6F8 28199 Ka

U6F8KAE0.
book Page 1 Tuesday, March 7, 2006 11:14 AM
2C
OWNER’S MANUAL
6F8-28199-KA-E0
U6F8KAE0.book Page 1 Tuesday, March 7, 2006 11:14 AM
Read this owner’s manual carefully before operating your outboard motor.
Important manual information

EMU25101
your machine and this manual. If there is any
To the owner question concerning this manual, please con-
Thank you for choosing a Yamaha outboard sult your Yamaha dealer.
motor. This Owner’s Manual contains infor- To ensure long product life, Yamaha recom-
mation needed for proper operation, mainte- mends that you use the product and perform
nance and care. A thorough understanding of the specified periodic inspections and mainte-
these simple instructions will help you obtain nance by correctly following the instructions in
maximum enjoyment from your new Yamaha. the owner’s manual. Note that if you do not
If you have any question about the operation follow these instructions, not only may the
or maintenance of your outboard motor, product break down, but the warranty will also
please consult a Yamaha dealer. be voided.
In this Owner’s Manual particularly important Some countries have laws or regulations re-
information is distinguished in the following stricting users from taking the product out of
ways. the country where it was purchased, and it
may be impossible to register the product in
The Safety Alert Symbol means AT- the destination country. Additionally, the war-
TENTION! BECOME ALERT! YOUR SAFE- ranty may not apply in certain regions. When
TY IS INVOLVED! planning to take the product to another coun-
EWM00780
try, consult the dealer where the product was
WARNING
purchased for further information.
Failure to follow WARNING instructions
If the product was purchased used, please
could result in severe injury or death to the
consult your closest dealer for customer re-
machine operator, a bystander, or a per-
registration, and to be eligible for the specified
son inspecting or repairing the outboard
services.
motor.
NOTE:
ECM00700
The 2CMH and the standard accessories are
CAUTION:
used as a base for the explanations and illus-
A CAUTION indicates special precautions trations in this manual. Therefore some items
that must be taken to avoid damage to the may not apply to every model.
outboard motor.
EMU25120
NOTE:
A NOTE provides key information to make 2C
procedures easier or clearer. OWNER’S MANUAL
©2006 by Yamaha Motor Co., Ltd.
Yamaha continually seeks advancements in 1st Edition, January 2006
product design and quality. Therefore, while All rights reserved.
Any reprinting or unauthorized use
this manual contains the most current product without the written permission of
information available at the time of printing, Yamaha Motor Co., Ltd.
there may be minor discrepancies between is expressly prohibited.
Printed in Japan
Table of contents
General information .......................... 1 Filling fuel and engine oil .............. 13
Identification numbers record .......... 1 Filling fuel for built-in tank................. 13
Outboard motor serial number ........... 1 Gasoline and oil mixing .................... 13
EC label........................................... 1 Operating engine .......................... 14
Safety information ........................... 1 Feeding fuel...................................... 14
Starting engine ................................. 15
Important labels............................... 3
Warning labels.................................... 3 Warming up engine....................... 17
Direct drive models........................... 17
Fueling instructions ......................... 3
Gasoline ............................................. 3 Shifting .......................................... 17
Engine oil............................................ 3 Forward ............................................ 17
Reverse ............................................ 17
Propeller selection........................... 4
Stopping engine ............................ 18
Procedure......................................... 18
Basic components ............................ 5
Trimming outboard motor.............. 18
Main components............................ 5
Adjusting trim angle for manual tilt
Fuel tank............................................. 5
models .......................................... 19
Fuel tank cap...................................... 6
Adjusting boat trim............................ 19
Air vent screw..................................... 6
Tilting up and down....................... 20
Fuel cock ............................................ 6
Procedure for tilting up
Tiller handle........................................ 6
(manual tilt models)....................... 21
Throttle lever ...................................... 7
Procedure for tilting down
Throttle friction adjuster...................... 7
(manual tilt models)....................... 21
Engine stop lanyard switch................. 7
Engine stop button ............................. 7 Cruising in other conditions........... 22
Choke knob ........................................ 8
Manual starter handle......................... 8 Maintenance .................................... 23
Steering friction adjuster..................... 8 Specifications................................ 23
Trim rod (tilt pin) ................................. 8 Transporting and storing outboard
Tilt support knob................................. 9 motor.......................................... 23
Clamp screw mounting models ........ 24
Operation ......................................... 10 Storing outboard motor..................... 24
Installation ..................................... 10 Procedure......................................... 24
Mounting the outboard motor ........... 10 Lubrication
Clamping the outboard motor........... 11 (except oil injection models).......... 25
Breaking in engine ........................ 12 Cleaning the outboard motor ............ 26
Gasoline and engine oil mixing Checking painted surface of motor... 26
chart (25:1).................................... 12 Periodic maintenance ................... 26
Procedure for pre-mixed models ...... 12 Replacement parts ........................... 26
Preoperation checks ..................... 13 Maintenance chart ............................ 27
Fuel .................................................. 13 Greasing ........................................... 28
Oil ..................................................... 13 Cleaning and adjusting spark plug ... 28
Controls ............................................ 13 Checking fuel system ....................... 29
Engine .............................................. 13 Inspecting idling speed ..................... 30
Checking wiring and connectors ...... 30
Exhaust leakage ............................... 30
Table of contents
Water leakage .................................. 30
Checking propeller ........................... 30
Removing the propeller .................... 31
Installing the Propeller...................... 31
Changing gear oil ............................. 32
Inspecting and replacing anode(s) ... 33
Checking top cowling ....................... 33
Coating the boat bottom ................... 33
Trouble Recovery ............................ 34

Troubleshooting ............................ 34
Temporary action in emergency.... 37
Impact damage................................. 37
Starter will not operate ..................... 37
Emergency starting engine............... 38
Treatment of submerged motor..... 39
Procedure......................................... 39
General information
EMU25170
Identification numbers record

EMU31290
Outboard motor serial number
The outboard motor serial number is stamped
on the label attached to the upper part of the
swivel 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-
1. EC label location
len.
ZMU01696
1. Outboard motor serial number location EMU25371
Safety information
● Before mounting or operating the outboard
motor, read this entire manual. Reading it
should give you an understanding of the
motor and its operation.
● Before operating the boat, read any own-
er’s or operator’s manuals supplied with it
and all labels. Be sure you understand each
item before operating.
EMU25202 ● Do not overpower the boat with this out-
EC label board motor. Overpowering the boat could
Engines affixed with this label conform to cer- result in loss of control. The rated power of
tain portions of the European Parliament di- the outboard should be equal to or less than
rective relating to machinery. Refer to the the rated horsepower capacity of the boat.
label and the EC Declaration of Conformity for If the rated horsepower capacity of the boat
more details. is unknown, consult the dealer or boat man-
ufacturer.
1
General information
● Do not modify the outboard. Modifications ● Tell someone where you are going: leave a
could make the motor unfit or unsafe to use. Float Plan with a responsible person. Be
● Incorrect propeller selection and incorrect sure to cancel the Float Plan when you re-
use may not only cause engine damage, turn.
but also adversely affect fuel consumption. ● Use common sense and good judgment
Consult your dealer for correct use. when boating. Know your abilities, and be
● Never operate after drinking alcohol or tak- sure you understand how your boat han-
ing drugs. About 50% of all boating fatalities dles under the different boating conditions
involve intoxication. you may encounter. Operate within your
● Have an approved personal flotation device limits, and the limits of your boat. Always
(PFD) on board for every occupant. It is a operate at safe speeds, and keep a careful
good idea to wear a PFD whenever boat- watch for obstacles and other traffic.
ing. At a minimum, children and non-swim- ● Always watch carefully for swimmers during
mers should always wear PFDs, and the engine operation.
everyone should wear PFDs when there ● Stay away from swimming areas.
are potentially hazardous boating condi- ● When a swimmer is in the water near you
tions. shift into neutral and shut off the engine.
● Gasoline is highly flammable, and its va- ● Do not illegally discard empty containers
pors are flammable and explosive. Handle used to replace or replenish oil. For the cor-
and store gasoline carefully. Make sure rect processing of empty containers, con-
there are no gas fumes or leaking fuel be- sult the dealer where you purchased the oil.
fore starting the engine. ● When replacing oils used to lubricate the
● This product emits exhaust gases which product (engine or gear oil), be sure to wipe
contain carbon monoxide, a colorless, away any spilt oil. Never pour oil without us-
odorless gas which may cause brain dam- ing a funnel or similar device. If necessary,
age or death when inhaled. Symptoms in- verify the necessary replacement proce-
clude nausea, dizziness, and drowsiness. dure with the dealer.
Keep cockpit and cabin areas well ventilat- ● Never illegally discard (dump) the product.
ed. Avoid blocking exhaust outlets. Yamaha recommends consulting the deal-
● Check throttle, shift, and steering for proper er on discarding the product.
operation before starting the engine.
● Attach the engine stop switch lanyard to a
secure place on your clothing, or your arm
or leg while operating. If you accidentally
leave the helm, the lanyard will pull from the
switch, stopping the engine.
● Know the marine laws and regulations
where you will be boating - and obey them.
● Stay informed about the weather. Check
weather forecasts before boating. Avoid
boating in hazardous weather.
2
General information
EMU25382
● Do not smoke when refueling, and keep
Important labels away from sparks, flames, or other
EMU25395
Warning labels sources of ignition.
● Stop engine before refueling.
● Refuel in a well-ventilated area.
● Take care not to spill gasoline. If gaso-
line spills, wipe it up immediately with
dry rags.
● Do not overfill the fuel tank.
● Tighten the filler cap securely after refu-
eling.
● If you should swallow some gasoline, in-
hale a lot of gasoline vapor, or get gaso-
EMU25401 line in your eyes, get immediate medical
Label attention.
EWM01260
● If any gasoline spills onto your skin, im-
WARNING
mediately wash with soap and water.
● Be sure shift control is in neutral before
Change clothing if gasoline spills on it.
starting engine. (except 2HP)
● Touch the fuel nozzle to the filler open-
● Do not touch or remove electrical parts
ing or funnel to help prevent electrostat-
when starting or during operation.
ic sparks.
● Keep hands, hair, and clothes away from
ECM00010
flywheel and other rotating parts while
engine is running. CAUTION:
Use only new clean gasoline which has
EMU25441
Label been stored in clean containers and is not
EWM01311 contaminated with water or foreign matter.
WARNING
EMU25590
LEAKING FUEL COULD CAUSE A FIRE. Gasoline
Before tilting up the engine or laying it on
its side: Recommended gasoline:
Regular unleaded gasoline
● Turn the fuel cock to the “closed” posi-
tion. If knocking or pinging occurs, use a different
● Tighten the air-vent screw on the fuel
brand of gasoline or premium unleaded fuel. If
tank cap. unleaded gasoline is not available, then pre-
EMU31490 mium gasoline can be used.
Fueling instructions EMU25650
EWM01490 Engine oil

WARNING Recommended engine oil:
GASOLINE AND ITS VAPORS ARE HIGH- YAMALUBE 2-stroke outboard motor
LY FLAMMABLE AND EXPLOSIVE! oil
3
General information
If the recommended engine oil is not avail-
NOTE:
able, another 2-stroke engine oil with an
Select a propeller which will allow the engine
NMMA-certified TC-W3 rating may be used.
EMU25742
to reach the middle or upper half of the oper-
Propeller selection ating range at full throttle with the maximum
The performance of your outboard motor will boat load. If operating conditions such as light
be critically affected by your choice of propel- boat loads then allow the engine r/min to rise
ler, as an incorrect choice could adversely af- above the maximum recommended range, re-
fect performance and could also seriously duce the throttle setting to maintain the en-
damage the motor. Engine speed depends on gine in the proper operating range.
the propeller size and boat load. If engine For instructions on propeller removal and in-
speed is too high or too low for good engine stallation, see page 30.
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 a greater operating load, a
smaller-pitch propeller is more suitable as it
enables the correct engine speed to be main-
tained. Conversely, a larger-pitch propeller is
more suitable for a smaller operating 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 appli-
cation.
x -
1 2 3
ZMU04604
1. Propeller diameter in inches

2. Propeller pitch in inches
3. Type of propeller (propeller mark)
4
Basic components
EMU25797
Main components
NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all models.
1. Air vent screw 17.Throttle lever

2. Fuel tank cap EMU25821
3. Top cowling Fuel tank
4. Anti-cavitation plate If your model included a fuel tank, its parts
5. Propeller and functions are as follows.
6. Cooling water inlet
7. Clamp bracket
8. Clamp screw
9. Tiller handle
10.Fuel cock
11.Manual starter handle
12.Choke knob
13.Engine stop button/Engine stop lanyard
switch
14.Trim rod
15.Rope attachment
16.Tilt support knob
5
Basic components
1. Air vent screw 1. Close position

2. Fuel tank cap EMU25891
EMU25850 Open
Fuel tank cap With the lever/knob in this position, fuel flows
This cap seals the fuel tank. When removed, to the carburetor.
the tank can be filled with fuel. To remove the Normal running is done with the lever/knob in
cap, turn it counterclockwise. this position.
EMU25860
Air vent screw
This screw is on the fuel tank cap. To loosen
the screw, turn it counterclockwise.
EMU25872
Fuel cock
The fuel cock turns on and off the supply of
fuel from the fuel tank to the engine.
1. Open position
EMU25911
Tiller handle
To change direction, move the tiller handle to
the left or right as necessary.
1. Fuel cock
EMU25881
Close
To stop fuel flow to the engine, turn the lever
or knob to close position.
Always turn the lever or knob to close position
when the engine is not running.
6
Basic components
EMU25952
operator’s clothing, or arm or leg. Should the
Throttle lever
operator fall overboard or leave the helm, the
To increase speed, push the lever upward.
lanyard will pull out the lock plate, stopping ig-
nition to the engine. This will prevent the boat
from running away under power.
EWM00120
WARNING
● Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg while operating.
● Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entan-
EMU25981
Throttle friction adjuster gled, preventing it from functioning.
An adjustable friction device within the aprons ● Avoid accidentally pulling the lanyard
restricts movement of the throttle lever ac- during normal operation. Loss of engine
cording to the operator’s preference. 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.
When constant speed is desired, tighten the

adjuster to maintain the desired throttle set-
ting.
EWM01480
WARNING
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to move the throttle lever, which
could result in an accident. 1. Lock plate
2. Lanyard
EMU25990
Engine stop lanyard switch EMU26001
The lock plate must be attached to the engine Engine stop button
stop switch for the engine to run. The lanyard To open the ignition circuit and stop the en-
should be attached to a secure place on the gine, push this button.
7
Basic components
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.
EMU26050
Choke knob
To supply the engine with the rich fuel mixture
required to start, turn this knob counterclock-
wise.
To increase resistance, turn the adjuster

clockwise.
To decrease resistance, turn the adjuster
counterclockwise.
EWM00040
WARNING
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
EMU26070 difficult to steer, which could result in an
Manual starter handle accident.
To start the engine, first gently pull the handle
EMU26261
out until resistance is felt. From that position,
Trim rod (tilt pin)
then pull the handle straight out quickly to
The position of the trim rod determines the
crank the engine.
minimum trim angle of the outboard motor in
relation to the transom.
8
Basic components
EMU26320
Tilt support knob
To keep the outboard motor in the tilted up po-
sition, push the tilt support knob under the
swivel bracket.
9
Operation
EMU26901 EWM00830
Installation WARNING
ECM00110
Improper mounting of the outboard motor
CAUTION:
could result in hazardous conditions such
Incorrect engine height or obstructions to as poor handling, loss of control, or fire
smooth water flow (such as the design or hazards. Observe the following:
condition of the boat, or accessories such ● For permanently mounted models, your
as transom ladders or depth finder trans- dealer or other person experienced in
ducers) can create airborne water spray proper rigging should mount the motor.
while the boat is cruising. Severe engine If you are mounting the motor yourself,
damage may result if the motor is operat- you should be trained by an experienced
ed continuously in the presence of air- person.
borne water spray. ● For portable models, your dealer or oth-
er person experienced in proper out-
NOTE: board motor mounting should show you
During water testing check the buoyancy of how to mount your motor.
the boat, at rest, with its maximum load.
Check that the static water level on the ex- Mount the outboard motor on the center line
haust housing is low enough to prevent water (keel line) of the boat, and ensure that the
entry into the powerhead, when water rises boat itself is well balanced. Otherwise the
due to waves when the outboard is not run- boat will be hard to steer. For boats without a
ning. keel or which are asymmetrical, consult your
dealer.
EMU26910
Mounting the outboard motor
EWM00820
WARNING
● Overpowering a boat could cause se-
vere instability. Do not install an out-
board motor with more horsepower than
the maximum rating on the capacity
plate of the boat. If the boat does not
have a capacity plate, consult the boat 1 ZMU01760
manufacturer.
● The information presented in this sec- 1. Center line (keel line)
tion is intended as reference only. It is EMU26920
Mounting height
not possible to provide complete in-
To run your boat at optimum efficiency, the
structions for every possible boat and
water resistance (drag) of the boat and out-
motor combination. Proper mounting
board motor must be made as little as possi-
depends in part on experience and the
ble. The mounting height of the outboard
specific boat and motor combination.
motor greatly affects the water resistance. If
the mounting height is too high, cavitation
10
Operation
tends to occur, thus reducing the propulsion; EWM00640
and if the propeller tips cut the air, the engine WARNING
speed will rise abnormally and cause the en- Loose clamp screws could allow the out-
gine to overheat. If the mounting height is too board motor to fall off or move on the tran-
low, the water resistance will increase and som. This could cause loss of control and
thereby reduce engine efficiency. Mount the serious injury. Make sure the transom
outboard motor so that the anti-cavitation screws are tightened securely. Occasion-
plate is between the bottom of the boat and a ally check the screws for tightness during
level 25 mm (1 in.) below it. operation.
0–25mm
(0–1in.) ZMU02011
ZMU02012
NOTE: 2. If the engine restraint cable attachment is

● The optimum mounting height of the out- equipped on your engine, an engine re-
board motor is affected by the boat and mo- straint cable or chain should be used. At-
tor combination and the desired use. Test tach one end to the engine restraint cable
runs at different heights can help determine attachment and the other to a secure
the optimum mounting height. Consult your mounting point on the boat. Otherwise
Yamaha dealer or boat manufacturer for the engine could be completely lost if it
further information on determining the prop- accidentally falls off the transom.
er mounting height.
● For instructions on setting the trim angle of
the outboard motor, see page 18.
EMU26970
Clamping the outboard motor
1. Place the outboard motor on the transom
so that it is positioned as close to the cen-
ter as possible. Tighten the transom
clamp screws evenly and securely. Oc-
ZMU02013
casionally check the clamp screws for
tightness during operation of the out-
board motor because they could become
loose due to engine vibration.
11
Operation
3. Secure the clamp bracket to the transom ECM00150
using the bolts provided with the out- CAUTION:

board (if packed). For details, consult Be sure to mix gasoline and oil complete-
your Yamaha dealer. ly, otherwise the engine may be damaged.
EWM00650
EMU27074
WARNING Procedure for pre-mixed models
Avoid using bolts, nuts or washers other Run the engine under load (in gear with a pro-
than those contained in the engine pack- peller installed) for 10 hours as follows.
aging. If used, they must be of at least the 1. First 10 minutes:
same quality of material and strength and Run the engine at the lowest possible
must be tightened securely. After tighten- speed. A fast idle in neutral is best.
ing, test run the engine and check their 2. Next 50 minutes:
tightness. Do not exceed half throttle (approximate-
EMU30173
ly 3000 r/min). Vary engine speed occa-
Breaking in engine sionally. If you have an easy-planing
Your new engine requires a period of break-in boat, accelerate at full throttle onto plane,
to allow mating surfaces of moving parts to then immediately reduce the throttle to
wear in evenly. Correct break-in will help en- 3000 r/min or less.
sure proper performance and longer engine 3. Next two hours:
life. Accelerate at full throttle onto plane, then
ECM00800 reduce engine speed to three-quarter
CAUTION: throttle (approximately 4000 r/min). Vary
Failure to follow the break-in procedure engine speed occasionally. Run at full
could result in reduced engine life or even throttle for one minute, then allow about
severe engine damage. 10 minutes of operation at three-quarter
throttle or less to let the engine cool.
EMU27050
Gasoline and engine oil mixing chart 4. Remaining seven hours:
(25:1) Run the engine at any speed. However,
avoid operating at full throttle for more
than 5 minutes at a time.
5. After the first 10 hours:
Operate the engine normally. Use the
standard premix ratio of gasoline and oil.
For details on mixing fuel and oil, see
page 13.
1. : Gasoline
2. : Engine oil
12
Operation
EMU27102 EMU27233
Preoperation checks Filling fuel and engine oil

EWM00080 EMU27253
WARNING Filling fuel for built-in tank

EWM00060
If any item in the preoperation check is not
WARNING
working properly, have it inspected and
Gasoline and its vapors are highly flam-
repaired before operating the outboard
mable and explosive. Keep away from
motor. Otherwise an accident could occur.
sparks, cigarettes, flames, or other sourc-
ECM00120 es of ignition.
CAUTION:
1. With the outboard motor tilted down (in
Do not start the engine out of water. Over-
the vertical running position), remove the
heating and serious engine damage can
fuel tank cap.
occur.
2. Use a funnel if the nozzle on the fuel can
EMU31500 or pump is not small enough or long
Fuel enough to fit into the mouth of the fuel
● Check to be sure you have plenty of fuel for
tank.
your trip.
3. Fill the fuel tank carefully.
● Make sure there are no fuel leaks or gaso-
4. Securely close the cap after refueling.
line fumes.
EMU27120
Wipe up any spilled fuel.
Oil
Fuel tank capacity:
● Check to be sure you have plenty of oil for
1.2 L (0.32 US gal) (0.26 Imp.gal)
your trip.
EMU27130
EMU27393
Controls Gasoline and oil mixing
● Check throttle, shift, and steering for proper
Gasoline to engine oil
operation before starting the engine. ratio
● The controls should work smoothly, without Break-in period 25:1
binding or unusual free play. After break-in 50:1
● Look for loose or damaged connections.
● Check operation of the starter and stop
switches when the outboard motor is in the
50:1
water. 1L 12 L 14 L 24 L
EMU27140 (0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal,
0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.3 Imp gal)
Engine
● Check the engine and engine mounting. 0.02 L 0.24 L 0.28 L 0.48 L
● Look for loose or damaged fasteners. (0.02 US qt,
0.02 Imp qt)
(0.25 US qt,
0.21 Imp qt)
(0.3 US qt,
0.25 Imp qt)
(0.51 US qt,
0.42 Imp qt)
● Check the propeller for damage.
ZMU04682
1. : Gasoline
2. : Engine oil
13
Operation
If equipped with a portable fuel tank ECM00810
1. Pour oil into the portable fuel tank, and CAUTION:

then add gasoline. ● Avoid using any oil other than the spec-
2. Replace the fuel tank cap and close tight- ified type.
ly. ● Use a thoroughly blended fuel-oil mix-
3. Shake the fuel tank to mix the fuel thor- ture.
oughly. ● If the mixture is not thoroughly mixed, or
4. Make sure that the oil and gasoline are if the mixing ratio is incorrect, the fol-
mixed. lowing problems could occur. Low oil
If equipped with a built-in fuel tank ratio: Lack of oil could cause major en-
1. Pour oil into a clean fuel can, and then gine trouble, such as piston seizure.
add gasoline. ● High oil ratio: Too much oil could cause
fouled spark plugs, smoky exhaust, and
heavy carbon deposits.
NOTE:
If using a permanently installed tank, pour the
oil gradually as the gasoline is being added to
the tank.
EMU27450
Operating engine
EMU31510
Feeding fuel
EWM00420
WARNING
● Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.
● When the air vent screw is loosened,
gasoline vapor will be released. Gaso-
1. Engine oil
line is highly flammable, and its vapors
2. Gasoline
are flammable and explosive. Refrain
2. Replace the fuel can cap and close tight- from smoking, and keep away from
ly. open flames and sparks while loosening
3. Shake the fuel can to mix the fuel thor- the air vent screw.
oughly. ● This product emits exhaust gases which
4. Make sure that the oil and gasoline are contain carbon monoxide, a colorless,
mixed. odorless gas which could cause brain
5. Pour the gasoline and oil mixture into the damage or death when inhaled. Symp-
built-in fuel tank. toms include nausea, dizziness, and
14
Operation
drowsiness. Keep cockpit and cabin ar- ● Do not attach the lanyard to clothing
eas well ventilated. Avoid blocking ex- that could tear loose. Do not route the
haust outlets. lanyard where it could become entan-
gled, preventing it from functioning.
1. Loosen the air vent screw on the fuel tank
● Avoid accidentally pulling the lanyard
cap by one turn.
during normal operation. Loss of engine
power means the loss of most steering
be thrown forward.
2. Open the fuel cock.
2. Place the throttle lever in the start posi-

tion.
EWM00100
WARNING
The propeller rotates whenever the engine
EMU27490 is running. Do not move the throttle con-
Starting engine trol lever from the start position during
EMU27511
Manual start models warm-up. The boat could unexpectedly
1. If the engine stop switch lanyard is start to move, which could result in an ac-
equipped, attach it to a secure place on cident.
your clothing, or your arm or leg. Then in-
stall the lock plate on the other end of the
lanyard into the engine stop switch.
EWM00120
WARNING
● Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg while operating.
15
Operation
3. Place the choke knob in the start position. 5. After the engine starts, slowly return the
After the engine starts, return the knob to manual starter handle to the original posi-
the home position. tion before releasing it.
6. Place the throttle control lever slowly to
the fully closed position.
NOTE:
● It is not necessary to use the choke when
starting a warm engine. NOTE:
● If the choke knob is left in the start position ● When the engine is cold, it needs to be
while the engine is running, the engine will warmed up. For further information, see
run poorly or stall. page 17.
● If the engine does not start on the first try,
4. Pull the manual starter handle slowly until
repeat the procedure. If the engine fails to
you feel resistance. Then give a strong
start after 4 or 5 tries, open the throttle a
pull straight out to start the engine. Re-
small amount (between 1/8 and 1/4) and try
peat if necessary.
again. Also if the engine is warm and fails to
start, open the throttle a same amount and
try to start the engine again. If the engine
still fails to start, see page 34.
16
Operation
EMU27670
Warming up engine
EMU27692
Direct drive models
EWM00100
WARNING
The propeller rotates whenever the engine
is running. Do not move the throttle con-
trol lever from the start position during
warm-up. The boat could unexpectedly
start to move, which could result in an ac-
cident. EMU27740
Shifting
1. Before beginning operation, allow the en- EWM00180
gine to warm up at idle speed for 3 min- WARNING

utes. Failure to do this will shorten engine Before shifting, make sure there are no
life. swimmers or obstacles in the water near
2. Check for a steady flow of water from the you.
cooling water pilot hole.
ECM00220
ECM00511
CAUTION: CAUTION:
To change the boat direction or shifting
A continuous flow of water from the cool-
position from forward to reverse or vice-
ing water pilot hole shows that the water
versa, first close the throttle so that the en-
pump is pumping water through the cool-
gine idles (or runs at low speeds).
ing passages. If water is not flowing out of
the hole at all times while the engine is EMU27750
running, overheating and serious damage Forward

could occur. Stop the engine and check When the engine is started, the propeller
whether the cooling water inlet on the low- turns and the boat begins to move forward.
EMU27770
er case or the cooling water pilot hole is Reverse
blocked. Consult your Yamaha dealer if EWM00190
the problem cannot be located and cor- WARNING

rected. When operating in reverse, go slowly. Do
not open the throttle more than half. Other-
wise the boat could become unstable,
which could result in loss of control and
an accident.
These models can turn a full 360° in its brack-

et (full-pivot system). To back up the boat,
simply turn the engine around 180° with the
tiller handle facing toward you.
17
Operation
EMU27820
Stopping engine
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.
EMU31520
Procedure
1. Push and hold the engine stop button un-
til the engine comes to a complete stop.
NOTE:
The engine can also be stopped by pulling the
lanyard and removing the lock plate from the
engine stop switch.
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-
2. After stopping the engine, tighten the air
prove performance and fuel economy while
vent screw on the fuel tank cap and set
reducing strain on the engine. Correct trim an-
the fuel cock to the closed position.
gle depends upon the combination of boat,
engine, and propeller. Correct trim is also af-
fected by variables such as the load in the
boat, sea conditions, and running speed.
EWM00740
WARNING
Excessive trim for the operating condi-
tions (either trim up or trim down) can
cause boat instability and can make steer-
ing the boat more difficult. This increases
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.
18
Operation
To raise the bow (“trim-out”), move the rod
away from the transom.
To lower the bow (“trim-in”), move the rod to-
ward the transom.
Make test runs with the trim set to different an-
gles to find the position that works best for
your boat and operating conditions.
EWM00400
WARNING
● Stop the engine before adjusting the
trim angle.
● Use care to avoid being pinched when
removing or installing the rod.
● Use caution when trying a trim position
for the first time. Increase speed gradu-
ally and watch for any signs of instability
or control problems. Improper trim an-
1 gle can cause loss of control.
ZMU02043
1. Trim operating angle NOTE:

The outboard motor trim angle can be
EMU27872
Adjusting trim angle for manual tilt changed approximately 4 degrees by shifting
models the trim rod one hole.
There are 4 or 5 holes provided in the clamp EMU27911
bracket to adjust the outboard motor trim an- Adjusting boat trim
gle. When the boat is on plane, a bow-up attitude
1. Stop the engine. results in less drag, greater stability and effi-
2. Tilt the outboard motor up, and then re- ciency. This is generally when the keel line of
move the trim rod from the clamp bracket. 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.
1. Trim rod
3. Reposition the rod in the desired hole.
19
Operation
Bow Up
Too much trim-out puts the bow of the boat
NOTE:
Depending on the type of boat, the outboard
too high in the water. Performance and econ-
motor trim angle may have little effect on the
omy are decreased because the hull of the
trim of the boat when operating.
boat is pushing the water and there is more air
drag. Excessive trim-out can also cause the EMU27921
propeller to ventilate, which reduces perfor- Tilting up and down

mance further, and the boat may “porpoise” If the engine will be stopped for some time or
(hop in the water), which could throw the op- if the boat is moored in shallows, the outboard
erator and passengers overboard. motor should be tilted up to protect the propel-
ler and casing from damage by collision with
obstructions, and also to reduce salt corro-
sion.
EWM00220
WARNING
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.
EWM00230
Bow Down WARNING

Too much trim-in causes the boat to “plow” Leaking fuel is a fire hazard. Tighten the
through the water, decreasing fuel economy air vent screw and place the fuel cock in
and making it hard to increase speed. Operat- the closed position if the outboard motor
ing with excessive trim-in at higher speeds will be tilted for more than a few minutes.
also makes the boat unstable. Resistance at Otherwise fuel may leak.
the bow is greatly increased, heightening the
ECM00231
danger of “bow steering” and making opera-
CAUTION:
tion difficult and dangerous.
● Before tilting the outboard motor, follow
the procedure under “Stopping engine”
in this chapter. Never tilt the outboard
20
Operation
motor while the engine is running. Se-
vere damage from overheating can re-
sult.
● Do not tilt up the engine by pushing the
tiller handle because this could break
the handle.
● Keep the power unit higher than the pro-
peller at all times. Otherwise water could
run into the cylinder and cause damage.
● The outboard motor cannot be tilted
when in reverse or when the outboard 7. Tilt support lever equipped models: Hold
motor is turned 180° (facing the rear). the rear handle and tilt the engine up fully
EMU27964
until the tilt support lever automatically
Procedure for tilting up (manual tilt locks.
models)
NOTE:
1. Place the gear shift lever in neutral (if
Tilt support lever/bar equipped models: If the
equipped) and face the outboard motor
motor is not facing forward, the tilt support le-
forward.
ver/bar cannot automatically turn to the
2. On full-pivot system models, tighten the
locked position. If the tilt support lever/bar
steering friction adjuster by turning it
does not automatically lock, swing the motor
clockwise to prevent the motor from turn-
a little to the left and right.
ing freely.
3. Tighten the air vent screw. On models EMU28032
Procedure for tilting down (manual tilt
equipped with a fuel joint, disconnect the
models)
fuel line from the outboard motor.
1. Slightly tilt the outboard motor up.
4. Close the fuel cock.
2. If equipped with the tilt support bar: Slow-
5. Tilt support bar equipped models: Hold
ly tilt the outboard motor down while pull-
the rear of the top cowling or the rear han-
ing the tilt support bar lever up.
dle (if equipped) with one hand and tilt the
3. If equipped with the tilt support knob: Pull
outboard motor up fully until the tilt sup-
the knob out, and then slowly tilt the out-
port bar automatically locks.
board motor down.
6. Tilt support knob equipped models: Hold
the rear of the top cowling with one hand,
fully tilt the outboard motor up, and push
the tilt support knob into the clamp brack-
et.
21
Operation
4. If equipped with the tilt support lever:
Slowly tilt the outboard motor down while
pulling the tilt support lever up.
5. Loosen the steering friction adjuster by
turning it counterclockwise, and adjust
the steering friction according to operator
preference.
EWM00720
WARNING
If there is too much resistance it could be
difficult to steer, which could result in an
accident.
EMU28192
Cruising in other conditions

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 depos-
its.
NOTE:
For cooling system flushing instructions, see
page 23.
Cruising in turbid water

Yamaha strongly recommends that you use
the optional chromium-plated water pump kit
(not available for some models) if you use the
outboard motor in turbid or muddy water con-
ditions.
22
Maintenance
EMU31480 Starting carburetion system:
Specifications Choke valve
Drive unit:
NOTE: Gear positions:
“(AL)” stated in the specification data below Forward
represents the numerical value for the alumi- Gear ratio:
num propeller installed. 2.08 (27/13)
Likewise, “(SUS)” represents the value for Trim and tilt system:
Manual tilt
stainless steel propeller installed and “(PL)”
Propeller mark:
for plastic propeller installed. A
EMU28218 Fuel and oil:
Recommended fuel:
Dimension: Regular unleaded gasoline
Overall length: Fuel tank capacity (built in type):
603 mm (23.7 in) 1.2 L (0.32 US gal) (0.26 Imp.gal)
Overall width: Recommended engine oil:
240 mm (9.4 in) YAMALUBE 2-stroke outboard motor oil
Overall height S: Fuel:oil ratio:
916 mm (36.1 in) Regular gasoline:
Transom height S: 50 :1
417 mm (16.4 in) Lubrication:
Weight (PL) S: Pre-mixed fuel and oil
9.8 kg (22 lb) Recommended gear oil:
Performance: Hypoid gear oil SAE#90
Full throttle operating range: Gear oil quantity:
4000–5000 r/min 45.0 cm³ (1.52 US oz) (1.59 Imp.oz)
Maximum output: Tightening torque for engine:
1.5 kW@4500 r/min (2 HP@4500 r/min) Spark plug:
Idling speed (in neutral): 25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
EMU28222
1150 ±50 r/min
Engine:
Transporting and storing out-
Type: board motor
2-stroke S EWM00690
Displacement: WARNING
50.0 cm³ (3.05 cu.in)
● Leaking fuel is a fire hazard. When trans-
Bore × stroke:
42.0 × 36.0 mm (1.65 × 1.42 in) porting and storing the outboard motor,
Ignition system: close the air vent screw and fuel cock to
CDI prevent fuel from leaking.
Spark plug (NGK): ● USE CARE when transporting fuel tank,
B7HS
whether in a boat or car.
BR7HS
Spark plug gap: ● DO NOT fill fuel container to maximum
0.6–0.7 mm (0.024–0.028 in) capacity. Gasoline will expand consider-
Control system: ably as it warms up and can build up
Tiller
Starting system:
Manual
23
Maintenance
pressure in the fuel container. This can
cause fuel leakage and a potential fire
hazard.
EWM00700
WARNING
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: NOTE:
Place a towel or something similar under the
Do not use the tilt support lever or knob
outboard motor to protect it from damage.
when trailering the boat. The outboard mo-
tor could shake loose from the tilt support EMU30272
and fall. If the motor cannot be trailered in

Storing outboard motor
When storing your Yamaha outboard motor
the normal running position, use an addi-
for prolonged periods of time (2 months or
tional support device to secure it in the tilt
longer), several important procedures must
position.
be performed to prevent excessive damage.
The outboard motor should be trailered and It is advisable to have your outboard motor
stored in the normal running position. If there serviced by an authorized Yamaha dealer pri-
is insufficient road clearance in this position, or to storage. However, you, the owner, with a
then trailer the outboard motor in the tilt posi- minimum of tools, can perform the following
tion using a motor support device such as a procedures.
ECM01411
transom saver bar. Consult your Yamaha
dealer for further details. CAUTION:
EMU28235 ● Do not place the outboard motor on its
Clamp screw mounting models side before the cooling water has
When transporting or storing the outboard
drained from it completely, otherwise
motor while removed from a boat, keep the
water may enter the cylinder through the
outboard motor in the attitude shown.
exhaust port and cause engine trouble.
● Store the outboard motor in a dry, well-
ventilated place, not in direct sunlight.
EMU28302
Procedure
EMU28313
Flushing in a water tank
1. Wash the outboard motor body using
fresh water. For further information, see
page 26.
ZMU02870
24
Maintenance
2. Place the fuel cock in the closed position ● Keep hands, hair, and clothes away from
and disconnect the fuel line if equipped. the flywheel and other rotating parts
Tighten the air vent screw, if equipped. while the engine is running.
3. Remove the engine top cowling and si-
7. Run the engine at a fast idle for a few
lencer cover.
minutes in neutral position.
4. Install the outboard motor on the test
8. Just prior to turning off the engine, quickly
tank.
spray “Fogging Oil” alternately into each
carburetor or the fogging hole of the si-
lencer cover, if equipped. When properly
done, the engine will smoke excessively
and almost stall.
9. If “Fogging Oil” is not available, run the
engine at a fast idle until the fuel system
empties and the engine stops.
10. Remove the outboard motor from the test
tank.
1. Water surface 11. Install the silencer cover or fogging hole
2. Lowest water level cap, and the top cowling.
5. Fill the tank with fresh water to above the 12. Drain the cooling water completely out of
level of the anti-cavitation plate. the motor. Clean the body thoroughly.
ECM00290 13. If “Fogging Oil” is not available, remove
CAUTION: the spark plug(s). Pour a teaspoonful of
If the fresh water level is below the level of clean engine oil into each cylinder. Crank
the anti-cavitation plate, or if the water several times manually. Replace the
supply is insufficient, engine seizure may spark plug(s).
occur. 14. Drain the fuel from both the built-in and
portable fuel tanks, on equipped models.
6. Cooling system flushing is essential to
prevent the cooling system from clogging NOTE:
Portable fuel tank equipped models: Store the
up with salt, sand, or dirt. In addition, fog-
portable fuel tank in a dry, well-ventilated
ging/lubricating of the engine is mandato-
place, not in direct sunlight.
ry to prevent excessive engine damage
due to rust. Perform the flushing and fog- EMU28400
ging at the same time. Lubrication (except oil injection mod-

EWM00090 els)
WARNING 1. Grease the spark plug threads and install
● Do not touch or remove electrical parts the spark plug(s) and torque to proper
when starting or during operation. specification. For information on spark
plug installation, see page 28.
25
Maintenance
2. Change the gear oil. For instructions, see iar with machine servicing, this work
page 32. Inspect the oil for the presence should be done by your Yamaha dealer or
of water that indicates a leaky seal. Seal other qualified mechanic.
replacement should be performed by an EMU28510
authorized Yamaha dealer prior to use. Replacement parts
3. Grease all grease fittings. For further de- If replacement parts are necessary, use only
tails, see page 28. genuine Yamaha parts or parts of the same
EMU28450
type and of equivalent strength and materials.
Cleaning the outboard motor
Any part of inferior quality may malfunction,
After use, wash the exterior of the outboard
and the resulting loss of control could endan-
motor with fresh water. Flush the cooling sys-
ger the operator and passengers. Yamaha
tem with fresh water.
genuine parts and accessories are available
from your Yamaha dealer.
NOTE:
For cooling system flushing instructions, see
page 23.
EMU28460
Checking painted surface of motor
Check the motor for scratches, nicks, or flak-
ing paint. Areas with damaged paint are more
likely to corrode. If necessary, clean and paint
the areas. A touch-up paint is available from
your Yamaha dealer.
EMU28476
Periodic maintenance
EWM01070
WARNING
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If you or the owner is not famil-
26
Maintenance
EMU28522
Maintenance chart
Frequency of maintenance operations may be adjusted according to the operating conditions,
but the following table gives general guidelines. Refer to the sections in this chapter for expla-
nations of each owner-specific action.
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean
water after each use.
The “ ” symbol indicates the check-ups which you may carry out yourself.
The “ ” symbol indicates work to be carried out by your Yamaha dealer.
Initial Every
Item Actions 10 hours 50 hours 100 hours 200 hours
(1 month) (3 months) (6 months) (1 year)
Inspection / replace-
Anode(s) (external)
ment
Cooling water passag-
Cleaning
es
Cowling clamp Inspection
Fuel filter (inside built-
Inspection / cleaning
in fuel tank)
Fuel system Inspection
Fuel tank (built-in tank) Inspection / cleaning
Gear oil Change
Greasing points Greasing
Idling speed (carbure-
Inspection
tor models)
Propeller and cotter pin
ment
Thermostat
ment
Throttle link / throttle
cable / throttle pick-up Inspection / adjustment
timing
Water pump
ment
Cleaning / adjustment /
Spark plug(s)
replacement
27
Maintenance
EMU28940
Greasing
Yamaha grease A (water resistant grease)
Yamaha grease D (corrosion resistant grease; for propeller shaft)
EMU28952
The spark plug is an important engine compo-
Cleaning and adjusting spark plug
EWM00560
nent and is easy to inspect. The condition of
WARNING the spark plug can indicate something about
the condition of the engine. For example, if the
When removing or installing a spark plug,
center electrode porcelain is very white, this
be careful not to damage the insulator. A
could indicate an intake air leak or carburetion
damaged insulator could allow external
problem in that cylinder. Do not attempt to di-
sparks, which could lead to explosion or
agnose any problems yourself. Instead, take
fire.
the outboard motor to a Yamaha dealer. You
should periodically remove and inspect the
28
Maintenance
spark plug because heat and deposits will tight. Have the spark plug adjusted to the cor-
cause the spark plug to slowly break down rect torque as soon as possible with a torque-
and erode. If electrode erosion becomes ex- wrench.
cessive, or if carbon and other deposits are EMU28962
excessive, you should replace the spark plug Checking fuel system
with another of the correct type. EWM00060
WARNING
Standard spark plug:
Gasoline and its vapors are highly flam-
B7HS
BR7HS mable and explosive. Keep away from
sparks, cigarettes, flames, or other sourc-
Before fitting the spark plug, measure the es of ignition.
electrode gap with a wire thickness gauge; EWM00910
adjust the gap to specification if necessary. WARNING
Leaking fuel can result in fire or explosion.
● Check for fuel leakage regularly.
● If any fuel leakage is found, the fuel sys-

tem must be repaired by a qualified me-
chanic. Improper repairs can make 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-
1. Spark plug gap pair it immediately.
2. Spark plug I.D. mark (NGK)
Spark plug gap:

0.6–0.7 mm (0.024–0.028 in)
When fitting the plug, always clean the gasket

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:

25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
Checkpoints
● Fuel system parts leakage
NOTE: ● Fuel line joint leakage
If a torque-wrench is not available when you
● Fuel line cracks or other damage
are fitting a spark plug, a good estimate of the
● Fuel connector leakage
correct torque is 1/4 to 1/2 a turn past finger-
29
Maintenance
EMU30810
2. Verify whether the idle speed is set to
Inspecting idling speed
EWM01440
specification. For idle speed specifica-
WARNING tions, see page 23.
EMU29112
● Do not touch or remove electrical parts Checking wiring and connectors
when starting or during operation. ● Check that each grounding wire is properly
● Keep hands, hair, and clothes away from secured.
the flywheel and other rotating parts ● Check that each connector is engaged se-
while the engine is running. curely.
● The propeller rotates whenever the en- EMU29120
gine is running. Do not move the throttle

Exhaust leakage
Start the engine and check that no exhaust
control lever from the start position dur-
leaks from the joints between the exhaust
ing warm-up. The boat could unexpect-
cover, cylinder head, and body cylinder.
edly start to move, which could result in EMU29130
an accident. Water leakage
ECM01520
Start the engine and check that no water
CAUTION: leaks from the joints between the exhaust
cover, cylinder head, and body cylinder.
This procedure must be performed while EMU29171
the outboard motor is in the water. A test Checking propeller
tank can be used. EWM00321
WARNING
A diagnostic tachometer should be used for
You could be seriously injured if the en-
this procedure. Results may vary depending
gine accidentally starts when you are near
on whether testing is conducted with the
the propeller.
flushing attachment, in a test tank, or with the
● Before inspecting, removing, or install-
outboard motor in the water.
ing the propeller, remove the spark plug
1. Start the engine and allow it to warm up
caps from the spark plugs. Also, place
fully with the throttle in the start position or
the shift control in neutral, turn the main
less until it is running smoothly. If the out-
switch to “ ” (off) and remove the key,
board is mounted on a boat, be sure the
and remove the lanyard from the engine
boat is tightly moored.
stop switch. Turn off the battery cut-off
NOTE: switch if your boat has one.
Correct idling speed inspection is only possi- ● Do not use your hand to hold the propel-
ble if the engine is fully warmed up. If not ler when loosening or tightening the
warmed up fully, the idle speed will measure propeller nut. Put a wood block between
higher than normal. If you have difficulty veri- the anti-cavitation plate and the propel-
fying the idle speed, or the idle speed requires ler to prevent the propeller from turning.
adjustment, consult a Yamaha dealer or other
qualified mechanic.
30
Maintenance
EMU30660
Removing the propeller
EMU29181
Shear pin models
1. Straighten the cotter pin and pull it out us-
ing a pair of pliers.
ZMU01896
Checkpoints
● Check each of the propeller blades for
wear, erosion from cavitation or ventilation,
or other damage.
● Check the propeller shaft for damage.
1. Cotter pin
● Check the splines / shear pin for wear or
2. Propeller
damage. 3. Shear pin
● Check for fish line tangled around the pro-
2. Remove the propeller nut and washer, if
peller shaft.
equipped.
3. Remove the shear pin and the propeller.
EMU30670
Installing the Propeller
EMU29221
Shear pin models
ECM00500
CAUTION:
Be sure to use a new cotter pin and bend
the ends over securely. Otherwise the pro-
peller could come off during operation and
be lost.
● Check the propeller shaft oil seal for dam-
age. 1. Apply Yamaha marine grease or corro-
sion resistant grease to the propeller
NOTE: shaft.
If the shear pin equipped: it is designed to
2. Insert the shear pin into the hole in the
break if the propeller hits a hard underwater
propeller shaft.
obstacle to help protect the propeller and
3. Align the shear pin with the groove in the
drive mechanism. The propeller will then spin
propeller boss, and slide the propeller
freely on the shaft. If this happens, the shear
over the propeller shaft.
pin must be replaced.
31
Maintenance
4. Align the hole in the propeller with the re-
NOTE:
cess in the propeller shaft. Insert a new
● If a magnetic gear oil drain screw is
cotter pin in the hole and bend the cotter
equipped, remove all metal particles from
pin ends.
the screw before installing it.
NOTE: ● Always use new gaskets. Do not reuse the
There is a holder on the steering handle for removed gaskets.
spare shear and cotter pins. Be sure to re-
4. Remove the oil level plug and gasket to
place a pin in the holder if one is used.
allow the oil to drain completely.
EMU29282 ECM00710
Changing gear oil CAUTION:
EWM00800
Inspect the used oil after it has been
WARNING
drained. If the oil is milky, water is getting
● Be sure the outboard motor is securely
into the gear case which can cause gear
fastened to the transom or a stable
damage. Consult a Yamaha dealer for re-
stand. You could be severely injured if
pair of the lower unit seals.
the outboard motor falls on you.
● Never get under the lower unit while it is
tilted, even when the tilt support lever or NOTE:
For disposal of used oil, consult your Yamaha
knob is locked. Severe injury could oc-
dealer.
cur if the outboard motor accidentally
falls. 5. With the outboard motor in a vertical po-
sition, and using a flexible or pressurized
1. Tilt the outboard motor so that the gear oil
filling device, inject the gear oil into the
drain screw is at the lowest point possi-
gear oil drain screw hole.
ble.
2. Place a suitable container under the gear Recommended gear oil:
case. Hypoid gear oil SAE#90
3. Remove the gear oil drain screw and gas- Gear oil quantity:
45.0 cm³ (1.52 US oz) (1.59 Imp.oz)
ket.
1. Gear oil drain screw

2. Oil level plug
32
Maintenance
6. Put a new gasket on the oil level plug. EMU29400
Coating the boat bottom
When the oil begins to flow out of the oil
A clean hull improves boat performance. The
level plug hole, insert and tighten the oil
boat bottom should be kept as clean of marine
level plug.
growth as possible. If necessary, the boat bot-
7. Put a new gasket on the gear oil drain
tom can be coated with an anti-fouling paint
screw. Insert and tighten the gear oil
approved for your area to inhibit marine
drain screw.
EMU29312
growth.
Inspecting and replacing anode(s) Do not use anti-fouling paint which includes
Yamaha outboard motors are protected from copper or graphite. These paints can cause
corrosion by sacrificial anodes. Inspect the more rapid engine corrosion.
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 an-
odes on equipped models. Consult a Yamaha
dealer for inspection and replacement of inter-
nal anodes attached to the power unit.
EMU29390
Checking top cowling
Check the fitting of the top cowling by pushing
it with both hands. If it is loose have it repaired
by your Yamaha dealer.
33
Trouble Recovery
EMU29424
Q. Is fuel filter clogged?
Troubleshooting A. Clean or replace filter.
A problem in the fuel, compression, or ignition
systems can cause poor starting, loss of pow- Q. Is starting procedure incorrect?
er, or other problems. This section describes A. See page 15.
basic checks and possible remedies, and cov-
ers all Yamaha outboard motors. Therefore Q. Has fuel pump malfunctioned?
some items may not apply to your model. A. Have serviced by a Yamaha dealer.
If your outboard motor requires repair, bring it
to your Yamaha dealer. Q. Are spark plug(s) fouled or of incorrect
If the engine trouble warning indicator is flash- type?
ing, consult your Yamaha dealer. A. Inspect spark plug(s). Clean or replace with
recommended type.
Starter will not operate.
Q. Is battery capacity weak or low? Q. Are spark plug cap(s) fitted incorrectly?
A. Check battery condition. Use battery of rec- A. Check and re-fit cap(s).
ommended capacity.
Q. Is ignition wiring damaged or poorly con-
Q. Are battery connections loose or corrod- nected?
ed? A. Check wires for wear or breaks. Tighten all
A. Tighten battery cables and clean battery loose connections. Replace worn or broken
terminals. wires.
Q. Is fuse for electric start relay or electric cir- Q. Are ignition parts faulty?
cuit blown? A. Have serviced by a Yamaha dealer.
A. Check for cause of electric overload and
repair. Replace fuse with one of correct am- Q. Is engine stop switch lanyard not at-
perage. tached?
A. Attach lanyard.
Q. Are starter components faulty?
A. Have serviced by a Yamaha dealer. Q. Are engine inner parts damaged?
A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear?
A. Shift to neutral. Engine idles irregularly or stalls.
Q. Are spark plug(s) fouled or of incorrect
Engine will not start (starter operates). type?
Q. Is fuel tank empty? A. Inspect spark plug(s). Clean or replace with
A. Fill tank with clean, fresh fuel. recommended type.
Q. Is fuel contaminated or stale? Q. Is fuel system obstructed?

A. Fill tank with clean, fresh fuel.
34
Trouble Recovery
A. Check for pinched or kinked fuel line or oth- A. Return to home position.
er obstructions in fuel system.
Q. Is motor angle too high?
Q. Is fuel contaminated or stale? A. Return to normal operating position.
A. Fill tank with clean, fresh fuel.
Q. Is carburetor clogged?
Q. Is fuel filter clogged? A. Have serviced by a Yamaha dealer.
A. Clean or replace filter.
Q. Is fuel joint connection incorrect?
Q. Have ignition parts failed? A. Connect correctly.
Q. Is throttle valve adjustment incorrect?
Q. Has warning system activated? A. Have serviced by a Yamaha dealer.
A. Find and correct cause of warning.
Q. Is battery cable disconnected?
Q. Is spark plug gap incorrect? A. Connect securely.
A. Inspect and adjust as specified.
Warning buzzer sounds or indicator lights.
Q. Is ignition wiring damaged or poorly con- Q. Is cooling system clogged?
nected? A. Check water intake for restriction.
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken Q. Is engine oil level low?
wires. A. Fill oil tank with specified engine oil.
Q. Is specified engine oil not being used? Q. Is heat range of spark plug incorrect?
A. Check and replace oil as specified. A. Inspect spark plug and replace it with rec-
ommended type.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer. Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Are carburetor adjustments incorrect?
A. Have serviced by a Yamaha dealer. Q. Is engine oil contaminated or deteriorated?
A. Replace oil with fresh, specified type.
Q. Is fuel pump damaged?
A. Have serviced by a Yamaha dealer. Q. Is oil filter clogged?
Q. Is air vent screw on fuel tank closed?
A. Open air vent screw. Q. Has oil feed/injection pump malfunc-
tioned?
Q. Is choke knob pulled out? A. Have serviced by a Yamaha dealer.
35
Trouble Recovery
Q. Is load on boat improperly distributed? A. Remove foreign matter and clean lower
A. Distribute load to place boat on an even unit.
plane.
Q. Is fuel system obstructed?
Q. Is water pump or thermostat faulty? A. Check for pinched or kinked fuel line or oth-
A. Have serviced by a Yamaha dealer. er obstructions in fuel system.
Q. Is there excess water in fuel filter cup? Q. Is fuel filter clogged?

A. Drain filter cup. A. Clean or replace filter.
Engine power loss. Q. Is fuel contaminated or stale?

Q. Is propeller damaged? A. Fill tank with clean, fresh fuel.
A. Have propeller repaired or replaced.
Q. Is spark plug gap incorrect?
Q. Is propeller pitch or diameter incorrect? A. Inspect and adjust as specified.
A. Install correct propeller to operate outboard
at its recommended speed (r/min) range. Q. Is ignition wiring damaged or poorly con-
nected?
Q. Is trim angle incorrect? A. Check wires for wear or breaks. Tighten all
A. Adjust trim angle to achieve most efficient loose connections. Replace worn or broken
operation. wires.
Q. Is motor mounted at incorrect height on Q. Have electrical parts failed?

transom? A. Have serviced by a Yamaha dealer.
A. Have motor adjusted to proper transom
height. Q. Is specified fuel not being used?
A. Replace fuel with specified type.
Q. Has warning system activated?
A. Find and correct cause of warning. Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Is boat bottom fouled with marine growth?
A. Clean boat bottom. Q. Is thermostat faulty or clogged?
Q. Are spark plug(s) fouled or of incorrect
type? Q. Is air vent screw closed?
A. Inspect spark plug(s). Clean or replace with A. Open the air vent screw.
recommended type.
Q. Is fuel pump damaged?
Q. Are weeds or other foreign matter tangled A. Have serviced by a Yamaha dealer.
on gear housing?
Q. Is fuel joint connection incorrect?
36
Trouble Recovery
A. Connect correctly. If the outboard motor hits an object in the wa-
ter, follow the procedure below.
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?
Q. Is engine not responding properly to shift

lever position?
A. Have serviced by a Yamaha dealer. 1. Stop the engine immediately.
2. Inspect the control system and all compo-
Engine vibrates excessively. nents for damage. Also inspect the boat
Q. Is propeller damaged? for damage.
A. Have propeller repaired or replaced. 3. Whether damage is found or not, return
to the nearest harbor slowly and careful-
Q. Is propeller shaft damaged? ly.
A. Have serviced by a Yamaha dealer. 4. Have a Yamaha dealer inspect the out-
board motor before operating it again.
Q. Are weeds or other foreign matter tangled EMU31310
on propeller? Starter will not operate

If the starter mechanism does not operate
A. Remove and clean propeller.
(the engine cannot be cranked with the start-
er), the engine can be started with an emer-
Q. Is motor mounting bolt loose?
gency starter rope.
A. Tighten bolt.
EWM01460
WARNING
Q. Is steering pivot loose or damaged?
● Use this procedure only in an emergen-
A. Tighten or have serviced by a Yamaha
cy to return to the nearest port for re-
dealer.
EMU29432
pairs.
Temporary action in emergency ● Attach the engine stop switch lanyard to
EMU29440 a secure place on your clothing, or your
Impact damage arm or leg while operating the boat.
EWM00870
● Do not attach the lanyard to clothing
WARNING
that could tear loose. Do not route the
The outboard motor can be seriously dam-
cord where it could become entangled,
aged by a collision while operating or
preventing it from functioning.
trailering. Damage could make the out-
● Avoid accidentally pulling the lanyard
board motor unsafe to operate.
during normal operation. Loss of engine
power means the loss of most steering
37
Trouble Recovery
be thrown forward.
● Make sure no one is standing behind
you when pulling the starter rope. It
could whip behind you and injure some-
one.
● An unguarded, rotating flywheel is very
dangerous. Keep loose clothing and
other objects away when starting the en- 2. Remove the aprons by removing the
gine. Use the emergency starter rope eight screws.
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.
● Do not touch the ignition coil, spark plug
wire, spark plug cap, or other electrical
components when starting or operating
the motor. You could get an electrical
shock.
● Do not move the throttle lever above the 3. Remove the starter mechanism by re-
start position when starting the engine. moving the three bolts.
Because the propeller rotates whenever
the engine is running, the boat could un-
expectedly start to move, which could
result in an accident.
EMU29550
Emergency starting engine
1. Remove the spark plug cap cover by re-
moving the two screws.
4. Prepare the engine for starting. For fur-

ther information, see page 15.
5. Insert the knotted end of the rope into the
notch in the flywheel rotor and wind the
rope several turns around the flywheel
one or two turns clockwise.
38
Trouble Recovery
6. Give a strong pull straight out to crank the
engine. Repeat if necessary.
ZMU01910
3. Drain the fuel from the carburetor, fuel fil-

ter, and fuel line.
EMU29760
4. Feed fogging oil or engine oil through the
Treatment of submerged motor carburetor(s) and spark plug holes while
If the outboard motor is submerged, immedi-
cranking with the manual starter or emer-
ately take it to a Yamaha dealer. Otherwise
gency starter rope.
some corrosion may begin almost immediate-
ly.
If you cannot immediately take the outboard
motor to a Yamaha dealer, follow the proce-
dure below in order to minimize engine dam-
age.
EMU29771
Procedure
1. Thoroughly wash away mud, salt, sea-
weed, and so on, with fresh water.
ZMU01911
5. 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.
ZMU01909
2. Remove the spark plugs and face the

spark plug holes downward to allow any
water, mud, or contaminants to drain.
39
YAMAHA MOTOR CO., LTD.

Printed in Japan
March 2006–1.0 × 1 CR Printed on recycled paper

6F8 28199 Ka

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book Page 1 Tuesday, March 7, 2006 11:14 AM

Important manual information

Trouble Recovery ............................ 34

Identification numbers record

1. Outboard motor serial number location EMU25371

EWM01490 Engine oil

1. Propeller diameter in inches

1. Air vent screw 17.Throttle lever

1. Air vent screw 1. Close position

When constant speed is desired, tighten the

To increase resistance, turn the adjuster

NOTE: 2. If the engine restraint cable attachment is

using the bolts provided with the out- CAUTION:

Preoperation checks Filling fuel and engine oil

WARNING Filling fuel for built-in tank

1. Pour oil into the portable fuel tank, and CAUTION:

2. Open the fuel cock.

2. Place the throttle lever in the start posi-

gine to warm up at idle speed for 3 min- WARNING

running, overheating and serious damage Forward

the problem cannot be located and cor- WARNING

These models can turn a full 360° in its brack-

Trimming outboard motor

1. Trim operating angle NOTE:

propeller to ventilate, which reduces perfor- Tilting up and down

Bow Down WARNING

Cruising in other conditions

Cruising in turbid water

and fall. If the motor cannot be trailered in

ging at the same time. Lubrication (except oil injection mod-

● If any fuel leakage is found, the fuel sys-

Check the fuel lines for leaks, crack, or mal-

Spark plug gap:

When fitting the plug, always clean the gasket

Spark plug torque:

gine is running. Do not move the throttle

1. Gear oil drain screw

Q. Is fuel contaminated or stale? Q. Is fuel system obstructed?

Q. Is there excess water in fuel filter cup? Q. Is fuel filter clogged?

Engine power loss. Q. Is fuel contaminated or stale?

Q. Is motor mounted at incorrect height on Q. Have electrical parts failed?

Q. Is high pressure fuel pump drive belt bro-

Q. Is engine not responding properly to shift

on propeller? Starter will not operate

4. Prepare the engine for starting. For fur-

3. Drain the fuel from the carburetor, fuel fil-

5. Take the outboard motor to a Yamaha

2. Remove the spark plugs and face the

YAMAHA MOTOR CO., LTD.

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