2C

OWNERS MANUAL
6A1-28199-2N-E0

Read this owners manual carefully before operating or working on your outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.

Important manual information

EMU25103

To the owner
Thank you for choosing a Yamaha outboard motor. This Owners Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owners Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
EWM00780

WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.
ECM00700

your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer. To ensure long product life, Yamaha recommends that you use the product and perform the specified periodic inspections and maintenance by correctly following the instructions in the owners manual. Any damage resulting from neglect of these instructions is not covered by warranty. Some countries have laws or regulations restricting users from taking the product out of the country where it was purchased, and it may be impossible to register the product in the destination country. Additionally, the warranty may not apply in certain regions. When planning to take the product to another country, consult the dealer where the product was purchased for further information. If the product was purchased used, please consult your closest dealer for customer reregistration, and to be eligible for the specified services.

NOTE:
The 2CMH and the standard accessories are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model.
EMU25121

CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

NOTE:
A NOTE provides key information to make procedures easier or clearer. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between

2C OWNERS MANUAL 2007 by Yamaha Motor Co., Ltd. 1st Edition, February 2007 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan

Table of contents
General information .......................... 1 Identification numbers record .......... 1
Outboard motor serial number ........... 1 Fuel cock ............................................ 9 Tiller handle ........................................ 9 Throttle lever .................................... 10 Throttle friction adjuster .................... 10 Engine shut-off switch ...................... 10 Engine stop button ........................... 10 Choke knob ...................................... 11 Manual starter handle....................... 11 Steering friction adjuster................... 11 Trim rod (tilt pin) ............................... 11 Tilt support knob ............................... 12

C-Tick label ..................................... 1 Important labels............................... 1

Warning labels.................................... 1

Safety information............................. 3 Safety information ........................... 3

Rotating parts ..................................... Hot parts............................................. Electric shock ..................................... Engine shut-off cord ........................... Gasoline ............................................. Gasoline exposure and spills ............. Carbon monoxide ............................... Modifications ...................................... Alcohol and drugs............................... Personal flotation devices .................. People in the water............................. Passengers ........................................ Overloading ........................................ Avoid collisions................................... Weather.............................................. Passenger training ............................. Boating safety publications................. Laws and regulations ......................... 3 3 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5

Operation ......................................... 13 Installation..................................... 13

Mounting the outboard motor ........... 13 Clamping the outboard motor ........... 14

Breaking in engine ........................ 15

Gasoline and engine oil mixing chart (25:1).................................... 15 Procedure for pre-mixed models ...... 15

Boating safety ................................. 4

Pre-operation checks .................... 16

Fuel .................................................. Oil ..................................................... Controls ............................................ Engine .............................................. 16 16 16 16

Filling fuel and engine oil .............. 16

Filling fuel for built-in tank................. 16 Gasoline and oil mixing (100:1) ........ 16

Operating engine .......................... 17

Feeding fuel...................................... 17 Starting engine ................................. 18

Basic requirements ........................... 6 Fueling instructions ......................... 6

Gasoline ............................................. 6 Engine oil............................................ 6

Warming up engine....................... 20
Direct drive models........................... 20

Installation requirements ................. 6

Boat horsepower rating ...................... 6 Mounting motor .................................. 6 Propeller selection.............................. 7

Shifting .......................................... 20
Forward ............................................ 20 Reverse ............................................ 20

Stopping engine ............................ 21

Procedure......................................... 21

Basic components ............................ 8 Main components............................ 8

Fuel tank............................................. 8 Fuel tank cap...................................... 9 Air vent screw..................................... 9

Trimming outboard motor.............. 21

Adjusting trim angle for manual tilt models .......................................... 22 Adjusting boat trim............................ 22

Table of contents
Tilting up and down ....................... 23
Procedure for tilting up (manual tilt models)....................... 24 Procedure for tilting down (manual tilt models)....................... 24

Cruising in other conditions ........... 25 Maintenance..................................... 26 Specifications ................................ 26 Transporting and storing outboard motor .......................................... 26
Clamp screw mounting models ........ Storing outboard motor..................... Procedure......................................... Lubrication........................................ Cleaning the outboard motor............ Checking painted surface of motor... Replacement parts ........................... Maintenance chart............................ Greasing........................................... Cleaning and adjusting spark plug ... Checking fuel system ....................... Inspecting idling speed..................... Checking wiring and connectors ...... Exhaust leakage............................... Water leakage .................................. Checking propeller ........................... Removing propeller .......................... Installing propeller ............................ Changing gear oil ............................. Inspecting and replacing anode(s) ... Checking top cowling ....................... Coating the boat bottom ................... 27 27 27 28 29 29 29 30 31 31 32 33 33 33 33 33 34 34 35 36 36 36

Periodic maintenance.................... 29

Trouble Recovery ............................ 37 Troubleshooting ............................ 37 Temporary action in emergency.... 40

Impact damage................................. 40 Starter will not operate ..................... 40 Emergency starting engine............... 41

Treatment of submerged motor..... 42

Procedure......................................... 42

General information
EMU25170

Identification numbers record

EMU31290

Outboard motor serial number

The outboard motor serial number is stamped on the label attached to the upper part of the swivel bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen.

1. C-Tick label location

ZMU01697

1. Outboard motor serial number location

EMU25382

Important labels
EMU25395

Warning labels

EMU25213

C-Tick label
Engines affixed with this label conform to certain portion(s) of the Australian Radio Communications Act.
EMU25401

Label
EWM01260

WARNING
G

Be sure shift control is in neutral before starting engine. (except 2HP)

General information
G G

Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from flywheel and other rotating parts while engine is running.

EMU25441

Label
EWM01311

WARNING
LEAKING FUEL COULD CAUSE A FIRE. Before tilting up the engine or laying it on its side: G Turn the fuel cock to the closed position. G Tighten the air-vent screw on the fuel tank cap.

Safety information
EMU33620

Safety information
Observe these precautions at all times.
EMU33630

Rotating parts
Hands, feet, hair, jewelry, clothing, PFD straps, etc. can become entangled with internal rotating parts of the engine, resulting in serious injury or death. Keep the top cowling in place whenever possible. Do not remove or replace the cowling with the engine running. Only operate the engine with the cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, PFD straps, etc. away from any exposed moving parts.
EMU33640

Do not route the cord where it is likely to be accidentally pulled out. If the cord is pulled during operation, the engine will shut off and you will lose most steering control. The boat could slow rapidly, throwing people and objects forward.
EMU33810

Gasoline
Gasoline and its vapors are highly flammable and explosive. Always, refuel according to the procedure on page 17 to reduce the risk of fire and explosion.
EMU33820

Gasoline exposure and spills

Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Dispose of rags properly. If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it. If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. Never siphon fuel by mouth.
EMU33900

Hot parts
During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the engine has cooled.
EMU33650

Electric shock
Do not touch any electrical parts while starting or operating the engine. They can cause shock or electrocution.
EMU33670

Carbon monoxide
This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets.
EMU33780

Engine shut-off cord

Attach the engine shut-off cord so that the engine stops if the operator falls overboard or leaves the helm. This prevents the boat from running away under power and leaving people stranded, or running over people or objects. Always attach the engine shut-off cord to a secure place on your clothing or your arm or leg while operating. Do not remove it to leave the helm while the boat is moving. Do not attach the cord to clothing that could tear loose, or route the cord where it could become entangled, preventing it from functioning.

Modifications
Do not attempt to modify this outboard motor. Modifications to your outboard motor may reduce safety and reliability, and render the outboard unsafe or illegal to use.

Safety information
EMU33740

Boating safety
This section includes a few of the many important safety precautions that you should follow when boating.
EMU33710

Even when people are positioned properly, alert your passengers if you must make any unusual maneuver. Always avoid jumping waves or wakes.
EMU33760

Alcohol and drugs

Never operate after drinking alcohol or taking drugs. Intoxication is one of the most common factors contributing to boating fatalities.
EMU33720

Overloading
Do not overload the boat. Consult the boat capacity plate or boat manufacturer for maximum weight and number of passengers. Be sure that weight is properly distributed according to the boat manufacturers instructions. Overloading or incorrect weight distribution can compromise the boats handling and lead to an accident, capsizing or swamping.
EMU33770

Personal flotation devices

Have an approved personal flotation device (PFD) on board for every occupant. Yamaha recommends that you must wear a PFD whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating conditions.
EMU33730

Avoid collisions
Scan constantly for people, objects, and other boats. Be alert for conditions that limit your visibility or block your vision of others. Operate defensively at safe speeds and keep a safe distance away from people, objects, and other boats. G Do not follow directly behind other boats or waterskiers. G Avoid sharp turns or other maneuvers that make it hard for others to avoid you or understand where you are going. G Avoid areas with submerged objects or shallow water. G Ride within your limits and avoid aggressive maneuvers to reduce the risk of loss of control, ejection, and collision. G Take early action to avoid collisions. Remember, boats do not have brakes, and stopping the engine or reducing throttle can reduce the ability to steer. If you are not sure that you can stop in time before hitting an obstacle, apply throttle and turn in another direction.

People in the water

Always watch carefully for people in the water, such as swimmers, skiers, or divers, whenever the engine is running. When someone is in the water near the boat, shift into neutral and shut off the motor. Stay away from swimming areas. Swimmers can be hard to see. The propeller can keep moving even when the motor is in neutral. Shut off the engine when a person is in the water near you.
EMU33750

Passengers
Consult your boat manufacturers instructions for details about appropriate passenger locations in your boat and be sure all passengers are positioned properly before accelerating and when operating above an idle speed. Standing or sitting in non-designated locations may result in being thrown either overboard or within the boat due to waves, wakes, or sudden changes in speed or direction.

Safety information
EMU33790

Weather
Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather.
EMU33880

Passenger training
Make sure at least one other passenger is trained to operate the boat in the event of an emergency.
EMU33890

Boating safety publications

Be informed about boating safety. Additional publications and information can be obtained from many boating organizations.
EMU33600

Laws and regulations

Know the marine laws and regulations where you will be boating- and obey them. Several sets of rules prevail according to geographic location, but all are basically the same as the International Rules of the Road.

Basic requirements
EMU31490

Fueling instructions
EWM01490

WARNING
GASOLINE AND ITS VAPORS ARE HIGHLY FLAMMABLE AND EXPLOSIVE! G Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. G Stop engine before refueling. G Refuel in a well-ventilated area. G Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. G Do not overfill the fuel tank. G Tighten the filler cap securely after refueling. G If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. G If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if gasoline spills on it. G Touch the fuel nozzle to the filler opening or funnel to help prevent electrostatic sparks.
ECM00010

Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Yamaha does not recommended gasohol containing methanol because it can cause fuel system damage or engine performance problems.
EMU25650

Engine oil
Recommended engine oil: YAMALUBE 2-stroke outboard motor oil If the recommended engine oil is not available, another 2-stroke engine oil with an NMMA-certified TC-W3 rating may be used.
EMU33550

Installation requirements
EMU33560

Boat horsepower rating

Before installing the outboard motor(s), confirm that the total horsepower of your motor(s) does not exceed the boats maximum horsepower rating. See the boats capacity plate or contact the manufacturer.
EWM01560

WARNING CAUTION:
Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign matter.
EMU33980

Overpowering a boat can cause severe instability.

EMU33570

Mounting motor
Your dealer or other person experienced in proper rigging should mount the motor using correct equipment and complete rigging instructions. For further information, see page 13.

Gasoline
Recommended gasoline: Regular unleaded gasoline If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel. If unleaded gasoline is not available, then premium gasoline can be used.

Basic requirements
EWM01570

WARNING
G

Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. Because the motor is very heavy, special equipment and training is required to mount it safely.

x 1

2 3

ZMU04604
EMU34190

Propeller selection
Next to selecting an outboard, choosing the right propeller is one of the most important purchasing decisions a boater can make. The type, size, and design of your propeller have a direct impact on acceleration, top speed, fuel economy, and even engine life. Yamaha designs and manufactures propellers for every Yamaha outboard motor and every application. Your outboard motor came with a Yamaha propeller chosen to perform well over a range of applications, but there may be uses where a different propeller would be more appropriate. Your Yamaha dealer can help you select the right propeller for your boating needs. Select a propeller that will allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boatload. Generally, chose a larger pitch propeller for a smaller operating load and a smaller pitch propeller for a heavier load. If you carry loads that vary widely, chose the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to reduce your throttle setting to stay within the recommended engine speed range when carrying lighter loads. For instructions on propeller removal and installation, see page 33.

1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark)

Basic components
EMU2579B

Main components
NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all models. 2C

1. Air vent screw 2. Fuel tank cap 3. Top cowling 4. Anti-cavitation plate 5. Propeller 6. Cooling water inlet 7. Clamp bracket 8. Clamp screw 9. Tiller handle 10.Fuel cock 11.Manual starter handle 12.Choke knob 13.Engine stop button/Engine shut-off switch 14.Trim rod 15.Rope attachment 16.Tilt support knob

17.Throttle lever
EMU25821

Fuel tank
If your model included a fuel tank, its parts and functions are as follows.

Basic components

1. Air vent screw 2. Fuel tank cap

EMU25850

1. Close position
EMU25891

Fuel tank cap

This cap seals the fuel tank. When removed, the tank can be filled with fuel. To remove the cap, turn it counterclockwise.
EMU25860

Open With the lever/knob in this position, fuel flows to the carburetor. Normal running is done with the lever/knob in this position.

Air vent screw

This screw is on the fuel tank cap. To loosen the screw, turn it counterclockwise.
EMU25872

Fuel cock
The fuel cock turns on and off the supply of fuel from the fuel tank to the engine.

1. Open position
EMU25911

Tiller handle
To change direction, move the tiller handle to the left or right as necessary.

1. Fuel cock
EMU25881

Close To stop fuel flow to the engine, turn the lever or knob to close position. Always turn the lever or knob to close position when the engine is not running.

Basic components
EMU25952

Throttle lever
To increase speed, push the lever upward.

operators clothing, or arm or leg. Should the operator fall overboard or leave the helm, the cord will pull out the clip, stopping ignition to the engine. This will prevent the boat from running away under power.
EWM00121

WARNING
G

EMU25981

Throttle friction adjuster

An adjustable friction device within the aprons restricts movement of the throttle lever according to the operators preference.
G

Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. Avoid accidentally pulling the cord during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

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

When constant speed is desired, tighten the adjuster to maintain the desired throttle setting.
EWM01480

WARNING
Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to move the throttle lever, which could result in an accident.
EMU25991

1. Clip 2. Cord
EMU26001

Engine shut-off switch

The clip must be attached to the engine shutoff switch for the engine to run. The cord should be attached to a secure place on the

Engine stop button

To open the ignition circuit and stop the engine, push this button.

10

Basic components
EMU26122

Steering friction adjuster

A friction device provides adjustable resistance to the steering mechanism, and can be set according to operator preference. An adjusting screw or bolt is located on the swivel bracket.

EMU26050

Choke knob
To supply the engine with the rich fuel mixture required to start, turn this knob counterclockwise.

To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise.
EWM00040

WARNING
Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident.
EMU26261

EMU26070

Manual starter handle

To start the engine, first gently pull the handle out until resistance is felt. From that position, then pull the handle straight out quickly to crank the engine.

Trim rod (tilt pin)

The position of the trim rod determines the minimum trim angle of the outboard motor in relation to the transom.

11

Basic components
EMU26321

Tilt support knob

To keep the outboard motor in the tilted up position, push the tilt support knob under the swivel bracket.

ECM00660

CAUTION:
Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position.

12

Operation
EMU26902

Installation
The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat and motor combination. Proper mounting depends in part on experience and the specific boat and motor combination.
EWM01590

WARNING
G

1
1. Center line (keel line)
EMU26921

ZMU01760

Overpowering a boat could cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer. Improper mounting of the outboard motor could result in hazardous conditions such as poor handling, loss of control, or fire hazards. For permanently mounted models, your dealer or other person experienced in proper rigging should mount the motor.

EMU26911

Mounting the outboard motor

EWM01720

WARNING
Your dealer or other person experienced in proper outboard motor mounting should show you how to mount your outboard motor. The outboard motor should be mounted so that the boat is well balanced. Otherwise, the boat could be hard to steer. For single-engine boats, mount the outboard motor on the centerline (keel line) of the boat.

Mounting height To run your boat at optimum efficiency, the water resistance (drag) of the boat and outboard motor must be made as little as possible. The mounting height of the outboard motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in.) below it.

025mm (01in.)

ZMU02011

13

Operation
ECM01630

CAUTION:
G

During water testing, check the buoyancy of the boat, at rest, with its maximum load. Check that the static water level on the exhaust housing is low enough to prevent water entry into the power head when water rises due to waves when the outboard is not running. Incorrect engine height or obstructions to the smooth flow of water (such as the design or condition of the boat, or accessories such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. If the motor is operated continuously in the presence of airborne water spray, enough water could enter the engine through the intake opening on the cowling to cause severe engine damage. Eliminate the cause of the airborne water spray.

tightness during operation of the outboard motor because they could become loose due to engine vibration.
EWM00640

WARNING
Loose clamp screws could allow the outboard motor to fall off or move on the transom. This could cause loss of control and serious injury. Make sure the transom screws are tightened securely. Occasionally check the screws for tightness during operation.

ZMU02012

NOTE:
G

2.

The optimum mounting height of the outboard motor is affected by the boat and motor combination and the desired use. Test runs at different heights can help determine the optimum mounting height. Consult your Yamaha dealer or boat manufacturer for further information on determining the proper mounting height. For instructions on setting the trim angle of the outboard motor, see page 21.

If the engine restraint cable attachment is equipped on your engine, an engine restraint cable or chain should be used. Attach one end to the engine restraint cable attachment and the other to a secure mounting point on the boat. Otherwise the engine could be completely lost if it accidentally falls off the transom.

EMU26970

Clamping the outboard motor

1. Place the outboard motor on the transom so that it is positioned as close to the center as possible. Tighten the transom clamp screws evenly and securely. Occasionally check the clamp screws for

ZMU02013

14

Operation
3. Secure the clamp bracket to the transom using the bolts provided with the outboard (if packed). For details, consult your Yamaha dealer.
ECM00150

CAUTION:
Be sure to mix gasoline and oil completely, otherwise the engine may be damaged.
EMU27074

EWM00650

WARNING
Avoid using bolts, nuts or washers other than those contained in the engine packaging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tightening, test run the engine and check their tightness.
EMU30173

Procedure for pre-mixed models

Run the engine under load (in gear with a propeller installed) for 10 hours as follows. 1. First 10 minutes: Run the engine at the lowest possible speed. A fast idle in neutral is best. 2. Next 50 minutes: Do not exceed half throttle (approximately 3000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3000 r/min or less. 3. Next two hours: Accelerate at full throttle onto plane, then reduce engine speed to three-quarter throttle (approximately 4000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three-quarter throttle or less to let the engine cool. 4. Remaining seven hours: Run the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time. 5. After the first 10 hours: Operate the engine normally. Use the standard premix ratio of gasoline and oil. For details on mixing fuel and oil, see page 16.

Breaking in engine
Your new engine requires a period of break-in to allow mating surfaces of moving parts to wear in evenly. Correct break-in will help ensure proper performance and longer engine life.
ECM00800

CAUTION:
Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage.
EMU27050

Gasoline and engine oil mixing chart (25:1)

1. 2.

: Gasoline : Engine oil

15

Operation
EMU27104 EMU27233

Pre-operation checks
EWM00081

Filling fuel and engine oil

EMU27253

WARNING
If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise an accident could occur.
ECM00120

Filling fuel for built-in tank

EWM00060

WARNING
Gasoline and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition. 1. With the outboard motor tilted down (in the vertical running position), remove the fuel tank cap. Use a funnel if the nozzle on the fuel can or pump is not small enough or long enough to fit into the mouth of the fuel tank. Fill the fuel tank carefully. Securely close the cap after refueling. Wipe up any spilled fuel. Fuel tank capacity: 1.2 L (0.32 US gal) (0.26 Imp.gal)
EMU27405

CAUTION:
Do not start the engine out of water. Overheating and serious engine damage can occur.
EMU31500

2.

Fuel
G

Check to be sure you have plenty of fuel for your trip. Make sure there are no fuel leaks or gasoline fumes. Check to be sure you have plenty of oil for your trip. 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 the water. Check the engine and engine mounting. Look for loose or damaged fasteners. Check the propeller for damage.

3. 4.

EMU27120

Oil
G

EMU27130

Gasoline and oil mixing (100:1)

Gasoline to engine oil ratio Break-in period After break-in See page 15 100:1

Controls
G

G G

1L (0.26 US gal, 0.22 Imp gal)

100:1 12 L 14 L (3.2 US gal, (3.7 US gal, 2.6 Imp gal) 3.1 Imp gal)

24 L (6.3 US gal, 5.3 Imp gal)

EMU27140

Engine
G G G

0.01 L (0.01 US qt, 0.01 Imp qt)

0.12 L (0.13 US qt, 0.11 Imp qt)

0.14 L (0.15 US qt, 0.12 Imp qt)

0.24 L (0.25 US qt, 0.21 Imp qt)

ZMU04910

1. 2.

: Gasoline : Engine oil

16

Operation
If equipped with a portable fuel tank 1. Pour oil into the portable fuel tank, and then add gasoline. 2. Replace the fuel tank cap and close tightly. 3. Shake the fuel tank to mix the fuel thoroughly. 4. Make sure that the oil and gasoline are mixed. If equipped with a built-in fuel tank 1. Pour oil into a clean fuel can, and then add gasoline.
ECM00811

CAUTION:
G

Avoid using any oil other than the specified type. Use a thoroughly blended fuel-oil mixture. If the mixture is not thoroughly mixed, or if the mixing ratio is incorrect, the following problems could occur. Low oil ratio: Lack of oil could cause major engine trouble, such as piston seizure. High oil ratio: Too much oil could cause fouled spark plugs, smoky exhaust, and heavy carbon deposits.

NOTE:
If using a permanently installed tank, pour the oil gradually as the gasoline is being added to the tank.
EMU27450

Operating engine
EMU31510

Feeding fuel
EWM00420

WARNING
G

1. Engine oil 2. Gasoline

2. 3. 4. 5.

Replace the fuel can cap and close tightly. Shake the fuel can to mix the fuel thoroughly. Make sure that the oil and gasoline are mixed. Pour the gasoline and oil mixture into the built-in fuel tank.

Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you. When the air vent screw is loosened, gasoline vapor will be released. Gasoline is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw. This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which could cause brain damage or death when inhaled. Symp-

17

Operation
toms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets. 1. Loosen the air vent screw on the fuel tank cap by one turn.
EMU27512

Manual start models 1. If the engine shut-off cord is equipped, attach it to a secure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch.
EWM00121

WARNING
G

2.

Open the fuel cock.

Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. Avoid accidentally pulling the cord during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

EMU27491

Starting engine
EWM01600

WARNING
Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you.

2.

Place the throttle lever in the start position.

EWM00100

WARNING
The propeller rotates whenever the engine is running. Do not move the throttle control lever from the start position during

18

Operation
warm-up. The boat could unexpectedly start to move, which could result in an accident.

5.

3.

Place the choke knob in the start position. After the engine starts, return the knob to the home position.

6.

After the engine starts, slowly return the manual starter handle to the original position before releasing it. Place the throttle control lever slowly to the fully closed position.

NOTE: NOTE:
G G

It is not necessary to use the choke when starting a warm engine. If the choke knob is left in the start position while the engine is running, the engine will run poorly or stall. Pull the manual starter handle slowly until you feel resistance. Then give a strong pull straight out to start the engine. Repeat if necessary.

4.

When the engine is cold, it needs to be warmed up. For further information, see page 20. If the engine does not start on the first try, repeat the procedure. If the engine fails to start after 4 or 5 tries, open the throttle a small amount (between 1/8 and 1/4) and try again. Also if the engine is warm and fails to start, open the throttle a same amount and try to start the engine again. If the engine still fails to start, see page 37.

19

Operation
EMU27670

Warming up engine
EMU27692

Direct drive models

EWM00100

WARNING
The propeller rotates whenever the engine is running. Do not move the throttle control lever from the start position during warm-up. The boat could unexpectedly start to move, which could result in an accident. 1. Before beginning operation, allow the engine to warm up at idle speed for 3 minutes. Failure to do this will shorten engine life. Check for a steady flow of water from the cooling water pilot hole.

EMU27740

Shifting
EWM00180

WARNING
Before shifting, make sure there are no swimmers or obstacles in the water near you.
ECM00220

2.

ECM00511

CAUTION:
A continuous flow of water from the cooling water pilot hole shows that the water pump is pumping water through the cooling passages. If water is not flowing out of the hole at all times while the engine is running, overheating and serious damage could occur. Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and corrected.

CAUTION:
To change the boat direction or shifting position from forward to reverse or viceversa, first close the throttle so that the engine idles (or runs at low speeds).
EMU27750

Forward
When the engine is started, the propeller turns and the boat begins to move forward.
EMU27770

Reverse
EWM00190

WARNING
When operating in reverse, go slowly. Do not open the throttle more than half. Otherwise the boat could become unstable, which could result in loss of control and an accident. These models can turn a full 360 in its bracket (full-pivot system). To back up the boat, simply turn the engine around 180 with the tiller handle facing toward you.

20

Operation
EMU27820

Stopping engine
Before stopping the engine, first let it cool off for a few minutes at idle or low speed. Stopping the engine immediately after operating at high speed is not recommended.
EMU31521

Procedure
1. Push and hold the engine stop button until the engine comes to a complete stop.

NOTE:
The engine can also be stopped by pulling the cord and removing the clip from the engine shut-off switch.
EMU27861

Trimming outboard motor

The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. Correct trim angle will help improve performance and fuel economy while reducing strain on the engine. Correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed.
EWM00740

2.

After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock to the closed position.

WARNING
Excessive trim for the operating conditions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle.

21

Operation
To raise the bow (trim-out), move the rod away from the transom. To lower the bow (trim-in), move the rod toward the transom. Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions.
EWM00400

WARNING
G

1
ZMU02043

Stop the engine before adjusting the trim angle. Use care to avoid being pinched when removing or installing the rod. Use caution when trying a trim position for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim angle can cause loss of control.

1. Trim operating angle

EMU27872

NOTE:
The outboard motor trim angle can be changed approximately 4 degrees by shifting the trim rod one hole.
EMU27911

Adjusting trim angle for manual tilt models

There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim angle. 1. Stop the engine. 2. Tilt the outboard motor up, and then remove the trim rod from the clamp bracket.

Adjusting boat trim

When the boat is on plane, a bow-up attitude results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane.

1. Trim rod

3.

Reposition the rod in the desired hole.

22

Operation

Bow Up Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces performance further, and the boat may porpoise (hop in the water), which could throw the operator and passengers overboard.

NOTE:
Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.
EMU27922

Tilting up and down

If the engine will be stopped for some time or if the boat is moored in shallows, the outboard motor should be tilted up to protect the propeller and lower casing from damage by collision with obstructions, and also to reduce salt corrosion.
EWM00221

WARNING
Be sure all people are clear of the outboard motor when tilting up and down, Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted. Bow Down Too much trim-in causes the boat to plow through the water, decreasing fuel economy and making it hard to increase speed. Operating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of bow steering and making operation difficult and dangerous.
EWM00230

WARNING
Leaking fuel is a fire hazard. Tighten the air vent screw and place the fuel cock in the closed position if the outboard motor will be tilted for more than a few minutes. Otherwise fuel may leak.

23

Operation
ECM00231

CAUTION:
G

Before tilting the outboard motor, follow the procedure under Stopping engine in this chapter. Never tilt the outboard motor while the engine is running. Severe damage from overheating can result. Do not tilt up the engine by pushing the tiller handle because this could break the handle. Keep the power unit higher than the propeller at all times. Otherwise water could run into the cylinder and cause damage. The outboard motor cannot be tilted when in reverse or when the outboard motor is turned 180 (facing the rear).

7.

Tilt support lever equipped models: Hold the rear handle and tilt the engine up fully until the tilt support lever automatically locks.

NOTE:
Tilt support lever/bar equipped models: If the motor is not facing forward, the tilt support lever/bar cannot automatically turn to the locked position. If the tilt support lever/bar does not automatically lock, swing the motor a little to the left and right.
EMU28032

EMU27964

Procedure for tilting up (manual tilt models)

1. Place the gear shift lever in neutral (if equipped) and face the outboard motor forward. On full-pivot system models, tighten the steering friction adjuster by turning it clockwise to prevent the motor from turning freely. Tighten the air vent screw. On models equipped with a fuel joint, disconnect the fuel line from the outboard motor. Close the fuel cock. Tilt support bar equipped models: Hold the rear of the top cowling or the rear handle (if equipped) with one hand and tilt the outboard motor up fully until the tilt support bar automatically locks. Tilt support knob equipped models: Hold the rear of the top cowling with one hand, fully tilt the outboard motor up, and push the tilt support knob into the clamp bracket.

2.

Procedure for tilting down (manual tilt models)

1. 2. Slightly tilt the outboard motor up. If equipped with the tilt support bar: Slowly tilt the outboard motor down while pulling the tilt support bar lever up. If equipped with the tilt support knob: Pull the knob out, and then slowly tilt the outboard motor down.

3.

3.

4. 5.

6.

24

Operation
4. If equipped with the tilt support lever: Slowly tilt the outboard motor down while pulling the tilt support lever up. Loosen the steering friction adjuster by turning it counterclockwise, and adjust the steering friction according to operator preference.

5.

EWM00720

WARNING
If there is too much resistance it could be difficult to steer, which could result in an accident.
EMU28193

Cruising in other conditions

Cruising in salt water After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged. Also rinse the outside of the outboard motor with fresh water and, if possible, rinse the power head under the cowling. Cruising in muddy or turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (available for V4 and large engines) if you use the outboard motor in water with a lot of sediment in it, such as muddy or other turbid (cloudy) water. Cruising in acidic water Water in some areas can be acidic. After operating in such water, flush the cooling passages with fresh water to prevent corrosion. Also rinse the outside of the outboard motor with fresh water.

25

Maintenance
EMU31480

Specifications
NOTE:
(AL) stated in the specification data below represents the numerical value for the aluminum propeller installed. Likewise, (SUS) represents the value for stainless steel propeller installed and (PL) for plastic propeller installed.
EMU28219

Starting carburetion system: Choke valve

Drive unit:
Gear positions: Forward Gear ratio: 2.08 (27/13) Trim and tilt system: Manual tilt Propeller mark: A

Fuel and oil:

Recommended fuel: Regular unleaded gasoline Fuel tank capacity (built in type): 1.2 L (0.32 US gal) (0.26 Imp.gal) Recommended engine oil: YAMALUBE 2-stroke outboard motor oil Fuel:oil ratio: Regular gasoline: 100 :1 Lubrication: Pre-mixed fuel and oil Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: 45.0 cm (1.52 US oz) (1.59 Imp.oz)

Dimension:
Overall length: 603 mm (23.7 in) Overall width: 240 mm (9.4 in) Overall height S: 916 mm (36.1 in) Transom height S: 417 mm (16.4 in) Weight (PL) S: 9.8 kg (22 lb)

Performance:
Full throttle operating range: 40005000 r/min Maximum output: 1.5 kW@4500 r/min (2 HP@4500 r/min) Idling speed (in neutral): 1150 50 r/min

Tightening torque for engine:

Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
EMU28223

Engine:
Type: 2-stroke S Displacement: 50.0 cm Bore stroke: 42.0 36.0 mm (1.65 1.42 in) Ignition system: CDI Spark plug (NGK): BR7HS Spark plug gap: 0.60.7 mm (0.0240.028 in) Control system: Tiller Starting system: Manual

Transporting and storing outboard motor

EWM00690

WARNING
G

Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. USE CARE when transporting fuel tank, whether in a boat or car. DO NOT fill fuel container to maximum capacity. Gasoline will expand considerably as it warms up and can build up

26

Maintenance
pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.
EWM00700

WARNING
Never get under the lower unit while it is tilted, even if a motor support bar is used. Severe injury could occur if the outboard motor accidentally falls.
ECM00660

CAUTION:
Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in the normal running position, use an additional support device to secure it in the tilt position. The outboard motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the tilt position using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details.
EMU28235

NOTE:
Place a towel or something similar under the outboard motor to protect it from damage.
EMU30272

Storing outboard motor

When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the following procedures.
ECM01411

CAUTION:
G

Clamp screw mounting models

When transporting or storing the outboard motor while removed from a boat, keep the outboard motor in the attitude shown.

Do not place the outboard motor on its side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trouble. Store the outboard motor in a dry, wellventilated place, not in direct sunlight.

EMU28303

Procedure
EMU28313

Flushing in a water tank 1. Wash the outboard motor body using fresh water. For further information, see page 29.
ZMU02870

27

Maintenance
2. Place the fuel cock in the closed position and disconnect the fuel line if equipped. Tighten the air vent screw, if equipped. Remove the engine top cowling and silencer cover. Install the outboard motor on the test tank.
G

Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. Run the engine at a fast idle for a few minutes in neutral position. Just prior to turning off the engine, quickly spray Fogging Oil alternately into each carburetor or the fogging hole of the silencer cover, if equipped. When properly done, the engine will smoke excessively and almost stall. If Fogging Oil is not available, run the engine at a fast idle until the fuel system empties and the engine stops. Remove the outboard motor from the test tank. Install the silencer cover or fogging hole cap, and the top cowling. Drain the cooling water completely out of the motor. Clean the body thoroughly. If Fogging Oil is not available, remove the spark plug(s). Pour a teaspoonful of clean engine oil into each cylinder. Crank several times manually. Replace the spark plug(s). Drain the fuel from both the built-in and portable fuel tanks, on equipped models.

3. 4.

7. 8.

9.

10.
1. Water surface 2. Lowest water level

11. 12. 13.

5.

Fill the tank with fresh water to above the level of the anti-cavitation plate.

ECM00290

CAUTION:
If the fresh water level is below the level of the anti-cavitation plate, or if the water supply is insufficient, engine seizure may occur. 6. Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fogging/lubricating of the engine is mandatory to prevent excessive engine damage due to rust. Perform the flushing and fogging at the same time.

14.

NOTE:
Portable fuel tank equipped models: Store the portable fuel tank in a dry, well-ventilated place, not in direct sunlight.
EMU28402

Lubrication
1. Install the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 31.

EWM00090

WARNING
G

Do not touch or remove electrical parts when starting or during operation.

28

Maintenance
2. Change the gear oil. For instructions, see page 35. Inspect the oil for the presence of water that indicates a leaky seal. Seal replacement should be performed by an authorized Yamaha dealer prior to use. Grease all grease fittings. For further details, see page 31.
EMU28478

Periodic maintenance
EWM01071

WARNING
Be sure to turn off the engine when you perform maintenance unless otherwise specified. If you are not familiar with machine servicing, this work should be done by your Yamaha dealer or other qualified mechanic.
EMU28511

3.

NOTE:
For long-term storage, fogging the engine with oil is recommended. Contact your Yamaha dealer for information about fogging oil and procedures for your engine.
EMU28450

Replacement parts
If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Yamaha genuine parts and accessories are available from your Yamaha dealer.

Cleaning the outboard motor

After use, wash the exterior of the outboard motor with fresh water. Flush the cooling system with fresh water.

NOTE:
For cooling system flushing instructions, see page 26.
EMU28460

Checking painted surface of motor

Check the motor for scratches, nicks, or flaking paint. Areas with damaged paint are more likely to corrode. If necessary, clean and paint the areas. A touch-up paint is available from your Yamaha dealer.

29

Maintenance
EMU28522

Maintenance chart
Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action.

NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. The The symbol indicates the check-ups which you may carry out yourself. symbol indicates work to be carried out by your Yamaha dealer.
Initial Item Actions Inspection / replacement Cleaning Inspection Inspection / cleaning Inspection Inspection / cleaning Change Greasing Inspection Inspection / replacement Inspection / replacement Inspection / adjustment Inspection / replacement Cleaning / adjustment / replacement Every

10 hours 50 hours 100 hours 200 hours (1 month) (3 months) (6 months) (1 year)

Anode(s) (external) Cooling water passages Cowling clamp Fuel filter (inside builtin fuel tank) Fuel system Fuel tank (built-in tank) Gear oil Greasing points Idling speed (carburetor models) Propeller and cotter pin Thermostat Throttle link / throttle cable / throttle pick-up timing Water pump Spark plug(s)

30

Maintenance
EMU28941

Greasing
Yamaha grease A (water resistant grease) Yamaha grease D (corrosion resistant grease; for propeller shaft) 2C

EMU28953

EWM01550

Cleaning and adjusting spark plug

EWM00560

WARNING
The engine will still be very hot when it has just been turned off. Take extremely care so that neither you nor anyone else gets burnt. To avoid burns, work on the engine when it has cooled down.

WARNING
When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire.

31

Maintenance
The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type. Standard spark plug: BR7HS Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification if necessary. When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque. Spark plug torque: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

NOTE:
If a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct torque is 1/4 to 1/2 a turn past fingertight. Have the spark plug adjusted to the correct torque as soon as possible with a torquewrench.
EMU28962

Checking fuel system

EWM00060

WARNING
Gasoline and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames, or other sources of ignition.
EWM00910

WARNING
Leaking fuel can result in fire or explosion. G Check for fuel leakage regularly. G If any fuel leakage is found, the fuel system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate.
1. Spark plug gap 2. Spark plug part number 3. Spark plug I.D. mark (NGK)

Spark plug gap: 0.60.7 mm (0.0240.028 in)

Check the fuel lines for leaks, crack, or malfunction. If a problem is found, your Yamaha dealer or other qualified mechanic should repair it immediately.

32

Maintenance
1. Start the engine and allow it to warm up fully with the throttle in the start position or less until it is running smoothly. If the outboard is mounted on a boat, be sure the boat is tightly moored.

NOTE:
Correct idling speed inspection is only possible if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty verifying the idle speed, or the idle speed requires adjustment, consult a Yamaha dealer or other qualified mechanic. 2. Verify whether the idle speed is set to specification. For idle speed specifications, see page 26. Check that each grounding wire is properly secured. Check that each connector is engaged securely.

Checkpoints G Fuel system parts leakage G Fuel line joint leakage G Fuel line cracks or other damage G Fuel connector leakage
EMU30810

Inspecting idling speed

EWM01440

EMU29112

WARNING
G

Checking wiring and connectors

G

Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. The propeller rotates whenever the engine is running. Do not move the throttle control lever from the start position during warm-up. The boat could unexpectedly start to move, which could result in an accident.

EMU29120

Exhaust leakage
Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head, and body cylinder.
EMU29130

Water leakage
Start the engine and check that no water leaks from the joints between the exhaust cover, cylinder head, and body cylinder.
EMU32120

ECM01520

CAUTION:
This procedure must be performed while the outboard motor is in the water. A test tank can be used. A diagnostic tachometer should be used for this procedure. Results may vary depending on whether testing is conducted with the flushing attachment, in a test tank, or with the outboard motor in the water.

Checking propeller
EWM01610

WARNING
You could be seriously injured if the engine accidentally starts when you are near the propeller. G Before inspecting, removing, or installing the propeller, remove the spark plug caps from the spark plugs. Also, place

33

Maintenance
the shift control in neutral, turn the main switch to (off) and remove the key, and remove the cord from the engine shut-off switch. Turn off the battery cutoff switch if your boat has one. Do not use your hand to hold the propeller when loosening or tightening the propeller nut. Put a wood block between the anti-cavitation plate and the propeller to prevent the propeller from turning.

NOTE:
It is designed to break if the propeller hits a hard underwater obstacle to help protect the propeller and drive mechanism. The propeller will then spin freely on the shaft. If this happens, the shear pin must be replaced.
EMU30661

Removing propeller
EMU29181

Shear pin models 1. Straighten the cotter pin and pull it out using a pair of pliers.

ZMU01896

Checkpoints G Check each of the propeller blades for wear, erosion from cavitation or ventilation, or other damage. G Check the propeller shaft for damage. G Check the shear pin for wear or damage. G Check for fish line tangled around the propeller shaft.

1. Cotter pin 2. Propeller 3. Shear pin

2. 3.

Remove the propeller nut and washer, if equipped. Remove the shear pin and the propeller.

EMU30671

Installing propeller
EMU29221

Shear pin models

ECM00500

CAUTION:
Be sure to use a new cotter pin and bend the ends over securely. Otherwise the propeller could come off during operation and be lost. 1.
G

Check the propeller shaft oil seal for damage.

Apply Yamaha marine grease or corrosion resistant grease to the propeller shaft.

34

Maintenance
2. 3. Insert the shear pin into the hole in the propeller shaft. Align the shear pin with the groove in the propeller boss, and slide the propeller over the propeller shaft. Align the hole in the propeller with the recess in the propeller shaft. Insert a new cotter pin in the hole and bend the cotter pin ends.
1. Gear oil drain screw 2. Oil level plug

4.

NOTE:
There is a holder on the steering handle for spare shear and cotter pins. Be sure to replace a pin in the holder if one is used.
EMU29282

NOTE:
G

Changing gear oil

EWM00800

WARNING
G

Be sure the outboard motor is securely fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you. Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor accidentally falls. Tilt the outboard motor so that the gear oil drain screw is at the lowest point possible. Place a suitable container under the gear case. Remove the gear oil drain screw and gasket.

If a magnetic gear oil drain screw is equipped, remove all metal particles from the screw before installing it. Always use new gaskets. Do not reuse the removed gaskets. Remove the oil level plug and gasket to allow the oil to drain completely.

4.

ECM00710

CAUTION:
Inspect the used oil after it has been drained. If the oil is milky, water is getting into the gear case which can cause gear damage. Consult a Yamaha dealer for repair of the lower unit seals.

1.

NOTE:
For disposal of used oil, consult your Yamaha dealer. 5. With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole. Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: 45.0 cm (1.52 US oz) (1.59 Imp.oz)

2. 3.

35

Maintenance

6.

7.

Put a new gasket on the oil level plug. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw.

EMU29391

Checking top cowling

ECM01650

CAUTION:
Be sure the cowling is closed securely and that there are no gaps. A loose or improperly fitting cover could allow water into the engine. Check the fitting of the top cowling by pushing it with both hands. If it is loose have it repaired by your Yamaha dealer.
EMU29400

EMU29312

Inspecting and replacing anode(s)

Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.
ECM00720

Coating the boat bottom

A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.

CAUTION:
Do not paint anodes, as this would render them ineffective.

NOTE:
Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit.

36

Trouble Recovery
EMU29425

Troubleshooting
A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. This section describes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer. If the engine trouble-warning indicator is flashing, consult your Yamaha dealer. Starter will not operate. Q. Is battery capacity weak or low? A. Check battery condition. Use battery of recommended capacity. Q. Are battery connections loose or corroded? A. Tighten battery cables and clean battery terminals. Q. Is fuse for electric start relay or electric circuit blown? A. Check for cause of electric overload and repair. Replace fuse with one of correct amperage. 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 18. Q. Has fuel pump malfunctioned? A. Have serviced by a Yamaha dealer. Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type. Q. Are spark plug cap(s) fitted incorrectly? A. Check and re-fit cap(s). Q. Is ignition wiring damaged or poorly connected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires. Q. Are ignition parts faulty? A. Have serviced by a Yamaha dealer. Q. Is engine shut-off cord not attached? A. Attach cord. Q. Are engine inner parts damaged? A. Have serviced by a Yamaha dealer. Engine idles irregularly or stalls. Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type. Q. Is fuel system obstructed?

37

Trouble Recovery
A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer. Q. Has warning system activated? A. Find and correct cause of warning. Q. Is spark plug gap incorrect? A. Inspect and adjust as specified. Q. Is ignition wiring damaged or poorly connected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires. Q. Is specified engine oil not being used? A. Check and replace oil as specified. Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer. Q. Are carburetor adjustments incorrect? A. Have serviced by a Yamaha dealer. Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer. Q. Is air vent screw on fuel tank closed? A. Open air vent screw. Q. Is choke knob pulled out? A. Return to home position. Q. Is motor angle too high? A. Return to normal operating position. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer. Q. Is fuel joint connection incorrect? A. Connect correctly. Q. Is throttle valve adjustment incorrect? A. Have serviced by a Yamaha dealer. Q. Is battery cable disconnected? A. Connect securely. Warning buzzer sounds or indicator lights. Q. Is cooling system clogged? A. Check water intake for restriction. Q. Is engine oil level low? A. Fill oil tank with specified engine oil. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended 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 malfunctioned? A. Have serviced by a Yamaha dealer.

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Trouble Recovery
Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer. Q. Is there excess water in fuel filter cup? A. Drain filter cup. Engine power loss. Q. Is propeller damaged? A. Have propeller repaired or replaced. Q. Is propeller pitch or diameter incorrect? A. Install correct propeller to operate outboard at its recommended speed (r/min) range. Q. Is trim angle incorrect? A. Adjust trim angle to achieve most efficient operation. Q. Is motor mounted at incorrect height on transom? A. Have motor adjusted to proper transom height. Q. Has warning system activated? A. Find and correct cause of warning. Q. Is boat bottom fouled with marine growth? A. Clean boat bottom. Q. Are spark plug(s) fouled or of incorrect type? A. Inspect spark plug(s). Clean or replace with recommended type. Q. Are weeds or other foreign matter tangled on gear housing? A. Remove foreign matter and clean lower unit. Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is spark plug gap incorrect? A. Inspect and adjust as specified. Q. Is ignition wiring damaged or poorly connected? A. Check wires for wear or breaks. Tighten all loose connections. Replace worn or broken wires. Q. Have electrical parts failed? A. Have serviced by a Yamaha dealer. Q. Is specified fuel not being used? A. Replace fuel with specified type. Q. Is specified engine oil not being used? A. Check and replace oil with specified type. Q. Is thermostat faulty or clogged? A. Have serviced by a Yamaha dealer. Q. Is air vent screw closed? A. Open the air vent screw. Q. Is fuel pump damaged? A. Have serviced by a Yamaha dealer. Q. Is fuel joint connection incorrect?

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Trouble Recovery
A. Connect correctly. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type. Q. Is high pressure fuel pump drive belt broken? A. Have serviced by a Yamaha dealer. Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer. Engine vibrates excessively. Q. Is propeller damaged? A. Have propeller repaired or replaced. Q. Is propeller shaft damaged? A. Have serviced by a Yamaha dealer. Q. Are weeds or other foreign matter tangled on propeller? A. Remove and clean propeller. Q. Is motor mounting bolt loose? A. Tighten bolt. Q. Is steering pivot loose or damaged? A. Tighten or have serviced by a Yamaha dealer.
EMU29433

If the outboard motor hits an object in the water, follow the procedure below.

1. 2.

3.

4.

Stop the engine immediately. Inspect the control system and all components for damage. Also inspect the boat for damage. Whether damage is found or not, return to the nearest harbor slowly and carefully. Have a Yamaha dealer inspect the outboard motor before operating it again.

EMU31311

Starter will not operate

If the starter mechanism does not operate (the engine cannot be cranked with the starter), the engine can be started with an emergency starter rope.
EWM01461

WARNING
G

Temporary action in emergency

EMU29440

Impact damage
EWM00870

WARNING
The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate.

Use this procedure only in an emergency to return to the nearest port for repairs. Attach the engine shut-off cord to a secure place on your clothing, or your arm or leg while operating the boat. Do not attach the cord to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. Avoid accidentally pulling the cord during normal operation. Loss of engine power means the loss of most steering

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Trouble Recovery
control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward. Make sure no one is standing behind you when pulling the starter rope. It could whip behind you and injure someone. An unguarded, rotating flywheel is very dangerous. Keep loose clothing and other objects away when starting the engine. Use the emergency starter rope only as instructed. Do not touch the flywheel or other moving parts when the engine is running. Do not install the starter mechanism or top cowling after the engine is running. Do not touch the ignition coil, spark plug wire, spark plug cap, or other electrical components when starting or operating the motor. You could get an electrical shock. Do not move the throttle lever above the start position when starting the engine. Because the propeller rotates whenever the engine is running, the boat could unexpectedly start to move, which could result in an accident.

2.

Remove the aprons by removing the eight screws.

3.

Remove the starter mechanism by removing the three bolts.

EMU29550

Emergency starting engine

1. Remove the spark plug cap cover by removing the two screws.

4. 5.

Prepare the engine for starting. For further information, see page 18. Insert the knotted end of the rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel one or two turns clockwise.

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Trouble Recovery
6. Give a strong pull straight out to crank the engine. Repeat if necessary.

ZMU01910

3.
EMU29760

Treatment of submerged motor

If the outboard motor is submerged, immediately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immediately. If you cannot immediately take the outboard motor to a Yamaha dealer, follow the procedure below in order to minimize engine damage.
EMU29771

4.

Drain the fuel from the carburetor, fuel filter, and fuel line. Feed fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking with the manual starter or emergency starter rope.

Procedure
1. Thoroughly wash away mud, salt, seaweed, and so on, with fresh water.
ZMU01911

5.

Take the outboard motor to a Yamaha dealer as soon as possible.

ECM00400

CAUTION:
Do not attempt to run the outboard motor until it has been completely inspected.

ZMU01909

2.

Remove the spark plugs and face the spark plug holes downward to allow any water, mud, or contaminants to drain.

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YAMAHA MOTOR CO., LTD.

Printed in Japan April 20070.4 1 CR

Printed on recycled paper