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F40 Owner`s Manual

1. 39 Adjusting trim angle eee 40 Adjusting trim angle for hydro tilt models iera tes 41 Adjusting boat trim sse 41 Tilting up and down 42 Procedure for tilting up hydro tilt models 42 Procedure for tilting up power trim and tilt models power tilt Models khan 43 Procedure for tilting down manual and hydro tilt models 04 45 Procedure for tilting down power trim and tilt models power tilt models alge 45 Cruising in shallow water 46 Hydro tilt models 46 Power trim and tilt models power tilts MOdElSt 24 ea Aves een 47 Cruising in other conditions 48 Maintenance 49 Specifications 49 Transporting and storing outboard MOIOT En Qt EAT 50 Storing outboard motor 50 Procedure 51 LUbrications sr Mrs ns 52 Cleaning and anticorrosion MASU E here bei Muse 52 Battery care 52 Flushing power unit 53 Cleaning the outboard motor 54 Checking painted surface of Table of contents MOTO cet ee ees ocd er rte 54 Periodic maintenance e 54 Replacement parts 54 Maintenance chart 56 Maintenance chart additional 57 Greasing ssh 58 Cleaning and adjusting spark plug te Keni Gia mn 58 Checking fuel system 59 Checking fuel filter 60 Inspecting idling speed 60 Changing engine Oil
2. eeee 60 Checking wiring and connectors 62 Exhaust leakage 62 Water leakage 62 Engine oil leakage 62 Checking power trim and tilt power tilt system n e 62 Checking propeller eceeeee 63 Removing the propeller n se 64 Installing the Propeller 64 Changing gear oil 65 Cleaning fuel tank 66 Inspecting and replacing Anode S ici wd ts 66 Checking battery for electric start models ap haiie Beatie 67 Connecting the battery 68 Disconnecting the battery 68 Checking top Cowling ecee 68 Coating the boat bottom 68 Trouble Recovery 70 Troubleshooting 70 Temporary action in emergency 73 Impact damage se 73 Replacing fuse s e 73 Power trim and tilt power tilt will NOLOPC Ale series 74 Starter will not operate 0 101 74 Emergency starting engine 75 Treatment of submerged motor 76 Procedure 76 Consumer information s 212 77 Important warranty information for U S A and Canada ce 77 Table of contents YAMAHA MOTOR CORPORATION U S A FOUR STROKE OUTBOARD MOTOR THREE YEAR LIMITED WARRANTY ccc seesseeeeeeeeeeeeees 79 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA nsen 81 EMU25170 Identification numbers record EMU25183 Outboard motor serial number
3. 1 Manual valve screw 2 Put the engine in the desired position then tighten the manual valve screw by turning it counterclockwise EMU29532 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 with an emer gency starter rope EWMO1021 e Use this procedure only in an emergen cy to return to the nearest port for re pairs e When the emergency starter rope is used to start the engine the start in gear protection device does not oper ate Make sure the remote control lever is in neutral Otherwise the boat could unexpectedly start to move which could result in an accident e Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg while operating the boat e Do not attach the lanyard to clothing that could tear loose Do not route the cord where it could become entangled Trouble Recover preventing it from functioning 3 Remove the starter flywheel cover after e Avoid accidentally pulling the lanyard removing the bolt s 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 e Make sure no one is standing behind you when pulling the starter rope It could whip behind you and injure someone e An unguarded rotating fly
4. 22 Digital tachometer sece 22 Low oil pressure warning INGICALOF rs lus aaa 23 Low oil pressure warning INCICALOM 25 54 return 23 Overheat warning indicator 23 Overheat warning indicator digital Ype ficial i eaten 24 Trim meter 24 Trim meter digital type 4 24 Hour meter digital type 24 Warning system 25 Overheat warning 25 Low oil pressure warning e 26 Operation 27 Installation 27 Mounting the outboard motor 27 Breaking in engine e 28 Procedure for 4 stroke models 28 Preoperation checks 6 28 Fuel acta hii nn aion 28 COMMONS sidi re nt des 29 ENQING issih atin deena ks 29 Checking the engine oil level 29 Filling fuel 29 Ring Free Fuel Additive 30 Operating engine eeeee 30 Feeding fuel portable tank 30 Starting engine 31 Warming up engine 35 Manual start and electric start MOGEIS ia sight hehe aai 35 Shifting 0 eee e eee eeeteeeeeteeeteteeeteees 35 Forward tiller handle and remote control Models 35 Reverse automatic reverse lock and power trim and tilt models 36 Reverse manual tilt and hydro tilt Models kassai iniae teas 37 Stopping engine s es 38 Procedure sinn acai ea aah 38 Trimming outboard motor
5. 2 Operate each of the power trim and tilt switches power tilt switches to check that all switches work 3 Tilt the outboard motor up and check that the trim and tilt rod the tilt rod is pushed out completely 4 Check that the trim and tilt rod the tilt rod is free of corrosion or other flaws 5 Tilt the outboard motor down Check that the trim and tilt rod the tilt rod oper ates smoothly NOTE Consult your Yamaha dealer if any operation is abnormal EMU29171 Checking propeller EWM00321 You could be seriously injured if the en gine accidentally starts when you are near the propeller e Before inspecting removing or install ing the propeller remove the spark plug caps from the spark plugs Also place the shift control in neutral turn the main switch to OFF off and re move the key and remove the lanyard from the engine stop switch Turn off the battery cut off switch if your boat Maintenance has one e Do not use your hand to hold the pro peller when loosening or tightening the propeller nut Put a wood block be tween the anti cavitation plate and the propeller to prevent the propeller from turning ZMU01897 Checkpoints e Check each of the propeller blades for wear erosion from cavitation or ventila tion or other damage e Check the propeller shaft for damage e Check the splines shear pin for wear or damage e Check for fish line tangled around the pro
6. Instead take the outboard motor to a Yamaha dealer You should periodically re move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should re place the spark plug with another of the cor rect type Standard spark plug DPR6EA 9 Before fitting the spark plug measure the electrode gap with a wire thickness gauge adjust the gap to specification if necessary ZMU02179 1 Spark plug gap 2 Spark plug I D mark NGK Spark plug gap 0 8 0 9 mm 0 031 0 035 in When fitting the plug always clean the gas ket surface and use a new gasket Wipe off any dirt from the threads and screw in the spark plug to the correct torque Spark plug torque 18 0 Nm 13 3 ft lb 1 84 kgf m NOTE If a torque wrench is not available when you are fitting a spark plug a good estimate of the correct torque is 1 4 to 1 2 a turn past fin ger tight Have the spark plug adjusted to the correct torque as soon as possible with a torque wrench EMU28962 Checking fuel system EWM00060 Gasoline and its vapors are highly flam mable and explosive Keep away from sparks cigarettes flames or other Maintenance sources of ignition EWM00910 Leaking fuel can result in fire or explo sion e Check for fuel leakage regularly e If any fuel leakage is found the fuel
7. ZMU04076 EMU28090 Power trim and tilt models power tilt models The outboard motor can be tilted up partially to allow operation in shallow water EWMO00660 e Place the gear shift in neutral before setting up for shallow water cruising e Return the outboard motor to its normal position as soon as the boat is back in deeper water ECM00260 CAUTION Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above 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 power tilt models 1 Place the remote control lever gear shift lever in neutral 47 Operation ZMU04077 e L ZMU05215 ZMU05226 2 Slightly tilt the outboard motor up to the 3 To return the outboard motor to the nor desired position using the power trim mal running position press the power and tilt switch power tilt switch trim and tilt switch power tilt switch and slowly tilt the outboard motor down EMU28192 up f Cruising in other conditions 4 C7 Cruising in salt water After operating in salt water flush the cooling water passages with fresh water to prevent them from becoming clogged with salt de posits ZMU01935 NOTE For cooling system flushing instructions see page 50 Cruising in turbid water Yamaha strongly recommends
8. peller shaft 63 Maintenance ZMU01803 e Check the propeller shaft oil seal for dam age NOTE If the shear pin equipped it is designed to break if the propeller hits a hard underwater obstacle to help protect the propeller and drive mechanism The propeller will then spin 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 out using a pair of pliers 2 Remove the propeller nut washer and spacer if equipped 1 amp w 2 EA 5 ZMU01804 1 Cotter pin 2 Propeller nut 3 Washer 4 Spacer 64 5 Propeller 6 Thrust washer 3 Remove the propeller and thrust wash er EMU30670 Installing the Propeller EMU29231 Spline models ECM00340 CAUTION e Be sure to install the thrust washer be fore installing the propeller otherwise the lower case and propeller boss could be damaged e Be sure to use a new cotter pin and bend the ends over securely Otherwise the propeller could come off during op eration and be lost 1 Apply Yamaha marine grease or a cor rosion resistant grease to the propeller shaft 2 Install the spacer if equipped thrust washer and propeller on the propeller shaft 3 Install the spacer if equipped and the washer Tighten the propeller nut to the specified torque 4 Align the propeller nut with the propeller shaft hole Insert a new
9. 19 Basic components ZMU01720 L ZMU05211 EMU26151 Power trim and tilt switch on bottom engine cowling The power trim and tilt switch is located on the side of the bottom engine cowling Press ing the switch UP up trims the outboard motor up then tilts it up Pressing the switch DN down tilts the outboard motor down and trims it down When the switch is re leased the outboard motor will stop in its current position EWM01030 Use the power trim and tilt switch located on the bottom engine cowling only when the boat is at a complete stop with the en gine off Attempting to use this switch while the boat is moving could increase the risk of falling overboard and could distract the operator increasing the risk of collision with another boat or an obsta 20 cle ZMU04038 NOTE For instructions on using the power trim and tilt switch see page 42 EMU26241 Trim tab with anode The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force EWM00840 An improperly adjusted trim tab could cause difficult steering Always test run after the trim tab has been installed or re placed to be sure steering is correct Be sure 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
10. 50 whether in a boat or car e DO NOT fill fuel container to maximum capacity Gasoline will expand consid erably as it warms up and can build up pressure in the fuel container This can cause fuel leakage and a potential fire hazard EWM00700 Never get under the lower unit while it is tilted even if a motor support bar is used Severe injury could occur if the outboard motor accidentally falls ECM00660 CAUTION Do not use the tilt support lever or knob when trailering the boat The outboard motor could shake loose from the tilt sup port and fall If the motor cannot be trail ered in the normal running position use an additional support device to secure it in the tilt position The outboard motor should be trailered and stored in the normal running position If there is insufficient road clearance in this position then trailer the outboard motor in the tilt po sition using a motor support device such as a transom saver bar Consult your Yamaha dealer for further details EMU28241 Storing outboard motor When storing your Yamaha outboard motor for prolonged periods of time 2 months or longer several important procedures must be performed to prevent excessive damage It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage However you the owner with a minimum of tools can perform the fol lowing procedures ECM01080 CAUTION e To prevent problems which
11. Battery requirement Battery specifications Without a rectifier or Rectifier Re gulator sissins ins Propeller selection Start in gear protection Basic components ssssssssnsennnnnee Main components Fuel tank e a ae e eneee aitaan Fuel jOint oireina Fuel gauge Fuel tank cap Air vent screw Remote control Remote control lever Neutral interlock trigger Neutral throttle lever Tiller handle Gear shift lever Throttle grip Throttle indicator Throttle friction adjuster Engine stop lanyard switch Engine stop button Manual starter handle 6 Main switch 18 Steering friction adjuster 18 Steering friction adjuster 19 Power trim and tilt switch on remote control or tiller handle 19 Power trim and tilt switch on bottom engine cowling 20 Trim tab with anode 20 Tilt lock mechanism 21 Tilt support knob 21 Top cowling lock lever s turn type 21 Flushing device 21 Warning indicator 22 Tachometer
12. Label EWM01300 e This engine is equipped with a neutral starting device e The engine will not start unless the shift control is in neutral position EMU25465 Caution labels ZMU04101 ZMU05276 General information EMU25473 Label ECM01191 CAUTION Transport and store the engine only as shown Otherwise engine damage could result from leaking oil EMU25500 Basic boating rules Rules of the road Just as there are rules which apply when you are driving on streets and high ways there are waterway rules which apply when you are driving your boat These rules are used internationally and are also enforced by the United States Coast Guard and local 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 The rules presented here in your Owner s Manual are condensed and have been pro vided for your convenience only Consult your local U S Coast Guard Auxiliary or De partment of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat EMU25510 Steering and sailing rules and sound signals Whenever two vessels on the water meet one another one vessel has the right of way it is called the stand on vessel The vessel which does not have the right of way
13. This label is attached to the clamp bracket or the swivel bracket ZMU04029 1 Manufactured date label location YAMAHA Manufactured ZMU01701 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 ZMU04977 1 Star labels location EMU25280 One Star Low Emission The one star label identifies engines that meet the Air Resources Board s 2001 ex haust emission standards Engines meeting these standards have 75 lower emissions than conventional carbureted two stroke en gines These engines are equivalent to the U S EPA s 2006 standards for marine en gines LOW Irn ZMU01702 EMU25290 Two Stars Very Low Emission The two star label identifies engines that meet the Air Resources Board s 2004 ex haust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines ZMU01703 EMU25300 Three Stars Ultra Low Emission The three star label identifies engines that meet the Air Resources Board s 2008 ex haust emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission engines ZMU01704 EMU25362 Safety information e Before mounting or operating the outboard motor read this entire manual Reading it should
14. Tiller handle To change direction move the tiller handle to the left or right as necessary ZMU05203 EMU25922 Gear shift lever Pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern 15 Basic components ZMU05204 1 Forward F 2 Neutral N 3 Reverse R EMU25941 Throttle grip The throttle grip is on the tiller handle Turn the grip counterclockwise to increase speed and clockwise to decrease speed ZMU05205 EMU25961 Throttle indicator The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position Choose the setting that offers the best performance and fuel economy for the desired operation 16 ey CC y oa ZMU05206 1 Throttle indicator EMU25971 Throttle friction adjuster A friction device provides adjustable resis tance to movement of the throttle grip or the remote control lever and can be set accord ing to operator preference To increase resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise EWMO0031 Do not overtighten the friction adjuster If there is too much resistance it could be difficult to move the remote control lever or throttle grip which could result in an accident Z
15. Valve clearance cold engine EX 0 25 0 35 mm 0 0098 0 0138 in Min cold cranking amps CCA SAE F40TR 380 0A Min marine cranking amps MCA ABYC F40TR 502 0A Min reserve capacity RC SAE F40TR 124 minutes Alternator output for battery DC 15 0A Drive unit Gear positions Forward neutral reverse Gear ratio 2 00 26 13 Trim and tilt system F40MH Hydro tilt F40TR Power trim and tilt Propeller mark G Fuel and oil 49 Maintenance Recommended fuel Regular unleaded gasoline Min pump octane 86 Fuel tank capacity 25 L 6 60 US gal 5 50 Imp gal Recommended engine oil 4 stroke outboard motor oil Engine oil grade API API SE SF SG SH SJ SL Engine oil type SAE SAE10W30 or SAE10W40 Lubrication Wet sump Engine oil quantity excluding oil filter 2 0 L 2 11 US qt 1 76 Imp qt Recommended gear oil Hypoid gear oil SAE 90 Gear oil quantity 430 0 cm 14 54 US oz 15 17 Imp oz Tightening torque for engine Spark plug 18 0 Nm 13 3 ft lb 1 84 kgf m Propeller nut 40 0 Nm 29 5 ft lb 4 08 kgf m Engine oil drain bolt 18 0 Nm 13 3 ft lb 1 84 kgf m Engine oil filter 18 0 Nm 13 3 ft lb 1 84 kgf m EMU28222 Transporting and storing outboard motor EWM00690 e Leaking fuel is a fire hazard When transporting and storing the outboard motor close the air vent screw and fuel cock to prevent fuel from leaking e USE CARE when transporting fuel tank
16. 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 Sailing vessel right of way Sailing vessels should normally be given the right 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 any fishing vessel 3 In a narrow channel a sailing vessel should not hamper the safe passage of a power driven vessel which can navi gate only in such a channel Reading buoys and other markers The waters of the United states are marked for safe navigation by the lateral system of buoyage Simply put buoys and markers have an arrangement of shapes colors numbers and lights to show which side of the buoy a boater should pass on when navigat ing in a particular direction The markings on these buoys are oriented from the perspec tive of being entered from seaward the boat er is going towards the port This means that red buoys are passed on the starboard right side when proceeding from open wa General information 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 and black buoys to starboard Many bodies of wat
17. is called the give way or burdened vessel These rules determine which vessel has the right of way and what each vessel should do General information Stand on vessel The vessel with the right of way has the duty to continue its course and speed except to avoid an immediate collision When you maintain your direction and speed the other vessel will be able to determine how best to avoid you Give way vessel The vessel which does not have the right of way has the duty to take positive and timely action to stay out of the way of the Stand On vessel Normally you should not cross in front of the vessel with the right of way You should slow down or change directions brief ly and pass behind the other vessel You should always move in such a way that the 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 immediate danger In other words follow the standard rules ex cept when a collision will occur unless both vessels try to avoid each other If that is the case both vessels become Give Way ves sels EMU25520 Rules when encountering vessels There are three main situations
18. The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto len ZMU04028 1 Outboard motor serial number location YAMAHA DE EE D Y Y Y YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON ZMU01692 EMU25190 Key number If a main key switch is equipped with the mo tor the key identification number is stamped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key General information ZMU01693 ZMU01694 1 Key number EMU25221 Emission control information EMU25230 North American models This engine conforms to U S Environmental Protection Agency EPA regulations for ma rine SI engines See the label affixed to your engine for details EMU25242 Approval label of emission control certif icate This label is attached to the bottom cowling New Technology 4 stroke HPDI EM ZMU04975 1 Approval label location General information EMISSION CONTROL INFORMATION EM SPARK PLUG G 4 FUEL GASOLINE ikw VALVE LASH mm INT O LTD DISPLACEMENT ADVERTISED POWE YAMAHA MOTO ZMU05159 EMU25262 Manufactured date label
19. The starter can also be damaged If the engine will not start after 5 seconds of cranking return the main switch to ON on wait 10 seconds then crank the engine again NOTE e When the engine is cold it needs to be warmed up For further information see page 35 e If the engine is warm and fails to start open the throttle slightly and try to start the engine again If the engine still fails to start see page 70 EMU27670 Warming up engine EMU27710 Manual start and electric start models 1 After starting the engine allow it to idle for 3 minutes to warm up Failure to do so will shorten engine life 2 Be sure the low oil pressure warning in dicator goes off after starting the engine 3 Check for a steady flow of water from the cooling water pilot hole ECM00210 CAUTION e If the low oil pressure warning indicator does not go off after the engine starts stop the engine Otherwise serious en gine damage could occur Check the oil level and add oil if necessary Consult your Yamaha dealer if the cause for the low oil pressure warning indicator can not be found e Acontinuous flow of water from the pi lot hole shows that the water pump is pumping water through the cooling passages If water is not flowing out of the pilot hole at all times while the en gine is running overheating and seri ous damage could occur Stop the engine and check whether the cooling water inlet on the lower case
20. Therefore while this manual contains the most current prod uct information available at the time of print ing there may be minor discrepancies between your machine and this manual If there is any question concerning this manu al please consult your Yamaha dealer NOTE The F40MH F40ER F40TR and the stan dard accessories are used as a base for the explanations and illustrations in this manual Therefore some items may not apply to ev ery model EMU25110 F40 OWNER S MANUAL 2006 by Yamaha Motor Corporation USA 1st edition April 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation USA is expressly prohibited Printed in Japan P N LIT 18626 07 10 Table of contents General information 00008 Identification numbers record Outboard motor serial number Key number Emission control information North American models Star labels Safety information Important labels Warning labels Caution labels Basic boating rules Rules of the TOAD ieissa inne wits Steering and sailing rules and sound signals Rules when encountering vessels Other special situations Fueling instructions Gasoline ss weenie Engine oik Jest ay
21. a greater operating load a smaller pitch propeller is more suit able as it enables the correct engine speed to be maintained Conversely a larger pitch propeller is more suitable for a smaller oper ating load Yamaha dealers stock a range of propellers and can advise you and install a propeller on your outboard that is best suited to your ap plication 11 General information ZMU04604 1 Propeller diameter in inches 2 Propeller pitch in inches 3 Type of propeller propeller mark NOTE Select a propeller which will allow the engine to reach the middle or upper half of the oper ating range at full throttle with the maximum boat load If operating conditions such as light boat loads then allow the engine r min to rise above the maximum recommended range reduce the throttle setting to maintain the engine in the proper operating range For instructions on propeller removal and in stallation see page 63 EMU25770 Start in gear protection Yamaha outboard motors or Yamaha ap proved remote control units are equipped with start in gear protection device s This feature permits the engine to be started only when it is in neutral Always select neutral before starting the engine 12 Basic components EMU25799 NOTE Main components May not be exactly as shown also may not be included as standard equipment on all mod els F40 1 Top cowling 2 Top cowling lock lever 3 Drain sc
22. angle of your out board motor t N oya 0 E va ZMU04581 NOTE Memorize the trim angles that work best for your boat under different conditions Adjust 24 the trim angle to the desired setting with the power trim and tilt switch EMU26620 Trim meter digital type This meter shows the trim angle of your out board motor NOTE a e Memorize the trim angles that work best for your boat under different conditions Adjust the trim angle to the desired using the power trim and tilt switch e If the trim angle of your motor exceeds the trim operating range the top segment on the trim meter display will blink TACH ak my ZMU01740 EMU26650 Hour meter digital type This meter shows the number of hours the engine has been run It can be set to show the total number of hours or the number of hours for the current trip The display can also be turned on and off Basic components TACH af A ZMU01741 e Changing the display format e Pressing the mode mode button chang es the display format in the following pat tern e Total hours Trip hours Display off e Resetting the trip hours e Simultaneously pressing the set set and mode mode buttons for more than 1 second while the trip hours are displayed resets the trip counter to O zero NOTE The total number of hours the engine has been run cannot be reset EMU268
23. are exclud ed from warranty coverage Specific parts excluded from the second and third year of warranty if applicable are e Top and Bottom Cowling e Electric Components other than ignition system Rubber Components such as hoses tubes rubber seals fittings and clamps TRANSFER OF WARRANTY Transfer of the warranty from the original purchaser to any subsequent purchaser is possible by having the motor inspected by an authorized Yamaha Outboard Motor Dealer and requesting the dealer to submit a change of registration to Yamaha Motor Corporation U S A within ten 10 days of the transfer YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSE QUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION USA 1270 Chastain Road K
24. cotter pin in the hole and bend the cotter pin ends ZMU02063 NOTE If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque tighten the nut further to align it with the hole EMU29282 Changing gear oil EWM00800 e Be sure the outboard motor is securely fastened to the transom or a stable stand You could be severely injured if the outboard motor falls on you e Never get under the lower unit while it is tilted even when the tilt support lever or knob is locked Severe injury could occur if the outboard motor accidental ly falls 1 Tilt the outboard motor so that the gear oil drain screw is at the lowest point pos sible 2 Place a suitable container under the gear case 3 Remove the gear oil drain screw and gasket ZMU04090 1 Gear oil drain screw 2 Oil level plug NOTE e lf a magnetic gear oil drain screw is Maintenance equipped remove all metal particles from the screw before installing it e Always use new gaskets Do not reuse the removed gaskets 4 Remove the oil level plug and gasket to allow the oil to drain completely ECM00710 CAUTION Inspect the used oil after it has been drained If the oil is milky water is getting into the gear case which can cause gear damage Consult a Yamaha dealer for re pair of the lower unit seals NOTE For disposal of used oil Yamaha dealer consult your 5 With th
25. gear protection device prevents the engine from starting except when in neu tral 2 Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg Then install the lock plate on the other end of the lanyard into the en gine stop switch EWM00120 e Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg while operating e Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning e Avoid accidentally pulling the lanyard 34 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 ZMU01772 w Turn the main switch to ON on Turn the main switch to START start and hold it for a maximum of 5 seconds ON START I a ZMU01774 5 Immediately after the engine starts re lease the main switch and allow it to re turn to ON on ECM00191 CAUTION e Never turn the main switch to START start while the engine is running e Do not keep the starter motor turning for more than 5 seconds If the starter motor is turned continuously for more than 5 seconds the battery will be Operation quickly discharged thus making it im possible to start the engine
26. hydro gen gas therefore you should always follow these preventive measures e Charge batteries in a well ventilated ar ea e Keep batteries away from fire sparks or open flames for example welding equipment lighted cigarettes and so on e 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 battery manufacturer s instructions Procedure 1 Disconnect and remove the battery from the boat Always disconnect the black negative cable first to prevent the risk of shorting 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 a cool dry well ventilated place out of di rect sunlight 4 Once a month check the specific gravity of the electrolyte and recharge as re quired to prolong battery life Maintenance EMU28442 Flushing power unit Perform this procedure right after operation for the most thorough flushing ECM01530 CAUTION Do not perform this procedure while the engine is running The water pump may be damaged and severe damage from overheating can result 1 After shutting off the engine unscrew the garden hose connector from the fit ting on the bottom cowling ZMU04080 1 Fitting 2 Garden hose connector 3 Gard
27. or the cooling water pilot hole is blocked Consult your Yamaha dealer if the prob lem cannot be located and corrected EMU27740 Shifting EWM00180 Before shifting make sure there are no swimmers or obstacles in the water near you ECM00220 CAUTION To change the boat direction or shifting position 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 models 1 Place the throttle grip in the fully closed position 35 Operation ZMU05219 2 Move the gear shift lever quickly and firmly from neutral to forward ZMU05220 Remote control models 1 Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from neutral to forward ZMU03319 36 EMU27785 Reverse automatic reverse lock and power trim and tilt models EWM00190 When operating in reverse go slowly Do not 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 models 1 Place the throttle grip in the fully closed position ZMU05219 2 Move the gear shift lever quickly and firmly from neutral to reverse Operation not open the throttle more than half Oth erwise the boat could become unstable which could res
28. system must be repaired by a qualified mechanic 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 Yamaha dealer or other qualified mechanic should re pair it immediately ZMU04082 Checkpoints e Fuel system parts leakage e Fuel line joint leakage e Fuel line cracks or other damage e Fuel connector leakage 59 Maintenance EMU28990 Checking fuel filter Check the fuel filter periodically The fuel fil ter is a one piece disposable type If foreign matter is found in the filter replace it For re placement of the fuel filter consult your Yamaha dealer ZMU04083 EMU29041 Inspecting idling speed EWM00451 e Do not touch or remove electrical parts when starting or during operation e Keep hands hair and clothes away from the flywheel and other rotating parts while the engine is running ECMO0490 CAUTION This procedure must be performed while the outboard motor is in the water A flushing attachment or test tank can be used A diagnostic tachometer should be used for this procedure Results may vary depending on whether testing is conducted with the flushing attachment in a test tank or with the outboard motor in the water 1 Start the engine and allow it to warm up fully in neutral until it is running smooth ly 60 NOTE Correct idling speed inspection is only possi ble if the engine i
29. 01 Warning system ECM00090 CAUTION Do not continue to operate the engine if a warning device has activated Consult your Yamaha dealer if the problem can not be located and corrected EMU26816 Overheat warning This engine has an overheat warning device If the engine temperature rises too high the warning device will activate Activation of warning device e The engine speed will automatically de crease to about 2000 r min e f equipped with an overheat warning indi cator it will light or blink YAMAHA x1000 rpm 7 ZMU05028 SS PAF ZMU04044 DIN ET e The buzzer will sound if equipped on the tiller handle remote control box or main switch panel If the warning system has activated stop the engine and check the cooling water inlet for clogging 25 Basic components switch panel C ZMU02392 EMU30167 Low oil pressure warning If the warning system has activated stop the If the oil pressure drops too low the warning engine as soon as it is safe to do so Check device will activate the oil level and add oil as needed If the oil Activation of warning device level is correct and the warning device does e The engine speed will automatically de hot switch off consult your Yamaha dealer crease to about 2000 r min ECM00100 e f equipped with a low oil pressure warning CAUTION indicator it will light or blink Do not continue to ru
30. A make sure that the nut is tightened to the specified torque NZ ZMU05376 1 Nut Nut tightening torque 3 7 Nm 2 7 ft lb 0 4 kgf m NOTE e Check the tiller handle for smooth move ment when the lever is turned to the star board side B e Do not apply lubricants such as grease to the friction areas of the steering friction ad juster EMU26122 Steering friction adjuster A friction device provides adjustable resis tance to the steering mechanism and can be set according to operator preference An ad justing screw or bolt is located on the swivel bracket ZMU02908 To increase resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise EWMO0040 Do not overtighten the friction adjuster If there is too much resistance it could be difficult to steer which could result in an accident EMU26141 Power trim and tilt switch on remote control or tiller handle The power trim and tilt system adjusts the outboard motor angle in relation to the tran som Pressing the switch UP up trims the outboard motor up then tilts it up Pressing the switch DN down tilts the outboard mo tor down and trims it down When the switch is released the outboard motor will stop in its current position NOTE For instructions on using the power trim and tilt switch see pages 39 and 42
31. Be aware that not all selling boat dealers are authorized Yamaha dealers Only authorized dealers have the factory training special tools and Yamaha support need ed to perform warranty repairs If you are away from home or your selling dealer is not an authorized Yamaha dealer use the following toll free numbers to find the nearest Yamaha dealer United States Dealer Locations 1 800 692 6242 Canada Dealer Locations 1 800 267 8577 ZMU01682 77 Consumer information 5 78 Your warranty applies specifically to repairs made in the country of purchase If your U S purchased Yamaha needs warranty service while in Canada or your Canadian purchased Yamaha needs service while in the United States Yamaha will assist the local dealer when ever possible However some products available in one country may not be sold or serviced in the other If you need any additional information about your Yamaha or warranty coverage which your dealer cannot provide please contact us directly Yamaha Motor Corporation USA 1270 Chastain Road Kennesaw GA 30144 Attention Customer Relations Department Telephone No 866 894 1626 Fax No 770 420 6106 Yamaha Motor Canada Ltd 480 Gordon Baker Road Toronto Ontario M2H 3B4 Attention Customer Relations Department Telephone No 416 498 1911 Fax No 416 491 3122 ZMU01683 Consumer information EMU29830 YAMAHA MOTOR CORPORATION U S A FOUR STROKE OUTBOARD MOTOR THR
32. EE YEAR LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants that new Yamaha 1999 or later model four stroke outboard motors originally distributed by Yamaha Motor Corporation U S A will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations Warranty coverage for outboards distributed by non US Yamaha affiliated companies may be different PERIOD OF WARRANTY Any new Yamaha 1999 or later model four stroke outboard motor purchased and registered with Yamaha Motor Corporation U S A for pleasure use in the United States will be warranted against defects in material or workmanship for a period of three 3 years from the date of purchase subject to exclusions noted herein Any Yamaha outboard motor purchased and utilized for commercial appli cations will be warranted for a period of one 1 year from the date of purchase subject to exclusions noted herein Yamaha peripheral equipment included with the motor such as gauges fuel tanks and hoses remote control boxes and wiring external from the motor unit will be warranted for one 1 year from the date of purchase of either pleasure or commercial use Replacement parts used in warranty repairs will be warranted for the balance of the applicable warranty period The second and third year of warranty if applicable shall be limited to covering the cost of parts and labor for major components only The major components
33. If the boat tends to veer the right starboard side turn the trim tab end to the starboard side B in the figure ECM00840 CAUTION The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode Basic components ZMU02822 1 Trim tab 2 Bolt EMU26312 Tilt lock mechanism The tilt lock mechanism is used to prevent the outboard motor from lifting out of the wa ter when in reverse gear ZMU04039 1 Tilt lock lever To lock it set the tilt lock lever in the lock position To release push the tilt lock lever in the release position EMU26320 Tilt support knob To keep the outboard motor in the tilted up position push the tilt support knob under the swivel bracket ZMU04040 EMU26372 Top cowling lock lever s turn type To remove the engine top cowling turn the lock lever s and lift off the cowling When in stalling the cowling check to be sure it fits properly in the rubber seal Then lock the cowling again by returning the lever s to the lock position 1 Top cowling lock lever s EMU26460 Flushing device This device is used to clean the cooling wa ter passages of the motor using a garden hose and tap water NOTE For details on usage see page 53 21 Basic components ZMU04042 1 Flushing device EMU26302 Warning indica
34. MU05207 Basic components ZMU03169 When constant speed is desired tighten the adjuster 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 The lanyard should be attached to a secure place on the operators clothing or arm or leg Should the operator fall overboard or leave the helm the lanyard will pull out the lock plate stopping ignition to the engine This will prevent the boat from running away un der power EWMO00120 e Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg while operating e Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning e 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 NOTE The engine cannot be started with the lock plate removed ZMU05208 1 Lanyard 2 Lock plate ZMU03171 1 Lock plate 2 Lanyard EMU26001 Engine stop button To open the ignition circuit and stop the en gine push this button 17 Basic components ZMU05209 EMU26070 Manual starter handle To start the engine first gently p
35. YAMAHA F40 OWNER S MANUAL U S A Edition LIT 18626 07 10 67C 28199 18 EMU25060 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 ZMU01690 Read this owner s manual carefully before operating your outboard motor Important manual information EMU31280 To the owner Thank you for choosing a Yamaha outboard motor This Owners Manual contains infor mation needed for proper operation mainte nance and care A thorough understanding of these simple instructions will help you ob 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 information is distinguished in the following ways A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED EWM00780 Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the out board motor ECMO0700 CAUTION A CAUTION indicates special precautions that 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 in product design and quality
36. as no lateral significance used for identification and location purposes Write Light Red Light old new No change ZMU01708 EMU25540 away from sparks flames or other pupting instructions sources of ignition sua e Stop engine before refueling o Refuel in a well ventilated area Refuel GASOLINE AND ITS VAPORS ARE HIGH portable fuel tanks off the boat LY FLAMMABLE AND EXPLOSIVE e Take care not to spill gasoline If gaso e Do not smoke when refueling and keep line spills wipe it up immediately with General information dry rags e Do not overfill the fuel tank e Tighten the filler cap securely after re fueling e If you should swallow some gasoline inhale a lot of gasoline vapor or get gasoline in your eyes get immediate medical attention e If any gasoline spills onto your skin im mediately wash with soap and water Change clothing if gasoline spills on it e Touch the fuel nozzle to the filler open ing or funnel to help prevent electro static sparks ECMO0010 CAUTION Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign mat ter EMU25570 Gasoline If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Recommended gasoline Regular unleaded gasoline with a min imum octane rating of 86 Pump Oc tane Number R M 2 Gasohol There are two types of gasohol gasohol con tai
37. be tilted up partially to allow operation in shallow water EMU28080 Hydro tilt models The outboard motor can be tilted up partially to allow operation in shallow water EWM00270 e Place the gear shift in neutral before us 46 ing the shallow water cruising system e Run the boat at the lowest possible speed when using the shallow water cruising system e Use extra care when operating in re verse Too much reverse thrust can cause the outboard motor to lift out of the water increasing the chance of ac cident and personal injury e Return the outboard motor to its normal position as soon as the boat is back in deeper water ECM00260 CAUTION Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set ting up for and cruising in shallow water Otherwise severe damage from overheat ing can result TER ZMU04074 EMU28174 Procedure for hydro tilt models 1 Place the gear shift lever in neutral Operation 2 ZMU05215 Pull the tilt lock lever up to the release position ZMU04075 Slightly tilt the outboard motor up to the desired position and push the tilt lock le ver down to the lock position To return the outboard motor to the nor mal running position pull the tilt lock le ver up to the release position and slowly tilt the outboard motor down Push the tilt lock lever down to the lock position
38. by a Yamaha dealer Q Is load on boat improperly distributed A Distribute load to place boat on an even plane 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 efficient operation Q Is motor mounted at incorrect height on transom A Have motor adjusted to proper transom height 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 spark plug s fouled or of incorrect type A Inspect spark plug s Clean or replace with recommended type 72 Q Are weeds or other foreign matter tangled on gear housing A Remove foreign matter and clean lower unit Q Is fuel system obstructed A Check for pinched or kinked fuel line or other obstructions in fuel system Q Is fuel filter clogged A Clean or replace filter 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 Is ignition wiring damaged or poorly con nected A Check wires for wear or brea
39. can be caused by oil entering the cylinder from the sump keep the outboard motor in the attitude shown when transporting and storing it If storing or transporting the outboard motor on its side not up right put it on a cushion after draining the engine oil e Do not place the outboard motor on its side before the cooling water has drained from it completely otherwise water may enter the cylinder through the exhaust port and cause engine trou ble e Store the outboard motor in a dry well ventilated place not in direct sunlight ZMU04078 ZMU04079 Maintenance EMU28303 Procedure EMU28372 Flushing in a test tank 1 Wash the outboard motor body using fresh water For further information see page 54 2 Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and 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 3 Remove the engine top cowling and si lencer cover 4 Install the outboard motor on the test tank ZMU02051 1 Water surface 2 Lowest water level 5 Fill the tank with fresh water to above the level of the anti cavitation plate ECM00300 CAUTION Do not run the engine without supplying it with cool
40. can be coated with an anti foul 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 Maintenance 69 Trouble Recovery EMU29424 Troubleshooting A problem in the fuel compression or igni tion systems can cause poor starting loss of power 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 your model If your outboard motor requires repair bring it to your Yamaha dealer If the engine trouble warning indicator is flashing consult your Yamaha dealer Starter will not operate Q Is battery capacity weak or low A Check battery condition Use battery of recommended capacity Q Are battery connections loose or corrod ed A Tighten battery cables and clean battery terminals Q Is fuse for electric start relay or electric cir cuit blown A Check for cause of electric overload and repair 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 70 A Fill tank with clean fresh fuel Q Is fuel filter clogg
41. covered are Power Unit Section e Power Head Intake Manifold Carburetor Assembly and its Related Components Fuel Injection System and its Related Components Fuel and Oil Pump Assemblies Ignition System Standard and Microcomputer Lower Unit Section Exhaust System Upper Casing Lower Unit Assembly Bracket Section Bracket System Power Trim and Tilt Assembly WARRANTY REGISTRATION To be eligible for warranty coverage the outboard motor must be registered with Yamaha Motor Corporation U S A Warranty registration can be accomplished by any authorized Yamaha Outboard Motor Dealer Upon receipt of the registration an Owner s Warranty Card will be sent by Yamaha to the registered purchaser OBTAINING REPAIRS UNDER WARRANTY To receive repairs under this warranty a valid Owner s Warranty Card must be presented to an authorized Yamaha Outboard Motor Dealer During the period of warranty any authorized Yamaha outboard dealer will free of charge repair or replace at Yamaha s option any parts adjudged defective by Yamaha due to faulty workmanship or material from the factory All replaced parts will become the property of Yamaha Motor Corporation U S A CUSTOMER S RESPONSIBILITY Under the terms of this warranty the customer will be responsible for ensuring that the outboard motor is prop erly operated maintained and stored as specified in the applicable Owner s Manual The owner of the outboar
42. d motor shall give notice to an authorized Yamaha Outboard Motor Dealer of any and all apparent defects within ten 10 days of discovery and make the motor available at that time for inspection and repairs at the dealer s place of business GENERAL EXCLUSIONS FROM WARRANTY This warranty will not cover the repair of damage if the damage is a result of abuse or neglect of the product Examples of abuse and neglect include but are not limited to 1 Racing or competition use modification of original parts abnormal strain 2 Lack of proper maintenance and off season storage as described in the Owner s Manual installation of parts or accessories that are not equivalent in design and quality genuine Yamaha parts Operation of the motor at an rpm other than specified use of lubricants or oils that are not suitable for outboard motor use Damage as a result of accidents collisions contact with foreign materials or submersion Growth of marine organism on motor surfaces Normal deterioration Dna ZMU01687 79 Consumer information SPECIFIC PARTS EXCLUDED FROM WARRANTY Parts replaced due to normal wear or routine maintenance such as oil spark plugs shear pins propellers hubs fuel and oil filters brushes for the starter motor and power tilt motor water pump impellers and anodes are not covered by warranty Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yamaha Outboard Motor Dealer
43. ds and in stall the spark plug s and torque to proper specification For information on spark plug installation see page 58 2 Change the gear oil For instructions see page 65 Inspect the oil for the pres ence of water that indicates a leaky seal Seal replacement should be performed by an authorized Yamaha dealer prior to use 3 Grease all grease fittings For further de tails see page 58 EMU28421 Cleaning and anticorrosion measures 1 Wash down the exterior of the outboard motor with fresh water and dry off com pletely 2 Spray the outboard motor exterior with Yamaha Silicone Protectant Part No LUB SILCNE 13 00 3 Wax the cowling with a non abrasive wax such as Yamaha Silicone Wax Part No ACC 11000 15 02 EMU28430 Battery care EWM00330 Battery electrolytic fluid is dangerous it contains sulfuric acid and therefore is poisonous and highly caustic Always follow these preventive mea sures e Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury e Wear protective eye gear when han dling or working near batteries Antidote EXTERNAL e SKIN Flush with water e EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL e Drink large quantities of water or milk followed by milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive
44. e connections Replace worn or bro ken wires 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 indicator lights 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 71 Trouble Recovery A Have serviced
45. e efficiency Mount the outboard motor so that the anti cavitation plate is in alignment with the bottom of the boat ZMU01762 NOTE e The optimum mounting height of the out board motor is affected by the boat motor combination and the desired use Test runs at different heights can help deter mine the optimum mounting height Con sult your Yamaha dealer or boat manufacturer for further information on de termining the proper mounting height e For instructions on setting the trim angle of the outboard motor see page 39 EMU30173 Breaking in engine Your new engine requires a period of break in to allow mating surfaces of moving parts to wear in evenly Correct break in will help en sure proper performance and longer engine 28 life ECM00800 CAUTION Failure to follow the break in procedure could result in reduced engine life or even severe engine damage EMU27081 Procedure for 4 stroke models Run the engine under load in gear with a propeller installed for 10 hours as follows 1 First hour Run the engine at 2000 r min or at ap proximately half throttle 2 Second hour Run the engine at 3000 r min or at ap proximately three quarter throttle 3 Remaining eight hours Run the engine at any speed However avoid operating at full throttle for more than 5 minutes at a time 4 After the first 10 hours Operate the engine normally EMU27103 Preoperation checks EWMmo0080 If any item in the pre
46. e outboard motor in a vertical po sition and using a flexible or pressur ized filling device inject the gear oil into the gear oil drain screw hole Recommended gear oil Hypoid gear oil SAE 90 Gear oil quantity 430 0 cm 14 54 US oz 15 17 Imp oz o ZMU04091 6 Put a new gasket on the oil level plug When the oil begins to flow out of the oil level plug hole insert and tighten the oil 65 Maintenance level plug 7 Put a new gasket on the gear oil drain screw Insert and tighten the gear oil drain screw EMU29302 Cleaning fuel tank EWM00920 Gasoline is highly flammable and its va pors are flammable and explosive e If you have any question about properly doing this procedure consult your Yamaha dealer e Keep away from sparks cigarettes flames or other sources of ignition when cleaning the fuel tank e Remove the fuel tank from the boat be fore cleaning it Work only outdoors in an area with good ventilation e Wipe up any spilled fuel immediately e Reassemble the fuel tank carefully Im proper assembly can result in a fuel leak which could result in a fire or ex plosion hazard e Dispose of old gasoline according to lo cal regulations 1 Empty the fuel tank into an approved container 2 Pour a small amount of suitable solvent into the tank Install the cap and shake the tank Drain the solvent completely 3 Remove the screws holding the fuel joint assembly Pull the asse
47. ed A Clean or replace filter Q Is starting procedure incorrect A See page 31 Q Has fuel pump malfunctioned A Have serviced by a Yamaha dealer Q Are spark plug s fouled or of incorrect type A Inspect spark plug s Clean or replace with 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 Tighten all 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 Q Are spark plug s fouled or of incorrect type A Inspect spark plug s Clean or replace with recommended type Trouble Recovery Q Is fuel system obstructed A Check for pinched or kinked fuel line or other obstructions in fuel system Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is fuel filter clogged A Clean or replace filter 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 ignition wiring damaged or poorly con nected A Check wires for wear or breaks Tighten all loos
48. en hose adapter 2 Screw the garden hose adapter onto a garden hose which is connected to a fresh water supply and then connect it to the garden hose connector 3 With the engine off turn on the water tap 53 Maintenance and let the water flush through the cool ing passages for about 15 minutes Turn off the water and disconnect the garden hose adapter from the garden hose con nector 4 Reinstall the garden hose connector onto the fitting on the bottom cowling Tighten the connector securely ECM00540 CAUTION Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal opera tion Water will leak out of the connector instead of cooling the engine which can cause serious overheating Be sure the connector is tightened securely on the fit ting after flushing the engine NOTE e When flushing the engine with the boat in the water tilting up the outboard motor un til it is completely out of the water will achieve better results e For cooling system flushing instructions see page 50 EMU28450 Cleaning the outboard motor After use wash the exterior of the outboard motor with fresh water Flush the cooling system with fresh water ZMU02550 54 NOTE For cooling system flushing instructions see page 50 EMU28460 Checking painted surface of motor Check the motor for scratches nicks or flak ing paint Areas with damaged pa
49. ennesaw GA 30144 ZMU01688 80 Consumer information EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA Welcome to the Yamaha Family Congratulations on the purchase of your new Yamaha Products Yamaha is commit ted to exceptional customer satisfaction and we want your ownership experience to be a satisfying one Please read the following warranty information to help ensure satisfaction with your Yamaha This model was manufactured as a USA specification model and the warranty statement shown in this manual is for the United States market Please note the following information 1 As explained in the Limited Warranty Statement the Yamaha warranty covers your Yamaha when it is registered and used in the United States or Canada 2 If you need repairs while temporarily using your Yamaha in another country contact the local authorized Yamaha distributor for that country Yamaha will work with that dis tributor to make the needed repairs as quickly as possible If you have to pay for a repair that you believe your warranty would have covered at home present all repair orders receipts or other related documents to your local dealer when you return home He will be able to contact Yamaha on your behalf to see if any refund can be provided NOTE Your Yamaha model may not be sold in some countries Therefore a Yamaha dealer out side the United States or Canada may not have all of the r
50. eplacement parts or technical information available to provide proper service This may unavoidably delay repairs Thank you for your understanding should this happen 3 If your Yamaha is registered or used primarily outside the United States or Canada the warranty printed in this manual does not apply to you Contact the dealer who sold the Yamaha marine power unit to you for customer support information ZMU05199 81 YAMAHA YAMAHA MOTOR CORPORATION USA Printed in Japan April 2006 0 6 x1 Printed on recycled paper VAMAHA 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 t faits dans le respect des directives d inspection et que la marche suivre pour la garantie et l entretien a t expliqu e l acheteur au d tail OUTBOARD MOTOR MODEL AND SERIAL NUMBER From I D label on clamp bracket For Dealer Use Only MODELE ET NO DE S RIE DU MOTEUR HORS BORD sur l tiquette d identification de la presse de fixation A l usage du concessionnaire YAMAHA MOTOR CO LTD YAMAHA DEALER NUMBER DEALER NAME YA M A H A HHAH Se ee RARE gt ar 1 MADE IN JAPAN PAYS D ORIGINE JAPON NOM DU CONCESSIONNAIRE DATE SOLD DATE DE LIVRAISON USAGE PLEASURE Check O
51. er used by boaters are entirely within the boundaries of a particular state The Uniform State Waterway Marking System 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 markers are white with black letters and orange boarders 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 in unfamiliar waters General information MAIN CHANNEL BUOYS wage ge ne LIGHTED BUOY Port Hand Odd number increasing toward head of naviga tion Leave to port left proceeding upstream White Light Green Light OR old new COLOR CODE eipig E BLACK O RED Q LIGHTED BUOY Starboard Hand 5 Even number increasing toward head of naviga LA GREEN tion Leave to starboard right proceeding up gt stream a White Light Red Light LIGHTED SAFE WATER BUOY Proceeding toward head No number Marks midchannel pass on either of navigation from seaward side Letter has no lateral significance used for identification and location purposes Top Mark White Light White Light CAN BUOY Odd number Leave to port g tt RG T6 LIGHTED PREFERRED CHANNEL TO NUN BUOY PORT BUOY Even number Leave to starboard No number Topmost band red preferred channel is to left of buoy Letter h
52. ering 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 the boat for damage 3 Whether damage is found or not return to the nearest harbor slowly and careful ly 4 Have a Yamaha dealer inspect the out board motor before operating it again EMU29471 Replacing fuse If a fuse has blown remove the electrical cover open the fuse holder and remove the fuse with a fuse puller if equipped Replace it with a spare one of the proper amperage EWM00630 Be sure to use the specified fuse An in correct fuse or a piece of wire could allow excessive current flow This could cause electric system damage and a fire hazard NOTE Consult your Yamaha dealer if the new fuse immediately blows again 73 Trouble Recover 1 Fuse box 2 Fuse 20 A 3 Spare fuse 20 A 4 Fuse puller ZMU04093 AN 1 Fuse puller EMU29511 Power trim and tilt power tilt will not operate If the engine cannot be tilted up or down with the power trim and tilt the power tilt because of a discharged battery or a failure with the power trim and tilt unit the power tilt unit the engine can be tilted manually 1 Loosen the manual valve screw by turn ing it clockwise until it stops 74 ZMU04095
53. fter and the throttle The electrical switch 14 es are mounted on the remote control box D ZMU01723 1 Power trim and tilt switch 2 Remote control lever 3 Neutral interlock trigger 4 Neutral throttle lever 5 Main switch choke switch 6 Engine stop lanyard switch 7 Throttle friction adjuster 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 The engine 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 ZMU01725 1 Neutral N 2 Forward F 3 Reverse R Basic components 4 Shift 5 Fully closed 6 Throttle 7 Fully open EMU26201 Neutral interlock trigger To shift out of neutral first pull the neutral in terlock trigger up T ti ZMU01727 1 Neutral interlock trigger 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 the neutral throttle lever NOTE The neutral throttle lever will operate only when the remote control lever is in neutral The remote control lever will operate only when the neutral throttle lever is in the closed position XX zm01728 I 1 Fully open 2 Fully closed EMU25911
54. give you an understanding of the motor and its operation e Before operating the boat read any own ers or operators manuals supplied with it and all labels Be sure you understand each item before operating e Do not overpower the boat with this out board motor Overpowering the boat could result in loss of control The rated power of General information the outboard should be equal to or less than the rated horsepower capacity of the boat If the rated horsepower capacity of the boat is unknown consult the dealer or boat manufacturer Do not modify the outboard Modifications could make the motor unfit or unsafe to use e Incorrect propeller selection and incorrect use 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 It is a good idea to wear a PFD whenever boating At a minimum children and non swimmers should always wear PFDs and everyone should wear PFDs when there are potentially hazardous boating condi tions Gasoline is highly flammable and its va pors are flammable and explosive Handle and store gasoline carefully Make sure there are no gas fumes or leaking fuel be fore starting the engine This product emits exhaust gases which contain carbon m
55. h trim rods Once the outboard motor is supported with the tilt support lever press the power trim and tilt switch power tilt switch DN down to retract the trim rods ECM00250 CAUTION Be sure to retract the trim rods complete ly during mooring This protects the rods ZMU04067 44 Operation from marine growth and corrosion which could damage the power trim and tilt mechanism EMU28041 Procedure for tilting down manual and hydro tilt models 1 Release the tilt lock lever ZMU04069 2 Hold the rear of the top cowling with one hand tilt the outboard motor up slightly and pull out the tilt support knob or re turn the tilt support lever ZMU04070 LC 3 Slowly tilt the outboard motor down 4 Place the tilt lock lever in the lock posi tion ZMU04071 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 up until the outboard motor is supported by the tilt rod and the tilt support lever tilt support knob be comes free 2 Release the tilt support lever or pull out the tilt support knob ZMU04072 3 Push the power trim and tilt switch pow er tilt switch DN down to lower the out board motor to the desired position 45 Operation a ow ZMU01936 ZMU04073 ZMU05228 EMU28060 Cruising in shallow water The outboard motor can
56. il quantity For further infor mation see page 29 ZMU04754 EMU26522 Low oil pressure warning indicator If oil pressure drops too low the warning in dicator will start to blink For further informa tion see page 25 ECMO0020 CAUTION e Do not continue to run the engine if the low oil pressure warning indicator is on and the engine oil level is lower Seri ous engine damage will occur e The low oil pressure warning indicator does not indicate the engine oil level Use the oil dipstick to check the re maining oil quantity For further infor mation see page 29 TACH 1 Low oil pressure warning indicator EMU26572 Overheat warning indicator If the engine temperature rises too high this indicator will flash For further information on reading the indicator see page 25 ECMO0050 CAUTION Do not continue to run the engine if the overheat warning indicator is on Serious engine damage will occur ZMU04715 23 Basic components EMU26581 Overheat warning indicator digital type If the engine temperature rises too high the warning indicator will start to blink For fur ther information on reading the indicator see page 25 ECMO0050 CAUTION Do not continue to run the engine if the overheat warning indicator is on Serious engine damage will occur TACH ZMU01737 1 Overheat warning indicator EMU26610 Trim meter This gauge shows the trim
57. ing water Either the engine water pump will be damaged or the en 51 Maintenance gine will be damaged from overheating Before starting the engine be sure to supply water to the cooling water passag es ECM00290 CAUTION If the fresh water level is below the level of the anti cavitation plate or if the water supply is insufficient engine seizure may occur 6 Cooling system flushing is essential to prevent the cooling system from clog ging up with salt sand or dirt In addi tion fogging of the engine is mandatory to prevent excessive engine damage due to rust Perform the flushing and fogging at the same time EWMO00090 e Do not touch or remove electrical parts when starting or during operation e Keep hands hair and clothes away from the flywheel and other rotating parts while the engine is running 7 Run the engine at a fast idle for 10 15 minutes in neutral position 8 Just prior to turning off the engine quick ly spray Yamaha Stor Rite Engine Fogging Oil Part No LUB STRRT 12 00 alternately into each carburetor or the fogging hole of the silencer cover if equipped When properly done the en gine will smoke excessively and almost stall 9 Remove the outboard motor from the test tank 10 Drain the cooling water completely out of the motor Clean the body thoroughly 11 Install the silencer cover cap and top cowling 52 EMU28401 Lubrication 1 Grease the spark plug threa
58. int are more likely to corrode If necessary clean and paint the areas A touch up paint is avail able from your Yamaha dealer EMU28486 Periodic maintenance EWM01070 Be sure to turn off the engine when you perform maintenance unless otherwise specified If you or the owner is not famil iar with machine servicing this work should be done by your Yamaha dealer or other qualified mechanic Maintenance replacement or repair of the emission control devices and sys tems may be performed by any marine engine repair establishment or individual All warranty repairs however including those to the emission control system must be performed by an authorized Yamaha marine dealership A service manual is available for purchase through your Yamaha dealer for owners who have the mechanical skills tools and other equipment necessary to perform mainte nance not covered by this owner s manual 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 endanger the operator and passengers Maintenance Yamaha genuine parts and accessories are available from your Yamaha dealer 55 Maintenance EMU28522 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating condi tions but the foll
59. ks Tighten all loose connections Replace worn or bro ken wires 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 Recover 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 shift lever 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 tangled on 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 Yamaha dealer EMU29433 Temporary action in emergency EMU29440 Impact damage EWM00870 The outboard motor can be seriously damaged by a collision while operating or trail
60. ling with one hand and tilt the engine to the desired angle 4 Place the tilt lock lever back into the lock position to support the engine To raise the bow trim out tilt the engine up To lower the bow trim in tilt the engine down Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions EMU27911 Adjusting boat trim When the boat is on plane a bow up attitude results in less drag greater stability and effi 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 Compen sate for this as you steer The trim tab can also be adjusted to help offset this effect When the bow of the boat is down it is easier to accelerate from a standing start onto plane ZMU01784 Bow Up Too much trim out puts the bow of the boat too high in the water Performance and econ omy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces per formance further and the boat may por poise hop in the water which could throw the operator and passengers overboard 41 Operation ZMU01785 Bow Down Too much trim in causes the boat to plow through the water decreasing fuel economy and making it hard to increa
61. mbly out of the tank 66 ZMU02066 4 Clean the filter located on the end of the suction pipe in a suitable cleaning sol vent Allow the filter to dry 5 Replace the gasket with a new one Re install the fuel joint assembly and tighten the screws firmly EMU29312 Inspecting and replacing anode s Yamaha outboard motors are protected from corrosion by sacrificial anodes Inspect the external anodes periodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes ECM00720 CAUTION Do not paint anodes as this would render them ineffective NOTE Inspect ground leads attached to external anodes on equipped models Consult a Yamaha dealer for inspection and replace ment of internal anodes attached to the pow er unit ZMU02820 ZMU04092 EMU29320 Checking battery for electric start models EWM00330 Battery electrolytic fluid is dangerous it contains sulfuric acid and therefore is poisonous and highly caustic Always follow these preventive mea sures e Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury e Wear protective eye gear when han dling or working near batteries Antidote EXTERNAL e SKIN Flush with water e EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL e Drink large quantities of water or milk Main
62. n the engine if the low oil pressure warning indicator is on Serious engine damage could occur YAMAHA ZMU04994 S yee 7 are e The buzzer will sound if equipped on the tiller handle remote control box or main 26 Operation EMU26901 Installation ECM00110 CAUTION Incorrect engine height or obstructions to smooth water flow such as the design or condition of the boat or accessories such as transom ladders or depth finder transducers can create airborne water spray while the boat is cruising Severe engine damage may result if the motor is operated continuously in the presence of airborne water spray NOTE During water testing check the buoyancy of the boat at rest with its maximum load Check that the static water level on the ex haust housing is low enough to prevent wa ter entry into the powerhead when water rises due to waves when the outboard is not running EMU26910 Mounting the outboard motor EWM00820 e Overpowering a boat could cause se vere instability Do not install an out board motor with more horsepower than the maximum rating on the capac ity plate of the boat If the boat does not have a capacity plate consult the boat manufacturer e The information presented in this sec tion is intended as reference only It is not possible to provide complete in structions for every possible boat and motor combination Proper mounting depend
63. n the fuel tank cap if equipped 4 Remove the key if the boat will be left unattended NOTE The engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop switch then turning the main switch to OFF 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 Correct trim angle depends upon the combination of boat engine and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed EWMO0740 Excessive trim for the operating condi tions either trim up or trim down can cause boat instability and can make steering the boat more difficult This in creases the possibility of an accident If the boat begins to feel unstable or is hard to steer slow down and or readjust the trim angle 39 Operation switch while the boat is moving Adjust the outboard motor trim angle using the power trim and tilt switch BN 8 4 e 1 ZMUO01781 1 Power trim and tilt switch ZMU04059 1 Trim operating angle EMU27882 Adjusting trim angle Power trim and tilt models EWMO0751 e Be sure all people are clear of the out board motor when adjusting the tilt an gle also be careful not to pinch any body part
64. n the upper and lower marks Fill with oil if it is below the lower mark or drain to the specified level if it is above the upper mark ZMU04046 EZI 1 Oil dipstick ZMU02082 1 Lower level mark 2 Oil dipstick 3 Upper level mark NOTE Be sure to completely insert the dipstick into the dipstick guide EMU27433 Filling fuel EWM00060 Gasoline and its vapors are highly flam mable and explosive Keep away from sparks 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 29 Operation tank Wipe up any spilled fuel Fuel tank capacity 25 L 6 60 US gal 5 50 Imp gal ZMU04047 EMU27270 Ring Free Fuel Additive Gasoline is a precise blend of many different substances each chosen to give certain characteristics Gasoline blends have been changing in recent years in response to con cerns about pollution and resulting emis sions regulations One of the most obvious changes has been the elimination of lead from most fuels As gasoline has changed the amount of ad ditives such as aromatics and oxygenates has increased These additives are impor tant for the engines in passenger cars but they can have detrimental effects in marine engines because of increased deposits in the combustion chamber When enough de posits collect piston rings begin sticking Performance drops and engine wea
65. ne LOISIR UTILISATION COMMERCIAL En cocher un COMMERCIAL OWNER S NAME NOM DU PROPRIETAIRE ADDRESS ADRESSE FIRST LAST PRENOM NOM DE FAMILLE STREET RUE PHONE NUMBER NUMERO DE TELEPHONE STATE PROVINCE ZIP PROVINCE CODE POSTAL PLACE POSTAGE HERE ATTN WARRANTY DEPARTMENT
66. ning ethanol and that containing metha nol 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 10 EMU31440 Engine oil Recommended engine oil YAMALUBE 4 M FC W oil or 4 stroke motor oil with a combination of the fol lowing SAE and API oil classifications Engine oil type SAE 10W 30 or 10W 40 Engine oil grade API SE SF SG SH SJ SL Engine oil quantity excluding oil filter 2 0 L 2 11 US qt 1 76 Imp qt NOTE If the recommended engine oil grades are not available select an alternative from the following chart according to the average temperatures in your area A EN i N EE Gece SN lt ZMU05190 ECM01050 CAUTION All 4 stroke engines are shipped from the factory without engine oil nr Fill engine oil A ada aceite de motor Colocar oleo de motor Faire le plein d huile moteur AINWEANTC RSW BMT IE ZMU01710 EMU25690 Battery requirement ECMO1060 CAUTION Do not use a battery that does not meet the specified capacity If a battery which does not meet specifications is used the electric system could perform poorly or be overloaded causing electric system damage For electric start models choose a battery which meets the following specification
67. o not illegally discard empty containers used to replace or replenish oil For the correct processing of empty containers consult the dealer where you purchased the oil e When replacing oils used to lubricate the product engine or gear oil be sure to wipe away any spilt oil Never pour oil with out using a funnel or similar device If nec essary verify the necessary replacement procedure with the dealer e Never illegally discard dump the product Yamaha recommends consulting the deal er on discarding the product Be informed about boating safety Additional publications 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 II 60611 Marine Retailers Association of America 155 N Michigan Ave Chicago II 60601 EMU25382 Important labels EMU25395 Warning labels ZMU04033 ZMU05275 EMU25401 Label EWM01260 e Be sure shift control is in neutral before starting engine except 2HP e Do not touch or remove electrical parts when starting or during operation e Keep hands hair and clothes away from flywheel and other rotating parts while engine is running EMU25431
68. onoxide 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 cord to a secure place on your clothing or your arm or leg while operating If you acciden tally leave the helm the cord will pull from General information the switch stopping the engine e Know the marine laws and regulations where you will be boating and obey them For basic boating rules see Rules of the road on page 5 e Stay informed about the weather Check weather forecasts before boating Avoid boating in hazardous weather e Tell someone where you are going leave a Float Plan with a responsible person Be sure to cancel the Float Plan when you re turn e Use common sense and good judgment when boating Know your abilities and be sure you understand how your boat han dles under the different boating conditions you may encounter Operate within your limits and the limits of your boat Always operate at safe speeds and keep a careful watch for obstacles and other traffic e Always watch carefully for swimmers dur ing the engine operation e Stay away from swimming areas e When a swimmer is in the water near you shift into neutral and shut off the engine e D
69. onth 100 hours 6 months 200 hours 1 year Water pump Engine oil Inspection replace ment Inspection change Oil filter cartridge Change Spark plug s Cleaning adjustment replacement Timing belt Inspection replace ment Valve clearance OHC OHV EMU28874 Inspection adjustment Maintenance chart additional Item Actions Every 500 hours 2 5 years 1000 hours 5 years Timing belt Replacement O Exhaust guide exhaust manifold EMU28910 NOTE Inspection replace ment O When using lead or high sulfur gasoline inspecting valve clearance may be required more frequently than every 500 hours 57 Maintenance EMU28931 Greasing Yamaha marine grease Water resistant grease F40 EMU28952 Cleaning and adjusting spark plug EWM00560 When removing or installing a spark plug be careful not to damage the insulator A damaged insulator could allow external sparks which could lead to explosion or fire The spark plug is an important engine com ponent and is easy to inspect The condition of the spark plug can indicate something about the condition of the engine For exam ple if the center electrode porcelain is very white this could indicate an intake air leak or carburetion problem in that cylinder Do not 58 ZMU04081 attempt to diagnose any problems yourself
70. operation check is not working properly have it inspected and repaired before operating the out board motor Otherwise an accident could occur ECM00120 CAUTION Do not start the engine out of water Over heating and serious engine damage can occur EMU27111 Fuel e Check to be sure you have plenty of fuel for your trip e Make sure there are no fuel leaks or gaso Operation line fumes e Check fuel line connections to be sure they are tight if equipped Yamaha fuel tank or boat tank e Be sure the fuel tank is positioned on a se cure flat surface and that the fuel line is not twisted or flattened or likely to contact sharp objects if equipped Yamaha fuel tank or boat tank EMU27130 Controls e Check throttle shift and steering for prop er operation before starting the engine e The controls should work smoothly with out binding or unusual free play e Look for loose or damaged connections e Check operation of the starter and stop switches when the outboard motor is in the water EMU27140 Engine e Check the engine and engine mounting e Look for loose or damaged fasteners e Check the propeller for damage EMU27163 Checking the engine oil level 1 Put the outboard motor in an upright po sition not tilted 2 Remove oil dipstick and wipe it clean 3 Completely insert the dipstick and re move it again 4 Check the oil level using the dipstick to be sure the level falls betwee
71. owing table gives general guidelines Refer to the sections in this chapter for explanations 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 O symbol indicates work to be carried out by your Yamaha dealer Actions Initial Every 10 hours 5 1 month 0 hours 3 months 100 hours 6 months 200 hours 1 year Anode s external Inspection replace ment O O Anode s internal Inspection replace ment O Battery Inspection charging Cooling water pas sages Cleaning Cowling clamp Inspection Fuel filter disposable Inspection replace ment Fuel system Inspection Fuel tank Yamaha por table tank Inspection cleaning Gear oil Change Greasing points Greasing Idling speed carbure tor models Inspection Power trim and tilt unit Inspection Propeller and cotter pin Inspection replace ment Shift link shift cable Inspection adjustment Thermostat Inspection replace ment Throttle link throttle cable throttle pick up timing 56 Inspection adjustment Actions Initial Maintenance Every 50 hours 3 months 10 hours 1 m
72. position ZMU05217 4 Pull the manual starter handle slowly un til you feel resistance Then give a strong pull straight out to crank and start the engine Repeat if necessary 32 ZMU04050 5 After the engine starts slowly return the manual starter handle to its original po sition before releasing it NOTE e When the engine is cold it needs to be warmed up For further information see page 35 e If the engine is warm and fails to start open the throttle slightly and try to start the engine again If the engine still fails to start see page 70 EMU27592 Electric start prime start models 1 Place the gear shift lever in neutral ZMU05215 NOTE The start in gear protection device prevents the engine from starting except when in neu tral 2 Attach the engine stop switch lanyard to a secure place on your clothing or your Operation arm or leg Then install the lock plate on the other end of the lanyard into the en gine stop switch EWM00120 e Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg while operating e Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entan gled preventing it from functioning e Avoid accidentally pulling the lanyard during normal operation Loss of en gine power means the loss of most steering control Also withou
73. provided the other vessel gives you the right of way as it should 1 eT 1 Erea __ fs I 1 1 1 __ZMU01707 Overtaking If you are passing another vessel you are the Give Way vessel This means that the other vessel is expected to maintain its course and speed You must stay out of its way until you are clear of it Likewise if an other vessel is passing you you should maintain your speed and direction so that the other vessel can steer itself around you EMU25530 Other special situations There are three other rules you should be aware of when driving your boat around oth er vessels Narrow channels and bends When navigating in narrow channels you should keep to the right when it is safe and practical to do so If the operator of a power driven vessel is preparing to go around a bend 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 General information If another vessel is around the bend it too should sound the whistle Even if no reply is heard however the vessel should still pro ceed around the bend with caution If you navigate such waters with your boat you will need to carry a portable air horn available from local marine supply stores Fishing vessel right of way All vessels which are fishing with nets lines or trawls are considered to be fishing ves sels under the International Rules
74. r in creases dramatically While many additives available may reduce deposits Yamaha recommends the use of Ring Free Fuel Additive available from your Yamaha dealer Ring Free Fuel Addi tive has repeatedly proven its ability to clean combustion deposits from inside the engine notably the critical piston ring land area and 30 fuel system components Follow product la beling for use instructions EMU27450 Operating engine EMU27461 Feeding fuel portable tank EWM00420 e 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 e When the air vent screw is loosened gasoline vapor will be released Gaso line is highly flammable and its vapors are flammable and explosive Refrain from smoking and keep away from open flames and sparks while loosen ing the air vent screw e This product emits exhaust gases which contain carbon monoxide a col orless odorless gas which could cause brain 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 fuel tank cap loosen it 2 or 3 turns amp WD 2 If there is a fuel joint on the motor firmly Operation connect the fuel line to the joint Then firmly connect the other end of the fuel line
75. rew 4 Anti cavitation plate 5 Trim tab anode 6 Propeller 7 Cooling water inlet 8 Clamp bracket 9 Power trim and tilt switch 10 Manual starter handle 11 Warning indicator s 12 Steering friction adjuster 13 Tilt support knob 14 Flushing device ZMU05026 15 Tiller handle 16 Fuel tank 17 Tachometer 18 Trim meter 19 Digital tachometer 20 Remote control box side mount type EMU25802 Fuel tank If your model was equipped with a portable fuel tank its function is as follows EWMO0020 The fuel tank supplied with this engine is 13 Basic components its dedicated fuel reservoir and must not be used as a fuel storage container Com mercial users should conform to relevant licensing or approval authority regula tions ZMU02219 1 Fuel joint 2 Fuel gauge 3 Fuel tank cap 4 Air vent screw EMU25830 Fuel joint This joint is used to connect the fuel line EMU25841 Fuel gauge This gauge is located on either the fuel tank cap or on the fuel joint base It shows the ap proximate amount of fuel remaining in the tank EMU25850 Fuel tank cap This cap seals the fuel tank When removed the tank can be filled with fuel To remove the cap turn it counterclockwise EMU25860 Air vent screw This screw is on the fuel tank cap To loosen the screw turn it counterclockwise EMU26180 Remote control The remote control lever actuates both the shi
76. s EMU25711 Battery specifications Minimum cold cranking amps CCA SAE F40TR 380 0 A Minimum marine cranking amps MCA ABYC F40TR 502 0A Minimum reserve capacity RC SAE F40TR 124 minutes EMU25730 Without a rectifier or Rectifier Regulator ECM01090 CAUTION A battery cannot be connected to models that do not have a rectifier or Rectifier General information Regulator If you wish to use a battery with the models without a rectifier or Rectifier Regulator in stall an optional Rectifier Regulator Using a maintenance free battery with the above models can shorten the life of the bat tery significantly Install an optional Rectifier Regulator or use accessories rated to withstand 18 volts or higher with the above models Consult your Yamaha dealer for details on installing an optional Rectifier Regulator EMU25742 Propeller selection The performance of your outboard motor will be critically affected by your choice of propel ler aS an incorrect choice could adversely affect performance and could also seriously damage the motor Engine speed depends on the propeller size and boat load If engine speed is too high or too low for good engine performance this will have an adverse effect on the engine Yamaha outboard motors are fitted with pro pellers chosen to perform well over a range of applications but there may be uses where a propeller with a different pitch would be more appropriate For
77. s between the drive unit and clamp bracket e Use caution when trying a trim position 7a UP for the first time Increase speed gradu l a ally and watch for any signs of instabil 3 ity or control problems Improper trim angle can cause loss of control e If equipped with a power trim and tilt ZMU05224 switch located on the bottom cowling use the switch only when the boat is at a complete stop with the engine off Do not adjust the trim angle with this ZMU04060 1 Power trim and tilt switch _ 1 Power trim and tilt switch To raise the bow trim out press the switch 40 Operation UP up To lower the bow trim in press the switch DN down Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions EMU27891 Adjusting trim angle for hydro tilt models EWM00490 e Stop the engine before adjusting the trim angle e Be sure all people are clear of the out board motor when adjusting the tilt an gle also be careful not to pinch any body parts between the drive unit and clamp bracket e Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any signs of instabil ity or control problems Improper trim angle can cause loss of control 1 Stop the engine 2 Place the tilt lock lever in the release po sition ZMU04061 3 Hold the rear of the top cow
78. s fully warmed up If not warmed up fully the idle speed will measure higher 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 to specification For idle speed specifica tions see page 49 EMU29073 Changing engine oil EWM00760 e Avoid draining the engine oil immedi ately after stopping the engine The oil is hot and should be handled with care to avoid burns e Be sure the outboard motor is securely fastened to the transom or a stable stand ECM00970 CAUTION e Do not overfill the oil and be sure the outboard motor is upright not tilted when checking and changing the en gine oil e If the oil level is above the upper level mark drain until the level meets the specified capacity Overfilling the oil could cause leakage or damage ECM01240 CAUTION Change the engine oil after the first 10 hours of operation and every 100 hours or at 6 month intervals thereafter Other wise the engine will wear quickly NOTE Change the engine oil when the oil is still warm 1 Put the outboard motor in an upright po sition not tilted ZMU04084 2 Prepare a suitable container that holds a larger amount than the engine oil capac ity Loosen and remove the drain screw while holding the container under the drain hole Then remove the oil filler cap Let
79. s in part on experience and the specific boat and motor combination EWM00830 Improper mounting of the outboard mo tor could result in hazardous conditions such as poor handling loss of control or fire hazards Observe the following e For permanently mounted models your dealer or other person experienced in proper rigging should mount the motor If you are mounting the motor yourself you should be trained by an experi enced person e 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 the boat itself is well balanced Otherwise the boat will be hard to steer For boats without a keel or which are asymmetrical consult your dealer a ZMU01760 1 Center line keel line EMU26930 Mounting height boat bottom To run your boat at optimum efficiency the water resistance drag of the boat and out board motor must be made as little as possi ble The mounting height of the outboard 27 Operation motor greatly affects the water resistance If the mounting height is too high cavitation tends to occur thus reducing the propulsion and if the propeller tips cut the air the engine speed will rise abnormally and cause the en gine to overheat If the mounting height is too low the water resistance will increase and thereby reduce engin
80. se some corrosion may begin almost immedi ately If you cannot immediately take the outboard motor to a Yamaha dealer follow the proce dure below in order to minimize engine dam age EMU29783 Procedure 1 Thoroughly wash away mud salt sea weed and so on with fresh water 2 Remove the spark plug s then face the spark plug holes downward to allow any water mud or contaminants to drain 3 Drain the fuel from the carburetor fuel filter and fuel line Drain the engine oil completely 4 Fill the sump with the fresh engine oil Engine oil capacity 2 0 L 2 11 US qt 1 76 Imp qt 5 Feed engine fogging oil or engine oil through the carburetor s and spark plug holes while cranking the engine with the manual starter or emergency starter rope 6 Take the outboard motor to a Yamaha dealer as soon as possible ECM00400 CAUTION Do not attempt to run the outboard motor until it has been completely inspected Consumer information EMU29811 Important warranty information for U S A and Canada Welcome to the Yamaha Family Congratulations on the purchase of your new Yamaha marine power Yamaha is commit ted to exceptional customer satisfaction and we want your ownership experience to be a satisfying one Please read the following warranty information to help ensure satisfac tion with your Yamaha Yamaha is ready to stand behind your purchase with strong warranty coverage To be sure you receive all
81. se speed Oper ating with excessive trim in at higher speeds also makes the boat unstable Resistance at the bow is greatly increased heightening the danger of bow steering and making opera tion difficult and dangerous ZMUO01786 NOTE Depending on the type of boat the outboard motor 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 or if the boat is moored in shallows the out board motor should be tilted up to protect the propeller and casing from damage by colli sion with obstructions and also to reduce 42 salt corrosion EWM00220 Be sure all people are clear of the out board motor when tilting up and down also be careful not to pinch any body parts between the drive unit and engine bracket EWM00250 Leaking fuel is a fire hazard If there is a fuel joint on the outboard motor discon nect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes Otherwise fuel may leak ECM00241 CAUTION e Before tilting the outboard motor stop the engine by following the procedure on page 38 Never tilt the outboard mo tor while the engine is running Severe damage from overheating can result e Do not tilt up the engine by pushing the tiller handle if equipped because this could break the handle EMU27995 Procedure for tilting up hydro tilt models 1 Place
82. t engine power the boat could slow rapidly This could cause people and objects in the boat to be thrown forward ZMU05216 3 Place the throttle grip in the START start position After the engine starts return the throttle to the fully closed po sition ZMU05217 4 Turn the main switch to START start and hold it for a maximum of 5 seconds OFF PR START ae ZMU05218 5 Immediately after the engine starts re lease the main switch and allow it to re turn to ON on ECM00191 CAUTION e Never turn the main switch to START start while the engine is running e Do not keep the starter motor turning for more than 5 seconds If the starter motor is turned continuously for more than 5 seconds the battery will be quickly discharged thus making it im possible to start the engine The starter can also be damaged If the engine will not start after 5 seconds of cranking return the main switch to ON on wait 10 seconds then crank the engine again 33 Operation NOTE e When the engine is cold it needs to be warmed up For further information see page 35 e If the engine is warm and fails to start open the throttle slightly and try to start the engine again If the engine still fails to start see page 70 EMU27662 Electric start and remote control models 1 Place the remote control lever in neutral ZMU01771 LS NOTE The start in
83. tenance 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 e Charge batteries in a well ventilated ar ea e Keep batteries away from fire sparks or open flames for example welding equipment lighted cigarettes and so on e DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN ECM00360 CAUTION e A poorly maintained battery will quickly deteriorate e Ordinary tap water contains minerals harmful to a battery and should not be used for topping up 1 Check the electrolyte level at least once a month Fill to the manufacturer s rec ommended level when necessary Top up only with distilled water or pure de ionized water suitable to use in batter ies ZMU01810 2 Always keep the battery in a good state 67 Maintenance of charge Installing a voltmeter will help you monitor your battery If you will not use the boat for a month or more re move the battery from the boat and store it in a cool dark place Completely re charge the battery before using it 3 If the battery will be stored for longer than a month check the specific gravity of 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 ba
84. that you use the optional chromium plated water pump kit not available for some models if you use the outboard motor in turbid or muddy water conditions 48 EMU31480 Specifications NOTE AL stated in the specification data below represents the numerical value for the alumi num propeller installed Likewise SUS represents the value for stainless steel propeller installed and PL for plastic propeller installed EMU28218 Dimension Overall length F40MH 1332 mm 52 4 in F40TR 700 mm 27 6 in Overall width 378 mm 14 9 in Overall height S 1217 mm 47 9 in Overall height L 1340 mm 52 8 in Transom height S 410 mm 16 1 in Transom height L 533 mm 21 0 in Weight without propeller S F40MH 83 0 kg 183 Ib Weight without propeller L F40MH 87 0 kg 192 Ib F40TR 89 0 kg 196 Ib Performance Full throttle operating range 5000 6000 r min Maximum output 29 4 KW 5500 r min 40 HP 5500 r min Idling speed in neutral 850 50 r min Engine Type 4 stroke L Maintenance Displacement 747 0 cm 45 58 cu in Bore x stroke 65 0 x 75 0 mm 2 56 x 2 95 in Ignition system CDI Spark plug with resistor NGk DPR6EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Control system F40MH Tiller F40TR Remote control Starting system F40MH Manual F40TR Electric Starting carburetion system Prime start Valve clearance cold engine IN 0 15 0 25 mm 0 0059 0 0098 in
85. the benefits of warranty please take the following steps 1 Be sure your new Yamaha is registered for warranty Your boat dealer should do this at the time of sale Make sure your dealer gives you a copy of the completed Yamaha registration card for your records If you are unsure whether or not your Yamaha is registered complete the Warranty Registration card found inside the cover of the Owner s Manual Mail it to the distributor for the country in which you live see step 6 for the correct address If your Yamaha is not properly registered a warranty repair could be unnecessarily delayed while registration records are checked Read the Limited Warranty statement which follows these instructions This warranty applies to Yamaha outboard motors sold in the United States whether purchased separately or when supplied as original equipment by a boat builder The terms also apply to original equipment packages sold in Canada with coverage provided by Yamaha Motor Canada see Warranty Guide for Canadian models This warranty explains the conditions of the warranty includ ing the obligations that your dealer and you as the owner have under the warranty For exam ple your Yamaha outboard must receive a proper pre delivery inspection PDI by the sell ing dealer Failure to take this important step could jeopardize warranty coverage If you need warranty repairs you must take your Yamaha outboard to an authorized Yamaha outboard dealer
86. the oil drain completely Wipe up any spilled oil immediately TASI ZMU04085 IT 1 Drain screw 3 Put a new gasket on the oil drain screw Apply a light coat of oil to the gasket and install the drain screw Drain screw tightening torque 18 0 Nm 13 3 ft lb 1 84 kgf m Maintenance NOTE If a torque wrench is not available when you are installing the drain screw finger tighten the screw just until the gasket comes into contact with the surface of the drain hole Then tighten 1 4 to 1 2 turn more Tighten the drain screw to the correct torque with a torque wrench as soon as possible 4 Add the correct amount of oil through the filler hole Install the filler cap Recommended engine oil 4 stroke outboard motor oil Engine oil quantity excluding oil filter 2 0 L 2 11 US qt 1 76 Imp qt ZMU04086 A 1 Oil filler cap 5 Start the engine and watch to make sure the low oil pressure warning indicator if equipped turns off Make sure that there are no oil leaks ECMO00680 CAUTION If the low oil pressure warning indicator does not turn off or if there are oil leaks stop the engine and find the cause Con tinued operation with a problem could cause severe engine damage Consult your Yamaha dealer if the problem can 61 Maintenance not be located and corrected 6 Turn off the engine and wait 3 minutes Recheck the oil level using the dipstick to be sure the level falls between the
87. the remote control lever gear shift lever in neutral ENS ZMU03087 Operation ZMU05215 2 Disconnect the fuel line from the out board motor Az ee 3 Place the tilt lock lever in the release po sition ZMU04063 ZMU04064 4 Hold the rear of the top cowling with one hand tilt the engine up and turn the tilt support lever toward you or tilt support knob into the clamp bracket and then place the tilt lock lever back into the lock position to support the outboard motor ZMU04065 Sts EMU28007 Procedure for tilting up power trim and tilt models power tilt models 1 Place the remote control lever gear shift lever in neutral a ZMU03196 ZMU05215 2 Disconnect the fuel line from the out board motor or close the fuel cock 43 Operation f UP 4g a NSS a NN war ZMU04066 ZMU05226 3 Press the power trim and tilt switch 4 Push the tilt support knob into the clamp power tilt switch UP up until the out bracket or pull the tilt support lever to board motor has tilted up completely ward you to support the engine ZMU01935 ZMU04068 EWM00260 After tilting the outboard motor be sure to support it with the tilt support knob or tilt support lever Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit loses pres sure 5 Models equipped wit
88. to the joint on the fuel tank ZMU02024 8 If a steering friction adjuster is provided on your outboard motor securely attach the fuel line to the fuel line clamp NOTE During engine operation place the tank hori zontally otherwise fuel cannot be drawn from the fuel tank 4 Squeeze the primer pump with the outlet end up until you feel it become firm ZMU02025 EMU27490 Starting engine EMU27541 Starting engine 1 Place the gear shift lever in neutral ZMU05215 NOTE The start in gear protection device prevents the engine from starting except when in neu tral 2 Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg Then install the lock plate on the other end of the lanyard into the en gine stop switch EWM00120 e Attach the engine stop switch lanyard to a secure place on your clothing or your arm or leg while operating e Do not attach the lanyard to clothing that could tear loose Do not route the 31 Operation lanyard where it could become entan gled preventing it from functioning e 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 ZMU05216 3 Place the throttle grip in the START start
89. tor If the engine develops a condition which is cause for warning the indicator lights up For details on how to read the warning indicator see page 25 aok aw 1 Warning indicator EMU26470 Tachometer This gauge shows the engine speed and has the following functions 22 ZMU04578 1 Tachometer 2 Warning indicator s EMU26491 Digital tachometer The tachometer shows the engine speed and has the following functions NOTE All segments of the display will light momen tarily after the main switch is turned on and will return to normal thereafter 9 ZMU04185 1 Tachometer 2 Trim meter 3 Hour meter 4 Low oil pressure warning indicator 5 Overheat warning indicator 6 Water separator warning indicator 7 Engine trouble warning indicator 8 Set button 9 Mode button Basic components NOTE The water separator and engine trouble warning indicators only operate when the en gine is equipped with the appropriate func tions EMU26503 Low oil pressure warning indicator If oil pressure drops too low this indicator will flash For further information see page 25 ECM00020 CAUTION e Do not continue to run the engine if the low oil pressure warning indicator is on and the engine oil level is lower Seri ous engine damage will occur e The low oil pressure warning indicator does not indicate the engine oil level Use the oil dipstick to check the re maining o
90. tteries EMU29331 Connecting the battery EWM00570 Mount the battery holder securely in a dry well ventilated vibration free loca tion in the boat Install a fully charged bat tery in the holder ECM01121 CAUTION e Make sure the main switch on applica ble models is OFF off before work ing on the battery e Reversal of the battery cables will dam age the electrical parts e Connect the red battery cable first when installing the battery and discon nect the black battery cable first when removing it Otherwise the electrical parts can be damaged e The electrical contacts of the battery and cables must be clean and properly connected or the battery will not start the engine Connect the red battery cable to the POSI TIVE terminal first Then connect the black battery cable to the NEGATIVE ter 68 minal 1 ZMU01811 1 Red cable 2 Black cable 3 Battery EMU29370 Disconnecting the battery Disconnect the BLACK cable from the NEG ATIVE terminal first Then disconnect the RED 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 ZMU02068 EMU29400 Coating the boat bottom A clean hull improves boat performance The boat bottom should be kept as clean of ma rine growth as possible If necessary the boat bottom
91. ull the han dle out until resistance is felt From that posi tion then pull the handle straight out quickly to crank the engine aa lt ZMU04037 EMU26090 Main switch The main switch controls the ignition system its operation is described below e OFF off With the main switch in the OFF off posi tion the electrical circuits are off and the key can be removed e ON on With the main switch in the ON on posi tion the electrical circuits are on and the key cannot be removed e START start With the main switch in the START start po sition the starter motor turns to start the en 18 gine When the key is released it returns automatically to the ON on position ZMU03590 ZMU05210 EMU31430 Steering friction adjuster A friction device provides adjustable resis tance to the steering mechanism and can be set according to operator preference An ad juster lever is located on the bottom of the tiller handle bracket To increase resistance turn the lever to the port side A To decrease resistance turn the lever to the starboard side B EWMO0040 Do not overtighten the friction adjuster If there is too much resistance it could be difficult to steer which could result in an accident Basic components gt R ZMU02810 LA If the resistance does not increase even when the lever is turned to the port side
92. ult in loss of control and an accident Tiller handle models 1 Place the throttle grip in the fully closed position ZMU05221 Remote control models 1 Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from neutral to reverse ZMU05219 4 T7 2 On models equipped with a tilt lock le ver check that it is in the lock down po sition ZMU03909 ZMU04054 3 Move the gear shift lever quickly and firmly from neutral to reverse EMU27796 Reverse manual tilt and hydro tilt models EWM00190 When operating in reverse go slowly Do 37 Operation ZMU05221 Remote control models EMU27820 f 1 Check that the tilt lock lever is in the lock Stopping engine position Before stopping the engine first let it cool off for a few minutes at idle or low speed Stop ping the engine immediately after operating at high speed is not recommended EMU27844 Procedure 1 Push and hold the engine stop button or turn the main switch to OFF off ZMU04053 2 Pull up the neutral interlock trigger if equipped and move the remote control lever quickly and firmly from neutral to reverse ZMU05209 ZMU03909 ZMU03630 38 Operation ZMU05223 2 After stopping the engine disconnect the fuel line if there is a fuel joint on the outboard motor 3 Tighten the air vent screw o
93. up per and lower marks Fill with oil if it is below the lower mark or drain to the specified level if it is above the upper mark ZMU02058 7 Dispose of used oil according to local regulations NOTE e For more information on the disposal of used oil consult your Yamaha dealer e Change the oil more often when operating the engine under adverse conditions such as extended trolling EMU29112 Checking wiring and connectors e Check that each grounding wire is properly secured e Check that each connector is engaged se curely 62 EMU29120 Exhaust leakage Start the engine and check that no exhaust leaks from the joints between the exhaust cover cylinder head and body cylinder EMU29130 Water leakage Start the engine and check that no water leaks from the joints between the exhaust cover cylinder head and body cylinder EMU29140 Engine oil leakage Check for oil leaks on the around the engine NOTE If any leaks are found consult your Yamaha dealer EMU29163 Checking power trim and tilt power tilt system EWM00430 e Never get under the lower unit while it is tilted even when the tilt support lever is locked Severe injury could occur if the outboard motor accidentally falls e Make sure no one is under the outboard motor before performing this test 1 Check the power trim and tilt unit power tilt unit for any sign of oil leaks ZMU04088 _ Trim and tilt rod
94. wheel is very dangerous Keep loose clothing and other objects away when starting the engine Use the emergency starter rope only as instructed Do not touch the fly wheel or other moving parts when the engine is running Do not install the starter mechanism or top cowling after the engine is running e Do not touch the ignition coil spark plug wire spark plug cap or other elec trical components when starting or op erating the motor You could get an electrical shock ZMU04098 2 HT IT 4 Prepare the engine for starting For fur ther information see page 31 Be sure the engine is in neutral and that the en gine stop switch lanyard lock plate is at tached to the engine stop switch The main switch must be ON on if equipped EMU30361 Emergency starting engine 1 Remove the top cowling 2 Disconnect the start in gear protection cable from the starter if equipped ZMU05216 75 T rouble Recover ZMU02334 OFF ON START vA AIR v ZMU01906 Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise Pull the rope slowly until resistance is felt Give a strong pull straight out to crank and start the engine Repeat if neces sary 76 EMU29760 Treatment of submerged motor If the outboard motor is submerged immedi ately take it to a Yamaha dealer Otherwi
95. which you may encounter with other vessels which could lead to a collision unless the Steering Rules 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 being passed by another vessel In the following illustration your boat is in the center You should give the right of way to any vessels shown in white area you are the Give Way vessel Any vessels in the shad ed area must yield to you they are the Give Way vessels Both you and the meeting vessel must alter course to avoid each other ZMU01705 Meeting If you are meeting another power vessel head on and are close enough to run the risk of collision neither of you has the right of way Both of you should alter course to avoid an accident You should keep the other ves sel on your port left side This rule doesn t apply if both of you will clear one another if you continue on your set course and speed EN ST UE Crossing When two power driven vessels are crossing each others path close enough to run the ZMU01706 risk of collision the vessel which has the oth er on the starboard right side must keep out of the way of the other If the other vessel is on your right you must keep out of its way you are the Give Way vessel If the other vessel is on your port left side remember that you should maintain course and direc tion

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