F75D
F90D
OWNER’S MANUAL
U.S.A.Edition
LIT-18626-06-12
6D6-28199-10
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Important manual information
EMU25100
your machine and this manual. If there is any
question concerning this manual, please con-
To the owner
Thank you for choosing a Yamaha outboard
motor. This Owner’s Manual contains infor-
mation needed for proper operation, mainte-
nance 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.
sult your Yamaha dealer.
NOTE:
The F75TR, F90TR and the standard acces-
sories are used as a base for the explanations
and illustrations in this manual. Therefore
some items may not apply to every model.
EMU25110
In this Owner’s Manual particularly important
information is distinguished in the following
ways.
F75D, F90D
OWNER’S MANUAL
©2004 by Yamaha Motor Corporation,
USA
1st edition, April 2004
All rights reserved.
The Safety Alert Symbol means AT-
TENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!
EWM00780
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in Japan
WARNING
Failure to follow WARNING instructions
could result in severe injury or death to the
machine operator, a bystander, or a per-
son inspecting or repairing the outboard
motor.
P/N LIT-18626-06-12
ECM00700
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
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Table of contents
Digital tachometer ........................ 17
indicator .................................... 17
Identification numbers record...... 1
Outboard motor serial number ....... 1
Key number.................................... 1
North American models.................. 1
Star labels ...................................... 2
Important labels........................... 4
Warning labels................................ 4
Basic boating rules
(Rules of the road) ................... 4
Steering and sailing rules and
sound signals.............................. 5
Rules when encountering
Gasoline ......................................... 9
Engine oil........................................ 9
Battery requirement..................... 9
Battery specifications ................... 10
Propeller selection..................... 10
Start-in-gear protection ............. 11
(digital type) .............................. 18
Trim meter (digital type) ............... 19
indicator .................................... 20
Fuel .............................................. 24
Engine .......................................... 25
Filling fuel.................................. 25
Feeding fuel.................................. 26
Starting engine ............................. 26
Warming up engine................... 28
Manual start and electric start
models ...................................... 28
Shifting...................................... 28
Forward (tiller handle and
remote control models) ............. 28
Reverse
(automatic reverse lock and
power trim and tilt models)........ 29
Stopping engine........................ 29
Main components...................... 12
Remote control lever .................... 13
Neutral interlock trigger ................ 13
Throttle friction adjuster................ 13
Engine stop lanyard switch........... 14
Main switch................................... 14
Power trim and tilt switch on
remote control or tiller handle ... 15
Power trim and tilt switch on
bottom engine cowling .............. 15
Trim tab with anode...................... 15
Tilt support lever for power trim
and tilt or hydro tilt model.......... 16
Top cowling lock lever
(pull up type) ............................. 16
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Procedure..................................... 29
Adjusting trim angle...................... 30
Adjusting boat trim........................ 31
Procedure for tilting up ................. 32
Procedure for tilting down............. 33
Cruising in shallow water .......... 34
Power trim and tilt models /
Checking power trim and tilt
Removing the propeller ................ 51
Changing gear oil ......................... 51
Inspecting and replacing
(for electric start models) .......... 53
Connecting the battery ................. 54
power tilt models....................... 34
Transporting and storing
Temporary action in
outboard motor....................... 37
Storing outboard motor................. 37
Procedure..................................... 38
Lubrication
(except oil injection models)...... 39
Cleaning and anticorrosion
measures .................................. 39
Battery care.................................. 39
Flushing power unit ...................... 40
Cleaning the outboard motor........ 40
Checking painted surface of
motor......................................... 41
Periodic maintenance................ 41
Replacement parts ....................... 41
Maintenance chart........................ 42
Greasing....................................... 44
Cleaning and adjusting spark
Impact damage............................. 59
Power trim and tilt will not
Starter will not operate ................. 60
Treatment of submerged
motor...................................... 62
Consumer information ............... 63
for U.S.A. and Canada........... 63
plug ........................................... 44
Checking fuel system ................... 45
Inspecting fuel filter ...................... 45
Cleaning fuel filter......................... 46
Inspecting idling speed................. 46
Changing engine oil...................... 47
Checking wiring and
connectors ................................ 49
Exhaust leakage........................... 49
Water leakage .............................. 49
Engine oil leakage........................ 49
CORPORATION, U.S.A.
FOUR-STROKE OUTBOARD
MOTOR THREE-YEAR
LIMITED WARRANTY........... 65
IMPORTANT WARRANTY
INFORMATION IF YOU USE
YOUR YAMAHA OUTSIDE
U.S.A. OR CANADA.............. 67
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General information
EMU25170
Identification numbers record
EMU25182
Outboard motor serial number
The outboard motor serial number is stamped
on the label attached to the port side of the
clamp bracket or the upper part of the swivel
bracket.
Record your outboard motor serial number in
the spaces provided to assist you in ordering
spare parts from your Yamaha dealer or for
reference in case your outboard motor is sto-
len.
1. Key number
EMEU25m220ission control information
ENMoU2r52t3h0 American models
1
This engine conforms to U.S. Environmental
Protection Agency (EPA) regulations for ma-
rine SI engines. See the label affixed to your
engine for details.
EMU25242
ZMU04214
Approval label of emission control certifi-
1. Outboard motor serial number location
cate
This label is attached to the bottom cowling.
New Technology; (4-stroke/HPDI) EM
1
EKMeU2y519n0 umber
ZMU04217
If a main key switch is equipped with the mo-
tor, the key identification number is stamped
on your key as shown in the illustration.
Record this number in the space provided for
reference in case you need a new key.
1. Approval label location
1
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General information
ZMU01699
1. Star labels location
EMU25262
Manufactured date label
This label is attached to the clamp bracket or
EMU25280
One Star—Low Emission
The one-star label identifies engines that
meet the Air Resources Board’s 2001 ex-
haust emission standards. Engines meeting
these standards have 75% lower emissions
than conventional carbureted two-stroke en-
gines. These engines are equivalent to the
U.S. EPA’s 2006 standards for marine en-
gines.
the swivel bracket.
1
ZMU04218
1. Manufactured date label location
ZMU01702
Manufactured:
EMU25290
Two Stars—Very Low Emission
The two-star label identifies engines that meet
the Air Resources Board’s 2004 exhaust
emission standards. Engines meeting these
standards have 20% lower emissions than
One Star-Low-Emission engines.
ZMU04346
ESMtUa25r27l2abels
Your outboard motor is labeled with a Califor-
nia Air Resources Board (CARB) star label.
See below for a description of your particular
label.
2
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General information
the rated horsepower capacity of the boat.
If the rated horsepower capacity of the boat
is unknown, consult the dealer or boat man-
ufacturer.
G Do not modify the outboard. Modifications
could make the motor unfit or unsafe to use.
G Never operate after drinking alcohol or tak-
ing drugs. About 50% of all boating fatalities
involve intoxication.
ZMU01703
G Have an approved personal flotation device
(PFD) on board for every occupant. It is a
good idea to wear a PFD whenever boat-
ing. At a minimum, children and non-swim-
mers should always wear PFDs, and
everyone should wear PFDs when there
are potentially hazardous boating condi-
tions.
EMU25300
Three Stars—Ultra Low Emission
The three-star label identifies engines that
meet the Air Resources Board’s 2008 ex-
haust emission standards. Engines meeting
these standards have 65% lower emissions
than One Star-Low-Emission engines.
G Gasoline is highly flammable, and its va-
pors are flammable and explosive. Handle
and store gasoline carefully. Make sure
there are no gas fumes or leaking fuel be-
fore starting the engine.
G This product emits exhaust gases which
contain 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.
operation before starting the engine.
G Attach the engine stop switch lanyard cord
to a secure place on your clothing, or your
arm or leg while operating. If you acciden-
tally leave the helm, the cord will pull from
the switch, stopping the engine.
ZMU01704
EMU25361
Safety information
G Before mounting or operating the outboard
motor, read this entire manual. Reading it
should give you an understanding of the
motor and its operation.
G Before operating the boat, read any own-
er’s or operator’s manuals supplied with it
and all labels. Be sure you understand each
item before operating.
G Do not overpower the boat with this out-
board motor. Overpowering the boat could
result in loss of control. The rated power of
the outboard should be equal to or less than
G Know the marine laws and regulations
where you will be boating—and obey them.
For basic boating rules, see “Rules of the
road” on page 4.
3
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General information
EMU25380
EMU25395
G Stay informed about the weather. Check
weather forecasts before boating. Avoid
boating in hazardous weather.
G Tell someone where you are going: leave a
Float Plan with a responsible person. Be
sure to cancel the Float Plan when you re-
turn.
Important labels
Warning labels
G Use common sense and good judgment
when boating. Know your abilities, and be
sure you understand how your boat han-
dles under the different boating conditions
you may encounter. Operate within your
limits, and the limits of your boat. Always
operate at safe speeds, and keep a careful
watch for obstacles and other traffic.
G Always watch carefully for swimmers during
the engine operation.
G Stay away from swimming areas.
G When a swimmer is in the water near you
shift into neutral and shut off the engine.
Be informed about boating safety. Additional
publications and information can be obtained
from many organizations, including the follow-
ing:
EMU25401
Label
EWM01260
WARNING
G Be sure shift control is in neutral before
starting engine. (except 2HP)
G Do not touch or remove electrical parts
when starting or during operation.
G Keep hands, hair, and clothes away from
flywheel and other rotating parts while
engine is running.
United States Coast Guard
Consumer Affairs Staff (G-BC)
EMBU25a500sic boating rules (Rules of
Office of Boating, Public, and Consumer Af-
fairs
U.S. Coast Guard Headquarters
Washington, D.C. 20593-0001
Boating Safety Hotline: 1-800-368-5647
National Marine Manufacturers Associa-
tion (NMMA)
401 N. Michigan Ave.
Chicago, Il 60611
Marine Retailers Association of America
155 N. Michigan Ave.
Chicago, Il 60601
the road)
Just as there are rules which apply when you
are driving on streets and high ways, there
are waterway rules which apply when you are
driving your boat. These rules are used 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 another
vessel on the water.
Several sets of rules prevail according to geo-
graphic location, but are all basically the same
as the International Rules of the Road. The
rules presented here in your Owner’s Manual
are condensed, and have been provided for
4
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General information
your convenience only. Consult your local In other words, follow the standard rules ex-
U.S. Coast Guard Auxiliary or Department of cept when a collision will occur unless both
Motor Vehicles for a complete set of rules vessels try to avoid each other. If that is the
governing the waters in which you will be us- case, both vessels become “Give-Way” ves-
ing your boat.
sels.
ESMtUe25e51r0ing and sailing rules and sound
signals
ERMuU2l5e52s0 when encountering vessels
There are three main situations which you
Whenever two vessels on the water meet one may encounter with other vessels which could
another, one vessel has the right-of-way; it is lead to a collision unless the Steering Rules
called the “stand-on” vessel. The vessel are followed:
which does not have the right-of-way is called Meeting: (you are approaching another ves-
the “give-way” or “burdened” vessel. These sel head-on)
rules determine which vessel has the right-of- Crossing: (you are traveling across the other
way, and what each vessel should do.
vessel’s path)
Stand-on vessel
Overtaking: (you are passing or being
passed by another vessel)
The vessel with the right-of-way has the duty
to continue its course and speed, except to
avoid an immediate collision. When you main-
tain your direction and speed, the other vessel
will be able to determine how best to avoid
you.
In the following illustration, your boat is in the
center. You should give the right-of-way to
any vessels shown in white area (you are the
Give-Way vessel). Any vessels in the shaded
area must yield to you (they are the Give-Way
vessels). Both you and the meeting vessel
must alter course to avoid each other.
Give-way vessel
The vessel which does not have the right-of-
way has the duty to take positive and timely
action to stay out of the way of the Stand-On
vessel. Normally, you should not cross in front
of the vessel with the right-of-way. You should
slow down or change directions briefly and
pass behind the other vessel. You should al-
ways move in such a way that the operator of
the other vessel can see what you are doing.
“The general prudential rule”
This rule is called Rule 2 in the International
Rules and says,
Meeting
“In obeying and construing these rules due re-
gard shall be had to all dangers of navigation
and collision, and to any special circumstanc-
es, which may render a departure from the
above rules necessary in order to avoid im-
mediate danger.”
If you are meeting another power vessel head
on, 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 on
5
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General information
your port (left) side. This rule doesn’t apply if passing you, you should maintain your speed
both of you will clear one another if you con- and direction so that the other vessel can
tinue on your set course and speed.
steer itself around you.
EMU25530
Other special situations
There are three other rules you should be
aware of when driving your boat around other
vessels.
Narrow channels and bends
When navigating in narrow channels, you
should keep to the right when it is safe and
practical to do so. If the operator of a power-
driven vessel is preparing to go around a
bend that may obstruct the view of other water
vessels, the operator should sound a pro-
longed blast on the whistle (4 to 6 seconds). If
another vessel is around the bend, it too
should sound the whistle. Even if no reply is
heard, however, the vessel should still pro-
ceed around the bend with caution. If you nav-
igate such waters with your boat, you will
need to carry a portable air horn, available
from local marine supply stores.
Crossing
When two power driven vessels are crossing
each other’s path close enough to run the risk
of collision, the vessel which has the other on
the starboard (right) side must keep out of the
way of the other. If the other vessel is on your
right, you must keep out of its way; you are the
Give-Way vessel. If the other vessel is on
your port (left) side, remember that you
should maintain course and direction, provid-
ed the other vessel gives you the right-of-way
as it should.
Fishing vessel right-of-way
All vessels which are fishing with nets, lines or
trawls are considered to be “fishing vessels”
under the International Rules. Vessels with
trolling 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-way
Sailing vessels should normally be given the
right-of-way. The exceptions to this are:
1. When the sailing vessel is overtaking the
power-driven vessel, the power-driven
vessel has the right-of-way.
Overtaking
If you are passing another vessel, you are the
“Give-Way” vessel. This means that the other
vessel is expected to maintain its course and
speed. You must stay out of its way until you
are clear of it. Likewise, if another vessel is
2. Sailing vessels should keep clear of any
fishing vessel.
6
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General information
3. In a narrow channel, a sailing vessel
should not hamper the safe passage of a
power-driven vessel which can navigate
only in such a channel.
Reading buoys and other markers
The waters of the United states are marked
for safe navigation by the lateral system of
buoyage. Simply put, buoys and markers
have an arrangement of shapes, colors, num-
bers and lights to show which side of the buoy
a boater should pass on when navigating in a
particular direction. The markings on these
buoys are oriented from the perspective of be-
ing entered from seaward (the boater is going
towards the port). This means that red buoys
are passed on the starboard (right) side when
proceeding from open water into port, and
black buoys are to port (left) side. When navi-
gating out of port, your position with respect to
the buoys should be reversed; red buoys
should be to port and black buoys to star-
board.
Many bodies of water used by boaters are en-
tirely within the boundaries of a particular
state. The Uniform State Waterway Marking
System has been devised for these waters.
This system uses buoys and signs with dis-
tinctive shapes and colors to show regulatory
or advisory information. These markers are
white 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 unfamiliar
waters.
7
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General information
ZMU01708
EMU25540
EWM00010
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. Refuel
portable fuel tanks off the boat.
Fueling instructions
WARNING
GASOLINE AND ITS VAPORS ARE HIGH-
LY FLAMMABLE AND EXPLOSIVE!
8
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General information
EEMnU2g56i8n0 e oil
G Take care not to spill gasoline. If gaso-
line spills, wipe it up immediately with
dry rags.
Recommended engine oil:
4-stroke motor oil with a combination of
corresponding SAE and API as shown
in the chart
Engine oil quantity (excluding oil filter):
4.3 L (4.55 US qt) (3.78 Imp.qt)
G Do not overfill the fuel tank.
G Tighten the filler cap securely after refu-
eling.
G If you should swallow some gasoline, in-
hale a lot of gasoline vapor, or get gaso-
line in your eyes, get immediate medical
attention.
G If any gasoline spills onto your skin, im-
mediately wash with soap and water.
Change clothing if gasoline spills on it.
G Touch the fuel nozzle to the filler open-
ing or funnel to help prevent electrostat-
ic sparks.
ECM00010
CAUTION:
ECM01050
Use only new clean gasoline which has
been stored in clean containers and is not
contaminated with water or foreign matter.
CAUTION:
All 4-stroke engines are shipped from the
factory without engine oil.
EMU25570
Gasoline
If knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel.
Recommended gasoline:
Regular unleaded gasoline with a mini-
mum octane rating of 86 (Pump Oc-
tane Number) = (R+M)/2
Gasohol
There are two types of gasohol: gasohol con-
taining 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.
ZMU01710
EMU25700
Battery requirement
ECM01060
CAUTION:
Do not use a battery that does not meet the
specified capacity. If a battery which does
not meet specifications is used, the elec-
9
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General information
tric system could perform poorly or be Yamaha dealers stock a range of propellers,
overloaded, causing electric system dam- and can advise you and install a propeller on
age.
your outboard that is best suited to your appli-
cation.
For electric start models, choose a battery
which meets the following specifications.
EBMaU2t5t71e1ry specifications
x
-
Minimum cold cranking amps
(CCA/SAE):
380.0 A
1
2 3
Minimum marine cranking amps
(MCA/ABYC):
502.0 A
ZMU04606
Minimum reserve capacity (RC/SAE):
124 minutes
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
NOTE:
The engine cannot be started if battery volt-
age is too low.
EMU25742
Propeller selection
The performance of your outboard motor will
be critically affected by your choice of propel-
ler, as an incorrect choice could adversely af-
fect performance and could also seriously
damage the motor. Engine speed depends on
the propeller size and boat load. If engine
speed is too high or too low for good engine
performance, this will have an adverse effect
on the engine.
x
-
1
2 3
ZMU04607
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
Yamaha outboard motors are fitted with pro-
pellers chosen to perform well over a range of
applications, but there may be uses where a
propeller with a different pitch would be more
appropriate. For a greater operating load, a
smaller-pitch propeller is more suitable as it
enables the correct engine speed to be main-
tained. Conversely, a larger-pitch propeller is
more suitable for a smaller operating load.
NOTE:
Select a propeller which will allow the engine
to reach the middle or upper half of the oper-
ating range at full throttle with the maximum
boat load. If operating conditions such as light
boat loads then allow the engine r/min to rise
above the maximum recommended range, re-
duce the throttle setting to maintain the en-
gine in the proper operating range.
10
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General information
For instructions on propeller removal and in-
stallation, see page 50.
EMU25770
Start-in-gear protection
Yamaha outboard motors or Yamaha-ap-
proved remote control units are equipped with
start-in-gear protection device(s). This feature
permits the engine to be started only when it
is in neutral. Always select neutral before
starting the engine.
11
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Basic components
EMU25795
Main components
NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all models.
ERMeU2m618o0 te control
1. Top cowling
2. Top cowling lock lever(s)
The remote control lever actuates both the
3. Anti-cavitation plate
shifter and the throttle. The electrical switches
4. Trim tab (anode)
are mounted on the remote control box.
5. Propeller*
6. Cooling water inlet
7. Clamp bracket
8. Flushing device
9. Power trim and tilt switch
10.Remote control box (side mount type)*
11.Digital speedometer*
12.Digital tachometer*
1. Power trim and tilt switch
12
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Basic components
2. Remote control lever
3. Neutral interlock trigger
4. Neutral throttle lever
5. Main switch / choke switch
6. Engine stop lanyard switch
7. Throttle friction adjuster
ERMeU2m619o0 te control lever
Moving the lever forward from the neutral po-
sition engages forward gear. Pulling the lever
back from neutral engages reverse. The en-
gine will continue to run at idle until the lever
is moved about 35° (a detent can be felt).
Moving the lever farther opens the throttle,
and the engine will begin to accelerate.
1. Neutral interlock trigger
ENMeU2u62t1r1 al throttle lever
To open the throttle without shifting into either
forward or reverse, put the remote control le-
ver in the neutral position and lift the neutral
throttle lever.
NOTE:
The neutral throttle lever will operate only
when the remote control lever is in neutral.
The remote control lever will operate only
when the neutral throttle lever is in the closed
position.
1. Neutral “ ”
2. Forward “ ”
3. Reverse “ ”
4. Shift
5. Fully closed
6. Throttle
7. Fully open
ENMeU2u62t01ral interlock trigger
To shift out of neutral, first pull the neutral in-
terlock trigger up.
1. Fully open
2. Fully closed
EMU25970
Throttle friction adjuster
A friction device provides adjustable resis-
tance to movement of the throttle grip or the
remote control lever, and can be set accord-
ing to operator preference.
13
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Basic components
To increase resistance, turn the adjuster G Avoid accidentally pulling the lanyard
clockwise. To decrease resistance, turn the
adjuster counterclockwise.
EWM00030
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.
WARNING
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to move throttle lever or grip,
which could result in an accident.
NOTE:
The engine cannot be started with the lock
plate removed.
When constant speed is desired, tighten the
adjuster to maintain the desired throttle set-
ting.
1. Lanyard
2. Lock plate
EEMnU2g59i9n0 e stop lanyard switch
EMU26090
Main switch
The main switch controls the ignition system;
its operation is described below.
The lock plate must be attached to the engine
stop switch for the engine to run. The lanyard
should be attached to a secure place on the
operator’s clothing, or arm or leg. Should the
operator fall overboard or leave the helm, the
lanyard will pull out the lock plate, stopping ig-
nition to the engine. This will prevent the boat
G “
” (off)
With the main switch in the “
tion, the electrical circuits are off, and the key
can be removed.
” (off) posi-
G “ ” (on)
from running away under power.
EWM00120
With the main switch in the “ ” (on) position,
the electrical circuits are on, and the key can-
not be removed.
WARNING
G Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg while operating.
G “
” (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 returns
automatically to the “ ” (on) position.
G Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entan-
gled, preventing it from functioning.
14
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Basic components
(down) tilts the outboard motor down and
trims it down. When the switch is released,
the outboard motor will stop in its current po-
sition.
EWM01030
WARNING
Use the power trim and tilt switch located
on the bottom engine cowling only when
the boat is at a complete stop with the en-
gine off. Attempting to use this switch
while the boat is moving could increase
the risk of falling overboard and could dis-
tract the operator, increasing the risk of
collision with another boat or an obstacle.
EPMoU2w614e1 r trim and tilt switch on remote
control or tiller handle
The 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 the
switch “ ” (down) tilts the outboard motor
down and trims it down. When the switch is re-
leased, the outboard motor will stop in its cur-
rent position.
UP
1
DN
NOTE:
For instructions on using the power trim and
tilt switch, see pages 29 and 32.
ZMU04231
1. Power trim and tilt switch
NOTE:
For instructions on using the power trim and
tilt switch, see page 32.
EMU26241
Trim tab with anode
The trim tab should be adjusted so that the
steering control can be turned to either the
right or left by applying the same amount of
force.
EPMoU2w615e1 r trim and tilt switch on bottom
engine cowling
EWM00840
WARNING
An improperly adjusted trim tab could
cause difficult steering. Always test run af-
ter the trim tab has been installed or re-
The power trim and tilt switch is located on the
side of the bottom engine cowling. Pressing
the switch “ ” (up) trims the outboard motor
up, then tilts it up. Pressing the switch “
”
15
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Basic components
EMU26340
placed to be sure steering is correct. Be
sure you have tightened the bolt after ad-
justing the trim tab.
Tilt support lever for power trim and
tilt or hydro tilt model
To keep the outboard motor in the tilted up po-
sition, lock the tilt support lever to the clamp
bracket.
If the boat tends to veer the left (port side),
turn the trim tab rear end to the port side “A” in
the figure. If the boat tends to veer the right
(starboard side), turn the trim tab end to the
starboard side “B” in the figure.
ECM00840
CAUTION:
The trim tab also serves as an anode to
protect the engine from electrochemical
corrosion. Never paint the trim tab as it will
become ineffective as an anode.
1. Tilt support lever
EMU26382
3
2
Top cowling lock lever (pull up type)
To remove the engine top cowling, pull up the
lock lever(s) and lift off the cowling. When in-
stalling the cowling, check to be sure it fits
properly in the rubber seal. Then lock the
cowling by moving the lever(s) downward.
B
1
A
ZMU02525
1. Trim tab
2. Bolt
1
3. Cap
ZMU04225
1. Top cowling lock lever(s)
A
B
ZMU01863
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Basic components
1
2
1
3
4
5
ZMU04226
7
6
ZMU01840
1. Tachometer
2. Trim meter
3. Hour meter
1. Top cowling lock lever(s)
EMU26460
Flushing device
4. Low oil pressure warning indicator
5. Overheat warning indicator
6. Set button
This device is used to clean the cooling water
passages of the motor using a garden hose
and tap water.
7. Mode button
NOTE:
For details on usage, see page 40.
NOTE:
The water separator and engine trouble warn-
ing indicators only operate when the engine is
equipped with the appropriate functions.
EMU26521
Low oil pressure warning indicator
If oil pressure drops too low, the warning indi-
cator will start to blink. For further information,
see page 21.
ECM00020
CAUTION:
G Do not continue to run the engine if the
low oil pressure warning indicator is on
and the engine oil level is lower. Serious
engine damage will occur.
1. Flushing device
EDMiUg26i4t9a1 l tachometer
The tachometer shows the engine speed and
G The low oil pressure warning indicator
does not indicate the engine oil level.
Use the oil dipstick to check the remain-
ing oil quantity. For further information,
see page 25.
has the following functions.
NOTE:
All segments of the display will light momen-
tarily after the main switch is turned on and
will return to normal thereafter.
17
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Basic components
1
ZMU01736
1. Speedometer
1. Low oil pressure warning indicator
2. Fuel gauge
EMU26581
3. Trip meter/clock/voltmeter
4. Warning indicator(s)
Overheat warning indicator (digital
type)
If the engine temperature rises too high, the
warning indicator will start to blink. For further
information on reading the indicator, see page
21.
ECM00050
NOTE:
After the main switch is first turned on, all seg-
ments of the display come on as a test. After
a few seconds, the gauge will change to nor-
mal operation. Watch the gauge when turning
on the main switch to make sure all segments
come on.
CAUTION:
Do not continue to run the engine if the
overheat warning indicator is on. Serious
engine damage will occur.
NOTE:
The speedometer displays km/h, mph, or
knots, according to operator preference. Se-
lect the desired unit of measurement by set-
ting the selector switch on the back of the
gauge. See the illustration for settings.
1
ZMU01737
1. Overheat warning indicator
ESMpU2e66e00dometer (digital type)
This gauge shows the boat speed.
1. Cap
2. Selector switch (for speed unit)
3. Selector switch (for fuel sensor)
18
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Basic components
EMU26620
G Changing the display format
Trim meter (digital type)
This meter shows the trim angle of your out-
board motor.
Pressing the “
” (mode) button chang-
es the display format in the following pat-
tern:
Total hours→Trip hours→Display off
G Resetting the trip hours
Simultaneously pressing the “ ” (set) and
NOTE:
G Memorize the trim angles that work best for
your boat under different conditions. Adjust
the trim angle to the desired using the pow-
er trim and tilt switch.
“
” (mode) buttons for more than 1 sec-
ond while the trip hours are displayed re-
sets the trip counter to 0 (zero).
G If the trim angle of your motor exceeds the
trim operating range, the top segment on
the trim meter display will blink.
NOTE:
The total number of hours the engine has
been run cannot be reset.
EMU26690
Trip meter
This gauge displays the distance the boat has
traveled since the gauge was last reset.
Press the “
until the indicator on the face of the gauge
points to “ ” (trip). To reset the trip meter to
” (mode) button repeatedly
zero, press the “ ” (set) and “
buttons at the same time.
” (mode)
ZMU01740
EHMoU2u665r0 meter (digital type)
This meter shows the number of hours the en-
gine has been run. It can be set to show the
total number of hours or the number of hours
for the current trip. The display can also be
turned on and off.
NOTE:
G The trip distance is shown in kilometers or
miles depending upon the unit of measure-
ment selected for the speedometer.
G The trip distance is kept in memory by bat-
tery power. The stored data will be lost if the
battery is disconnected.
ZMU01741
19
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Basic components
ECMlUo26c70k0
Press the “
NOTE:
The fuel level reading can be affected by the
position of the sensor in the fuel tank and the
attitude of the boat in the water. Operation
with bow-up trim or continuous turning can
give false readings.
” (mode) button repeatedly
until the indicator on the face of the gauge
points to “ ” (time). To set the clock, be
sure the gauge is in the “ ” (time) mode.
Press the “ ” (set) button; the hour display
will begin blinking. Press the “ ” (mode)
button until the desired hour is displayed.
Press the “ ” (set) button again, the minute
display will begin blinking. Press the “
”
(mode) button until the desired minute is dis-
played. Press the “ ” (set) button again to
start the clock.
ZMU01745
EMU26720
Fuel warning indicator
If the fuel level decreases to one segment, the
fuel level warning segment will begin to blink.
ECM00880
CAUTION:
Do not continue to operate the engine with
full throttle if a warning device has activat-
ed. Get back to the port within trolling en-
gine speed.
NOTE:
The clock operates on battery power. Discon-
necting the battery will stop the clock. Reset
the clock after connecting the battery.
EMU26710
Fuel gauge
The fuel level is indicated by eight segments.
When all segments are showing, the fuel tank
is full.
ECM00860
CAUTION:
The Yamaha fuel tank sensor differs from
conventional sensors. Incorrectly setting
the selector switch on the gauge will give
false readings. Consult your Yamaha deal-
er on how to correctly set the selector
switch.
1. Fuel level warning segment
EMU26730
Low battery voltage warning indicator
If battery voltage drops, the display will auto-
matically turn on and begin to blink.
20
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Basic components
ECM00870
CAUTION:
Get back to the port soon if a warning de-
vice has activated. For charging the bat-
tery, consult your Yamaha dealer.
ZMU01757
G The buzzer will sound (if equipped on the
tiller handle, remote control box, or main
switch panel).
1. Low battery indicator
EMU26801
Warning system
ECM00090
CAUTION:
Do not continue to operate the engine if a
warning device has activated. Consult
your Yamaha dealer if the problem cannot
be located and corrected.
If the warning system has activated, stop the
engine and check the cooling water inlet for
clogging.
EMU26813
Overheat warning
This engine has an overheat warning device.
If the engine temperature rises too high, the
warning device will activate.
Activation of warning device
G The engine speed will automatically de-
crease to about 2000 r/min.
G The overheat warning indicator will light (if
equipped on the bottom cowling or the ta-
chometer).
ZMU02630
EMU26853
Low oil pressure warning
If the oil pressure drops too low, the warning
device will activate.
Activation of warning device
21
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Basic components
G The engine speed will automatically de-
crease to about 2000 r/min.
G The low oil pressure warning indicator will
light.
ZMU01828
G The buzzer will sound.
If the warning system has activated, stop the
engine as soon as it is safe to do so. Check
the oil level and add oil as needed. If the oil
level is correct and the warning device does
not switch off, consult your Yamaha dealer.
ECM00100
CAUTION:
Do not continue to run the engine if the
low oil pressure warning indicator is on.
Serious engine damage could occur.
22
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Operation
EMU26901
EWM00830
Installation
WARNING
ECM00110
Improper mounting of the outboard motor
could result in hazardous conditions such
as poor handling, loss of control, or fire
hazards. Observe the following:
G For permanently mounted models, your
dealer or other person experienced in
proper rigging should mount the motor.
If you are mounting the motor yourself,
you should be trained by an experienced
person.
CAUTION:
Incorrect engine height or obstructions to
smooth water flow (such as the design or
condition of the boat, or accessories such
as transom ladders or depth finder trans-
ducers) can create airborne water spray
while the boat is cruising. Severe engine
damage may result if the motor is operat-
ed continuously in the presence of air-
borne water spray.
G For portable models, your dealer or oth-
er person experienced in proper out-
board motor mounting should show you
how to mount your motor.
NOTE:
During water testing check the buoyancy of
the boat, at rest, with its maximum load.
Check that the static water level on the ex-
haust housing is low enough to prevent water
entry into the powerhead, when water rises
due to waves when the outboard is not run-
ning.
Mount the outboard motor on the center line
(keel line) of the boat, and ensure that the
boat itself is well balanced. Otherwise the
boat will be hard to steer. For boats without a
keel or which are asymmetrical, consult your
dealer.
EMU26910
Mounting the outboard motor
EWM00820
WARNING
G Overpowering a boat could cause se-
vere instability. Do not install an out-
board motor with more horsepower than
the maximum rating on the capacity
plate of the boat. If the boat does not
have a capacity plate, consult the boat
manufacturer.
G The information presented in this sec-
tion is intended as reference only. It is
not possible to provide complete in-
structions for every possible boat and
motor combination. Proper mounting
depends in part on experience and the
specific boat and motor combination.
1
ZMU01760
1. Center line (keel line)
EMU26930
Mounting height (boat bottom)
To run your boat at optimum efficiency, the
water resistance (drag) of the boat and out-
board motor must be made as little as possi-
ble. The mounting height of the outboard
motor greatly affects the water resistance. If
the mounting height is too high, cavitation
23
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Operation
ECM00800
tends to occur, thus reducing the propulsion;
and if the propeller tips cut the air, the engine
speed will rise abnormally and cause the en-
gine to overheat. If the mounting height is too
low, the water resistance will increase and
thereby reduce engine efficiency. Mount the
outboard motor so that the anti-cavitation
plate is in alignment with the bottom of the
boat.
CAUTION:
Failure to follow the break-in procedure
could result in reduced engine life or even
severe engine damage.
EPMrUo27c080edure for 4-stroke models
Run the engine under load (in gear with a pro-
peller installed) as follows.
1. For the first hour of operation:
Run the engine at 2000 r/min or at ap-
proximately half throttle.
2. For the second hour of operation:
Run the engine at 3000 r/min or at ap-
proximately three-quarter throttle.
3. For the next eight hours of operation:
Avoid continuous operation at full throttle
for more than five minutes at a time.
4. After the first 10 hours:
ZMU01762
EMU27101
NOTE:
G The optimum mounting height of the out-
board motor is affected by the boat/motor
combination and the desired use. Test runs
at different heights can help determine the
optimum mounting height. Consult your
Yamaha dealer or boat manufacturer for
further information on determining the prop-
er mounting height.
Preoperation checks
EWM00080
WARNING
If any item in the preoperation check is not
working properly, have it inspected and
repaired before operating the outboard
motor. Otherwise an accident could occur.
ECM00120
G For instructions on setting the trim angle of
the outboard motor, see page 29.
CAUTION:
Do not start the engine out of water. Over-
heating and serious engine damage can
occur.
EMU30172
Breaking in engine
Your new engine requires a period of break-in
to allow mating surfaces of moving parts to
wear in evenly. Correct break-in will help en-
sure proper performance and longer engine
life.
EMU27110
Fuel
G Check to be sure you have plenty of fuel for
your trip.
G Make sure there are no fuel leaks or gaso-
line fumes.
24
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Operation
G Check fuel line connections to be sure they
are tight (if equipped Yamaha fuel tank or
boat tank).
1
G Be sure the fuel tank is positioned on a se-
cure, flat surface, and that the fuel line is not
twisted or flattened, or likely to contact
sharp objects (if equipped Yamaha fuel
tank or boat tank).
ECMoU2n71t30rols
ZMU04257
G Check throttle, shift, and steering for proper
operation before starting the engine.
G The controls should work smoothly, without
binding or unusual free play.
1. Oil dipstick
G Look for loose or damaged connections.
G Check operation of the starter and stop
switches when the outboard motor is in the
water.
EEMnU2g71i5n0 e
G Check the engine and engine mounting.
G Look for loose or damaged fasteners.
G Check the propeller for damage.
G Check that the battery is in good condition
and the battery connections are secure.
1. Lower level mark
2. Oil dipstick
3. Upper level mark
ECMhU2e71c63king the engine oil level
1. Put the outboard motor in an upright po-
sition (not tilted).
NOTE:
Be sure to completely insert the dipstick into
the dipstick guide.
2. Remove oil dipstick and wipe it clean.
3. Completely insert the dipstick and re-
move it again.
EMU30021
Filling fuel
EWM00060
4. Check the oil level using the dipstick to be
sure the level falls between the upper and
lower marks. Fill with oil if it is below the
lower mark, or drain to the specified level
if it is above the upper mark.
WARNING
Gasoline and its vapors are highly flam-
mable and explosive. Keep away from
sparks, cigarettes, flames, or other sourc-
es of ignition.
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.
25
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Operation
ERMiUn27g270Free Fuel Additive
are flammable and explosive. Refrain
from smoking, and keep away from
open flames and sparks while loosening
the air vent screw.
G This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which could cause brain
damage or death when inhaled. Symp-
toms include nausea, dizziness, and
drowsiness. Keep cockpit and cabin ar-
eas well ventilated. Avoid blocking ex-
haust outlets.
Gasoline is a precise blend of many different
substances, each chosen to give certain char-
acteristics. Gasoline blends have been
changing in recent years in response to con-
cerns about pollution and resulting emissions
regulations. One of the most obvious changes
has been the elimination of lead from most fu-
els.
As gasoline has changed, the amount of addi-
tives such as aromatics and oxygenates has
increased. These additives are important for
the engines in passenger cars, but they can
have detrimental effects in marine engines,
because of increased deposits in the combus-
tion chamber. When enough deposits collect,
piston rings begin sticking. Performance
drops and engine wear increases dramatical-
ly.
1. If there is an air vent screw on the fuel
tank cap, loosen it 2 or 3 turns.
2. If there is a fuel joint or a fuel cock on the
boat, firmly connect the fuel line to the
joint or open the fuel cock.
3. Squeeze the primer pump with the outlet
end up until you feel it become firm.
While many additives available may reduce
deposits, Yamaha recommends the use of
Ring Free Fuel Additive, available from your
Yamaha dealer. Ring Free Fuel Additive
has repeatedly proven its ability to clean com-
bustion deposits from inside the engine, nota-
bly the critical piston-ring-land area, and fuel
system components. Follow product labeling
for use instructions.
EMU27450
Operating engine
ESMtUa27r4t90ing engine
EMU27480
Feeding fuel
EWM00420
EMU27624
Electric start and remote control models
1. Place the remote control lever in “ ”
WARNING
G 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.
G When the air vent screw is loosened,
gasoline vapor will be released. Gaso-
line is highly flammable, and its vapors
(neutral).
NOTE:
The start-in-gear protection device prevents
the engine from starting except when in neu-
tral.
26
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Operation
3. Turn the main switch to “ ” (on).
NOTE:
Dual engine users: When the main switch is
turned on, the buzzer operates for a few sec-
onds then stops automatically. The buzzer
also operates if one of the engines stalls.
2. Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg. Then install the lock plate on
the other end of the lanyard into the en-
gine stop switch.
EWM00120
WARNING
G Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg while operating.
4. Turn the main switch to “
” (start),
and hold it for a maximum of 5 seconds.
G Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entan-
gled, preventing it from functioning.
G Avoid accidentally pulling the lanyard
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.
ON
OFF
START
ZMU01881
5. Immediately after the engine starts, re-
lease the main switch to return it to “
”
(on).
ECM00191
CAUTION:
G Never turn the main switch to “
”
(start) while the engine is running.
G Do not keep the starter motor turning for
more than 5 seconds. If the starter motor
is turned continuously for more than 5
seconds, the battery will be quickly dis-
charged, thus making it impossible to
27
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Operation
start the engine. The starter can also be
damaged. If the engine will not start after
5 seconds of cranking, return the main
switch to “ ” (on), wait 10 seconds,
then crank the engine again.
EMU27670
Warming up engine
EMU30030
Manual start and electric start models
1. After starting the engine, allow it to idle for
3 minutes to warm up. Failure to do so will
shorten engine life.
2. Be sure the low oil pressure warning indi-
cator goes off after starting the engine.
3. Check for a steady flow of water from the
EMU27740
EWM00180
Shifting
WARNING
Before shifting, make sure there are no
swimmers or obstacles in the water near
you.
cooling water pilot hole.
ECM01340
CAUTION:
ECM00220
G If the low oil pressure warning indicator
does not go off after the engine starts,
stop the engine. Otherwise serious en-
gine damage could occur. Check the oil
level and add oil if necessary. Consult
your Yamaha dealer if the cause for the
low oil pressure warning indicator can-
not be found.
G A continuous flow of water from the pilot
hole shows that the water pump is
pumping water through the cooling pas-
sages. If water is not flowing out of the
pilot hole at all times while the engine is
running, overheating and serious dam-
age 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 vice-
versa, first close the throttle so that the en-
gine idles (or runs at low speeds).
EMU27763
Forward (tiller handle and remote
control models)
Tiller control models
1. 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 models
Pull up the neutral interlock trigger (if
equipped) and move the remote control lever
quickly and firmly from neutral to forward.
G If the cooling passage is frozen, it may
take awhile for water to start flowing out
of the pilot hole.
28
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Operation
EMU27820
Stopping engine
Before stopping the engine, first let it cool off
for a few minutes at idle or low speed. Stop-
ping the engine immediately after operating at
high speed is not recommended.
EPMrUo27c851edure
1. Turn the main switch to “
” (off).
ERMeU2v77e84rse (automatic reverse lock and
power trim and tilt models)
EWM00190
WARNING
When operating in reverse, go slowly. Do
not open the throttle more than half. Other-
wise the boat could become unstable,
which could result in loss of control and
an accident.
2. After stopping the engine, disconnect the
fuel line or close the fuel cock if there is a
fuel joint or a fuel cock on the boat.
3. Tighten the air vent screw on the fuel tank
cap (if equipped).
Tiller control models
1. Place the throttle grip in the fully closed
position.
2. Move the gear shift lever quickly and firm-
ly from neutral to reverse.
4. Remove the key if the boat will be left un-
attended.
Remote control models
NOTE:
Pull up the neutral interlock trigger (if
equipped) and move the remote control lever
quickly and firmly from neutral to reverse.
The engine can also be stopped by pulling the
lanyard and removing the clip from the engine
stop switch, then turning the main switch to
“
” (off).
EMU27T861rimming outboard motor
The trim angle of the outboard motor helps
determine the position of the bow of the boat
in the water. Correct trim angle will help im-
prove performance and fuel economy while
reducing strain on the engine. Correct trim an-
gle depends upon the combination of boat,
29
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Operation
EAMdU2j7u88s1 ting trim angle
engine, and propeller. Correct trim is also af-
fected by variables such as the load in the
boat, sea conditions, and running speed.
EWM00740
Power trim and tilt models
EWM00750
WARNING
WARNING
G Be sure all people are clear of the out-
board motor when adjusting the tilt an-
gle, also be careful not to pinch any
body parts between the drive unit and
clamp bracket.
G Use caution when trying a trim position
for the first time. Increase speed gradu-
ally and watch for any signs of instability
or control problems. Improper trim an-
gle can cause loss of control.
Excessive trim for the operating condi-
tions (either trim up or trim down) can
cause boat instability and can make steer-
ing the boat more difficult. This increases
the possibility of an accident. If the boat
begins to feel unstable or is hard to steer,
slow down and/or readjust the trim angle.
G Use the power tilt switch located on the
bottom engine cowling (if equipped)
only when the boat is at a complete stop
with the engine off.
Adjust the outboard motor trim angle using
the power trim and tilt switch.
1
ZMU04258
1. Power trim and tilt switch
1. Trim operating angle
30
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Operation
UP
1
DN
ZMU04231
1. Power trim and tilt switch
Bow Up
Too much trim-out puts the bow of the boat
too high in the water. Performance and econ-
omy are decreased because the hull of the
boat is pushing the water and there is more air
drag. Excessive trim-out can also cause the
propeller to ventilate, which reduces perfor-
mance further, and the boat may “porpoise”
(hop in the water), which could throw the op-
erator and passengers overboard.
To raise the bow (trim-out), press the switch
” (up).
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 for
your boat and operating conditions.
“
“
NOTE:
To adjust the trim angle while the boat is mov-
ing, use the power trim and tilt switch located
on the remote control device or tiller handle, if
equipped.
EAMdU2j7u91s1 ting boat trim
When the boat is on plane, a bow-up attitude
results in less drag, greater stability and effi-
ciency. This is generally when the keel line of
the boat is up about 3 to 5 degrees. With the
bow up, the boat may have a greater tenden-
cy to steer to one side or the other. Compen-
sate for this as you steer. The trim tab can
also be adjusted to help offset this effect.
When the bow of the boat is down, it is easier
to accelerate from a standing start onto plane.
Bow Down
Too much trim-in causes the boat to “plow”
through the water, decreasing fuel economy
and making it hard to increase speed. Operat-
ing with excessive trim-in at higher speeds
also makes the boat unstable. Resistance at
the bow is greatly increased, heightening the
danger of “bow steering” and making opera-
tion difficult and dangerous.
31
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Operation
ECM00241
CAUTION:
G Before tilting the outboard motor, stop
the engine by following the procedure
on page 29. Never tilt the outboard mo-
tor while the engine is running. Severe
damage from overheating can result.
G Do not tilt up the engine by pushing the
tiller handle (if equipped) because this
could break the handle.
EPMrUo28c00e5 dure for tilting up
Power trim and tilt models / power tilt models
1. Place the remote control lever / the gear
shift lever in neutral.
NOTE:
Depending on the type of boat, the outboard
motor trim angle may have little effect on the
trim of the boat when operating.
EMU27933
Tilting up and down
N
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 propel-
ler and casing from damage by collision with
obstructions, and also to reduce salt corro-
sion.
EWM00220
ZMU03196
WARNING
Be sure all people are clear of the out-
board motor when tilting up and down,
also be careful not to pinch any body parts
between the drive unit and engine bracket.
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 outboard
motor has tilted up completely.
EWM00250
WARNING
Leaking fuel is a fire hazard. If there is a
fuel joint on the outboard motor, discon-
nect the fuel line or close the fuel cock if
the engine will be tilted for more than a few
minutes. Otherwise fuel may leak.
32
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Operation
ECM00250
UP
CAUTION:
Be sure to retract the trim rods completely
during mooring. This protects the rods
from marine growth and corrosion which
could damage the power trim and tilt
mechanism.
EPMrUo28c05e3 dure for tilting down
ZMU04232
Power trim and tilt models / power tilt models
1. Push the power tilt / power trim and tilt
switch “ ” (up) until the outboard motor
is supported by the tilt rod and the tilt sup-
port lever / tilt support knob becomes
free.
4. Push the tilt support knob into the clamp
bracket or pull the tilt support lever toward
you to support the engine.
2. Release the tilt support lever or pull out
the tilt support knob.
EWM00260
WARNING
After tilting the outboard motor, be sure to
support it with the tilt support knob or tilt
support lever. Otherwise the outboard mo-
tor could fall back down suddenly if oil in
the power trim and tilt unit loses pressure.
3. Push the power tilt / power trim and tilt
switch “ ” (down) to lower the outboard
motor to the desired position.
5. Models equipped with trim rods: Once the
outboard motor is supported with the tilt
support lever, press the power trim and
tilt switch “ ” (down) to retract the trim
rods.
UP
DN
DN
ZMU01936
33
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Operation
DN
ZMU04255
EMU28060
2. Slightly tilt the outboard motor up to the
desired position using the power trim / tilt
switch.
Cruising in shallow water
The outboard motor can be tilted up partially
to allow operation in shallow water.
EPMoU2w809e0 r trim and tilt models / power tilt
models
The outboard motor can be tilted up partially
to allow operation in shallow water.
EWM00660
WARNING
G Place the gear shift in neutral before set-
ting up for shallow water cruising.
G Return the outboard motor to its normal
position as soon as the boat is back in
deeper water.
3. To return the outboard motor to the nor-
mal running position, press the power
trim / tilt switch and slowly tilt the out-
ECM00260
board motor down.
EMU28190
CAUTION:
Do not tilt the outboard motor up so that
the cooling water inlet on the lower unit is
above the surface of the water when set-
ting up for and cruising in shallow water.
Otherwise severe damage from overheat-
ing can result.
Cruising in other conditions
Cruising in salt water
After operating in salt water, wash out the
cooling water passages with fresh water to
prevent them from becoming clogged with salt
deposits.
EMU28184
NOTE:
Procedure for power trim and tilt / power
tilt models
1. Place the gear shift lever in neutral.
For cooling system flushing instructions, see
page 37.
34
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Operation
Cruising in turbid water
Yamaha strongly recommends that you use
the optional chromium-plated water pump kit
if you use the outboard motor in turbid (mud-
dy) water conditions.
35
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Maintenance
EMU28216
Valve clearance (cold engine) IN:
Specifications
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
Dimension:
Overall length:
817 mm (32.2 in)
Overall width:
Min. marine cranking amps (MCA/ABYC):
502.0 A
479 mm (18.9 in)
Overall height L:
Min. reserve capacity (RC/SAE):
124 minutes
Alternator output for battery DC:
25.0 A
Drive unit:
Gear positions:
Forward-neutral-reverse
Gear ratio:
2.31(30/13)
Trim and tilt system:
Power trim and tilt
Propeller mark:
K
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Min. pump octane:
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:
86
Recommended engine oil:
4-stroke outboard motor oil
Engine oil grade API:
API SE, SF, SG, SH, SJ
Engine oil type SAE:
SAE10W30 or SAE10W40
Lubrication:
4-stroke L
Displacement:
Wet sump
1596.0 cm³ (97.39 cu.in)
Engine oil quantity (excluding oil filter):
4.3 L (4.55 US qt) (3.78 Imp.qt)
Recommended gear oil:
Hypoid gear oil SAE#90
Gear oil quantity:
670.0 cm³ (22.65 US oz) (23.63 Imp.oz)
Tightening torque for engine:
Spark plug:
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
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
Propeller nut:
Starting system:
Electric
Starting carburetion system:
Electronic fuel injection
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)
36
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Maintenance
EMU28222
ESMtUo30r06i1ng outboard motor
Transporting and storing
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 ser-
viced by an authorized Yamaha dealer prior to
storage. However, you, the owner, with a min-
imum of tools, can perform the following pro-
outboard motor
EWM00690
WARNING
G Leaking fuel is a fire hazard. When trans-
porting and storing the outboard motor,
close the air vent screw and fuel cock to
prevent fuel from leaking.
G USE CARE when transporting fuel tank,
whether in a boat or car.
cedures.
ECM01360
G DO NOT fill fuel container to maximum
capacity. Gasoline will expand consider-
ably as it warms up and can build up
pressure in the fuel container. This can
cause fuel leakage and a potential fire
hazard.
CAUTION:
G To prevent problems which can be
caused by oil entering the cylinder from
the sump, keep the outboard motor in
the attitude shown when transporting
and storing it. Do not store or transport
the outboard motor on its side (not up-
right).
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.
G 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.
G Store the outboard motor in a dry, well-
ventilated place, not in direct sunlight.
ECM00660
CAUTION:
Do not use the tilt support lever or knob
when trailering the boat. The outboard mo-
tor could shake loose from the tilt support
and fall. If the motor cannot be trailered in
the normal running position, use an addi-
tional 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 posi-
tion using a motor support device such as a
transom saver bar. Consult your Yamaha
dealer for further details.
ZMU03659
37
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Maintenance
EPMrUo28c30e1 dure
EMU30001
Flushing with the flushing attachment
1. Wash the outboard motor body using
fresh water. For further information, see
page 40.
2. Fill the fuel tank with fresh fuel and add
one ounce of “Yamaha Fuel Conditioner
and Stabilizer” (Part No. LUB-FUELC-12-
00) to each gallon of fuel.
1. Flushing attachment
NOTE:
5. Cooling system flushing is essential to
prevent the cooling system from clogging
up with salt, sand, or dirt. In addition, fog-
ging/lubricating of the engine is mandato-
ry to prevent excessive engine damage
due to rust. Perform the flushing and fog-
The use of “Yamaha Fuel Conditioner and
Stabilizer” eliminates the need to drain the
fuel system. Consult your Yamaha dealer or
other qualified mechanic if the fuel system is
to be drained instead.
3. Remove the top cowling and propeller.
4. Install the flushing attachment over the
ging at the same time.
EWM00090
WARNING
cooling water inlet.
ECM00300
G Do not touch or remove electrical parts
when starting or during operation.
G Keep hands, hair, and clothes away from
the flywheel and other rotating parts
while the engine is running.
CAUTION:
Do not run the engine without supplying it
with cooling water. Either the engine water
pump will be damaged or the engine will
be damaged from overheating. Before
starting the engine, be sure to supply wa-
ter to the cooling water passages.
NOTE:
G When using the flushing attachment, main-
tain adequate water pressure and a steady
water flow.
ECM00310
CAUTION:
G If the overheat warning device is activated,
turn the engine off, and consult your
Yamaha dealer.
Avoid running the outboard motor at high
speed while on the flushing attachment,
otherwise overheating could occur.
6. Run the engine at a fast idle for a few
minutes in neutral position while supply-
ing fresh water.
7. Just prior to turning off the engine, quickly
spray “Yamaha Stor-Rite Engine Fogging
Oil” (Part No. LUB-STRRT-12-00) alter-
nately into the intake silencer or the fog-
ging hole of the silencer cover, if
38
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Maintenance
EBMaU2t8t43e0ry care
equipped. When properly done, the en-
gine will smoke excessively and almost
stall.
EWM00330
WARNING
8. Remove the flushing attachment and
wipe 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.
Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is poi-
sonous and highly caustic.
Always follow these preventive measures:
fluid as it can cause severe burns or per-
manent eye injury.
NOTE:
Yamaha dealer.
G Wear protective eye gear when handling
or working near batteries.
EMU28400
Antidote (EXTERNAL):
G SKIN - Flush with water.
Lubrication (except oil injection
models)
G EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
G Drink large quantities of water or milk
followed by milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive hydro-
gen gas; therefore, you should always fol-
low these preventive measures:
G Charge batteries in a well-ventilated ar-
ea.
G Keep batteries away from fire, sparks, or
open flames (for example: welding
equipment, lighted cigarettes, and so
on.)
the spark plug(s) and torque to proper
specification. For information on spark
plug installation, see page 44.
2. Change the gear oil. For instructions, see
page 51. 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.
3. Grease all grease fittings. For further de-
tails, see page 44.
ECMlUe28a42n1 ing and anticorrosion measures
1. Wash down the exterior of the outboard
motor with fresh water and dry off com-
pletely.
2. Spray the outboard motor exterior with
“Yamaha Silicone Protectant” (Part No.
LUB-SILCNE-13-00).
G DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
3. Wax the cowling with a non-abrasive wax
such as “Yamaha Silicone Wax” (Part No.
ACC-11000-15-02).
Batteries vary among manufacturers. There-
fore the following procedures may not always
apply. Consult your battery manufacturer’s in-
structions.
39
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Maintenance
Procedure
3. Garden hose connector
1. Disconnect and remove the battery from
the boat. Always disconnect the black
negative cable first to prevent the risk of
shorting.
2. Clean the battery casing and terminals.
Fill each cell to the upper level with dis-
tilled water.
3. Store the battery on a level surface in a
cool, dry, well-ventilated place out of di-
rect sunlight.
4. Once a month, check the specific gravity
of the electrolyte and recharge as re-
2. Screw the garden hose connector onto a
garden hose which is connected to a
fresh water supply.
3. With the engine off, turn on the water tap
and let the water flush through the cool-
ing passages for about 15 minutes. Turn
off the water and disconnect the garden
hose.
4. When flushing is complete, reinstall the
garden hose connector on the fitting on
the bottom cowling. Tighten the connec-
tor securely.
ECM00540
quired to prolong battery life.
EMU28440
CAUTION:
Flushing power unit
Do not leave the garden hose connector
loose on the bottom cowling fitting or let
the hose hang free during normal opera-
tion. Water will leak out of the connector
instead of cooling the engine, which can
connector is tightened securely on the fit-
ting after flushing the engine.
Perform this procedure right after operation
for the most thorough flushing.
1. After shutting off the engine, unscrew the
garden hose connector from the fitting on
the bottom cowling.
NOTE:
G When flushing the engine with the boat in
the water, tilting up the outboard motor until
it is completely out of the water will achieve
better results.
G For cooling system flushing instructions,
see page 37.
ECMlUe28a45n0 ing the outboard motor
After use, wash the exterior of the outboard
motor with fresh water. Flush the cooling sys-
tem with fresh water.
1. Fitting
2. Garden hose
40
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Maintenance
A service manual is available for purchase
through your Yamaha dealer for owners who
have the mechanical skills, tools, and other
equipment necessary to perform mainte-
nance not covered by this owner’s manual.
ERMeU2p85l1a0 cement parts
If replacement parts are necessary, use only
genuine Yamaha parts or parts of the same
type 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. Yamaha
genuine parts and accessories are available
from your Yamaha dealer.
ZMU04265
NOTE:
For cooling system flushing instructions, see
page 37.
ECMhU2e84c60king painted surface of motor
Check the motor for scratches, nicks, or flak-
ing paint. Areas with damaged paint are more
likely to corrode. If necessary, clean and paint
the areas. A touch-up paint is available from
your Yamaha dealer.
EMU28485 Periodic maintenance
EWM01070
WARNING
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If you or the owner is not famil-
iar with machine servicing, this work
should be done by your Yamaha dealer or
other qualified mechanic.
Maintenance, replacement, or repair of the
emission control devices and systems
may be performed by any marine engine
repair establishment or individual. All war-
ranty repairs, however, including those to
the emission control system, must be per-
formed by an authorized Yamaha marine
dealership.
41
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Maintenance
EMU30560
Maintenance chart
NOTE:
G Refer to the sections in this chapter for explanations of each owner-specific action.
G The maintenance cycle on these charts assume usage of 200 hours per year. Maintenance
frequency should be adjusted according to usage conditions.
G Disassembly or repairs may be necessary depending on the outcome of maintenance
checks.
G Expendable or consumable parts and lubricants will lose their effectiveness over time and
through normal usage regardless of the warranty period.
The “ ” symbol indicates the check-ups which you may carry out yourself.
The “ ” symbol indicates work to be carried out by your Yamaha dealer.
Initial
Every
Item
Actions
10 hours 50 hours 100 hours 200 hours
(1 month) (3 months) (6 months) (1 year)
Inspection / replace-
ment
Anode(s) (external)
Inspection / replace-
ment
Anode(s) (internal)
Battery
Inspection / charging
Cooling water passag-
es
Cleaning
Cowling clamp
Inspection
Fuel filter (can be dis-
assembled)
Inspection / cleaning
Fuel system
Gear oil
Inspection
Change
Greasing points
Greasing
Idling speed (EFI mod-
els)
Inspection / adjustment
PCV (Pressure Con-
trol Valve)
Inspection
Inspection
Power trim and tilt unit
Inspection / replace-
ment
Propeller and cotter pin
Shift link / shift cable
Thermostat
Inspection / adjustment
Inspection
Throttle link / throttle
cable / throttle pick-up
timing
Inspection / adjustment
Inspection
Water pump
42
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Maintenance
Initial
Every
Item
Actions
10 hours 50 hours 100 hours 200 hours
(1 month) (3 months) (6 months) (1 year)
Engine oil
Inspection / change
Change
Oil filter (cartridge)
Cleaning / adjustment /
replacement
Inspection / replace-
ment
Spark plug(s)
Timing belt
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean
water after each use.
EMU28871
Maintenance chart (additional)
Every
Item
Actions
Replacement
Inspection / adjustment
500 hours (2.5 years)
1000 hours (5 years)
Timing belt
Valve clearance
(DOHC)
EMU28910
NOTE:
When using lead or high-sulfur gasoline, inspecting valve clearance may be required more fre-
quently than every 500 hours.
43
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Maintenance
EMU28931
Greasing
Yamaha marine grease (Water resistant grease)
ZMU04266
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 ex-
cessive, or if carbon and other deposits are
excessive, you should replace the spark plug
with another of the correct type.
ECMlUe28a95n1 ing and adjusting spark plug
EWM00560
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.
Standard spark plug:
LFR5A-11
The spark plug is an important engine compo-
nent 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 di-
agnose any problems yourself. Instead, take
Before fitting the spark plug, measure the
electrode gap with a wire thickness gauge;
adjust the gap to specification if necessary.
44
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Maintenance
G Check for fuel leakage regularly.
G If any fuel leakage is found, the fuel sys-
tem must be repaired by a qualified me-
chanic. Improper repairs can make the
outboard unsafe to operate.
Check the fuel lines for leaks, crack, or mal-
function. If a problem is found, your Yamaha
dealer or other qualified mechanic should re-
pair it immediately.
1. Spark plug gap
2. Spark plug I.D. mark (NGK)
Spark plug gap:
1.0–1.1 mm (0.039–0.043 in)
When fitting the plug, always clean the gasket
surface and use a new gasket. Wipe off any
dirt from the threads and screw in the spark
plug to the correct torque.
Spark plug torque:
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
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 finger-
tight. Have the spark plug adjusted to the cor-
rect torque as soon as possible with a torque-
wrench.
Checkpoints
ECMhU2e89c62king fuel system
G Fuel system parts leakage
G Fuel line joint leakage
G Fuel line cracks or other damage
G Fuel connector leakage
EWM00060
WARNING
Gasoline and its vapors are highly flam-
mable and explosive. Keep away from
sparks, cigarettes, flames, or other sourc-
es of ignition.
EInMUs28p98e0 cting fuel filter
EWM00310
WARNING
Gasoline is highly flammable, and its va-
pors are flammable and explosive.
EWM00910
WARNING
Leaking fuel can result in fire or explosion.
45
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Maintenance
G If you have any question about properly
doing this procedure, consult your
Yamaha dealer.
sary. If any water is found in the fuel, the
Yamaha portable fuel tank or other fuel
tanks should be checked and cleaned.
G Do not perform this procedure on a hot 3. Reinstall the filter element in the cup.
or running engine. Allow the engine to
cool.
G There will be fuel in the fuel filter. Keep
Make sure the O-ring is in proper position
in the cup. Firmly screw the cup onto the
filter housing.
away from sparks, cigarettes, flames or 4. Attach the filter assembly to the bracket.
other sources of ignition.
G This procedure will allow some fuel to
spill. Catch fuel in a rag. Wipe up any
4
2
spilled fuel immediately.
G The fuel filter must be reassembled
carefully with the O-ring, filter cup, and
hoses in place. Improper assembly or
replacement could result in a fuel leak,
which could result in a fire or explosion
hazard.
3
5
1
ZMU04269
1. Filter cup
2. Filter element
3. O-ring
ECMlUe30a64n0 ing fuel filter
4. Filter housing
5. Float
NOTE:
If any water is in the fuel, the float will rise. If
so, remove the cup and drain the water.
5. Run the engine and check the filter and
lines for leaks.
1. Unscrew the filter cup, catching any
spilled fuel in a rag.
EInMUs29p04e0 cting idling speed
EWM00450
WARNING
G Do not touch or remove electrical parts
when starting or during operation.
G Keep hands, hair, and clothes away from
the flywheel and other rotating parts
while the engine is running.
G 2-hp models: 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.
2. Remove the filter element, and wash it in
solvent. Allow it to dry. Inspect the filter el-
ement and O-ring to make sure they are
in good condition. Replace them if neces-
46
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Maintenance
ECM00490
ECM00970
CAUTION:
CAUTION:
This procedure must be performed while G Do not overfill the oil, and be sure the
the outboard motor is in the water. A flush-
ing attachment or test tank can be used.
outboard motor is upright (not tilted)
when checking and changing the engine
oil.
G If the oil level is above the upper level
mark, drain until the level meets the
specified capacity. Overfilling the oil
could cause leakage or damage.
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.
ECM01240
1. Start the engine and allow it to warm up
fully in neutral until it is running smoothly.
2-hp model: Warm the engine with the
throttle in the start position or less. If the
outboard is mounted on a boat, be sure
the boat is tightly moored.
CAUTION:
Change the engine oil after the first 10
hours of operation, and every 100 hours or
at 6-month intervals thereafter. Otherwise
the engine will wear quickly.
NOTE:
NOTE:
Correct idling speed inspection is only possi-
ble if the engine is fully warmed up. If not
warmed up fully, the idle speed will measure
higher than normal. If you have difficulty veri-
fying the idle speed, or the idle speed requires
adjustment, consult a Yamaha dealer or other
qualified mechanic.
Change the engine oil when the oil is still
warm.
1. Put the outboard motor in an upright po-
sition (not tilted).
2. Verify whether the idle speed is set to
specification. For idle speed specifica-
tions, see page 36.
ECMhU2a90n73ging engine oil
EWM00760
WARNING
ZMU04270
G Avoid draining the engine oil immediate-
ly after stopping the engine. The oil is
hot and should be handled with care to
avoid burns.
G Be sure the outboard motor is securely
fastened to the transom or a stable
stand.
2. Prepare a suitable container that holds a
larger amount than the engine oil capaci-
ty. Loosen and remove the drain screw
while holding the container under the
drain hole. Then remove the oil filler cap.
Let the oil drain completely. Wipe up any
spilled oil immediately.
47
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Maintenance
1
1
ZMU04271
ZMU04241
1. Oil filler cap
1. Drain screw
5. Start the engine and watch to make sure
the low oil pressure warning indicator (if
equipped) turns off. Make sure that there
3. Put a new gasket on the oil drain screw.
Apply a light coat of oil to the gasket and
install the drain screw.
are no oil leaks.
Drain screw tightening torque:
28.0 Nm (20.7 ft-lb) (2.86 kgf-m)
ECM00680
CAUTION:
If the low oil pressure warning indicator
does not turn off or if there are oil leaks,
stop the engine and find the cause. Con-
tinued operation with a problem could
cause severe engine damage. Consult
your Yamaha dealer if the problem cannot
be located and corrected.
NOTE:
If a torque wrench is not available when you
are installing the drain screw, finger tighten
the screw just until the gasket comes into con-
tact with the surface of the drain hole. Then
tighten 1/4 to 1/2 turn more. Tighten the drain
screw to the correct torque with a torque
wrench as soon as possible.
6. Turn off the engine and wait 3 minutes.
Recheck the oil level using the dipstick to
be sure the level falls between the upper
and lower marks. Fill with oil if it is below
the lower mark, or drain to the specified
level if it is above the upper mark.
4. Add the correct amount of oil through the
filler hole. Install the filler cap.
Recommended engine oil:
4-stroke outboard motor oil
Engine oil quantity (excluding oil filter):
4.3 L (4.55 US qt) (3.78 Imp.qt)
1. Lower level mark
48
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Maintenance
2. Oil dipstick
3. Upper level mark
NOTE:
If any leaks are found, consult your Yamaha
dealer.
7. Dispose of used oil according to local
regulations.
ECMhU2e91c61king power trim and tilt system
NOTE:
EWM00430
G For more information on the disposal of
used oil, consult your Yamaha dealer.
G Change the oil more often when operating
the engine under adverse conditions such
as extended trolling.
WARNING
G Never get under the lower unit while it is
tilted, even when the tilt support lever is
locked. Severe injury could occur if the
outboard motor accidentally falls.
G Make sure no one is under the outboard
motor before performing this test.
ECMhU2e91c12king wiring and connectors
G Check that each grounding wire is properly
secured.
G Check that each connector is engaged se-
curely.
1. Check the power trim and tilt unit for any
sign of oil leaks.
1
ZMU04244
ZMU04243
1. Tilt rod
EEMxU2h91a20ust leakage
2. Operate each of the power trim and tilt
switches / the power tilt switches on the
remote control and engine bottom cowl-
ing (if equipped) to check that all switches
work.
Start the engine and check that no exhaust
leaks from the joints between the exhaust
cover, cylinder head, and body cylinder.
EMU29130
Water leakage
3. Tilt the outboard motor up and check that
the trim and tilt rod is pushed out com-
pletely.
4. Check that the trim and tilt rod is free of
corrosion or other flaws.
Start the engine and check that no water
leaks from the joints between the exhaust
cover, cylinder head, and body cylinder.
EEMnU2g91i4n0 e oil leakage
Check for oil leaks on the around the engine.
5. Tilt the outboard motor down. Check that
the trim and tilt rod operates smoothly.
49
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Maintenance
NOTE:
Consult your Yamaha dealer if any operation
is abnormal.
ECMhU2e91c71king propeller
EWM00321
WARNING
You could be seriously injured if the en-
gine accidentally starts when you are near
the propeller.
G Before inspecting, removing, or install-
ing the propeller, remove the spark plug
caps from the spark plugs. Also, place
the shift control in neutral, turn the main
ZMU01897
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 splines / shear pin for wear or
damage.
G Check for fish line tangled around the pro-
peller shaft.
switch to “
” (off) and remove the key,
and remove the lanyard from the engine
stop switch. Turn off the battery cut-off
switch if your boat has one.
G Do not use your hand to hold the propel-
ler when loosening or tightening the
propeller nut. Put a wood block between
the anti-cavitation plate and the propel-
ler to prevent the propeller from turning.
G Check the propeller shaft oil seal for dam-
age.
NOTE:
ZMU04262
If the shear pin equipped: it is designed to
break if the propeller hits a hard underwater
obstacle to help protect the propeller and
drive mechanism. The propeller will then spin
freely on the shaft. If this happens, the shear
pin must be replaced.
50
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Maintenance
ERMeU2m919o3 ving the propeller
1. 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. Install the spacer (if equipped) and the
washer. Tighten the propeller nut to the
specified torque.
4. Align the propeller nut with the propeller
shaft hole. Insert a new cotter pin in the
hole and bend the cotter pin ends.
1
3
6
2
4
5
ZMU03228
ZMU02063
1. Cotter pin
2. Propeller nut
3. Washer
4. Spacer
5. Propeller
6. Thrust washer
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 it
with the hole.
3. Remove the propeller and thrust washer.
ECMhU2a92n81ging gear oil
EInMUs29t2a30lling the propeller
EWM00800
ECM00340
CAUTION:
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.
G Never get under the lower unit while it is
tilted, even when the tilt support lever or
knob is locked. Severe injury could oc-
cur if the outboard motor accidentally
falls.
G Be sure to install the thrust washer be-
fore installing the propeller, otherwise
the lower case and propeller boss could
be damaged.
G Be sure to use a new cotter pin and bend
the ends over securely. Otherwise the
propeller could come off during opera-
tion and be lost.
1. Apply Yamaha marine grease or a corro-
sion resistant grease to the propeller
shaft.
2. Install the spacer(if equipped), thrust
washer, and propeller on the propeller
shaft.
1. Tilt the outboard motor so that the gear oil
drain screw is at the lowest point possi-
ble.
2. Place a suitable container under the gear
case.
3. Remove the gear oil drain screw.
51
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Maintenance
2
1
ZMU03273
ZMU03274
1. Gear oil drain screw
2. Oil level plug
6. When the oil begins to flow out of the oil
level plug hole, insert and tighten the oil
level plug.
7. Insert and tighten the gear oil drain
screw.
EInMUs29p31e2 cting 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
NOTE:
If the magnetic gear oil drain screw equipped:
remove all metal particles from the screw be-
fore installing it.
4. Remove the oil level plug to allow the oil
to drain completely.
ECM00710
CAUTION:
Inspect the used oil after it has been
drained. If the oil is milky, water is getting
into the gear case which can cause gear
damage. Consult a Yamaha dealer for re-
pair of the lower unit seals.
anodes.
ECM00720
CAUTION:
Do not paint anodes, as this would render
them ineffective.
NOTE:
NOTE:
For disposal of used oil consult your Yamaha
dealer.
Inspect ground leads attached to external an-
odes on equipped models. Consult a Yamaha
dealer for inspection and replacement of inter-
nal anodes attached to the power unit.
5. With the outboard motor in a vertical po-
sition, 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:
670.0 cm³ (22.65 US oz) (23.63
Imp.oz)
52
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Maintenance
G Drink large quantities of water or milk
followed by milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive hydro-
gen gas; therefore, you should always fol-
low these preventive measures:
G Charge batteries in a well-ventilated ar-
ea.
G Keep batteries away from fire, sparks, or
open flames (for example: welding
equipment, lighted cigarettes, and so
on.)
G DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTIC
FLUID OUT OF REACH OF CHILDREN.
ECM00360
CAUTION:
ZMU04245
G A poorly maintained battery will quickly
deteriorate.
G Ordinary tap water contains minerals
harmful to a battery, and should not be
used for topping up.
ECMhU2e93c20king battery (for electric start
models)
EWM00330
WARNING
Battery electrolytic fluid is dangerous; it
contains sulfuric acid and therefore is poi-
sonous and highly caustic.
Always follow these preventive measures:
G Avoid bodily contact with electrolytic
fluid as it can cause severe burns or per-
manent eye injury.
1. Check the electrolyte level at least once a
month. Fill to the manufacturer’s recom-
mended level when necessary. Top up
only with distilled water (or pure de-ion-
ized water suitable to use in batteries).
G Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
G SKIN - Flush with water.
G EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
53
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Maintenance
2. Always keep the battery in a good state of Connect the red battery cable to the POSI-
charge. Installing a voltmeter will help TIVE (+) terminal first. Then connect the black
you monitor your battery. If you will not battery cable to the NEGATIVE (-) terminal.
use the boat for a month or more, remove
the battery from the boat and store it in a
cool, dark place. Completely recharge
the battery before using it.
3. If the battery will be stored for longer than
a month, check the specific gravity of the
fluid at least once a month and recharge
the battery when it is low.
NOTE:
Consult a Yamaha dealer when charging or
re-charging batteries.
1. Red cable
2. Black cable
3. Battery
ECMoU2n933n1ecting the battery
EDMiUs29c37o0 nnecting the battery
Disconnect the BLACK cable from the NEGA-
TIVE (-) terminal first. Then disconnect the
RED cable from the POSITIVE (+) terminal.
ECMhU2e93c90king top cowling
Check the fitting of the top cowling by pushing
it with both hands. If it is loose have it repaired
by your Yamaha dealer.
EWM00570
WARNING
Mount the battery holder securely in a dry,
well-ventilated, vibration-free location in
the boat. Install a fully charged battery in
the holder.
ECM01121
CAUTION:
G Make sure the main switch (on applica-
ble models) is “
” (off) before working
on the battery.
G Reversal of the battery cables will dam-
age the electrical parts.
G Connect the red battery cable first when
installing the battery and disconnect the
black battery cable first when removing
it. Otherwise, the electrical parts can be
damaged.
G The electrical contacts of the battery
and cables must be clean and properly
connected, or the battery will not start
the engine.
ECMoU2a94t00ing 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 bot-
54
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Maintenance
tom 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.
ZMU04246
55
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Trouble Recovery
EMU29422
Q. Is fuel filter clogged?
A. Clean or replace filter.
Troubleshooting
A problem in the fuel, compression, or ignition
systems can cause poor starting, loss of pow-
er, or other problems. This section describes
basic checks and possible remedies, and cov-
ers 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.
Q. Is starting procedure incorrect?
A. See page 26.
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.
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 spark plug cap(s) fitted incorrectly?
A. Check and re-fit cap(s).
Q. Is ignition wiring damaged or poorly con-
nected?
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires.
Q. Are battery connections loose or corrod-
ed?
A. Tighten battery cables and clean battery
terminals.
Q. Is fuse for electric start relay or electric cir-
cuit blown?
A. Check for cause of electric overload and
repair. Replace fuse with one of correct am-
perage.
Q. Are ignition parts faulty?
A. Have serviced by a Yamaha dealer.
Q. Is engine stop switch lanyard not at-
tached?
A. Attach lanyard.
Q. Are starter components faulty?
A. Have serviced by a Yamaha dealer.
Q. Are engine inner parts damaged?
A. Have serviced by a Yamaha dealer.
Q. Is shift lever in gear?
A. Shift to neutral.
Engine idles irregularly or stalls.
Q. Are spark plug(s) fouled or of incorrect
type?
A. Inspect spark plug(s). Clean or replace with
recommended type.
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 system obstructed?
56
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Trouble Recovery
A. Check for pinched or kinked fuel line or oth- A. Return to home position.
er obstructions in fuel system.
Q. Is motor angle too high?
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
A. Return to normal operating position.
Q. Is carburetor clogged?
Q. Is fuel filter clogged?
A. Clean or replace filter.
A. Have serviced by a Yamaha dealer.
Q. Is fuel joint connection incorrect?
A. Connect correctly.
Q. Have ignition parts failed?
A. Have serviced by a Yamaha dealer.
Q. Is throttle valve adjustment incorrect?
A. Have serviced by a Yamaha dealer.
Q. Has warning system activated?
A. Find and correct cause of warning.
Q. Is battery cable disconnected?
A. Connect securely.
Q. Is spark plug gap incorrect?
A. Inspect and adjust as specified.
Warning buzzer sounds or indicator lights.
Q. Is ignition wiring damaged or poorly con- Q. Is cooling system clogged?
nected?
A. Check water intake for restriction.
A. Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken Q. Is engine oil level low?
wires.
A. Fill oil tank with specified engine oil.
Q. Is specified engine oil not being used?
A. Check and replace oil as specified.
Q. Is heat range of spark plug incorrect?
A. Inspect spark plug and replace it with rec-
ommended type.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Are carburetor adjustments incorrect?
A. Have serviced by a Yamaha dealer.
Q. Is engine oil contaminated or deteriorated?
A. Replace oil with fresh, specified type.
Q. Is fuel pump damaged?
A. Have serviced by a Yamaha dealer.
Q. Is oil filter clogged?
A. Have serviced by a Yamaha dealer.
Q. Is air vent screw on fuel tank closed?
A. Open air vent screw.
Q. Has oil feed/injection pump malfunc-
tioned?
Q. Is choke knob pulled out?
57
A. Have serviced by a Yamaha dealer.
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Trouble Recovery
Q. Is load on boat improperly distributed?
A. Remove foreign matter and clean lower
A. Distribute load to place boat on an even unit.
plane.
Q. Is fuel system obstructed?
Q. Is water pump or thermostat faulty?
A. Have serviced by a Yamaha dealer.
A. Check for pinched or kinked fuel line or oth-
er obstructions in fuel system.
Q. Is there excess water in fuel filter cup?
A. Drain filter cup.
Q. Is fuel filter clogged?
A. Clean or replace filter.
Engine power loss.
Q. Is propeller damaged?
Q. Is fuel contaminated or stale?
A. Fill tank with clean, fresh fuel.
A. Have propeller repaired or replaced.
Q. Is spark plug gap incorrect?
Q. Is propeller pitch or diameter incorrect?
A. Install correct propeller to operate outboard
at its recommended speed (r/min) range.
A. Inspect and adjust as specified.
Q. Is ignition wiring damaged or poorly con-
nected?
Q. Is trim angle incorrect?
A. Check wires for wear or breaks. Tighten all
A. Adjust trim angle to achieve most efficient loose connections. Replace worn or broken
operation. wires.
Q. Is motor mounted at incorrect height on Q. Have ignition parts failed?
transom?
A. Have serviced by a Yamaha dealer.
A. Have motor adjusted to proper transom
height.
Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Has warning system activated?
A. Find and correct cause of warning.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer.
Q. Is boat bottom fouled with marine growth?
A. Clean boat bottom.
Q. Is air vent screw closed?
A. Open the air vent screw.
Q. Are spark plug(s) fouled or of incorrect
type?
Q. Is fuel pump damaged?
A. Inspect spark plug(s). Clean or replace with A. Have serviced by a Yamaha dealer.
recommended type.
Q. Is fuel joint connection incorrect?
Q. Are weeds or other foreign matter tangled A. Connect correctly.
on gear housing?
Q. Is heat range of spark plug incorrect?
58
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Trouble Recovery
A. Inspect spark plug and replace it with rec-
ommended type.
Q. Is high pressure fuel pump drive belt bro-
ken?
A. Have serviced by a Yamaha dealer.
Q. Is engine not responding properly to shift
lever position?
A. Have serviced by a Yamaha dealer.
1. Stop the engine immediately.
2. Inspect the control system and all compo-
nents for damage. Also inspect the boat
for damage.
Engine vibrates excessively.
Q. Is propeller damaged?
A. Have propeller repaired or replaced.
3. Whether damage is found or not, return
to the nearest harbor slowly and careful-
ly.
Q. Is propeller shaft damaged?
A. Have serviced by a Yamaha dealer.
4. Have a Yamaha dealer inspect the out-
board motor before operating it again.
ERMeU2p94l7a1 cing fuse
If a fuse has blown, remove the electrical cov-
er, open the fuse holder and remove the fuse
with a fuse puller (if equipped). Replace it with
Q. Are weeds or other foreign matter tangled
on propeller?
A. Remove and clean propeller.
Q. Is motor mounting bolt loose?
A. Tighten bolt.
a spare one of the proper amperage.
EWM00630
Q. Is steering pivot loose or damaged?
A. Tighten or have serviced by a Yamaha
dealer.
WARNING
Be sure to use the specified fuse. An in-
correct fuse or a piece of wire could allow
excessive current flow. This could cause
electric system damage and a fire hazard.
ETMeU29m432porary action in emergency
EImMU2p94a40ct damage
NOTE:
EWM00870
Consult your Yamaha dealer if the new fuse
immediately blows again.
WARNING
The outboard motor can be seriously dam-
aged by a collision while operating or
trailering. 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.
59
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Trouble Recovery
ZMU04249
1
1. Manual valve screw
2. Put the engine in the desired position,
then tighten the manual valve screw by
turning it clockwise.
ESMtUa29r5t40er will not operate
If the starter mechanism does not operate
(the engine cannot be cranked with the start-
er), the engine can be started manually with
an emergency starter rope. However, the en-
gine cannot be started manually if the battery
voltage is low. If the battery is discharged to 9
volts or below, the electric fuel pump will not
1. Electrical cover
2. Fuse puller
3. Fuse holder
4. Starter relay fuse (30 A)
5. Rectifier Regulator (Main) fuse (20 A)
6. Main switch / trim switch fuse (20 A)
operate.
EWM01020
WARNING
7. Engine control unit / ignition coil / electric
fuel pump / fuel injector / ISC (idle speed
control) fuse (20 A)
G Use this procedure only in an emergen-
cy and only to return to port for repairs.
G When the emergency starter rope is
used to start the engine, the start-in-
gear protection device does not operate.
Make sure the remote control lever is in
neutral. Otherwise the boat could unex-
pectedly start to move, which could re-
sult in an accident.
8. Spare fuse (20 A, 30 A)
EPMoU2w952e0 r trim and tilt will not operate
If the engine cannot be tilted up or down with
the power trim and tilt/ the power tilt because
of a discharged battery or a failure with the
power trim and tilt unit/the power tilt, the en-
gine can be tilted manually.
G Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg while operating.
1. Loosen the manual valve screw by turn-
ing it counterclockwise until it stops.
G Do not attach the lanyard to clothing
that could tear loose. Do not route the
cord where it could become entangled,
preventing it from functioning.
60
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Trouble Recovery
G Avoid accidentally pulling the lanyard 3. Prepare the engine for starting. For fur-
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.
ther information, see page 26. Be sure
the engine is in neutral and that the en-
gine stop switch lanyard lock plate is at-
tached to the engine stop switch. The
main switch must be “ ” (on).
G Be sure no one is standing behind you
when pulling the starter rope. It could
whip behind you and injure someone.
G An unguarded, rotating flywheel is very
dangerous. Keep loose clothing and
other objects away when starting the en-
gine. Use the emergency starter rope
only as instructed. Do not touch the fly-
wheel or other moving parts when the
engine is running. Do not install the
starter mechanism or top cowling after
the engine is running.
G 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.
ZMU02334
4. Insert the knotted end of the emergency
starter rope into the notch in the flywheel
rotor 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.
EEMmU30e65r0gency starting engine
1. Remove the top cowling.
2. Lift up the rear of flywheel cover and pull
it forward to remove it.
ZMU04272
61
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Trouble Recovery
EMU29760
Treatment of submerged motor
If the outboard motor is submerged, immedi-
ately take it to a Yamaha dealer. Otherwise
some corrosion may begin almost immediate-
ly.
If you cannot immediately take the outboard
motor to a Yamaha dealer, follow the proce-
dure below in order to minimize engine dam-
age.
EPMrUo29c79e0 dure
1. 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 any
water, 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 the
intake manifold and spark plug holes
while cranking with the emergency starter
rope.
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.
62
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Consumer information
64
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Consumer information
66
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YAMAHA MOTOR CORPORATION, USA
Printed in Japan
May 2004–2.0 × 1 CR
Printed on recycled paper
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