z200 / lz200 owner's manual - yamaha motor company lz200 owner’s manual 68f-28199-19 ... trim...

Z200LZ200

OWNER’S MANUAL

68F-28199-19

U.S.A.EditionLIT-18626-07-00

68F-9-19 Hyoshi 06.3.17 1:23 PM ページ 1

EMU25071

ZMU01690

Read this owner’s manual carefully before operating your outboard motor.

68F-9-19 Hyoshi 06.3.17 1:23 PM ページ 2

Important manual information

EMU31280

To the owner

Thank you for choosing a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understandingof these simple instructions will help you ob-tain maximum enjoyment from your newYamaha. If you have any question about theoperation or maintenance of your outboardmotor, please consult a Yamaha dealer.In this Owner’s Manual particularly importantinformation is distinguished in the followingways.

The Safety Alert Symbol meansATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

WARNING

EWM00780

Failure to follow WARNING instructionscould result in severe injury or death tothe machine operator, a bystander, or aperson inspecting or repairing the out-

board motor.

CAUTION:

ECM00700

A CAUTION indicates special precautionsthat must be taken to avoid damage to the

outboard motor.

NOTE:

A NOTE provides key information to make

procedures easier or clearer.

Yamaha continually seeks advancements inproduct design and quality. Therefore, whilethis manual contains the most current prod-uct information available at the time of print-ing, there may be minor discrepanciesbetween your machine and this manual. Ifthere is any question concerning this manu-

al, please consult your Yamaha dealer.

NOTE:

The Z200TR, LZ200TR and the standard ac-cessories are used as a base for the expla-nations and illustrations in this manual.Therefore some items may not apply to ev-

ery model.

EMU25110

Z200, LZ200OWNER’S MANUAL

©2006 by Yamaha Motor Corporation, USA1st edition, April 2006

All rights reserved.Any reprinting or unauthorized usewithout the written permission ofYamaha Motor Corporation, USA

is expressly prohibited.Printed in Japan

P/N LIT-18626-07-00

Table of contents

General information .......................... 1

Identification numbers record.......... 1

Outboard motor serial number .......... 1Key number....................................... 1

Emission control information ........... 1

North American models..................... 1Star labels ......................................... 2

Safety information ........................... 3Important labels............................... 4

Warning labels .................................. 4Caution labels ................................... 5

Basic boating rules (Rules of the road) ........................ 5

Steering and sailing rules and sound signals.................................. 6

Rules when encountering vessels .... 6Other special situations..................... 7

Fueling instructions ......................... 9

Gasoline.......................................... 10Engine oil ........................................ 10

Battery requirement....................... 10

Battery specifications ...................... 11

Propeller selection......................... 11Start-in-gear protection ................. 11

Basic components .......................... 12

Main components.......................... 12

Remote control................................ 13Remote control lever ....................... 14Neutral interlock trigger ................... 14Neutral throttle lever........................ 14Free accelerator .............................. 15Throttle friction adjuster................... 15Engine stop lanyard switch ............. 16Main switch ..................................... 16Power trim and tilt switch on

remote control or tiller handle ....... 17Power trim and tilt switch on

bottom engine cowling .................. 17Power trim and tilt switches

(twin binnacle type)....................... 18Trim tab with anode ........................ 18Tilt support lever for power trim

and tilt or hydro tilt model.............. 19Top cowling lock levers ................... 19Flushing device ............................... 20

Water separator ..............................20Tachometer .....................................20Digital tachometer ...........................20Oil level indicators

(three indicators) ...........................21Oil level indicator (digital type) ........21Overheat warning indicator

(digital type) ..................................21Speedometer (digital type) ..............22Trim meter .......................................22Trim meter (digital type) ..................23Hour meter (digital type)..................23Trip meter ........................................23Clock ...............................................24Fuel gauge ......................................24Fuel warning indicator .....................24Low battery voltage warning

indicator ........................................25Fuel management meter .................25Fuel flow meter................................25Fuel consumption meter..................26Fuel economy..................................26Twin-engine speed synchronizer ....27Command link multifunction

meters ...........................................27Tachometer unit ..............................27Speed & fuel meter unit...................31Speedometer unit ............................32Fuel management meter .................33

Warning system ............................ 33

Overheat warning (twin engines) ....33Oil level warning and oil filter

clogging warning ...........................34

Operation ......................................... 36

Installation..................................... 36

Mounting the outboard motor ..........36

Breaking in engine ........................ 37

Procedure for HPDI models ............38

Preoperation checks ..................... 38

Fuel .................................................38Oil ....................................................39Controls...........................................39Engine .............................................39Operation after a long period of

storage ..........................................39

Table of contents

Filling fuel and engine oil............... 40

Filling fuel for models without a fuel joint ........................................ 40

Ring Free Fuel Additive .................. 40Filling oil for oil injection models...... 40Oil level indicator operation............. 42

Operating engine........................... 43

Feeding fuel .................................... 43Starting engine................................ 43

Warming up engine ....................... 45

Electric start and prime start models .......................................... 45

Shifting .......................................... 45

Forward (tiller handle and remote control models) ............................. 46

Reverse (automatic reverse lock and power trim and tilt models)..... 46

Stopping engine ............................ 47

Procedure ....................................... 47

Trimming outboard motor.............. 47

Adjusting trim angle ........................ 48Adjusting boat trim .......................... 49

Tilting up and down ....................... 49

Procedure for tilting up (power trim and tilt models / power tilt models).......................... 50

Procedure for tilting down (power trim and tilt models / power tilt models).......................... 51

Cruising in shallow water .............. 52

Power trim and tilt models / power tilt models........................... 52

Cruising in other conditions........... 53

Maintenance..................................... 54

Specifications ................................ 54Transporting and storing outboard

motor ........................................... 55

Storing outboard motor ................... 55Procedure ....................................... 56Lubrication (oil injection models)..... 57Cleaning and anticorrosion

measures ...................................... 57Battery care..................................... 57Flushing power unit ......................... 58Cleaning the outboard motor .......... 59

Checking painted surface of motor.............................................59

Periodic maintenance ................... 59

Replacement parts ..........................59Maintenance chart...........................60Maintenance chart (additional) ........61Greasing..........................................62Cleaning and adjusting spark

plug ...............................................62Checking fuel system ......................63Inspecting idling speed....................64Checking water in engine oil tank ...64Checking wiring and connectors .....64Exhaust leakage..............................65Water leakage .................................65Checking power trim and tilt

system...........................................65Checking propeller ..........................66Removing the propeller ...................67Installing the Propeller.....................67Changing gear oil ............................68Inspecting and replacing

anode(s)........................................69Checking battery (for electric start

models) .........................................69Connecting the Battery....................70Disconnecting the battery................71Checking top cowling ......................71Coating the boat bottom..................72

Trouble Recovery............................ 73

Troubleshooting ............................ 73Temporary action in emergency ... 76

Impact damage ...............................76Running single engine.....................76Replacing fuse ................................77Power trim and tilt / power tilt will

not operate....................................77Water separator warning indicator

blinks while cruising ......................78Starter will not operate ....................79Emergency starting engine .............80

Engine fails to operate .................. 81

Low oil level warning activates........81

Treatment of submerged motor .... 82

Procedure........................................82

Table of contents

Consumer information.................... 83

Important warranty information for U.S.A. and Canada ..................... 83

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ...... 85

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA .............. 88

1

General information

EMU25170

Identification numbers record

EMU25183

Outboard motor serial number

The outboard motor serial number isstamped on the label attached to the portside of the clamp 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.

EMU25190

Key number

If a main key switch is equipped with the mo-tor, the key identification number is stampedon your key as shown in the illustration.Record this number in the space provided forreference in case you need a new key.

EMU25221

Emission control information

EMU25230

North American models

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

EMU31471

Approval label of emission control certif-icate

This label is attached to the bottom cowling.New Technology ; (HPDI) DFI/HO2S

1. Outboard motor serial number location

1 ZMU04426

1. Key number

1. Approval label location

1

ZMU04741

General information

2

EMU25262

Manufactured date label

This label is attached to the clamp bracket orthe swivel bracket.

EMU25272

Star labels

Your outboard motor is labeled with a Cali-fornia Air Resources Board (CARB) star la-bel. See below for a description of your

particular label.

EMU25280

One Star—Low Emission

The 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 Emission

The two-star label identifies engines thatmeet the Air Resources Board’s 2004 ex-haust emission standards. Engines meetingthese standards have 20% lower emissionsthan One Star-Low-Emission engines.

1. Manufactured date label location

ZMU05380

1ZMU04726

Manufactured:

ZMU04346

1. Star labels location

1

ZMU04745

ZMU01702

General information

3

EMU25300

Three Stars—Ultra Low Emission

The 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.

EMU25362

Safety information

�

Before mounting or operating the outboardmotor, read this entire manual. Reading itshould give you an understanding of themotor and its operation.

�

Before operating the boat, read any own-er’s or operator’s manuals supplied with itand all labels. Be sure you understandeach item before operating.

�

Do not overpower the boat with this out-board motor. Overpowering the boat couldresult in loss of control. The rated power of

the outboard should be equal to or lessthan the rated horsepower capacity of theboat. If the rated horsepower capacity ofthe boat is unknown, consult the dealer orboat manufacturer.

�

Do not modify the outboard. Modificationscould make the motor unfit or unsafe touse.

�

Incorrect propeller selection and incorrectuse may not only cause engine damage,but also adversely affect fuel consumption.Consult your dealer for correct use.

�

Never operate after drinking alcohol or tak-ing drugs. About 50% of all boating fatali-ties involve intoxication.

�

Have an approved personal flotation de-vice (PFD) on board for every occupant. Itis a good idea to wear a PFD wheneverboating. At a minimum, children and non-swimmers should always wear PFDs, andeveryone should wear PFDs when thereare potentially hazardous boating condi-tions.

�

Gasoline is highly flammable, and its va-pors are flammable and explosive. Handleand store gasoline carefully. Make surethere are no gas fumes or leaking fuel be-fore starting the engine.

�

This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which may cause brain dam-age or death when inhaled. Symptoms in-clude nausea, dizziness, and drowsiness.Keep cockpit and cabin areas well ventilat-ed. Avoid blocking exhaust outlets.

�

Check throttle, shift, and steering for prop-er operation before starting the engine.

�

Attach the engine stop switch lanyard cordto a secure place on your clothing, or yourarm or leg while operating. If you acciden-tally leave the helm, the cord will pull from

ZMU01703

ZMU01704

General information

4

the switch, stopping the engine.

�

Know the marine laws and regulationswhere you will be boating—and obeythem. For basic boating rules, see “Rulesof the road” on page 5.

�

Stay informed about the weather. Checkweather forecasts before boating. Avoidboating in hazardous weather.

�

Tell someone where you are going: leavea Float Plan with a responsible person. Besure to cancel the Float Plan when you re-turn.

�

Use common sense and good judgmentwhen boating. Know your abilities, and besure you understand how your boat han-dles under the different boating conditionsyou may encounter. Operate within yourlimits, and the limits of your boat. Alwaysoperate at safe speeds, and keep a carefulwatch for obstacles and other traffic.

�

Always watch carefully for swimmers dur-ing the engine operation.

�

Stay away from swimming areas.

�

When a swimmer is in the water near youshift into neutral and shut off the engine.

�

Do not illegally discard empty containersused to replace or replenish oil. For thecorrect processing of empty containers,consult the dealer where you purchasedthe oil.

�

When replacing oils used to lubricate theproduct (engine or gear oil), be sure towipe away any spilt oil. Never pour oil with-out using a funnel or similar device. If nec-essary, verify the necessary replacementprocedure with the dealer.

�

Never illegally discard (dump) the product.Yamaha recommends consulting the deal-er on discarding the product.

Be informed about boating safety. Additionalpublications and information can be obtained

from many organizations, including the fol-lowing:

United States Coast Guard

Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Af-fairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647

National Marine Manufacturers Associa-tion (NMMA)

401 N. Michigan Ave. Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave. Chicago, Il 60601

EMU25382

Important labels

EMU25395

Warning labels

ZMU04852

ZMU01948

General information

5

EMU25401

Label

WARNING

EWM01260

�

Be sure shift control is in neutral beforestarting engine. (except 2HP)

�

Do not touch or remove electrical partswhen starting or during operation.

�

Keep hands, hair, and clothes awayfrom flywheel and other rotating parts

while engine is running.

EMU25413

Label (counter rotation models)

WARNING

EWM01281

Use only a counterclockwise rotationpropeller with this engine.Counterclockwise propellers are markedwith a letter “L” after the size indication.The wrong type of propeller could causethe boat to go in an unexpected direction,

which could lead to an accident.

EMU25451

Label

ENGINE OIL ONLY

�

Pour the engine oil into this oil tank, notgasoline.

RECOMMENDED OIL:YAMALUBE 2 STROKE OUTBOARD OIL oran equivalent TC-W3 certified ouboard oil.

WARNING

EWM01270

Do not add gasoline to the oil tank. Fire

explosion could result.

EMU30471

Label

WARNING

EWM01411

Hot surface under this cover during andafter operation. To avoid burns, do not

touch finned resistor with bare hands.

EMU25465

Caution labels

EMU30430

Label

CAUTION:

ECM01440

USE UNLEADED STRAIGHT GASOLINEONLY

�

Gasoline containing lead can causeperformance loss and engine damage.

�

Do not use gasoline mixed with oil (pre-mix).

�

Use YAMALUBE 2-stroke outboard oilor another 2-stroke engine oil with aNMMA-certified TC-W3 rate.

Refer to Owner’s manual.

EMU25500

Basic boating rules (Rules of the road)

Just as there are rules which apply when youare driving on streets and high ways, thereare waterway rules which apply when youare driving your boat. These rules are usedinternationally, and are also enforced by theUnited States Coast Guard and local agen-cies. You should be aware of these rules,and follow them whenever you encounteranother vessel on the water.Several sets of rules prevail according togeographic location, but are all basically thesame as the International Rules of the Road.

ZMU04435

General information

6

The rules presented here in your Owner’sManual are condensed, and have been pro-vided for your convenience only. Consultyour local U.S. Coast Guard Auxiliary or De-partment of Motor Vehicles for a completeset of rules governing the waters in whichyou will be using your boat.

EMU25510

Steering and sailing rules and sound signals

Whenever two vessels on the water meetone another, one vessel has the right-of-way; it is called the “stand-on” vessel. Thevessel which does not have the right-of-wayis called the “give-way” or “burdened” vessel.These rules determine which vessel has theright-of-way, and what each vessel shoulddo.

Stand-on vessel

The vessel with the right-of-way has the dutyto continue its course and speed, except toavoid an immediate collision. When youmaintain your direction and speed, the othervessel will be able to determine how best toavoid you.

Give-way vessel

The vessel which 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 infront of the vessel with the right-of-way. Youshould slow down or change directions brief-ly and pass behind the other vessel. Youshould always move in such a way that theoperator of the other vessel can see whatyou 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.

EMU25520

Rules when encountering vessels

There are three main situations which youmay encounter with other vessels whichcould lead to a collision unless the SteeringRules are followed:

Meeting:

(you are approaching another ves-sel head-on)

Crossing:

(you are traveling across the oth-er vessel’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 shad-ed area must yield to you (they are the Give-Way vessels). Both you and the meetingvessel must alter course to avoid each other.

Meeting

If you are meeting another power vesselhead on, and are close enough to run the riskof collision, neither of you has the right-of-

General information

7

way! Both of you should alter course to avoidan accident. You should keep the other ves-sel on your port (left) side. This rule doesn’tapply if both of you will clear one another ifyou continue on your set course and speed.

Crossing

When two power driven vessels are crossingeach other’s path close enough to run therisk of collision, the vessel which has the oth-er on the starboard (right) side must keep outof the way of the other. If the other vessel ison your right, you must keep out of its way;you are the Give-Way vessel. If the othervessel is on your port (left) side, rememberthat you should maintain course and direc-tion, provided the other vessel gives you theright-of-way as it should.

Overtaking

If you are passing another vessel, you arethe “Give-Way” vessel. This means that theother vessel is expected to maintain its

course and speed. You must stay out of itsway until you are clear of it. Likewise, if an-other vessel is passing you, you shouldmaintain your speed and direction so that theother vessel can steer itself around you.

EMU25530

Other special situations

There are three other rules you should beaware of when driving your boat around oth-er vessels.

Narrow channels and bends

When 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 wa-ter vessels, the operator should sound a pro-longed blast on the whistle (4 to 6 seconds).If another 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 younavigate such waters with your boat, you willneed to carry a portable air horn, availablefrom local marine supply stores.

Fishing vessel right-of-way

All vessels which are fishing with nets, linesor trawls are considered to be “fishing ves-sels” under the International Rules. Vesselswith trolling lines are not considered fishingvessels. Fishing vessels have the right-of-way regardless of position. Fishing vesselscannot, however, impede the passage ofother vessels in narrow channels.

Sailing vessel right-of-way

Sailing 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-driv-en vessel has the right-of-way.

2. Sailing vessels should keep clear of anyfishing vessel.

General information

8

3. In a narrow channel, a sailing vesselshould not hamper the safe passage ofa power-driven vessel which can navi-gate only in such a channel.

Reading buoys and other markers

The waters of the United states are markedfor safe navigation by the lateral system ofbuoyage. Simply put, buoys and markershave an arrangement of shapes, colors,numbers and lights to show which side of thebuoy a boater should pass on when navigat-ing in a particular direction. The markings onthese buoys are oriented from the perspec-tive of being entered from seaward (the boat-er is going towards the port). This means thatred buoys are passed on the starboard(right) side when proceeding from open wa-ter into port, and black buoys are to port (left)side. When navigating out of port, your posi-tion with respect to the buoys should be re-versed; red buoys should be to port andblack buoys to starboard.Many bodies of water used by boaters areentirely 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 regulato-ry or advisory information. These markersare white with black letters and orangeboarders. They signify speed zones, restrict-ed areas, danger areas, and general infor-mation.Remember, markings may vary by geo-graphic location. Always consult local boat-ing authorities before driving your boat inunfamiliar waters.

General information

9

EMU25540

Fueling instructions

WARNING

EWM00010

GASOLINE AND ITS VAPORS ARE HIGH-LY FLAMMABLE AND EXPLOSIVE!

�

Do not smoke when refueling, and keep

away from sparks, flames, or othersources of ignition.

�

Stop engine before refueling.

�

Refuel in a well-ventilated area. Refuelportable fuel tanks off the boat.

�

Take care not to spill gasoline. If gaso-line spills, wipe it up immediately with

ZMU01708

General information

10

dry rags.

�

Do not overfill the fuel tank.

�

Tighten the filler cap securely after re-fueling.

�

If you should swallow some gasoline,inhale a lot of gasoline vapor, or getgasoline in your eyes, get immediatemedical attention.

�

If any gasoline spills onto your skin, im-mediately wash with soap and water.Change clothing if gasoline spills on it.

�

Touch the fuel nozzle to the filler open-ing or funnel to help prevent electro-

static sparks.

CAUTION:

ECM00010

Use only new clean gasoline which hasbeen stored in clean containers and is notcontaminated with water or foreign mat-

ter.

EMU25570

Gasoline

If knocking or pinging occurs, use a differentbrand of gasoline or premium unleaded fuel.

Gasohol

There are two types of gasohol: gasohol con-taining ethanol and that containing metha-nol. Gasohol containing ethanol can be usedif ethanol content does not exceed 10% andthe fuel meets minimum octane ratings.Yamaha does not recommended gasoholcontaining methanol because it can causefuel system damage or engine performanceproblems.

EMU25660

Engine oil

Use Yamalube 2-M outboard oil. If Ya-malube 2-M is not available, use only anoth-er outboard motor manufacturer’s factory-brand oil with TC-W3 rating.

CAUTION:

ECM01290

Serious engine damage can result fromthe use of lower quality oil, includingsome commonly available oil brands with“TC-W3” on their label. To avoid the risk,use only Yamalube 2-M or, if necessary,another outboard motor manufacturer’s

factory-brand TC-W3 oil.

EMU25700

Battery requirement

CAUTION:

ECM01060

Do not use a battery that does not meetthe specified capacity. If a battery whichdoes not meet specifications is used, theelectric system could perform poorly orbe overloaded, causing electric system

damage.

For electric start models, choose a batterywhich meets the following specifications.

Recommended gasoline:Regular unleaded gasoline with a min-imum octane rating of 86 (Pump Oc-tane Number) = (R+M)/2

Recommended engine oil:YAMALUBE 2 STROKE OUTBOARD OIL

General information

11

EMU25711

Battery specifications

NOTE:

The engine cannot be started if battery volt-

age is too low.

EMU25742

Propeller selection

The performance of your outboard motor willbe critically affected by your choice of propel-ler, as an incorrect choice could adverselyaffect performance and could also seriouslydamage the motor. Engine speed dependson the propeller size and boat load. If enginespeed is too high or too low for good engineperformance, this will have an adverse effecton the engine.Yamaha outboard motors are fitted with pro-pellers chosen to perform well over a rangeof applications, but there may be uses wherea propeller with a different pitch would bemore appropriate. For a greater operatingload, a smaller-pitch propeller is more suit-able as it enables the correct engine speedto be maintained. Conversely, a larger-pitchpropeller is more suitable for a smaller oper-ating load.Yamaha dealers stock a range of propellers,and can advise you and install a propeller onyour outboard that is best suited to your ap-plication.

NOTE:

Select a propeller which will allow the engineto reach the middle or upper half of the oper-ating range at full throttle with the maximumboat load. If operating conditions such aslight boat loads then allow the engine r/min torise above the maximum recommendedrange, reduce the throttle setting to maintain

the engine in the proper operating range.

For instructions on propeller removal and in-stallation, see page 66.

EMU25770

Start-in-gear protection

Yamaha outboard motors or Yamaha-ap-proved remote control units are equippedwith start-in-gear protection device(s). Thisfeature permits the engine to be started onlywhen it is in neutral. Always select neutralbefore starting the engine.

Minimum cold cranking amps (CCA/SAE):

512.0 AMinimum marine cranking amps (MCA/ABYC):

675.0 AMinimum reserve capacity (RC/SAE):

182 minutes

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

ZMU04608

-x1 2 3

12

Basic components

EMU25799

Main componentsNOTE:

* May not be exactly as shown; also may not be included as standard equipment on all mod-

els.

Z200, LZ200

15 16

1412 13

19

1

2

3

4

910

8

6

5

7

2

20

17 18

11

ZMU04850

1. Top cowling2. Top cowling lock lever(s)3. Trim tab (anode)4. Propeller*5. Cooling water inlet6. Anti-cavitation plate7. Anode8. Tilt support lever9. Flushing device10. Power trim and tilt switch11. Water separator12. Remote control box (side mount type)*13. Remote control box (binnacle mount type)*14. Switch panel (for use with binnacle type)*

15. Digital tachometer*16. Digital speedometer*17. Tachometer*18. Trim meter*19. Fuel management meter*20. Remote oil tank

Basic components

13

EMU26180

Remote control

The remote control lever actuates both theshifter and the throttle. The electrical switch-es are mounted on the remote control box.

1

4 6

32

5

ZMU05429

1. Tachometer unit (Square type)*2. Tachometer unit (Round type)*3. Speedometer unit (Square type)*4. Speed & fuel meter unit (Square type)*5. Speed & fuel meter unit (Round type)*6. Fuel management meter (Square type)*

1. Power trim and tilt switch2. Remote control lever3. Neutral interlock trigger4. Neutral throttle lever5. Main switch / choke switch6. Engine stop lanyard switch7. Throttle friction adjuster

Basic components

14

EMU26190

Remote control lever

Moving the lever forward from the neutral po-sition engages forward gear. Pulling the le-ver back from neutral engages reverse. Theengine will continue to run at idle until the le-ver is moved about 35° (a detent can be felt).Moving the lever farther opens the throttle,and the engine will begin to accelerate.

EMU26201

Neutral interlock trigger

To shift out of neutral, first pull the neutral in-terlock trigger up.

EMU26211

Neutral throttle lever

To open the throttle without shifting into ei-ther forward or reverse, put the remote con-trol lever in the neutral position and lift theneutral throttle lever.

1. Remote control lever2. Power trim and tilt switch3. Free accelerator4. Throttle friction adjuster

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”4. Shift5. Fully closed6. Throttle7. Fully open

23

21

4

ZMU04569

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”4. Shift5. Fully closed6. Throttle7. Fully open

1. Neutral interlock trigger

N1F

7

6

2R

34 4

65

7

5

ZMU04573

Basic components

15

NOTE:

The neutral throttle lever will operate onlywhen the remote control lever is in neutral.The remote control lever will operate onlywhen the neutral throttle lever is in the closed

position.

EMU26232

Free accelerator

To open the throttle without shifting into ei-ther forward or reverse, push the free accel-erator button and move the remote controllever.

NOTE:

�

The free accelerator button can only be

used when the remote control lever is inthe neutral position.

�

After the button is pushed, the throttle be-gins to open after the remote control leveris moved at least 35°.

�

After using the free accelerator, return theremote control lever to the neutral position.The free accelerator button will return au-tomatically to its set position. The remotecontrol will then engage forward and re-

verse normally.

EMU25971

Throttle friction adjuster

A friction device provides adjustable resis-tance to movement of the throttle grip or theremote control lever, and can be set accord-ing to operator preference.To increase resistance, turn the adjusterclockwise. To decrease resistance, turn theadjuster counterclockwise.

WARNING

EWM00031

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to move the remote control leveror throttle grip, which could result in an

accident.

1. Fully open2. Fully closed

1. Fully open2. Fully closed3. Free accelerator

1

3

2

ZMU04575

Basic components

16

When constant speed is desired, tighten theadjuster to maintain the desired throttle set-ting.

EMU25990

Engine stop lanyard switch

The lock plate must be attached to the en-gine stop switch for the engine to run. Thelanyard should be attached to a secure placeon the operator’s clothing, or arm or leg.Should the operator fall overboard or leavethe helm, the lanyard will pull out the lockplate, stopping ignition to the engine. Thiswill prevent the boat from running away un-der power.

WARNING

EWM00120

�

Attach the engine stop switch lanyardto a secure place on your clothing, oryour arm or leg while operating.

�

Do not attach the lanyard to clothingthat could tear loose. Do not route thelanyard where it could become entan-gled, preventing it from functioning.

�

Avoid accidentally pulling the lanyardduring normal operation. Loss of en-gine power means the loss of moststeering control. Also, without enginepower, the boat could slow rapidly. Thiscould cause people and objects in the

boat to be thrown forward.

NOTE:

The engine cannot be started with the lock

plate removed.

EMU26090

Main switch

The main switch controls the ignition system;its operation is described below.

�

“ ”

(off)

With the main switch in the “ ” (off) posi-tion, the electrical circuits are off, and the keycan be removed.

�

“ ”

(on)

With the main switch in the “ ” (on) posi-tion, the electrical circuits are on, and the keycannot be removed.

ZMU04646

1. Lanyard2. Lock plate

1. Lanyard2. Lock plate

ONSTARTOFF

ONSTARTOFF

1ZMU04564

2

Basic components

17

�

“ ”

(start)

With the main switch in the “ ” (start) po-sition, the starter motor turns to start the en-gine. When the key is released, it returnsautomatically to the “ ” (on) position.

EMU26141

Power trim and tilt switch on remote control or tiller handle

The power trim and tilt system adjusts theoutboard motor angle in relation to the tran-som. Pressing the switch “ ” (up) trims theoutboard motor up, then tilts it up. Pressingthe switch “ ” (down) tilts the outboard mo-tor down and trims it down. When the switchis released, the outboard motor will stop in itscurrent position.

NOTE:

For instructions on using the power trim and

tilt switch, see pages 47 and 49.

EMU26151

Power trim and tilt switch on bottom engine cowling

The power trim and tilt switch is located onthe side of the bottom engine cowling. Press-ing the switch “ ” (up) trims the outboardmotor up, then tilts it up. Pressing the switch“ ” (down) tilts the outboard motor downand trims it down. When the switch is re-leased, the outboard motor will stop in itscurrent position.

WARNING

EWM01030

Use the power trim and tilt switch locatedon the bottom engine cowling only whenthe boat is at a complete stop with the en-gine off. Attempting to use this switchwhile the boat is moving could increasethe risk of falling overboard and coulddistract the operator, increasing the riskof collision with another boat or an obsta-

cle.

ONOFF START

ONOFF START

ZMU04566

Basic components

18

NOTE:

For instructions on using the power trim and

tilt switch, see page 49.

EMU26161

Power trim and tilt switches (twin binnacle type)

The power trim and tilt system adjusts theoutboard motor angle in relation to the tran-som. Pushing the switch “ ” (up) trims theoutboard motor up, then tilts it up. Pressingthe switch “ ” (down) tilts the outboard mo-tor down and trims it down. When the switchis released, the outboard motor will stop in itscurrent position.

NOTE:

�

On the dual engine control, the switch onthe remote control grip controls both out-board motors at the same time.

�

For instructions on using the power trim

and tilt switches, see pages 47 and 49.

EMU26241

Trim tab with anode

The trim tab should be adjusted so that thesteering control can be turned to either theright or left by applying the same amount offorce.

WARNING

EWM00840

An improperly adjusted trim tab couldcause difficult steering. Always test runafter the trim tab has been installed or re-placed to be sure steering is correct. Besure you have tightened the bolt after ad-

justing the trim tab.

If the boat tends to veer the left (port side),turn the trim tab rear end to the port side “A”in the figure. If the boat tends to veer the right(starboard side), turn the trim tab end to thestarboard side “B” in the figure.

CAUTION:

ECM00840

The trim tab also serves as an anode toprotect the engine from electrochemicalcorrosion. Never paint the trim tab as it

will become ineffective as an anode.

1. Power trim and tilt switch

UP

DN

ZMU03985

ZMU04601

DN

UP

1

Basic components

19

EMU26340

Tilt support lever for power trim and tilt or hydro tilt model

To keep the outboard motor in the tilted upposition, lock the tilt support lever to theclamp bracket.

EMU26391

Top cowling lock levers

To remove the outboard motor top cowling,pull up the front and rear lock levers. Then liftoff the cowling. When the cowling, check tobe sure it fits properly in the rubber seal.Then lock the cowling again by moving thelevers downward.

CAUTION:

ECM00550

The air intake grille on the top cowling isnot designed as a handle and could break

if used as such.

1. Trim tab2. Bolt3. Cap

AB

ZMU01863

1. Tilt support lever

1. Top cowling lock lever(s)

ZMU03979

1

ZMU03986

1

Basic components

20

EMU26460

Flushing device

This device is used to clean the cooling wa-ter passages of the motor using a gardenhose and tap water.

NOTE:

For details on usage, see page 58.

EMU31702

Water separator

This engine has a combination fuel filter/wa-ter separator and associated warning sys-tem. If water separated from the fuelexceeds a specific volume, the warning de-vice will activate.

Activation of warning device

�

The water separator warning indicator willblink.

�

The buzzer will sound intermittently onlywhen the gear shift is in neutral.

�

If the warning system has activated, stopthe engine and consult a Yamaha dealerimmediately.

EMU26470

Tachometer

This gauge shows the engine speed and hasthe following functions.

EMU26491

Digital tachometer

The tachometer shows the engine speedand has the following functions.

NOTE:

All segments of the display will light momen-

1. Air intake grille2. Top cowling lock lever(s)

1. Flushing device

1

2

1

2ZMU04437

1

ZMU04011

1. Tachometer2. Oil level indicator

ZMU05499

ZMU04577

1

2

Basic components

21

tarily after the main switch is turned on and

will return to normal thereafter.

NOTE:

The water separator and engine troublewarning indicators only operate when the en-gine is equipped with the appropriate func-

tions.

EMU26540

Oil level indicators (three indicators)

The indicators on the gauge show the statusof the oil level. For details on how to read theindicators, see page 42.

CAUTION:

ECM00030

Do not operate the engine without oil. Se-

rious engine damage will occur.

EMU26550

Oil level indicator (digital type)

This indicator shows the engine oil level. Ifthe oil level falls below the lower limit, thewarning indicator will start to blink. For fur-ther information, see page 34.

CAUTION:

ECM00030

Do not operate the engine without oil. Se-

rious engine damage will occur.

EMU26581

Overheat warning indicator (digital type)

If the engine temperature rises too high, thewarning indicator will start to blink. For fur-ther information on reading the indicator, see

1. Tachometer2. Trim meter3. Hour meter4. Oil level indicator5. Overheat warning indicator6. Water separator warning indicator7. Engine trouble warning indicator8. Set button9. Mode button

67

2

498

5

3

1

ZMU01958

1. Oil level indicators

1. Oil level indicator

ZMU04580

1

1ZMU01867

Basic components

22

page 33.

CAUTION:

ECM00050

Do not continue to run the engine if theoverheat warning indicator is on. Serious

engine damage will occur.

EMU26600

Speedometer (digital type)

This gauge shows the boat speed.

NOTE:

After the main switch is first turned on, allsegments of the display come on as a test.After a few seconds, the gauge will changeto normal operation. Watch the gauge when

turning on the main switch to make sure all

segments come on.

NOTE:

The speedometer displays km/h, mph, orknots, according to operator preference. Se-lect the desired unit of measurement by set-ting the selector switch on the back of the

gauge. See the illustration for settings.

EMU26610

Trim meter

This gauge shows the trim angle of your out-board motor.

NOTE:

Memorize the trim angles that work best foryour boat under different conditions. Adjustthe trim angle to the desired setting with the

1. Overheat warning indicator

1. Speedometer2. Fuel gauge3. Trip meter/clock/voltmeter4. Warning indicator(s)

1

ZMU01868

1. Cap2. Selector switch (for speed unit)3. Selector switch (for fuel sensor)

ZMU04581

Basic components

23

power trim and tilt switch.

EMU26620

Trim meter (digital type)

This meter shows the trim angle of your out-board motor.

NOTE:

�

Memorize the trim angles that work bestfor your boat under different conditions.Adjust the trim angle to the desired usingthe power trim and tilt switch.

�

If the trim angle of your motor exceeds thetrim operating range, the top segment on

the trim meter display will blink.

EMU26650

Hour meter (digital type)

This meter shows the number of hours theengine has been run. It can be set to showthe total number of hours or the number ofhours for the current trip. The display canalso be turned on and off.

�

Changing the display format

�

Pressing the “ ” (mode) button chang-es the display format in the following pat-tern:

�

Total hours

→

Trip hours

→

Display off

�

Resetting the trip hours

�

Simultaneously pressing the “ ” (set)and “ ” (mode) buttons for more than1 second while the trip hours are displayedresets the trip counter to 0 (zero).

NOTE:

The total number of hours the engine has

been run cannot be reset.

EMU26690

Trip meter

This gauge displays the distance the boathas traveled since the gauge was last reset.Press the “ ” (mode) button repeatedlyuntil the indicator on the face of the gaugepoints to “ ” (trip). To reset the trip meterto zero, press the “ ” (set) and “ ”(mode) buttons at the same time.

NOTE:

�

The trip distance is shown in kilometers ormiles depending upon the unit of measure-ment selected for the speedometer.

�

The trip distance is kept in memory by bat-tery power. The stored data will be lost if

the battery is disconnected.

ZMU01869

ZMU01870

Basic components

24

EMU26700

Clock

Press the “ ” (mode) button repeatedlyuntil the indicator on the face of the gaugepoints to “ ” (time). To set the clock, besure the gauge is in the “ ” (time) mode.Press the “ ” (set) button; the hour displaywill begin blinking. Press the “ ” (mode)button until the desired hour is displayed.Press the “ ” (set) button again, the minutedisplay will begin blinking. Press the “ ”(mode) button until the desired minute is dis-played. Press the “ ” (set) button again tostart the clock.

NOTE:

The clock operates on battery power. Dis-connecting the battery will stop the clock.

Reset the clock after connecting the battery.

EMU26710

Fuel gauge

The fuel level is indicated by eight segments.When all segments are showing, the fueltank is full.

CAUTION:

ECM00860

The Yamaha fuel tank sensor differs fromconventional sensors. Incorrectly settingthe selector switch on the gauge will givefalse readings. Consult your Yamahadealer on how to correctly set the selec-

tor switch.

NOTE:

The fuel level reading can be affected by theposition of the sensor in the fuel tank and theattitude of the boat in the water. Operationwith bow-up trim or continuous turning can

give false readings.

EMU26720

Fuel warning indicator

If the fuel level decreases to one segment,the fuel level warning segment will begin toblink.

CAUTION:

ECM00880

Do not continue to operate the enginewith full throttle if a warning device hasactivated. Get back to the port within troll-

ing engine speed.

1. Fuel level warning segment

ZMU01745

Basic components

25

EMU26730

Low battery voltage warning indicator

If battery voltage drops, the display will auto-matically turn on and begin to blink.

CAUTION:

ECM00870

Get back to the port soon if a warning de-vice has activated. For charging the bat-

tery, consult your Yamaha dealer.

EMU26740

Fuel management meter

The fuel management meter shows the stateof the fuel consumption while the engine isrunning.

NOTE:

After the main switch is first turned on, allsegments of the display come on as a test.After a few seconds, the gauge will changeto normal operation. Watch the gauge whenturning on the main switch to make sure all

segments come on.

EMU26750

Fuel flow meter

The fuel flow meter displays the amount offuel flow over a one hour period, at the cur-rent rate of engine operation.If twin engines are installed on your boat, thefuel flow meter displays the total fuel flow ofboth the port and starboard engines. It alsodisplays “ ” (for port and starboard).

Use the “ ” (set) button to rotate the fuelflow display in the following order:

�

Press the “ ” (set) button once to displaythe fuel flow of the starboard engine. An“ ” (for starboard) will also be displayed.

�

Press the “ ” (set) button a second timeto display the fuel flow of the port engine.A “ ” (for port) will also be displayed.

�

Press the “ ” (set) button a third time toreturn the display to the total fuel flow ofboth engines. “ ” (for port and starboard)will also be displayed to indicate both the

1. Low battery indicator

1. Fuel flow meter2. Fuel consumption meter / Fuel economy meter / Twin engine speed synchronizer

ZMU01748

1

23

3. Water separator warning indicator (operates only if the sensor has been installed)

ZMU01749

Basic components

26

port and starboard engines.

NOTE:

�

The fuel flow meter displays gallons/houror liters/hour according to operator prefer-ence. Select the desired unit of measure-ment by setting the selector switch on theback of the gauge during installation.

�

The fuel consumption meter and fueleconomy meter will indicate the same unit

of measurement.

EMU26760

Fuel consumption meter

This gauge displays the total amount of fuelconsumed since the gauge was last reset.Press the “ ” (mode) button repeatedlyuntil the indicator on the face of the gaugepoints to total “ ” (total). To reset the totalfuel consumption to zero, press the “ ”(set) and “ ” (mode) buttons at the sametime.

EMU26770

Fuel economy

This gauge displays the distance per liter orgallon when cruising, and is only for refer-ence use by the operator.Press the “ ” (mode) button repeatedlyuntil the indicator on the face of the gaugepoints to “ ” (economy).

NOTE:

If twin engines are installed on your boat, thegauge will only display the total fuel economy

of both engines.

NOTE:

�

Fuel consumption varies greatly with boatdesign, weight, propeller used, engine trimangle, sea conditions (including wind), andthrottle position. Fuel consumption alsovaries slightly with the type of water (salt,fresh, and contaminate levels), air temper-ature and humidity, cleanliness of the boat

1. Selector switch

ZMU01751

ZMU01752

Basic components

27

bottom, engine mounting height, skill ofthe operator, and individual gasoline for-mulation (winter or summer fuel andamount of additives).

�

The Yamaha digital speedometer and fuelmanagement meter calculates speed,miles traveled, and fuel economy by watermovement at the stern of the boat. Thisdistance can vary greatly from the actualdistance traveled because of water cur-rents, sea swells, and the condition of thewater speed sensor (partially plugged ordamaged).

�

Individual engines may slightly vary in theirfuel consumption due to manufacturingvariations. These variations can be evengreater if the engines are of different yearmodels. In addition, variations in propel-lers, even of the same basic dimensions ofthe same design, can also cause a slight

variation in fuel consumption.

EMU26780

Twin-engine speed synchronizer

This gauge displays the difference in enginespeed (r/min) between the port and star-board engines for reference purposes whensynchronizing the two engines’ speeds.Press the “ ” (mode) button repeatedlyuntil the indicator on the face of the gaugepoints to “ ” (synchronizer).

NOTE:

If the two engines’ speeds are not synchro-nized while cruising, they can be synchro-

nized by adjusting trim angle or throttle.

EMU31640

Command link multifunction meters

Command link multifunction meters have 6kinds of meter units; tachometer unit (squareor round types), speedometer unit (squaretype), speed & fuel meter unit (square orround types), and fuel management meter(square type). The indicator system is slight-ly different between the round and squaretypes. Check the model and type of your unitcarefully. This manual describes mainly thewarning indicators. For more details on set-ting meters or changing indicator systems,see the attached operation manual.

EMU31660

Tachometer unit

The tachometer shows the engine revolu-tions per minute. It has functions of trimmeter, adjusting trolling speed, cooling wa-ter/engine temperature display, battery volt-

ZMU01753

1. Port engine speed is higher2. Port engine speed is slightly higher3. Engine speed is synchronized evenly between port and starboard engines4. Starboard engine speed is slightly higher5. Starboard engine speed is higher

ZMU01754

1

2

3

4

5

Basic components

28

age display, total hour/trip hour display, oillevel display, water detection warning, en-gine trouble warning, and periodic mainte-nance notification. If optional sensors areconnected to the unit, cooling water pressuredisplay will be available. For the optionalsensor, consult your Yamaha dealer. The ta-chometer unit is available in round or squaretypes. Check your tachometer unit type.

NOTE:

The tachometer unit shows various kinds ofinformation according to the setting madeusing the “ ” (set) and “ ” (mode) but-tons. For details, see the attached operation

manual.

1. Set button2. Mode button

1. Tachometer2. Trim meter3. Multifunction display4. Cooling water pressure5. Cooling water/engine temperature6. Water detection warning indicator7. Battery voltage8. Oil level (2-stroke models)

21

ZMU05415

2

3

1

4

5

6

7

8ZMU05452


1. Tachometer2. Trim meter3. Multifunction display4. Water detection warning indicator5. Engine trouble warning/maintenance indica-tor6. Cooling water pressure7. Oil level (2-stroke models)8. Cooling water/engine temperature9. Battery voltage

21

ZMU05417

1 4 5 2

3

6 97 8 ZMU05453

Basic components

29

Preoperation checks

Place the gear shift lever in neutral and turnthe main switch to “ ” (on). After all the dis-plays come on and the total hour displaycomes on, the gauge will change to normaloperation. If the buzzer sounds and the wa-ter separator warning indicator blinks, con-sult your Yamaha dealer immediately.

NOTE:

To stop the buzzer, press the “ ” (set) or

“ ” (mode) button.

Oil level warning

When the oil level is low while cruising, theoil level warning indicator will start to blink.The engine speed will automatically de-crease to about 2000 r/min.

When the buzzer sounds and the oil levelwarning indicator blinks, check the oil leveland add the oil if necessary. If the warningdevice has activated while the appropriate

engine oil level is maintained, consult yourYamaha dealer.

CAUTION:

ECM01580

Do not continue to run the engine if the oillevel warning device has activated. Seri-

ous engine damage will occur.

Overheat warning

If the engine temperature rises too high whilecruising, the overheat warning indicator willstart to blink. The engine speed will automat-ically decrease to about 2000 r/min.

Stop the engine immediately if the buzzersounds and the overheat warning device hasactivated. Check the cooling water inlet forclogging.

CAUTION:

ECM01590

�

Do not continue to run the engine if theoverheat warning indicator blinks. Seri-

ZMU05419

ZMU05420

ZMU05421

ZMU05422

Basic components

30

ous engine damage will occur.

�

Do not continue to operate the engine ifa warning device has activated. Con-sult your Yamaha dealer if the problem

cannot be located and corrected.

Water separator warning

This indicator will blink when water has accu-mulated in the water separator (fuel filter)while cruising. In such an event, stop the en-gine immediately and see page 76 of thismanual to drain the water from the fuel filter.Get back to the port soon and consult aYamaha dealer immediately.

CAUTION:

ECM00910

Gasoline mixed with water could cause

damage to the engine.

Engine trouble warning

This indicator will blink when the engine mal-functions while cruising. Get back to the port

soon and consult a Yamaha dealer immedi-ately.

CAUTION:

ECM00920

In such an event, the engine will not oper-ate properly. Consult a Yamaha dealer

immediately.

Low battery voltage warning

When the battery voltage drops, the low bat-tery voltage warning indicator and the bat-tery voltage value will start to blink. Get backto the port soon if the low battery voltagewarning device has activated. For chargingthe battery, consult your Yamaha dealer.

ZMU05423

ZMU05424

ZMU05425

ZMU05426

Basic components

31

EMU31610

Speed & fuel meter unit

This unit shows the boat speed and has thefunctions of fuel meter, total fuel consump-tion display, fuel economy display, fuel flowdisplay, and system voltage display. If op-tional sensors are connected to the unit, tripdisplay, water surface temperature display,depth display, and clock will be available. Forthe optional sensor, consult your Yamahadealer. The speed & fuel meter unit is avail-able in round or square types. Check yourspeed & fuel meter unit type.

ZMU05427

ZMU05428


1. Speedometer2. Fuel meter3. Multifunction display


21

ZMU05432

1

23

ZMU05433

21

ZMU05434

Basic components

32

NOTE:

After the main switch is first turned on, all thedisplays come on as a test. After a few sec-onds, the gauge will change to normal oper-

ation.

NOTE:

The speed & fuel meter unit shows variouskinds of information according to the settingmade with the “ ” (set) and “ ” (mode)buttons. For details, see the attached opera-

tion manual.

EMU31620

Speedometer unit

This unit shows the boat speed and hasfunctions of fuel meter and system voltagedisplay. If optional sensors are connected tothe unit, trip display, water surface tempera-ture display, depth display, and clock will beavailable. For the optional sensor, consultyour Yamaha dealer.

NOTE:


ation.

NOTE:

The speedometer unit shows various kindsof information according to the setting madeusing the “ ” (set) and “ ” (mode) but-tons. In addition, the speedometer can showthe desired unit of measurement such as km/h, mph, or knots. For details, see the at-

tached operation manual.


1 2

3 ZMU05435



21

ZMU05436

1

23

ZMU05437

Basic components

33

EMU31630

Fuel management meter

This meter has functions of fuel flow meter,total consumption display, fuel economy dis-play, and remaining fuel display.

NOTE:


ation.

NOTE:

The fuel management meter shows variouskinds of information when the operator usesthe “ ” (set) and “ ” (mode) buttons.For details, see the attached operation man-

ual.

EMU26801

Warning system

CAUTION:

ECM00090

Do not continue to operate the engine if awarning device has activated. Consultyour Yamaha dealer if the problem can-

not be located and corrected.

EMU26824

Overheat warning (twin engines)

This engine has an overheat warning device.If the engine temperature rises too high, thewarning device will activate.Activation of warning device

�

The engine speed will automatically de-crease to about 2000 r/min.

�

If equipped with an overheat warning indi-cator, it will light or blink.

�

The buzzer will sound.


1. Fuel flow meter2. Multifunction display

21

ZMU05438

1

2

ZMU05439

ZMU01757

ZMU04766

Basic components

34

If the warning system has activated, stop theengine and check the cooling water inlet forclogging.

NOTE:

Dual engine drive users:Should the overheat warning system of oneengine activate, the engine will slow downand the buzzer will sound. This will cause theother engine to slow down and the buzzer tosound. To switch off the warning activation

on the engine not affected by overheating,turn off the main switch of the engine over-

heating.

EMU26846

Oil level warning and oil filter clogging warning

Oil injection models

This engine has an oil level warning system.If the oil level falls below the lower limit, thewarning system will activate.

Activation of warning device

�

Engine speed will automatically decreaseto about 2000 r/min.

�

The oil level warning indicator will light orblink.

�

The buzzer will sound (if equipped on thetiller handle, remote control box, or mainswitch panel).

OFF START

ON

OFF START

ON

ZMU04584

ZMU02630

ZMU03942

ZMU04586

Basic components

35

If the warning system has been activated,stop the engine and check for the cause.

NOTE:

The warning for oil filter clogging is similar tothe warnings for low oil level and overheat-ing. To make troubleshooting easier, checkfor engine overheating first, then oil level,

and finally oil filter clogging.

1. Oil filter

ZMU03025

OFF START

ON

OFF START

ON

ZMU04584

1

ZMU03987

1. Oil filter

1ZMU01952

36

Operation

EMU26901

Installation

CAUTION:

ECM00110

Incorrect engine height or obstructionsto smooth water flow (such as the designor condition of the boat, or accessoriessuch as transom ladders or depth findertransducers) can create airborne waterspray while the boat is cruising. Severeengine damage may result if the motor isoperated continuously in the presence of

airborne water spray.

NOTE:

During water testing check the buoyancy ofthe boat, at rest, with its maximum load.Check that the static water level on the ex-haust housing is low enough to prevent wa-ter entry into the powerhead, when waterrises due to waves when the outboard is not

running.

EMU26910

Mounting the outboard motor

WARNING

EWM00820

�

Overpowering a boat could cause se-vere instability. Do not install an out-board motor with more horsepowerthan the maximum rating on the capac-ity plate of the boat. If the boat does nothave a capacity plate, consult the boatmanufacturer.

�

The information presented in this sec-tion is intended as reference only. It isnot possible to provide complete in-structions for every possible boat andmotor combination. Proper mountingdepends in part on experience and the

specific boat and motor combination.

WARNING

EWM00830

Improper mounting of the outboard mo-tor could result in hazardous conditionssuch as poor handling, loss of control, orfire hazards. Observe the following:

�

For permanently mounted models, yourdealer or other person experienced inproper rigging should mount the motor.If you are mounting the motor yourself,you should be trained by an experi-enced person.

�

For portable models, your dealer or oth-er person experienced in proper out-board motor mounting should show

you how to mount your motor.

Mount the outboard motor on the center line(keel line) of the boat, and ensure that theboat itself is well balanced. Otherwise theboat will be hard to steer. For boats withouta keel or which are asymmetrical, consultyour dealer.

1. Center line (keel line)

1 ZMU01873

Operation

37

EMU26930

Mounting height (boat bottom)

To 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 in alignment with the bottom of theboat.

NOTE:

�

The optimum mounting height of the out-

board motor is affected by the boat/motorcombination and the desired use. Testruns at different heights can help deter-mine the optimum mounting height. Con-sult your Yamaha dealer or boatmanufacturer for further information on de-termining the proper mounting height.

�

For instructions on setting the trim angle of

the outboard motor, see page 47.

EMU27041

Breaking in engine

Your new engine requires a period of break-in to allow mating surfaces of moving parts towear in evenly. Correct break-in will help en-sure proper performance and longer enginelife.

CAUTION:

ECM00750

�

Failure to follow the break-in procedurecould result in reduced engine life oreven severe engine damage.

�

Do not use premixed fuel in this enginebecause it could cause carbon depos-its on the fuel injector and engine trou-ble.

�

Follow the instructions for break-in

carefully.

NOTE:

Leave the label pictured below on the topcowling until the break-in procedure hasbeen completed. It may be removed after-

wards.

1. Center line (keel line)

ZMU01762

Operation

38

EMU27091

Procedure for HPDI models

Run the engine under load (in gear with apropeller installed) for 10 hours as follows.1. First 10 minutes:

Run the engine at the lowest possiblespeed. A fast idle in neutral is best.

2. Next 50 minutes:Do not exceed half throttle (approxi-mately 3000 r/min). Vary engine speedoccasionally. If you have an easy-plan-ing boat, accelerate at full throttle ontoplane, then immediately reduce thethrottle to 3000 r/min or less.

3. Next two hours:Accelerate at full throttle onto plane,then reduce engine speed to three-quar-ter throttle (approximately 4000 r/min).Vary engine speed occasionally. Run atfull throttle for one minute, then allowabout 10 minutes of operation at three-

quarter throttle or less to let the enginecool.

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

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

EMU27103

Preoperation checks

WARNING

EWM00080

If any item in the preoperation check isnot working properly, have it inspectedand repaired before operating the out-board motor. Otherwise an accident

could occur.

CAUTION:

ECM00120

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

occur.

EMU31550

Fuel

�

Check to be sure you have plenty of fuelfor your trip.

�

Make sure there are no fuel leaks or gaso-line fumes.

�

Check fuel line connections to be sure theyare tight (if equipped Yamaha fuel tank orboat tank).

�

Be sure the fuel tank is positioned on a se-cure, flat surface, and that the fuel line isnot twisted or flattened, or likely to contactsharp objects (if equipped Yamaha fueltank or boat tank).

�

Check the water in the fuel filter with thewater separator warning device. Place thegear shift lever in neutral and turn the mainswitch to “ ”(on). If the buzzer soundsand the water separator warning indicator

ZMU01945

Operation

39

blinks, consult your Yamaha dealer imme-diately.

EMU27120

Oil

�

Check to be sure you have plenty of oil foryour trip.

EMU27130

Controls

�

Check throttle, shift, and steering for prop-er operation before starting the engine.

�

The controls should work smoothly, with-out binding or unusual free play.

�

Look for loose or damaged connections.

�

Check operation of the starter and stopswitches when the outboard motor is in thewater.

EMU27150

Engine

�

Check the engine and engine mounting.

�

Look for loose or damaged fasteners.

�

Check the propeller for damage.

�

Check that the battery is in good conditionand the battery connections are secure.

EMU27221

Operation after a long period of storage

When operating the engine after a long peri-od (12 months) of storage, proceed as fol-lows:1. Start the engine. Leave it idling.

WARNING

EWM00090

�


�

Keep hands, hair, and clothes awayfrom the flywheel and other rotating

parts while the engine is running.

2. Watch for oil flowing through the oil feedpipes. After any air in the oil lines hasbeen expelled, the oil injection systemshould supply oil normally. If no oil isflowing after 10 minutes of idling, consult

your Yamaha dealer.

CAUTION:

ECM00560

�

Be sure to take the above steps whenoperating the engine after a long periodof storage. Otherwise engine seizurecould occur.

�

Use straight gasoline only. If premixfuel is used, the fuel injector could be

damaged.

ZMU03988

Operation

40

EMU27233

Filling fuel and engine oil

EMU30320

Filling fuel for models without a fuel joint

WARNING

EWM00060

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

sources of ignition.

1. Remove the fuel tank cap.2. Carefully fill the fuel tank.3. Securely close the cap after filling the

tank. Wipe up any spilled fuel.

EMU27270

Ring Free Fuel Additive

Gasoline is a precise blend of many differentsubstances, each chosen to give certaincharacteristics. Gasoline blends have beenchanging in recent years in response to con-cerns about pollution and resulting emis-

sions regulations. One of the most obviouschanges has been the elimination of leadfrom most fuels.As gasoline has changed, the amount of ad-ditives such as aromatics and oxygenateshas increased. These additives are impor-tant for the engines in passenger cars, butthey can have detrimental effects in marineengines, because of increased deposits inthe combustion chamber. When enough de-posits collect, piston rings begin sticking.Performance drops and engine wear in-creases dramatically.While many additives available may reducedeposits, Yamaha recommends the use of

Ring Free Fuel Additive

, available fromyour Yamaha dealer.

Ring Free Fuel Addi-tive

has repeatedly proven its ability to cleancombustion deposits from inside the engine,notably the critical piston-ring-land area, andfuel system components. Follow product la-beling for use instructions.

EMU27292

Filling oil for oil injection models

WARNING

EWM00530

Do not add gasoline into the oil tank. Fire

or explosion could result.

This engine uses the Yamaha oil injectionsystem, which provides superior lubricationby ensuring the proper oil ratio for all operat-ing conditions. No fuel premixing is needed.Simply pour gasoline into the fuel tank andoil into the oil tank. Convenient indicatorsshow the status of the oil supply. For detailson how to read the indicators, see page 42.To fill the engine oil tank, proceed as follows:1. Pour engine oil into the remote oil tank.

ZMU03989

Remote oil tank capacity:10.5 L (11.10 US qt) (9.24 Imp.qt)

Operation

41

NOTE:

The oil level lines on the remote oil tank indi-cate the amount of additional oil that can beadded to the tank. The top oil level line indi-cates approximately 1.9 L (0.5 US gal, 0.4Imp gal) can be added, and the bottom oillevel line indicates approximately 3.8 L (1 US

gal, 0.8 Imp gal) can be added.

2. Turn on the main switch. The Yamahaoil injection system will automaticallyfeed oil from the remote oil tank to theengine oil tank.

3. Operate the engine normally.

CAUTION:

ECM00570

When the engine is operated for the firsttime or stored for a period of time, a min-imum of 5 liters (5.3 US qt, 4.4 Imp qt) ofoil should be kept in the remote oil tank.Otherwise the oil-feed pump chamber willnot be filled with oil, and no oil will be

supplied.

ZMU01877

Operation

42

EMU27321

Oil level indicator operation

The various functions of the oil level system are as follows:

EMU27381

Oil level indicator

Electric start models

Oil level warning indicator (digital

tachometer)

Oil level warning indicator (analog

tachometer)

Engine oil tank

Remote oil tank

Remarks

Green

more than 300

cm

3

(0.32 US qt, 0.26

Imp qt)

more than

1500 cm

3

(1.6 US qt, 1.31

Imp qt)

�

No refilling necessary.

Yellow

more than 300

cm

3

(0.32 US qt, 0.26

Imp qt)

1500 cm

3

(1.6 US qt, 1.31 Imp qt) or less

�

Add oil; see page 40.

Red–Yellow–Green

300 cm

3

(0.32 US qt, 0.26

Imp qt) or less

more than

1500 cm

3

(1.6 US qt, 1.31 Imp qt)

�

Check oil filter for clog-ging.

�

Check battery cable connection. Buzzer will sound.

�

Engine speed is auto-matically reduced to about 2000 r/min.

Red

300 cm

3

(0.32 US qt, 0.26

Imp qt) or less

1500 cm

3

(1.6 US qt, 1.31 Imp qt) or less

�

Oil has not been added.

�

Buzzer will sound.

�

Engine speed is auto-matically reduced to about 2000 r/min.

�

Buzzer sounds in remote control box and engine speed is limited to about 2000 r/min to help conserve oil.

Operation

43

EMU27450

Operating engine

EMU27482

Feeding fuel

WARNING

EWM00420

�

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 loosen-ing the air vent screw.

�

This product emits exhaust gaseswhich contain carbon monoxide, a col-orless, odorless gas which could causebrain damage or death when inhaled.Symptoms include nausea, dizziness,and drowsiness. Keep cockpit and cab-in areas well ventilated. Avoid blocking

exhaust outlets.

1. If there is an air vent screw on the fueltank cap, loosen it 2 or 3 turns.

2. If there is a fuel joint or a fuel cock on theboat, firmly connect the fuel line to thejoint or open the fuel cock.

3. Squeeze the primer pump, with the ar-row pointing up, until you feel it becomefirm.

EMU27490

Starting engine

EMU27624

Electric start and remote control models

1. Place the remote control lever in “ ”(neutral).

NOTE:

The start-in-gear protection device preventsthe engine from starting except when in neu-

tral.

1. Arrow

Operation

44

2. Attach the engine stop switch lanyard toa secure place on your clothing, or yourarm or leg. Then install the lock plate onthe other end of the lanyard into the en-gine stop switch.

WARNING

EWM00120

�

Attach the engine stop switch lanyardto a secure place on your clothing, oryour arm or leg while operating.

�

Do not attach the lanyard to clothingthat could tear loose. Do not route thelanyard where it could become entan-gled, preventing it from functioning.

�



3. Turn the main switch to “ ” (on).

NOTE:

Dual engine users: When the main switch isturned on, the buzzer operates for a few sec-onds then stops automatically. The buzzer

also operates if one of the engines stalls.

4. Turn the main switch to “ ” (start),and hold it for a maximum of 5 seconds.

N

ZMU04588

ONSTARTOFF

ONSTARTOFF

ZMU04589

OFF

ON

ZMU01880

OFFON

OFFON

ZMU04591

Operation

45

5. Immediately after the engine starts, re-lease the main switch to return it to “ ”(on).

CAUTION:

ECM00191

�

Never turn the main switch to “ ”(start) while the engine is running.

�

Do not keep the starter motor turningfor more than 5 seconds. If the startermotor is turned continuously for morethan 5 seconds, the battery will bequickly discharged, thus making it im-possible to start the engine. The startercan also be damaged. If the engine willnot start after 5 seconds of cranking,return the main switch to “ ” (on), wait10 seconds, then crank the engine

again.

EMU27670

Warming up engine

EMU27702

Electric start and prime start models

1. After starting the engine, allow it to idlefor 3 minutes to warm up. Failure to doso will shorten engine life.

2. Check for a steady flow of water from thecooling water pilot hole.

CAUTION:

ECM00511

A continuous flow of water from the cool-ing water pilot hole shows that the waterpump is pumping water through the cool-ing passages. If water is not flowing outof the hole at all times while the engine isrunning, overheating and serious dam-age could occur. Stop the engine andcheck whether the cooling water inlet onthe lower case or the cooling water pilothole is blocked. Consult your Yamahadealer if the problem cannot be located

and corrected.

EMU27740

Shifting

WARNING

EWM00180

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

ON STARTOFF

ZMU01881

STARTON

ZMU04590

ZMU01882

Operation

46

you.

CAUTION:

ECM00220

To change the boat direction or shiftingposition from forward to reverse or vice-versa, first close the throttle so that the

engine idles (or runs at low speeds).

EMU27764

Forward (tiller handle and remote control models)

Tiller handle models1. Place the throttle grip in the fully closed

position.2. Move the gear shift lever quickly and

firmly from neutral to forward.Remote control models1. Pull up the neutral interlock trigger (if

equipped) and move the remote controllever quickly and firmly from neutral toforward.

EMU27785

Reverse (automatic reverse lock and power trim and tilt models)

WARNING

EWM00190

When operating in reverse, go slowly. Donot open the throttle more than half. Oth-erwise the boat could become unstable,which could result in loss of control and

an accident.

Tiller handle models1. Place the throttle grip in the fully closed

position.2. Move the gear shift lever quickly and

firmly from neutral to reverse.Remote control models1. Pull up the neutral interlock trigger (if

equipped) and move the remote controllever quickly and firmly from neutral toreverse.

NF

ZMU04597

NR

ZMU04598

Operation

47

EMU27820

Stopping engine

Before stopping the engine, first let it cool offfor a few minutes at idle or low speed. Stop-ping the engine immediately after operatingat high speed is not recommended.

EMU27852

Procedure

1. Turn the main switch to “ ” (off).

2. After stopping the engine, disconnectthe fuel line or close the fuel cock if thereis a fuel joint or a fuel cock on the boat.

3. Tighten the air vent screw on the fueltank cap (if equipped).

4. Remove the key if the boat will be leftunattended.

NOTE:

The engine can also be stopped by pullingthe lanyard and removing the clip from theengine stop switch, then turning the main

switch to “ ” (off).

EMU27861

Trimming outboard motor

The trim angle of the outboard motor helpsdetermine the position of the bow of the boatin the water. Correct trim angle will help im-prove performance and fuel economy whilereducing strain on the engine. Correct trimangle depends upon the combination ofboat, engine, and propeller. Correct trim isalso affected by variables such as the load inthe boat, sea conditions, and running speed.

WARNING

EWM00740

Excessive trim for the operating condi-tions (either trim up or trim down) cancause boat instability and can makesteering the boat more difficult. This in-creases the possibility of an accident. Ifthe boat begins to feel unstable or is hardto steer, slow down and/or readjust the

trim angle.OFFON

OFFON

ZMU04600

Operation

48

EMU27882

Adjusting trim angle

Power trim and tilt models

WARNING

EWM00751

�

Be sure all people are clear of the out-board motor when adjusting the tilt an-gle, also be careful not to pinch anybody parts between the drive unit andclamp bracket.

�

Use caution when trying a trim positionfor the first time. Increase speed gradu-ally and watch for any signs of instabil-ity or control problems. Improper trimangle can cause loss of control.

�

If equipped with a power trim and tiltswitch located on the bottom cowling,use the switch only when the boat is ata complete stop with the engine off. Do

not adjust the trim angle with this

switch while the boat is moving.

Adjust the outboard motor trim angle usingthe power trim and tilt switch.

1. Trim operating angle

1ZMU04718




ZMU04601

DN

UP

1

UP

DN

ZMU04615

1

Operation

49

To raise the bow (trim-out), press the switch“ ” (up).To lower the bow (trim-in), press the switch“ ” (down).Make test runs with the trim set to differentangles to find the position that works best foryour boat and operating conditions.

EMU27911

Adjusting boat trim

When the boat is on plane, a bow-up attituderesults in less drag, greater stability and effi-ciency. This is generally when the keel line ofthe boat is up about 3 to 5 degrees. With thebow up, the boat may have a greater tenden-cy to steer to one side or the other. Compen-sate for this as you steer. The trim tab canalso be adjusted to help offset this effect.When the bow of the boat is down, it is easierto accelerate from a standing start ontoplane.

Bow Up

Too much trim-out puts the bow of the boattoo high in the water. Performance and econ-omy are decreased because the hull of theboat is pushing the water and there is moreair drag. Excessive trim-out can also causethe propeller to ventilate, which reduces per-formance further, and the boat may “por-poise” (hop in the water), which could throwthe operator and passengers overboard.

Bow Down

Too much trim-in causes the boat to “plow”through the water, decreasing fuel economyand making it hard to increase speed. Oper-ating with excessive trim-in at higher speedsalso makes the boat unstable. Resistance atthe bow is greatly increased, heightening thedanger of “bow steering” and making opera-tion difficult and dangerous.

NOTE:

Depending on the type of boat, the outboardmotor trim angle may have little effect on the

trim of the boat when operating.

EMU27933

Tilting up and down

If the engine will be stopped for some time orif the boat is moored in shallows, the out-board motor should be tilted up to protect thepropeller and casing from damage by colli-sion with obstructions, and also to reduce

Operation

50

salt corrosion.

WARNING

EWM00220

Be sure all people are clear of the out-board motor when tilting up and down,also be careful not to pinch any bodyparts between the drive unit and engine

bracket.

WARNING

EWM00250

Leaking fuel is a fire hazard. If there is afuel joint on the outboard motor, discon-nect the fuel line or close the fuel cock ifthe engine will be tilted for more than a

few minutes. Otherwise fuel may leak.

CAUTION:

ECM00241

�

Before tilting the outboard motor, stopthe engine by following the procedureon page 47. Never tilt the outboard mo-tor while the engine is running. Severedamage from overheating can result.

�

Do not tilt up the engine by pushing thetiller handle (if equipped) because this

could break the handle.

EMU28007

Procedure for tilting up (power trim and tilt models / power tilt models)

1. Place the remote control lever / gearshift lever in neutral.

2. Disconnect the fuel line from the out-board motor or close the fuel cock.

3. Press the power trim and tilt switch /power tilt switch “ ” (up) until the out-board motor has tilted up completely.

N

ZMU03196

N

ZMU04588

ZMU04602

UP

Operation

51

4. Push the tilt support knob into the clampbracket or pull the tilt support lever to-ward you to support the engine.

WARNING

EWM00260

After tilting the outboard motor, be sureto support it with the tilt support knob ortilt support lever. Otherwise the outboardmotor could fall back down suddenly if oilin the power trim and tilt unit loses pres-

sure.

5. Models equipped with trim rods: Oncethe outboard motor is supported with thetilt support lever, press the power trimand tilt switch / power tilt switch “ ”(down) to retract the trim rods.

CAUTION:

ECM00250

Be sure to retract the trim rods complete-ly during mooring. This protects the rods

from marine growth and corrosion whichcould damage the power trim and tilt

mechanism.

EMU28055

Procedure for tilting down (power trim and tilt models / power tilt models)

1. Push the power trim and tilt switch / pow-er tilt switch “ ” (up) until the outboardmotor is supported by the tilt rod and thetilt support lever / tilt support knob be-comes free.

2. Release the tilt support lever or pull outthe tilt support knob.

3. Push the power trim and tilt switch / pow-er tilt switch “ ” (down) to lower the out-board motor to the desired position.

UP

ZMU03995

ZMU03996

ZMU03997

ZMU03998

Operation

52

EMU28060

Cruising in shallow water

The outboard motor can be tilted up partiallyto allow operation in shallow water.

EMU28090

Power trim and tilt models / power tilt models

The outboard motor can be tilted up partially

to allow operation in shallow water.

WARNING

EWM00660

�

Place the gear shift in neutral beforesetting up for shallow water cruising.

�

Return the outboard motor to its normalposition as soon as the boat is back in

deeper water.

CAUTION:

ECM00260

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.

EMU28185

Procedure for power trim and tilt / powertilt models

1. Place the remote control lever / gearshift lever in neutral.

DN

ZMU01936

UP

DN

ZMU04603

DN

DN

ZMU03999

N

ZMU04588

Operation

53

2. Slightly tilt the outboard motor up to thedesired position using the power trimand tilt switch / power tilt switch.

3. To return the outboard motor to the nor-mal running position, press the powertrim and tilt switch / power tilt switch andslowly tilt the outboard motor down.

EMU28192

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the cooling

water passages with fresh water to preventthem from becoming clogged with salt de-posits.

NOTE:

For cooling system flushing instructions, see

page 55.

Cruising in turbid water

Yamaha strongly recommends that you usethe optional chromium-plated water pump kit(not available for some models) if you usethe outboard motor in turbid or muddy waterconditions.

UP

ZMU01935

UP

DN

ZMU04602

UP

UP

ZMU04000

54

Maintenance

EMU31480

SpecificationsNOTE:

“(AL)” stated in the specification data belowrepresents the numerical value for the alumi-num propeller installed.Likewise, “(SUS)” represents the value forstainless steel propeller installed and “(PL)”

for plastic propeller installed.

EMU28218

Dimension:

Overall length: 792 mm (31.2 in)

Overall width: 554 mm (21.8 in)

Overall height X: 1782 mm (70.2 in)

Transom height X: 643 mm (25.3 in)

Weight (without propeller) X: 216.0 kg (476 lb)

Performance:

Full throttle operating range: 4500–5500 r/min

Maximum output: 147.1 kW@5000 r/min (200 HP@5000 r/min)

Idling speed (in neutral): 700

±

30 r/min

Engine:

Type: 2-stroke V

Displacement: 2596.0 cm

3

(158.41 cu.in)Bore

×

stroke: 90.0

×

68.0 mm (3.54

×

2.68 in)Ignition system:

TCISpark plug with resistor (NGK):

BKR7EKU

Spark plug gap: 1.5–1.6 mm (0.059–0.063 in)

Control system: Remote control

Starting system: Electric

Starting carburetion system: Electronic fuel injection

Min. cold cranking amps (CCA/SAE): 512.0 A

Min. marine cranking amps (MCA/ABYC): 675.0 A

Min. reserve capacity (RC/SAE): 182 minutes

Alternator output for battery DC: 45.0 A

Drive unit:

Gear positions: Forward-neutral-reverse

Gear ratio: 1.86 (26/14)

Trim and tilt system: Power trim and tilt

Propeller mark: LZ200TR MLZ200TR M

Fuel and oil:

Recommended fuel: Regular unleaded gasoline

Min. pump octane: 86

Recommended engine oil: YAMALUBE 2-stroke outboard motor oil

Lubrication: Oil injection

Engine oil tank capacity: 0.9 L (0.95 US qt) (0.79 Imp.qt)

Remote oil tank capacity: 10.5 L (11.10 US qt) (9.24 Imp.qt)

Recommended gear oil:

Maintenance

55

Hypoid gear oil SAE#90Gear oil quantity:

LZ200TR 870.0 cm

3

(29.41 US oz) (30.68 Imp.oz)Z200TR 980.0 cm

3

(33.13 US oz) (34.56 Imp.oz)

Tightening torque for engine:

Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Propeller nut: 55.0 Nm (40.6 ft-lb) (5.61 kgf-m)

EMU28222

Transporting and storing outboard motor

WARNING

EWM00690

�

Leaking fuel is a fire hazard. Whentransporting and storing the outboardmotor, close the air vent screw and fuelcock to prevent fuel from leaking.

�

USE CARE when transporting fuel tank,whether in a boat or car.

�

DO NOT fill fuel container to maximumcapacity. Gasoline will expand consid-erably as it warms up and can build uppressure in the fuel container. This cancause fuel leakage and a potential fire

hazard.

WARNING

EWM00700

Never get under the lower unit while it istilted, even if a motor support bar is used.Severe injury could occur if the outboard

motor accidentally falls.

CAUTION:

ECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboardmotor could shake loose from the tilt sup-port and fall. If the motor cannot be trail-

ered in the normal running position, usean additional support device to secure it

in the tilt position.

The outboard motor should be trailered andstored in the normal running position. If thereis insufficient road clearance in this position,then trailer the outboard motor in the tilt po-sition using a motor support device such asa transom saver bar. Consult your Yamahadealer for further details.

EMU28250

Storing outboard motor

When storing your Yamaha outboard motorfor prolonged periods of time (2 months orlonger), several important procedures mustbe performed to prevent excessive damage.This is especially important for your oil injec-tion equipped outboard motor due to the leanoil ratios used at idle prior to shutting the en-gine off for the season. It is advisable to haveyour outboard motor serviced by an autho-rized Yamaha dealer prior to storage. How-ever, you, the owner, with a minimum oftools, can perform the following procedures.

CAUTION:

ECM01070

Do not use any chemical goods contain-ing Silicon, Phosphorus, or Lead. Other-wise the oxygen sensor for the ElectronicFuel Injection system could be damaged.Consult your Yamaha dealer for details

ZMU04720

Maintenance

56

on the use of chemical goods for storage.

EMU28303

Procedure

EMU30001

Flushing with the flushing attachment

1. Wash the outboard motor body usingfresh water. For further information, seepage 59.

2. Fill the fuel tank with fresh fuel and addone ounce of “Yamaha Fuel Conditionerand Stabilizer” (Part No. LUB-FUELC-12-00) to each gallon of fuel.

NOTE:

The use of “Yamaha Fuel Conditioner andStabilizer” eliminates the need to drain thefuel system. Consult your Yamaha dealer orother qualified mechanic if the fuel system is

to be drained instead.

3. Remove the top cowling and propeller.4. Install the flushing attachment over the

cooling water inlet.

CAUTION:

ECM00300

Do not run the engine without supplyingit with cooling water. Either the enginewater pump will be damaged or the en-gine will be damaged from overheating.Before starting the engine, be sure tosupply water to the cooling water passag-

es.

CAUTION:

ECM00310

Avoid running the outboard motor at highspeed while on the flushing attachment,

otherwise overheating could occur.

5. Cooling system flushing is essential toprevent the cooling system from clog-ging up with salt, sand, or dirt. In addi-tion, fogging/lubricating of the engine ismandatory to prevent excessive enginedamage due to rust. Perform the flush-ing and fogging at the same time.

WARNING

EWM00090

�


�



NOTE:

�

When using the flushing attachment,maintain adequate water pressure and asteady water flow.

�

If the overheat warning device is activated,turn the engine off, and consult your

Yamaha dealer.

6. Run the engine at a fast idle for a fewminutes in neutral position while supply-ing fresh water.

7. Just prior to turning off the engine, quick-ly spray “Yamaha Stor-Rite EngineFogging Oil” (Part No. LUB-STRRT-12-00) alternately into the intake silencer or

1. Flushing attachment

Maintenance

57

the fogging hole of the silencer cover, ifequipped. When properly done, the en-gine will smoke excessively and almoststall.

8. Remove the flushing attachment andwipe off any excess water.

9. Install the top cowling and propeller.10. Drain the cooling water completely out

of the motor. Clean the body thoroughly.

NOTE:

A flushing attachment is available from your

Yamaha dealer.

EMU28410

Lubrication (oil injection models)

1. Grease the spark plug threads and in-stall the spark plug(s) and torque toproper specification. For information onspark plug installation, see page 62.

2. Fill the oil tanks. This prevents the for-mation of condensation. For models witha remote oil tank, it may be necessary tomanually override the control unit tocompletely fill the engine oil tank.

3. Change the gear oil. For instructions,see page 68. Inspect the oil for the pres-ence of water which indicates a leakyseal. Seal replacement should be per-formed by an authorized Yamaha dealerprior to use.

4. Grease all grease fittings. For further de-tails, see page 62.

EMU30261

Cleaning and anticorrosion measures

1. Wash down the exterior of the outboardmotor with fresh water and dry off com-pletely.

2. Spray the outboard motor exterior with“Yamaha Silicone Protectant” (Part No.

LUB-SILCNE-13-00).

CAUTION:

ECM01401

Do not spray when the engine is running.Also, do not spray near the silencer orinto the engine. Otherwise the engine

could be damaged.

3. Wax the cowling with a non-abrasivewax such as “Yamaha Silicone Wax”(Part No. ACC-11000-15-02).

EMU28430

Battery care

WARNING

EWM00330

Battery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore ispoisonous and highly caustic.Always follow these preventive mea-sures:

�

Avoid bodily contact with electrolyticfluid as it can cause severe burns orpermanent eye injury.

�

Wear protective eye gear when han-dling or working near batteries.

Antidote (EXTERNAL):

�

SKIN - Flush with water.

�

EYES - Flush with water for 15 minutesand get immediate medical attention.

Antidote (INTERNAL):

�

Drink large quantities of water or milkfollowed by milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.

Batteries also generate explosive hydro-gen gas; therefore, you should alwaysfollow these preventive measures:

�

Charge batteries in a well-ventilated ar-ea.

�

Keep batteries away from fire, sparks,or open flames (for example: weldingequipment, lighted cigarettes, and so

Maintenance

58

on.)

�

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

Batteries vary among manufacturers. There-fore the following procedures may not al-ways apply. Consult your batterymanufacturer’s instructions.Procedure1. Disconnect and remove the battery from

the boat. Always disconnect the blacknegative cable first to prevent the risk ofshorting.

2. Clean the battery casing and terminals.Fill each cell to the upper level with dis-tilled water.

3. Store the battery on a level surface in acool, dry, well-ventilated place out of di-rect sunlight.

4. Once a month, check the specific gravityof the electrolyte and recharge as re-quired to prolong battery life.

EMU28442

Flushing power unit

Perform this procedure right after operationfor the most thorough flushing.

CAUTION:

ECM01530

Do not perform this procedure while theengine is running. The water pump maybe damaged and severe damage from

overheating can result.

1. After shutting off the engine, unscrewthe garden hose connector from the fit-ting on the bottom cowling.

2. Screw the garden hose adapter onto agarden hose, which is connected to afresh water supply, and then connect itto the garden hose connector.

3. With the engine off, turn on the water tapand let the water flush through the cool-ing passages for about 15 minutes. Turnoff the water and disconnect the gardenhose adapter from the garden hose con-nector.

4. Reinstall the garden hose connectoronto the fitting on the bottom cowling.Tighten the connector securely.

CAUTION:

ECM00540

Do not leave the garden hose connectorloose on the bottom cowling fitting or letthe hose hang free during normal opera-

1. Fitting2. Garden hose connector3. Garden hose adapter

12 3

ZMU04723

Maintenance

59

tion. Water will leak out of the connectorinstead of cooling the engine, which cancause serious overheating. Be sure theconnector is tightened securely on the fit-

ting after flushing the engine.

NOTE:

�

When flushing the engine with the boat inthe water, tilting up the outboard motor un-til it is completely out of the water willachieve better results.

�

For cooling system flushing instructions,

see page 55.

EMU28450

Cleaning the outboard motor

After use, wash the exterior of the outboardmotor with fresh water. Flush the coolingsystem with fresh water.

NOTE:

For cooling system flushing instructions, see

page 55.

EMU28460

Checking painted surface of motor

Check the motor for scratches, nicks, or flak-ing paint. Areas with damaged paint aremore likely to corrode. If necessary, cleanand paint the areas. A touch-up paint is avail-able from your Yamaha dealer.

EMU28486

Periodic maintenance

WARNING

EWM01070

Be sure to turn off the engine when youperform maintenance unless otherwisespecified. If you or the owner is not famil-iar with machine servicing, this workshould be done by your Yamaha dealer or

other qualified mechanic.

Maintenance, replacement, or repair ofthe emission control devices and sys-tems may be performed by any marineengine repair establishment or individual.All warranty repairs, however, includingthose to the emission control system,must be performed by an authorizedYamaha marine dealership.

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.

EMU28510

Replacement parts

If replacement parts are necessary, use onlygenuine Yamaha parts or parts of the sametype and of equivalent strength and materi-als. Any part of inferior quality may malfunc-tion, and the resulting loss of control couldendanger the operator and passengers.Yamaha genuine parts and accessories areavailable from your Yamaha dealer.

ZMU02550

Maintenance

60

EMU28522

Maintenance chart

Frequency of maintenance operations may be adjusted according to the operating condi-tions, but the following table gives general guidelines. Refer to the sections in this chapter forexplanations of each owner-specific action.

NOTE:

When operating in salt water, turbid or muddy water, the engine should be 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

10 hours (1 month)

50 hours (3

months)

100 hours (6 months)

200 hours (1

year)

Anode(s) (external)Inspection / replace-ment

Anode(s) (internal)Inspection / replace-ment

Battery Inspection / charging

Cooling water pas-sages

Cleaning

Cowling clamp Inspection

Fuel filter (can be dis-assembled)

Inspection / replace-ment

Fuel system Inspection

Gear oil Change

Greasing points Greasing

Idling speed Inspection

PCV (Pressure Con-trol Valve)

Inspection

Power trim and tilt unit Inspection

Propeller and cotter pinInspection / replace-ment

Shift link / shift cable Inspection / adjustment

ThermostatInspection / replace-ment

Throttle link / throttle cable / throttle pick-up timing

Inspection / adjustment

Throttle position sen-sor

Inspection / adjustment

Maintenance

61

EMU28874

Maintenance chart (additional)

Water pumpInspection / replace-ment

High pressure fuel pump drive belt

Inspection / replace-ment

High pressure fuel pump oil level

Inspection / filling

Oil pump Inspection / adjustment

Oil tank water drain Inspection / cleaning

Spark plug(s)Cleaning / adjustment / replacement

Item ActionsEvery

500 hours (2.5 years) 1000 hours (5 years)

High pressure fuel pump drive belt

Replacement

Fuel filter (vapor sepa-rator tank)

Replacement

Item Actions

Initial Every

10 hours (1 month)

50 hours (3

months)

100 hours (6 months)

200 hours (1

year)

Maintenance

62

EMU28931

Greasing

Yamaha marine grease (Water resistant grease)

Z200, LZ200

EMU28952

Cleaning and adjusting spark plug

WARNING

EWM00560

When removing or installing a spark plug,be careful not to damage the insulator. Adamaged insulator could allow external

sparks, which could lead to explosion or

fire.

The spark plug is an important engine com-ponent and is easy to inspect. The conditionof the spark plug can indicate somethingabout the condition of the engine. For exam-

ZMU04724

Maintenance

63

ple, if the center electrode porcelain is verywhite, this could indicate an intake air leak orcarburetion problem in that cylinder. Do notattempt to diagnose any problems yourself.Instead, take the outboard motor to aYamaha dealer. You should periodically re-move and inspect the spark plug becauseheat and deposits will cause the spark plugto slowly break down and erode. If electrodeerosion becomes excessive, or if carbon andother deposits are excessive, you should re-place the spark plug with another of the cor-rect type.

Before fitting the spark plug, measure theelectrode gap with a wire thickness gauge;adjust the gap to specification if necessary.

When fitting the plug, always clean the gas-ket surface and use a new gasket. Wipe offany dirt from the threads and screw in the

spark plug to the correct torque.

NOTE:

If a torque-wrench is not available when youare fitting a spark plug, a good estimate ofthe correct torque is 1/4 to 1/2 a turn past fin-ger-tight. Have the spark plug adjusted to thecorrect torque as soon as possible with a

torque-wrench.

EMU28962

Checking fuel system

WARNING

EWM00060

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

sources of ignition.

WARNING

EWM00910

Leaking fuel can result in fire or explo-sion.

�

Check for fuel leakage regularly.

�

If any fuel leakage is found, the fuelsystem must be repaired by a qualifiedmechanic. Improper repairs can make

the outboard unsafe to operate.

Check the fuel lines for leaks, crack, or mal-function. If a problem is found, your Yamahadealer or other qualified mechanic should re-pair it immediately.

Standard spark plug:BKR7EKU

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

Spark plug gap:1.5–1.6 mm (0.059–0.063 in)

1

12

ZMU01892

Spark plug torque:25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

Maintenance

64

Checkpoints

�

Fuel system parts leakage

�

Fuel line joint leakage

�

Fuel line cracks or other damage

�

Fuel connector leakage

EMU29041

Inspecting idling speed

WARNING

EWM00451

�


�



CAUTION:

ECM00490

This procedure must be performed whilethe outboard motor is in the water. Aflushing attachment or test tank can be

used.

A diagnostic tachometer should be used for

this procedure. Results may vary dependingon whether testing is conducted with theflushing attachment, in a test tank, or with theoutboard motor in the water.1. Start the engine and allow it to warm up

fully in neutral until it is running smooth-ly.

NOTE:

Correct idling speed inspection is only possi-ble if the engine is fully warmed up. If notwarmed up fully, the idle speed will measurehigher than normal. If you have difficulty ver-ifying the idle speed, or the idle speed re-quires adjustment, consult a Yamaha dealer

or other qualified mechanic.

2. Verify whether the idle speed is set tospecification. For idle speed specifica-tions, see page 54.

EMU29050

Checking water in engine oil tank

Oil injection models

There is a water trap at the bottom of the en-gine oil tank. If water or foreign matter is vis-ible in this trap, consult your Yamaha dealer.

EMU29112

Checking wiring and connectors

�

Check that each grounding wire is properlysecured.

ZMU04004

1. Water trap2. Engine oil tank

21

ZMU01895

Maintenance

65

�

Check that each connector is engaged se-curely.

EMU29120

Exhaust leakage

Start the engine and check that no exhaustleaks from the joints between the exhaustcover, cylinder head, and body cylinder.

EMU29130

Water leakage

Start the engine and check that no waterleaks from the joints between the exhaustcover, cylinder head, and body cylinder.

EMU29153

Checking power trim and tilt system

WARNING

EWM00430

�

Never get under the lower unit while itis tilted, even when the tilt support leveris locked. Severe injury could occur ifthe outboard motor accidentally falls.

�

Make sure no one is under the outboard

motor before performing this test.

1. Check the power trim and tilt unit for anysign of oil leaks.

2. Operate each of the power trim and tiltswitches on the remote control and en-gine bottom cowling (if equipped) tocheck that all switches work.

3. Tilt the outboard motor up and checkthat the tilt rod and trim rods are extend-ed completely.

4. Use the tilt support lever to lock the mo-tor in the up position. Operate the tiltdown switch briefly so the motor is sup-ported by the tilt support lever.

5. Check that the tilt rod and trim rods arefree of corrosion or other flaws.

6. Activate the tilt-down switch until the trimrods have retracted completely into thecylinders.

ZMU04007

1. Tilt rod2. Trim rods

1. Tilt support lever

ZMU03458

1

2

ZMU04155

1

Maintenance

66

7. Activate the trim-up switch until the tiltrod is fully extended. Unlock the tilt sup-port lever.

8. Tilt the outboard motor down. Checkthat the tilt rod and trim rods operatesmoothly.

NOTE:

Consult your Yamaha dealer if any operation

is abnormal.

EMU29171

Checking propeller

WARNING

EWM00321

You could be seriously injured if the en-gine accidentally starts when you arenear the propeller.

�

Before inspecting, removing, or install-ing the propeller, remove the sparkplug caps from the spark plugs. Also,place the shift control in neutral, turn

the main switch to “ ” (off) and re-move the key, and remove the lanyardfrom the engine stop switch. Turn offthe battery cut-off switch if your boathas one.

�

Do not use your hand to hold the pro-peller when loosening or tightening thepropeller nut. Put a wood block be-tween the anti-cavitation plate and thepropeller to prevent the propeller from

turning.

Checkpoints

�

Check each of the propeller blades forwear, erosion from cavitation or ventila-tion, or other damage.

�

Check the propeller shaft for damage.

�

Check the splines / shear pin for wear ordamage.

�

Check for fish line tangled around the pro-peller shaft.

ZMU04156

ZMU03460

ZMU01896

ZMU01897

Maintenance

67

�

Check the propeller shaft oil seal for dam-age.

NOTE:

If the shear pin equipped: it is designed tobreak if the propeller hits a hard underwaterobstacle to help protect the propeller anddrive mechanism. The propeller will thenspin freely on the shaft. If this happens, the

shear pin must be replaced.

EMU30660

Removing the propeller

EMU29194

Spline models

1. Straighten the cotter pin and pull it outusing a pair of pliers.

2. Remove the propeller nut, washer, andspacer (if equipped).

3. Remove the propeller and thrust wash-er.

EMU30670

Installing the Propeller

EMU29242

Spline models

WARNING

EWM00770

On counter rotation models, be sure touse a propeller intended for counter-clockwise rotation. These propellers areidentified with the letter “L” after the sizeindication on the propeller. Otherwise theboat could move in the opposite direction

from that expected.

CAUTION:

ECM00340

�

Be sure to install the thrust washer be-fore installing the propeller, otherwisethe lower case and propeller bosscould be damaged.

�

Be sure to use a new cotter pin andbend the ends over securely. Otherwisethe propeller could come off during op-

eration and be lost.

1. Apply Yamaha marine grease or a cor-rosion resistant grease to the propellershaft.

2. Install the thrust washer and propelleron the propeller shaft.

3. Install the spacer and washer. Tightenthe propeller nut to the specified torque.

4. Align the propeller nut with the propellershaft hole. Insert a new cotter pin in thehole and bend the cotter pin ends.

1. Cotter pin2. Propeller nut3. Washer4. Spacer

1

6 54

32

ZMU01898

5. Propeller6. Thrust washer

Propeller nut tightening torque:55.0 Nm (40.6 ft-lb) (5.61 kgf-m)

Maintenance

68

NOTE:

If the propeller nut does not align with thepropeller shaft hole after tightening to thespecified torque, tighten the nut further to

align it with the hole.

EMU29282

Changing gear oil

WARNING

EWM00800

�

Be sure the outboard motor is securelyfastened to the transom or a stablestand. You could be severely injured ifthe outboard motor falls on you.

�

Never get under the lower unit while itis tilted, even when the tilt support leveror knob is locked. Severe injury couldoccur if the outboard motor accidental-

ly falls.

1. Tilt the outboard motor so that the gearoil drain screw is at the lowest point pos-sible.

2. Place a suitable container under thegear case.

3. Remove the gear oil drain screw andgasket.

NOTE:

�

If a magnetic gear oil drain screw isequipped, remove all metal particles fromthe screw before installing it.

�

Always use new gaskets. Do not reuse the

removed gaskets.

4. Remove the oil level plug and gasket toallow the oil to drain completely.

CAUTION:

ECM00710

Inspect the used oil after it has beendrained. If the oil is milky, water is gettinginto the gear case which can cause geardamage. Consult a Yamaha dealer for re-

pair of the lower unit seals.

NOTE:

For disposal of used oil, consult your

Yamaha dealer.

5. With the outboard motor in a vertical po-sition, and using a flexible or pressur-ized filling device, inject the gear oil into

1. Gear oil drain screw2. Oil level plug

1

2

ZMU01899

Maintenance

69

the gear oil drain 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.

EMU29312

Inspecting and replacing anode(s)

Yamaha outboard motors are protected fromcorrosion by sacrificial anodes. Inspect theexternal anodes periodically. Remove scalesfrom the surfaces of the anodes. Consult aYamaha dealer for replacement of externalanodes.

CAUTION:

ECM00720

Do not paint anodes, as this would render

them ineffective.

NOTE:

Inspect ground leads attached to external

anodes on equipped models. Consult aYamaha dealer for inspection and replace-ment of internal anodes attached to the pow-

er unit.

EMU29320

Checking battery (for electric start models)

WARNING

EWM00330

Battery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore ispoisonous and highly caustic.Always follow these preventive mea-sures:

�

Avoid bodily contact with electrolyticfluid as it can cause severe burns orpermanent eye injury.

�

Wear protective eye gear when han-

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:LZ200TR 870.0 cm

3

(29.41 US oz) (30.68 Imp.oz)Z200TR 980.0 cm

3

(33.13 US oz) (34.56 Imp.oz)

ZMU01900

ZMU01901

ZMU04008

Maintenance

70

dling or working near batteries.Antidote (EXTERNAL):

�

SKIN - Flush with water.

�

EYES - Flush with water for 15 minutesand get immediate medical attention.

Antidote (INTERNAL):

�

Drink large quantities of water or milkfollowed by milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.

Batteries also generate explosive hydro-gen gas; therefore, you should alwaysfollow these preventive measures:

�

Charge batteries in a well-ventilated ar-ea.

�

Keep batteries away from fire, sparks,or open flames (for example: weldingequipment, lighted cigarettes, and soon.)

�

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

CAUTION:

ECM00360

�

A poorly maintained battery will quicklydeteriorate.

�

Ordinary tap water contains mineralsharmful to a battery, and should not be

used for topping up.

1. Check the electrolyte level at least oncea month. Fill to the manufacturer’s rec-ommended level when necessary. Topup only with distilled water (or pure de-ionized water suitable to use in batter-ies).

2. Always keep the battery in a good stateof charge. Installing a voltmeter will helpyou monitor your battery. If you will notuse the boat for a month or more, re-move the battery from the boat and storeit in a cool, dark place. Completely re-charge the battery before using it.

3. If the battery will be stored for longerthan a month, check the specific gravityof the fluid at least once a month and re-charge the battery when it is low.

NOTE:

Consult a Yamaha dealer when charging or

re-charging batteries.

EMU29351

Connecting the Battery

WARNING

EWM00570

Mount the battery holder securely in adry, well-ventilated, vibration-free loca-tion in the boat. Install a fully charged bat-

tery in the holder.

CAUTION:

ECM01121

�

Make sure the main switch (on applica-ble models) is “ ” (off) before work-ing on the battery.

�

Reversal of the battery cables will dam-age the electrical parts.

�

Connect the red battery cable first

Maintenance

71

when installing the battery and discon-nect the black battery cable first whenremoving it. Otherwise, the electricalparts can be damaged.

�

The electrical contacts of the batteryand cables must be clean and properlyconnected, or the battery will not start

the engine.

Connect the RED lead to the POSITIVE (+)terminal first. Then connect the BLACK leadto the NEGATIVE (-) terminal.

Using an accessory battery (option)

Use a connecting cable between the (-) ter-minals of the starting battery and accessorybattery. See the illustrations of the wiringconnections. This cable must be made fromwire equivalent to the starting battery cable.

WARNING

EWM00600

Use of smaller wire could lead to a fire.

NOTE:

If a battery selector switch is desired, consult

your YAMAHA dealer about correct wiring.

EMU29370

Disconnecting the battery

Disconnect the BLACK cable from the NEG-ATIVE (-) terminal first. Then disconnect theRED cable from the POSITIVE (+) terminal.

EMU29390

Checking top cowling

Check the fitting of the top cowling by push-ing it with both hands. If it is loose have it re-paired by your Yamaha dealer.

1. Red cable2. Black cable3. Battery

1. Battery for accessories2. Battery for starting3. Large black lead4. Large red lead for starting battery5. Negative connecting cable6. Power for accessories7. Small red lead for accessory battery charg-ing (optional part)

7

ZMU01942

4 3 5

16

2

Maintenance

72

EMU29400

Coating the boat bottom

A clean hull improves boat performance. Theboat bottom should be kept as clean of ma-rine growth as possible. If necessary, theboat bottom can be coated with an anti-foul-ing paint approved for your area to inhibitmarine growth.Do not use anti-fouling paint which includescopper or graphite. These paints can causemore rapid engine corrosion.

ZMU04679

ZMU01943

73

Trouble Recovery

EMU29424

Troubleshooting

A problem in the fuel, compression, or igni-tion systems can cause poor starting, loss ofpower, or other problems. This section de-scribes basic checks and possible remedies,and covers all Yamaha outboard motors.Therefore some items may not apply to yourmodel.If your outboard motor requires repair, bringit to your Yamaha dealer.If the engine trouble warning indicator isflashing, consult your Yamaha dealer.

Starter will not operate.

Q. Is battery capacity weak or low?A. Check battery condition. Use battery ofrecommended capacity.

Q. Are battery connections loose or corrod-ed?A. Tighten battery cables and clean batteryterminals.

Q. Is fuse for electric start relay or electric cir-cuit blown?A. Check for cause of electric overload andrepair. Replace fuse with one of correct am-perage.

Q. Are starter components faulty?A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear?A. Shift to neutral.

Engine will not start (starter operates).

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 starting procedure incorrect?A. See page 43.

Q. Has fuel pump malfunctioned?A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replacewith recommended type.

Q. Are spark plug cap(s) fitted incorrectly?A. Check and re-fit cap(s).

Q. Is ignition wiring damaged or poorly con-nected?A. Check wires for wear or breaks. Tightenall loose connections. Replace worn or bro-ken wires.

Q. Are ignition parts faulty?A. Have serviced by a Yamaha dealer.

Q. Is engine stop switch lanyard not at-tached?A. Attach lanyard.

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

Engine idles irregularly or stalls.


Trouble Recovery

74

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

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


Q. Have ignition parts failed?A. Have serviced by a Yamaha dealer.

Q. Has warning system activated?A. Find and correct cause of warning.

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


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

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

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

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

Q. Is air vent screw on fuel tank closed?A. Open air vent screw.

Q. Is choke knob pulled out?

A. Return to home position.

Q. Is motor angle too high?A. Return to normal operating position. Q. Is carburetor clogged?A. Have serviced by a Yamaha dealer.

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

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

Q. Is battery cable disconnected?A. Connect securely.

Warning buzzer sounds or indicatorlights.

Q. Is cooling system clogged?A. Check water intake for restriction.

Q. Is engine oil level low?A. Fill oil tank with specified engine oil.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

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

Q. Is engine oil contaminated or deteriorat-ed?A. Replace oil with fresh, specified type.

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

Q. Has oil feed/injection pump malfunc-tioned?

Trouble Recovery

75

A. Have serviced by a Yamaha dealer.

Q. Is load on boat improperly distributed?A. Distribute load to place boat on an evenplane.

Q. Is water pump or thermostat faulty?A. Have serviced by a Yamaha dealer.

Q. Is there excess water in fuel filter cup?A. Drain filter cup.

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 out-board at its recommended speed (r/min)range.

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

Q. Is motor mounted at incorrect height ontransom?A. Have motor adjusted to proper transomheight.

Q. Has warning system activated?A. Find and correct cause of warning.

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


Q. Are weeds or other foreign matter tangledon gear housing?A. Remove foreign matter and clean lowerunit.

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


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

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


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

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 faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw closed?A. Open the air vent screw.

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

Trouble Recovery

76

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

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is high pressure fuel pump drive belt bro-ken?A. Have serviced by a Yamaha dealer.

Q. Is engine not responding properly to shiftlever position?A. Have serviced by a Yamaha dealer.

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 matter tangledon propeller?A. Remove and clean propeller.

Q. Is motor mounting bolt loose?A. Tighten bolt.

Q. Is steering pivot loose or damaged?A. Tighten or have serviced by a Yamahadealer.

EMU29433

Temporary action in emergency

EMU29440

Impact damage

WARNING

EWM00870

The outboard motor can be seriously

damaged 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 com-

ponents for damage. Also inspect theboat for 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.

EMU29450

Running single engine

When using only engine in an emergency, besure to keep the unused one tilted up and op-erate the other engine at low speed.

CAUTION:

ECM00370

If the boat is operated with one engine inthe water but not running, water may runinto the exhaust pipe due to wave action,

causing engine trouble.

NOTE:

When you are maneuvering at low speed,such as near a dock, it is recommended thatboth engines be running with one in neutral

gear if possible.

Trouble Recovery

77

EMU29492

Replacing fuse

If the fuse has blown on an electric startmodel, open the fuse box and use a fusepuller to replace the fuse with a spare one ofthe proper amperage.

WARNING

EWM00630

Be sure to use the specified fuse. An in-correct fuse or a piece of wire could allowexcessive current flow. This could cause

electric system damage and a fire hazard.

CAUTION:

ECM01382

�

If a main fuse has blown, be sure to alsocheck the other main fuse.

�

If the outboard motor is operated after amain fuse has blown charging capabili-ty will be insufficient, and the engine

will not start.NOTE:

Consult your Yamaha dealer if the new fuse

immediately blows again.

EMU29522

Power trim and tilt / power tilt will not operate

If the engine cannot be tilted up or down withthe power trim and tilt / the power tilt becauseof a discharged battery or a failure with thepower trim and tilt unit / the power tilt unit, theengine can be tilted manually.1. Loosen the manual valve screw by turn-

ing it counterclockwise until it stops.

1. Electrical cover2. Fuse holder3. Fuse (20 A

×

3, 30 A, 80 A

×

2)4. Spare fuse (20 A, 30 A, 80 A)5. Fuse puller

1. Fuse puller

45

2

34

3

1ZMU04009

1

ZMU03562

Trouble Recovery

78

2. Put the engine in the desired position,then tighten the manual valve screw byturning it clockwise.

EMU31780

Water separator warning indicator blinks while cruising

WARNING

EWM01500

Gasoline is highly flammable, and its va-pors are flammable and explosive.

�

Do not perform this procedure on a hotor running engine. Allow the engine tocool.

�

There will be fuel in the fuel filter. Keepaway from sparks, cigarettes, flames orother sources of ignition.

�

This procedure will allow some fuel tospill. Catch fuel in a rag. Wipe up anyspilled fuel immediately.

�

The fuel filter must be reassembledcarefully with the O-ring, filter cup, andhoses in place. Improper assembly orreplacement could result in a fuel leak,which could result in a fire or explosion

hazard.

If the water separator warning indicator onthe tachometer blinks, perform the followingprocedure.

1. Stop the engine.2. Remove the top cowling.3. Disconnect the water detection switch

coupler.

CAUTION:

ECM01570

Be careful not to get any water on the wa-ter detection switch coupler, otherwise a

malfunction could occur.

4. Unscrew the filter cup from the filterhousing.

NOTE:

Be careful not to twist the water detection

switch lead when unscrewing the filter cup.

1. Manual valve screw

ZMU05018

1

1. Water separator warning indicator

1. Water detection switch coupler

1

ZMU05502

Trouble Recovery

79

5. Drain the water in the filter cup by soak-ing it up with a rag.

NOTE:

Properly dispose of the rag.

6. Firmly screw the filter cup onto the filterhousing.

NOTE:

Be careful not to twist the water detectionswitch lead when screwing the filter cup onto

the filter housing.

7. Connect the water detection switch cou-pler securely until a click is heard.

8. Install the top cowling.9. Start the engine and make sure that the

water separator warning indicator re-

mains off.

NOTE:

Have a Yamaha dealer inspect the outboard

motor after returning to port.

EMU29541

Starter will not operate

If the starter mechanism does not operate(the engine cannot be cranked with the start-er), the engine can be started manually withan emergency starter rope. However, the en-gine cannot be started manually if the batteryvoltage is low. If the battery is discharged to9 volts or below, the electric fuel pump willnot operate.

WARNING

EWM01021

�

Use this procedure only in an emergen-cy to return to the nearest port for re-pairs.

�

When the emergency starter rope isused to start the engine, the start-in-gear protection device does not oper-ate. Make sure the remote control leveris in neutral. Otherwise the boat couldunexpectedly start to move, whichcould result in an accident.

�

Attach the engine stop switch lanyardto a secure place on your clothing, oryour arm or leg while operating theboat.

�

Do not attach the lanyard to clothingthat could tear loose. Do not route thecord where it could become entangled,preventing it from functioning.

�


1. Filter cup2. Water detection switch lead

1. Water detection switch coupler

1

2

ZMU05501

1

ZMU05500

Trouble Recovery

80


�

Make sure no one is standing behindyou when pulling the starter rope. Itcould whip behind you and injuresomeone.

�

An unguarded, rotating flywheel is verydangerous. Keep loose clothing andother objects away when starting theengine. 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, sparkplug wire, spark plug cap, or other elec-trical components when starting or op-erating the motor. You could get an

electrical shock.

EMU29581

Emergency starting engine

1. Remove the top cowling.2. Remove the flywheel cover.

3. Prepare the engine for starting. For fur-ther information, see page 43. Be surethe engine is in neutral and that the en-gine stop switch lanyard lock plate is at-tached to the engine stop switch.

4. Turn on the main switch.

5. Insert the knotted end of the emergencystarter rope into the notch in the flywheelrotor and wind the rope around the fly-wheel several turns clockwise.

6. Give a strong pull straight out to crankthe engine. Repeat if necessary.

WARNING

EWM00620

Do not install the top cowling when en-

ZMU04443

ZMU02334

ONSTARTOFF

ONSTARTOFF

ZMU04589

ON STARTOFF

ZMU01906

Trouble Recovery

81

gine is running.

EMU29670

Engine fails to operate

EMU29741

Low oil level warning activates

If the oil level is allowed to drop too low, thered segment will appear on the oil level indi-cator, the buzzer will sound, and enginespeed will be limited to about 2000 r/min. Ifthis happens, a reserve amount of oil can bepumped from the remote oil tank to the en-gine oil tank using the emergency switch.

WARNING

EWM01050

Be sure to stop the engine before per-

forming this procedure.

CAUTION:

ECM00900

�

If the emergency switch is held up toolong, too much oil will be pumped intothe engine oil tank, overflowing it. Re-lease the switch when oil reaches theupper level line on the engine oil tank.

�

Do not use this emergency procedureunless the oil level warning indicators

are working.

1. Remove the top cowling.2. Turn on the main switch.

3. Lift the emergency switch to pump re-serve oil into the engine oil tank from theremote oil tank.

4. After using the emergency switch, turnoff the main switch, then turn it back on.This resets the warning system to nor-

ZMU04444

1. Emergency switch

1. Engine oil tank2. Remote oil tank

ON STARTOFF

ZMU01906

1

ZMU04010

1 2ZMU01908

Trouble Recovery

82

mal operation. The yellow segment willcontinue to be displayed on the oil levelindicator.

5. Start the engine and return to the near-est port for more oil.

NOTE:

�

The maximum reserve oil capacity is 1500cm

3

(1.6 US qt, 1.31 Imp qt).

�

The oil-feed pump will not operate if theengine is tilted up more than 35°. Put theengine in the upright position (not tilted)

before using the emergency switch.

EMU29760

Treatment of submerged motor

If the outboard motor is submerged, immedi-ately take it to a Yamaha dealer. Otherwisesome corrosion may begin almost immedi-ately.If you cannot immediately take the outboardmotor to a Yamaha dealer, follow the proce-dure below in order to minimize engine dam-age.

EMU29790

Procedure

1. Thoroughly wash away mud, salt, sea-weed, and so on, with fresh water.

2. Remove the spark plugs and face thespark plug holes downward to allow anywater, mud, or contaminants to drain.

3. Drain the fuel from the vapor separator,fuel filter, and fuel line.

4. Feed fogging oil or engine oil throughthe intake manifold and spark plug holeswhile cranking with the emergency start-er rope.

5. Take the outboard motor to a Yamahadealer as soon as possible.

CAUTION:

ECM00400

Do not attempt to run the outboard motor

until it has been completely inspected.

ZMU01909

ZMU01910

ZMU01911

83

Consumer information

EMU29811

Important warranty information for U.S.A. and Canada


84


85

EMU29820

YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY


86


87


88

EMU29841

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

68F-9-19 Hyoshi 06.3.17 1:23 PM ページ 3

Printed in JapanMay 2006–0.2 × 1 ! Printed on recycled paper

68F-9-19 Hyoshi 06.3.17 1:23 PM ページ 4

YAMAHA MOTOR CO., LTD.MADE IN JAPANPAYS D'ORIGINE JAPON

OUTBOARD MOTOR WARRANTY REGISTRATION

ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD

Please complete and mail this card. This information is necessary to accurately register your unit for warranty.Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et

que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.

OUTBOARD MOTOR MODEL AND SERIAL NUMBER (From I.D. label on clamp bracket)MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation)

(For Dealer Use Only)(A l’usage du concessionnaire)YAMAHA DEALER NUMBERNO. DU CONCESSIONNAIRE YAMAHA

DEALER NAMENOM DU CONCESSIONNAIRE

DATE SOLDDATE DELIVRAISON

OWNER’S NAMENOM DUPROPRIÉTAIRE

ADDRESSADRESSE

PHONE NUMBER ( )NUMÉRO DE TÉLÉPHONE

USAGE(Check One)UTILISATION(En cocher un.)

PLEASURELOISIRCOMMERCIALCOMMERCIAL

MONTH DAY YEARMOIS JOUR ANNÉE

FIRST LASTPRÉNOM NOM DE FAMILLE

STREETRUE

CITY STATE/PROVINCE ZIPVILLE PROVINCE CODE POSTAL

Warranty card-04 2/17/03 2:41 PM Page 1

PLACEPOSTAGEHERE

ATTN: WARRANTY DEPARTMENT

Warranty card-04 2/17/03 2:41 PM Page 2

z200 / lz200 owner's manual - yamaha motor company lz200 owner’s manual 68f-28199-19 ... trim...

Documents