

Connector connec-tions/lead connections


Fuel tank (optional Yamaha portable fuel tank)

Inspection and clean-ing as necessary

Fuel tank (built-in tank) Inspection and clean-ing as necessary

Item Actions

Initial Every

20 hours (3 months)

100 hours (1 year)

300 hours (3 years)

500 hours (5 years)


Maintenance

56

EMU34451

Maintenance chart 2

Item ActionsEvery

1000 hours

Exhaust guide/exhaust manifold



Maintenance

57

EMU28941

GreasingYamaha grease A (water resistant grease)Yamaha grease D (corrosion resistant grease; for propeller shaft)F4, F6

ZMU06764


Maintenance

58

EMU39291

Cleaning and adjusting spark plugThe spark plug is an important engine compo-nent. The condition of the spark plug can indi-cate something about the condition of theengine. For example, if the center electrodeporcelain is very white, this could indicate anintake air leak or carburetion problem in thatcylinder. Do not attempt to diagnose anyproblems yourself. Instead, take the outboardmotor to a Yamaha dealer. You should peri-odically remove and inspect the spark plugbecause heat and deposits will cause thespark plug to slowly break down and erode.1. Remove the spark plug cap from the

spark plug.

2. Remove the spark plug. If electrode ero-sion becomes excessive, or if carbon andother deposits are excessive, you shouldreplace the spark plug with another of thecorrect type. WARNING! When remov-ing or installing a spark plug, be care-ful not to damage the insulator. Adamaged insulator could allow exter-nal sparks, which could lead to explo-sion or fire. [EWM00561]

3. Be sure to use the specified spark plug,otherwise the engine may not operateproperly. Before fitting the spark plug,measure the electrode gap with a wirethickness gauge; replace it if out of spec-ification.

4. When fitting the plug, wipe off any dirtfrom the threads, and then screw it in tothe correct torque.

TIP:If a torque-wrench is not available when youare fitting a spark plug, a good estimate of thecorrect torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the cor-rect torque as soon as possible with a torque-wrench.EMU39920

Checking fuel filterThe fuel filters are located in the filler hole ofthe built-in fuel tank and in the bottom cowling.Check the fuel filters periodically. If foreign

1. Spark plug cap

Standard spark plug:CR6HSB

ZMU068031

1. Spark plug gap2. Spark plug part number3. Spark plug I.D. mark (NGK)

Spark plug gap:0.6–0.7 mm (0.024–0.028 in)

Spark plug torque:13.0 Nm (1.33 kgf-m, 9.6 ft-lb)


Maintenance

59

material is found in the filters, clean or replacethem. For cleaning or replacement of the fuelfilters, consult a Yamaha dealer.

EMU40140

Inspecting idle speed

NOTICEECM02230

When checking the engine idle speed,make sure to supply water to the coolingwater passages by placing the outboardmotor in the water or by using a flushingattachment or test tank.

To check the engine idle speed, a diagnostictachometer is required. For checking or ad-justment of the engine idle speed, consult aYamaha dealer.EMU39515

Changing engine oil

NOTICEECM01710

Change the engine oil after the first 20hours of operation or 3 months, and every100 hours or at 1-year intervals thereafter.Otherwise the engine will wear quickly.

Extract the engine oil with an oil changer.1. Put the outboard motor in an upright po-

sition (not tilted). NOTICE: If the motoris not level, the oil level indicated onthe dipstick may not be accurate.[ECM01860]

2. Start the engine. Warm it up and keep theidle speed for 5-10 minutes.

3. Stop the engine and leave it for 5-10 min-utes.

4. Remove the top cowling.5. Remove the oil filler cap.

TIP:The oil lubrication check window does not in-dicate the engine oil level. Use the oil lubrica-tion check window to make sure that theengine is being lubricated with oil while it isrunning.6. Insert the tube of the oil changer into the

oil filler hole, and then extract the engineoil completely using the oil changer.

1. Fuel filter

ZMU067651

1

1. Oil filler cap2. Oil lubrication check window

ZMU06766

ZMU06769

1 2


Maintenance

60

7. If the oil changer is not available, removethe drain screw while holding a containerunder the drain hole. Let the oil draincompletely. Wipe up any spilled oil imme-diately.

8. If the drain screw was removed, install anew washer and drain screw, and thentighten the drain screw.

9. Add the correct amount of oil through thefiller hole. NOTICE: Overfilling the oiltank could cause leakage or damage.If the oil level is above the upper mark,extract oil until the oil is between theupper and lower marks. [ECM02181]


11. Leave the outboard motor for 5-10 min-utes.

12. Remove the oil filler cap and wipe the at-tached oil dipstick clean.


14. Remove the oil filler cap again and checkthat the oil level on the dipstick is be-tween the upper and lower marks. If theoil level is not at the proper level, add orextract oil until the oil is between the up-per and lower marks.

15. Start the engine and make sure that thereare no oil leaks. NOTICE: If there are oilleaks, stop the engine and find thecause. Consult your Yamaha dealer ifthe problem cannot be located andcorrected. Continued operation with aproblem could cause severe enginedamage. [ECM02150]

1. Oil changer

1. Drain screw2. Washer

Engine oil drain bolt:18.0 Nm (1.84 kgf-m, 13.3 ft-lb)

ZMU067671

12

ZMU06768

Recommended engine oil:4-stroke outboard motor oil


1. Oil dipstick2. Upper mark3. Lower mark

1

23

ZMU06737


Maintenance

61

16. Dispose of used oil according to localregulations.

TIP:� For more information on the disposal of

used oil, consult your Yamaha dealer.� Change the oil more often when operating

the engine under adverse conditions suchas extended trolling.

17. Install the top cowling.EMU39771

Checking connector and leadFor checking of the following items for theconnectors and leads, consult a Yamahadealer.� Check that each connector is connected

securely.� Check that each ground lead is secured

properly.EMU39301

Checking propeller

WARNINGEWM02280

You could be seriously injured if the en-gine accidentally starts when you are nearthe propeller. Before inspecting, remov-ing, or installing the propeller, place thegear shift lever in neutral, and remove theclip from the engine shut-off switch.

Do not use your hand to hold the propellerwhen loosening or tightening the propellernut. Put a wood block between the anti-cavi-tation plate and the propeller to prevent thepropeller from turning.

Checkpoints� Check each of the propeller blades for ero-

sion from cavitation or ventilation, or otherdamage.

� Check the propeller shaft for damage.� Check the splines for wear or damage.� Check for fish line tangled around the pro-

peller shaft.� Check the propeller shaft oil seal for dam-

age.

EMU30662

Removing propellerEMU39310

Spline models1. Straighten the cotter pin and pull it out us-

ing a pair of pliers.2. Remove the propeller nut and washer.

WARNING! Do not use your hand tohold the propeller when loosening thepropeller nut. [EWM01890]

1. Propeller shaft

ZMU06879

ZMU06777

1


Maintenance

62

3. Remove the propeller and thrust washer.EMU30672

Installing propellerEMU39322

Spline models

NOTICEECM00500

Be sure to use a new cotter pin and bendthe ends over securely. Otherwise the pro-peller could come off during operation andbe lost.

1. Apply Yamaha grease D (corrosion resis-tant grease) into the propeller shaft.

2. Install the thrust washer and propelleronto the propeller shaft. NOTICE: Besure to install the thrust washer beforeinstalling the propeller, otherwise thelower case and propeller boss couldbe damaged. [ECM01880]

3. Install the washer and tighten the propel-ler nut until there is no looseness in thepropeller.

4. Align the propeller nut hole with the pro-peller shaft hole. Insert a new cotter pin inthe holes and bend the cotter pin ends.

NOTICE: Do not reuse the cotter pininstalled. Otherwise the propeller cancome off during operation. [ECM01890]

TIP:If the propeller nut hole does not align with thepropeller shaft hole after tightening the pro-peller nut, tighten the nut further or loosen thenut to align the holes.EMU39780

Changing gear oil

WARNINGEWM02350

Be sure the outboard motor is securelyfastened to the transom or a stable stand.You could be severely injured if the out-board motor falls on you.

1. Put the outboard motor in an upright po-sition (not tilted).

2. Place a suitable container under the gearcase.

3. Remove the gear oil drain screw and gas-ket.

1. Cotter pin2. Propeller nut3. Washer4. Propeller5. Thrust washer


Maintenance

63

4. Remove the oil level plug and gasket toallow the oil to drain completely.NOTICE: Check the used oil after ithas been drained. If the oil is milky orcontains a large amount of metal par-ticles, the gear case may be damaged.Have a Yamaha dealer check and re-pair the outboard motor. [ECM00712]

TIP:For disposal of used oil, consult your Yamahadealer.5. Using a flexible or pressurized filling de-

vice, inject the gear oil into the gear oildrain screw hole.

6. Put a new gasket on the oil level plug.When the oil begins to flow out of the oillevel plug hole, insert and tighten the oillevel plug.

7. Put a new gasket on the gear oil drainscrew. Insert and tighten the gear oildrain screw.

EMU39331

Inspecting and replacing anode (ex-ternal)Yamaha outboard motors are protected fromcorrosion by sacrificial anode. Inspect the ex-ternal anode periodically. Remove scalesfrom the surface of the anode. Consult aYamaha dealer for replacement of the exter-nal anode.

NOTICEECM00720

Do not paint anodes, as this would renderthem ineffective.

1. Gear oil drain screw2. Oil level plug

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:0.100 L (0.106 US qt, 0.088 Imp.qt)

1

2

ZMU06779

ZMU06780

Tightening torque:9.0 Nm (0.92 kgf-m, 6.6 ft-lb)

Tightening torque:9.0 Nm (0.92 kgf-m, 6.6 ft-lb)

1. Anode

ZMU06781

1


Trouble Recovery

64

EMU39523

TroubleshootingThis section describes the likely causes andremedies for problems, such as those in thefuel, compression, and ignition systems, poorstarting, and loss of power. Please note thatall of the items in this section may not apply toyour model.If your outboard motor requires repair, bring itto a Yamaha dealer.

Engine will not start.Q. Is fuel tank empty?A. Fill tank with clean, fresh fuel.

Q. Is fuel contaminated or stale?A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged?A. Clean or replace filter.

Q. Is fuel pump malfunctioning?A. Have serviced by a Yamaha dealer.

Q. Is spark plug fouled or of incorrect type?A. Inspect spark plug. Clean or replace withrecommended type.

Q. Is spark plug cap fitted incorrectly?A. Check and re-fit cap.

Q. Is spark plug wiring damaged or poorlyconnected?A. Check wires for wear or breaks. Tighten allloose connections. Replace worn or brokenwires.

Q. Are electrical parts malfunctioning?A. Have serviced by a Yamaha dealer.

Q. Is clip on engine shut-off cord (lanyard) in-stalled?

A. Install clip to engine shut-off switch.

Q. Are engine inner parts damaged?A. Have serviced by a Yamaha dealer.

Engine idles irregularly or stalls.Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line or oth-er obstructions in fuel system.




Q. Is spark plug gap incorrect?A. Replace spark plug.


Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is thermostat malfunctioning or clogged?A. Have serviced by a Yamaha dealer.

Q. Are carburetor adjustments incorrect?A. Have serviced by a Yamaha dealer.


Q. Is air vent screw tightened?


Trouble Recovery

65

A. Loosen air vent screw.

Q. Is choke knob pulled out?A. Return to home position.

Q. Is carburetor clogged?A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect?A. Connect correctly.

Q. Is throttle cable adjustment incorrect?A. Have serviced by a Yamaha dealer.

Engine power loss.Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller pitch or diameter incorrect?A. Install correct propeller to operate outboardat its recommended speed (r/min) range.

Q. Is trim angle incorrect?A. Adjust trim angle to achieve most efficientoperation.

Q. Is outboard motor mounted at incorrectheight on transom?A. Have outboard motor adjusted to propertransom height.

Q. Is boat bottom fouled with marine growth?A. Clean boat bottom.

Q. Is spark plug fouled or of incorrect type?A. Inspect spark plug. Clean or replace withrecommended type.

Q. Are weeds or other foreign material tan-gled on gear housing?

A. Remove foreign material and clean lowerunit.

Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line or oth-er obstructions in fuel system.



Q. Is spark plug gap incorrect?A. Replace spark plug.



Q. Is specified fuel not being used?A. Replace fuel with specified type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is thermostat malfunctioning or clogged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw tightened?A. Loosen air vent screw.


Q. Is fuel joint connection incorrect?


Trouble Recovery

66

A. Connect correctly.

Engine vibrates excessively.Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged?A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign material tan-gled on propeller?A. Remove and clean propeller.

Q. Is steering pivot loose or damaged?A. Have serviced by a Yamaha dealer.EMU29433

Temporary action in emergencyEMU29440

Impact damage

WARNINGEWM00870

The outboard motor can be seriously dam-aged by a collision while operating ortrailering. Damage could make the out-board motor unsafe to operate.

If the outboard motor hits an object in the wa-ter, follow the procedure below.

1. Stop the engine immediately.2. Inspect the control system and all compo-

nents for damage. Also inspect the boatfor damage.

3. Whether damage is found or not, returnto the nearest harbor slowly and careful-ly.

4. Have a Yamaha dealer inspect the out-board motor before operating it again.

EMU39791

Starter will not operateIf the starter mechanism does not operate(the engine cannot be cranked with the start-er), the engine can be started with an emer-gency starter rope.

WARNINGEWM02361

� Use this procedure only for emergencyengine starting to return to the nearestport for repairs.

� When the emergency starter rope isused to start the engine, the start-in-gear protection device does not operate.Make sure that the shift lever is in theneutral position. Otherwise, the boatcould unexpectedly start to move, whichcould result in an accident.

� Attach the engine shut-off cord to a se-cure place on your clothing, or your armor leg while operating the boat.

� Do not attach the cord to clothing thatcould tear loose. Do not route the cordwhere it could become entangled, pre-venting it from functioning.

� Avoid accidentally pulling the cord dur-ing normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power, theboat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

� Make sure that no one is standing be-hind you when pulling the starter rope. Itcould whip behind you and injure some-one.


Trouble Recovery

67

� An unguarded, rotating flywheel is verydangerous. Keep loose clothing andother objects away when starting the en-gine. Use the emergency starter ropeonly as instructed. Do not touch the fly-wheel or other moving parts when theengine is running. Do not install thestarter mechanism or top cowling afterthe engine is running.

� Do not touch the ignition coil, spark plugwire, spark plug cap, or other electricalcomponents when starting or operatingthe outboard motor. You could get anelectrical shock.

EMU39533

Emergency engine startingBefore performing the following procedure,make sure to read the emergency starting la-bel on the manual starter/flywheel magnetcover.


2. Remove the top cowling.3. Loosen the nut, and then disconnect the

start-in-gear protection cable.

4. Remove the manual starter/flywheelmagnet cover by removing the bolts.

5. Reinstall 2 bolts to secure the fuel tank.

1. Emergency starting label

ZMU06866

1

1. Neutral position

1. Start-in-gear protection cable2. Nut

1. Bolts2. Manual starter/flywheel magnet cover

1

ZMU06749

ZMU06872

2

1

ZMU06782

1

2

1


Trouble Recovery

68

6. Insert the knotted end of the emergencystarter rope into the notch in the flywheelmagnet and wind the rope several turnsaround the flywheel magnet clockwise.

7. Attach the engine shut-off cord to a se-cure place on your clothing, or your armor leg. Then, install the clip on the otherend of the cord to the engine shut-offswitch.

8. Align the engine start mark “ ” on thethrottle grip with the notch in the tiller han-dle.

9. Give a strong pull straight out to crankand start the engine.

TIP:If the engine does not start after several at-tempts, pull out the choke knob.

1. Notch2. Emergency starter rope

ZMU06783

ZMU06876

1

2

ZMU06744


1. Choke knob

ZMU06808

12

ZMU06785

ZMU06816

1


Trouble Recovery

69

EMU33501

Treatment of submerged motorIf the outboard motor is submerged, immedi-ately take it to a Yamaha dealer. Otherwisesome corrosion may begin almost immediate-ly. NOTICE: Do not attempt to run the out-board motor until it has been completelyinspected. [ECM00401]


Consumer information

70

EMU29830

YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY



71



72

EMU29841

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA


A5-tate_Blank.fm Page 1 Friday, May 16, 2003 9:00 AM

December 2009–0.3 × 1 CRPrinted in France

YAMAHA MOTOR CORPORATION, USA

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