C40A C50A OWNER S MANUAL. U.S.A.Edition LIT

Transcription

1 C40A C50A OWNER S MANUAL U.S.A.Edition LIT

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3 MU01449 Thank you for choosing a Yamaha outboard motor. This Oner s manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions ill help you obtain maximum enjoyment from your ne Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Oner s Manual particularly important information is distinguished in the folloing ays. Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! TO THE OWNER cc E 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. Therefore, hile this manual contains the most current product information available at the time of printing, there may be minor discrepancies beteen your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer. Failure to follo WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. NOTE: The C40TR, C50TR and their standard accessories are used as a base for the explanations and illustrations in this manual. Therefore, some items may not apply to every model. EMU01446 C40A/C50A OWNER'S MANUAL 2001 by Yamaha Motor Corporation, USA 1st Edition, March 2001 All rights reserved. Any reprinting or unauthorized use ithout the ritten permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in Japan P/N LIT

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5 CONTENTS E GENERAL INFORMATION 1 BASIC COMPONENTS 2 OPERATION 3 MAINTENANCE 4 TROUBLE RECOVERY 5 INDEX 6 READ THIS OWNER S MANUAL CAREFULLY BEFORE OPERATING YOUR OUTBOARD MOTOR.

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7 EMB00010 Chapter 1 GENERAL INFORMATION IDENTIFICATION NUMBERS RECORD..1-1 Outboard motor serial number Key number EMISSION CONTROL INFORMATION SAFETY INFORMATION IMPORTANT LABELS BASIC BOATING RULES FUELING INSTRUCTIONS Gasoline (Petrol) Engine oil BATTERY REQUIREMENT PROPELLER SELECTION START-IN-GEAR PROTECTION

8 EMU00005 IDENTIFICATION NUMBERS RECORD EMU00007 OUTBOARD MOTOR SERIAL NUMBER YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D ORIGINE JAPON 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 stolen. 1 Outboard motor serial number EMU00008 KEY NUMBER q YAMAHA 123 If a main key sitch is equipped ith the motor, the key identification number is stamped on your key as shon in the illustration. Record this number in the space provided for reference in case you need a ne key. 1 Key number * 1-1

9 q EMU01385 EMISSION CONTROL INFORMATION ****** EMU01386 NORTH AMERICAN MODELS This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details. Approval label of Emission control certificate This label is attached to the bottom coling. 1 Emission control information label EMISSION CONTROL INFORMATION ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES. FELs : g/k-hr IDLE SPEED : rpm IN NEUTRAL SPARK PLUG : SPARK PLUG GAP (mm) : Existing Technology ; N/A Manufactured date label This label is attached to the clamp bracket or the sivel bracket. 2 Manufactured date label Manufactured: 1-2

10 EMU00917 Q SAFETY INFORMATION 8 Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation. 8 Before operating the boat, read any oner s or operator s manuals supplied ith it and all labels. Be sure you understand each item before operating. 8 Do not overpoer the boat ith this outboard motor. Overpoering the boat could result in loss of control. The rated poer of the outboard should be equal to or less than the rated horsepoer capacity of the boat. If the rated horsepoer capacity of the boat is unknon, consult the dealer or boat manufacturer. 8 Do not modify the outboard. Modifications could make the motor unfit or unsafe to use. 8 Never operate after drinking alcohol or taking drugs. About 50% of all boating fatalities involve intoxication. 8 Have an approved personal flotation device (PFD) on board for every occupant. It is a good idea to ear a PFD henever boating. At a minimum, children and non-simmers should alays ear PFDs, and everyone should ear PFDs hen there are potentially hazardous boating conditions. 8 Gasoline is highly flammable, and its vapors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel before starting the engine. 8 This product emits exhaust gases hich contain carbon monoxide, a colorless, odorless gas hich may cause brain damage or death hen inhaled. Symptoms include nausea, dizziness, and drosiness. Keep cockpit and cabin areas ell ventilated. Avoid blocking exhaust outlets. 8 Check throttle, shift, and steering for proper operation before starting the engine. 8 Attach the engine stop sitch lanyard to a secure place on your clothing, or your arm or leg hile operating. If you accidentally leave the helm, the lanyard ill pull from the sitch, stopping the engine. 8 Kno the marine las and regulations here you ill be boating - and obey them. Refer to the RULES OF THE ROAD section for basic boating rules. 8 Stay informed about the eather. Check eather forecasts before boating. Avoid boating in hazardous eather. 8 Tell someone here you are going: leave a Float Plan ith a responsible person. Be sure to cancel the Float Plan hen you return. 8 Use common sense and good judgment hen boating. Kno your abilities, and be sure you understand ho your boat handles under the different boating conditions you may encounter. Operate ithin your limits, and the limits of your boat. Alays operate at safe speeds, and keep a careful atch for obstacles and other traffic. 8 Alays atch carefully for simmers during the engine operation. 8 Stay aay from simming areas. 1-3

11 8 When a simmer is in the ater near you shift into neutral and shut off the engine. 8 Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the folloing: United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast Guard Headquarters Washington, D.C Boating Safety Hotline: National Marine Manufacturers Association (NMMA) 401 N. Michigan Ave. Chicago, Il Marine Retailers Association of America 155 N. Michigan Ave. Chicago, Il

12 q * EMB30010 IMPORTANT LABELS WARNING LABELS 1 WARNING Be sure shift control is in neutral before starting engine. (except 2HP) Do not touch or remove electrical parts hen starting or during operation. Keep hands,hair,and clothes aay from flyheel and other rotating parts hile engine is running. E 6A CAUTION LABELS 2 CAUTION Use premix fuel only. 1-5

13 EMB40010 BASIC BOATING RULES (Rules of the road) Just as there are rules hich apply hen you are driving on streets and high ays, there are ateray rules hich apply hen you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast Guard and local agencies. You should be aare of these rules, and follo them henever you encounter another vessel on the ater. 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 Oner s Manual are condensed, and have been provided for your convenience only. Consult your local U.S. Coast Guard Auxiliary or Department of Motor Vehicles for a complete set of rules governing the aters in hich you ill be using your boat. STEERING AND SAILING RULES AND SOUND SIGNALS Whenever to vessels on the ater meet one another, one vessel has the right-ofay; it is called the stand-on vessel. The vessel hich does not have the rightof-ay is called the give-ay or burdened vessel. These rules determine hich vessel has the right-of-ay, and hat each vessel should do. Stand-on vessel The vessel ith the right-of-ay 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 ill be able to determine ho best to avoid you. Give-ay vessel The vessel hich does not have the rightof-ay has the duty to take positive and timely action to stay out of the ay of the Stand-On vessel. Normally, you should not cross in front of the vessel ith the right-of-ay. You should slo don or change directions briefly and pass behind the other vessel. You should alays move in such a ay that the operator of the other vessel can see hat 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 navigation and collision, and to any special circumstances, hich may render a departure from the above rules necessary in order to avoid immediate danger. In other ords, follo the standard rules except hen a collision ill occur unless both vessels try to avoid each other. If that is the case, both vessels become Give-Way vessels. 1-6

14 RULES WHEN ENCOUNTERING VES- SELS There are three main situations hich you may encounter ith other vessels hich could lead to a collision unless the Steering Rules are folloed: Meeting (you are approaching another vessel head-on) Crossing (you are travelling across the other vessel s path) Overtaking (you are passing or being passed by another vessel) In the folloing illustration, your boat is in the center. You should give the right-ofay to any vessels shon in hite area (you are the Give-Way vessel). Any vessels in the shaded area must yield to you (they are the Give-Way vessels). Both you and the meeting vessel must alter course to avoid each other. ill clear one another if you continue on your set course and speed Crossing When to poer driven vessels are crossing each other s path close enough to run the risk of collision, the vessel hich has the other on the starboard (right) side must keep out of the ay of the other. If the other vessel is on your right, you must keep out of its ay; you are the Give-Way vessel. If the other vessel is on your port (left) side, remember that you should maintain course and direction, provided the other vessel gives you the right-of-ay as it should Meeting If you are meeting another poer vessel head on, and are close enough to run the risk of collision, neither of you has the right-of-ay! Both of you should alter course to avoid an accident. You should keep the other vessel on your port (left) side. This rule doesn t apply if both of you Overtaking If you are passing another vessel, you are the Give-Way vessel. This means that the other vessel is expected to maintain 1-7

15 its course and speed. You must stay out of its ay until you are clear of it. Likeise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you. OTHER SPECIAL SITUATIONS There are three other rules you should be aare of hen driving your boat around other vessels. Narro channels and bends When navigating in narro channels, you should keep to the right hen it is safe and practical to do so. If the operator of a poer-driven vessel is preparing to go around a bend that may obstruct the vie of other ater vessels, the operator should sound a prolonged blast on the histle (4 to 6 seconds). If another vessel is around the bend, it too should sound the histle. Even if no reply is heard, hoever, the vessel should still proceed around the bend ith caution. If you navigate such aters ith your boat, you ill need to carry a portable air horn, available from local marine supply stores. Fishing vessel right-of-ay All vessels hich are fishing ith nets, lines or trals are considered to be fishing vessels under the International Rules. Vessels ith trolling lines are not considered fishing vessels. Fishing vessels have the right-of-ay regardless of position. Fishing vessels cannot, hoever, impede the passage of other vessels in narro channels. Sailing vessel right-of-ay Sailing vessels should normally be given the right-of-ay. The exceptions to this are: 1. When the sailing vessel is overtaking the poer-driven vessel, the poerdriven vessel has the right-of-ay. 2. Sailing vessels should keep clear of any fishing vessel. 3. In a narro channel, a sailing vessel should not hamper the safe passage of a poer-driven vessel hich can navigate only in such a channel. Reading buoys and other markers The aters 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 sho hich side of the buoy a boater should pass on hen navigating in a particular direction. The markings on these buoys are oriented from the perspective of being entered from seaard (the boater is going toards the port). This means that red buoys are passed on the starboard (right) side hen proceeding from open ater into port, and black buoys are to port (left) side. When navigating out of port, your position ith respect to the buoys should be reversed; red buoys should be to port and black buoys to starboard. Many bodies of ater used by boaters are entirely ithin the boundaries of a particular state. The Uniform State Wateray Marking System has been devised for these aters. This system uses buoys and signs ith distinctive shapes and colors to sho regulatory or advisory informa- 1-8

16 tion. These markers are hite ith black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geographic location. Alays consult local boating authorities before driving your boat in unfamiliar aters. MAIN CHANNEL " 6" " 7" RB " L" or RG " L" " 5" C " 1" N " 2" SECONDARY CHANNEL MAIN CHANNEL BUOYS " 1" " 3" " 5" " 7" LIGHTED BUOY (Port Hand)` Odd number. increasing toard head of navigation.leave to port (left) proceeding upstream. White Light Green Light 1 1 OR " 4" BUOY COLOR CODE old ne BLACK " 2" " 4" " 6" " 3" RED GREEN LIGHTED BUOY (Starboard Hand)` Even number,increasing toard head of navigation. Leave to starboard (right) proceeding upstream. " A" White Light Red Light 2 2 OR " 2" old ne " 1" " A" LIGHTED SAFE WATER BUOY C " 1" Proceeding toard head of navigation from seaard SECONDARY CHANNEL BUOYS STARTS NEW NUMBERING SYSTEM CAN BUOY Odd number. Leave to port. 1 1 OR No number. Marks midchannel, pass on either side. Letter has no lateral significance, used for identification and location purposes. Top Mark White Light White Light A A OR old ne N " 2" old NUN BUOY Even number. Leave to starboard 2 ne RB " L" RG " L" LIGHTED PREFERRED CHANNEL TO PORT BUOY No number. Topmost band red - preferred channel is to left of buoy. Letter has no lateral significance, used for identification and location purposes. Red or Red Light White Light L L No change old ne

17 MU00016 FUELING INSTRUCTIONS GASOLINE AND ITS VAPORS ARE HIGH- LY FLAMMABLE AND EXPLOSIVE! 8 Do not smoke hen refueling, and keep aay from sparks, flames, or other sources of ignition. 8 Stop engine before refueling. 8 Refuel in a ell-ventilated area. Refuel portable fuel tanks off the boat. 8 Take care not to spill gasoline. If gasoline spills, ipe it up immediately ith dry rags. 8 Do not overfill the fuel tank. 8 Tighten the filler cap securely after refueling. 8 If you should sallo some gasoline inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. 8 If any gasoline spills onto your skin, immediately ash ith soap and ater. Change clothing if gasoline spills on it. 8 Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks. cc Use only ne clean gasoline hich has been stored in clean containers and is not contaminated ith ater or foreign matter. E 1-10 EMU00018 GASOLINE (PETROL) Recommended gasoline: Regular unleaded gasoline ith a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2

18 If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. If unleaded gasoline is not available, then leaded regular gasoline can be used. E EMU00027 Gasohol There are to types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or engine performance problems. EMU00858 ENGINE OIL Recommended engine oil: YAMALUBE 2 STROKE OUTBOARD OIL If the recommended engine oil is not available, another 2-stroke engine oil ith a NMMA-certified TC-W3 rating may be used. 1-11

19 MU00031 BATTERY REQUIREMENT cc Do not use the battery that does not meet the specified capacity. If different battery from the specification is used, the electric system may perform poorly or be overloaded, causing electrical system damage. Choose battery hich meets the folloing specifications for Electric start model. Minimum cold crank performance 380 Amps at C (0 F) Minimum reserve capacity 124 minutes at 26.7 C (80 F) E EMU01395 PROPELLER SELECTION 1-12 The performance of your outboard motor ill be critically affected by your choice of propeller, 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 lo for good engine performance, this ill have an adverse effect on the engine.

20 Yamaha outboard motors are fitted ith propellers chosen to perform ell over a range of applications, but there may be uses here a propeller ith a different pitch ould be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct engine speed to be maintained. Conversely, a larger-pitch propeller is more suitable for a smaller operating load. E Yamaha dealers stock a range of propellers, and can advise you and install a propeller on your outboard that is best suited to your application. NOTE: At full throttle and under a maximum boat load, the engine s rpm should be ithin the upper half of the full throttle operating range, as listed in SPECIFICA- TIONS on page 4-1. Select a propeller hich fulfills this requirement. If operating under conditions hich allo the engine s rpm to rise above the maximum recommended range (such as light boat loads), reduce the throttle setting to maintain the rpm in the proper operating range. 1 Propeller diameter (in inches) 2 Propeller pitch (in inches) 3 Type of propeller (propeller mark) 10-3/4x17-G 1 23 Refer to the section CHECKING PRO- PELLER for instructions on propeller removal and installation

21 MU01209 START-IN-GEAR PROTECTION E Yamaha outboard motors or Yamaha approved remote control units are equipped ith start-in-gear protection device(s). This feature permits the engine to be started only hen it is Neutral. Alays select Neutral before starting the engine. 1-14

22 MEMO E

23 EMC00010 Chapter 2 BASIC COMPONENTS 1 MAIN COMPONENTS OPERATIONS OF CONTROLS AND OTHER FUNCTIONS Fuel tank Remote control Trim tab Trim angle adjusting rod Tilt support lever Top coling lock lever WARNING SYSTEM Overheat arning

24 EMU01206 MAIN COMPONENTS!0 o q i u y t r e! * Clamp bracket 2 Anode 3 Battery lead 4 Cooling ater inlet 5 Trim tab 6 Anti-cavitation plate 7 Anode 8 Trim angle adjusting-rod 9 Tilt-support lever 0 Top coling q Fuel hose * May not be exactly as shon; also may not be included as standard equipment on all models. 2-1

25 EMC20010 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS EMC21111 FUEL TANK If your model as equipped ith a portable fuel tank, its function is as follos. q e r 1 Fuel hose joint 2 Fuel meter(if equipped) 3 Fuel tank cap 4 Air vent scre(if equipped) Fuel hose joint This connector is provided for connecting or disconnecting fuel hose Fuel meter This meter is on the fuel tank cap. It shos current fuel quantity in the fuel tank approximately. Fuel tank cap This cap is for filling fuel. To remove it, turn it counterclockise. Air Vent scre This scre is on the fuel tank cap. To loosen it, turn it counterclockise. 2-2

26 y q u e r t * EMC80612 REMOTE CONTROL Both the shifter and the throttle are actuated by the remote control lever. In addition, this control also has the electrical sitches. 1 Remote control lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Main sitch 5 Engine stop lanyard sitch 6 Poer trim and tilt sitch 7 Throttle friction adjusting scre F y u Nq r r t t e R y u Remote control lever Moving the lever forard from the Neutral position engages Forard gear. Pulling the lever back from Neutral engages Reverse. The engine ill continue to run at idle until the lever is moved about 35 (a detent can be felt). Moving the lever farther opens the throttle, and the engine ill begin to accelerate. 1 Neutral 2 Forard 3 Reverse 4 Shift 5 Fully closed 6 Throttle 7 Fully open Neutral interlock trigger To shift out of Neutral, the neutral interlock trigger of the remote control lever must first be pulled up

27 N q Neutral throttle lever To open the throttle ithout shifting into either Forard or Reverse, place the remote control lever in the Neutral position and lift the neutral throttle lever. NOTE: The neutral throttle lever ill operate only hen the remote control lever is in Neutral. The remote control lever ill operate only hen the neutral throttle lever is in the closed position * 1 Fully open 2 Fully closed OFF ON START Main sitch The main sitch controls the ignition system; its operation is described belo. 8 OFF Electrical circuits sitched off. (The key can be removed.) 8 ON Electrical circuits sitched on. (The key cannot be removed.) 8 START Starter-motor ill turn and start engine. (When the key is released, it returns automatically to ON.) 2-4

28 EMC28210 Engine stop lanyard sitch The lock-plate on the end of the lanyard must be attached to the engine stop sitch for the engine to run. The lanyard should be attached to a secure place on the operator s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard ill pull out the lock plate, stopping ignition to the engine. This ill prevent the boat from running aay under poer. 8 Attach the engine stop sitch lanyard to a secure place on your clothing, your arm or leg hile operating. 8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard in such a ay that it could become entangled, preventing it from functioning. 8 Avoid accidentally pulling the lanyard during normal operation. Loss of engine poer means the loss of most steering control. Also, ithout engine poer, the boat could slo rapidly. This could cause people and objects in the boat to be thron forard. NOTE: The engine cannot be started ith the lock-plate removed. q 1 Lock-plate 2 Lanyard

29 UP DN UP DN * EMU01331 Poer Trim/Tilt Sitch The poer trim/tilt adjusts the motor angle in relation to the transom. The poer trim/tilt sitch is located on the remote control lever grip. Pushing the sitch UP trims the motor up, then tilts the motor up. Pressing the sitch DN tilts the motor don and trims the motor don. When the sitch button is released, the motor ill stop in its current position. NOTE: Refer to the sections ADJUSTING TRIM ANGLE and TILTING UP/DOWN in Chapter 3 for instructions on usage. EMU01155 Throttle Friction Adjusting Scre A friction device in the remote control box provides adjustable resistance to movement of the remote control lever, and can be set according to operator preference. An adjusting scre is located on the front of the remote control box. Resistance Scre Increase Decrease Turn clockise Turn counterclockise Do not overtighten the friction adjusting scre. If there is too much resistance, it may be difficult to move the lever, hich could result in an accident

30 EMD04011* TRIM TAB 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. An improperly adjusted trim tab may cause difficult steering. Alays test run after the trim tab has been installed or replaced to be sure steering is correct. Be sure you have tightened the bolt after adjusting the trim tab. q A B Trim tab 2 Bolt Boat tends to veer To the left (port side) To the right (starboard side) The rear end of trim tab Turn the left(port side), A in the figure Turn the right (starboard side), B in the figure cc The trim tab also serves as an anode to protect the engine from electroche mical corrosion. Never paint the trim tab as it ill become ineffective as an anode. EMU01297 TRIM ANGLE ADJUSTING ROD The position of the trim angle adjusting rod determines the minimum trim angle of the outboard motor in relation to the transom

31 MD60010 TILT SUPPORT LEVER To keep the outboard motor in the tiltedup position, lock the tilt support lever to the clamp bracket. E EMD62010 TOP COWLING LOCK LEVER To remove the engine top coling, push the lock lever donard. Then lift off the coling. When replacing the coling, check to be sure it fits properly in the rubber seal. Then lock the coling again by moving the lever upard

32 EMD80010 WARNING SYSTEM cc Do not continue to operate the engine if the arning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU00170 OVERHEAT WARNING This engine has an overheat arning device. If the engine temperature rises too high, the arning device ill activate (2); Included ( ); N/A Activation of arning device The engine speed ill automatically decrease to about 2,000 r/min. The overheat arning indicator ill come on. The buzzer ill sound. Tiller control model Remote control model If the arning system has been activated, stop the engine and check the ater inlet for clogging. 2-9

33 EMF00010 Chapter 3 OPERATION 1 INSTALLATION Mounting the outboard motor FILLING FUEL AMD ENGINE OIL Filling fuel Gasoline (petrol) and oil mixing PRE-OPERATION CHECKS BREAKING IN (RUNNING IN) ENGINE..3-8 STARTING ENGINE WARMING UP ENGINE SHIFTING Forard Reverse STOPPING ENGINE TRIMMING OUTBOARD MOTOR Adjusting trim angle TILTING UP/DOWN CRUISING IN OTHER CONDITIONS Cruising in salt ater Cruising in turbid ater

34 EMF10010 INSTALLATION cc Incorrect engine height or obstructions to smooth ater flo (such as the design or condition of the boat or accessories such as transom ladders/depth finder transducers) can create airborne ater spray hile the boat is cruising. Severe engine damage may result if the motor is operated continuously in the presence of airborne ater spray. NOTE: During ater testing check the buoyancy of the boat, at rest, ith its maximum load. Check that the static ater level on the exhaust housing is lo enough to prevent ater entry into the poerhead, hen ater rises due to aves hen the outboard is not running. 3-1

35 EMU00176 MOUNTING THE OUTBOARD MOTOR Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Observe the folloing: 8 The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat/motor combination. Proper mounting depends in part on experience and the specific boat/motor combination. 8 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 experienced person. [permanent mounted type] 8 Your dealer or other person experienced in proper outboard motor mounting should sho you ho to mount your motor. [portable type] Mount the outboard motor on the center line (keel line) of the boat, and ensure that the boat itself is ell balanced. Otherise, the boat ill be hard to steer. For boats ithout a keel or hich are asymmetrical, consult your dealer. 1 Center line (keel line) q

36 E Overpoering a boat may cause severe instability. Do not install an outboard motor ith more horsepoer than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer. 0 ~ 25 mm (0 ~ 1 in.) EMU01298 Mounting Height To run your boat at optimum efficiency, the ater-resistance (drag) of the boat and outboard motor must be made as little as possible. The mounting-height of the outboard motor greatly affects the ater-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 ill rise abnormally and cause the engine to overheat. If the mounting-height is too lo, the ater-resistance ill increase and thereby reduce engine efficiency. Mount the engine so that the anti-cavitation plate is beteen the bottom of the boat and a level 25 mm (1 in.) belo it. NOTE: 8 The optimum mounting height of the outboard motor is affected by the boat/motor combination and the desired use. Test runs at different heights can help determine the optimum mounting height. 8 Refer to the section TRIMMING OUT- BOARD MOTOR for instructions on setting the trim angle of the outboard. 3-3

37 EMU00186 FILLING FUEL AND ENGINE OIL EMU01031 FILLING FUEL 1) Remove the fuel tank cap. 2) Fill the fuel tank carefully. 3) Close the cap securely after refueling. Wipe up any spilled fuel. EMU01019 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 concerns about pollution and resulting emissions regulations. One of the most obvious changes has been the elimination of lead from most fuels. As gasoline has changed, the amount of additives such as aromatics and oxygenates has increased. These additives are important 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 deposits collect, piston rings begin sticking. Performance drops and engine ear increases dramatically. 3-4

38 While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer. Ring Free has repeatedly proven its ability to clean combustion deposits from inside the engine, notably the critical piston-ringland area, and fuel system components. Follo product labeling for use instructions. E q EMF35011* GASOLINE (PETROL) AND OIL MIXING Pre-mix model Engine oil : Gasoline (Petrol) Break-in period 1 : 25 After break-in 1 : 50 1) Pour oil and gasoline into the fuel tank, in that order. 1 Engine oil 2 Gasoline (Petrol) 2) Then mix the fuel thoroughly by shaking. 3) Make sure the oil is mixed ith gasoline

39 cc E 8 Avoid using any oil other than the designated type. 8 Use a thoroughly blended fuel-oil mixture. 8 If the mixture is not thoroughly blended, or if the mixing ratio is incorrect, the folloing problems could occur: Lo oil ratio: Lack of oil could cause major engine trouble, such as piston seizure. High oil ratio: Too much oil could cause fouled spark plugs, smoky exhaust, and heavy carbon deposits. Mixing ratio 25 : 1 Gasoline (Petrol) 1 L 12 L 14 L 24 L (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 oil 0.04 L 0.48 L 0.56 L 0.96 L (0.04 US qt, (0.51 US qt, (0.59 US qt, (1.01 US qt, 0.04 Imp qt) 0.42 Imp qt) 0.49 Imp qt) 0.84 Imp qt) Mixing ratio 50 : 1 Gasoline (Petrol) 1 L 12 L 14 L 24 L (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 oil 0.02 L 0.24 L 0.28 L 0.48 L (0.02 US qt, (0.26 US qt, (0.30 US qt, (0.51 US qt, 0.02 Imp qt) 0.21 Imp qt) 0.24 Imp qt) 0.42 Imp qt) NOTE: If using a permanently installed tank, pour the oil gradually as the fuel is being added to the tank. 3-6

40 3-7 E EMF40111 PRE-OPERATION CHECKS If any item in the pre-operation check is not orking properly, have it inspected and repaired before operating the outboard motor. Otherise, an accident could occur. Fuel 8 Check to be sure you have plenty of fuel for your trip. 8 Make sure there are no fuel leaks or gasoline fumes. 8 Be sure the fuel hose is not being flattened or kinked by objects in the boat, and that there are no sharp objects near it. Oil 8 Check to be sure you have plenty of oil for your trip. Controls 8 Check throttle, shift, and steering for proper operation before starting the engine. 8 The controls should ork smoothly, ithout binding or unusual free play. 8 Look for loose or damaged connections. 8 Check operation of the starter and stop sitches hen the outboard moter is in the ater. Engine 8 Check the engine and engine mounting. 8 Look for loose or damaged fasteners. 8 Check the propeller for damage. cc Do not start the engine out of ater. Overheating and serious engine damage can occur.

41 EMF50011 BREAKING IN (RUNNING IN) ENGINE Your ne engine requires a period of break-in (running-in) to allo mating surfaces of moving parts to ear-in evenly. Correct break-in (running-in) ill help ensure proper performance and longer engine life. cc Failure to follo the break-in (running-in) procedure may result in reduced engine life or even severe engine damage. Break-in (running-in) time: 10 hours Break-in (running-in) premix ratio: Refer to Gasoline/Petrol and Oil Mixing. EMU00226* Run the engine under load (in gear ith a propeller installed) as follos. 1) First 10 minutes: Run the engine at the loest possible-speed. A fast idle in neutral is best. 2) Next 50 minutes: Do not exceed half throttle (approximately 3,000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 r/min or less. 3-8

42 3) Second hour: Accelerate at full throttle onto plane, then reduce engine speed to threequarter throttle (approximately 4,000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allo about 10 minutes of operation at three-quarter throttle or less to let the engine cool. 4) Third through tenth hours: Avoid operating at full throttle for more than 5 minutes at a time. Let the engine cool beteen full-throttle runs. Vary engine speed occasionally. 5) After the first 10 hours: Operate the engine normally. Use the standard premix ratio of gasoline : Oil. (Refer to Gasoline/Petrol and Oil Mixing.) 3-9

43 EMU01147 STARTING ENGINE 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 simmers in the ater near you. 8 When the air vent scre is loosened, gasoline (petrol) vapor ill be released. Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep aay from open flames and sparks hile loosening the air vent scre. 8 This product emits exhaust gases hich contain carbon monoxide, a colorless, odorless gas hich may cause brain damage or death hen inhaled. Symptoms include nausea, dizziness, and drosiness. Keep cockpit and cabin areas ell ventilated. Avoid blocking exhaust outlets ) If there is an air vent scre on the fuel tank cap, loosen it 2 or 3 turns. 2) If there is a fuel joint on the motor, firmly connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank. NOTE: During engine operation place the tank horizontally, or fuel cannot be dran into the engine

44 3) Squeeze the primer bulb ith the outlet end up until you feel it become firm N EMU00247 PROCEDURE FOR REMOTE CONTROL MODEL 4) Place the remote control lever in the Neutral position. NOTE: The start-in-gear protection device prevents the engine from starting except hen in Neutral ) Attach the engine stop sitch 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 in the engine stop sitch. 8 Attach the engine stop sitch lanyard to a secure place on your clothing, your arm or leg hile operating. 8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard here it could become entangled, preventing from functioning. 8 Avoid accidentally pulling the lanyard during normal operation. Loss of engine poer means the loss of most steering control. Also, ithout engine poer, the boat could slo rapidly. This could cause people and objects in the boat to be thron forard. 6) Turn the main sitch to ON. 3-11

45 ON OFF START E EMU00254 Electric Start Model 7) Turn the main sitch to START, and hold it for a maximum of 5 seconds. 8) Immediately the engine starts, release the main sitch to return it to ON. cc 8 Do not turn the main sitch to START hen the engine is running. 8 Do not keep the starter-motor turning for more than 5 seconds ith the main sitch in the START position. If the starter-motor is run continuously for more than 5 seconds, the battery ill rapidly become exhausted and it ill be impossible for it to start the engine. If the engine does not start ithin 5 seconds, return the main sitch to ON, ait 10 seconds, and then crank the engine again. 3-12

46 MG00210 WARMING UP ENGINE E ) Before beginning operation, allo the engine to arm up at idling speed for 3 minutes. (Failure to do this ill shorten engine life.) 2) Check for a steady flo of ater from the cooling-ater pilot hole. cc A continuous flo of ater from the pilot hole shos that the ater pump is pumping ater through the cooling passages. If ater is not floing out of the pilot hole at all times hile the engine is running, do not continue to run the engine. Overheating and serious damage could occur. Stop the engine and check to see if the ater inlet on the loer casing is blocked. If the problem cannot be found and corrected, consult your Yamaha dealer. NOTE: After the engine starts, arm-up operation is automatically controlled by the Prime Start system. Automatic control is cancelled if the throttle is opened more than halfay. 3-13

47 EMG20310 SHIFTING F N Before shifting, make sure there are no simmers or obstacles in the ater near you. cc To change the shifting position from forard to reverse or vice-versa, close the throttle first so that the engine idles (or runs at lo speeds) FORWARD Pull up the neutral interlock trigger (If equipped) and move the remote control lever quickly and firmly from Neutral to Forard. N R REVERSE Pull up the neutral interlock trigger (If equipped) and move the remote control lever quickly and firmly from Neutral to Reverse. When operating in Reverse, go sloly. Do not open the throttle more than half. Otherise, the boat may become unstable, hich could result in loss of control and an accident. 3-14

48 EMG38010 STOPPING ENGINE Let it cool off for a fe minutes at idle or lo speed first. Stopping the engine immediately after operating at high speed is not recommended. OFF ON START EMG41211 PROCEDURE 1) Turn the main sitch to OFF NOTE: The engine can also be stopped by pulling the lanyard from the engine stop sitch (then turning the main sitch to OFF ). 2) If the fuel joints are provided, disconnect the fuel line from the motor after stopping the engine ) Tighten the air vent scre on the fuel tank cap after stopping the engine, if it is equipped. 4) Remove the key if the boat ill be left unattended

49 MU01412 TRIMMING OUTBOARD MOTOR E The trim angle of the outboard motor helps determine the position of the bo of the boat in the ater. The correct trim angle ill help improve performance and fuel economy hile reducing strain on the engine. The 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. q Excessive trim for the operating conditions (either trim up or trim don) can cause boat instability and can make steering the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slo don and/or readjust the trim angle. NOTE: Refer to the section ADJUSTING TRIM ANGLE for instructions on usage. 1 Trim operating angle 3-16

50 UP DN q UP DN ADJUSTING TRIM ANGLE EMU01401 Poer Trim/Tilt Model 8 Be sure all people are clear of the outboard motor hen adjusting the trim/tilt angle, also be careful not to pinch any body parts beteen the drive unit and clamp bracket. 8 Use caution hen trying a trim position for the first time. Increase speed gradually and atch for any signs of instability or control problems. 8 Use the poer trim/tilt sitch located on the bottom engine coling (if equipped) only hen the boat is at a complete stop ith the engine off The outboard motor trim angle can be adjusted operating the poer trim/tilt sitch 1. To raise the bo ( trim-out ), push the sitch UP. To loer the bo ( trim-in ), push the sitch DN. Make test runs ith the trim set to different angles to find the position that orks best for your boat and operating conditions. NOTE: To adjust the trim angle hile the boat is moving, use the poer trim and tilt sitch located on the remote control device or tiller handle, if so equipped. 3-17

51 q EMU00282 Bo Up When the boat is on plane, a bo-up attitude result in less drag, greater stability and efficiency. This is generally hen the keel line of the boat is up about 3 to 5 degrees. When trimmed out, the boat may have more tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adjusted to help offset this effect. Too much trim-out puts the bo of the boat too high in the ater. Performance and economy are decreased because the hull of the boat is pushing the ater and there is more air drag. Excessive trim-up can cause the propeller to ventilate, hich reduces performance further. When trimmed-out too much, a boat may porpoise (hop in the ater), hich could thro the operator and passengers overboard. EMU00283 Bo Don When the bo of the boat is don, it is easier to accelerate from a standing start onto plane. e Too much trim-in causes the boat to plo through the ater, decreasing fuel economy and making in hard to increase speed. Operating ith excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bo is greatly increased, heightening the danger of bo steering and making operation difficult and dangerous Bo up 2 Bo don 3 Optimum angle

52 EMU01200 TILTING UP/DOWN If the engine ill be stopped for some time, or if the boat is moored in shallos, the engine should be tilted up to protect the propeller and casing from damage by collision ith obstructions, and also to reduce salt corrosion. cc Before tilting the motor, follo the procedures under STOPPING ENGINE. Never tilt the motor hile the engine is running. Severe damage from overheating can result. Be sure all people are clear of the outboard motor hen adjusting the tilt angle, also be careful not to pinch any body parts beteen the drive unit and engine bracket. Leaking fuel is a fire hazard. Disconnect the fuel line or close the fuel cock if the engine ill be tilted for more than a fe minutes. Otherise, fuel may leak. (If the fuel connector is provided on the motor.) 3-19

53 EMU00293 PROCEDURE FOR TILTING UP Poer trim/tilt model 1) Remove the fuel-line connection from the motor UP 2) Push the poer trim/tilt sitch UP until the outboard has tilted up completely ) Turn the tilt-support lever toard engine bracket and support the engine. After tilting the engine, be sure to support it ith the tilt-support lever. Otherise, the engine could fall back don suddenly if oil in the poer trim/tilt unit should lose pressure EMU00303 PROCEDURE FOR TILTING DOWN Poer trim/tilt model 1) Push the poer trim/tilt sitch UP until the engine is supported by the tilt rod. 2) Release the tilt-support lever. 3) Push the poer trim/tilt sitch DN (Don) to loer the engine to the desired position. 3-20

54 EMH60010 CRUISING IN OTHER CONDITIONS CRUISING IN SALT WATER After operating in salt ater, ash out the cooling-ater passages ith fresh ater to prevent them from becoming cloggedup ith salt deposits. NOTE: Refer to cooling system flushing instructions in TRANSPORTING AND STORING OUTBOARD MOTOR. CRUISING IN TURBID WATER It is strongly recommended that the optional chromium-plated ater-pump kit be installed if the outboard is to be used in turbid (muddy) ater conditions. 3-21

55 EMK00010 Chapter 4 MAINTENANCE 1 SPECIFICATION DATA TRANSPORTING AND STORING OUTBOARD MOTOR Trailering outboard motor Storing outboard motor PERIODIC MAINTENANCE Replacement parts Maintenance chart Greasing Cleaning and adjusting spark plug Checking fuel system Cleaning fuel filter Adjusting idling speed Replacing fuse Checking iring and connectors Exhaust leakage Water leakage Checking poer trim and tilt system Checking propeller Changing gear oil Cleaning fuel tank Inspecting and replacing anode Checking battery Checking bolts and nuts Motor exterior Coating the boat bottom

56 EMK10011* SPECIFICATION DATA Item Model Unit C40TRA DIMENSIONS 8Overall Length mm (in.) 8Overall Width mm (in.) 8Overall Height L mm (in.) 8Transom height L mm (in.) 8Weight L kg (lb.) 646 (25.4) 350 (13.8) 1,319 (51.9) 533 (21.0) 87 (192) PERFORMANCE 8Full throttle operating range 8Maximum output 8Idling speed ENGINE 8Type Number of cylinder Displacement Bore stroke 8Ignition system 8Spark plug Spark plug gap 8Control system 8Starting system 8Battery capacity Minimum cold crank performance Minimum reserve capacity 8Alternator output 8Starting carburetion system DRIVE UNIT 8Gear positions Gear ratio 8Trim/tilt system 8 Propeller mark FUEL AND OIL 8Fuel Fuel tank capacity 8Recommended engine oil Oil tank capacity 8Fuel/oil ratio 8Recommended gearcase oil Gear oil capacity TIGHTENING TORQUE 8Spark plug 8Propeller nut r/min kw (HP) r/min cm 3 (cu.in.) mm (in.) NGK mm (in.) V-AH Amps at C (0 F) minutes at 26.7 C (80 F) V-A (W) L (US gal, Imp gal) L (US qt, Imp qt) cm 3 (US oz, Imp oz) N m (kgf m, lb ft) N m (kgf m, lb ft) 4-1 4,500 ~ 5, (40) at 5,000 r/min 750 ~ stroke, L (42.60) ( ) C.D.I system B7HS ~ 1.0 (0.035 ~ 0.039) Remote control Electric start ~ Prime start system Forard-Neutral-Reverse 1.85 (24 : 13) Poer trim & tilt G Regular-unleaded gasoline (P.O.N.: minimum 86) YAMALUBE 2 STROKE OUTBOARD OIL, or an equivalent TC-W3 certified outboard oil Remote: ( ) Engine: ( ) 50: 1 Hypoid gear oil (SAE 90) 430 (14.5, 15.1) 25 (2.5, 18) 35 (3.5, 2.5)

57 C50TRA 670 (26.4) 360 (14.2) 1,319 (51.9) 533 (21.0) 87 (192) 4,500 ~ 5, (50) at 5,000 r/min 750 ~ stroke, L (42.60) ( ) C.D.I system B8HS ~ 1.0 (0.035 ~ 0.039) Remote control Electric start ~ Prime start system Forard-Neutral-Reverse 1.85 (24 : 13) Poer trim & tilt G Regular-unleaded gasoline (P.O.N.: minimum 86) YAMALUBE 2 STROKE OUTBOARD OIL, or an equivalent TC-W3 certified outboard oil Remote: ( ) Engine: ( ) 50: 1 Hypoid gear oil (SAE 90) 430 (14.5, 15.1) 25 (2.5, 18) 35 (3.5, 2.5) 4-2

58 MU01369 TRANSPORTING AND STORING OUTBOARD MOTOR Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent scre and fuel cock to prevent fuel from leaking. TRAILERING OUTBOARD MOTOR The motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the motor in the tilt position using a motor support device such as a transom saver bar. cc Do not use the tilt support lever/knob hen trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor can not be trailered in the don position, use an additional support device to secure it in the up position. E Never get under the loer unit hile it is tilted, even if a motor support bar is used. Severe injury could occur if the outboard accidentally falls. 8 USE CARE hen transporting fuel tank, hether in a boat or car. DO NOT fill fuel container to maximum capacity. Gasoline ill expand considerably as it arms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.

59 MK16010 STORING OUTBOARD MOTOR When storing your Yamaha outboard for prolonged periods of time, (2 months or longer), several important procedures must be performed to prevent expensive damage. This is especially important for your Precision Blend equipped outboard due to the lean oil ratios used at idle prior to shutting the engine off for the season. It is advisable to have your outboard serviced by an authorized Yamaha dealer prior to storage. Hoever, the folloing procedures can be performed by you, the oner, ith a minimum of tools. E EMK21010 Filling Fuel Tank Fill the fuel tank ith 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. EMU00338 Flushing Cooling System and Fogging Engine Cooling system flushing is essential to prevent the cooling system from clogging up ith salt, sand, or dirt. In addition, fogging of the engine is mandatory to prevent expensive engine damage due to rust. Perform the flushing and fogging at the same time. 4-4

60 8 Do not touch or remove electrical parts hen starting or during operation. 8 Keep hands, hair and clothes aay from flyheel and other rotating parts hile engine is running. E EMU Flushing in a Water Tank cc If the fresh ater level is belo the level of the anti-cavitation plate, or if the ater supply is insufficient, engine seizure may occur. q 1) Remove the engine top coling and silencer cover. 2) Install the outboard motor on the ater tank. 3) Fill the tank ith fresh ater to above the level of the anti-cavitation plate. 4) Run the engine at a fast idle for 10~15 minutes. 5) Just prior to turning off the engine, quickly spray Yamaha Stor-Rite Engine Fogging Oil (Part No. LUB- STRRT-12-00) alternately into each carburetor. When properly done, the engine ill smoke excessively and almost stall. 6) Remove the motor from the ater tank. 7) Install the silencer cover and top coling. 1 Water surface 2 Loest ater level

61 Flushing ith the flushing attachment 1) Remove the top coling and silencer cover. Remove the propeller. 2) Install a flushing attachment to the loer unit. (Flushing attachment available from your Yamaha dealer). cc Avoid running the outboard at high speed hile on the flushing attachment, or overheating could occur. 8 Do not touch or remove electrical parts hen starting or during operation. 8 Keep hands, hair and clothes aay from flyheel and other rotating parts hile engine is running. 3) Run the engine at a fast idle for 10~15 minutes. 4) Just prior to turning off the engine, quickly spray Yamaha Stor-Rite Engine Fogging Oil (Part No. LUB- STRRT-12-00) alternately into each carburetor. When properly done, the engine ill smoke excessively and almost stall. 5) Remove the flushing attachment and ipe off any excess ater. 6) Install the silencer cover and top coling. Install the propeller. 4-6

62 MK26011 Lubrication 1) Remove the spark plugs, and spray a 10 second spray of Yamaha Stor- Rite Engine Fogging Oil into each cylinder. Grease the spark plug threads and reinstall the spark plugs and torque to proper specification. (Refer to the CLEANING AND ADJUSTING SPARK PLUG ). 2) Turn the engine over ith the stop lanyard disconnected to ork the fogging oil into the piston rings. 3) Change the loer unit oil. (Refer to CHANGING GEAR OIL ). Inspect the oil for the presence of ater hich indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealership prior to use. 4) Grease all grease fittings. (Refer to the GREASING ) E EMK27011 Cleaning and Anti-corrosion Measure 1) Wash don the exterior of the outboard ith fresh ater and dry off completely. 2) Spray the engine s exterior ith Yamaha Silicone Protectant (Part No. LUB-SILCNE-13-00). 3) Wax the coling ith a non-abrasive ax such as Yamaha Silicone Wax (Part No. ACC ). 4-7

63 MK29010 Battery Care Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact ith skin, eyes, or clothing. Antidote: EXTERNAL; Flush ith ater. INTERNAL; Drink large quantities of ater or milk. Follo ith milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. EYES; Flush ith ater for 15 minutes and get prompt medical attention. Batteries produce explosive gases: Keep sparks, flame, cigarettes, etc. aay. Ventilate hen charging or using in a closed space. Alays ear eye protection hen orking near batteries. KEEP OUT OF REACH OF CHILDREN. E UPPER LEVEL LOWER LEVEL NOTE: Batteries vary among manufacturers. Therefore the folloing procedures may not alays apply. Consult your battery manufacturer s instructions ) Disconnect and remove the battery from the boat. Alays disconnect the black negative lead first to prevent the risk of shorting. 2) Clean the battery casing and terminals. Fill each cell to the upper level ith distilled ater. 3) Store the battery on a level surface in a cool, dry, ell-ventilated place out of direct sunlight. 4) Once a month, check the specific gravity of the electrolyte and recharge as required to prolong battery life. 4-8

64 MK32110 PERIODIC MAINTENANCE Be sure to turn off the engine hen you perform maintenance unless otherise specified. If the oner is not familiar ith machine servicing, this ork should be done by a Yamaha dealer or other qualified mechanic. A service manual is available for purchase through a Yamaha dealer for oners ho have the mechanical skills, tools, and other equipment necessary to perform maintenance not covered by this oner s manual. EMK33011 REPLACEMENT PARTS If replacement parts are necessary, use only genuine Yamaha parts or equivalents of the same type and of equivalent strength and materials. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from a Yamaha dealer. E 4-9

65 MK30114* MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating conditions, but the folloing table gives general guidelines. The mark ( ) indicates the check-ups hich you may carry out yourself. The mark (1) indicates ork to be carried out by your Yamaha dealer. Item Carburetor Cleaning Fuel filter Cleaning 4-15 Fuel system Inspection 4-14 Fuel tank *2 Cleaning Throttle link Inspection/Adjustment 1 Idling speed Inspection/Adjustment 4-16 Spark plug Cleaning/Adjustment/ Replacement 4-12 Oil tank ater drain Cleaning Oil pump Inspection/Adjustment 1 Poer trim and tilt system *1 Inspection 4-18 Wiring & Connectors Inspection/Reconnect 4-17 Exhaust leakage Inspection 4-17 Water leakage Inspection 4-17 Grease points Greasing 4-11 Gear oil Change 4-21 Bolts & Nuts Retightening 4-26 Coling clamp Inspection Anode Inspection 4-23 Propeller Inspection 4-19 Motor exterior Inspection 4-27 Cooling ater passages *3 Cleaning 4-5 Battery Inspection Interval 10 hours (every month) Initial Every 50 hours 100 hours (3 months) (6 months) 200 hours (1 year) E Refer page 4-24 *1.For Poer trim/tilt model *2.If a portable fuel tank is equipped *3.When operating in salt ater, turbid or muddy ater, the engine should be flushed ith clean ater after each use. 4-10

66 EMU00366 GREASING Yamaha marine grease (Water resistant grease) 4-11

67 MU01202 CLEANING AND ADJUSTING SPARK PLUG When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allo external sparks, hich could lead to explosion or fire. The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very hite, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits ill cause the spark plug to sloly break don and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug ith another of the correct type. Standard spark plug: Refer to SPECIFICATIONS, page 4-1. Before fitting the spark plug, measure the electrode gap ith a ire thickness gauge; adjust the gap to specification if necessary. Spark plug gap: Refer to SPECIFICATIONS, page 4-1. E 4-12

68 When fitting the plug, alays clean the gasket surface and use a ne gasket. Wipe off any dirt from the threads and scre in the spark plug to the correct torque. Spark plug torque: Refer to SPECIFICATIONS, page 4-1. NOTE: If a torque-rench is not available hen you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the correct torque as soon as possible ith a torque-rench. E q Initial of spark plug I.D. mark B C/BK D Plug rench size 21 mm (13/16 in.) 16 mm (5/8 in.) 18.3 mm (23/32 in.) 1 Spark plug gap 2 Spark plug I.D. mark (NGK) 4-13

69 MK38010 CHECKING FUEL SYSTEM Gasoline (petrol) and its vapors are highly flammable and explosive. Keep aay from sparks, cigarettes, flames or other sources of ignition. Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by Yamaha dealer or other qualified mechanic. E Checking points 8 Fuel system parts leakage. 8 Fuel hose joint leakage. 8 Fuel hose cracks or other damage. 8 Fuel connector leakage. Leaking fuel can result in fire or explosion. 8 Check for fuel leakage regularly. 8 If any fuel leakage is found, the fuel system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate. 4-14

70 EMK50011 CLEANING FUEL FILTER Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly doing this procedure, consult your Yamaha dealer. 8 Do not perform this procedure on a hot or running engine. Allo the engine to cool. 8 There ill be fuel in the fuel filter. Keep aay from sparks, cigarettes, flames or other sources of ignition. 8 This procedure ill allo some fuel to spill. Catch fuel in a rag. Wipe up any spilled fuel immediately. 8 The fuel filter must be reassembled carefully ith O-ring, filter cup, and hoses in place. Improper assembly can result in a fuel leak, hich could result in a fire or explosion hazard. q e 1 Filter element 2 O-ring 3 Filter cap 4 Filter housing r To clean the fuel filter: 1) Remove the nut holding the fuel filter assembly if equipped. 2) Unscre the filter cup, catching any spilled fuel in a rag. 3) Remove the filter element, and ash it in solvent. Allo it to dry. Inspect the filter element and O-ring to make sure they are in good condition. Replace them if necessary. 4) Reinstall the filter element in the cup. Make sure the O-ring in position in the cup. Firmly scre the cup onto the filter housing. 5) Attach the filter assembly to the bracket ith that the fuel hoses are attached to the filter assembly. 6) Run the engine and check the filter and lines for leaks. 4-15

71 MK54110 ADJUSTING IDLING SPEED 8 Do not touch or remove electrical parts hen starting or during operation. 8 Keep hands, hair and clothes aay from flyheel and other rotating parts hile engine is running. cc This procedure must be performed hile the outboard motor is in the ater. A flushing attachment or test tank can be used. Procedure NOTE: A diagnostic tachometer should be used for this procedure. E q ) Start the engine and allo it to arm up fully in Neutral until it is running smoothly. If the outboard is mounted on a boat, be sure the boat is tightly moored. 2) Adjust the throttle stop-scre to set the idling speed to specification (see SPECIFICATIONS ) by turning the stop-scre clockise to increase the idling speed, and turning it counterclockise to decrease the idling speed. NOTE: Correct idling-speed adjustment is only possible if the engine is fully armed-up. If not armed up fully, the speed setting ill tend to be too high. If you have difficulty obtaining the specified idle, consult a Yamaha dealer or other qualified mechanic. 1 Throttle stop-scre 4-16

72 EMU01329 REPLACING FUSE If the fuse has blon on an Electric start model, open the fuse holder and replace the fuse ith a ne one of proper amperage. Be sure to use the specified fuse. An incorrect fuse or a piece of ire may allo excessive current flo. This could cause electrical system damage and a fire hazard. q NOTE: If the ne fuse blos again immediately, consult a Yamaha dealer. 1 Fuse holder 2 Fuse (20A) EMK78010 CHECKING WIRING AND CONNECTORS 1) Check that each grounding ire is properly secured. 2) Check that each connector is engaged securely. EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints beteen the exhaust cover, cylinder head and crank case. WATER LEAKAGE Start the engine and check that no ater leaks from the joints beteen the exhaust cover, cylinder head and crank case. 4-17

73 MU00387 CHECKING POWER TRIM AND TILT SYSTEM 8 Never get under the loer unit hile it is tilted, even hen the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls. 8 Make sure no one is under the outboard before performing this test. E 1 1) Check the poer trim and tilt unit for any sign of oil leaks. 2) Operate each of the poer trim and tilt sitches on remote control and engine bottom coling (If equipped) to check that all sitches ork. 3) Tilt up the motor and check that the trim and tilt rod is pushed out completely. 4) Check that the trim and tilt rod is free of corrosion or other flas. 5) Operate the motor to trim and tilt don. Check that the trim and tilt rod operates smoothly. 1 Trim and tilt rod NOTE: If any operation is abnormal, consult a Yamaha dealer. Recommended fluid; Yamaha poer trim & tilt fluid or ATF (DEXRON-II) 4-18

74 EML08011 CHECKING PROPELLER You could be seriously injured if the engine accidentally starts hile you are near the propeller. 8 Before inspecting, removing or installing the propeller, remove the spark plug caps from the spark plugs. Also, put the shift control in Neutral, put the main sitch in the OFF position and remove the key, and remove the lanyard from the engine stop sitch. Turn off the battery cut-off sitch if your boat has one. 8 Do not use your hand to hold the propeller hen loosening or tightening the propeller nut. Put a ood block beteen the cavitation plate and the propeller to prevent the propeller from turning. 1) Check each of the propeller blades for ear, erosion from cavitation or ventilation, or other damage. 2) Check the splines for ear and damage. 3) Check for fish line inding around the propeller shaft. Check the propeller shaft oil seal for damage. Removal 1) Using the pliers provided, straighten the cotter-pin and pull it out. 2) Remove the propeller nut. 3) Remove the propeller. 1 Thrust asher 2 Propeller 3 Spacer 4 Washer 5 Propeller nut 6 Cotter pin 4-19

75 Installation 1) Apply Yamaha Marine grease A (ater-resistant grease) to the propeller-shaft. 2) Slide the propeller over the propellershaft. cc Be sure to install the thrust asher before installing propeller, otherise, loer case and propeller boss may be damaged. E 3) Tighten the propeller nut to the specified torque. Tightening torque: Refer to SPECIFICATIONS page ) Align the propeller nut ith the propeller shaft hole. Insert a ne cotter pin in the hole and bend the cotter pin ends. NOTE: When the propeller nut does not align ith the propeller shaft hole after tightening to the specified torque, then tighten it more to align the hole cc Be sure to use a ne cotter pin and bend the ends over securely. Otherise, the propeller could come off during operation and be lost. 4-20

76 ML20010 CHANGING GEAR OIL Never get under the loer unit hile it is tilted, even hen the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls. E 1) Put the outboard in a vertical position (not tilted). Be sure the outboard is securely fastened to the transom or a stable stand. You could be severely injured if the outboard falls on you q 2) Place a suitable container under the gearcase. 3) Remove the oil drain plug. NOTE: The oil drain plug is magnetic. Remove all metal particles from the plug before reinstalling it. 4) Remove the oil level plug to allo the oil to drain completely Oil-level plug 2 Oil drain-plug cc Inspect the used oil after it has been drained. If the oil is milky, ater is getting into the gearcase hich can cause gear damage. Consult a Yamaha dealer for repair of the loer unit seals. NOTE: For disposal of used oil consult your Yamaha dealer. 4-21

77 5) With the outboard motor in an vertical position, using a flexible or pressurized filling device, inject outboard motor hypoid gear oil (SAE 90) into the oil drain plug hole. Gear oil capacity: Refer to SPECIFICATIONS, page 4-1. E ) When oil begins to flo out of the oil level plug hole, insert and tighten the oil level plug. 7) Insert and tighten the oil drain plug EML22011 CLEANING FUEL TANK Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly doing this procedure, consult your Yamaha dealer. 8 Keep aay from sparks, cigarettes, flames or other sources of ignition hen cleaning the fuel tank. 8 Remove the fuel tank from the boat before cleaning it. Work only outdoors in an area ith good ventilation. 8 Wipe up any spilled fuel immediately. 8 Reassemble the fuel tank carefully. Improper assembly can result in a fuel leak, hich could result in a fire or explosion hazard. 8 Dispose of old gasoline (petrol)according to local regulations.

78 To clean the fuel tank 1) Empty the fuel tank into an approved gasoline (petrol) container. 2) Pour a small amount of suitable solvent in the tank. Reinstall the cap and shake the tank. Drain the solvent completely. To clean the fuel filter 1) Remove the scres holding the fuel hose joint assembly. Pull the assembly out of the tank. 2) Clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allo the filter to dry. 3) Replace the gasket ith a ne one. Reinstall the fuel hose joint assembly and tighten the scres firmly. EML24010 INSPECTING AND REPLACING ANODE Yamaha outboard motor is protected from corrosion by a sacrificial anode(s) Check the anode periodically. Remove the scales from surfaces of the anode. For the replacement of the anode, consult a Yamaha dealer. cc Do not paint the anode, for this ould render it ineffective

79 ML26010 CHECKING BATTERY (for Electric start model) Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Alays follo these preventive measures: 8 Avoid bodily contact ith electrolytic fluid as it can cause severe burns or permanent eye injury. 8 Wear protective eye gear hen handling or orking near batteries. Antidote (EXTERNAL): 8 SKIN - Flush ith ater. 8 EYES - Flush ith ater for 15 minutes and get immediate medical attention. Antidote (INTERNAL): 8 Drink large quantities of ater or milk folloed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries also generate explosive hydrogen gas; therefore, you should alays follo these preventive measures: 8 Charge batteries in a ell-ventilated area. 8 Keep batteries aay from fire, sparks, or open flames (e.g., elding equipment, lighted cigarettes, etc.). 8 DO NOT SMOKE hen charging or handling batteries. 8 KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN. cc A poorly maintained battery ill quickly deteriorate. E 4-24

80 UPPER LEVEL LOWER LEVEL ) Check the electrolyte level at least once a month. Fill to the manufacturer s recommended level hen necessary. Top up only ith distilled ater (or pure de-ionized ater suitable to use in batteries). cc Ordinary tap-ater contains minerals harmhul to a battery, and should not be used for topping-up. E 2) Keep the battery alays in a good state of charge. Installing a voltmeter ill help you monitor your battery. If you ill not use the boat for a month or more, remove the battery from the boat and store it in a cool, dark place. Completely recharge the battery before using it. 3) If the battery ill be stored for longer than a month, check the specific gravity of the fluid at least once a month and recharge the battery hen it is lo. EMU01279 Connecting the Battery Mount the battery holder securely in a dry, ell-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder. 4-25

81 cc 8 Make sure the main sitch (on applicable models) is OFF before orking on the battery. 8 Reversal of the battery leads ill damage the rectifier. 8 Connect the RED lead first hen installing the battery and disconnect the RED lead last hen removing it. Otherise, the electrical system can be damaged. 8 The electrical contacts of the battery and cables must be clean and properly connected, or the battery ill not start the engine. Connect the RED lead to the POSITIVE (+) terminal first. Then connect the BLACK lead to the NEG- ATIVE (-) terminal. e UPPER LEVEL LOWER LEVEL q Red lead 2 Black lead 3 Battery EMU01280 Disconnecting the Battery Disconnect the BLACK lead from the NEG- ATIVE (-) terminal first. Then disconnect the RED lead from the POSITIVE (+) terminal. EML40010 CHECKING BOLTS AND NUTS 1) Check that bolts securing the cylinder head and engine and the nut securing the flyheel are tightened ith their specified tightening torques. 2) Check the tightening torques of other bolts and nuts. 4-26

82 ML42011 MOTOR EXTERIOR Cleaning the Outboard Motor After use, ash the exterior of the outboard ith fresh ater. Flush the cooling system ith fresh ater. E * Cleaning cooling-ater passages NOTE: Refer to cooling system flushing instructions in TRANSPORTING AND STORING OUTBOARD MOTOR. Checking Painted Surface of Motor Check the motor for scratches, nicks, or flaking paint. Areas ith damaged paint are more likely to corrode. If necessary, clean and paint the areas. Consult a Yamaha dealer for touch-up paint EML44010 COATING THE BOAT BOTTOM A clean hull improves boat performance. The boat bottom should be kept as clean of marine groths as possible. If necessary, the boat bottom can be coated ith an anti-fouling paint approved for your area to inhibit marine groth. Do not use anti-fouling paint hich includes copper or graphite. These paints can cause more rapid engine corrosion. 4-27

83 EMN00010 Chapter 5 TROUBLE RECOVERY 1 TROUBLESHOOTING TEMPORARY ACTION IN EMERGENCY Impact damage Poer trim/tilt ill not operate Starter ill not operate Engine fails to operate Treatment of submerged motor

84 EMU01204 TROUBLESHOOTING A problem in the fuel, compression, or ignition systems can cause poor starting, loss of poer, or other problems. The troubleshooting chart describes basic checks and possible remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.) If your outboard motor requires repair, bring it to a Yamaha dealer. Trouble Possible Cause Remedy A. Starter ill not operate. B. Engine ill not start (Starter operates). 1. Battery capacity eak or lo. 2. Battery connections loose or corroded. 3. Fuse for electric start circuit blon. 4. Starter components faulty. 5. Engine stop sitch lanyard not attached. 6. Shift lever in gear. 1. Fuel tank empty. 2. Fuel contaminated or stale. 3. Fuel filter clogged. 4. Starting procedure incorrect. 5. Fuel pump malfunctions. 6. Spark plug(s) fouled or incorrect type. 7. Spark plug cap(s) fitted incorrectly. 8. Poor connections or damaged ignition iring. 9. Ignition parts faulty. 10. Engine stop sitch lanyard not attached. 11. Shift lever in gear. 12. Engine inner parts damaged. 1. Check battery condition. Use battery of recommended capacity. 2. Tighten battery cables and clean battery terminals. 3. Check for cause of electric overload and repair. Replace fuse ith one of correct amperage. 4. Have serviced by a Yamaha dealer. 5. Attach lanyard. 6. Shift to neutral. 1. Fill tank ith clean, fresh fuel. 2. Fill tank ith clean, fresh fuel. 3. Clean or replace filter. 4. Read "STARTING ENGINE" section. 5. Have serviced by a Yamaha dealer. 6. Inspect spark plug(s). Clean or replace ith recommended type. 7. Check and re-fit cap(s). 8. Check ires for ear or breaks. Tighten all loose connections. Replace orn or broken ires. 9. Have serviced by a Yamaha dealer. 10. Attach lanyard. 11. Shift to neutral. 12. Have serviced by a Yamaha dealer. 5-1

85 Trouble Possible Cause Remedy C. Engine idles irregularly or stalls. 1. Spark plug(s) fouled or incorrect type. 2. Fuel system obstructed. 3. Fuel contaminated or stale. 4. Fuel filter clogged. 5. Failed ignition parts. 6. Warning system activated. 7. Spark plug gap incorrect. 8. Poor connections or damaged ignition iring. 9. Specified engine oil not used. 10. Thermostat faulty or clogged. 11. Carburetor adjustments incorrect. 12. Fuel pump damaged. 13. Air vent scre on the fuel tank closed. 14. Motor angle too high. 15. Carburetor clogged. 16. Fuel joint connection incorrect. 17. Throttle valve adjustment incorrect. 18. Battery lead disconnected. 1. Inspect spark plug(s). Clean or replace ith recommended type. 2. Check for pinched or kinked fuel line or other obstructions in fuel system. 3. Fill tank ith clean, fresh fuel. 4. Clean or replace filter. 5. Have serviced by a Yamaha dealer. 6. Find and correct cause of arning. 7. Inspect and adjust as specified. 8. Check ires for ear or breaks. Tighten all loose connections. Replace orn or broken ires. 9. Check and replace oil as specified. 10. Have serviced by a Yamaha dealer. 11. Have serviced by a Yamaha dealer. 12. Have serviced by a Yamaha dealer. 13. Open the air vent scre. 14. Return to normal operating position. 15. Have serviced by a Yamaha dealer. 16. Connect correctly. 17. Have serviced by a Yamaha dealer. 18. Connect securely. 5-2

86 Trouble Possible Cause Remedy D. Warning buzzer sounds or indicator lamp lights. E. Engine poer loss. 1. Cooling system clogged. 2. Engine oil level lo. 3. Heat range of spark plug incorrect. 4. Specified engine oil not used. 5. Engine oil contaminated or deteriorated. 6. Oil filter clogged. 7. Oil feed/injection pump malfunctions. 8. Load on boat improperly distributed. 9. Water pump/thermostat faulty. 1. Propeller damaged. 2. Propeller pitch or diameter incorrect. 3. Trim angle incorrect. 4. Motor mounted at incorrect height on transom. 5. Warning system activated. 6. Boat bottom fouled ith marine groth. 7. Spark plug(s) fouled or incorrect type. 8. Weeds or other foreign matter tangled on gear housing. 9. Fuel system obstructed. 10. Fuel filter clogged. 11. Fuel contaminated or stale. 12. Spark plug gap incorrect. 1. Check ater intake for restriction. 2. Fill oil tank ith specified engine oil. 3. Inspect spark plug and replace it ith recommended type. 4. Check and replace oil ith specified type. 5. Replace oil ith fresh, specified type. 6. Have serviced by a Yamaha dealer. 7. Have serviced by a Yamaha dealer. 8. Distribute load to place boat on an even plane. 9. Have serviced by a Yamaha dealer. 1. Have propeller repaired or replaced. 2. Install correct propeller to operate outboard at its recommended speed (r/min) range. 3. Adjust trim angle to achieve most efficient operation. 4. Have motor adjusted to proper transom height. 5. Find and correct cause of arning. 6. Clean boat bottom. 7. Inspect spark plug(s). Clean or replace ith recommended type. 8. Remove foreign matter and clean loer unit. 9. Check for pinched or kinked fuel line or other obstructions in fuel system. 10. Clean or replace filter. 11. Fill tank ith clean, fresh fuel. 12. Inspect and adjust as specified. 5-3

87 Trouble Possible Cause Remedy E. Engine poer loss. F. Engine vibrates excessively. 13. Poor connections or damaged ignition iring. 14. Failed ignition parts. 15. Specified engine oil not used. 16. Thermostat faulty or clogged. 17. Air vent scre closed. 18. Fuel pump damaged. 19. Fuel joint connection incorrect. 20. Heat range of spark plug incorrect. 21. Engine not responding properly to shift lever position. 1. Propeller damaged. 2. Propeller shaft damaged. 3. Weeds or other foreign matter tangled on propeller. 4. Motor mounting bolt loose. 5. Steering pivot loose or damaged. 13. Check ires for ear or breaks. Tighten all loose connections. Replace orn or broken ires. 14. Have serviced by a Yamaha dealer. 15. Check and replace oil ith specified type. 16. Have serviced by a Yamaha dealer. 17. Open the air vent scre. 18. Have serviced by a Yamaha dealer. 19. Connect correctly. 20. Inspect spark plug and replace it ith recommended type. 21. Have serviced by a Yamaha dealer. 1. Have propeller repaired or replaced. 2. Have serviced by a Yamaha dealer. 3. Remove and clean propeller. 4. Tighten bolt. 5. Tighten or have serviced by a Yamaha dealer. 5-4

88 MN20010 TEMPORARY ACTION IN EMERGENCY EMH80010 IMPACT DAMAGE The outboard motor can be seriously damaged by a collision hile operating or trailering. Damage could make the outboard motor unsafe to operate. E If the outboard motor hits any object in the ater, follo the procedure belo; 1) Stop the engine immediately. 2) Inspect control system and all components for damage. Also, inspect the boat damage. 3) Hoever damage is found or not found, go back to a nearest harbor sloly and carefully. 4) Have a Yamaha dealer inspection of the outboard motor, before operating it again. EMG65210 POWER TRIM / TILT WILL NOT OPER- ATE If the engine cannot be tilted up or don ith the poer trim and tilt because of a discharged battery or a failure ith the poer trim and tilt unit, the engine can be tilted manually. q Manual valve scre EMG65111* 1) Loosen the manual valve scre counterclockise until it stops. 2) Put the engine in the desired position, then tighten the manual valve scre clockise. 5-5

89 EMN30410 STARTER WILL NOT OPERATE If the starter mechanism does not operate (engine cannot be cranked ith the starter), the engine can be started ith an emergency starter rope. 8 Use this procedure only in an emergency and only to return to port for repairs. 8 When the emergency starter rope is used to start the engine, the start-ingear protection device does not operate. Make sure the transmission is in neutral. Otherise, the boat could unexpectedly start to move, hich could result in an accident. 8 Be sure no one is standing behind you hen pulling the starter rope. It could hip behind you and injure someone. 8 An unguarded rotating flyheel is very dangerous. Keep loose clothing and other objects aay hen starting the engine. Use the emergency starter rope only as instructed. Do not touch the flyheel or other moving parts hen the engine is running. Do not install the starter mechanism or top coling after the engine is running. 8 Do not touch the ignition coil, high voltage ire, spark plug cap or other electrical components hen starting of operating the motor. You could be shocked. 5-6

90 Procedure 1) Remove the top coling. 2) Remove the flyheel cover by removing the bolts. E OFF ON START ) Prepare the engine for starting. See STARTING ENGINE for procedures. Be sure the engine is in Neutral and that the lanyard is attached to the engine stop sitch. The main sitch must be on if the main sitch is equipped on the electric start model. NOTE: Prime start model If the engine ill not start ith this procedure, refer to ENGINE FAILS TO OPER- ATE ) To start the engine ith emergency starter rope, insert the knotted end of the rope into the notch in the flyheel rotor and ind the rope several turns clockise. Then, give a strong pull straight out to crank the engine. Repeat if necessary

91 EMU00434 ENGINE FAILS TO OPERATE EMU00955* Cold Engine Fails to Start If a cold engine fails to start for prime start model, use the folloing procedure. When starting or operating the engine, do not touch the ignition coil, high voltage ire, spark plug cap or other electrical parts carrying high voltage. Keep loose clothing and other objects aay from the engine hen starting it ith an emergency starter rope. An unguarded rotating flyheel is very dangerous. Do not attempt to replace the top coling hen the engine is running. Proceed at once to the nearest port to get the engine repaired. Take care to prevent ater splashing onto the flyheel. CLOSE OPEN 1) Adjust the trim angle so that the drive shaft is at right angles to the ater surface or is trimmed in. 2) Open the emergency starter valve located behind the silencer cover on the front side ) Squeeze the priming pump to or three times to feed fuel

92 N 4) Open the throttle slightly ithout shifting using the throttle control grip, neutral throttle lever or free accelerator. (It is necessary to change the throttle opening slightly depending on the engine temperature.) After the engine starts, return the throttle to the original position ON OFF START ) Set the MAIN SWITCH to ON. 6) Set the MAIN SWITCH to START. cc 8 Do not turn the main sitch to START hen the engine is running. 8 Do not keep the starter-motor turning for more than 5 seconds. The battery ill rapidly become exhausted and it ill be impossible for the starter-motor to start the engine. If the engine does not start ithin 5 seconds, return the main sitch to ON, ait 10 seconds, and then crank the engine again. OPEN CLOSE ) After the engine starts, return the emergency starter valve (if used) to CLOSE. NOTE: When the starter mechanism malfunctions, refer to STARTER WILL NOT OPERATE. 5-9

93 EMN50011 TREATMENT OF SUBMERGED MOTOR If the outboard motor is submerged, immediately take it a Yamaha dealer. Otherise, some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follo the procedure bello for taking care to minimize engine damage. 1) Thoroughly ash aay mud, salt, seaeed, etc. ith fresh ater. 2) Remove the spark plugs and face the spark plug holes donard to allo any ater, mud or contaminants to drain. 3) Drain the fuel from the carburetor. 4) Feed fogging oil or engine oil through the carburetors and spark plug holes hile cranking ith the manual starter or emergency starter rope. 5) Take the outboard motor to a Yamaha dealer as soon as possible. cc Do not attempt to run the motor until it has been completely inspected

94 MEMO E

95 EMP00010 Chapter 6 INDEX 1 INDEX