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  • Page 1

    OWNER’S MANUAL U.S.A.Edition LIT-18626-06-63 6N6-28199-1D...

  • Page 2

    EMU25060 ZMU01690 Read this owner’s manual carefully before operating your outboard motor.

  • Page 3: Important Manual Information

    EMU25110 tain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important OWNER’S MANUAL...

  • Page 4: Table Of Contents

    Table of contents General information ......1 indicators) ........18 Oil level indicator (digital type) ..18 Identification numbers record..1 Overheat warning indicator (digital Outboard motor serial number ..1 type) ..........18 Key number........1 Speedometer (digital type) ....18 Emission control information ...

  • Page 5

    Greasing ......... 49 IMPORTANT WARRANTY Cleaning and adjusting spark INFORMATION IF YOU USE plug ..........49 YOUR YAMAHA OUTSIDE THE Checking fuel system ...... 50 USA OR CANADA ...... 74 Inspecting fuel filter ......51 Cleaning fuel filter ......51 Inspecting idling speed ....

  • Page 6: General Information

    Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto- len. 1. Key number...

  • Page 7: Safety Information

    General information should give you an understanding of the motor and its operation. Before operating the boat, read any own- EMISSION CONTROL INFORMATION er’s or operator’s manuals supplied with it ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES. REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.

  • Page 8: Important Labels

    Never illegally discard (dump) the product. Attach the engine stop switch lanyard cord Yamaha recommends consulting the deal- to a secure place on your clothing, or your er on discarding the product. arm or leg while operating. If you acciden- Be informed about boating safety.

  • Page 9: Basic Boating Rules (rules Of The Road)

    General information United States Coast Guard and local agen- cies. You should be aware of these rules, and follow them whenever you encounter another vessel on the water. Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the Road.

  • Page 10: Rules When Encountering Vessels

    General information operator of the other vessel can see what you are doing. “The general prudential rule” This rule is called Rule 2 in the International Rules and says, “In obeying and construing these rules due regard shall be had to all dangers of naviga- tion and collision, and to any special circum- stances, which may render a departure from the above rules necessary in order to avoid...

  • Page 11: Other Special Situations

    General information or trawls are considered to be “fishing ves- sels” under the International Rules. Vessels with trolling lines are not considered fishing vessels. Fishing vessels have the right-of- way regardless of position. Fishing vessels cannot, however, impede the passage of other vessels in narrow channels.

  • Page 12

    General information This system uses buoys and signs with dis- tinctive shapes and colors to show regulato- ry or advisory information. These markers are white with black letters and orange boarders. They signify speed zones, restrict- ed areas, danger areas, and general infor- mation.

  • Page 13: Fueling Instructions

    General information ZMU01708 EMU25540 away from sparks, flames, or other Fueling instructions sources of ignition. EWM00010 Stop engine before refueling. WARNING Refuel in a well-ventilated area. Refuel GASOLINE AND ITS VAPORS ARE HIGH- portable fuel tanks off the boat. LY FLAMMABLE AND EXPLOSIVE! Take care not to spill gasoline.

  • Page 14: Gasoline

    Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Yamaha does not recommended gasohol containing methanol because it can cause fuel system damage or engine performance problems.

  • Page 15: Battery Specifications

    Yamaha outboard motors are fitted with pro- pellers chosen to perform well over a range For instructions on propeller removal and in- of applications, but there may be uses where stallation, see page 54.

  • Page 16: Basic Components

    Basic components EMU25796 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. ZMU04764 1. Top cowling 15. Digital tachometer* 2. Power trim and tilt switch 16. Digital speedometer* 3.

  • Page 17: Remote Control Lever

    Basic components 6. Throttle 7. Fully open EMU26201 Neutral interlock trigger To shift out of neutral, first pull the neutral in- terlock trigger up. 1. Power trim and tilt switch 2. Remote control lever 3. Neutral interlock trigger 4. Neutral throttle lever 5.

  • Page 18: Choke Switch

    Basic components adjuster counterclockwise. EWM00030 WARNING Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move throttle lever or grip, which could result in an accident. 1. Fully open 2. Fully closed EMU26221 Choke switch To activate the choke system, press in the...

  • Page 19: Choke Knob For Pull Type

    Basic components during normal operation. Loss of en- “ ” (off) gine power means the loss of most With the main switch in the “ ” (off) posi- steering control. Also, without engine tion, the electrical circuits are off, and the key power, the boat could slow rapidly.

  • Page 20: Power Trim And Tilt Switch On Bottom Engine Cowling

    Basic components ZMU03517 EMU26151 NOTE: Power trim and tilt switch on bottom For instructions on using the power trim and engine cowling tilt switch, see page 37. The power trim and tilt switch is located on EMU26241 the side of the bottom engine cowling. Press- Trim tab with anode ing the switch “...

  • Page 21: Tilt Support Lever For Power Trim And Tilt Or Hydro Tilt Model

    Basic components EMU26400 Top cowling release lever The top cowling can be removed by operat- ing the cowling release lever. Pulling the front lever unlocks the top cowling for remov- ZMU02525 1. Trim tab 2. Bolt 3. Cap ZMU03518 When installing the top cowling: Set the top cowling straight down onto the engine, being careful to avoid catch- ing spark plug wires or other wires.

  • Page 22: Flushing Device

    Basic components cable is operating correctly before rein- stalling the top cowling. When the release lever is operated, both the front and rear cowling hooks should be released at the same time. If not, adjust the rear clamp cable adjust- ers.

  • Page 23: Oil Level Indicators

    Basic components warning 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 status of the oil level. For details on how to read the indicators, see page 30.

  • Page 24: Trim Meter

    Basic components 3. Selector switch (for fuel sensor) EMU26610 Trim meter This gauge shows the trim angle of your out- board motor. 1. Speedometer 2. Fuel gauge 3. Trip meter/clock/voltmeter 4. Warning indicator(s) ZMU04581 NOTE: After the main switch is first turned on, all NOTE: segments of the display come on as a test.

  • Page 25: Hour Meter (digital Type)

    Basic components EMU26690 Trip meter This gauge displays the distance the boat has traveled since the gauge was last reset. Press the “ ” (mode) button repeatedly until the indicator on the face of the gauge points to “ ” (trip). To reset the trip meter to zero, press the “...

  • Page 26: Fuel Gauge

    Get back to the port within troll- ECM00860 ing engine speed. CAUTION: The Yamaha fuel tank sensor differs from conventional sensors. Incorrectly setting the selector switch on the gauge will give false readings. Consult your Yamaha dealer on how to correctly set the selec- tor switch.

  • Page 27: Warning System

    Do not continue to operate the engine if a ZMU04766 warning device has activated. Consult your Yamaha dealer if the problem can- The buzzer will sound (if equipped on the not be located and corrected. tiller handle, remote control box, or main switch panel).

  • Page 28: Oil Level Warning And Oil Filter Clogging Warning

    Basic components The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel). ZMU02630 EMU26845 Oil level warning and oil filter ZMU03025 clogging warning Oil injection models If the warning system has been activated, This engine has an oil level warning system.

  • Page 29

    Basic components ZMU01952 1. Oil filter...

  • Page 30: Operation

    Operation EMU26901 specific boat and motor combination. Installation EWM00830 ECM00110 WARNING CAUTION: Improper mounting of the outboard mo- Incorrect engine height or obstructions tor could result in hazardous conditions to smooth water flow (such as the design such as poor handling, loss of control, or or condition of the boat, or accessories fire hazards.

  • Page 31: Breaking In Engine

    Be sure to mix gasoline and oil complete- mine the optimum mounting height. Con- ly, otherwise the engine may be dam- sult your Yamaha dealer boat aged. manufacturer for further information on de- EMU30310 termining the proper mounting height.

  • Page 32: Preoperation Checks

    Operation throttle to 3000 r/min or less. are tight (if equipped Yamaha fuel tank or Second hour: boat tank). Accelerate at full throttle onto plane, Be sure the fuel tank is positioned on a se- then reduce engine speed to three-quar- cure, flat surface, and that the fuel line is ter throttle (approximately 4000 r/min).

  • Page 33: Filling Fuel And Engine Oil

    Yamaha recommends the use of Ring Free Fuel Additive, available from Be sure to take the above steps when op- your Yamaha dealer. Ring Free Fuel Addi- erating the engine after a long period of tive has repeatedly proven its ability to clean storage.

  • Page 34

    Imp gal) can be added, and the bottom oil level line indicates approximately 3.8 L (1 US gal, 0.8 Imp gal) can be added. Turn on the main switch. The Yamaha oil injection system will automatically feed oil from the remote oil tank to the engine oil tank.

  • Page 35: Oil Level Indicator Operation

    Operation 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 Oil level warning Engine oil Remote oil indicator indicator (analog Remarks tank tank (digital tachometer) tachometer)

  • Page 36: Operating Engine

    Operation EMU27450 Operating engine EMU27480 Feeding fuel EWM00420 WARNING Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you. EMU27490 When the air vent screw is loosened, Starting engine...

  • Page 37

    Operation lanyard where it could become entan- gled, preventing it from functioning. Avoid accidentally pulling the lanyard during normal operation. Loss of en- gine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

  • Page 38: Warming Up Engine

    Immediately after the engine starts, re- the lower case or the cooling water pilot lease the main switch and allow it to re- hole is blocked. Consult your Yamaha turn to “ ” (on). dealer if the problem cannot be located ECM00191 and corrected.

  • Page 39: Forward

    Operation EMU27763 lever quickly and firmly from neutral to Forward (tiller handle and remote reverse. control models) Tiller control models Place the throttle grip in the fully closed position. Move the gear shift lever quickly and firmly from neutral to forward. Remote control models Pull up the neutral interlock trigger (if equipped) and move the remote control...

  • Page 40: Trimming Outboard Motor

    Operation engine stop switch, then turning the main switch to “ ” (off). EMU27861 Trimming outboard motor The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help im- prove performance and fuel economy while reducing strain on the engine.

  • Page 41: Adjusting Boat Trim

    Operation Adjust the outboard motor trim angle using results in less drag, greater stability and effi- the power trim and tilt switch. ciency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden- cy to steer to one side or the other.

  • Page 42: Tilting Up And Down

    Operation Bow Down bracket. Too much trim-in causes the boat to “plow” EWM00250 through the water, decreasing fuel economy WARNING and making it hard to increase speed. Oper- Leaking fuel is a fire hazard. If there is a ating with excessive trim-in at higher speeds fuel joint on the outboard motor, discon- also makes the boat unstable.

  • Page 43: Procedure For Tilting Down

    Operation sure. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim and tilt switch “ ” (down) to retract the trim rods. ECM00250 CAUTION: Be sure to retract the trim rods complete- ly during mooring.

  • Page 44: Cruising In Shallow Water

    Operation to allow operation in shallow water. EWM00660 WARNING Place the gear shift in neutral before setting up for shallow water cruising. Return the outboard motor to its normal position as soon as the boat is back in deeper water. ECM00260 ZMU03998 CAUTION:...

  • Page 45: Cruising In Other Conditions

    NOTE: For cooling system flushing instructions, see page 42. Cruising in turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (not available for some models) if you use the outboard motor in turbid (muddy) water...

  • Page 46: Maintenance

    Performance: Power trim and tilt Full throttle operating range: Propeller mark: 4500–5500 r/min Maximum output: Fuel and oil: 84.6 kW@5000 r/min (115 HP@5000 Recommended fuel: r/min) Regular unleaded gasoline Idling speed (in neutral): Min. pump octane: 750 ±50 r/min Engine:...

  • Page 47: Transporting And Storing Outboard Motor

    Spark plug: sition using a motor support device such as 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) a transom saver bar. Consult your Yamaha Propeller nut: dealer for further details. 55.0 Nm (40.6 ft-lb) (5.61 kgf-m)

  • Page 48

    Stabilizer” (Part No. LUB-FUELC- 12-00) to each gallon of fuel. NOTE: The use of “Yamaha Fuel Conditioner and Stabilizer” eliminates the need to drain the fuel system. Consult your Yamaha dealer or other qualified mechanic if the fuel system is to be drained instead.

  • Page 49: Lubrication (oil Injection Models)

    Batteries also generate explosive hydro- seal. Seal replacement should be per- gen gas; therefore, you should always formed by an authorized Yamaha dealer follow these preventive measures: prior to use. Charge batteries in a well-ventilated ar- Grease all grease fittings.

  • Page 50: Flushing Power Unit

    Maintenance tilled water. 2. Garden hose connector Store the battery on a level surface in a 3. Garden hose cool, dry, well-ventilated place out of di- Screw the garden hose connector onto a rect sunlight. garden hose which is connected to a Once a month, check the specific gravity fresh water supply.

  • Page 51: Checking Painted Surface Of Motor

    EMU28510 Replacement parts If replacement parts are necessary, use only genuine Yamaha parts or parts of the same type and of equivalent strength and materi- als. Any part of inferior quality may malfunc- tion, and the resulting loss of control could ZMU02550 endanger the operator and passengers.

  • Page 52: Maintenance Chart

    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. Initial Every 50 hours Item...

  • Page 53

    Maintenance Initial Every 50 hours Item Actions 10 hours hours (6 hours (1 (1 month) months) months) year) Inspection / replace- Water pump ment Oil pump Inspection / adjustment Oil tank water drain Inspection / cleaning Cleaning / adjustment / Spark plug(s) replacement...

  • Page 54: Greasing

    Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) ZMU04149 sparks, which could lead to explosion or EMU28952 Cleaning and adjusting spark plug fire. EWM00560 The spark plug is an important engine com- WARNING ponent and is easy to inspect. The condition...

  • Page 55: Checking Fuel System

    Check the fuel lines for leaks, crack, or mal- 1. Spark plug gap function. If a problem is found, your Yamaha 2. Spark plug I.D. mark (NGK) dealer or other qualified mechanic should re- pair it immediately.

  • Page 56: Inspecting Fuel Filter

    If any water is found in the pors are flammable and explosive. If you have any question about properly fuel, the Yamaha portable fuel tank or other fuel tanks should be checked and doing this procedure, consult your Yamaha dealer.

  • Page 57: Inspecting Idling Speed

    There is a water trap at the bottom of the en- filter assembly. gine oil tank. If water or foreign matter is vis- Run the engine and check the filter and ible in this trap, consult your Yamaha dealer. lines for leaks. EMU29041 Inspecting idling speed...

  • Page 58: Water Leakage

    Maintenance EMU29130 Water leakage Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head, and body cylinder. EMU29153 Checking power trim and tilt system EWM00430 WARNING Never get under the lower unit while it ZMU04155 is tilted, even when the tilt support lever 1.

  • Page 59: Checking Propeller

    Maintenance that the tilt rod and trim rods operate smoothly. NOTE: Consult your Yamaha dealer if any operation is abnormal. EMU29171 Checking propeller EWM00321 WARNING ZMU01897 You could be seriously injured if the en- Checkpoints gine accidentally starts when you are Check each of the propeller blades for near the propeller.

  • Page 60: Removing The Propeller

    Severe injury could the propeller could come off during op- occur if the outboard motor accidental- eration and be lost. ly falls. Apply Yamaha marine grease or a cor- Tilt the outboard motor so that the gear...

  • Page 61: Inspecting And Replacing Anode(s)

    ECM00720 pair of the lower unit seals. CAUTION: NOTE: Do not paint anodes, as this would render For disposal of used oil consult your Yamaha them ineffective. dealer. NOTE: With the outboard motor in a vertical po- Inspect ground leads attached to external sition, and using a flexible or pressur- anodes on equipped models.

  • Page 62: Checking Battery (for Electric Start Models)

    Maintenance followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries also generate explosive hydro- gen gas; therefore, you should always follow these preventive measures: Charge batteries in a well-ventilated ar- Keep batteries away from fire, sparks, ZMU01901 or open flames (for example: welding equipment, lighted cigarettes, and so...

  • Page 63: Connecting The Battery

    NOTE: Consult a Yamaha dealer when charging or 1. Red cable re-charging batteries. 2. Black cable 3.

  • Page 64

    Maintenance ing paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion. ZMU01943...

  • Page 65: Trouble Recovery

    Q. Has fuel pump malfunctioned? If your outboard motor requires repair, bring A. Have serviced by a Yamaha dealer. it to your Yamaha dealer. If the engine trouble warning indicator is Q. Are spark plug(s) fouled or of incorrect flashing, consult your Yamaha dealer.

  • Page 66

    Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Is fuel joint connection incorrect? A.

  • Page 67

    Trouble Recovery A. Have serviced by a Yamaha dealer. Q. Are weeds or other foreign matter tangled on gear housing? Q. Is load on boat improperly distributed? A. Remove foreign matter and clean lower A. Distribute load to place boat on an even unit.

  • Page 68: Temporary Action In Emergency

    EWM00630 Q. Is steering pivot loose or damaged? WARNING A. Tighten or have serviced by a Yamaha Be sure to use the specified fuse. An in- dealer. correct fuse or a piece of wire could allow EMU29432 excessive current flow.

  • Page 69: Power Trim And Tilt / Power Tilt Will Not Operate

    NOTE: ate. Make sure the remote control lever Consult your Yamaha dealer if the new fuse is in neutral. Otherwise the boat could immediately blows again. unexpectedly start to move, which could result in an accident.

  • Page 70: Emergency Starting Engine

    Trouble Recovery engine is running. Do not install the starter mechanism or top cowling after the engine is running. Do not touch the ignition coil, spark plug wire, spark plug cap, or other elec- trical components when starting or op- erating the motor.

  • Page 71: Engine Fails To Operate

    Trouble Recovery and start the engine. Repeat if neces- sary. ON START ZMU01906 Lift the emergency switch to pump re- ZMU03466 serve oil into the engine oil tank from the EMU29670 remote oil tank. Engine fails to operate EMU29741 Low oil level warning activates If the oil level is allowed to drop too low, the red segment will appear on the oil level indi- cator, the buzzer will sound, and engine...

  • Page 72: Top Cowling Does Not Unlock

    The oil-feed pump will not operate if the If the outboard motor is submerged, immedi- engine is tilted up more than 35°. Put the ately take it to a Yamaha dealer. Otherwise engine in the upright position (not tilted) some corrosion may begin almost immedi- before using the emergency switch.

  • Page 73

    Feed fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking with the manual starter or emergency starter rope. ZMU01911 Take the outboard motor to a Yamaha dealer as soon as possible. ECM00400 CAUTION: Do not attempt to run the outboard motor...

  • Page 74: Consumer Information

    Consumer information EMU29811 Important warranty information for U.S.A. and Canada...

  • Page 75

    Consumer information...

  • Page 76: Yamaha Motor Corporation, U.s.a. Outboard Motor Two Year Limited Warranty


  • Page 77

    Consumer information...

  • Page 78

    Consumer information...

  • Page 79: Important Warranty Information If You Use Your Yamaha Outside The Usa Or Canada


  • Page 80

    Printed in Japan May 2005–0.3 × 1 ! Printed on raecycled paper...

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