yamaha owners manual 40 50 hp

8/12/2019 Yamaha Owners Manual 40 50 HP

1/88

OWNER S M NU L

out o rdmotor

14 HED5 DEO 5DDETD


2/88

A 989

[

IMPORTANT: W ~ ~ _ c r U i i n gb ~ ~ u r eto c a ~ Ys ~ r Oil _

If the yel low all level warning lamp comes on during a cruise add oil to the oil tank im-mediately.Should spare all be unavailable:Proceed to the nearest por t for oil refilling.

T lt l N_.I . _U- t: IS wAvoid contln lng engine operationseizure could occur.

with the re level warning lamp on or engine


3/88


4/88

ooo

TO THE OWNER

Thank you for choosing a Yamaha outboard motor Thismanual cont lJns the information required fo r proper mam-tenance care and opera tion A thorough understanding of

these simple Instructions will help you to obtain maximumenjoyment from your ne w Yamaha

A

I M P O RTA N T.Before o pe ra ti ng t hi s outboard motor. read thisOwner s Manual thoroughly an d carefully It willgive you a good grasp of th e engme s c h r c t e r i s ~tiCS an d th e t e chn ica l i n fo rma t ion required fo rsafe operat ion

SpecIfIcatIons given In thIs manual may be subject tochange without pnor notice

Yamaha Motor Co Ltd

PartIcularly Important informatIon lS dIstInguIshed In thIsman ual by th e following notatIons

NOTE - - A NOTE prOVIdes key informatIon make procedureseasier or clearer

A200

1 ;tNlN - Beforeoperat ing this outboard motor famIliar-

iz e yourself with the regulations se t forth byyour s ta te relation to outboard motor opera -tion

Gasoline is highly inflammable and explosiveHandle it with specIal care

Never a t t empt to modify this ou tboard motor Be sure to wear l if e j a ck e ts on board.

Exercise speCial care to p ro te ct t he environ-ment

I ~ ~ ~ ~ ~ ~ ~ d l c a t e ss p e l ~~ ~ e ~ r e st ~ ~m u ~ t

followed to avoId damage to the outboard motor

> t ; j ~ . ~ ~ - WARNING I ndi ca te s spec ia l procedures that

must be followed to avoid personal injury o r d am -8g e to the Unit


5/88

C O N T E N TS

L O C A T iO N O F M IN C O M P O N E N T S

A cc e s s or y pa rt s

S P E C IF IC A T IO N S .

O U T B O A R D M O T O R ID E N T IF IC A T IO N

Outboar d m ot or s enal n u m be rEngme se nal nu mber

E N G IN E M O U N T IN G

o u n t in g p o s it io n

Mo u n t in g h e ig h t

C la m p

Remote control m ou n tin g

I d lim.ii,N ., Ins talling the s teering gUide a tta c hm e n ts

Ilu l:tet4iuni, h ),it.B a t te ry m o u n t in g 1In: +ili,J nN i' [ns ta li lng t h e m e te rs

F U E L N D L U B R IC A T IO N O IL

O P E R A T IO N A L IN S T R U C T IO N S

St a r ti n g .

Cranking the eng ineEmergency st ar ting In s ta rtIng sy st em tro uble

Engine w r ~ u p

Break inG ea r se le ct io n F or w ar d an d Revers e

S h al lo w w at er cruISing IEImmIS t o p p in g th e e n g m e

O p e ra t Io n n t u r b id w a t e r

Opera tion In salt wa te r

1

7

9

1 5

5 5

6

6

1 7

1 6

2

9 3

3

3 237

37

4 5

4 7

485

5253

5

5

D J U S T M EN T S

S te er in g fr ict io n ad ju s tm e n t I U I : @ fiU lli i_

A d ju s tm e n t o f t h ro tt le t W is t g r ip fn c tl o n ImDDAdjus ting th e st iffne s s o f th e re m ot e c o n tr o l le v e r

I,n; 8 I'&1 I 'Tnm angle a dj us tm e n tTrim tab a d ju st m en tIdle s pe ed adjust men t

T IL T U P N D M O O R IN G .

Tilt u p .P E R IO D IC M I N T E N N C E

Fuel s ys tem.Electrical s ys tem

Lower unitGreas ing pOIntsCoatmg o f the b o tto m o f a bo atReplacem ent parts .

O F F S E A S O N S T O R A G E

Ope ra tion a fter a long tim e s torageCleaning the w a te r In tak e pas s ages

S to rag e o f th e b a tte ry 1 llluM_I,I ,i. ,P R O P E LLE R S E LE C T IO N .

S U B M E R G E D M O T O RT R O U B L E S H O O T IN G

W I R I N G

5 5

5 5

5 5

5 6

5 6

5 6

59

5

6

63

6 46 6

66

697

7 7

7

7 2

7 3

73 7 4

7 5

7 7


6/88

LO TION M IN OMPONENTS

3

8 ~ - -

i i~ J \ . ~ \ , \ - - - - - - - ~ i J

~ ~ ~ ~

- - - f j- 1

~ H l - - - - - - - - J V

~ - = Y J ~ - _ _ - - - - - - - - C ~ )


7/88

Y 65 Y72 Y 36

Top cowling j Trim tab @ Steering handle throttle control

Y-09O X 6 V-560 V ShIft handle Propeller j} Choke knob

V-905 Y 235 X 41

mergency stop sWitch Splash board Overheat warning lamp

Y6 Y-590 Y-2BO

@ T lt up lock TIlt Pin Recoil starter handle

Y 65 Y-560 Shallow water lever q] Transom clamp handle

V-09O X 96

Anti cavitation plate @ Reverse lock


8/88

IIiIDm-- j3J

\

J2o

Ql

(9)

- - 8C

3 ~ j : : r;;

5 - - -

- 3 - -

-(6)


9/88

Y-650

G Top cowlingV26

attery wireV-560

jJ Choke knob

---Y-630

Tilt up lock

V 9O

nti cavitation plate

y o Tnmtab

X-600

ropeller

Y-235

j Splash board

Y 59

t pin

Y680 Transom clamp handle

X 96

Reverse lock

X-333

level warning lamps

X 7

all tank cap


10/88

3 ) ) - - - - - -1 - fd l

4 - - - - ~

5 \ - - ~ - - - /r - - - P

6 / - - - - 1 _ _

- 5 -

t - - - - 9 ~

~ ~ - - 8

\ \ \ - - - - - ~ ~ 7


11/88

Y6

To p cowling

Y 6

@ T it t uP lo ck

Y 5 9

@ n ltP ln

v 9O

@ n ti c a v it a t io n p la t e

Y 7

T n m ta b

X 5

rop eller

V 2 6

J atter y wire

V 8O

@ A n o d e

i iJ iW X 9

Revers e loc k

V 5 6

C h o ke k n o b

X 33 3

Q lev e l warn ing lamps

X 337

l ta n k c a p


12/88

O lO

e s s o r y r t s

u l t n

e m o t e c o n t r o l b o x

f I I a c h o m e te r


13/88

Y Sl

uel tank cap

W 6

uelhne

.. nl It.X56

Power tilt sWitch

X 9

Remote control lever

X 21

Neutral throttle lever

X OlD

Main sWitch

V 577

j hoke sWitch

v 9 mergency stop sWitch


14/88

D 110

SPECIFICATIONS

Item

DIMENSIONS

JModel u ~ Y A M A B A 4 ~ M

Overall length

-Overall wIdth

-Overall height

-Boat transom height

-Weight

mm In

mm In

mm In

mm In

kg li b I

1 114143 9

37811491S 1 203147 3 L 1 324152

S 38 5 L 5 8 2

S 6751148 51/L 69 5 52 9

PERFORMANCE

F u l I ~ h ~ t t 1 e o p e r a t l n g r a n g e- E ~ ~ ~ ~ R ~ M- D 5 ~ - 5 5 0 0 MaXimum output kW HP1/mln I RPM 294 401/5,500-Idle speed r/mln 750 - 850 ENGINE

~

-Type

-Number of cylinders

- ore and stroke

-Total pIston displacement-Cooling system

-Ignition system

-Spark plug

-Spark plug gap

mm In

em J eu In

NGK

mm ln}

Two stroke3

67 x 66 6X 6

69814261Water

CDIB lHS O

9 1 010035 0 39


15/88

Idel n t YAMAHA4 HM ForwardNeutral Reverse

1 85124 131

Regular gasoline

Yamaha outboard motor

1 1

L IUSgall 2416 341cm J ec US azl 350 8

Fuel

Recommended 011

Fueloll ratio

Fuel tank capacity Gear 011 capacity

Item

M

Gear shIfting Gear ratio

DRIVE UNIT

FUEL N OIL

f

1


16/88

0250

SPECIFICATIONS

Model

Item

DIMENSIONS

Unl I - ~- A M A H ~ 4 0 H E O- ~ ~ A M A H A 5 0 D

n

- 500 - 5 500

36 81501/5 500

75 - 85

r/mln R P ~ ~ - - 1 4 5 ~ 0- ~ , 5 0 0 -

kW IHPl/m,n- RPMI 2941401/5 500r RPM 750 - 850

.Overall length

.Overalt wIdth

.Overall height

.Boat transom heIght

Welght

PERFORMANCE

.Full throttle operatIng range

.Maxlmum output

.ldle speed

ENGINE

mm In

mm ln

mm I n

mm ln

kg lib I

542 25 3

35011381S 1 1721461J/L 1 29315091S 381 15 OI/L 5 8 2S 685 15071/L 705115511

5421253135 113 8

S 1 172146111L 1 29315091

S 38111501/L 50812001S 74 5 163 911L 76 5 168 3

Type

.Number of cyhnders

.Bore and stroke

.Total piston displacement

.Cooling system

.Igmtlon system

.Spark plug

Spark plug gap

mm I n

m J u In

NGKmm I n

Two stroke

67x66 2 6 x 2

698 4261Water l

B-7HSlOo 9 - 1 0 35 - 0 391

Two stroke

67 X 6 6 26 X 26 l

698 42 6Water l

B-8HS10

09-1010035-00391


17/88

Gear shiftIng

Gear ratio

U L N OIL

Fuel Recommended

Oil tank capacity

Fuel tank capacity Gear capacIty

LlUS gall

L IUS gallcm J US Z

Regular gasolineYamaha outboard motor

4

24 63435 8

2

Regular gasolineYamaha outboard motor

24 63435 8


18/88

D

SPECIFICATIONS

Model

Item

DIMENSIONS

Unit _L Y M 5 DETO Overall length-Overall width

-Overall heIght

- oat transom height

-Weigh

mm ln)mm In )

mm ln)

mm In )

k9 lib 1

64212531350 3 8

S 1,172 461 /L 1 29315091

S 381115011L 50812001

S 7601167 2 L 7801171

PERFORMANCE

FuJI throttle operatIng range

-MaxImum output

-Idle speed

ENGINE I

i m n RPM)

kW HP)/mln RPM)

r/mln

4 500 5 500

3681501/5 500

75 850

-Type

-Number of cylinders

-Sore and stroke

-Total piston displacement-Cooling system

- gnltlon system

-Spark plug

-Spark plug gap

NGK

mm ln)

3

Two stroke

3

67x6612 6x2

69814261Water

COlB 8HS10

09-1010035-00391


19/88

Item

RIV UNIT

Gear shlftmg Gear ratio

FU L ND DIL

Model

J r Forward Neutral Reverse1 85124 131 Fuel

Recommended all

a ll tank capacIty

u l tank capacity Gear all capacity

i U gall

L IUS gall

cm 3 ccl US ozl

4

Regular gasoline

Yamaha outboard motor

1 3 4

241634135 11181

Q Q


20/88

5

Q Q

OUT O RD MOTOR IDENTIFIC TION utboard t r serial numberThe outboard motor senal number IS stamped on the plateattached to the port SIde of the clamp bracket

ngine serial numberThe engine senal number IS stamped on the port side of thecylinder body

NOTEBoth outboard motor and engine senal numbers are Impor-tant when you want to have service performed or place anorder for parts Please take note of th e numbers


21/88

,

=-

-c

6

000

ENGINE MOUNTIN

Never equip a boat with an outboard motor whosepower exceeds th e maximum rating shown on th ecapacity plate Over powering th e b oa t m a y c au s e

severe inst bihtyIf

th e boat has no capacityplate consult your Yamaha dealer or the boatmanufacturer

Mount ing positionThe outboard motor must be mounted on the boat centerhne keel hne , and the boat must be well balanced so thatthe drafts re on the same level both on the starboard andthe port side Otherwise, the boat wil l be very hard to steer or boats without keel or which re asymmetrical, consultyour Yamaha dealer

F 10 0


22/88

25mm 0 -1

F 10 0

Mounting he igh tTo run your boat with maxImum efficiency, water resist-ance to the boat hull and outboard motor must be minimiZ-ed The mounting height of the outboard motor greatly af-fec ts the water resistance I f the mounting height high,cavItatIon tends t o o cc ur thus reduclllg propulsion by theengine I f the propel le r ti S are too high, t he y c ut the airand the engine speed rises abnormally, thus cauSing theengine to overheat If the mounting height S to o lowsplash resistance wIll Increase and thereby reduce engineeffiCiency The engIne should be mounted so that the antl-cavitatIon plate between the bottom of the boat and alevel 25mm 1 ) below It

Mk iVmoun ting he igh t varies dependmg on th e ~ -

pose of th e boat an d t he ou tboard motor Th e prope r height should thus be determmed b y m ak in gtest-runs

7


23/88

- - - - - - - - - - - - - - - - - - - -

- - - - - - - - - - - - - -

8

F 21

Clam5 11 :huII.J:lj

1 Place the outboard on th e transom so that It IS posItIon-ed as close to the centre as possIble Tighten the clampscrews v n y and securely

Make four holes n the transom board so that the holes

align with the clamp bracket holes and secure theclamp bracket wIth bolts

W ; Y ~ M I ~

VOId using bolts n ut s o r washers other than con-tamed th e engme packing If used they must beof th e same or super io r in t he qual ity of materialan d strength an d must be t ightened securely

After t ightening test run th e engine and c he ckthe i r t ightness

F 220


24/88

F 220

Clamp @ml' f1nlJ .it.Make four holes In the transom board so that th e holesalign with the clamp bracket holes, and secure the clampbracket with bolts accessories For details, consult yourYamaha dealer

fu ; m MW ~Avoid using bol ts , nuts or washers other than con-tained m th e engine packing I f used, they must beof th e same or supenor in t he q u al it y of matenalan d strength an d must be t ightened securelyAfter t ightenmg. t e s t ~ r u nth e engme an d checkthe ir t ightness

e,

122mm 051

327mm 129)

2508mm 99

508mm 2)

69 3mm 2 7 187 8m m 3 5 ) 6 3mm 2 )

254mm 110

309 5mm 12 2 )

9

F 4


25/88

2

Remote control mount ing 11,IUg Uin ,,,.in.1iit.@ iJNW

Incorrect selection or installation of a remote o ~t ro l m ay r es ul t i n s ud de n a nd u ne xp ec te d l os s ofcontrol thus resulting a serious accidentPlease consul t your Yamaha dealer

or Installation of the steering system see your nearestYamaha dealer It lso advisable to ask your Yamahadealer to Install the remote control box and cables Theremote control In this manual IS deSigned for starboard sidesteering wheels

F 4


26/88

Remote control box positioningThe remote control box should be set In a pos tion In which t does n ot o bs tr uc t t he operations of the remote con trollever Make sure there no obstruction In the path of theremote control cables

Remote control box

Remote control lever Remote control cable

F 42

hecking the remote control cable l n ~ l tPosition the remote con trol cables and check I f t he y arelong e no ug h on ne ct the cables to the eng ine and makesure they do no t ge t tangled or bent when the steeringwheel turned

~

~ v ~ ~ ~ ~ ~ ~the cables s h a r P l y t h a ; ~ s l m a ~ u ~ cables do n ot form a loop With a diameter of less than

406mm 16m

2

F 435


27/88

2 Loosen the tw o screws, and remove the lower backpanel.

Back panel

3 Screw In th e cable JOInts accessories about 11 mm 0 4In over the ends of the remote control cables, andtighten the lock nuts Before Installing the cable JOints,apply the water-resistance grease Yamaha Grease Ato th e threaded holes n th e cable JOints

Remote control cable ocknut

CableJomt

Wire cover

Remote control cable installation On the remote controlbox side1 PInch the wire cover with your fingers and pull It ou t to

remove

-

1 -


28/88

3

Insert the femote control cable outer for shif t ing Into thehousing clamp so tha t the groove on Its end frts over theridge In th e clamp Fit the cable Jomt over the pin on theend of th e shift arm, and lock It with the crrchp

5 Fit the grommet accessory In th e clamp groove

Grommet Clamp groove Circhp Sh ftarm

Connect the remote control cable f or t he t hr ot tl e t o t hethrottle arm In the same manner

Remote control cable for throttle Remote control cable fo r shift J errel,p

7 Secure the lower back panel with the tw o screws, and - - -Install the wire cover


29/88

8 fter connecting the remote control cables Install theremote control box n th prevIously determined pOSI-tion uSing the accessory fittings screws, nuts washersand spacer

Remote control box

crew p cer a s h e r

u u

4

_ . ~ _ .F

I lli h l bl h id ) d


30/88

_ ~ _

Installing th e remote control cables on the motor side) andwire harness Remove the to p cowling2 Remove th e u pper and lower fittIng plates and the

grommet

Wire harness Remote control cable fo r shift Remote control cable for thrott le

3 Pass the wire harness through the grommet and Installthe grommet then Install the lower frttlng plate on It

4 Connect th e remote control cable to t he l ow er fittingplate When connecting align the groove In the remotecontrol outer with the ndge on the lower f it ting plate,

andfi t

them together

5 LikewIse, fi t th e upper fI tt ing plate to the groove In theremote ontrol c le outer

5

F468


31/88

~ ~

~ J y ~ ~

0__ L

~

_ _ _

Cable int installationShift side1 Place the remote control lever n n eutra l N), and also

set the gear shIft lever n neutral N l

2 Screw n the cable JOint over the end of th e remote con-

trol cable so that the cable int

hole aligns wi th thecable JOint set pm, and lock t with the lock nut

~ n ~ T O ft r : : o t : ; : ~ ; r ~ ~ ~ : ~ n~ h ~

cable Join t a minimum of 8 mm O 3 10 an d lock it

wi th th e l ocknu t ~

~ ~ e ~ ~ ~ e~ ~ ~ ~ ~ ~ ~ n ~ f r o m~ ~ ~ I n ;~ O ~ ~ ~t ~ ~ ~ ; n

1the lock nut ~Locknut

3l Lock the cable JOint w it h t he half pm

2 6

F 478


32/88

Throttle side Turn the remote control lever downward 32 to th e For

wa rd Side and place the neutral throttle lever In aholrzontal position

NOTEA

click can be heard when the lever

turned3

Don tturn beyond thIs pOInt

2 Set the throttle control lever In the full-closed POSition

Throttle control lever

Screw rn the cable Jornt over the end of the remote con-t rol cable so t ha t the cable JOint hole alrgns with the

cable jornt set pIn and lock It with the lock nu t

~ c l r ~ ; ~ ~ n ~ T o fth m o t e ~ o ~ t r ~ ~ ~ a ~ I ei n ; ~~ h lcable Joint a minimum o mm 3 m and lock twith th lock nu t

ITo ~ ~ ~ ~ ? ~ ~cable ~ n tfrom c ~ ~ ; ~l o o s e ~ ; h t ~the lock nu t

~ Lock nu t

7

Lock the cable JOint wth the ha lf pin


33/88

\ - -

; - - - - - - - - - - - - - - - - - - - - .

J

Lock the cable JOint w th the ha lf pin

5 ouple the Wire harnesses with the rrow and tnanglealigned and lo k them with the wire harness lo k

Wire harness lock

2 8

F 6 ltI: g piU. j +i tl itnst lling th e steermg guide tt hments


34/88

9

nst lling th e steermg guide tt hmentsHold on e end of the s teer ing l Ink rod to the steering hookwi th the bolt and nut and hold the other end to the steeringcable wi th the nu t and washers

NOT

or details consult your Yamaha dealer

Steering hook@ Steering link rod Steering cable

When removing I t ll i g th b tt d as


35/88

~ = ;, ; O O ~_ ; - d - , s t a r t ~ n g f a l lma y result

2 If the bat te ry connec tiOns are reversed, the rec ti fi erWill b e damaged

_ ~ ~

When removingfollowsRemoval

Installation

or Install ing th e battery, proceed as

Disconnect the negative terminal Side black lead firstConnect the posItive terminal S de red lead first

F n

Battery mount ing IUlII iU.J .rijli.Ji

N Y h MI ~ JWhen installing or removing e l ec tr ic al p a rt s, be

re to di.sconnect t he ba tt e ry Wires fr om t he t ~

te ry termmals

The battery should be securely mounted n a dry, vlbratlon-

free location tn th e boa t The bat te ry should be a 12V, 252kC 170AHI

To wire th e battery, connect the red lead to the P Sitive ter-minal of the bat te ry and the black lead to the negative ter-mInal

3 0

t Z iN NtI - - - - - - - . - - - - -Th e bat tery f lu id electrolyte is corrosive. I f i t getsIn your eyes or on your sk in , immed ia te ly wash th earea with water an d se e y ou r d oc to r. I f t he f lu idspills on or around th e engine, thoroughly wash i taway. When the battery S being charged, e x ~

p lo slve hydr o gen gas i s p ro du ce d. Th e batteryshould therefore be charged In a w e l l ~ v e n t l l a t e darea

D Redlead

Blacklead Battery

5nst lling the meters


36/88

o nst lling the meters

Install the meters on the dashboard no dashboard ISavailable Install them In a place free f rom water splashesFor wIring refer to th e WIRING section

o

Vll--- 3

Y A ~ Ho

3

liiu lijF 865

TachometerThis meter Indicates th e engme speedNOTEBefore Installing the tachometer make sure the terminalplate S set on the ~ p o r e de IfI t set on the 12 pole side

the tachometer will no t show correct measurement

Black Green@ Dashboard

G

FUEL AN D LUBRICATION OIL MIxing ratio


37/88

Gasohne 0 1

Fuel tank capacity 24ltters 6 34 US gall

Gasoline h ighly in fl ammable and explosive.When mlxmg gasoline wIth oi l Or when refuelling. refrain f ro m s m ok in g a nd k ee p a w ay f ro mopen flames Or sparks

When refuelling. be sure to stop th e engineAlso take care not to spill gasoline or ad

Be sure to wipe o f f a ny g as ol in e o r oi l spilt onboard immediately an d thoroughly with dr yrags

Never f il l t he fuel tank to more than th e specif ie d l ev el . Safe fil l ing level 5 mm 0 2 inchbelow bottom of f i ll e r neck

After fill ing tighten th e tank filler cap securely.

The mixing o f fuel must be done offboard In awell-ventilated area

Fuel Regular gasoline

Lubncatlon all YAMAHA outboard motor all or aneqUIvalent two stroke outboard motor whIch meets the BIA rating TC W

3

Break In penod

After break In

25

l

Mixture


38/88

1 First pour Into the fuel tank and then gasolrne2 MIx the fuel thoroughly by shakIng the fuel t nk

CAUTION: ~

AvoId USing any other than th t designated Always use ne w gasoline Use a thoroughly blended fuel oll mixture If the mixture not thorou hly blended or the mix-

Ing ratio incorrect the following problems WIlloc-cu

ow ratiO Due to lack of 011 major engine trou-ble such as seizure will result

High oll rat io Fouled spark plugs smoky exhaustor heavy carbon deposIts will result

0 1@ Gasoline

57 1 t1; j_Sin JiI .FUEL ND LUB RIC T ION OIL


39/88

FUEL ND LUB RIC T ION OILPrecIsion blend systemThis engine uses the PrecIsIon Blend System whIch pro-vides superior lubrication by ensuring the proper ad ratio forall operating conditions so no fuel premixing IS necessarySimply pour gasoline Into th e fuel tank and Into the

tank

Recommended gasolineRegular gasoline

u el tank capacIty 24 l it er s 6 34 US gal l

Recommended Y M H outboard motor allIf Y M H outboard motor olliS not available another -stroke engine all WIth BIAcertlfled ~ Wmay be used

Olltankcapaclty 1 311ter5 1 USq t l

4


40/88

, . - - - ~ . _ - - - - -

o

WIll start sounding If th e engine keeps on operation undersuch conditions the engine may seize up Avoid keep the


41/88

such conditions the engine may seize up Avoid keep theengine running with the red lamp beIng turned on

G-620 Ilti:'#'fjOin,J# f'tl,l ii11 level warning systemThis engine IS equipped with an 11 level warning system to

warn the operator of the necesSlty of oll refilling to preventengine seizureWhen the all tank IS full of 11 the green 11 level warninglamp IS on When th e 11 tank level decreases to 5 cc 5US qtl the yel low 11 level warning lamp wil l come on Soadd all to the a ll tankIf no spare Ollis available proceed to the nearest port for 11

refillingWhen

the engine keeps on operation wIth theyerrowlamp being turned on and the all tank level lowers to300 cc 04 US qtl the engine speed decreases automati-cally to about 2 000 rpm and th e red level warning lampWill hgh t In add it ion the buzzer In the femote control box

NOTE. - ~ - - - - - - ~ - - - - - - - - - - -._ When the engine speed has dropped you must stop

the engine by turning off the main sWitch and add 11 to the 11 tank then start the engine If ollis add-ed without turning of f the main sWitch the enginespeed Will no t rise to more than 2 000 rpm After ad-ding oil t ur n on t he main sWitch and make sure thered all warning lamp comes of f before starting theengine

To operate the 11 level warning system be sure toInstall the all level warnIng lamps

When the engine temperature rises to o high theengine speed Will decrease and the buzzer In theremote control box Will sound as In the all level warnlng system However the red l amp wil l no t comeon

Red lead Yellow lamp Green lamp

6

~


42/88

J

lJm

Io

[]

7


43/88

Before operating the engIne for the first t ime or after a longtime of disuse sure to bleed the olllnJectlon pump Tobleed loosen the air bleedIng screw attached to the all In-Jection pump and the all wil l flow to th e olllnJectlon pumpdue to a head thus expelling the air n the pump ftermaking sure tha t the starts overflOWing through thescrew hole t ighten the screw completely

CAUTION: r ; e sure to bleed th olllnJeetlon pump otherwIse t w

Impossible to supply oil thus damaging th e engine

8

Firmly connect fuel hose connector 2 positioned on thetank mark sIde to the fuel tank


44/88

tank mark sIde to the fuel tank

When inserting th e fuel JOint into th e fuel tankvapor ized gasol ine will squirt ou t of th e ai r bleed-in g hole asoline IS highly Inflammable and ex-

plosive under certain conditions Refrain fromsmoking and keep away from open flam es orsparks when mserting th e fuel joint

Fuel hose connector 2

2 Firmly connect fuel hose connector 2 to fuel hose con-nector 1on the motor

Fuel hose connector 1

9

Squeeze the prtmer bulb until firm pressure felt


45/88

4-1 Place the shift handle In neutral Nl

C UTIONhe engme may only be started when the shift handle IS

In the N positIon ~

4-2 Place the throttle gn p m the START posItIon Thethrottle openlng must be adjusted slightly accordingto th e engine temperature)

4

4 1 Place the remote control lever on the remote control


46/88

4-1 Place the remote control lever on the remote control

box neutral N

C UTION

If the remote control lever no tmotor cannot

beturned

N the

4

4-2 Turn the neutral throttle lever on the remote controlbox upward It necessary to change the throttleopening slightly depending on the engine temperature

IUI lg in,luijli.I,.,' 5l Install the lock plate fIrmly onto the emergency stopsWitch


47/88

ST T

4

Tie the rope attached to the lock plate to your Wrist

Lock plateNOTE The emergency stop sWitch provided fo r the safety of th eoperator When the lock plate pulled out from theemergency stop sWitch the engine stops Immediately Theengine will no t start when the lock plate removedShould th e operator fall off the boat or lean to o far over onesIde the lock plate will pull ou t causmg the engine to stop

IIiDID Pull the choke knob out completely

1 ';'i u 1 .I,.,' Turn the main sWitch to O N and turn the choke

sWitch lever upward The remote choke sWitch leverreturns to ItS home position when It IS released There-fore keep the lever pressed upward.l

NOTE If the engine still warm do no t use the choke


48/88

,In l: tk . ijttJ:j ,Ji1 Set the main sWitch to START and the starting motor


49/88

\

1 Set the main sWitch to START and the starting motorwill turn

2 After making sure the engme has started release themain sWitch and remote choke lever

3 Slowly return the neutral throttle lever to It s home pOSI-tion so that the engine does not stop

CAUTIONNever t ur n t he main sWitch to the STAAT p S -tion while the engme IS runnIng

2 Do no t keep the starting motor tur ning for mor ethan five seconds with the main sWitch In START If the engme wil l no t start after fiveseconds return the main sWitch to O N and crankthe engine again after waiting 1 seconds.

If the starting motor 15 turned continuously for morethan fIVe seconds th e battery wil l qUickly run deadmaking t Impossible to start the engme

r ~ _ _ _ _ _Emergency start ing n s ta r tmg system t roubleIf It Impossible to start t he engine due t o a dIs charged


50/88

tlll:'g h ''#fijn,'ii,'

5

If It Impossible to start t he engine due t o a dIs chargedbattery or starting system trouble the engme can bestarted uSing the emergency starter rope

- tU ;' N. When th e engine IS started with an emergencyrope the start In gear protection system wil l notwork sure to check t ha t t he gear IS n NeutralOtherwise th e boat may lurch ahead or asterncausmg seriOus damage or personal injury

Remove the to p cowling by depressing the latch at therear of the cowling Lif t up and back to remove

Il mi2 Remove the starter by removing the 3 bolts secunng

the rewind mechanism to the flywheel,UJI *,'pn,jje #m,)i

2-1} Remove the flywheel cover by removIng the 3 bolts22 Turn mam sWitch to O N

NOTE - - Without setting the main sWitch at O N It ImpossIble tostart the engine

Wind emergency starter rope one or tw o turns aroundflywheel rotor the n pull t he starter rope to startengine and If reqUired pull ou t choke knob to choke


51/88

6 ~

engine and If reqUired pull ou t choke knob to chokemanually

4 To release choke push In choke knob

t i NNdWhen starting or operating th e engine nevert ou ch t he I gn it io n coil hightenslon wire sparkp lu g c ap o r a ny other electrical parts to which highvoltage IS applied

When pulling th e emergency starter rope be sureto ke ep loo se clothing and other objects awayfrom t he eng me

ro ta t ing f lywhee l IS very d an ge ro us Nev er ~

tempt to i ns ta ll t he t op c ow li ng on th e engmewhen i t i s i n operationProceed to th e nearest port to g et t he st artin gsystem repai red as quickly as p os si bl e Tak e carethat no water splashes o n to t he flywheel

H 32

ngin w rm upBefore beglnnrng operation the engine should be warmedup at Idle speed fo r three minutes Failure to do so will


52/88

Iln#l#'*+i I)#'W I)iie'

up at Idle speed fo r three minutes Failure to do so willshorten the life of the engine

CAUTION

IMake sure that water runs o ut f ro m the cooling water Jpilot hole

Overheat warning system

li IiThIs eng ine has n overhe at wa rn in g device Before theengine becomes t oo h ot the engine speed will automatical-ly reduce to a safe r pm and the overh eat w arn in g l amp onthe bottom cowling Will flash

Im: ij W I j fi,ll i

Check that water runs ou t of the pilot hole f not stop theengine and check the water Inlet for clogging f clogged t

shou ld be cleaned and If not clogged operate to your

nearest port at lo w speed and co nsu lt a Yamaha dealerNever run the engIne at h igh speed otherWise engineseizure could occur resulting n Irreparable damage

7

H-430

Break In EI IIIDA penod of break-In required to allowthe matIng surfaces


53/88

~ J I ~ ; TSLOW ~ ~ ;: < .

3I ,V .,.START

W U WI, , , I

of all moving parts to wear evenly when new This procedure will ensure proper performance and greater durability

1) Break-In time10 hours

2) MI xi ng ratioGasoline al l 25 1

3) Procedurea Run the engIne at trolling speeds The lowest pOSSI-

ble speed) for th e first 10 minutes.b With an easy planing boat, bring It into th e planmg

posItion; then Immediately reduce the throttle toapproxImately 3,000 rpm one-half throttle), continue running at this throttle setting fo r 50 minutes

c Bring th e boat Into th e pla mng state a nd redu cethrottle to 4,000 rpm or three-quarter throttle approxImate) while maintaining planing. Continue running at this throttle setting fo r one (1 I hour

NOTE

Run at full thrott le for approximately one (11 o ut o f every 10minutes

d For th e next eight (8) hours, avoid continuous fullthrottle operation fo r more than fIve {51 minutes

e fter the first 10 hours, return to 100 1 r atio

CAUTION --------------:J

ailure to follow the break-In operation procedure ma yresult In severe engIne damage.

8 .

H 420

reak In ' I I ''tin. nijl'I'''''A penod of break-In IS required to allow th e mating surfacesof all moving parts to wear evenly when ne w This pro


54/88

,

9

of all moving parts to wear evenly when ne w This pro-cedure will ensure maximum performance and engine l ife1} Break-In time

10 hours2 MIxIng ratio

Gasoline 0,1 50 3} Procedure

a Run th e engine at trolling speeds The lowest pOSSI-ble speed for th e fIrst 10 mInutes

b With an easy plamng boat bnng It Into th e planingposltlon then Immediately reduce th e throttle toapproximately 3,000 rpm fone-half throttle cont inue running at this throttle setting fo r 50 mrnutes

C Bring the boat Into the planing state and reducethrottle to 4,000 rp m or three-quarter throttle approximate while maintaining planing Continue fun-ning at th,s throttle setting fo r onE 1 hour

NOTERun a t ful l th ro t tl e for approximately one 1 ou t of every 10minutes

d For th e n ex t e ig ht 8 hours. avoid continuous fullthrottle operation fo r m o re t ha n f iv e 5 minutes

e Afterthe first 10 hours use straIght gasoline fo r nor-mal operation of th e precIsion blend system

CAUTION:

Failure t o f ol lo w th e break-In operatIon procedure mayresult In severe engine damage


55/88

A Forward (F)Turn the remote control lever to F


56/88

mt i l

B Reverse (R)

Lock the reverse lock U1Ud,WiIIIJm

4 ' ; U ~ C I-When operating REVERSE, be sure to se t th ereverse lock to LO K an d keep th e throttle at1/2 or less I f this IS not done reverse lockmechanism wil l not prevent th e engine f rom IIf-tlOg ou t o f th e water a nd l os s o f c on tr ol m ay oc -cur possibly causing injury t o t he passengers

2 Turn the remote control lever to A

~ ~ ~ ~ ~ ~ ~ n ~ fs a f e t y ~ ~ ~ ethrottle 1 designed n ~ t ~open more than 2 when operating In REVERSENever attempt to force the throt tle to more than 1/ 2

_ ------- -- -------

5

H7

Shallow water cruising II 1IIiIN iNNtI


57/88

5

N i N NtI n sh llows ru n th e bo t t trolling speed or there -abouts The reverse lock will no t operate an d mayt h us c u se th e engine to ft out of th e w te r n dt he b o t to lose control when th e lower c s ing hits

an underwater obstacle Personal i nj ur y m ay ra su it when th e engine is operating in reverse as tc an e as il y b e l if ted by th e force o f reverse thrus t

To crUIse In shallows proceed as follows1 Place the shift handle In neutral2 Push the reverse lock down to release3 Slightly tilt up the engine and pull the shallow water

lever toward you4 When bTlnglng the engme from the shallow water pOSI-

tIon back t o t he home pOSition t t It up a httle push theshallow water lever downward and tilt the engine downslowly

H 618

Stopping th e engine mi1-1 Turn the thrott le gnp to the fully closed


58/88

-

D

1 1 Turn the thrott le gnp to the fully closed1-2 Place the shl f handle In neutral

2 To s top the eng ine push the emergency stop sWitchbutton

t1t :I ,@n' 'binnji., } Place the remote control lever In neutral

2 Turn the main SWitch to OFF and the engIne will stopPull ou t the lock plate from the emergency stop sWitchand the engine will stop

1 Lock plate

I n ; t ~ .

It IS impossible to stop the engine by d i sco nnec-

t in g t he w ir e harness Furthermore w he n t he w ir eharness IS disconnected th e enuine cannot bestopped b y t ur nm g o ff th e main sWitch or by p u l l ~In g o ut t he emergency stop s wi tc h l oc k plate Besure to keep th e w ire harness connected dUringoperation

3 After stopping the engine remove the fuel hose

- CAUTION: 1Before stopping the engine reduce the engine tempera- /ture by running It at Idle or lo w speeds for 2 or 3minutes

5

H900

per tion in turbid w terIt IS strongly recommended that the optional chrome-platedwater pump kit be Installed If the outboard to be used In


59/88

p pturbId water conditions

H 9

per tion s lt w ter

After operatingIn

saltwater

washout the

coolingwater

passage with fresh water Otherwise the cooling waterpassage may clog up wIth salt collections For washingrefer to Cleaning the water Intake passages In t he O FF -SEASON STORAGE section

5

H 71

JUSTMENTS ~ ~ n ~ g~ n t i o nadjustment II Jliltn,m ,.,

h b d d


60/88

The tension of the steenng fnctlon can be adjusted by turn- ng the adjusting bolt attached t o t he sWivel bracket

To ncrease tensionTurn the adjusting bolt clockwise

To decrease tenSionTurn the adjusting bolt counterclockwise

H7

Adjustment o f throttle twis t gnp n t i o ~II mI

The throttle tWiSt grip has an adjustable fnctlon dev ice Thefnctlon device located In the steering handle and fnctloncan be adjusted by tightening or loosening the fnctlon boltTo ncrease tension

Turn the fnc t lon bol t clockWiseTo decrease tension

Turn the fnctlon bolt counterclockwise

H 7 37 ,'el;II'PMt' 'E '. 'Adjusting th e stiffness o f th e remote control lever

By turning n or ou t the throttle friction screw at the front of


61/88

/

y gthe remote control box the stIffness of the control levercan be adjusted Tur ni ng t he s cr ew to th e right makes th econtrol lever stIff to turn and turning It to th e left makesthe lever light

Makehght Make stiff

F 33

Trim angle adjustmentTo maintain steeTing stabilIty and good performancealways maintain correct trim angle The appropriate trimangle vanes depending on th e combination of the boat en-gIne and propeller as well as operating condItIon. bu t It

safe to say th t when th e tnm IS to bys tern t he b o tIS In a stable tn mIf the tnm angle IS too large the buoyancy center of theboat Will sh ift to wa rd th e stern If this happens and the

stability moment at the bo wIS

great t he b oa t Will tend to porpoise possibly causing th e operator and passengersto be thrown overboard If th e tn m angle to o small th ebo w W ll p low thus making th e boat unstable

6

To adjust the t r im angle remove the tilt pin f rom the sternbracket assembly and whIle tIl ting the motor repositIonthe pin In th e desIred hole


62/88

~

IW iN N. When mounting th e outboard motOr on a boat be sure to make a test run and set th e proper trim ngle

Tilt pIn

NOTE To l ow er the bow move pin towards the mountrng

plate To raise the bow ov pm t ow ar ds t heengine

When o per ati ng against a strong wind It IS ad-

vIsable to make the trim angle slightly smaller thanthe standard for steering stability If the wind ISfavorable the trim angle should be Increased forbetter steenng stability

MCAUTION:

r

Never at tempt to adjust th e trim angle uSing t he p ow er

tilt sWitch dunng operation or power ti lt assembly trou-ble could occur

7

H OO

Trim t adjustmen_t

The tn m tab should be adjusted so t h at t he steering handle


63/88

can be turned to either the n gh t o r left by applying th e Sameamount of force

An improperly adjusted trim ta b will cause loss o fcontrol. Test run to determine proper adjustment.

Trim t Trim ta b screw

A When th e o t tends to veer to portTurn the rear en d of tn m tab to the le ft port side)

AN In the figureB When th e boat tends to veer to starboard

Turn th e rear en d of t nm t ab to the nght starboard side) B In the figure

CAUTION:

The trim tab also serves s anode to protect the

engine from electrochemical corrosion Never pamt th et rim tab as It will become ineffective as an anode

8

H85

le spee justment1 Start the engIne, and warm It up for a fe w minutes2 Set the Idle speed to the specifIed by adJustmg the


64/88

9

throttle s top screw see SPECIFICATIONS prece-dmgTo increase the Idle speed

Turn the thrott le stop screw clockwise

To decrease the Idle speedTurn thethrott le stop screw cour1terclockwlse

Throttle stop screw


65/88

1055

TILT UP AND MOORING 1 m I'imIf the engine wil l be stopped for some time or the boat 1moored In shallows the engme should be tilted up Thisprotects the propeller and lower casing from damage b


66/88

protects the propeller and lower casing from damage byrocks or any other underwater obstacle when the tide 1 eb-bing and from fast corrosion by salt water

IW dNN I ~ ~he n tr nsporting the engine or keeping It tilted

up fo r more than a fe w minutes be sure to discon-nect th e fuel line link mg the engme to th e fueltank Otherwise . fue l may leak out

CAUTION:Make sure the power unit IS kept higher than the pro-peller at all times Otherwise w at er m ay run Into the

engine and damage It

Tilt up

1) Push the upper portion of the power t t sWitch on theremote cont ro l lever until the power t il t m ot or nOisechanges A nd t he engine trlts up completely

2) Turn the tilt up lock toward you and support the engIne

[

~ t ~ ~ t ~ t ~ ~ ~ ~the engine be ~to ~ l ~ P r tIt w ~ ~ t h ~tilt up lock so that the engine will no t ttlt down suddenly /du e to lack of orl pressure

~ 6

When tilting d ow n t he engine, release t he t il t up lock,and keep pushIng th e lower portion of th e power t il tsWitch to t i lt down the engine completely.


67/88

6

Manual operationIf It Impossible to tilt th e engine up and down due to adischarged battery or power tilt trouble, tighten th e manu al

valve screwcounterclockwise until It stopsThe engine can no w be t il te d up and down To lo k theengine In that posIt ion, turn the manual valve screw l o ~wIse until It stops

CAUTION:

hen the engine IS not used f or a long penod of timethe bat te ry wires pOSitive and negative) should bedisconnected from the battery

J 06O

PERIODIC MAINTENANCE n the following check-up list, the mark l Indicates the check-ups which may be done by yourselfThe mark O Indicates work to be earned ou t by your Yamaha dealer


68/88

Grease

Check POint

Outboard motor body

Retighten bolts and nuts

Time Interval

10 hours 50 hours lOa hoursEvery 100 Off seasonhours or after the Procedure

0 0 0every 6 boating

, month 3 months 6 months months season

0 0 0 0 0

Cleaning of filter Checking for fuel leakage _

Cleaning of tank Intenor Cleaning of strainer

Spark plug gap

09-10mrn 0035-0039 ) 0 0 0 0

_

0 0 0 0 0 Check speCifiC gravity_ _ _

Checkmg for damage to bladesReplacement Replacement Checking for water leaks .

Checking for wear _0 0 0 0

Check for ddmage to extenor _ == r Greasing _ _ _

Gearoll

Spark plug

Fuel hose

uel tank

Trim tab Zinc

Ignition t iming

Battery

Propeller

uel tank strainer

Carburetor settmg

Fuel filter

Lower Unit

Fuel system

Electricsystem

NOT The time rntervals specIfied n thiS chart are based on general use and ma y vary depending on operatrng condItions

6 3

6

Fuel system

Gasol ine is highly inflammable and explosive


69/88

Handle it with speCial care

Fuel lineCheck the fuel line for leaks, cracks, foults. If any problem found, do the necessary repalTlng or replacIng fno cause can be found, ask your nearest Yamahadealer,

Checking points1 Carburetor s leakage2 Fuel pump fault or leakage3. Fuel tank leakage.4 Fuel hose JOlnt s leakage5 Fuel hose s crack or any damage6 Fuel filter leakage7. Fuel connector s fault8 Primer bulbfault or crack

6

J 75

Cleanmg th e f u ~ l . a n kan d ~ n ~ _ i r l ~ uel tank

dd a small quantity of SUItable cleaning solvent to thefuel tank and thoroughly clean the tank Intenor by shak


70/88

6

Ing t he t ank After cleaning, dram of f the cleaning solvent completely

Fuel tan k straIner

Thoroughly clean the strainer on the end of the suctionpipe with SUitable cleaning solvent

J 55

Cleaning th e f U ~ } l l t e r

Remove the filter cup, remove the filter and wash It InsUItable cleanIng solventNOTE

e careful not to lose the O-r ing Without the O-ring,fuel leakage may occur

tU i NN w--------- -- -Wh en c leaning th e fuel fil ter be sure to stop th e

Jngme lso refrain from smokmg a nd k ee p awayfrom op en f l ames or sparks

J-305o lectrical system

While sta rtin g o r o pe ra tin g th e engine never


71/88

IUI:@tli :'8

. 8 9 1 m m

NGK B-7HS10

NGK B-8HSlO

to uc h t he Ign it ion coi l h i g h ~ t n s i o nwire sparkplug cap or an y other electrical parts to whichhigh voltage is applied

~ p r kplug inspectionThe spark plug an Important engine component and easy to Inspect The condition of the spark plug can IndIcate somethIng of the OndItion of the englOe.For example, If the center electrode porcelalO verywhite, this could Indicate an Intake tract aIr leak or carburetlon problem for that cylinderDo not attempt to diagnose any problems yourself In

stead, take the outboard motor to a Yamaha dealerYou should penodlcally remove and Inspect the sparkplug because heat and deposits WIll cause the sparkplug to slowly break down and erode If electrode erosIon becomes exceSSive Or If carbon and other depositsare exceSSive you should replace the spark plug with aproper type plug

4 HM 4 HEO

6 6

Standard spark plug 'MJ ,n.1 jI.,NGK B-7HS10NGK B-8HS10

Before installing the spark plug measure the electrodegap with a w ir e th ickn ess g aug e, adj ust the gap tospecIfication as necessary

J

J 380 tiU :'# AUlt'#,Uint'iie.Battery maintenance an d f l U l ~replenishingA poorly maintained battery WIll deteriorate qUIckly Thebattery flUid should be checked at least once amonth1 The level should be between the upper and lower


72/88

[ ~ ~ k ~ ~ ~ ~ ~ ~ ~ _ _0~ = - ;~ m ~~ o0 3 5 - - _ 0 ~ _ ~ 3 9 1 ~ - )JWhen Instalhng the plug always clean the gasket sur-face and use a ne w gasket Wipe of f any grime from thethreads, and torque the spark plug properly

[ s ~ a ; - ~ ~ g ~ o ~ ; \ g ,1 4 ~ l NOTEIf a torque wrench no t available when you are install ing aspark plug a good estimate of the cor rect torque 1/ 4 to1/ 2 turns past finger tIght Have the spark plug torqued to

the correct value as soon as possIble with a torque wrench

tn'iV NtI [ : h e n mstalling or removing a sp rk plug be

careful no t to damage th e Insulator

J 7

I~

CAUTION: - -

When Installing the spark plug make sure the terminal no t loose If loose, be sure to tIghten completelybefore installing the plug It IS adVIsable to use a sparkplug Integrated With the terminal

pplevel marks Use only distilled water If refilling - -necessary

- ; ; o ; : ~ ; ~ ~ : : a wc o n t a l n ~ ~ ; ~ e ~ a ;whlC; are ; a ~ m f u l

Ito a b ~ t e r ytherefore, refll o ~ ~ ~ ~ ~~ I s t i l l e d _ ~ ~ ~_ _2 Always make sure the battery IS charged suffiCIent-

ly It adVisable to Install a vol tmeter for bet ter bat-tery maIntenance

J 360

E : l ~ r g e n c ystop s j t ~

Keep the emergency stop sWitch In )ood working orderBefore start ing the engine check the sWitch If faulty,have It repaIred by your nearest Yamaha dealer

7

J 81

o Lower n tChanging th e gear

lace an empty all can under the lower casing andremove t he l ow er drain plug uSing a slotted*head


73/88

J t 2

screwdnver Next remove the upper level plug Withthe outboard In an upnght posItion, uSing a flexible orpressunzed fIlling device, Inject outboard motor hypOidgear a ll SAE 90 Into the lower all drain plug hole Whenth e begins t o f lo w ou t of th e upper level plug hole,Insert and t ighten the plug Next, screw n the lower drain plug

CAUTION: Replace th e gear all after the f irst 10hours of opera-tion and check the every 100 hours thereafterI f the gear oil becomes milky consult a Yamahadealer

~

NOTE: This engine has an v nt ge of gear all being replaceeven In a tdtup state

level plug

@ drain plugJ 86

Trim ta b ZincThe lower unIt S protected from corroSion WIth a tramtab {Zinc InstalledIf the trim ta b S worn more than 2/3 replace It

8

J reasing po ts

Iln:hU :'j,1 4 .' ,*,,,.,,.,,


74/88

-11

I

o

Y M Grease

9

Y M Grease

J 4 5

o o ting o f t h ottom of bo tAVOId coating the boat bottom with anti-fouling paintconta in ing copper Such anti-fouling paint will corrodeth e engine faster

c Wash the fuel tank Intenor and strainer with sUItablecleaning solventRefer to Cleaning the fuel tank and strainer In the PERIODIC M INTEN NCE section


75/88

J

o epl cement p rtsWhenever the replacement of parts IS necessary, besure to use genuine Yamaha parts or eqUIvalents of thesame type and of equal strength and matenal ny -fenor quality part can malfunction and the resulting lossof control may endanger the operator and passengers

K 4O

OFF-SEASON STORAGEWhen storing your engine for a long period of time for example, after the boating season IS over) , we recommendyo u have your engine checked by a Yamaha dealer

The follOWing check-ups and service you m ay performyourselfo Cooling system

Wash the cooling water passages With fresh watero Fuel system

a Idle the engine until the carbure tor IS drained offb Wash the fuel filter In sUItable cleaning so v nt

Refer to Cleaning the fuel filter In the PERIODICMAINTENANCE section

o Lubncatlon systema Replace th e g ear

Refer to Changmg the gear all m the PERIODICMAINTENANCE section

b Add 5 to 1 cm J of outboard motor through thespark plug holes In the cylinders

c Apply grease to the specified places.Refer to Greasing POints In the PERIODICM INTEN NCE section

o Electrical system In #l#.f&ju.J# # '.Jiit'Store the battery In a cool, dark place.C VnON

For long penods of storage, the outboard motor shouldbe placed on a stand or with Its front faCing downward VO d direct sunlight and humidity

7

K 055 IUI lj,@ .'j IM.','.' per tion fter a long time stor geWhen operating the engine after a long time (about 12months) storage, proceed as follows1 Use a 50 1 gasOII mIxture to start the engine


76/88

7

2 Keep the engine running Idle -.-3 Disconnect the feed pipe connected to the top Intake

manifold on the port SIde

4 After making sure

runs out of the

feed pipe, connect the pipe to Its onglnal POSition and operate theengine uSing the PrecIsion Blend System If no flowsout of the feed pipe after more than 10 minutes, consult a Yamaha dealer

K ll0

o Cleaning the water intake passagesa Install the outboard motor on the water tank and

add water up to above the anti cavitat on plate.

Next, shift rnto NEUTRAL, start the engine and run1 1 l l i IC D


77/88

at lo w speed for a few minutes

. q A I J T l O N : ~ ~ ~ ~ ~ ~ ~ ~ ~

When the fresh water level below the anti-cavitation plate or when water supply IS insuffiCient, engine seizure may occur

v

Water surface Lowest water level

J

CD

r ~ _ _ _ _ _ _

iV NM J~ nus.ng th e w a te r c he c k plug b e s ur e to re -move the propeller fo r safety

Water check plug

b. Remove the screw located beside the WASHmark on the lower casing, Install the water checkplug accessory , and connect It to a water faucet

Next, shift Into NEUTRAL, s ta rt the engine whi le

supplying water, then run at lo w speed for a fewminutes,

~ e ~ ~ ~the engine even momentarily withoutrunmng cooling water. Either the water pump willbecome damaged or the engme will overheat Beforestartmg the engine, be sure to Install the water checkplug and feed water

===

7

K 4

o Storage of th e battery IUllIg.W1 . getf1 . ;it.1 When th e outboard motor will no t be used for month or

longer remove the bat te ry and sto re It In a co ol d arkplace Completely recharge the battery before reusing t

L 110

PROPELLER SELECTIONThe propeller IS one of the most cntlcal elements In the per-formance of an outboard Selection of an Incorrect pro-pel ler can adversely affect the performance and It couldseriously damage the motor


78/88

2 If the battery Wilt be stored for a longer penod than theabove check the specific gravity of the flUId at leastonce a manth and recharge the battery when It too

lowNOTE

Follow the manufacturer s Instructions for battery details

7

A Yamaha outboard eqUIpped wIth a propeller that hasbeen selected to perform well In a variety of applicationsThere ma y be uses however where a propeller with a d if-

ferent diameter or pItch would work bet ter For greater loadof operatron a smaller pitch propeller sUited because Itcan maintain proper eng ine rpm LikeWise a large p itchpropeller sUited fo r smaller load of operation The enginespeed changes greatly depending o n t he propeller Size andboat load I f t he engine speed extremely lo w o r high ItWill adversely affect the engine For thIS reason Yamahadealers stock a variety of propellers and can Instal l a SUIt-

able propeller on your outboard Consult your dealer when

selectIng a proper propeller for your particular application

1tiZ i NlNtI When removing or installing th e propeller shift in -to NEUTRAL an d remove th e spark plug capsOtherwise th e engme may start suddenly result-In g In a serious injury or aCCident I t is a good prac-tice to msert a piece of wood between th e anti-cavitation plate an d th e propeller to Jock th e pro-

peller This protects your hands from th e propellerblades

M 2

SU MERGE MOTOR

An accidentally submerged motor must be completelyoverhauled as soon as possible not rust and corrosionwill develop If your engine should be accidentally submerged the following steps should be taken as emergency


79/88

7

merged the following steps should be taken as emergencymeasures1 Bnng the engine up out of the water as qUickly as pOSSI

ble Wash It with fresh water All salt mud and seaweed

should be completely removed3 Remove the spark plugs and drain the water from the

cylinders through the spark plug holes Also drain thecarburetors and fuel hnes

4 Pour engine 011 Into the motor through the spark plugholes and carburetors while turnmg the engine overrepeatedly by operating the starter so that 11 spreadsout over the surfaces of engme Inner parts

5 Have the engine overhauled by your Yamaha dealer assoon as possIble

N 065

TROU L SHOOTING

Problem Situations w it h y ou r outboard motor can In most cases be prevented by ensuring proper scheduled maintenanceMany problems result from careless handling and abuse The situations hsted and their possible causes dr e Intended to assistthe opera tor In IdentifyIng an d rectifyIng such p ro bl em s S ho ul d y ou c on ti nu e to experience any diffIcul t ies after following


80/88

p y g y g p y p y g

these procedures please contact your Yamaha dealer

A The engine will no t start

B The engIne runs Irregular ly or stallsC The engIneIdles roughlyD The engine runs to o fastE The engine runs too slowF The boat speed IS t oo l ow

7

ossible ause

Fuel hoses are connected ncorrectly

Fuel tank S empty

Fuel hose S flattened or kmked

FB C 0 E

0

0

0 0 0

A

ooo


81/88

Spark plug ts fouled or defective

SpeCified ol l i no t used

o Cavitation takes placeSpark plug S ncorrect n heat range

Fuel hose flattened or kmked

o Propeller IS damagedo Tnm angle S ncorrect

ue l filter IS clogged

a ll t an k empty IIU lj,@ ,' .Will.I'it.

0 0 0

0 0

0 0 0

0 0 0

0 0 0

0

0

0

o

o Loads on boat are mproperly distributedo Transom 1 t oo l ow

oo o

oo

Transom IS to o hIgh

Propeller S ncorrect In pitch Or diameter

ooo

o

o

Starter motor IS faulty Iln:'jtf'M,I'tfti t'i'Solenoid IS faulty 1I,1:. tfPUi,'t@u ji,.W ring or wire connections are faulty

SWitch IS faulty 1 ':'lubin.II_Wi elilt'

Battery 1 undercharged 'Itll' fint' fi t ie' 7

0-000W R N

@

T


82/88

(1) [-rr- I ~ ~ O T ~ray

1 .,e J'tll I Il > @ ~ J ] ~ w ~ w ~ ~ - -6 ~~ ~ ~

W W W M

Y Yellow

a C < W _ _ _ _ _ _.J[J : = _ 7 7


83/88


84/88

-

Y 525 V 575 V 570

Thermo SWitch hoke solenoid @ hoke sWitch

W-505 Y 315 V 905

IgnitIon c il Starting motor Emergency stop sWitch


85/88

g

X 800 V 685 Y 500

Rectifier ontrol unIt j]) Tachometer

W 235 X-333 V 235

@) Fuse lOA @ v warning lamps Batte,y

X-660 X-334 Y 305

Pulser c il @ v sensor @ Starter relay

V 535 x 1

harge il MaIn sWitch

w v 395 J lighting li @ uzzer

v 515 X 205

D l u m t @ Neutral SWitch

8


86/88

Y525 Thermo sWitch

w-5051 Ignition cOil

V 575

Choke solenoid

Y-315

j]l Starting motor

X-205

jJ Neutral sWitch

V-578@ Choke sWitch


87/88

X-800 Rectifier

W235

@ Fuse 10A

X-680 Pulser cOil

V 5 5

Charge COli

w Wj Lighting cOil

V-515

CDlu

V 685 jJ Control umt

X-333

@ level warnmg lamps

X 4

@ level sensor

X-568

(j] Power tilt sWitch

X Ol

@ MaIn SWitch

V 95

@ Buzzer

8

v-oo;@ Emergency stop SWitch

Y500

@ Tachometer

X 56

@ Power t i lt motor

V 235

@ Battery

Y 305@ Starter relay

X 56

< ~Power tilt relay

YA M A H A M O T O R CO LTD


88/88

nnted apan y 1984 x t6H4 28 99 2

yamaha owners manual 40 50 hp

Documents