F75 F90 - · PDF fileF75 F90 OWNER’S MANUAL ... F75, F90 OWNER ’S MANUAL ©2006 by Yamaha Motor Corporation, USA 1st edition, ... Emission control information

F75F90

OWNER’S MANUAL

LIT-18626-07-126D6-28199-13

U.S.A.Edition

ZMU01690

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

U6D613E0.book Page 1 Thursday, March 2, 2006 11:28 AM

Important manual informationEMU31280

To the ownerThank you for choosing a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understanding ofthese simple instructions will help you obtainmaximum enjoyment from your new Yamaha.If you have any question about the operationor maintenance of your outboard motor,please consult a Yamaha dealer.In this Owner’s Manual particularly importantinformation is distinguished in the followingways.

The Safety Alert Symbol means AT-TENTION! BECOME ALERT! YOUR SAFE-TY IS INVOLVED!

WARNINGEWM00780

Failure to follow WARNING instructionscould result in severe injury or death to themachine operator, a bystander, or a per-son inspecting or repairing the outboardmotor.

CAUTION:ECM00700

A CAUTION indicates special precautionsthat must be taken to avoid damage to theoutboard motor.

NOTE:A NOTE provides key information to makeprocedures easier or clearer.

Yamaha continually seeks advancements inproduct design and quality. Therefore, whilethis manual contains the most current productinformation available at the time of printing,there may be minor discrepancies between

your machine and this manual. If there is anyquestion concerning this manual, please con-sult your Yamaha dealer.

NOTE:The F75TR, F90TR and the standard acces-sories are used as a base for the explanationsand illustrations in this manual. Thereforesome items may not apply to every model.

EMU25110

F75, F90OWNER’S MANUAL

©2006 by Yamaha Motor Corporation, USA

1st edition, February 2006All rights reserved.

Any reprinting or unauthorized usewithout the written permission ofYamaha Motor Corporation, USA

is expressly prohibited.Printed in Japan

P/N LIT-18626-07-12


Table of contents

General information ..........................1Identification numbers record.......... 1

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

Emission control information ........... 1North American models...................... 1Star labels .......................................... 2

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

Warning labels.................................... 4Basic boating rules

(Rules of the road) ....................... 5Steering and sailing rules and sound

signals............................................. 5Rules when encountering vessels...... 5Other special situations ...................... 6

Fueling instructions ......................... 8Gasoline ............................................. 9Engine oil............................................ 9

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

Propeller selection......................... 10Start-in-gear protection ................. 11

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

Remote control ................................. 13Remote control lever ........................ 14Neutral interlock trigger .................... 14Neutral throttle lever ......................... 14Tiller handle...................................... 14Gear shift lever ................................. 15Throttle grip ...................................... 15Throttle indicator............................... 15Throttle friction adjuster.................... 15Engine stop lanyard switch............... 16Engine stop button ........................... 16Main switch....................................... 17Power trim and tilt switch on remote

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

engine cowling .............................. 17Variable trolling RPM switches......... 18

Trim tab with anode.......................... 18Tilt support lever for power trim and

tilt or hydro tilt model ..................... 19Top cowling lock lever

(pull up type) ................................. 19Flushing device ................................ 20Water separator................................ 20Digital tachometer ............................ 20Low oil pressure warning indicator ... 20Overheat warning indicator

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

indicator ........................................ 24Command link multifunction

meters ........................................... 24Tachometer unit ............................... 24Speed & fuel meter unit .................... 28Speedometer unit ............................. 29Fuel management meter .................. 30

Warning system ............................ 30Overheat warning ............................. 30Low oil pressure warning.................. 31

Operation ......................................... 32Installation..................................... 32

Mounting the outboard motor ........... 32Breaking in engine ........................ 33

Procedure for 4-stroke models ......... 33Preoperation checks ..................... 33

Fuel .................................................. 33Controls ............................................ 34Engine .............................................. 34Checking the engine oil level............ 34

Filling fuel...................................... 34Ring Free Fuel Additive.................... 35

Operating engine .......................... 35Feeding fuel...................................... 35


Table of contents

Starting engine ................................. 36Warming up engine ....................... 38

Electric start models ......................... 38Shifting .......................................... 39

Forward (tiller handle and remote control models) ............................. 39

Reverse (automatic reverse lock and power trim and tilt models)..... 40

Trolling .......................................... 40Adjusting trolling speed .................... 40

Stopping engine ............................ 41Procedure......................................... 41

Trimming outboard motor.............. 41Adjusting trim angle.......................... 42Adjusting boat trim............................ 43

Tilting up and down ....................... 43Procedure for tilting up (power trim

and tilt models / power tilt models) ......................................... 44

Procedure for tilting down (power trim and tilt models / power tilt models) ......................................... 45

Cruising in shallow water .............. 46Power trim and tilt models / power

tilt models...................................... 46Cruising in other conditions........... 47

Maintenance..................................... 48Specifications ................................ 48Transporting and storing outboard

motor .......................................... 49Storing outboard motor..................... 49Procedure......................................... 50Lubrication........................................ 51Cleaning and anticorrosion

measures ...................................... 51Battery care ...................................... 51Flushing power unit .......................... 52Cleaning the outboard motor............ 53Checking painted surface of motor... 53

Periodic maintenance.................... 53Replacement parts ........................... 53Maintenance chart............................ 54Maintenance chart (additional) ......... 55

Greasing........................................... 56Cleaning and adjusting spark plug ... 56Checking fuel system ....................... 57Changing engine oil.......................... 58Checking wiring and connectors ...... 59Exhaust leakage............................... 60Water leakage .................................. 60Engine oil leakage ............................ 60Checking power trim and tilt / power

tilt system ...................................... 60Checking propeller ........................... 60Removing the propeller .................... 61Installing the Propeller ...................... 61Changing gear oil ............................. 62Inspecting and replacing anode(s) ... 63Checking battery (for electric start

models) ......................................... 63Connecting the battery ..................... 64Disconnecting the battery ................. 65Checking top cowling ....................... 65Coating the boat bottom ................... 65

Trouble Recovery............................ 66Troubleshooting ............................ 66Temporary action in emergency ... 69

Impact damage................................. 69Replacing fuse.................................. 69Power trim and tilt / power tilt will not

operate.......................................... 70Water separator warning indicator

blinks while cruising ...................... 70Starter will not operate ..................... 72Emergency starting engine............... 73

Treatment of submerged motor .... 74Procedure......................................... 74


Table of contents

Consumer information.................... 75Important warranty information for

U.S.A. and Canada .................... 75YAMAHA MOTOR

CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY ............... 77

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ............. 79


General information

1

EMU25170

Identification numbers recordEMU25183

Outboard motor serial numberThe outboard motor serial number is stampedon the label attached to the port side of theclamp bracket.Record your outboard motor serial number inthe spaces provided to assist you in orderingspare parts from your Yamaha dealer or forreference in case your outboard motor is sto-len.

EMU25190

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

EMU25221

Emission control informationEMU25230

North American modelsThis engine conforms to U.S. EnvironmentalProtection Agency (EPA) regulations for ma-rine SI engines. See the label affixed to yourengine for details.EMU31560

Approval label of emission control certifi-cateThis label is attached to the bottom cowling.New Technology; (4-stroke) MFI

1. Outboard motor serial number location

1

ZMU04214

1. Key number

1. Approval label location

1

ZMU04217


General information

2

EMU25262

Manufactured date labelThis label is attached to the clamp bracket orthe swivel bracket.

EMU25272

Star labelsYour outboard motor is labeled with a Califor-nia Air Resources Board (CARB) star label.See below for a description of your particularlabel.

EMU25280

One Star—Low EmissionThe one-star label identifies engines thatmeet the Air Resources Board’s 2001 ex-haust emission standards. Engines meetingthese standards have 75% lower emissionsthan conventional carbureted two-stroke en-gines. These engines are equivalent to theU.S. EPA’s 2006 standards for marine en-gines.

EMU25290

Two Stars—Very Low EmissionThe two-star label identifies engines that meetthe Air Resources Board’s 2004 exhaustemission standards. Engines meeting thesestandards have 20% lower emissions thanOne Star-Low-Emission engines.

1. Manufactured date label location

1

ZMU04218

Manufactured:

ZMU04346

1. Star labels location

ZMU01702


General information

3

EMU25300

Three Stars—Ultra Low EmissionThe three-star label identifies engines thatmeet the Air Resources Board’s 2008 ex-haust emission standards. Engines meetingthese standards have 65% lower emissionsthan One Star-Low-Emission engines.

EMU25362

Safety information� Before mounting or operating the outboard

motor, read this entire manual. Reading itshould give you an understanding of themotor and its operation.

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

� Do not overpower the boat with this out-board motor. Overpowering the boat couldresult in loss of control. The rated power ofthe outboard should be equal to or less than

the rated horsepower capacity of the boat.If the rated horsepower capacity of the boatis unknown, consult the dealer or boat man-ufacturer.

� Do not modify the outboard. Modificationscould make the motor unfit or unsafe to use.

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

� Never operate after drinking alcohol or tak-ing drugs. About 50% of all boating fatalitiesinvolve intoxication.

� Have an approved personal flotation device(PFD) on board for every occupant. It is agood idea to wear a PFD whenever boat-ing. At a minimum, children and non-swim-mers should always wear PFDs, andeveryone should wear PFDs when thereare potentially hazardous boating condi-tions.

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

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

� Check throttle, shift, and steering for properoperation before starting the engine.

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

ZMU01703

ZMU01704


General information

4

� Know the marine laws and regulationswhere you will be boating—and obey them.For basic boating rules, see “Rules of theroad” on page 5.

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

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

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

� Always watch carefully for swimmers duringthe engine operation.

� Stay away from swimming areas.� When a swimmer is in the water near you

shift into neutral and shut off the engine.� Do not illegally discard empty containers

used to replace or replenish oil. For the cor-rect processing of empty containers, con-sult the dealer where you purchased the oil.

� When replacing oils used to lubricate theproduct (engine or gear oil), be sure to wipeaway any spilt oil. Never pour oil without us-ing a funnel or similar device. If necessary,verify the necessary replacement proce-dure with the dealer.

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

Be informed about boating safety. Additionalpublications and information can be obtainedfrom many organizations, including the follow-ing:

United States Coast GuardConsumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Af-fairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647National Marine Manufacturers Associa-tion (NMMA)401 N. Michigan Ave. Chicago, Il 60611Marine Retailers Association of America155 N. Michigan Ave. Chicago, Il 60601EMU25382

Important labelsEMU25395

Warning labels

EMU25401

Label

WARNINGEWM01260

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

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

� Keep hands, hair, and clothes away fromflywheel and other rotating parts whileengine is running.


General information

5

EMU25500

Basic boating rules (Rules of the road)

Just as there are rules which apply when youare driving on streets and high ways, thereare waterway rules which apply when you aredriving your boat. These rules are used inter-nationally, and are also enforced by the Unit-ed States Coast Guard and local agencies.You should be aware of these rules, and fol-low them whenever you encounter anothervessel on the water.Several sets of rules prevail according to geo-graphic location, but are all basically the sameas the International Rules of the Road. Therules presented here in your Owner’s Manualare condensed, and have been provided foryour convenience only. Consult your localU.S. Coast Guard Auxiliary or Department ofMotor Vehicles for a complete set of rulesgoverning the waters in which you will be us-ing your boat.EMU25510

Steering and sailing rules and sound signalsWhenever two vessels on the water meet oneanother, one vessel has the right-of-way; it iscalled the “stand-on” vessel. The vesselwhich does not have the right-of-way is calledthe “give-way” or “burdened” vessel. Theserules determine which vessel has the right-of-way, and what each vessel should do.Stand-on vesselThe vessel with the right-of-way has the dutyto continue its course and speed, except toavoid an immediate collision. When you main-tain your direction and speed, the other vesselwill be able to determine how best to avoidyou.

Give-way vesselThe vessel which does not have the right-of-way has the duty to take positive and timelyaction to stay out of the way of the Stand-Onvessel. Normally, you should not cross in frontof the vessel with the right-of-way. You shouldslow down or change directions briefly andpass behind the other vessel. You should al-ways move in such a way that the operator ofthe other vessel can see what you are doing.“The general prudential rule”This rule is called Rule 2 in the InternationalRules and says,“In obeying and construing these rules due re-gard shall be had to all dangers of navigationand collision, and to any special circumstanc-es, which may render a departure from theabove rules necessary in order to avoid im-mediate danger.”In other words, follow the standard rules ex-cept when a collision will occur unless bothvessels try to avoid each other. If that is thecase, both vessels become “Give-Way” ves-sels.EMU25520

Rules when encountering vesselsThere are three main situations which youmay encounter with other vessels which couldlead to a collision unless the Steering Rulesare followed:Meeting: (you are approaching another ves-sel head-on)Crossing: (you are traveling across the othervessel’s path)Overtaking: (you are passing or beingpassed by another vessel)In the following illustration, your boat is in thecenter. You should give the right-of-way toany vessels shown in white area (you are theGive-Way vessel). Any vessels in the shaded


General information

6

area must yield to you (they are the Give-Wayvessels). Both you and the meeting vesselmust alter course to avoid each other.

MeetingIf you are meeting another power vessel headon, and are close enough to run the risk of col-lision, neither of you has the right-of-way!Both of you should alter course to avoid an ac-cident. You should keep the other vessel onyour port (left) side. This rule doesn’t apply ifboth of you will clear one another if you con-tinue on your set course and speed.

CrossingWhen two power driven vessels are crossingeach other’s path close enough to run the riskof collision, the vessel which has the other onthe starboard (right) side must keep out of theway of the other. If the other vessel is on yourright, you must keep out of its way; you are theGive-Way vessel. If the other vessel is onyour port (left) side, remember that you

should maintain course and direction, provid-ed the other vessel gives you the right-of-wayas it should.

OvertakingIf you are passing another vessel, you are the“Give-Way” vessel. This means that the othervessel is expected to maintain its course andspeed. You must stay out of its way until youare clear of it. Likewise, if another vessel ispassing you, you should maintain your speedand direction so that the other vessel cansteer itself around you.EMU25530

Other special situationsThere are three other rules you should beaware of when driving your boat around othervessels.Narrow channels and bendsWhen navigating in narrow channels, youshould keep to the right when it is safe andpractical to do so. If the operator of a power-driven vessel is preparing to go around abend that may obstruct the view of other watervessels, the operator should sound a pro-longed blast on the whistle (4 to 6 seconds). Ifanother vessel is around the bend, it tooshould sound the whistle. Even if no reply isheard, however, the vessel should still pro-ceed around the bend with caution. If you nav-igate such waters with your boat, you willneed to carry a portable air horn, availablefrom local marine supply stores.


General information

7

Fishing vessel right-of-wayAll vessels which are fishing with nets, lines ortrawls are considered to be “fishing vessels”under the International Rules. Vessels withtrolling lines are not considered fishing ves-sels. Fishing vessels have the right-of-way re-gardless of position. Fishing vessels cannot,however, impede the passage of other ves-sels in narrow channels.Sailing vessel right-of-waySailing vessels should normally be given theright-of-way. The exceptions to this are:1. When the sailing vessel is overtaking the

power-driven vessel, the power-drivenvessel has the right-of-way.

2. Sailing vessels should keep clear of anyfishing vessel.

3. In a narrow channel, a sailing vesselshould not hamper the safe passage of apower-driven vessel which can navigateonly in such a channel.

Reading buoys and other markersThe waters of the United states are markedfor safe navigation by the lateral system ofbuoyage. Simply put, buoys and markershave an arrangement of shapes, colors, num-bers and lights to show which side of the buoya boater should pass on when navigating in aparticular direction. The markings on thesebuoys are oriented from the perspective of be-ing entered from seaward (the boater is goingtowards the port). This means that red buoysare passed on the starboard (right) side whenproceeding from open water into port, andblack buoys are to port (left) side. When navi-gating out of port, your position with respect tothe buoys should be reversed; red buoysshould be to port and black buoys to star-board.Many bodies of water used by boaters are en-tirely within the boundaries of a particularstate. The Uniform State Waterway Marking

System has been devised for these waters.This system uses buoys and signs with dis-tinctive shapes and colors to show regulatoryor advisory information. These markers arewhite with black letters and orange boarders.They signify speed zones, restricted areas,danger areas, and general information.Remember, markings may vary by geograph-ic location. Always consult local boating au-thorities before driving your boat in unfamiliarwaters.


General information

8

EMU25540

Fueling instructions

WARNINGEWM00010

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

� Do not smoke when refueling, and keepaway from sparks, flames, or othersources of ignition.

� Stop engine before refueling.� Refuel in a well-ventilated area. Refuel

portable fuel tanks off the boat.

ZMU01708


General information

9

� Take care not to spill gasoline. If gaso-line spills, wipe it up immediately withdry 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-line in your eyes, get immediate medicalattention.

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

� Touch the fuel nozzle to the filler open-ing or funnel to help prevent electrostat-ic sparks.

CAUTION:ECM00010

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

EMU25570

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

GasoholThere are two types of gasohol: gasohol con-taining ethanol and that containing methanol.Gasohol containing ethanol can be used ifethanol content does not exceed 10% and thefuel meets minimum octane ratings. Yamahadoes not recommended gasohol containingmethanol because it can cause fuel systemdamage or engine performance problems.

EMU31440

Engine oil

NOTE:If the recommended engine oil grades are notavailable, select an alternative from the fol-lowing chart according to the average temper-atures in your area.

CAUTION:ECM01050

All 4-stroke engines are shipped from thefactory without engine oil.

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

Recommended engine oil:YAMALUBE 4-M FC-W oil or 4-stroke motor oil with a combination of the fol-lowing SAE and API oil classifications

Engine oil type SAE:10W-30 or 10W-40

Engine oil grade API:SE, SF, SG, SH, SJ, SL

Engine oil quantity (excluding oil filter):4.3 L (4.55 US qt) (3.78 Imp.qt)


General information

10

EMU25700

Battery requirement

CAUTION:ECM01060

Do not use a battery that does not meet thespecified capacity. If a battery which doesnot meet specifications is used, the elec-tric system could perform poorly or beoverloaded, causing electric system dam-age.

For electric start models, choose a batterywhich meets the following specifications.EMU25711

Battery specifications

NOTE:The engine cannot be started if battery volt-age is too low.

EMU25742

Propeller selectionThe performance of your outboard motor willbe critically affected by your choice of propel-ler, as an incorrect choice could adversely af-fect performance and could also seriously

damage the motor. Engine speed depends onthe propeller size and boat load. If enginespeed is too high or too low for good engineperformance, this will have an adverse effecton the engine.Yamaha outboard motors are fitted with pro-pellers chosen to perform well over a range ofapplications, but there may be uses where apropeller with a different pitch would be moreappropriate. For a greater operating load, asmaller-pitch propeller is more suitable as itenables the correct engine speed to be main-tained. Conversely, a larger-pitch propeller ismore suitable for a smaller operating load.Yamaha dealers stock a range of propellers,and can advise you and install a propeller onyour outboard that is best suited to your appli-cation.

Minimum cold cranking amps (CCA/SAE):

380.0 AMinimum marine cranking amps (MCA/ABYC):

502.0 AMinimum reserve capacity (RC/SAE):

124 minutes

ZMU01710

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

ZMU04606

-x1 2 3


General information

11

NOTE:Select a propeller which will allow the engineto reach the middle or upper half of the oper-ating range at full throttle with the maximumboat load. If operating conditions such as lightboat loads then allow the engine r/min to riseabove the maximum recommended range, re-duce the throttle setting to maintain the en-gine in the proper operating range.

For instructions on propeller removal and in-stallation, see page 60.EMU25770

Start-in-gear protectionYamaha outboard motors or Yamaha-ap-proved remote control units are equipped withstart-in-gear protection device(s). This featurepermits the engine to be started only when itis in neutral. Always select neutral beforestarting the engine.

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

ZMU04607

-x1 2 3


Basic components

12

EMU25799

Main components

NOTE:* May not be exactly as shown; also may not be included as standard equipment on all models.

1. Top cowling2. Top cowling lock lever(s)3. Anti-cavitation plate4. Trim tab (anode)5. Propeller*6. Cooling water inlet7. Clamp bracket8. Flushing device9. Water separator10.Power trim and tilt switch11.Remote control box (side mount type)*12.Digital speedometer*13.Digital tachometer*


Basic components

13

EMU26180

Remote controlThe remote control lever actuates both theshifter and the throttle. The electrical switchesare mounted on the remote control box.

1

4 6

32

5

ZMU05429

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

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


Basic components

14

EMU26190

Remote control leverMoving the lever forward from the neutral po-sition engages forward gear. Pulling the leverback from neutral engages reverse. The en-gine will continue to run at idle until the leveris moved about 35° (a detent can be felt).Moving the lever farther opens the throttle,and the engine will begin to accelerate.

EMU26201

Neutral interlock triggerTo shift out of neutral, first pull the neutral in-terlock trigger up.

EMU26211

Neutral throttle leverTo open the throttle without shifting into eitherforward or reverse, put the remote control le-ver in the neutral position and lift the neutralthrottle lever.

NOTE:The neutral throttle lever will operate onlywhen the remote control lever is in neutral.The remote control lever will operate onlywhen the neutral throttle lever is in the closedposition.

EMU25911

Tiller handleTo change direction, move the tiller handle tothe left or right as necessary.

1. Neutral “ ”2. Forward “ ”3. Reverse “ ”4. Shift5. Fully closed6. Throttle7. Fully open

1. Neutral interlock trigger

1. Fully open2. Fully closed


Basic components

15

EMU25922

Gear shift leverPulling the gear shift lever towards you putsthe engine in forward gear so that the boatmoves ahead. Pushing the lever away fromyou puts the engine in reverse gear so that theboat moves astern.

EMU25941

Throttle gripThe throttle grip is on the tiller handle. Turnthe grip counterclockwise to increase speedand clockwise to decrease speed.

EMU25961

Throttle indicatorThe fuel consumption curve on the throttle in-dicator shows the relative amount of fuel con-sumed for each throttle position. Choose thesetting that offers the best performance andfuel economy for the desired operation.

EMU25971

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

WARNINGEWM00031

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

1. Forward “ ”2. Neutral “ ”3. Reverse “ ”

1. Throttle indicator


Basic components

16

When constant speed is desired, tighten theadjuster to maintain the desired throttle set-ting.EMU25990

Engine stop lanyard switchThe lock plate must be attached to the enginestop switch for the engine to run. The lanyardshould be attached to a secure place on theoperator’s clothing, or arm or leg. Should theoperator fall overboard or leave the helm, thelanyard will pull out the lock plate, stopping ig-nition to the engine. This will prevent the boatfrom running away under power.

WARNINGEWM00120

� Attach the engine stop switch lanyard toa secure place on your clothing, or yourarm or leg while operating.

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

� Avoid accidentally pulling the lanyardduring normal operation. Loss of enginepower means the loss of most steeringcontrol. Also, without engine power, theboat could slow rapidly. This couldcause people and objects in the boat tobe thrown forward.

NOTE:The engine cannot be started with the lockplate removed.

EMU26001

Engine stop buttonTo open the ignition circuit and stop the en-gine, push this button.

1. Lanyard2. Lock plate

1. Lanyard2. Lock plate


Basic components

17

EMU26090

Main switchThe main switch controls the ignition system;its operation is described below.� “ ” (off)With the main switch in the “ ” (off) posi-tion, the electrical circuits are off, and the keycan be removed.� “ ” (on)With the main switch in the “ ” (on) position,the electrical circuits are on, and the key can-not be removed.� “ ” (start)With the main switch in the “ ” (start) po-sition, the starter motor turns to start the en-gine. When the key is released, it returnsautomatically to the “ ” (on) position.

EMU26141

Power trim and tilt switch on remote control or tiller handleThe power trim and tilt system adjusts the out-board motor angle in relation to the transom.Pressing the switch “ ” (up) trims the out-board motor up, then tilts it up. Pressing theswitch “ ” (down) tilts the outboard motordown and trims it down. When the switch is re-leased, the outboard motor will stop in its cur-rent position.

NOTE:For instructions on using the power trim andtilt switch, see pages 41 and 43.

EMU26151

Power trim and tilt switch on bottom engine cowlingThe power trim and tilt switch is located on theside of the bottom engine cowling. Pressingthe switch “ ” (up) trims the outboard motorup, then tilts it up. Pressing the switch “ ”


Basic components

18

(down) tilts the outboard motor down andtrims it down. When the switch is released,the outboard motor will stop in its current po-sition.

WARNINGEWM01030

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

NOTE:For instructions on using the power trim andtilt switch, see page 43.

EMU30900

Variable trolling RPM switchesThe trolling speed can be adjusted when theoutboard motor is trolling. Press the “ ”switch to increase the trolling speed andpress the “ ” switch to decrease the trollingspeed.

NOTE:� The trolling speed changes approximately

50 r/min each time a switch is pressed.

� If the trolling speed has been adjusted, theengine returns to the normal trolling speedwhen the engine is stopped and restartedor when the engine speed exceeds approx-imately 3000 r/min.

� For instructions on using the variable troll-ing RPM switches, see page 40.

EMU26241

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

WARNINGEWM00840

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

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

1. Power trim and tilt switch

UP

DN

1

ZMU04231

1. Variable trolling RPM switch


Basic components

19

CAUTION:ECM00840

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

EMU26340

Tilt support lever for power trim and tilt or hydro tilt modelTo keep the outboard motor in the tilted up po-sition, lock the tilt support lever to the clampbracket.

EMU26382

Top cowling lock lever (pull up type)To remove the engine top cowling, pull up thelock lever(s) and lift off the cowling. When in-stalling the cowling, check to be sure it fitsproperly in the rubber seal. Then lock thecowling by moving the lever(s) downward.1. Trim tab

2. Bolt3. Cap

1

2

3

ZMU02525

A

B

AB

ZMU01863

1. Tilt support lever

1. Top cowling lock lever(s)

1. Top cowling lock lever(s)

ZMU04225

1

ZMU04226

1


Basic components

20

EMU26460

Flushing deviceThis device is used to clean the cooling waterpassages of the motor using a garden hoseand tap water.

NOTE:For details on usage, see page 52.

EMU31702

Water separatorThis engine has a combination fuel filter/waterseparator and associated warning system. Ifwater separated from the fuel exceeds a spe-cific volume, the warning device will activate.

Activation of warning device� The water separator warning indicator will

blink.� The buzzer will sound intermittently only

when the gear shift is in neutral.

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

EMU31410

Digital tachometerThe tachometer shows the engine speed andhas the following functions.

NOTE:All segments of the display will light momen-tarily after the main switch is turned on andwill return to normal thereafter.

NOTE:The water separator warning indicator andengine trouble warning indicator on the digitaltachometer do not operate for this engine.

EMU26522

Low oil pressure warning indicatorIf oil pressure drops too low, the warning indi-cator will start to blink. For further information,see page 30.

1. Flushing device

1. Tachometer2. Trim meter3. Hour meter4. Low oil pressure warning indicator5. Overheat warning indicator6. Set button7. Mode button

ZMU01840

1

5

2

4

3

6 7


Basic components

21

CAUTION:ECM00020

� Do not continue to run the engine if thelow oil pressure warning indicator is onand the engine oil level is lower. Seriousengine damage will occur.

� The low oil pressure warning indicatordoes not indicate the engine oil level.Use the oil dipstick to check the remain-ing oil quantity. For further information,see page 34.

EMU26581

Overheat warning indicator (digital type)If the engine temperature rises too high, thewarning indicator will start to blink. For furtherinformation on reading the indicator, see page30.

CAUTION:ECM00050

Do not continue to run the engine if theoverheat warning indicator is on. Seriousengine damage will occur.

EMU26600

Speedometer (digital type)This gauge shows the boat speed.

NOTE:After the main switch is first turned on, all seg-ments of the display come on as a test. Aftera few seconds, the gauge will change to nor-mal operation. Watch the gauge when turningon the main switch to make sure all segmentscome on.

1. Low oil pressure warning indicator

ZMU017361

1. Overheat warning indicator

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

ZMU01737

1


Basic components

22

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

EMU26620

Trim meter (digital type)This meter shows the trim angle of your out-board motor.

NOTE:� Memorize the trim angles that work best for

your boat under different conditions. Adjustthe trim angle to the desired using the pow-er trim and tilt switch.

� If the trim angle of your motor exceeds thetrim operating range, the top segment onthe trim meter display will blink.

EMU26650

Hour meter (digital type)This meter shows the number of hours the en-gine has been run. It can be set to show thetotal number of hours or the number of hoursfor the current trip. The display can also beturned on and off.

� Changing the display formatPressing the “ ” (mode) button chang-es the display format in the following pat-tern:Total hours→Trip hours→Display off

� Resetting the trip hoursSimultaneously pressing the “ ” (set) and“ ” (mode) buttons for more than 1 sec-ond while the trip hours are displayed re-sets the trip counter to 0 (zero).

NOTE:The total number of hours the engine hasbeen run cannot be reset.

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

ZMU01740

ZMU01741


Basic components

23

EMU26690

Trip meterThis gauge displays the distance the boat hastraveled since the gauge was last reset.Press the “ ” (mode) button repeatedlyuntil the indicator on the face of the gaugepoints to “ ” (trip). To reset the trip meter tozero, press the “ ” (set) and “ ” (mode)buttons at the same time.

NOTE:� The trip distance is shown in kilometers or

miles depending upon the unit of measure-ment selected for the speedometer.

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

EMU26700

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

NOTE:The clock operates on battery power. Discon-necting the battery will stop the clock. Resetthe clock after connecting the battery.

EMU26710

Fuel gaugeThe fuel level is indicated by eight segments.When all segments are showing, the fuel tankis full.

CAUTION:ECM00860

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

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


Basic components

24

EMU26720

Fuel warning indicatorIf the fuel level decreases to one segment, thefuel level warning segment will begin to blink.

CAUTION:ECM00880

Do not continue to operate the engine withfull throttle if a warning device has activat-ed. Get back to the port within trolling en-gine speed.

EMU26730

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

CAUTION:ECM00870

Get back to the port soon if a warning de-vice has activated. For charging the bat-tery, consult your Yamaha dealer.

EMU31640

Command link multifunction metersCommand link multifunction meters have 6kinds of meter units; tachometer unit (squareor round types), speedometer unit (squaretype), speed & fuel meter unit (square orround types), and fuel management meter(square type). The indicator system is slightlydifferent between the round and square types.Check the model and type of your unit careful-ly. This manual describes mainly the warningindicators. For more details on setting metersor changing indicator systems, see the at-tached operation manual.EMU31680

Tachometer unitThe tachometer shows the engine revolutionsper minute. It has functions of trim meter, ad-justing trolling speed, cooling water/enginetemperature display, battery voltage display,total hour/trip hour display, oil pressure dis-play, water detection warning, engine troublewarning, and periodic maintenance notifica-tion. If optional sensors are connected to theunit, cooling water pressure display will beavailable. For the optional sensor, consultyour Yamaha dealer. The tachometer unit isavailable in round or square types. Checkyour tachometer unit type.

1. Fuel level warning segment

ZMU01745

1. Low battery indicator


Basic components

25

NOTE:The tachometer unit shows various kinds ofinformation according to the setting made us-ing the “ ” (set) and “ ” (mode) buttons.For details, see the attached operation manu-al.

Preoperation checksPlace the gear shift lever in neutral and turnthe main switch to “ ” (on). After all the dis-plays come on and the total hour displaycomes on, the gauge will change to normaloperation. If the buzzer sounds and the waterseparator warning indicator blinks, consultyour Yamaha dealer immediately.

NOTE:To stop the buzzer, press the “ ” (set) or“ ” (mode) button.

1. Set button2. Mode button

1. Tachometer2. Trim meter3. Multifunction display4. Cooling water pressure5. Cooling water/engine temperature6. Water detection warning indicator7. Battery voltage8. Oil pressure (4-stroke models)


21

ZMU05415

2

3

1

4

5

6

7

8 ZMU05416

21

ZMU05417

1. Tachometer2. Trim meter3. Multifunction display4. Water detection warning indicator5. Engine trouble warning/maintenance indica-

tor6. Cooling water pressure7. Oil pressure (4-stroke models)8. Cooling water/engine temperature9. Battery voltage

1 4 5 2

3

6 87 9 ZMU05418


Basic components

26

Low oil pressure warningWhen the engine oil pressure drops too low,the low oil pressure warning indicator will startto blink, and the engine speed will automati-cally decrease to about 2000 r/min.

Stop the engine immediately if the buzzersounds and the low oil pressure warning indi-cator blinks. Check the engine oil quantity andreplenish oil if necessary. If the warning de-vice has activated while the appropriate en-gine oil quantity is maintained, consult yourYamaha dealer.

CAUTION:ECM01600

Do not continue to run the engine if thelow oil pressure warning device has acti-vated. Serious engine damage will occur.

Overheat warningIf the engine temperature rises too high whilecruising, the overheat warning indicator willstart to blink. The engine speed will automati-cally decrease to about 2000 r/min.

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

CAUTION:ECM01590

� Do not continue to run the engine if theoverheat warning indicator blinks. Seri-ous engine damage will occur.

� Do not continue to operate the engine ifa warning device has activated. Consultyour Yamaha dealer if the problem can-not be located and corrected.

ZMU05430

ZMU05431

ZMU05421

ZMU05422


Basic components

27

Water separator warningThis indicator will blink when water has accu-mulated in the water separator (fuel filter)while cruising. In such an event, stop the en-gine immediately and see page 69 of thismanual to drain the water from the fuel filter.Get back to the port soon and consult aYamaha dealer immediately.

CAUTION:ECM00910

Gasoline mixed with water could causedamage to the engine.

Engine trouble warningThis indicator will blink when the engine mal-functions while cruising. Get back to the portsoon and consult a Yamaha dealer immedi-ately.

CAUTION:ECM00920

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

Low battery voltage warningWhen the battery voltage drops, the low bat-tery voltage warning indicator and the batteryvoltage value will start to blink. Get back to theport soon if the low battery voltage warningdevice has activated. For charging the bat-tery, consult your Yamaha dealer.

ZMU05423

ZMU05424

ZMU05425

ZMU05426


Basic components

28

EMU31610

Speed & fuel meter unitThis unit shows the boat speed and has thefunctions of fuel meter, total fuel consumptiondisplay, fuel economy display, fuel flow dis-play, and system voltage display. If optionalsensors are connected to the unit, trip display,water surface temperature display, depth dis-play, and clock will be available. For the op-tional sensor, consult your Yamaha dealer.The speed & fuel meter unit is available inround or square types. Check your speed &fuel meter unit type.

ZMU05427

ZMU05428


1. Speedometer2. Fuel meter3. Multifunction display


21

ZMU05432

1

23

ZMU05433

21

ZMU05434


Basic components

29

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

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

EMU31620

Speedometer unitThis unit shows the boat speed and has func-tions of fuel meter and system voltage dis-play. If optional sensors are connected to theunit, trip display, water surface temperaturedisplay, depth display, and clock will be avail-able. For the optional sensor, consult yourYamaha dealer.


NOTE:The speedometer unit shows various kinds ofinformation according to the setting made us-ing the “ ” (set) and “ ” (mode) buttons.In addition, the speedometer can show thedesired unit of measurement such as km/h,mph, or knots. For details, see the attachedoperation manual.


1 2

3 ZMU05435



21

ZMU05436

1

23

ZMU05437


Basic components

30

EMU31630

Fuel management meterThis meter has functions of fuel flow meter, to-tal consumption display, fuel economy dis-play, and remaining fuel display.


NOTE:The fuel management meter shows variouskinds of information when the operator usesthe “ ” (set) and “ ” (mode) buttons. Fordetails, see the attached operation manual.

EMU26801

Warning system

CAUTION:ECM00090

Do not continue to operate the engine if awarning device has activated. Consultyour Yamaha dealer if the problem cannotbe located and corrected.

EMU26816

Overheat warningThis engine has an overheat warning device.If the engine temperature rises too high, thewarning device will activate.Activation of warning device� The engine speed will automatically de-

crease to about 2000 r/min.� If equipped with an overheat warning indi-

cator, it will light or blink.

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


1. Fuel flow meter2. Multifunction display

21

ZMU05438

1

2

ZMU05439

ZMU01757


Basic components

31

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

EMU26855

Low oil pressure warningIf the oil pressure drops too low, the warningdevice will activate.Activation of warning device� The engine speed will automatically de-

crease to about 2000 r/min.� The low oil pressure warning indicator will

light or blink.

� The buzzer will sound.

If the warning system has activated, stop theengine as soon as it is safe to do so. Checkthe oil level and add oil as needed. If the oillevel is correct and the warning device doesnot switch off, consult your Yamaha dealer.

CAUTION:ECM00100

Do not continue to run the engine if thelow oil pressure warning indicator is on.Serious engine damage could occur.

ZMU02630

ZMU01828


Operation

32

EMU26901

Installation

CAUTION:ECM00110

Incorrect engine height or obstructions tosmooth water flow (such as the design orcondition of the boat, or accessories suchas transom ladders or depth finder trans-ducers) can create airborne water spraywhile the boat is cruising. Severe enginedamage may result if the motor is operat-ed continuously in the presence of air-borne water spray.

NOTE:During water testing check the buoyancy ofthe boat, at rest, with its maximum load.Check that the static water level on the ex-haust housing is low enough to prevent waterentry into the powerhead, when water risesdue to waves when the outboard is not run-ning.

EMU26910

Mounting the outboard motor

WARNINGEWM00820

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

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

WARNINGEWM00830

Improper mounting of the outboard motorcould result in hazardous conditions suchas poor handling, loss of control, or firehazards. Observe the following:� For permanently mounted models, your

dealer or other person experienced inproper rigging should mount the motor.If you are mounting the motor yourself,you should be trained by an experiencedperson.

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

Mount the outboard motor on the center line(keel line) of the boat, and ensure that theboat itself is well balanced. Otherwise theboat will be hard to steer. For boats without akeel or which are asymmetrical, consult yourdealer.

EMU26930

Mounting height (boat bottom)To run your boat at optimum efficiency, thewater resistance (drag) of the boat and out-board motor must be made as little as possi-ble. The mounting height of the outboardmotor greatly affects the water resistance. Ifthe mounting height is too high, cavitation

1. Center line (keel line)

ZMU017601


Operation

33

tends to occur, thus reducing the propulsion;and if the propeller tips cut the air, the enginespeed will rise abnormally and cause the en-gine to overheat. If the mounting height is toolow, the water resistance will increase andthereby reduce engine efficiency. Mount theoutboard motor so that the anti-cavitationplate is in alignment with the bottom of theboat.

NOTE:� The optimum mounting height of the out-

board motor is affected by the boat/motorcombination and the desired use. Test runsat different heights can help determine theoptimum mounting height. Consult yourYamaha dealer or boat manufacturer forfurther information on determining the prop-er mounting height.

� For instructions on setting the trim angle ofthe outboard motor, see page 41.

EMU30173

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

CAUTION:ECM00800

Failure to follow the break-in procedurecould result in reduced engine life or evensevere engine damage.

EMU27081

Procedure for 4-stroke modelsRun the engine under load (in gear with a pro-peller installed) for 10 hours as follows.1. First hour:

Run the engine at 2000 r/min or at ap-proximately half throttle.

2. Second hour:Run the engine at 3000 r/min or at ap-proximately three-quarter throttle.

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

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

EMU27103

Preoperation checks

WARNINGEWM00080

If any item in the preoperation check is notworking properly, have it inspected andrepaired before operating the outboardmotor. Otherwise an accident could occur.

CAUTION:ECM00120

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

EMU31550

Fuel� Check to be sure you have plenty of fuel for

your trip.� Make sure there are no fuel leaks or gaso-

line fumes.

ZMU01762


Operation

34

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

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

� Check the water in the fuel filter with the wa-ter separator warning device. Place thegear shift lever in neutral and turn the mainswitch to “ ”(on). If the buzzer sounds andthe water separator warning indicatorblinks, consult your Yamaha dealer imme-diately.

EMU27130

Controls� Check throttle, shift, and steering for proper

operation before starting the engine.� The controls should work smoothly, without

binding or unusual free play.� Look for loose or damaged connections.� Check operation of the starter and stop

switches when the outboard motor is in thewater.

EMU27150

Engine� Check the engine and engine mounting.� Look for loose or damaged fasteners.� Check the propeller for damage.� Check that the battery is in good condition

and the battery connections are secure.EMU27163

Checking the engine oil level1. Put the outboard motor in an upright po-

sition (not tilted).2. Remove oil dipstick and wipe it clean.3. Completely insert the dipstick and re-

move it again.

4. Check the oil level using the dipstick to besure the level falls between the upper andlower marks. Fill with oil if it is below thelower mark, or drain to the specified levelif it is above the upper mark.

NOTE:Be sure to completely insert the dipstick intothe dipstick guide.

EMU30021

Filling fuel

WARNINGEWM00060

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

1. Oil dipstick

1. Lower level mark2. Oil dipstick3. Upper level mark

ZMU04257

1


Operation

35

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

tank. Wipe up any spilled fuel.EMU27270

Ring Free Fuel AdditiveGasoline is a precise blend of many differentsubstances, each chosen to give certain char-acteristics. Gasoline blends have beenchanging in recent years in response to con-cerns about pollution and resulting emissionsregulations. One of the most obvious changeshas been the elimination of lead from most fu-els.As gasoline has changed, the amount of addi-tives such as aromatics and oxygenates hasincreased. These additives are important forthe engines in passenger cars, but they canhave detrimental effects in marine engines,because of increased deposits in the combus-tion chamber. When enough deposits collect,piston rings begin sticking. Performancedrops and engine wear increases dramatical-ly.While many additives available may reducedeposits, Yamaha recommends the use ofRing Free Fuel Additive, available from yourYamaha dealer. Ring Free Fuel Additivehas repeatedly proven its ability to clean com-bustion deposits from inside the engine, nota-bly the critical piston-ring-land area, and fuelsystem components. Follow product labelingfor use instructions.

EMU27450

Operating engineEMU27482

Feeding fuel

WARNINGEWM00420

� Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in thewater near you.

� When the air vent screw is loosened,gasoline vapor will be released. Gaso-line is highly flammable, and its vaporsare flammable and explosive. Refrainfrom smoking, and keep away fromopen flames and sparks while looseningthe air vent screw.

� This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which could cause braindamage or death when inhaled. Symp-toms include nausea, dizziness, anddrowsiness. Keep cockpit and cabin ar-eas well ventilated. Avoid blocking ex-haust outlets.

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

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

3. Squeeze the primer pump, with the arrowpointing up, until you feel it become firm.


Operation

36

EMU27490

Starting engineEMU27592

Electric start / prime start models1. Place the gear shift lever in neutral.

NOTE:The start-in-gear protection device preventsthe engine from starting except when in neu-tral.

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

WARNINGEWM00120




3. Place the throttle grip in the “ ”(start) position. After the engine starts, re-turn the throttle to the fully closed posi-tion.

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

1. Arrow


Operation

37

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

CAUTION:ECM00191

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

� Do not keep the starter motor turning formore than 5 seconds. If the starter motoris turned continuously for more than 5seconds, the battery will be quickly dis-charged, thus making it impossible tostart the engine. The starter can also bedamaged. If the engine will not start after5 seconds of cranking, return the mainswitch to “ ” (on), wait 10 seconds,then crank the engine again.

NOTE:� When the engine is cold, it needs to be

warmed up. For further information, seepage 38.

� If the engine is warm and fails to start, openthe throttle slightly and try to start the en-gine again. If the engine still fails to start,see page 66.

EMU27624

Electric start and remote control models1. Place the remote control lever in “ ”

(neutral).

NOTE:The start-in-gear protection device preventsthe engine from starting except when in neu-tral.

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

WARNINGEWM00120





Operation

38

3. Turn the main switch to “ ” (on).

NOTE:Dual engine users: When the main switch isturned on, the buzzer operates for a few sec-onds then stops automatically. The buzzeralso operates if one of the engines stalls.

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

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

CAUTION:ECM00191

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

� Do not keep the starter motor turning formore than 5 seconds. If the starter motoris turned continuously for more than 5seconds, the battery will be quickly dis-charged, thus making it impossible tostart the engine. The starter can also bedamaged. If the engine will not start after5 seconds of cranking, return the mainswitch to “ ” (on), wait 10 seconds,then crank the engine again.

EMU27670

Warming up engineEMU30031

Electric start models1. After starting the engine, allow it to idle for

3 minutes to warm up. Failure to do so willshorten engine life.

2. Be sure the low oil pressure warning indi-cator remains off after starting the en-gine.

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

CAUTION:ECM01341

� If the low oil pressure warning indicatorblinks after the engine starts, stop theengine. Otherwise serious engine dam-age could occur. Check the oil level andadd oil if necessary. Consult yourYamaha dealer if the cause for the lowoil pressure warning indicator cannot befound.

� A continuous flow of water from the pilothole shows that the water pump ispumping water through the cooling pas-

ON STARTOFF

ZMU01881


Operation

39

sages. If water is not flowing out of thepilot hole at all times while the engine isrunning, overheating and serious dam-age could occur. Stop the engine andcheck whether the cooling water inlet onthe lower case or the cooling water pilothole is blocked. Consult your Yamahadealer if the problem cannot be locatedand corrected.

� If the cooling passage is frozen, it maytake awhile for water to start flowing outof the pilot hole.

EMU27740

Shifting

WARNINGEWM00180

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

CAUTION:ECM00220

To change the boat direction or shiftingposition from forward to reverse or vice-versa, first close the throttle so that the en-gine idles (or runs at low speeds).

EMU27764

Forward (tiller handle and remote con-trol models)Tiller handle models1. Place the throttle grip in the fully closed

position.

2. Move the gear shift lever quickly and firm-ly from neutral to forward.

Remote control modelsPull up the neutral interlock trigger (ifequipped) and move the remote control leverquickly and firmly from neutral to forward.


Operation

40

EMU27785

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

WARNINGEWM00190

When operating in reverse, go slowly. Donot open the throttle more than half. Other-wise the boat could become unstable,which could result in loss of control andan accident.

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

position.

2. Move the gear shift lever quickly and firm-ly from neutral to reverse.

Remote control modelsPull up the neutral interlock trigger (ifequipped) and move the remote control leverquickly and firmly from neutral to reverse.

EMU30880

TrollingEMU30890

Adjusting trolling speedThe trolling speed on outboard motorsequipped with the variable trolling RPMswitches can be adjusted approximately 50r/min with each press of a switch.

To increase the trolling speed, press the “ ”switch.To decrease the trolling speed, press the “ ”switch.

NOTE:� The trolling speed changes approximately

50 r/min each time a switch is pressed.

1. “ ” switch2. “ ” switch


Operation

41

� If the trolling speed has been adjusted, theengine returns to the normal trolling speedwhen the engine is stopped and restartedor when the engine speed exceeds approx-imately 3000 r/min.

EMU27820

Stopping engineBefore stopping the engine, first let it cool offfor a few minutes at idle or low speed. Stop-ping the engine immediately after operating athigh speed is not recommended.EMU27844

Procedure1. Push and hold the engine stop button or

turn the main switch to “ ” (off).

2. After stopping the engine, disconnect thefuel line if there is a fuel joint on the out-board motor.

3. Tighten the air vent screw on the fuel tankcap (if equipped).

4. Remove the key if the boat will be left un-attended.

NOTE:The engine can also be stopped by pulling thelanyard and removing the lock plate from theengine stop switch, then turning the mainswitch to “ ” (off).

EMU27861

Trimming outboard motorThe trim angle of the outboard motor helpsdetermine the position of the bow of the boatin the water. Correct trim angle will help im-prove performance and fuel economy whilereducing strain on the engine. Correct trim an-gle depends upon the combination of boat,engine, and propeller. Correct trim is also af-fected by variables such as the load in theboat, sea conditions, and running speed.

WARNINGEWM00740

Excessive trim for the operating condi-tions (either trim up or trim down) cancause boat instability and can make steer-ing the boat more difficult. This increases


Operation

42

the possibility of an accident. If the boatbegins to feel unstable or is hard to steer,slow down and/or readjust the trim angle.

EMU27882

Adjusting trim anglePower trim and tilt models

WARNINGEWM00751

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

� Use caution when trying a trim positionfor the first time. Increase speed gradu-ally and watch for any signs of instabilityor control problems. Improper trim an-gle can cause loss of control.

� If equipped with a power trim and tiltswitch located on the bottom cowling,use the switch only when the boat is at a

complete stop with the engine off. Donot adjust the trim angle with this switchwhile the boat is moving.

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

To raise the bow (trim-out), press the switch“ ” (up).

1. Trim operating angle

1ZMU04258




UP

DN

1

ZMU04231


Operation

43

To lower the bow (trim-in), press the switch“ ” (down).Make test runs with the trim set to different an-gles to find the position that works best foryour boat and operating conditions.EMU27911

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

Bow UpToo much trim-out puts the bow of the boattoo high in the water. Performance and econ-omy are decreased because the hull of theboat is pushing the water and there is more airdrag. Excessive trim-out can also cause thepropeller to ventilate, which reduces perfor-mance further, and the boat may “porpoise”(hop in the water), which could throw the op-erator and passengers overboard.

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

NOTE:Depending on the type of boat, the outboardmotor trim angle may have little effect on thetrim of the boat when operating.

EMU27933

Tilting up and downIf the engine will be stopped for some time orif the boat is moored in shallows, the outboardmotor should be tilted up to protect the propel-ler and casing from damage by collision withobstructions, and also to reduce salt corro-sion.


Operation

44

WARNINGEWM00220

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

WARNINGEWM00250

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

CAUTION:ECM00241

� Before tilting the outboard motor, stopthe engine by following the procedureon page 41. Never tilt the outboard mo-tor while the engine is running. Severedamage from overheating can result.

� Do not tilt up the engine by pushing thetiller handle (if equipped) because thiscould break the handle.

EMU28007

Procedure for tilting up (power trim and tilt models / power tilt models)1. Place the remote control lever / gear shift

lever in neutral.

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

3. Press the power trim and tilt switch / pow-er tilt switch “ ” (up) until the outboardmotor has tilted up completely.

N

ZMU03196


Operation

45

4. Push the tilt support knob into the clampbracket or pull the tilt support lever towardyou to support the engine.

WARNINGEWM00260

After tilting the outboard motor, be sure tosupport it with the tilt support knob or tiltsupport lever. Otherwise the outboard mo-tor could fall back down suddenly if oil inthe power trim and tilt unit loses pressure.

5. Models equipped with trim rods: Once theoutboard motor is supported with the tiltsupport lever, press the power trim andtilt switch / power tilt switch “ ” (down) toretract the trim rods.

CAUTION:ECM00250

Be sure to retract the trim rods completelyduring mooring. This protects the rodsfrom marine growth and corrosion whichcould damage the power trim and tiltmechanism.

EMU28055

Procedure for tilting down (power trim and tilt models / power tilt models)1. Push the power trim and tilt switch / pow-

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

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

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

UP

ZMU04232

DN

ZMU01936

UP

DN


Operation

46

EMU28060

Cruising in shallow waterThe outboard motor can be tilted up partiallyto allow operation in shallow water.EMU28090

Power trim and tilt models / power tilt modelsThe outboard motor can be tilted up partiallyto allow operation in shallow water.

WARNINGEWM00660

� Place the gear shift in neutral before set-ting up for shallow water cruising.

� Return the outboard motor to its normalposition as soon as the boat is back indeeper water.

CAUTION:ECM00260

Do not tilt the outboard motor up so thatthe cooling water inlet on the lower unit isabove the surface of the water when set-

ting up for and cruising in shallow water.Otherwise severe damage from overheat-ing can result.

EMU28185

Procedure for power trim and tilt / powertilt models1. Place the remote control lever / gear shift

lever in neutral.

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

DN

ZMU04255


Operation

47

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

EMU28192

Cruising in other conditionsCruising in salt waterAfter operating in salt water, flush the coolingwater passages with fresh water to preventthem from becoming clogged with salt depos-its.

NOTE:For cooling system flushing instructions, seepage 49.

Cruising in turbid waterYamaha strongly recommends that you usethe optional chromium-plated water pump kit(not available for some models) if you use theoutboard motor in turbid or muddy water con-ditions.


Maintenance

48

EMU31480

Specifications

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

EMU28218

Dimension:Overall length:

817 mm (32.2 in)Overall width:

479 mm (18.9 in)Overall height L:

1582 mm (62.3 in)Overall height X:

1710 mm (67.3 in)Transom height L:

536 mm (21.1 in)Transom height X:

664 mm (26.1 in)Weight (without propeller) L:

168.0 kg (370 lb)Weight (without propeller) X:

172.0 kg (379 lb)Performance:

Full throttle operating range:5000–6000 r/min

Maximum output:F75TR 55.2 kW@5500 r/min (75 HP@5500 r/min)F90TR 66.2 kW@5500 r/min (90 HP@5500 r/min)

Idling speed (in neutral):700 ±50 r/min

Engine:Type:

4-stroke LDisplacement:

1596.0 cm³ (97.39 cu.in)Bore × stroke:

79.0 × 81.4 mm (3.11 × 3.20 in)Ignition system:

TCI

Spark plug (NGK):LFR5A-11

Spark plug gap:1.0–1.1 mm (0.039–0.043 in)

Control system:Remote control

Starting system:Electric

Starting carburetion system:Electronic fuel injection

Valve clearance (cold engine) IN:0.17–0.23 mm (0.0067–0.0091 in)

Valve clearance (cold engine) EX:0.31–0.37 mm (0.0122–0.0146 in)

Min. cold cranking amps (CCA/SAE):380.0 A

Min. marine cranking amps (MCA/ABYC):502.0 A

Min. reserve capacity (RC/SAE):124 minutes

Alternator output for battery DC:25.0 A

Drive unit:Gear positions:

Forward-neutral-reverseGear ratio:

2.31 (30/13)Trim and tilt system:

Power trim and tiltPropeller mark:

KFuel and oil:

Recommended fuel:Regular unleaded gasoline

Min. pump octane:86

Recommended engine oil:4-stroke outboard motor oil

Engine oil grade API:API SE, SF, SG, SH, SJ, SL

Engine oil type SAE:SAE10W30 or SAE10W40

Lubrication:Wet sump


Recommended gear oil:Hypoid gear oil SAE#90


Maintenance

49

Gear oil quantity:670.0 cm³ (22.65 US oz) (23.63 Imp.oz)

Tightening torque for engine:Spark plug:

25.0 Nm (18.4 ft-lb) (2.55 kgf-m)Propeller nut:

35.0 Nm (25.8 ft-lb) (3.57 kgf-m)Engine oil drain bolt:

28.0 Nm (20.7 ft-lb) (2.86 kgf-m)Engine oil filter:

18.0 Nm (13.3 ft-lb) (1.84 kgf-m)EMU28222

Transporting and storing out-board motor

WARNINGEWM00690

� Leaking fuel is a fire hazard. When trans-porting and storing the outboard motor,close the air vent screw and fuel cock toprevent fuel from leaking.

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

� DO NOT fill fuel container to maximumcapacity. Gasoline will expand consider-ably as it warms up and can build uppressure in the fuel container. This cancause fuel leakage and a potential firehazard.

WARNINGEWM00700

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

CAUTION:ECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboard mo-tor could shake loose from the tilt supportand fall. If the motor cannot be trailered in

the normal running position, use an addi-tional support device to secure it in the tiltposition.

The outboard motor should be trailered andstored in the normal running position. If thereis insufficient road clearance in this position,then trailer the outboard motor in the tilt posi-tion using a motor support device such as atransom saver bar. Consult your Yamahadealer for further details.EMU30061

Storing outboard motorWhen storing your Yamaha outboard motorfor prolonged periods of time (2 months orlonger), several important procedures mustbe performed to prevent excessive damage. Itis advisable to have your outboard motor ser-viced by an authorized Yamaha dealer prior tostorage. However, you, the owner, with a min-imum of tools, can perform the following pro-cedures.

CAUTION:ECM01360

� To prevent problems which can becaused by oil entering the cylinder fromthe sump, keep the outboard motor inthe attitude shown when transportingand storing it. Do not store or transportthe outboard motor on its side (not up-right).

� Do not place the outboard motor on itsside before the cooling water hasdrained from it completely, otherwisewater may enter the cylinder through theexhaust port and cause engine trouble.

� Store the outboard motor in a dry, well-ventilated place, not in direct sunlight.


Maintenance

50

EMU28303

ProcedureEMU30001

Flushing with the flushing attachment1. Wash the outboard motor body using

fresh water. For further information, seepage 53.

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

NOTE:The use of “Yamaha Fuel Conditioner andStabilizer” eliminates the need to drain thefuel system. Consult your Yamaha dealer orother qualified mechanic if the fuel system isto be drained instead.

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

cooling water inlet.

CAUTION:ECM00300

Do not run the engine without supplying itwith cooling water. Either the engine waterpump will be damaged or the engine willbe damaged from overheating. Beforestarting the engine, be sure to supply wa-ter to the cooling water passages.

CAUTION:ECM00310

Avoid running the outboard motor at highspeed while on the flushing attachment,otherwise overheating could occur.

5. Cooling system flushing is essential toprevent the cooling system from cloggingup with salt, sand, or dirt. In addition, fog-ging/lubricating of the engine is mandato-ry to prevent excessive engine damagedue to rust. Perform the flushing and fog-ging at the same time.

WARNINGEWM00090

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

� Keep hands, hair, and clothes away fromthe flywheel and other rotating partswhile the engine is running.

NOTE:� When using the flushing attachment, main-

tain adequate water pressure and a steadywater flow.

� If the overheat warning device is activated,turn the engine off, and consult yourYamaha dealer.

ZMU03659

1. Flushing attachment


Maintenance

51

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

7. Just prior to turning off the engine, quicklyspray “Yamaha Stor-Rite Engine FoggingOil” (Part No. LUB-STRRT-12-00) alter-nately into the intake silencer or the fog-ging hole of the silencer cover, ifequipped. When properly done, the en-gine will smoke excessively and almoststall.

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

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

the motor. Clean the body thoroughly.

NOTE:A flushing attachment is available from yourYamaha dealer.

EMU28401

Lubrication1. Grease the spark plug threads and install

the spark plug(s) and torque to properspecification. For information on sparkplug installation, see page 56.

2. Change the gear oil. For instructions, seepage 62. Inspect the oil for the presenceof water that indicates a leaky seal. Sealreplacement should be performed by anauthorized Yamaha dealer prior to use.

3. Grease all grease fittings. For further de-tails, see page 56.

EMU28421

Cleaning and anticorrosion measures1. Wash down the exterior of the outboard

motor with fresh water and dry off com-pletely.

2. Spray the outboard motor exterior with“Yamaha Silicone Protectant” (Part No.LUB-SILCNE-13-00).

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

EMU28430

Battery care

WARNINGEWM00330

Battery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore is poi-sonous and highly caustic.Always follow these preventive measures:� Avoid bodily contact with electrolytic

fluid as it can cause severe burns or per-manent eye injury.

� Wear protective eye gear when handlingor working near batteries.

Antidote (EXTERNAL):� SKIN - Flush with water.� EYES - Flush with water for 15 minutes

and get immediate medical attention.Antidote (INTERNAL):� Drink large quantities of water or milk

followed by milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.

Batteries also generate explosive hydro-gen gas; therefore, you should always fol-low these preventive measures:� Charge batteries in a well-ventilated ar-

ea.� Keep batteries away from fire, sparks, or

open flames (for example: weldingequipment, lighted cigarettes, and soon.)

� DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTICFLUID OUT OF REACH OF CHILDREN.


Maintenance

52

Batteries vary among manufacturers. There-fore the following procedures may not alwaysapply. Consult your battery manufacturer’s in-structions.Procedure1. Disconnect and remove the battery from

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

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

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

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

EMU28442

Flushing power unitPerform this procedure right after operationfor the most thorough flushing.

CAUTION:ECM01530

Do not perform this procedure while theengine is running. The water pump may bedamaged and severe damage from over-heating can result.

1. After shutting off the engine, unscrew thegarden hose connector from the fitting onthe bottom cowling.

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

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

4. Reinstall the garden hose connector ontothe fitting on the bottom cowling. Tightenthe connector securely.

CAUTION:ECM00540

Do not leave the garden hose connectorloose on the bottom cowling fitting or letthe hose hang free during normal opera-tion. Water will leak out of the connector

1. Fitting2. Garden hose adapter3. Garden hose connector


Maintenance

53

instead of cooling the engine, which cancause serious overheating. Be sure theconnector is tightened securely on the fit-ting after flushing the engine.

NOTE:� When flushing the engine with the boat in

the water, tilting up the outboard motor untilit is completely out of the water will achievebetter results.

� For cooling system flushing instructions,see page 49.

EMU28450

Cleaning the outboard motorAfter use, wash the exterior of the outboardmotor with fresh water. Flush the cooling sys-tem with fresh water.

NOTE:For cooling system flushing instructions, seepage 49.

EMU28460

Checking painted surface of motorCheck the motor for scratches, nicks, or flak-ing paint. Areas with damaged paint are morelikely to corrode. If necessary, clean and paintthe areas. A touch-up paint is available fromyour Yamaha dealer.

EMU28486

Periodic maintenance

WARNINGEWM01070

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

Maintenance, replacement, or repair of theemission control devices and systemsmay be performed by any marine enginerepair establishment or individual. All war-ranty repairs, however, including those tothe emission control system, must be per-formed by an authorized Yamaha marinedealership.A service manual is available for purchasethrough your Yamaha dealer for owners whohave the mechanical skills, tools, and otherequipment necessary to perform mainte-nance not covered by this owner’s manual.EMU28510

Replacement partsIf replacement parts are necessary, use onlygenuine Yamaha parts or parts of the sametype and of equivalent strength and materials.Any part of inferior quality may malfunction,and the resulting loss of control could endan-ger the operator and passengers. Yamahagenuine parts and accessories are availablefrom your Yamaha dealer.

ZMU04265


Maintenance

54

EMU30563

Maintenance chart

NOTE:� Refer to the sections in this chapter for explanations of each owner-specific action.� The maintenance cycle on these charts assume usage of 200 hours per year and regular

flushing of the cooling water passages. Maintenance frequency should be adjusted when op-erating the engine under adverse conditions such as extended trolling.

� Disassembly or repairs may be necessary depending on the outcome of maintenancechecks.

� Expendable or consumable parts and lubricants will lose their effectiveness over time andthrough normal usage regardless of the warranty period.

� When operating in salt water, turbid or muddy water, the engine should be flushed with cleanwater after each use.

The “ ” symbol indicates the check-ups which you may carry out yourself.The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

10 hours (1 month)

50 hours (3 months)

100 hours (6 months)

200 hours (1 year)

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

Anode(s) (cylinder head, thermostat cov-er)

Inspection / replace-ment

Battery Inspection / charging

Cooling water passag-es Cleaning

Cowling clamp Inspection

Fuel filter (can be dis-assembled) Inspection / cleaning

Fuel system Inspection

Gear oil Change

Greasing points Greasing

Idling speed Inspection

PCV (Pressure Con-trol Valve) Inspection

Power trim and tilt unit Inspection

Propeller and cotter pin Inspection / replace-ment

Shift link / shift cable Inspection / adjustment

Thermostat Inspection / replace-ment


Maintenance

55

EMU28874

Maintenance chart (additional)

EMU28910

NOTE:When using lead or high-sulfur gasoline, inspecting valve clearance may be required more fre-quently than every 500 hours.

Throttle link / throttle cable / throttle pick-up timing

Inspection / adjustment

Water pump Inspection / replace-ment

Engine oil Inspection / change

Oil filter (cartridge) Change

Spark plug(s) Cleaning / adjustment / replacement

Timing belt Inspection / replace-ment

Item ActionsEvery

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

Timing belt Replacement

Valve clearance (DOHC) Inspection / adjustment

Fuel filter (vapor sepa-rator tank) Replacement

Anode(s) (exhaust cov-er, cover joint) Replacement

Exhaust guide, exhaust manifold

Inspection / replace-ment

Item Actions

Initial Every

10 hours (1 month)

50 hours (3 months)

100 hours (6 months)

200 hours (1 year)


Maintenance

56

EMU28931

GreasingYamaha marine grease (Water resistant grease)

EMU28952

Cleaning and adjusting spark plug

WARNINGEWM00560

When removing or installing a spark plug,be careful not to damage the insulator. Adamaged insulator could allow externalsparks, which could lead to explosion orfire.

The spark plug is an important engine compo-nent and is easy to inspect. The condition ofthe spark plug can indicate something aboutthe condition of the engine. For example, if thecenter electrode porcelain is very white, thiscould indicate an intake air leak or carburetionproblem in that cylinder. Do not attempt to di-agnose any problems yourself. Instead, take

the outboard motor to a Yamaha dealer. Youshould periodically remove and inspect thespark plug because heat and deposits willcause the spark plug to slowly break downand erode. If electrode erosion becomes ex-cessive, or if carbon and other deposits areexcessive, you should replace the spark plugwith another of the correct type.

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

ZMU04266

Standard spark plug:LFR5A-11


Maintenance

57

When fitting the plug, always clean the gasketsurface and use a new gasket. Wipe off anydirt from the threads and screw in the sparkplug to the correct torque.

NOTE:If a torque-wrench is not available when youare fitting a spark plug, a good estimate of thecorrect torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adjusted to the cor-rect torque as soon as possible with a torque-wrench.

EMU28962

Checking fuel system

WARNINGEWM00060

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

WARNINGEWM00910

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 theoutboard unsafe to operate.

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

Checkpoints� Fuel system parts leakage� Fuel line joint leakage� Fuel line cracks or other damage� Fuel connector leakage

1. Spark plug gap2. Spark plug part number3. Spark plug I.D. mark (NGK)

Spark plug gap:1.0–1.1 mm (0.039–0.043 in)

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


Maintenance

58

EMU29073

Changing engine oil

WARNINGEWM00760

� Avoid draining the engine oil immediate-ly after stopping the engine. The oil ishot and should be handled with care toavoid burns.

� Be sure the outboard motor is securelyfastened to the transom or a stablestand.

CAUTION:ECM00970

� Do not overfill the oil, and be sure theoutboard motor is upright (not tilted)when checking and changing the engineoil.

� If the oil level is above the upper levelmark, drain until the level meets thespecified capacity. Overfilling the oilcould cause leakage or damage.

CAUTION:ECM01240

Change the engine oil after the first 10hours of operation, and every 100 hours orat 6-month intervals thereafter. Otherwisethe engine will wear quickly.

NOTE:Change the engine oil when the oil is stillwarm.

1. Put the outboard motor in an upright po-sition (not tilted).

2. Prepare a suitable container that holds alarger amount than the engine oil capaci-ty. Loosen and remove the drain screwwhile holding the container under thedrain hole. Then remove the oil filler cap.Let the oil drain completely. Wipe up anyspilled oil immediately.

3. Put a new gasket on the oil drain screw.Apply a light coat of oil to the gasket andinstall the drain screw.

NOTE:If a torque wrench is not available when youare installing the drain screw, finger tightenthe screw just until the gasket comes into con-tact with the surface of the drain hole. Then

1. Drain screw

Drain screw tightening torque:28.0 Nm (20.7 ft-lb) (2.86 kgf-m)

ZMU04270

1

ZMU04241


Maintenance

59

tighten 1/4 to 1/2 turn more. Tighten the drainscrew to the correct torque with a torquewrench as soon as possible.

4. Add the correct amount of oil through thefiller hole. Install the filler cap.

5. Start the engine and watch to make surethe low oil pressure warning indicator (ifequipped) turns off. Make sure that thereare no oil leaks.

CAUTION:ECM00680

If the low oil pressure warning indicatordoes not turn off or if there are oil leaks,stop the engine and find the cause. Con-tinued operation with a problem couldcause severe engine damage. Consultyour Yamaha dealer if the problem cannotbe located and corrected.

6. Turn off the engine and wait 3 minutes.Recheck the oil level using the dipstick tobe sure the level falls between the upperand lower marks. Fill with oil if it is belowthe lower mark, or drain to the specifiedlevel if it is above the upper mark.

7. Dispose of used oil according to localregulations.

NOTE:� For more information on the disposal of

used oil, consult your Yamaha dealer.� Change the oil more often when operating

the engine under adverse conditions suchas extended trolling.

EMU29112

Checking wiring and connectors� Check that each grounding wire is properly

secured.� Check that each connector is engaged se-

curely.

Recommended engine oil:4-stroke outboard motor oil


1. Oil filler cap

1

ZMU04271

1. Lower level mark2. Oil dipstick3. Upper level mark

ZMU04243


Maintenance

60

EMU29120

Exhaust leakageStart the engine and check that no exhaustleaks from the joints between the exhaustcover, cylinder head, and body cylinder.EMU29130

Water leakageStart the engine and check that no waterleaks from the joints between the exhaustcover, cylinder head, and body cylinder.EMU29140

Engine oil leakageCheck for oil leaks on the around the engine.

NOTE:If any leaks are found, consult your Yamahadealer.

EMU29163

Checking power trim and tilt / power tilt system

WARNINGEWM00430

� Never get under the lower unit while it istilted, even when the tilt support lever islocked. Severe injury could occur if theoutboard motor accidentally falls.

� Make sure no one is under the outboardmotor before performing this test.

1. Check the power trim and tilt unit / powertilt unit for any sign of oil leaks.

2. Operate each of the power trim and tiltswitches / power tilt switches to checkthat all switches work.

3. Tilt the outboard motor up and check thatthe trim and tilt rod / the tilt rod is pushedout completely.

4. Check that the trim and tilt rod / the tilt rodis free of corrosion or other flaws.

5. Tilt the outboard motor down. Check thatthe trim and tilt rod / the tilt rod operatessmoothly.

NOTE:Consult your Yamaha dealer if any operationis abnormal.

EMU29171

Checking propeller

WARNINGEWM00321

You could be seriously injured if the en-gine accidentally starts when you are nearthe propeller.� Before inspecting, removing, or install-

ing the propeller, remove the spark plugcaps from the spark plugs. Also, placethe shift control in neutral, turn the mainswitch to “ ” (off) and remove the key,and remove the lanyard from the enginestop switch. Turn off the battery cut-offswitch if your boat has one.

� Do not use your hand to hold the propel-ler when loosening or tightening thepropeller nut. Put a wood block betweenthe anti-cavitation plate and the propel-ler to prevent the propeller from turning.

1. Tilt rod

1

ZMU04244


Maintenance

61

Checkpoints� Check each of the propeller blades for

wear, erosion from cavitation or ventilation,or other damage.

� Check the propeller shaft for damage.� Check the splines / shear pin for wear or

damage.� Check for fish line tangled around the pro-

peller shaft.

� Check the propeller shaft oil seal for dam-age.

NOTE:If the shear pin equipped: it is designed tobreak if the propeller hits a hard underwaterobstacle to help protect the propeller anddrive mechanism. The propeller will then spinfreely on the shaft. If this happens, the shearpin must be replaced.

EMU30660

Removing the propellerEMU29194

Spline models1. Straighten the cotter pin and pull it out us-

ing a pair of pliers.2. Remove the propeller nut, washer, and

spacer (if equipped).

3. Remove the propeller and thrust washer.EMU30670

Installing the PropellerEMU29231

Spline models

CAUTION:ECM00340

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

ZMU04262

ZMU01897

1. Cotter pin2. Propeller nut3. Washer4. Spacer5. Propeller6. Thrust washer

ZMU03228

1

2

3

4

5

6


Maintenance

62

� Be sure to use a new cotter pin and bendthe ends over securely. Otherwise thepropeller could come off during opera-tion and be lost.

1. Apply Yamaha marine grease or a corro-sion resistant grease to the propellershaft.

2. Install the spacer (if equipped), thrustwasher, and propeller on the propellershaft.

3. Install the spacer (if equipped) and thewasher. Tighten the propeller nut to thespecified torque.

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

NOTE:If the propeller nut does not align with the pro-peller shaft hole after tightening to the speci-fied torque, tighten the nut further to align itwith the hole.

EMU29282

Changing gear oil

WARNINGEWM00800

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

� Never get under the lower unit while it istilted, even when the tilt support lever orknob is locked. Severe injury could oc-cur if the outboard motor accidentallyfalls.

1. Tilt the outboard motor so that the gear oildrain screw is at the lowest point possi-ble.

2. Place a suitable container under the gearcase.

3. Remove the gear oil drain screw and gas-ket.

NOTE:� If a magnetic gear oil drain screw is

equipped, remove all metal particles fromthe screw before installing it.

� Always use new gaskets. Do not reuse theremoved gaskets.

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

CAUTION:ECM00710

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

ZMU02063

1. Gear oil drain screw2. Oil level plug

ZMU03273

2

1


Maintenance

63

NOTE:For disposal of used oil, consult your Yamahadealer.

5. With the outboard motor in a vertical po-sition, and using a flexible or pressurizedfilling device, inject the gear oil into thegear oil drain screw hole.

6. Put a new gasket on the oil level plug.When the oil begins to flow out of the oillevel plug hole, insert and tighten the oillevel plug.

7. Put a new gasket on the gear oil drainscrew. Insert and tighten the gear oildrain screw.

EMU29312

Inspecting and replacing anode(s)Yamaha outboard motors are protected fromcorrosion by sacrificial anodes. Inspect theexternal anodes periodically. Remove scalesfrom the surfaces of the anodes. Consult aYamaha dealer for replacement of externalanodes.

CAUTION:ECM00720

Do not paint anodes, as this would renderthem ineffective.

NOTE:Inspect ground leads attached to external an-odes on equipped models. Consult a Yamahadealer for inspection and replacement of inter-nal anodes attached to the power unit.

EMU29320

Checking battery (for electric start models)

WARNINGEWM00330

Battery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore is poi-sonous and highly caustic.Always follow these preventive measures:

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:670.0 cm³ (22.65 US oz) (23.63 Imp.oz)

ZMU03274

ZMU04245


Maintenance

64

� Avoid bodily contact with electrolyticfluid as it can cause severe burns or per-manent eye injury.

� Wear protective eye gear when handlingor working near batteries.

Antidote (EXTERNAL):� SKIN - Flush with water.� EYES - Flush with water for 15 minutes

and get immediate medical attention.Antidote (INTERNAL):� Drink large quantities of water or milk

followed by milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.

Batteries also generate explosive hydro-gen gas; therefore, you should always fol-low these preventive measures:� Charge batteries in a well-ventilated ar-

ea.� Keep batteries away from fire, sparks, or

open flames (for example: weldingequipment, lighted cigarettes, and soon.)

� DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTICFLUID OUT OF REACH OF CHILDREN.

CAUTION:ECM00360

� A poorly maintained battery will quicklydeteriorate.

� Ordinary tap water contains mineralsharmful to a battery, and should not beused for topping up.

1. Check the electrolyte level at least once amonth. Fill to the manufacturer’s recom-mended level when necessary. Top uponly with distilled water (or pure de-ion-ized water suitable to use in batteries).

2. Always keep the battery in a good state ofcharge. Installing a voltmeter will helpyou monitor your battery. If you will notuse the boat for a month or more, removethe battery from the boat and store it in acool, dark place. Completely rechargethe battery before using it.

3. If the battery will be stored for longer thana month, check the specific gravity of thefluid at least once a month and rechargethe battery when it is low.

NOTE:Consult a Yamaha dealer when charging orre-charging batteries.

EMU29331

Connecting the battery

WARNINGEWM00570

Mount the battery holder securely in a dry,well-ventilated, vibration-free location inthe boat. Install a fully charged battery inthe holder.

CAUTION:ECM01121

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

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


Maintenance

65

� Connect the red battery cable first wheninstalling the battery and disconnect theblack battery cable first when removingit. Otherwise, the electrical parts can bedamaged.

� The electrical contacts of the batteryand cables must be clean and properlyconnected, or the battery will not startthe engine.

Connect the red battery cable to the POSI-TIVE (+) terminal first. Then connect the blackbattery cable to the NEGATIVE (-) terminal.

EMU29370

Disconnecting the batteryDisconnect the BLACK cable from the NEGA-TIVE (-) terminal first. Then disconnect theRED cable from the POSITIVE (+) terminal.EMU29390

Checking top cowlingCheck the fitting of the top cowling by pushingit with both hands. If it is loose have it repairedby your Yamaha dealer.

EMU29400

Coating the boat bottomA clean hull improves boat performance. Theboat bottom should be kept as clean of marinegrowth as possible. If necessary, the boat bot-tom can be coated with an anti-fouling paintapproved for your area to inhibit marinegrowth.Do not use anti-fouling paint which includescopper or graphite. These paints can causemore rapid engine corrosion.

1. Red cable2. Black cable3. Battery

ZMU04246


Trouble Recovery

66

EMU29424

TroubleshootingA problem in the fuel, compression, or ignitionsystems can cause poor starting, loss of pow-er, or other problems. This section describesbasic checks and possible remedies, and cov-ers all Yamaha outboard motors. Thereforesome items may not apply to your model.If your outboard motor requires repair, bring itto your Yamaha dealer.If the engine trouble warning indicator is flash-ing, consult your Yamaha dealer.

Starter will not operate.Q. Is battery capacity weak or low?A. Check battery condition. Use battery of rec-ommended capacity.

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

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

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

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

Engine will not start (starter operates).Q. Is fuel tank empty?A. Fill tank with clean, fresh fuel.

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

Q. Is fuel filter clogged?A. Clean or replace filter.

Q. Is starting procedure incorrect?A. See page 36.

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

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

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

Q. Is ignition wiring damaged or poorly con-nected?A. Check wires for wear or breaks. Tighten allloose connections. Replace worn or brokenwires.

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

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

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

Engine idles irregularly or stalls.Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replace withrecommended type.

Q. Is fuel system obstructed?


Trouble Recovery

67

A. Check for pinched or kinked fuel line or oth-er obstructions in fuel system.



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

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

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


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

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

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

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

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

Q. Is choke knob pulled out?

A. Return to home position.

Q. Is motor angle too high?A. Return to normal operating position.

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

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

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

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

Warning buzzer sounds or indicator lights.Q. Is cooling system clogged?A. Check water intake for restriction.

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

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

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

Q. Is engine oil contaminated or deteriorated?A. Replace oil with fresh, specified type.

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

Q. Has oil feed/injection pump malfunc-tioned?A. Have serviced by a Yamaha dealer.


Trouble Recovery

68

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

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

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

Engine power loss.Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller pitch or diameter incorrect?A. Install correct propeller to operate outboardat its recommended speed (r/min) range.

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

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

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

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

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

Q. Are weeds or other foreign matter tangledon gear housing?

A. Remove foreign matter and clean lowerunit.

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



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


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

Q. Is specified fuel not being used?A. Replace fuel with specified type.

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

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

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

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

Q. Is fuel joint connection incorrect?


Trouble Recovery

69

A. Connect correctly.

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

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

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

Engine vibrates excessively.Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged?A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangledon propeller?A. Remove and clean propeller.

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

Q. Is steering pivot loose or damaged?A. Tighten or have serviced by a Yamahadealer.EMU29433

Temporary action in emergencyEMU29440

Impact damage

WARNINGEWM00870

The outboard motor can be seriously dam-aged by a collision while operating ortrailering. Damage could make the out-board motor unsafe to operate.

If the outboard motor hits an object in the wa-ter, follow the procedure below.

1. Stop the engine immediately.2. Inspect the control system and all compo-

nents for damage. Also inspect the boatfor damage.

3. Whether damage is found or not, returnto the nearest harbor slowly and careful-ly.

4. Have a Yamaha dealer inspect the out-board motor before operating it again.

EMU29471

Replacing fuseIf a fuse has blown, remove the electrical cov-er, open the fuse holder and remove the fusewith a fuse puller (if equipped). Replace it witha spare one of the proper amperage.

WARNINGEWM00630

Be sure to use the specified fuse. An in-correct fuse or a piece of wire could allowexcessive current flow. This could causeelectric system damage and a fire hazard.

NOTE:Consult your Yamaha dealer if the new fuseimmediately blows again.


Trouble Recovery

70

EMU29522

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

ing it counterclockwise until it stops.

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

EMU31601

Water separator warning indicator blinks while cruising

WARNINGEWM01500

Gasoline is highly flammable, and its va-pors are flammable and explosive.� Do not perform this procedure on a hot

or running engine. Allow the engine tocool.

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

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

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

If the water separator warning indicator on thetachometer blinks, perform the following pro-cedure.

1. Electrical cover2. Fuse puller3. Fuse holder4. Starter relay fuse (30 A)5. Rectifier Regulator (Main) fuse (20 A)6. Main switch / trim switch fuse (20 A)7. Engine control unit / ignition coil / electric

fuel pump / fuel injector / ISC (idle speed control) fuse (20 A)

8. Spare fuse (20 A, 30A)

1. Manual valve screw

ZMU042491


Trouble Recovery

71

1. Stop the engine.2. Remove the top cowling.3. Remove the plastic tie.

4. Disconnect the water detection switchcoupler.

CAUTION:ECM01570

Be careful not to get any water on the wa-ter detection switch coupler, otherwise amalfunction could occur.

5. Unscrew the filter cup from the filter hous-ing.

NOTE:Be careful not to twist the water detectionswitch lead when unscrewing the filter cup.

6. Drain the water in the filter cup by soakingit up with a rag.

1. Water separator warning indicator

1. Plastic tie

1. Water detection switch coupler

1. Filter cup2. Water detection switch lead


Trouble Recovery

72

NOTE:Properly dispose of the rag.

7. Firmly screw the filter cup onto the filterhousing.

NOTE:Be careful not to twist the water detectionswitch lead when screwing the filter cup ontothe filter housing.

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

9. Fasten the water detection switch leadwith the plastic tie.

10. Install the top cowling.11. Start the engine and make sure that the

water separator warning indicator re-mains off.

NOTE:Have a Yamaha dealer inspect the outboardmotor after returning to port.

EMU29541

Starter will not operateIf the starter mechanism does not operate(the engine cannot be cranked with the start-er), the engine can be started manually withan emergency starter rope. However, the en-gine cannot be started manually if the batteryvoltage is low. If the battery is discharged to 9volts or below, the electric fuel pump will notoperate.

WARNINGEWM01021

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

� When the emergency starter rope isused to start the engine, the start-in-gear protection device does not operate.Make sure the remote control lever is inneutral. Otherwise the boat could unex-pectedly start to move, which could re-sult in an accident.

� Attach the engine stop switch lanyard toa secure place on your clothing, or yourarm or leg while operating the boat.

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


1. Water detection switch coupler

1. Plastic tie


Trouble Recovery

73

� Make sure no one is standing behindyou when pulling the starter rope. Itcould whip behind you and injure some-one.

� An unguarded, rotating flywheel is verydangerous. Keep loose clothing andother objects away when starting the en-gine. Use the emergency starter ropeonly as instructed. Do not touch the fly-wheel or other moving parts when theengine is running. Do not install thestarter mechanism or top cowling afterthe engine is running.

� Do not touch the ignition coil, spark plugwire, spark plug cap, or other electricalcomponents when starting or operatingthe motor. You could get an electricalshock.

EMU30650

Emergency starting engine1. Remove the top cowling.2. Lift up the rear of flywheel cover and pull

it forward to remove it.

3. Prepare the engine for starting. For fur-ther information, see page 36. Be surethe engine is in neutral and that the en-gine stop switch lanyard lock plate is at-tached to the engine stop switch. Themain switch must be “ ” (on).

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

5. Pull the rope slowly until resistance is felt.6. Remove the rope from the flywheel tem-

porarily.7. Rewind the rope around the flywheel ap-

proximately 3/4 of a turn clockwise.8. Give a strong pull straight out to crank

and start the engine. Repeat if neces-sary.

ZMU02334


Trouble Recovery

74

EMU29760

Treatment of submerged motorIf the outboard motor is submerged, immedi-ately take it to a Yamaha dealer. Otherwisesome corrosion may begin almost immediate-ly.If you cannot immediately take the outboardmotor to a Yamaha dealer, follow the proce-dure below in order to minimize engine dam-age.EMU29790

Procedure1. Thoroughly wash away mud, salt, sea-

weed, and so on, with fresh water.2. Remove the spark plugs and face the

spark plug holes downward to allow anywater, mud, or contaminants to drain.

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

4. Feed fogging oil or engine oil through theintake manifold and spark plug holeswhile cranking with the emergency starterrope.

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

CAUTION:ECM00400

Do not attempt to run the outboard motoruntil it has been completely inspected.

ZMU04272


Consumer information

75

EMU29811

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



76



77

EMU29830

YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY



78



79

EMU29841

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


A5-tate_Blank.fm Page 1 Friday, May 16, 2003 9:00 AM

A5-tate_Blank.fm Page 1 Friday, May 16, 2003 9:00 AM

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Documents

F75 F90 - · PDF fileF75 F90 OWNER’S MANUAL ... F75, F90 OWNER ’S MANUAL ©2006 by Yamaha Motor Corporation, USA 1st edition, ... Emission control information