f6c f8c t8c Owner S Manual Yamaha

Download as pdf or txt
Download as pdf or txt
You are on page 1of 129

F6C

F8C
T8C

YAMAHA MOTOR CORPORATION, USA


Printed in Japan
OWNER’S MANUAL
March 2003–3.0 × 1 CR
68T-28199-15
(F6AMH, F8CMH, FT8DEHP, FT8DWH, FT8DEP)
U.S.A.Edition
(E)
LIT-18626-05-31
Printed on recycled paper
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

E
EMU01449

TO THE OWNER

Thank you for choosing a Yamaha outboard CAUTION:


motor. This Owner’s manual contains infor-
A CAUTION indicates special precau-
mation needed for proper operation, mainte-
tions that must be taken to avoid damage
nance and care. A thorough understanding
to the outboard motor.
of these simple instructions will help you @

obtain maximum enjoyment from your new NOTE:


Yamaha. If you have any question about the
@

A NOTE provides key information to make


operation or maintenance of your outboard procedures easier or clearer.
motor, please consult a Yamaha dealer. @

Yamaha continually seeks advancements in


In this Owner’s Manual particularly impor- product design and quality. Therefore, while
tant information is distinguished in the fol- this manual contains the most current prod-
lowing ways. uct information available at the time of print-
ing, there may be minor discrepancies
The Safety Alert Symbol means between your machine and this manual. If
ATTENTION! BECOME ALERT! there is any question concerning this man-
YOUR SAFETY IS INVOLVED! ual, please consult your Yamaha dealer.

WARNING NOTE:
@ @

Failure to follow WARNING instructions The F8MH, T8PR and their standard acces-
could result in severe injury or death to sories are used as a base for the explana-
the machine operator, a bystander, or a tions and illustrations in this manual.
person inspecting or repairing the out- Therefore, some items may not apply to
board motor. every model.
@ @

EMU01446

F6C, F8C, T8C


OWNER’S MANUAL
©2003 by Yamaha Motor Corporation, USA
1st Edition, February 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in Japan
P/N LIT-18626-05-31
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

EMU00003

CONTENTS E

GENERAL INFORMATION 1

BASIC COMPONENTS 2

OPERATION 3

MAINTENANCE 4

TROUBLE RECOVERY
5

INDEX 6
READ THIS OWNER’S MANUAL CAREFULLY
BEFORE OPERATING YOUR OUTBOARD MOTOR.
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

EMU00004

Chapter 1
GENERAL
1
INFORMATION
IDENTIFICATION NUMBERS
RECORD .....................................................1-1
Outboard motor serial number ................1-1
Key number .............................................1-1

EMISSION CONTROL INFORMATION ....1-2


North american models............................1-2
Star labels.................................................1-3

SAFETY INFORMATION ...........................1-4

IMPORTANT LABELS ...............................1-6


Warning labels .........................................1-6
Caution labels...........................................1-6

BASIC BOATING RULES


(Rules of the road).....................................1-7
Steering and sailing rules and sound
signals ......................................................1-7
Rules when encountering vessels...........1-8
Other special situations............................1-9

FUELING INSTRUCTIONS......................1-11
Gasoline .................................................1-12

ENGINE OIL..............................................1-13

BATTERY REQUIREMENT .....................1-14

PROPELLER SELECTION ......................1-15

START-IN-GEAR PROTECTION ............1-16


U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

E
EMU00005

IDENTIFICATION NUMBERS
RECORD
EMU00007

OUTBOARD MOTOR SERIAL


NUMBER

The outboard motor serial number is


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

1 Outboard motor serial number

EMU00008

KEY NUMBER

If a main key switch is equipped with the


motor, the key identification number is
stamped on your key as shown in the illus-
tration. Record this number in the space
provided for reference in case you need a
new key.

1 Key number
1-1
U68T15.book Page 2 Thursday, March 20, 2003 11:28 AM

E
EMU01385

EMISSION CONTROL
INFORMATION
EMU01444

NORTH AMERICAN MODELS


This engine conforms to U.S. Environmental
Protection Agency (EPA) regulations for
marine SI engines. See the label affixed to
your engine for details.

Approval label of Emission control certif-


icate
This label is attached to the bottom cowling.

1 Emission control information label

New Technology ; (4-stroke/HPDI) EM

Manufactured date label


This label is attached to the clamp bracket.

2 Manufactured date label

1-2
U68T15.book Page 3 Thursday, March 20, 2003 11:28 AM

E
EMU01389

STAR LABELS
Your outboard motor is labeled with a Cali-
fornia Air Resources Board (CARB) star
label. See below for a description of your
particular label.

1 Star label

One Star - Low Emission


The one-star label identifies engines that
meet the Air Resources Board’s 2001
exhaust emission standards. Engines meet-
ing these standards have 75% lower emis-
sions than conventional carbureted two-
stroke engines. These engines are equiva-
lent to the U.S. EPA’s 2006 standards for
marine engines.

Two Stars - Very Low Emission


The two-star label identifies engines that
meet the Air Resources Board’s 2004
exhaust emission standards. Engines meet-
ing these standards have 20% lower emis-
sions than One Star-Low-Emission engines.

Three Stars - Ultra Low Emission


The three-star label identifies engines that
meet the Air Resources Board’s 2008
exhaust emission standards. Engines meet-
ing these standards have 65% lower emis-
sions than One Star-Low-Emission engines.

1-3
U68T15.book Page 4 Thursday, March 20, 2003 11:28 AM

E
EMU00917
● This product emits exhaust gases which
SAFETY contain carbon monoxide, a colorless,
INFORMATION odorless gas which may cause brain
damage or death when inhaled. Symp-
● Before mounting or operating the out- toms include nausea, dizziness, and
board motor, read this entire manual. drowsiness. Keep cockpit and cabin areas
Reading it should give you an under- well ventilated. Avoid blocking exhaust
standing of the motor and its operation. outlets.
● Check throttle, shift, and steering for
● Before operating the boat, read any
owner’s or operator’s manuals supplied proper operation before starting the
with it and all labels. Be sure you under- engine.
● Attach the engine stop switch lanyard to a
stand each item before operating.
● Do not overpower the boat with this out- secure place on your clothing, or your
board motor. Overpowering the boat arm or leg while operating. If you acciden-
could result in loss of control. The rated tally leave the helm, the lanyard will pull
power of the outboard should be equal to from the switch, stopping the engine.
● Know the marine laws and regulations
or less than the rated horsepower capac-
ity of the boat. If the rated horsepower where you will be boating - and obey
capacity of the boat is unknown, consult them. Refer to the “RULES OF THE
the dealer or boat manufacturer. ROAD” section for basic boating rules.
● Stay informed about the weather. Check
● Do not modify the outboard. Modifications
could make the motor unfit or unsafe to weather forecasts before boating. Avoid
use. boating in hazardous weather.
● Tell someone where you are going: leave
● Never operate after drinking alcohol or
taking drugs. About 50% of all boating a Float Plan with a responsible person.
fatalities involve intoxication. Be sure to cancel the Float Plan when
● Have an approved personal flotation you return.
● Use common sense and good judgment
device (PFD) on board for every occu-
pant. It is a good idea to wear a PFD when boating. Know your abilities, and be
whenever boating. At a minimum, children sure you understand how your boat han-
and non-swimmers should always wear dles under the different boating conditions
PFDs, and everyone should wear PFDs you may encounter. Operate within your
when there are potentially hazardous limits, and the limits of your boat. Always
boating conditions. operate at safe speeds, and keep a care-
● Gasoline is highly flammable, and its ful watch for obstacles and other traffic.
● Always watch carefully for swimmers dur-
vapors are flammable and explosive.
Handle and store gasoline carefully. Make ing the engine operation.
● Stay away from swimming areas.
sure there are no gas fumes or leaking
fuel before starting the engine.

1-4
U68T15.book Page 5 Thursday, March 20, 2003 11:28 AM

E
● When a swimmer is in the water near you
shift into neutral and shut off the engine.
● Be informed about boating safety. Addi-
tional publications and information can be
obtained from many organizations, includ-
ing the following:

United States Coast Guard


Consumer Affairs Staff (G-BC)
Office of Boating, Public, and Consumer
Affairs
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

1-5
U68T15.book Page 6 Thursday, March 20, 2003 11:28 AM

E
EMU00014

IMPORTANT LABELS

WARNING LABELS
1

CAUTION LABELS
3

1-6
U68T15.book Page 7 Thursday, March 20, 2003 11:28 AM

E
EMU00015

BASIC BOATING RULES Stand-on vessel


The vessel with the right-of-way has the duty
(Rules of the road) to continue its course and speed, except to
avoid an immediate collision. When you
Just as there are rules which apply when maintain your direction and speed, the other
you are driving on streets and high ways, vessel will be able to determine how best to
there are waterway rules which apply when avoid you.
you are driving your boat. These rules are
used internationally, and are also enforced Give-way vessel
by the United States Coast Guard and local The vessel which does not have the right-of-
agencies. You should be aware of these way has the duty to take positive and timely
rules, and follow them whenever you action to stay out of the way of the Stand-On
encounter another vessel on the water. vessel. Normally, you should not cross in
front of the vessel with the right-of-way. You
Several sets of rules prevail according to should slow down or change directions
geographic location, but are all basically the briefly and pass behind the other vessel.
same as the International Rules of the You should always move in such a way that
Road. The rules presented here in your the operator of the other vessel can see
Owner’s Manual are condensed, and have what you are doing.
been provided for your convenience only.
Consult your local U.S. Coast Guard Auxil- “The general prudential rule”
iary or Department of Motor Vehicles for a This rule is called Rule 2 in the International
complete set of rules governing the waters Rules and says,
in which you will be using your boat.
‘In obeying and construing these rules
STEERING AND SAILING RULES due regard shall be had to all dangers of
AND SOUND SIGNALS navigation and collision, and to any spe-
Whenever two vessels on the water meet cial circumstances, which may render a
one another, one vessel has the right-of- departure from the above rules neces-
way; it is called the “stand-on” vessel. The sary in order to avoid immediate danger.’
vessel which does not have the right-of-way
is called the “give-way” or “burdened” ves- In other words, follow the standard rules
sel. These rules determine which vessel has except when a collision will occur unless
the right-of-way, and what each vessel both vessels try to avoid each other. If that is
should do. the case, both vessels become “Give-Way”
vessels.

1-7
U68T15.book Page 8 Thursday, March 20, 2003 11:28 AM

E
RULES WHEN ENCOUNTERING avoid an accident. You should keep the
VESSELS other vessel on your port (left) side. This
There are three main situations which you rule doesn’t apply if both of you will clear
may encounter with other vessels which one another if you continue on your set
could lead to a collision unless the Steering course and speed.
Rules are followed:

Meeting
(you are approaching another vessel
head-on)
Crossing
(you are traveling across the other ves-
sel’s path)
Overtaking
(you are passing or being passed by
another vessel) Crossing
When two power driven vessels are crossing
In the following illustration, your boat is in each other’s path close enough to run the
the center. You should give the right-of-way risk of collision, the vessel which has the
to any vessels shown in white area (you are other on the starboard (right) side must keep
the Give-Way vessel). Any vessels in the out of the way of the other. If the other ves-
shaded area must yield to you (they are the sel is on your right, you must keep out of its
Give-Way vessels). Both you and the meet- way; you are the Give-Way vessel. If the
ing vessel must alter course to avoid each other vessel is on your port (left) side,
other. remember that you should maintain course
and direction, provided the other vessel
gives you the right-of-way as it should.

Meeting
If you are meeting another power vessel
head on, and are close enough to run the Overtaking
risk of collision, neither of you has the right- If you are passing another vessel, you are
of-way! Both of you should alter course to the “Give-Way” vessel. This means that the

1-8
U68T15.book Page 9 Thursday, March 20, 2003 11:28 AM

E
other vessel is expected to maintain its 1. When the sailing vessel is overtaking
course and speed. You must stay out of its the power-driven vessel, the power-
way until you are clear of it. Likewise, if driven vessel has the right-of-way.
another vessel is passing you, you should 2. Sailing vessels should keep clear of any
maintain your speed and direction so that fishing vessel.
the other vessel can steer itself around you. 3. In a narrow channel, a sailing vessel
should not hamper the safe passage of
OTHER SPECIAL SITUATIONS a power-driven vessel which can navi-
There are three other rules you should be gate only in such a channel.
aware of when driving your boat around
other vessels. Reading buoys and other markers
The waters of the United states are marked
Narrow channels and bends for safe navigation by the lateral system of
When navigating in narrow channels, you buoyage. Simply put, buoys and markers
should keep to the right when it is safe and have an arrangement of shapes, colors,
practical to do so. If the operator of a power- numbers and lights to show which side of
driven vessel is preparing to go around a the buoy a boater should pass on when nav-
bend that may obstruct the view of other igating in a particular direction. The mark-
water vessels, the operator should sound a ings on these buoys are oriented from the
prolonged blast on the whistle (4 to 6 sec- perspective of being entered from seaward
onds). If another vessel is around the bend, (the boater is going towards the port). This
it too should sound the whistle. Even if no means that red buoys are passed on the
reply is heard, however, the vessel should starboard (right) side when proceeding from
still proceed around the bend with caution. If open water into port, and black buoys are to
you navigate such waters with your boat, port (left) side. When navigating out of port,
you will need to carry a portable air horn, your position with respect to the buoys
available from local marine supply stores. should be reversed; red buoys should be to
port and black buoys to starboard.
Fishing vessel right-of-way Many bodies of water used by boaters are
All vessels which are fishing with nets, lines entirely within the boundaries of a particular
or trawls are considered to be “fishing ves- state. The Uniform State Waterway Marking
sels” under the International Rules. Vessels System has been devised for these waters.
with trolling lines are not considered fishing This system uses buoys and signs with dis-
vessels. Fishing vessels have the right-of- tinctive shapes and colors to show regula-
way regardless of position. Fishing vessels tory or advisory information. These markers
cannot, however, impede the passage of are white with black letters and orange
other vessels in narrow channels. boarders. They signify speed zones,
restricted areas, danger areas, and general
Sailing vessel right-of-way information.
Sailing vessels should normally be given the
right-of-way. The exceptions to this are:

1-9
U68T15.book Page 10 Thursday, March 20, 2003 11:28 AM

E
Remember, markings may vary by geo-
graphic location. Always consult local boat-
ing authorities before driving your boat in
unfamiliar waters.

1-10
U68T15.book Page 11 Thursday, March 20, 2003 11:28 AM

E
EMU00016

FUELING INSTRUCTIONS

WARNING
@

GASOLINE AND ITS VAPORS ARE


HIGHLY FLAMMABLE AND EXPLOSIVE!
● Do not smoke when refueling, and
keep away from sparks, flames, or
other sources of ignition.
● Stop engine before refueling.
● Refuel in a well-ventilated area. Refuel
portable fuel tanks off the boat.
● Take care not to spill gasoline. If gaso-
line spills, wipe it up immediately with
dry rags.
● Do not overfill the fuel tank.
● Tighten the filler cap securely after re-
fueling.
● If you should swallow some gasoline
inhale a lot of gasoline vapor, or get
gasoline in your eyes, get immediate
medical attention.
● If any gasoline spills onto your skin,
immediately wash with soap and
water. Change clothing if gasoline
spills on it.
● Touch the fuel nozzle to the filler open-
ing or funnel to help prevent electro-
static sparks.
@

CAUTION:
@

Use only new clean gasoline which has


been stored in clean containers and is
not contaminated with water or foreign
matter.
@

1-11
U68T15.book Page 12 Thursday, March 20, 2003 11:28 AM

E
EMU01804

GASOLINE
Recommended gasoline:
Regular unleaded gasoline with a
minimum octane rating of 86
(Pump Octane Number) = (R+M)/2

If knocking or pinging occurs, use a different


brand of gasoline or premium unleaded fuel.

EMU00027

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

1-12
U68T15.book Page 13 Thursday, March 20, 2003 11:28 AM

E
EMU01769

ENGINE OIL

Recommended engine oil:


4-stroke motor oil with a combination of cor-
responding SAE and API as shown in the
chart.

Engine oil quantity:


See Chapter 4, “Specifications.”

CAUTION:
@

All 4-stroke engines are shipped from the


factory without engine oil.
@

1-13
U68T15.book Page 14 Thursday, March 20, 2003 11:28 AM

E
EMU01775

BATTERY REQUIREMENT

CAUTION:
@

Do not use a battery that does not meet


the specified capacity. If a battery which
does not meet specifications is used, the
electric system could perform poorly or
be overloaded, causing electric system
damage.
@

For electric start models, choose a battery


which meets the following specifications.

EMU01859

Minimum cold cranking amps (CCA/SAE):


245 amps at -18°C (-0.4°F)
Minimum marine cranking amps
(MCA/ABYC):
323 amps at 0°C (32°F)
Minimum reserve capacity (RC/SAE):
52 minutes

EMU01783¯

CAUTION:
@

A battery cannot be connected to models


that do not have a rectifier or Rectifier
Regulator.
Models without a rectifier or Rectifier
Regulator: F6MHC/F8MHC
● If you wish to use a battery with the
above models, install an optional Rec-
tifier Regulator.
@

1-14
U68T15.book Page 15 Thursday, March 20, 2003 11:28 AM

E
EMU01395

PROPELLER SELECTION

The performance of your outboard motor will


be critically affected by your choice of pro-
peller, as an incorrect choice could
adversely affect performance and could also
seriously damage the motor. Engine speed
depends on the propeller size and boat load.
If engine speed is too high or too low for
good engine performance, this will have an
adverse effect on the engine.

Yamaha outboard motors are fitted with pro-


pellers chosen to perform well over a range
of applications, but there may be uses
where a propeller with a different pitch would
be more appropriate. For a greater operat-
ing load, a smaller-pitch propeller is more
suitable as it enables the correct engine
speed to be maintained. Conversely, a
larger-pitch propeller is more suitable for a
smaller operating load.

Yamaha dealers stock a range of propellers,


and can advise you and install a propeller on
your outboard that is best suited to your
application.
NOTE:
@

At full throttle and under a maximum boat


load, the engine’s rpm should be within the
upper half of the full throttle operating range,
as listed in “SPECIFICATIONS” on page 4-1.
Select a propeller which fulfills this require-
ment.
If operating under conditions which allow the
engine’s rpm to rise above the maximum rec-
ommended range (such as light boat loads),
reduce the throttle setting to maintain the
rpm in the proper operating range.
@

1-15
U68T15.book Page 16 Thursday, March 20, 2003 11:28 AM

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

Refer to the section “CHECKING PROPEL-


LER” for instructions on propeller removal
and installation.

EMU01209¯

START-IN-GEAR PROTECTION

Yamaha outboard motors or Yamaha


approved remote control units are equipped
with start-in-gear protection device(s). This
feature permits the engine to be started only
when it is Neutral. Always select Neutral
before starting the engine.

1-16
U68T15.book Page 17 Thursday, March 20, 2003 11:28 AM

-MEMO-

1-17
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

EMU00037

Chapter 2
BASIC COMPONENTS

MAIN COMPONENTS................................2-1

OPERATIONS OF CONTROLS AND


2
OTHER FUNCTIONS..................................2-3
Fuel tank...................................................2-3
Choke knob ..............................................2-3
Recoil starter handle
(if equipped) .............................................2-4
Starter button (for tiller control model).....2-4
Multifunction tiller handle .........................2-4
Remote control.........................................2-8
Steering friction adjusting lever..............2-13
Trim angle adjusting rod ........................2-13
Power trim/tilt switch ..............................2-14
Tilt lock mechanism
(for manual tilt model) ............................2-14
Tilt support knob.....................................2-15
Tilt support bar .......................................2-15
Power tilt unit..........................................2-15
Top cowling lock lever............................2-16
Flushing device ......................................2-16
Warning indicator(s)...............................2-16

WARNING SYSTEM.................................2-17
Low oil pressure warning.......................2-17
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

E
EMU01206

MAIN COMPONENTS

F6/F8

1 Top cowling B Gear shift lever


2 Top cowling lock lever C Tiller handle
3 Anti-cavitation plate D Steering friction adjusting lever
* 4 Propeller E Tilt lock lever
5 Cooling water inlet F Clamp screw
6 Oil drain bolt G Rope attachment
7 Trim angle adjusting rod H Flushing device
8 Clamp bracket I Choke knob
9 Recoil starter handle
0 Warning indicator * May not be exactly as shown; also may not be in-
A Engine stop lanyard switch/ cluded as standard equipment on all models.
Engine stop button
2-1
U68T15.book Page 2 Thursday, March 20, 2003 11:28 AM

T8

1 Top cowling * D Gear shift lever


2 Top cowling lock lever * E Tiller handle
3 Anti-cavitation plate * F Steering friction adjusting lever
4 Propeller * G Tilt lock lever
5 Cooling water inlet H Clamp screw
6 Oil drain bolt I Rope attachment
7 Trim angle adjusting rod J Flushing device
8 Clamp bracket K Choke knob
* 9 Power tilt switch * L Remote control box
* 0 Recoil starter handle
A Warning indicator * May not be exactly as shown; also may not be in-
* B Starter button cluded as standard equipment on all models.
* C Engine stop layard switch/
Engine stop button
2-2
U68T15.book Page 3 Thursday, March 20, 2003 11:28 AM

E
EMU00039

OPERATIONS OF CONTROLS
AND
OTHER FUNCTIONS
EMU01465

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

1 Fuel hose joint


2 Fuel meter (if equipped)
3 Fuel tank cap
4 Air vent screw (if equipped)

EMU00042

Fuel Hose Joint


This connector is provided for connecting or
disconnecting fuel hose.

EMU01531

Fuel Meter
This meter is on the fuel tank cap. It shows
the approximate amount of fuel remaining in
the tank.

EMU00045

Fuel Tank Cap


This cap is for filling fuel. To remove it, turn it
counterclockwise.

EMU00046

Air Vent Screw


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

2-3
U68T15.book Page 4 Thursday, March 20, 2003 11:28 AM

E
EMU00057

Tiller control model


CHOKE KNOB
Pulling out this knob (setting it to ON) sup-
plies a rich mixture required to start the
engine.

EMU00059

RECOIL STARTER HANDLE


(If equipped)
Pull the handle gently until resistance is felt.
Then vigorously pull the handle straight out
to crank the engine to start it.

EMU00060

STARTER BUTTON (for Tiller control


model) (T8PH)
When you push the starter button, the elec-
tric starter motor cranks the engine to start
it.

2-4
U68T15.book Page 5 Thursday, March 20, 2003 11:28 AM

E
EMU01122¯

MULTIFUNCTION TILLER HANDLE


The tiller handle centralized most of func-
tions for the outboard motor operation.

1 Tiller handle
2 Gear shift lever
3 Throttle control grip
4 Throttle indicator
5 Throttle friction adjusting knob
6 Engine stop lanyard switch / Engine stop but-
ton (If equipped)
7 Main switch (if equipped)
8 Power tilt switch (if equipped)

EMU00079

Tiller handle
Moving the tiller handle sideways to adjust
the steering direction.

EMU00080

Gear shift lever


Turning the gear-shift lever forward (bow
side) engages the clutch with the forward
gear so that the boat moves ahead. Turning
the lever backward (stern side) engages the
reverse gear so that the boat moves astern.

1 Neutral
2 Forward
3 Reverse

2-5
U68T15.book Page 6 Thursday, March 20, 2003 11:28 AM

E
EMU00081

Throttle control grip


The throttle control grip is on the tiller han-
dle. Turn the grip counterclockwise to
increase speed and clockwise to decrease
speed.

EMU00082

Throttle Indicator
The fuel consumption curve on the throttle
indicator shows the relative amount of fuel
consumed for each throttle position. Choose
the setting that offers the best performance
and fuel economy for the desired operation.

1 Throttle indicator

EMU01157

Throttle Friction Adjusting Knob


A friction device in the tiller handle provides
adjustable resistance to movement of the
throttle grip, and can be set according to
operator preference.
Resistance Knob
Increase Turn clockwise
Decrease Turn counterclockwise
When constant speed is desired, tighten the
adjusting knob to maintain the desired throt-
tle setting.
WARNING
@

Do not overtighten the friction adjusting


knob. If there is too much resistance, it
may be difficult to move the throttle grip,
which could result in an accident.
@

2-6
U68T15.book Page 7 Thursday, March 20, 2003 11:28 AM

E
EMU00933

Engine Stop Lanyard Switch


The lock-plate 1 must be attached to the
engine stop lanyard switch for the engine to
run. The lanyard 2 should be attached to a
secure place on the operator’s clothing, or
arm or leg. Should the operator fall over-
board or leave the helm, the lanyard will pull
out the lock plate, stopping ignition to the
engine. This will prevent the boat from run-
ning away under power.
WARNING
@

● Attach the lanyard to a secure place on


your clothing, your arm or leg while
operating.
● Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard in such a way that it could
become entangled, preventing it from
functioning.
● 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.
@

NOTE:
@

The engine cannot be started with the lock-


plate removed.
@

EMU00085

Engine Stop Button


Pushing this button opens the ignition circuit
and stops the engine.

2-7
U68T15.book Page 8 Thursday, March 20, 2003 11:28 AM

E
EMU01323

Power Tilt Switch


The power tilt adjusts the motor angle in
relation to the transom. The power tilt switch
is located on the tiller handle. Pushing the
switch “UP” tilts the motor up. Pressing the
switch “DN” tilts the motor down. When the
switch button is released, the motor will stop
in its current position.
NOTE:
@

Refer to the section “TILTING UP/DOWN”


for instructions on usage.
@

EMU00094

REMOTE CONTROL
Both the shifter and the throttle are actuated
by the remote control lever. In addition, this
remote control also has the electrical
switches.

1 Remote control lever


2 Neutral interlock trigger
3 Neutral throttle lever
4 Main switch / Choke switch
5 Engine stop lanyard switch
6 Power tilt switch
7 Throttle friction adjusting screw

2-8
U68T15.book Page 9 Thursday, March 20, 2003 11:28 AM

E
EMU00098

Remote Control Lever


Moving the lever forward from the Neutral
position engages Forward gear. Pulling the
lever back from Neutral engages Reverse.
The engine 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 acceler-
ate.

1 Neutral
2 Forward
3 Reverse
4 Shift
5 Fully closed
6 Throttle
7 Fully open

EMU00099

Neutral Interlock Trigger


To shift out of Neutral, the neutral interlock
trigger of the remote control lever must first
be pulled up.

2-9
U68T15.book Page 10 Thursday, March 20, 2003 11:28 AM

E
EMU00100

Neutral Throttle Lever


To open the throttle without shifting into
either Forward or Reverse, place the remote
control lever 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 Fully open
2 Fully closed

EMU00101

Main switch
The main switch controls the ignition sys-
tem; its operation is described below.
● OFF
Electrical circuits switched off.
(The key can be removed.)
● ON
Electrical circuits switched on.
(The key cannot be removed.)
● START
Starter-motor will turn and start engine.
(When the key is released, it returns auto-
matically to “ON”.)

2-10
U68T15.book Page 11 Thursday, March 20, 2003 11:28 AM

E
EMU00102

Choke Switch
While the main switch is being pressed in at
“ON” or “START”, the choke system will
switch on, to supply a rich mixture required
to start the engine. (When the key is
released, it will switch off automatically.)

EMU00934

Engine Stop Lanyard Switch


The lock-plate 1 must be attached to the
engine stop lanyard switch for the engine to
run. The lanyard 2 should be attached to a
secure place on the operator’s clothing, or
arm or leg. Should the operator fall over-
board or leave the helm, the lanyard will pull
out the lock plate, stopping ignition to the
engine. This will prevent the boat from run-
ning away under power.
WARNING
@

● Attach the lanyard to a secure place on


your clothing, your arm or leg while
operating.
● Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard in such a way that it could
become entangled, preventing it from
functioning.
● 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.
@

NOTE:
@

The engine cannot be started with the lock-


plate removed.
@

2-11
U68T15.book Page 12 Thursday, March 20, 2003 11:28 AM

E
EMU01316

Power Tilt Switch


The power tilt adjusts the motor angle in
relation to the transom. The power tilt switch
is located on the remote control lever grip.
Pushing the switch “UP” tilts the motor up.
Pressing the switch “DN” tilts the motor
down. When the switch button is released,
the motor will stop in its current position.
NOTE:
@

Refer to the section “TILTING UP/DOWN”


for instructions on usage.
@

EMU01155

Throttle Friction Adjusting Screw


A friction device in the remote control box
provides adjustable resistance to move-
ment of the remote control lever, and can be
set according to operator preference. An
adjusting screw is located on the front of the
remote control box.
Resistance Screw
Increase Turn clockwise
Decrease Turn counterclockwise

WARNING
@

Do not overtighten the friction adjusting


screw. If there is too much resistance, it
may be difficult to move the lever, which
could result in an accident.
@

2-12
U68T15.book Page 13 Thursday, March 20, 2003 11:28 AM

E
EMU01295

STEERING FRICTION ADJUSTING


LEVER
A friction device provides resistance to
steering movement. This is adjustable
according to operator preference.
Resistance Lever
Increase Turn to port
Decrease Turn to starboard

WARNING
@

Do not overtighten the friction adjusting


lever. If there is too much resistance, it
may be difficult to steer, which could
result in an accident.
@

EMU01297

TRIM ANGLE ADJUSTING ROD


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

2-13
U68T15.book Page 14 Thursday, March 20, 2003 11:28 AM

E
EMU01501¯

POWER TILT SWITCH


The power tilt adjusts the motor angle in
relation to the transom. The power tilt switch
is located on top of the steering bracket.
Pushing the switch “UP” trims the motor up,
then tilts the motor up. Pressing the switch
“DN” tilts the motor down and trims the
motor down. When the switch button is
released, the motor will stop in its current
position.
WARNING
Use the power tilt switch located on top
of the steering bracket only when the
boat is at a complete stop with the
engine off. Attempting to use the cowl-
ing-mounted power tilt switch while the
boat is moving could increase the risk of
falling overboard and could distract the
operator, increasing the risk of collision
with another boat or an obstacle.

NOTE:
Refer to the section “Tilting Up/Down” for
instructions on usage.

EMU00152

TILT LOCK MECHANISM


(for Manual tilt model)
The tilt-lock mechanism is used to prevent
reverse thrust from the propeller lifting the
outboard motor when reversing. To lock it,
set the tilt-lock lever in the up position. To
release it, push the tilt-lock lever down.

1 Tilt-lock lever

2-14
U68T15.book Page 15 Thursday, March 20, 2003 11:28 AM

E
EMU00155

TILT SUPPORT KNOB


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

EMU00156¯

TILT SUPPORT BAR


The tilt support bar 1 keeps the outboard
motor in the tilted up position.

EMU01348

POWER TILT UNIT


This unit tilts the motor up and down and is
controlled via the power tilt switch.

1 Power tilt unit


2 Power tilt motor

CAUTION:
@

Do not step on or exert pressure on the


power tilt motor. The power tilt unit could
be damaged as a result.
@

2-15
U68T15.book Page 16 Thursday, March 20, 2003 11:28 AM

E
EMU00161

TOP COWLING LOCK LEVER


To remove the engine top cowling, pull up
the lock lever. Then lift off the cowling. When
replacing the cowling, check to be sure it fits
properly in the rubber seal. Then lock the
cowling again by moving the lever down-
ward.

EMU01701

FLUSHING DEVICE
This device 1 is used to clean the cooling
water passages of the motor using a garden
hose and tap water.
NOTE:
@

Refer to “CLEANING COOLING-WATER


PASSAGES” in Chapter 4 for instructions on
usage.
@

EMU01128

WARNING INDICATOR(S)
If the engine develops a condition monitored
by the warning system, an indicator will
come on. Refer to the “WARNING SYSTEM”
section for details.

1 Warning indicator(s)

2-16
U68T15.book Page 17 Thursday, March 20, 2003 11:28 AM

E
EMU00169

WARNING SYSTEM

CAUTION:
@

Do not continue to operate the engine if


the warning device has activated. Con-
sult your Yamaha dealer if the problem
cannot be located and corrected.
@

EMU00173

LOW OIL PRESSURE WARNING


If oil pressure drops too low, the warning
device will activate.

(❍):Included (—):N/A
Tiller Remote
Activation of
control control
warning device
model model
Engine speed will au-
tomatically decrease ❍ ❍
to about 2,000 r/min.
The low oil pressure
warning indicator will ❍ ❍
come on.
The buzzer will

sound.

If the warning system has been activated,


stop the engine as soon as it is safe to do
so. Check oil level and add oil as needed. If
the oil level is correct, consult your Yamaha
dealer.
CAUTION:
@

Do not continue to run the engine if the


low oil pressure lamp is “ON”. Serious
engine damage may occur.
@

2-17
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

EMU00174

Chapter 3
OPERATION

INSTALLATION ..........................................3-1
Mounting the outboard motor ..................3-2
Clamping the outboard motor..................3-4
BREAKING IN (RUNNING IN) ENGINE....3-5
PRE-OPERATION CHECKS .....................3-6
Checking the engine oil level...................3-7
FILLING FUEL ............................................3-8
STARTING ENGINE ...................................3-9
Procedure for tiller control model...........3-10
3
Procedure for remote control model......3-13
WARMING UP ENGINE ...........................3-15
CHECKING POINTS AFTER
STARTING ENGINE .................................3-15
SHIFTING ..................................................3-16
Forward ..................................................3-16
Reverse ..................................................3-17
STOPPING ENGINE.................................3-18
TRIMMING OUTBOARD MOTOR...........3-19
Adjusting trim angle................................3-20
TILTING UP/DOWN..................................3-24
Procedure for tilting up...........................3-25
Procedure for tilting down ......................3-25
Procedure for tilting up...........................3-26
Procedure for tilting down ......................3-27
CRUISING IN SHALLOW WATER..........3-28
Procedure...............................................3-29
Returning to original position .................3-29
CRUISING IN SHALLOW WATER..........3-30
Procedure...............................................3-30
CRUISING IN OTHER CONDITIONS......3-32
Cruising in salt water..............................3-32
Cruising in turbid water ..........................3-32
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

E
EMU00175

INSTALLATION

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/depth finder
transducers) can create airborne water
spray while the boat is cruising. Severe
engine damage may result if the motor is
operated continuously in the presence of
airborne water spray.
@

NOTE:
@

During water testing check the buoyancy of


the boat, at rest, with its maximum load.
Check that the static water level on the
exhaust housing is low enough to prevent
water entry into the powerhead, when water
rises due to waves when the outboard is not
running.
@

3-1
U68T15.book Page 2 Thursday, March 20, 2003 11:28 AM

E
EMU01478

MOUNTING THE OUTBOARD MOTOR


WARNING
@

● Overpowering a boat may cause


severe instability. Do not install an out-
board motor with more horsepower
than the maximum rating on the capac-
ity plate of the boat. If the boat does
not have a capacity plate, consult the
boat manufacturer.
● The information presented in this sec-
tion is intended as reference only. It is
not possible to provide complete
instructions for every possible boat/
motor combination. Proper mounting
depends in part on experience and the
specific boat/motor combination.
@

WARNING
@

Improper mounting of the outboard


motor could result in hazardous condi-
tions such as poor handling, loss of con-
trol, or fire hazards. Observe the
following:
● For permanently mounted models,
your dealer or other person experi-
enced in proper rigging should mount
the motor. If you are mounting the
motor yourself, you should be trained
by an experienced person.
● For portable models, your dealer or
other person experienced in proper
outboard motor mounting should
show you how to mount your motor.
@

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.

1 Center line (keel line)

3-2
U68T15.book Page 3 Thursday, March 20, 2003 11:28 AM

E
EMU01298

Mounting Height
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
tends to occur, thus reducing the propulsion;
and if the propeller tips cut the air, the
engine speed will rise abnormally and cause
the engine to overheat. If the mounting-
height is too low, the water-resistance will
increase and thereby reduce engine effi-
ciency. Mount the engine so that the anti-
cavitation plate is between the bottom of the
boat and a level 25 mm (1 in.) below it.
NOTE:
@

● 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 deter-
mine the optimum mounting height.
● Refer to the section “TRIMMING OUT-
BOARD MOTOR” for instructions on set-
ting the trim angle of the outboard.
@

3-3
U68T15.book Page 4 Thursday, March 20, 2003 11:28 AM

E
EMU01318¯

CLAMPING THE OUTBOARD MOTOR


1) Place the outboard on the transom so
that it is positioned as close to the cen-
ter as possible. Tighten the transom
clamp screws evenly and securely.
Check the clamp-screws for tightness
occasionally during operation of the
motor as they can work loose due to
engine vibration.
WARNING
@

Loose clamp screws could allow the


motor to move on the transom or fall off
the transom. This could cause loss of
control and serious injury. Make sure the
transom screws are tightened securely.
Occasionally check the screws for tight-
ness during operation.
@

2) An engine restraint cable or chain


should be used. Attach one end to the
engine restraint cable attachment point
and the other to a secure mounting point
on the boat. Otherwise, the engine could
be completely lost if it accidentally falls
off the transom.
Secure the clamp bracket to the transom
with the bolts provided with the out-
board. For details, consult your dealer.
WARNING
@

Avoid using bolts, nuts or washers other


than those contained in the engine pack-
aging. If used, they must be of at least
the same quality of material and strength
and must be tightened securely. After
tightening, test run the engine and check
their tightness.
@

1 Motor mounting parts

3-4
U68T15.book Page 5 Thursday, March 20, 2003 11:28 AM

E
EMU00224

BREAKING IN (RUNNING IN)


ENGINE

Your new engine requires a period of break-


in (running-in) to allow mating surfaces of
moving parts to wear-in evenly. Correct
break-in (running-in) will help ensure proper
performance and longer engine life.
CAUTION:
@

Failure to follow the break-in (running-in)


procedure may result in reduced engine
life or even severe engine damage.
@

Break-in (running-in) time: 10 hours

EMU01367¯

Run the engine under load (in gear with a


propeller installed) as follows.
1) For the first hour of operation:
Run the engine at 2,000 r/min or at
approximately half throttle.
2) For the second hour of operation:
Run the engine at 3,000 r/min or at
approximately three-quarter throttle.
3) For the next eight hours of operation:
Avoid continuous operation at full throt-
tle for more than five minutes at a time.
4) After the first 10 hours:
Operate the engine normally.

3-5
U68T15.book Page 6 Thursday, March 20, 2003 11:28 AM

E
EMU00204

PRE-OPERATION CHECKS

WARNING
@

If any item in the pre-operation check is


not working properly, have it inspected
and repaired before operating the out-
board motor. Otherwise, an accident
could occur.
@

CAUTION:
@

Do not start the engine out of water.


Overheating and serious engine damage
can occur.
@

EMU00206

Fuel
● Check to be sure you have plenty of fuel
for your trip.
● Make sure there are no fuel leaks or gas-
oline fumes.
● Check fuel line connections to be sure
they are tight.
● Be sure the fuel tank is positioned on a
secure, flat surface, and that the fuel hose
is not twisted or flattened, or likely to con-
tact sharp objects.

EMU00208

Oil
● Check the level of the oil in the sump with
the dipstick. If necessary, add oil to bring
the level up to the upper mark.

3-6
U68T15.book Page 7 Thursday, March 20, 2003 11:28 AM

E
EMU00209

Controls
● Check throttle, shift, and steering for
proper operation before starting the
engine.
● The controls should work smoothly, with-
out binding or unusual free play.
● Look for loose or damaged connections.
● Check operation of the starter and stop
switches when the outboard motor is in
the water.

EMU00210

Engine
● Check the engine and engine mounting.
● Look for loose or damaged fasteners.
● Check the propeller for damage.

EMU01436

CHECKING THE ENGINE OIL LEVEL


1) Put the outboard motor in an upright
position (not tilted).
2) Pull out the oil dipstick and wipe it clean.
3) Completely re-insert the dipstick and
pull out it again.
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.

1 Oil dipstick
2 Lower level mark
3 Upper level mark

3-7
U68T15.book Page 8 Thursday, March 20, 2003 11:28 AM

E
EMU00202

FILLING FUEL

1) Remove the fuel tank cap.


2) Fill the fuel tank carefully.
3) Close the cap securely after refueling.
Wipe up any spilled fuel.

Fuel tank capacity:


Refer to SPECIFICATIONS, page 4-1.

EMU00203

Ring Free Fuel Additive


Gasoline is a precise blend of many different
substances, each chosen to give certain
characteristics. Gasoline blends have been
changing in recent years in response to con-
cerns about pollution and resulting emis-
sions regulations. One of the most obvious
changes has been the elimination of lead
from most fuels.

As gasoline has changed, the amount of


additives such as aromatics and oxygenates
has increased. These additives are impor-
tant for the engines in passenger cars, but
they can have detrimental effects in marine
engines, because of increased deposits in
the combustion chamber. When enough
deposits collect, piston rings begin sticking.
Performance drops and engine wear
increases dramatically.

While many additives available may reduce


deposits, Yamaha recommends the use of
Ring Free Fuel Additive, available from
your Yamaha dealer. Ring Free has repeat-
edly proven its ability to clean combustion
deposits from inside the engine, notably the
critical piston-ring-land area, and fuel sys-
tem components. Follow product labeling for
use instructions.

3-8
U68T15.book Page 9 Thursday, March 20, 2003 11:28 AM

E
EMU01461

STARTING ENGINE

WARNING
@

● Before starting the engine, make sure


that the boat is tightly moored and that
you can steer clear of any obstruc-
tions. Be sure there are no swimmers
in the water near you.
● When the air vent screw is loosened,
gasoline (petrol) vapor will be
released. Gasoline (petrol) is highly
flammable, and its vapors are flamma-
ble and explosive. Refrain from smok-
ing, and keep away from open flames
and sparks while loosening the air
vent screw.
● This product emits exhaust gases
which contain carbon monoxide, a col-
orless, odorless gas which may cause
brain damage or death when inhaled.
Symptoms include nausea, dizziness,
and drowsiness. Keep cockpit and
cabin areas well ventilated. Avoid
blocking exhaust outlets.
@

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 on the motor, firmly
connect the fuel line to the joint. Then
firmly connect the other end of the fuel
line to the joint on the fuel tank.
NOTE:
@

During engine operation place the tank hori-


zontally, or fuel cannot be drawn from the
fuel tank.
@

3) Squeeze the primer bulb with the outlet


end up until you feel it become firm.

3-9
U68T15.book Page 10 Thursday, March 20, 2003 11:28 AM

E
EMU01497

PROCEDURE FOR TILLER


CONTROL MODEL
4) Place the gear-shift lever in the neutral
position.
NOTE:
@

The start-in-gear protection device prevents


the engine from starting except when in
Neutral.
@

5) 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 in the
engine stop switch.
WARNING
@

● Attach the engine stop switch lanyard


to a secure place on your clothing,
your arm or leg while operating.
● Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entan-
gled, preventing it from functioning.
● 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.
@

6) Place the throttle control grip in the


“START” position.

3-10
U68T15.book Page 11 Thursday, March 20, 2003 11:28 AM

E
EMU01514¯

Manual Start Models


7) Pull out the choke knob completely.
NOTE:
@

It is not necessary to use the choke when


restarting a warm engine.
@

8) Pull the starter handle slowly until you


feel resistance. Then give a strong pull
straight out to crank and start the
engine. Repeat if necessary.
9) After the engine starts, return the starter
handle slowly to the original position
before releasing it.
NOTE:
@

If the engine doesn’t start on the first try,


repeat the procedure. If the engine fails to
start after 4 or 5 tries, open the throttle a
small amount (between 1/8 and 1/4) and try
again. If the engine still fails to start, refer to
“TROUBLESHOOTING” in Chapter 5.
@

3-11
U68T15.book Page 12 Thursday, March 20, 2003 11:28 AM

E
EMU01491

Electric Start Models


7) Pull out the choke knob completely.
NOTE:
@

● It is not necessary to use the choke when


restarting a warm engine.
● If the choke knob is left pulled out, the
engine will stall.
@

8) Push the starter button to start the


motor.
9) Immediately after the engine starts,
release the starter button to return it to
the original position.
10) Return the throttle control grip slowly to
the fully closed position so that the
engine does not stall.
CAUTION:
@

● Never push the starter button while the


engine is running.
● 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 discharged, thus making it
impossible to start the engine. If the
engine will not start after 5 seconds of
cranking, release your hand from the
starter button, and crank the engine
again after an interval of 10 seconds.
@

NOTE:
@

● When starting a cold engine, the engine


needs to be warmed up. Refer to “WARM-
ING UP ENGINE” for details.
● If the engine doesn’t start on the first try,
repeat the procedure. If the engine fails to
start after 4 or 5 tries, open the throttle a
small amount (between 1/8 and 1/4) and try
again. If the engine still fails to start, refer to
“TROUBLESHOOTING” in Chapter 5.
@

3-12
U68T15.book Page 13 Thursday, March 20, 2003 11:28 AM

E
EMU01000

PROCEDURE FOR REMOTE


CONTROL MODEL
4) Place the remote control lever in the
Neutral position. When the engine is
warm, open the throttle slightly using the
neutral throttle lever or the free acceler-
ator. After the engine starts, return the
throttle to the fully closed position.
NOTE:
@

The start-in-gear protection device prevents the


engine from starting except when in Neutral.
@

5) 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 in the
engine stop switch.
WARNING
@

● Attach the engine stop switch lanyard


to a secure place on your clothing,
your arm or leg while operating.
● Do not attach the lanyard to clothing
that could tear loose. Do not route the
lanyard where it could become entan-
gled, preventing from functioning.
● 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.
@

6) Turn the main switch to “ON”.

3-13
U68T15.book Page 14 Thursday, March 20, 2003 11:28 AM

E
EMU01512

Electric Start Models


7) Open the throttle slightly lifting the neu-
tral throttle lever upwards partially. You
may need to change the throttle opening
slightly depending on engine tempera-
ture.
After the engine starts, return the throt-
tle to the original position.
NOTE:
@

● As a starting point, lift the lever just until


you feel resistance, then lift slightly more.
● The operation of the neutral throttle lever
is possible only when the remote control
lever is in “N”.
@

8) Press in and hold the main switch to


operate the remote choke system. (The
remote choke switch returns to its home
position when you release your hand.
Therefore, keep the switch pressed in.)
NOTE:
@

● It is not necessary to use the choke when


the engine is warm.
● Set the choke knob to the home position,
or the remote choke system will not oper-
ate.
@

9) Turn the main switch to “START”, and


hold it for a maximum of 5 seconds.
10) Immediately after the engine starts,
release the main switch to return it to
the “ON” position.
CAUTION:
@

● Do not turn the main switch to


“START” when the engine is running.
● Do not keep the starter-motor turning
for more than 5 seconds. The battery
will rapidly become exhausted and it
will be impossible for it to start the
engine. If the engine does not start
within 5 seconds, return the main
switch to “ON”, wait 10 seconds, and
then crank the engine again.
@

3-14
U68T15.book Page 15 Thursday, March 20, 2003 11:28 AM

E
EMU01368¯

WARMING UP ENGINE

1) After the engine starts, return the choke


knob to the half-way position. For
approximately the first 5 minutes after
starting, warm up the engine by operat-
ing at one fifth throttle or less. After the
engine has warmed up, completely push
in the choke knob. (Failure to do so will
shorten engine life.)
NOTE:
@

● If the choke knob is left pulled out after


the engine starts, the engine will stall.
● In temperatures of –5 °C or less, leave the
choke knob completely pulled out for
approximately 30 seconds after starting.
Then follow the standard instructions for
warming up the engine.

EMU01751

CHECKING POINTS AFTER


STARTING ENGINE

● Check for a steady flow of water from the


cooling-water pilot hole.
● Check that the low oil pressure warning
indicator light is off. (Refer to “WARNING
SYSTEM” section.)
● After the engine has warmed up, check
that the engine idling speed is stable.
CAUTION:
@

If water is not flowing out of the pilot hole


at all times while the engine is running,
do not continue to run the engine. Over-
heating and serious damage could occur.
Stop the engine and check if the water
inlet on the lower casing is blocked. If the
problem cannot be found and corrected,
consult your Yamaha dealer.
@

3-15
U68T15.book Page 16 Thursday, March 20, 2003 11:28 AM

E
EMU00261

SHIFTING

WARNING
@

Before shifting, make sure there are no


swimmers or obstacles in the water near
you.
@

CAUTION:
@

To change the shifting position from for-


ward to reverse or vice-versa, close the
throttle first so that the engine idles (or
runs at low speeds).
@

EMU00265

FORWARD
Tiller control model
1) Place the throttle control grip in the fully
closed position.

2) Turn the gear-shift lever quickly and


firmly from Neutral to Forward.

Remote control model


Pull up the neutral interlock trigger if
equipped and move the remote control lever
quickly and firmly from Neutral to Forward.

3-16
U68T15.book Page 17 Thursday, March 20, 2003 11:28 AM

E
EMU01326¯

REVERSE
WARNING
@

When operating in Reverse, go slowly.


Do not open the throttle more than half.
Otherwise, the boat may become unsta-
ble, which could result in loss of control
and an accident.
@

1) Place the throttle control grip in the fully


closed position (for Tiller control model).
2) Check that the tilt-lock lever (for Manual
tilt model) is in the locked position.

Tiller control model


3) Turn the gear-shift lever quickly and
firmly from Neutral to Reverse.

Remote control model


3) Pull up the neutral interlock trigger if
equipped and move the remote control
lever quickly and firmly from Neutral to
Reverse.

3-17
U68T15.book Page 18 Thursday, March 20, 2003 11:28 AM

E
EMU00273

STOPPING ENGINE

Let it cool off for a few minutes at idle or low


speed first. Stopping the engine immediately
after operating at high speed is not recom-
mended.

EMU00277¯

1) Push and hold the engine stop button or


turn the main switch to “OFF”.

2) If the fuel joints are provided, disconnect


the fuel line from the motor after stop-
ping the engine.

3) Tighten the air vent screw on the fuel


tank cap after stopping the engine, if it is
equipped.
4) Remove the key if the boat will be left
unattended.
NOTE:
@

The engine can also be stopped by pulling


the lanyard and removing the lock plate from
the engine stop lanyard switch (then turning
the main switch to “OFF”).
@

3-18
U68T15.book Page 19 Thursday, March 20, 2003 11:28 AM

E
EMU01412

TRIMMING OUTBOARD
MOTOR

The trim angle of the outboard motor helps


determine the position of the bow of the boat
in the water. The correct trim angle will help
improve performance and fuel economy
while reducing strain on the engine. The cor-
rect trim angle depends upon the combina-
tion of boat, engine, and propeller. Correct
trim is also affected by variables such as the
load in the boat, sea conditions, and running
speed.
WARNING
@

Excessive trim for the operating condi-


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

NOTE:
@

Refer to the section “ADJUSTING TRIM


ANGLE” for instructions on usage.
@

1 Trim operating angle

3-19
U68T15.book Page 20 Thursday, March 20, 2003 11:28 AM

E
ADJUSTING TRIM ANGLE

EMU00951

Manual tilt model


There are 4 or 5 holes provided in the clamp
bracket to adjust the outboard motor trim
angle.
1) Stop the engine.
2) Remove the trim angle adjusting rod 1
from the clamp bracket while tilting the
motor up slightly.
3) Reposition the rod in the desired hole.
To raise the bow (“trim-out”), move the rod
away from the transom.
To lower the bow (“trim-in”), move the rod
toward the transom.
Make test runs with the trim set to different
angles to find the position that works best for
your boat and operating conditions.
WARNING
@

● Stop the engine before adjusting the


trim angle.
● Use care to avoid being pinched when
removing or installing the rod.
● Use caution when trying a trim posi-
tion for the first time. Increase speed
gradually and watch for any signs of
instability or control problems.
Improper trim angle can cause loss of
control.
@

NOTE:
@

The outboard motor trim angle can be


changed approximately 4 degrees by shift-
ing the trim adjusting-rod one hole.
@

3-20
U68T15.book Page 21 Thursday, March 20, 2003 11:28 AM

E
EMU01414

Power Tilt Model


WARNING
@

● Be sure all people are clear of the out-


board motor when adjusting the tilt
angle, also be careful not to pinch any
body parts between the drive unit and
clamp bracket.
● Use caution when trying a trim posi-
tion for the first time. Increase speed
gradually and watch for any signs of
instability or control problems.
Improper trim angle can cause loss of
control.
● 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.
@

1) Place the gear-shift lever in the neutral


position.

3-21
U68T15.book Page 22 Thursday, March 20, 2003 11:28 AM

E
2) Tilt the engine to the desired angle
using the power tilt switch.
NOTE:
@

Stay within the trim operating angle when


trimming the outboard motor using the
power tilt system.
@

To raise the bow (“trim-out”), tilt the engine


up.

To lower the bow (“trim-in”), tilt the engine


down.

Make test runs with the trim set to different


angles to find the position that works best for
your boat and operating conditions.

3-22
U68T15.book Page 23 Thursday, March 20, 2003 11:28 AM

E
EMU19160

Trim angle settings and boat handling


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

1 Optimum angle (level keel line)


2 Bow up
3 Bow down

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 per-
formance further, and the boat may “por-
poise” (hop in the water), which could throw
the operator and passengers overboard.

Bow Down
When the bow of the boat is down, it is eas-
ier to accelerate from a standing start onto
plane. Too much trim-in causes the boat to
“plow” through the water, decreasing fuel
economy and making it hard to increase
speed. Operating with excessive trim-in at
higher speeds also makes the boat unstable.
Resistance at the bow is greatly increased,
heightening the danger of “bow steering” and
making operation difficult and dangerous.
NOTE:
@

Depending on the type of boat, the outboard


motor trim angle may have little effect on the
trim of the boat when operating.
@

3-23
U68T15.book Page 24 Thursday, March 20, 2003 11:28 AM

E
EMU00285

TILTING UP/DOWN

If the engine will be stopped for some time,


or if the boat is moored in shallows, the
engine should be tilted up to protect the pro-
peller and casing from damage by collision
with obstructions, and also to reduce salt
corrosion.
CAUTION:
@

● Before tilting the motor, follow the pro-


cedures under “STOPPING ENGINE”.
Never tilt the motor while the engine is
running. Severe damage from over-
heating can result.
● Do not tilt up the engine by pushing
the steering handle as this could break
the handle.
@

WARNING
@

Be sure all people are clear of the out-


board motor when adjusting the tilt
angle, also be careful not to pinch any
body parts between the drive unit and
engine bracket.
@

WARNING
@

Leaking fuel is a fire hazard. Disconnect


the fuel line if the engine will be tilted for
more than a few minutes. Otherwise, fuel
may leak. (If the fuel connector is pro-
vided on the motor.)
@

3-24
U68T15.book Page 25 Thursday, March 20, 2003 11:28 AM

E
EMU00290

PROCEDURE FOR TILTING UP


Manual tilt model
1) Place the gear shift lever in Neutral.
2) Remove the fuel line connection from
the motor.

3) Place the tilt lock lever in the release


position.

4) Hold the rear of the top cowling with one


hand and fully tilt the engine up.
5) The tilt support bar turns to the locked
position automatically.

EMU00300

PROCEDURE FOR TILTING DOWN


Manual tilt model
1) Place the tilt lock lever in the lock posi-
tion.
2) Slightly tilt up the engine until the tilt
support bar is released automatically.
3) Tilt down the engine.

3-25
U68T15.book Page 26 Thursday, March 20, 2003 11:28 AM

E
EMU01573

PROCEDURE FOR TILTING UP


Power tilt models
1) Disconnect the fuel line or close the fuel
cock.

2) Push the power tilt switch “UP” until the


outboard has tilted up completely.

3-26
U68T15.book Page 27 Thursday, March 20, 2003 11:28 AM

E
3) Push the tilt support knob into the clamp
bracket to support the engine.
WARNING
@

● After tilting the engine, be sure to sup-


port it with the tilt support knob. Oth-
erwise, the engine could fall back
down suddenly if oil in the power tilt
unit should lose pressure.
● Never operate the engine while it is
supported by the tilt support knob.
@

EMU01313

PROCEDURE FOR TILTING DOWN


Power tilt model
1) Push the power tilt switch “UP” until the
engine is supported by the tilt rod.
2) Pull out the tilt support knob.
3) Push the power tilt switch “DN” (Down)
to lower the engine to the desired posi-
tion.

3-27
U68T15.book Page 28 Thursday, March 20, 2003 11:28 AM

E
EMU01370

CRUISING IN SHALLOW
WATER

Manual tilt model


The outboard motor can be tilted up partially
to allow operation in shallow water.
WARNING
@

● Place the gear shift in the Neutral posi-


tion before using the shallow water
cruising system.
● Run the boat at the lowest possible
speed when using the shallow water
cruising system. The tilt-lock mecha-
nism does not work while the shallow
water cruising system is being used.
Hitting an underwater obstacle could
cause the engine to lift out of the
water, resulting in loss of control.
● Do not rotate the engine 180° and
operate the boat in reverse. Place the
gear-shift in the Reverse position to
operate the boat in reverse.
● Use extra care when operating in
reverse. Too much reverse thrust can
cause the engine to lift out of the
water, increasing the chance of acci-
dent and personal injury.
● Return the engine to its normal posi-
tion as soon as the boat is back in
deeper water.
@

CAUTION:
@

Place the gear-shift in the Neutral posi-


tion before using the shallow water cruis-
ing system.
@

3-28
U68T15.book Page 29 Thursday, March 20, 2003 11:28 AM

E
EMU00310

PROCEDURE
1) Place the gear shift lever in the neutral
position.

2) Place the tilt lock lever in the release


position.

3) Slightly tilt up the engine. The tilt-sup-


port bar will lock automatically, support-
ing the engine in a partially raised
position.
NOTE:
@

This motor has 2 positions for shallow water


cruising.
@

RETURNING TO ORIGINAL
POSITION
1) Place the tilt lock lever in the lock posi-
tion.
2) Slightly tilt up the engine until the tilt-
support bar automatically returns to the
free position.
3) Then, slowly lower the engine to the nor-
mal position.

3-29
U68T15.book Page 30 Thursday, March 20, 2003 11:28 AM

E
EMU01319

CRUISING IN SHALLOW
WATER

Power tilt model


The engine can be tilted up partially to allow
operation in shallow water.
WARNING
@

● Place the gear shift in the Neutral posi-


tion before setting for shallow water
cruising.
● Return the engine to its normal posi-
tion as soon as the boat is back in
deeper water.
@

CAUTION:
@

Do not tilt up the outboard motor so that


the cooling water inlet of the lower unit is
above the surface of the water when set-
ting for and cruising in shallow water.
Otherwise severe damage from overheat-
ing can result.
@

EMU01320

PROCEDURE
1) Place the gear shift lever in the neutral
position.

3-30
U68T15.book Page 31 Thursday, March 20, 2003 11:28 AM

E
2) Slightly tilt up the engine using the
power tilt switch.

3-31
U68T15.book Page 32 Thursday, March 20, 2003 11:28 AM

E
EMU00316

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-up
with salt deposits.
NOTE:
@

Refer to cooling system flushing instructions


in “TRANSPORTING AND STORING OUT-
BOARD MOTOR”.
@

CRUISING IN TURBID WATER


It is strongly recommended that the optional
chromium-plated water-pump kit be installed
if the outboard is to be used in turbid
(muddy) water conditions.

3-32
U68T15.book Page 33 Thursday, March 20, 2003 11:28 AM

-MEMO-

3-33
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

EMU00317

Chapter 4
MAINTENANCE

SPECIFICATIONS ......................................4-1

TRANSPORTING AND STORING


OUTBOARD MOTOR.................................4-4
Trailering outboard motor ........................4-4
Transporting outboard when
unmounted ...............................................4-5
Storing outboard motor ............................4-5

PERIODIC MAINTENANCE.....................4-10
Replacement parts.................................4-10
Maintenance chart .................................4-11
Greasing.................................................4-12
Cleaning and adjusting spark plug ........4-13
Checking fuel system.............................4-15
Inspecting fuel filter ................................4-16
Inspecting idling speed ..........................4-17
4
Changing engine oil ...............................4-18
Replacing fuse .......................................4-20
Checking wiring and connectors ...........4-20
Exhaust leakage.....................................4-20
Water leakage........................................4-20
Checking power tilt system....................4-21
Checking propeller .................................4-22
Changing gear oil...................................4-24
Cleaning fuel tank ..................................4-26
Inspecting and replacing anode(s) ........4-27
Checking battery
(for electric start models) .......................4-28
Checking bolts and nuts ........................4-31
Cleaning cooling-water passages .........4-32
Checking top cowling.............................4-33
Motor exterior .........................................4-33
Coating the boat bottom ........................4-33
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

E
EMU01870¯

SPECIFICATIONS
Model
Item Unit F6MHC
DIMENSIONS
Overall length mm (in.) 927 (36.5)
Overall width mm (in.) 350 (13.8)
Overall height S/L/X mm (in.) 998 (39.3)/1,125 (44.3)/–
Transom height S/L/X mm (in.) 435 (17.1)/562 (22.1)/–
Weight S/L/X kg (lb.) 38 (84)/39.5 (87)/–
PERFORMANCE
Full throttle operating range r/min 4,500–5,500
Maximum output kW (HP) @ r/min 4.4 (6) @ 5,000
Idling speed (in neutral) r/min 1,000–1,100
ENGINE
Type 4-stroke, L2
Displacement cm3 (cu.in.) 197 (12.02)
Bore × stroke mm (in.) 56.0 × 40.0 (2.20 × 1.57)
Ignition system CDI system
Spark plug NGK BR6HS-10
Spark plug gap mm (in.) 0.9–1.0 (0.035–0.039)
Control system Tiller control
Starting system Manual start
Valve clearance (cold engine) IN mm (in.) 0.15–0.20 (0.006–0.008)
EX mm (in.) 0.20–0.25 (0.008–0.010)
Battery
Min. cold cranking amps (CCA/SAE) amps at -18°C (-0.4°F) —
Min. marine cranking amps (MCA/ABYC) amps at 0°C (32°F) —
Min. reserve capacity (RC/SAE) minutes —
Alternator output V-A (W) 12 - (80)
Starting carburation system Choke start
DRIVE UNIT
Gear positions Forward-Neutral-Reverse
Gear ratio 2.08 (27/13)
Trim and tilt system Manual tilt
Propeller mark N
FUEL AND OIL
Recommended fuel Regular unleaded gasoline
P.O.N. Minimum 86
Fuel tank capacity L (US gal, Imp gal) 12 (3.17, 2.64)
Recommended engine oil 4-stroke motor oil
API SE, SF, SG, SH, SJ
SAE 10W-30,10W-40
Engine oil capacity (excluding oil filter) L (US qt, Imp qt) 0.8 (0.85, 0.70)
(including oil filter) L (US qt, Imp qt) —
Recommended gear oil Hypoid gear oil (SAE 90)
Gear oil capacity cm3 (US oz, Imp oz) 150 (5.07, 5.29)
TIGHTENING TORQUE
Spark plug N·m (kgf·m, lb·ft) 25 (2.5, 18)
Propeller nut N·m (kgf·m, lb·ft) 17 (1.7, 12)
Engine oil drain bolt N·m (kgf·m, lb·ft) 24 (2.4, 17)
Engine oil filter N·m (kgf·m, lb·ft) —

4-1
U68T15.book Page 2 Thursday, March 20, 2003 11:28 AM

F8MHC T8PHC T8EHC

1,038 (40.9) 1,038 (40.9) 1,038 (40.9)


371 (14.6) 371 (14.6) 371 (14.6)
998 (39.3)/1,125 (44.3)/– –/1,187 (46.7)/1,255 (49.4) –/1,187 (46.7)/1,255 (49.4)
435 (17.1)/562 (22.1)/– –/557 (21.9)/625 (24.6) –/557 (21.9)/625 (24.6)
38 (84)/39.5 (87)/– –/52 (115)/53 (117) –/46.5 (103)/47.5 (105)

5,000–6,000 5,000–6,000 5,000–6,000


5.9 (8) @ 5,500 5.9 (8) @ 5,500 5.9 (8) @ 5,500
1,000–1,100 1,000–1,100 1,000–1,100

4-stroke, L2 4-stroke, L2 4-stroke, L2


197 (12.02) 197 (12.02) 197 (12.02)
56.0 × 40.0 (2.20 × 1.57) 56.0 × 40.0 (2.20 × 1.57) 56.0 × 40.0 (2.20 × 1.57)
CDI system CDI system CDI system
BR6HS-10 BR6HS-10 BR6HS-10
0.9–1.0 (0.035–0.039) 0.9–1.0 (0.035–0.039) 0.9–1.0 (0.035–0.039)
Tiller control Tiller control Tiller control
Manual start Electric start Manual and electric start
0.15–0.20 (0.006–0.008) 0.15–0.20 (0.006–0.008) 0.15–0.20 (0.006–0.008)
0.20–0.25 (0.008–0.010) 0.20–0.25 (0.008–0.010) 0.20–0.25 (0.008–0.010)

— 245 245
— 323 323
— 52 52
12 - (80) 12 - 6 12 - 6
Choke start Choke start Choke start

Forward-Neutral-Reverse Forward-Neutral-Reverse Forward-Neutral-Reverse


2.08 (27/13) 2.92 (38/13) 2.92 (38/13)
Manual tilt Power tilt Manual tilt
N R R

Regular unleaded gasoline Regular unleaded gasoline Regular unleaded gasoline


Minmum 86 Minmum 86 Minmum 86
12 (3.17, 2.64) 12 (3.17, 2.64) 12 (3.17, 2.64)
4 stroke motor oil 4 stroke motor oil 4 stroke motor oil
SE, SF, SG, SH, SJ SE, SF, SG, SH, SJ SE, SF, SG, SH, SJ
10W-30, 10W-40 10W-30, 10W-40 10W-30, 10W-40
0.8 (0.85, 0.70) 0.8 (0.85, 0.70) 0.8 (0.85, 0.70)
— — —
Hypoid gear oil (SAE 90) Hypoid gear oil (SAE 90) Hypoid gear oil (SAE 90)
150 (5.07, 5.29) 370 (12.51, 13.05) 370 (12.51, 13.05)

25 (2.5, 18) 24 (2.4, 17) 24 (2.4, 17)


17 (1.7, 12) 21 (2.1, 15) 21 (2.1, 15)
24 (2.4, 17) 24 (2.4, 17) 24 (2.4, 17)
— — —

4-2
U68T15.book Page 3 Thursday, March 20, 2003 11:28 AM

Model
Item Unit T8PRC
DIMENSIONS
Overall length mm (in.) 552 (21.7)
Overall width mm (in.) 312 (12.3)
Overall height S/L/X mm (in.) –/1,187 (46.7)/1,255 (49.4)
Transom height S/L/X mm (in.) –/557 (21.9)/625 (24.6)
Weight S/L/X kg (lb.) –/49 (108)/50 (110)
PERFORMANCE
Full throttle operating range r/min 5,000–6,000
Maximum output kW (HP) @ r/min 5.9 (8) @ 5,500
Idling speed (in neutral) r/min 1,000–1,100
ENGINE
Type 4-stroke, L2
Displacement cm3 (cu.in.) 197 (12.02)
Bore × stroke mm (in.) 56.0 × 40.0 (2.20 × 1.57)
Ignition system CDI system
Spark plug NGK BR6HS-10
Spark plug gap mm (in.) 0.9–1.0 (0.035–0.039)
Control system Remote control
Starting system Electric start
Valve clearance (cold engine) IN mm (in.) 0.15–0.20 (0.006–0.008)
EX mm (in.) 0.20–0.25 (0.008–0.010)
Battery
Min. cold cranking amps (CCA/SAE) amps at -18°C (-0.4°F) 245
Min. marine cranking amps (MCA/ABYC) amps at 0°C (32°F) 323
Min. reserve capacity (RC/SAE) minutes 52
Alternator output V-A (W) 12 - 6
Starting carburation system Choke start
DRIVE UNIT
Gear positions Forward-Neutral-Reverse
Gear ratio 2.92 (38/13)
Trim and tilt system Power tilt
Propeller mark R
FUEL AND OIL
Recommended fuel Regular unleaded gasoline
P.O.N. Minmum 86
Fuel tank capacity L (US gal, Imp gal) 12 (3.17, 2.64)
Recommended engine oil 4 stroke motor oil
API SE, SF, SG, SH, SJ
SAE 10W-30, 10W-40
Engine oil capacity (excluding oil filter) L (US qt, Imp qt) 0.8 (0.85, 0.70)
(including oil filter) L (US qt, Imp qt) —
Recommended gear oil Hypoid gear oil (SAE 90)
Gear oil capacity cm3 (US oz, Imp oz) 370 (12.51, 13.05)
TIGHTENING TORQUE
Spark plug N·m (kgf·m, lb·ft) 24 (2.4, 17)
Propeller nut N·m (kgf·m, lb·ft) 21 (2.1, 15)
Engine oil drain bolt N·m (kgf·m, lb·ft) 24 (2.4, 17)
Engine oil filter N·m (kgf·m, lb·ft) —

4-3
U68T15.book Page 4 Thursday, March 20, 2003 11:28 AM

E
EMU01369

TRANSPORTING AND
STORING OUTBOARD MOTOR

WARNING
@

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.
@

EMU00326

TRAILERING OUTBOARD MOTOR


The motor should be trailered and stored in
the normal running position. If there is insuf-
ficient road clearance in this position, then
trailer the motor in the tilt position using a
motor support device such as a transom
saver bar.
For further details, consult your Yamaha
dealer.
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 accidentally falls.
● USE CARE when transporting fuel
tank, whether in a boat or car.
● DO NOT fill fuel container to maximum
capacity. Gasoline will expand consid-
erably as it warms up and can build up
pressure in the fuel container. This can
cause fuel leakage and a potential fire
hazard.
@

CAUTION:
@

Do not use the tilt support lever/knob


when trailering the boat. The outboard
motor could shake loose from the tilt
support and fall. If the motor can not be
trailered in the down position, use an
additional support device to secure it in
the up position.
@

4-4
U68T15.book Page 5 Thursday, March 20, 2003 11:28 AM

E
EMU01362

TRANSPORTING OUTBOARD WHEN


UNMOUNTED
Transport in an upright position to prevent
engine oil from entering the cylinder head
and causing damage to the motor.

EMU00883

STORING OUTBOARD MOTOR


When storing your Yamaha outboard for pro-
longed periods of time, (2 months or longer),
several important procedures must be per-
formed to prevent expensive damage. It is
advisable to have your outboard serviced by
an authorized Yamaha dealer prior to stor-
age. However, the following procedures can
be performed by you, the owner, with a mini-
mum of tools.
1 CAUTION:
@

● Keep the engine in one of the posi-


tions shown when storing it. Other-
wise, oil could enter the cylinder from
the sump, which could cause mechani-
cal damage or leakage.
● Drain cooling water completely before
placing the engine on its side. Other-
wise, water may enter the engine
through the exhaust manifold and
cause corrosion or other mechanical
2 damage.
● Store the engine in a dry, well-venti-
lated place, not in direct sunlight.

1 Vertical position
2 Horizontal position (On the tiller handle)

4-5
U68T15.book Page 6 Thursday, March 20, 2003 11:28 AM

E
EMU00335

Filling Fuel Tank


Fill the fuel tank with fresh fuel and add one
ounce of “Yamaha Fuel Conditioner and Sta-
bilizer” (Part No. LUB-FUELC-12-00) to
each gallon of fuel.
NOTE:
@

The use of “Yamaha Fuel Conditioner and


Stabilizer” eliminates the need to drain the
fuel system. Consult your Yamaha dealer or
other qualified mechanic if the fuel system is
to be drained instead.
@

EMU00338

Flushing Cooling System and Fogging


Engine
Cooling system flushing is essential to pre-
vent the cooling system from clogging up
with salt, sand, or dirt. In addition, fogging of
the engine is mandatory to prevent expen-
sive engine damage due to rust. Perform the
flushing and fogging at the same time.
WARNING
@

● Do not touch or remove electrical parts


when starting or during operation.
● Keep hands, hair and clothes away
from flywheel and other rotating parts
while engine is running.
@

4-6
U68T15.book Page 7 Thursday, March 20, 2003 11:28 AM

E
EMU00340

● Flushing in a Water Tank


CAUTION:
@

If the fresh water level is below the level


of the anti-cavitation plate, or if the water
supply is insufficient, engine seizure may
occur.
@

1) Remove the engine top cowling.


2) Install the outboard motor on the water
tank.
3) Fill the tank with fresh water to above
the level of the anti-cavitation plate.
4) Run the engine at a fast idle for 10~15
minutes.
5) Just prior to turning off the engine, quickly
spray “Yamaha Stor-Rite Engine Fogging
Oil” (Part No. LUB-STRRT-12-00) into the
silencer cover. When properly done, the
engine will smoke excessively and almost
stall.
6) Remove the motor from the water tank.
7) Install the top cowling.

1 Water surface
2 Lowest water level

4-7
U68T15.book Page 8 Thursday, March 20, 2003 11:28 AM

E
EMU00349

Lubrication
1) Remove the spark plug(s). Spray a
Yamaha “Stor-Rite Engine Fogging Oil”
into each cylinder for 10 seconds.
Grease the spark plug threads and rein-
stall the spark plug(s) and torque to
proper specification. (Refer to the
“CLEANING AND ADJUSTING SPARK
PLUG”).
2) Turn the engine over with the stop lan-
yard disconnected to work the fogging
oil into the piston rings.
3) Change the gear-case oil. (Refer to
“CHANGING GEAR OIL”). Inspect the
oil for the presence of water which indi-
cates a leaky seal. Seal replacement
should be performed by an authorized
Yamaha dealership prior to use.
4) Grease all grease fittings. (Refer to the
“GREASING”)

EMU00351

Cleaning and Anti-corrosion Measure


1) Wash down the exterior of the outboard
with fresh water and dry off completely.
2) Spray the engine’s exterior with
“Yamaha Silicone Protectant” (Part No.
LUB-SILCNE-13-00).
3) Wax the cowling with a non-abrasive
wax such as “Yamaha Silicone Wax”
(Part No. ACC-11000-15-02).

4-8
U68T15.book Page 9 Thursday, March 20, 2003 11:28 AM

E
EMU01545

Battery Care
WARNING
@

Battery electrolyte is poisonous and dan-


gerous, causing severe burns, etc. It con-
tains sulfuric acid. Avoid contact with
skin, eyes, or clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of
water or milk. Follow with milk of magne-
sia, beaten egg, or vegetable oil. Call
physician immediately.
EYES: Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases: Keep
sparks, flame, cigarettes, etc. away. Ven-
tilate when charging or using in a closed
space. Always wear eye protection when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
@

Batteries vary among manufacturers. There-


fore the following procedures may not
always apply. Consult your battery manufac-
turer’s instructions.
1) Disconnect and remove the battery from
the boat. Always disconnect the black
negative lead first to prevent the risk of
shorting.
2) Clean the battery casing and terminals.
Fill each cell to the upper level with dis-
tilled water.
3) Store the battery on a level surface in a
cool, dry, well-ventilated place out of
direct sunlight.
4) Once a month, check the specific gravity
of the electrolyte and recharge as
required to prolong battery life.

4-9
U68T15.book Page 10 Thursday, March 20, 2003 11:28 AM

E
EMU00354

PERIODIC MAINTENANCE

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 a Yamaha dealer or
other qualified mechanic.
@

A service manual is available for purchase


through a 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.

EMU00356

REPLACEMENT PARTS
If replacement parts are necessary, use only
genuine Yamaha parts or equivalents of the
same type and of equivalent strength and
materials. Any part of inferior quality may
malfunction, and the resulting loss of control
could endanger the operator and passen-
gers.
Yamaha genuine parts and accessories are
available from a Yamaha dealer.

4-10
U68T15.book Page 11 Thursday, March 20, 2003 11:28 AM

E
EMU19351

MAINTENANCE CHART
Frequency of maintenance operations may be adjusted according to the operating condi-
tions, but the following table gives general guidelines. Refer to the sections in this chapter for
explanations of each owner-specific action.
The mark (●) indicates the check-ups which you may carry out yourself.
The mark (❍) 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)
Cleaning / adjustment /
Spark plug(s) ● ●
replacement
Greasing points Greasing ●
Gear oil Change ● ●
Fuel system Inspection ● ● ●
Fuel filter (disposable) Inspection / replacement ●/❍ ●/❍ ●/❍
Fuel tank (Yamaha portable
Cleaning ●
tank)
Idling speed (carburetor
Inspection / adjustment ●/❍ ●/❍
models)
Anode(s) Inspection / replacement ●/❍ ●/❍ ❍
Cooling water passages Cleaning ● ●
Propeller and cotter pin Inspection / replacement ● ●
Timing belt Inspection / replacement ❍ ❍
Battery Inspection / charging ●/❍
Throttle link / throttle cable /
Inspection / adjustment ❍
throttle pick-up timing
Shift link / shift cable Inspection / adjustment ❍
Thermostat Inspection ❍
Power trim and tilt unit Inspection ❍
Water pump Inspection ❍
Engine oil Inspection / change ● ●
Inspection / cleaning /
Oil filter (built into oil pan) ❍
change
Valve clearance (OHC,
Inspection / adjustment ❍ ❍
OHV)
Cowling clamp Inspection ●
NOTE:
@

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

Every
Item Actions 500 hours 1000 hours
(2.5 years) (5 years)
Timing belt Replacement ❍

4-11
U68T15.book Page 12 Thursday, March 20, 2003 11:28 AM

E
EMU00366

GREASING
Yamaha marine grease
(Water resistant grease)

4-12
U68T15.book Page 13 Thursday, March 20, 2003 11:28 AM

E
EMU01202

CLEANING AND ADJUSTING SPARK


PLUG
WARNING
@

When removing or installing a spark


plug, be careful not to damage the insu-
lator. A damaged insulator could allow
external sparks, which could lead to
explosion or fire.
@

The spark plug is an important engine com-


ponent and is easy to inspect. The condition
of the spark plug can indicate something
about the condition of the engine. For exam-
ple, if the center electrode porcelain is very
white, this could indicate an intake air leak
or carburetion problem in that cylinder. Do
not attempt to diagnose any problems your-
self. Instead, take the outboard motor to a
Yamaha dealer. You should periodically
remove and inspect the spark plug because
heat and deposits will cause the spark plug
to slowly break down and erode. If electrode
erosion becomes excessive, or if carbon and
other deposits are excessive, you should
replace the spark plug with another of the
correct type.

Standard spark plug:


Refer to “SPECIFICATIONS”, page 4-1.

Before fitting the spark plug, measure the


electrode gap with a wire thickness gauge;
adjust the gap to specification if necessary.

Spark plug gap:


Refer to “SPECIFICATIONS”, page 4-1.

4-13
U68T15.book Page 14 Thursday, March 20, 2003 11:28 AM

E
When fitting the plug, always clean the gas-
ket 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:


Refer to “SPECIFICATIONS”, page 4-1.

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 correct torque as soon as possible with a
torque-wrench.
@

Initial of spark plug


Plug wrench size
I.D. mark
B 21 mm (13/16 in.)
C/BK 16 mm (5/8 in.)
D 18.3 mm (23/32 in.)

1 Spark plug gap


2 Spark plug I.D. mark (NGK)

4-14
U68T15.book Page 15 Thursday, March 20, 2003 11:28 AM

E
EMU01509

CHECKING FUEL SYSTEM


WARNING
@

Gasoline (petrol) and its vapors are


highly flammable and explosive. Keep
away from sparks, cigarettes, flames or
other sources of ignition.
@

Check the fuel line for leaks, cracks, or mal-


functions. If any problem is found, it should
be repaired immediately by Yamaha dealer
or other qualified mechanic.

Checkpoints
● Fuel system parts leakage.
● Fuel hose joint leakage.
● Fuel hose cracks or other damage.
● Fuel connector leakage.

WARNING
@

Leaking fuel can result in fire or explo-


sion.
● Check for fuel leakage regularly.
● If any fuel leakage is found, the fuel
system must be repaired by a qualified
mechanic. Improper repairs can make
the outboard unsafe to operate.
@

4-15
U68T15.book Page 16 Thursday, March 20, 2003 11:28 AM

E
EMU00370

INSPECTING FUEL FILTER


WARNING
@

Gasoline (petrol) is highly flammable,


and its vapors are flammable and explo-
sive.
● If you have any question about prop-
erly doing this procedure, consult your
Yamaha dealer.
● Do not perform this procedure on a hot
or running engine. Allow the engine to
cool.
● There will be fuel in the fuel filter. Keep
away from sparks, cigarettes, flames
or other sources of ignition.
● This procedure will allow some fuel to
spill. Catch fuel in a rag. Wipe up any
spilled fuel immediately.
● The fuel filter must be reassembled
carefully with O-ring, filter cup, and
hoses in place. Improper assembly or
replacement can result in a fuel leak,
which could result in a fire or explo-
sion hazard.
@

EMU00374¯

Check the fuel filter periodically.


The fuel filter is a one-piece, disposable
type. If foreign matter is found in the filter,
replace it. For replacement of the fuel filter,
consult a Yamaha dealer.

4-16
U68T15.book Page 17 Thursday, March 20, 2003 11:28 AM

E
EMU09912

INSPECTING IDLING SPEED


WARNING
@

● Do not touch or remove electrical parts


when starting or during operation.
● Keep hands, hair and clothes away
from flywheel and other rotating parts
while engine is running.
@

CAUTION:
@

This procedure must be performed while


the outboard motor is in the water. A
flushing attachment or test tank can also
be used.
@

A diagnostic tachometer should be used for


this procedure. Results may vary depending
on whether testing is conducted with the
flushing attachment, in a test tank, or with
the outboard motor in the water.
1) Start the engine and allow it to warm up
fully in neutral until it is running
smoothly. If the outboard motor is
mounted on a boat, be sure the boat is
tightly moored.
2) Verify whether the idle speed is set to
specification. For idle speed specifica-
tions, see “Specifications” in this chap-
ter.
NOTE:
@

Correct idling speed inspection is only pos-


sible if the engine is fully warmed up. If not
warmed up fully, the idle speed will measure
higher than normal. If you have difficulty ver-
ifying the idle speed, or the idle speed
requires adjustment, consult a Yamaha
dealer or other qualified mechanic.
@

4-17
U68T15.book Page 18 Thursday, March 20, 2003 11:28 AM

E
EMU01415¯

CHANGING ENGINE OIL


WARNING
@

● Avoid draining the engine oil immedi-


ately after stopping the engine. The oil
is hot and should be handled with care
to avoid burns.
● Be sure the outboard is securely fas-
tened to the transom or a stable stand.
@

CAUTION:
@

● Change the engine oil after the first 10


hours of operation, and every 100
hours or at 6-month intervals thereaf-
ter. Otherwise, the engine will wear
quickly.
● Do not overfill the oil, and be sure the
engine is in an upright position (not
tilted) when checking and changing
the engine oil.
● If the oil level is above the upper level
mark, drain until the level meets the
specified capacity. Overfilling the oil
may cause leakage or damage.
@

1) Put the outboard motor in an upright


position.
2) Prepare a suitable container which can
hold a larger amount than the engine oil
capacity. Loosen and remove the drain
bolt 1 while holding the container under
the drain hole. Let the oil drain com-
pletely. Wipe up any spilled oil immedi-
ately.
3) Put a new gasket on the drain bolt.
Apply a light coat of oil to the gasket and
reinstall the drain bolt.

Tightening torque:
Refer to “SPECIFICATIONS”, page 4-1.

4-18
U68T15.book Page 19 Thursday, March 20, 2003 11:28 AM

E
NOTE:
@

If a torque wrench is not available when you


are installing the drain plug, finger tighten
the bolt just until the gasket comes into con-
tact with the surface of the drain hole. Then
tighten 1/4 - 1/2 turn. Have the drain plug
torqued to the correct value with a torque
wrench as soon as possible.
@

4) Remove the oil filler cap 2. Add the cor-


rect amount of oil through the filler hole.
Reinstall the filler cap.

Engine oil grade/capacity:


Refer to “SPECIFICATIONS”, page 4-1.

5) Start the engine and watch to make sure


the low oil pressure warning lamp turns
off. Make sure that there are no oil
leaks.
CAUTION:
@

If the oil lamp does not turn off, or if there


are oil leaks, stop the engine and find the
cause. Continued operation with a prob-
lem could cause severe engine damage.
If the problem cannot be found and cor-
rected, consult your Yamaha dealer.
@

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.
7) Dispose of used oil according to local
regulations.
NOTE:
@

● For disposal of used oil consult your


Yamaha dealer.
● The oil should be changed more often
when the engine is operated under
adverse conditions such as extended
trolling.
@

4-19
U68T15.book Page 20 Thursday, March 20, 2003 11:28 AM

E
EMU01315

REPLACING FUSE
If the fuse has blown on an Electric start
model, open the fuse box and replace the
fuse with a spare one of proper amperage,
using a fuse puller.
WARNING
@

Be sure to use the specified fuse. An incor-


rect fuse or a piece of wire may allow
excessive current flow. This could cause
electrical system damage and a fire hazard.
@

NOTE:
@

If the new fuse blows again immediately,


consult a Yamaha dealer.
@

1 Fuse box
2 Fuse (10 A)
3 Spare fuse (10 A)
4 Fuse puller

EMU00383

CHECKING WIRING AND


CONNECTORS
1) Check that each grounding wire is prop-
erly secured.
2) Check that each connector is engaged
securely.

EMU00384

EXHAUST LEAKAGE
Start the engine and check that no exhaust
leaks from the joints between the exhaust
cover, cylinder head and crank case.

EMU00385

WATER LEAKAGE
Start the engine and check that no water
leaks from the joints between the exhaust
cover, cylinder head and crank case.

4-20
U68T15.book Page 21 Thursday, March 20, 2003 11:28 AM

E
EMU01322

CHECKING POWER TILT SYSTEM


WARNING
@

● Never get under the lower unit while it


is tilted, even when the tilt-support
knob is locked. Severe injury could
occur if the outboard accidentally falls.
● Make sure no one is under the out-
board before performing this test.
@

1) Check the power tilt unit for any sign of


oil leaks.
2) Operate each of the power tilt switches
on remote control and engine bottom
cowling (if equipped) to check that all
switches work.
3) Tilt up the motor and check that the tilt
rod 1 is pushed out completely.
4) Check that the tilt rod is free of corrosion
or other flaws.
5) Operate the motor to tilt down. Check
that the tilt rod operates smoothly.
NOTE:
@

If any operation is abnormal, consult a


Yamaha dealer.
@

Recommended fluid;
Yamaha power trim & tilt fluid or ATF
(DEXRON-II)

4-21
U68T15.book Page 22 Thursday, March 20, 2003 11:28 AM

E
EMU00388

CHECKING PROPELLER
WARNING
@

You could be seriously injured if the


engine accidentally starts while you are
near the propeller.
● Before inspecting, removing or install-
ing the propeller, remove the spark
plug caps from the spark plugs. Also,
put the shift control in Neutral, put the
main switch in the “OFF” position and
remove the key, and remove the lan-
yard from the engine stop switch. Turn
off the battery cut-off switch if your
boat has one.
● Do not use your hand to hold the pro-
peller when loosening or tightening
the propeller nut. Put a wood block
between the cavitation plate and the
propeller to prevent the propeller from
turning.
@

EMU00390

Propeller Checking Point


● Check each of the propeller blades for
wear, erosion from cavitation or ventila-
tion, or other damage.
● Check the splines for wear and damage.
● Check for fish line winding around the
propeller shaft.
● Check the propeller shaft oil seal for dam-
age.

4-22
U68T15.book Page 23 Thursday, March 20, 2003 11:28 AM

E
EMU01504
F6/F8 Removing the Propeller
1) Straighten the cotter pin 1 and pull it
out using a pair of pliers.
2) Remove the propeller nut 2, washer 3
and spacer 4.
3) Remove the propeller 5, washer 6 and
spacer 7.

EMU01505
T8 Installing the Propeller
CAUTION:
@

● Be sure to install the spacer and


washer before installing the propeller,
otherwise, the lower case and propel-
ler boss may be damaged.
● Be sure to use a new cotter pin and
bend the ends over securely, other-
wise, the propeller could come off dur-
ing operation and be lost.
@

1) Apply Yamaha Marine grease or Corro-


sion resistant grease to the propeller
shaft.
2) Install the spacer, washer and propeller
on the propeller shaft.
3) Install the spacer, washer and the pro-
peller nut, and then tighten the nut to the
specified torque.

Tightening torque:
Refer to “SPECIFICATIONS” page 4-1.

4) Align the propeller nut with the propeller


shaft hole. Insert a new cotter pin in the
hole and bend the cotter pin ends.
NOTE:
@

If the propeller nut does not align with the


propeller shaft hole after tightening to the
specified torque, then tighten the nut further
to align it with the hole.
@

4-23
U68T15.book Page 24 Thursday, March 20, 2003 11:28 AM

E
EMU01460

CHANGING GEAR OIL


WARNING
@

● Be sure the outboard is securely fas-


tened to the transom or a stable stand.
You could be severely injured if the
outboard falls on you.
● Never get under the lower unit while it
is tilted, even when the tilt-support
lever/knob is locked. Severe injury
could occur if the outboard acciden-
tally falls.
@

1) Tilt the outboard motor so that the oil


drain plug is at the lowest point possible.
2) Place a suitable container under the
gear-case.
3) Remove the oil drain plug 1.
NOTE:
@

The oil drain plug is magnetic. Remove all


metal particles from the plug before rein-
stalling it.
@

4) Remove the oil level plug 2 to allow the


oil to drain completely.
CAUTION:
@

Inspect the used oil after it has been


drained. If the oil is milky, water is getting
into the gear-case which can cause gear
damage. Consult a Yamaha dealer for
repair of the lower unit seals.
@

NOTE:
@

For disposal of used oil consult your Yamaha


dealer.
@

4-24
U68T15.book Page 25 Thursday, March 20, 2003 11:28 AM

E
5) With the outboard motor in a vertical
position, and using a flexible or pressur-
ized filling device, inject the gear oil into
the oil drain plug hole.

Gear oil grade/capacity:


Refer to “SPECIFICATIONS,” page 4-1.

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 oil drain plug.

4-25
U68T15.book Page 26 Thursday, March 20, 2003 11:28 AM

E
EMU01510

CLEANING FUEL TANK


WARNING
@

Gasoline (petrol) is highly flammable,


and its vapors are flammable and explo-
sive.
● If you have any question about prop-
erly doing this procedure, consult your
Yamaha dealer.
● Keep away from sparks, cigarettes,
flames or other sources of ignition
when cleaning the fuel tank.
● Remove the fuel tank from the boat
before cleaning it. Work only outdoors
in an area with good ventilation.
● Wipe up any spilled fuel immediately.
● Reassemble the fuel tank carefully.
Improper assembly can result in a fuel
leak, which could result in a fire or
explosion hazard.
● Dispose of old gasoline (petrol)
according to local regulations.
@

1) Empty the fuel tank into an approved


container.
2) Pour a small amount of suitable solvent
in the tank. Reinstall the cap and shake
the tank. Drain the solvent completely.

EMU00402

Cleaning the Fuel Filter


1) Remove the screws holding the fuel
hose joint assembly. Pull the assembly
out of the tank.
2) Clean the filter (located on the end of
the suction pipe) in a suitable cleaning
solvent. Allow the filter to dry.
3) Replace the gasket with a new one.
Reinstall the fuel hose joint assembly
and tighten the screws firmly.

4-26
U68T15.book Page 27 Thursday, March 20, 2003 11:28 AM

E
EMU14622
F6/F8 INSPECTING AND REPLACING
ANODE(S)
Yamaha outboard motors are protected from
corrosion by sacrificial anodes. Inspect the
external anodes periodically. Remove scales
from the surfaces of the anodes. Consult a
Yamaha dealer for replacement of external
anodes.
CAUTION:
@

Do not paint anodes, as this would ren-


T8 der them ineffective.
@

NOTE:
@

Inspect ground leads attached to external


anodes on equipped models. Consult a
Yamaha dealer for inspection and replace-
ment of internal anodes attached to the
power unit.
@

T8

4-27
U68T15.book Page 28 Thursday, March 20, 2003 11:28 AM

E
EMU04041

CHECKING BATTERY
(for Electric start models)
WARNING
@

Battery electrolytic fluid is dangerous; it


contains sulfuric acid and therefore is
poisonous and highly caustic.
Always follow these preventive mea-
sures:
● Avoid bodily contact with electrolytic
fluid as it can cause severe burns or
permanent eye injury.
● Wear protective eye gear when han-
dling or working near batteries.
Antidote (EXTERNAL):
● SKIN - Flush with water.
● EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
● Drink large quantities of water or milk
followed by milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive hydro-
gen gas; therefore, you should always
follow these preventive measures:
● Charge batteries in a well-ventilated
area.
● Keep batteries away from fire, sparks,
or open flames (e.g., welding equip-
ment, lighted cigarettes, etc.).
● DO NOT SMOKE when charging or
handling batteries.
● KEEP BATTERIES AND ELECTRO-
LYTIC FLUID OUT OF REACH OF CHIL-
DREN.
@

CAUTION:
@

● A poorly maintained battery will


quickly deteriorate.
● Ordinary tap-water contains minerals
harmful to a battery, and should not be
used for topping-up.
@

4-28
U68T15.book Page 29 Thursday, March 20, 2003 11:28 AM

E
1) Check the electrolyte level at least once
a month. Fill to the manufacturer’s rec-
ommended level when necessary. Top
up only with distilled water (or pure de-
ionized water suitable to use in batter-
ies).
2) Always keep the battery in a good state
of charge. Installing a voltmeter will help
you monitor your battery. If you will not
use the boat for a month or more,
remove the battery from the boat and
store it in a cool, dark place. Completely
recharge the battery before using it.
3) If the battery 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.
@

4-29
U68T15.book Page 30 Thursday, March 20, 2003 11:28 AM

E
EMU01279¯

Connecting the Battery


WARNING
@

Mount the battery holder securely in a


dry, well-ventilated, vibration-free loca-
tion in the boat. Install a fully charged
battery in the holder.
@

CAUTION:
@

● Make sure the main switch (on applica-


ble models) is “OFF” before working
on the battery.
● Reversal of the battery leads will dam-
age the rectifier.
● Connect the RED lead first when
installing the battery and disconnect
the RED lead last when removing it.
Otherwise, the electrical system can
be damaged.
● The electrical contacts of the battery
and cables must be clean and properly
connected, or the battery will not start
the engine.
@

Connect the RED lead to the POSITIVE (+)


terminal first.
Then connect the BLACK lead to the NEGA-
TIVE (-) terminal.

1 Red lead
2 Black lead
3 Battery

EMU01280

Disconnecting the Battery


Disconnect the BLACK lead from the NEGA-
TIVE (-) terminal first. Then disconnect the
RED lead from the POSITIVE (+) terminal.

4-30
U68T15.book Page 31 Thursday, March 20, 2003 11:28 AM

E
EMU00408

CHECKING BOLTS AND NUTS


1) Check that bolts securing the cylinder
head and engine and the nut securing
the flywheel are tightened with their
specified tightening torque.
2) Check the tightening torque of other
bolts and nuts.

4-31
U68T15.book Page 32 Thursday, March 20, 2003 11:28 AM

E
EMU01172

CLEANING COOLING-WATER
PASSAGES
Flushing device equipped model
Perform this procedure right after operation
for the most thorough flushing.
1) After shutting off the engine, unscrew
the garden-hose connector 2 from the
fitting 1 on the bottom cowling.
2) Screw the garden-hose connector 2
onto a garden hose 3 which is con-
nected to a fresh-water supply.
3) With the engine off, turn on the water
tap and let the water flush through the
cooling passages for about 15 minutes.
Turn off the water and disconnect the
garden hose 3.
4) When flushing is complete, reinstall the
garden-hose connector 2 on the fitting
1 on the bottom cowling. Tighten the
connector securely.
CAUTION:
@

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
cause serious overheating. Be sure the
connector is tightened securely on the
fitting after flushing the engine.
@

NOTE:
@

● When flushing the engine with the boat in


the water, tilting up the engine until it is
completely out of the water will achieve
better results.
● Refer to cooling system flushing instruc-
tions in “TRANSPORTING AND STOR-
ING OUTBOARD MOTOR”.
@

4-32
U68T15.book Page 33 Thursday, March 20, 2003 11:28 AM

E
EMU16350

CHECKING TOP COWLING


Check the fitting of the top cowling by push-
ing it with both hands.
If the fitting is loose have it repaired by a
Yamaha dealer.

EMU00409

MOTOR EXTERIOR

EMU00410

Cleaning the Outboard Motor


After use, wash the exterior of the outboard
with fresh water. Flush the cooling system
with fresh water.
NOTE:
@

Refer to Flushing Cooling System instruc-


tions in “TRANSPORTING AND STORING
OUTBOARD MOTOR”.
@

EMU00412

Checking Painted Surface of Motor


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

EMU00413

COATING THE BOAT BOTTOM


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

4-33
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

EMU00414

Chapter 5
TROUBLE RECOVERY

TROUBLESHOOTING ...............................5-1

TEMPORARY ACTION IN
EMERGENCY .............................................5-4
Impact damage ........................................5-4
Power tilt will not operate.........................5-4
Starter will not operate .............................5-5
Engine fails to operate .............................5-8
Treatment of submerged motor...............5-9

5
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

E
EMU01752¯

TROUBLESHOOTING

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of
power, or other problems. The troubleshooting chart describes basic checks and possible
remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not
apply to your model.)

If your outboard motor requires repair, bring it to a Yamaha dealer.


If the engine warning indicator is flashing, consult your Yamaha dealer.

Trouble Possible Cause Remedy

1. Battery capacity weak or low. 1. Check battery condition. Use battery of


recommended capacity.
2. Battery connections loose or corroded. 2. Tighten battery cables and clean bat-
tery terminals.
A. Starter will not
3. Fuse for electric start circuit blown. 3. Check for cause of electric overload
operate.
and repair. Replace fuse with one of
correct amperage.
4. Starter components faulty. 4. Have serviced by a Yamaha dealer.
5. Shift lever in gear. 5. Shift to neutral.
1. Fuel tank empty. 1. Fill tank with clean, fresh fuel.
2. Fuel contaminated or stale. 2. Fill tank with clean, fresh fuel.
3. Fuel filter clogged. 3. Clean or replace filter.
4. Starting procedure incorrect. 4. Read “STARTING ENGINE” section.
5. Fuel pump malfunctions. 5. Have serviced by a Yamaha dealer.
6. Spark plug(s) fouled or incorrect type. 6. Inspect spark plug(s). Clean or replace
with recommended type.
B. Engine will not start
(Starter operates). 7. Spark plug cap(s) fitted incorrectly. 7. Check and re-fit cap(s).
8. Poor connections or damaged ignition 8. Check wires for wear or breaks.
wiring. Tighten all loose connections.
Replace worn or broken wires.
9. Ignition parts faulty. 9. Have serviced by a Yamaha dealer.
10. Engine stop switch lanyard not 10. Attach lanyard.
attached.
11. Engine inner parts damaged. 11. Have serviced by a Yamaha dealer.

5-1
U68T15.book Page 2 Thursday, March 20, 2003 11:28 AM

Trouble Possible Cause Remedy

1. Spark plug(s) fouled or incorrect type. 1. Inspect spark plug(s). Clean or replace
with recommended type.
2. Fuel system obstructed. 2. Check for pinched or kinked fuel line or
other obstructions in fuel system.
3. Fuel contaminated or stale. 3. Fill tank with clean, fresh fuel.
4. Fuel filter clogged. 4. Clean or replace filter.
5. Failed ignition parts. 5. Have serviced by a Yamaha dealer.
6. Warning system activated. 6. Find and correct cause of warning.
7. Spark plug gap incorrect. 7. Inspect and adjust as specified.
8. Poor connections or damaged ignition 8. Check wires for wear or breaks.
wiring. Tighten all loose connections.
Replace worn or broken wires.
C. Engine idles
irregularly or stalls. 9. Specified engine oil not used. 9. Check and replace oil as specified.
10. Thermostat faulty or clogged. 10. Have serviced by a Yamaha dealer.
11. Carburetor adjustments incorrect. 11. Have serviced by a Yamaha dealer.
12. Fuel pump damaged. 12. Have serviced by a Yamaha dealer.
13. Air vent screw on the fuel tank closed. 13. Open the air vent screw.
14. Choke knob pulled out. 14. Return to home position.
15. Motor angle too high. 15. Return to normal operating position.
16. Carburetor clogged. 16. Have serviced by a Yamaha dealer.
17. Fuel joint connection incorrect. 17. Connect correctly.
18. Throttle valve adjustment incorrect. 18. Have serviced by a Yamaha dealer.
19. Battery lead disconnected. 19. Connect securely.
1. Engine oil level low. 1. Fill oil tank with specified engine oil.
2. Specified engine oil not used. 2. Check and replace oil with specified
type.
D. Warning buzzer
sounds or indicator 3. Engine oil contaminated or deterio- 3. Replace oil with fresh, specified type.
lamp lights. rated.
4. Oil filter clogged. 4. Have serviced by a Yamaha dealer.
5. Oil feed/injection pump malfunctions. 5. Have serviced by a Yamaha dealer.

5-2
U68T15.book Page 3 Thursday, March 20, 2003 11:28 AM

Trouble Possible Cause Remedy

1. Propeller damaged. 1. Have propeller repaired or replaced.


2. Propeller pitch or diameter incorrect. 2. Install correct propeller to operate out-
board at its recommended speed
(r/min) range.
3. Trim angle incorrect. 3. Adjust trim angle to achieve most effi-
cient operation.
4. Motor mounted at incorrect height on 4. Have motor adjusted to proper transom
transom. height.
5. Warning system activated. 5. Find and correct cause of warning.
6. Boat bottom fouled with marine growth. 6. Clean boat bottom.
7. Spark plug(s) fouled or incorrect type. 7. Inspect spark plug(s). Clean or replace
with recommended type.
8. Weeds or other foreign matter tangled 8. Remove foreign matter and clean lower
on gear housing. unit.
9. Fuel system obstructed. 9. Check for pinched or kinked fuel line or
other obstructions in fuel system.
10. Fuel filter clogged. 10. Clean or replace filter.
E. Engine power loss.
11. Fuel contaminated or stale. 11. Fill tank with clean, fresh fuel.
12. Spark plug gap incorrect. 12. Inspect and adjust as specified.
13. Poor connections or damaged ignition 13. Check wires for wear or breaks.
wiring. Tighten all loose connections.
Replace worn or broken wires.
14. Failed ignition parts. 14. Have serviced by a Yamaha dealer.
15. Specified engine oil not used. 15. Check and replace oil with specified
type.
16. Thermostat faulty or clogged. 16. Have serviced by a Yamaha dealer.
17. Air vent screw closed. 17. Open the air vent screw.
18. Fuel pump damaged. 18. Have serviced by a Yamaha dealer.
19. Fuel joint connection incorrect. 19. Connect correctly.
20. Heat range of spark plug incorrect. 20. Inspect spark plug and replace it with
recommended type.
21. Engine not responding properly to shift 21. Have serviced by a Yamaha dealer.
lever position.
1. Propeller damaged. 1. Have propeller repaired or replaced.
2. Propeller shaft damaged. 2. Have serviced by a Yamaha dealer.
3. Weeds or other foreign matter tangled 3. Remove and clean propeller.
F. Engine vibrates on propeller.
excessively. 4. Motor mounting bolt loose. 4. Tighten bolt.
5. Clamp screw is loose. 5. Tighten the clamp screw.
6. Steering pivot loose or damaged. 6. Tighten or have serviced by a Yamaha
dealer.

5-3
U68T15.book Page 4 Thursday, March 20, 2003 11:28 AM

E
EMU00416

TEMPORARY ACTION IN
EMERGENCY
EMU01492

IMPACT DAMAGE
WARNING
@

The outboard motor can be seriously


damaged by a collision while operating
or trailering. Damage could make the
outboard motor unsafe to operate.
@

If the outboard motor hits any object in the


water, follow the procedure below.
1) Stop the engine immediately.
2) Inspect the control system and all com-
ponents for damage. Also, inspect the
boat for damage.
3) Whether damage is found or not, return
to the nearest harbor slowly and care-
fully.
4) Have a Yamaha dealer inspect the out-
board motor before operating it again.

EMU01321

POWER TILT WILL NOT OPERATE


If the engine cannot be tilted up or down
with the power tilt because of a discharged
battery or a failure with the power tilt unit,
the engine can be tilted manually.

1 Manual valve screw

EMU00421¯

1) Loosen the manual valve screw counter-


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

5-4
U68T15.book Page 5 Thursday, March 20, 2003 11:28 AM

E
EMU00423

STARTER WILL NOT OPERATE


If the starter mechanism does not operate
(engine cannot be cranked with the starter),
the engine can be started with an emer-
gency starter rope.
WARNING
@

● Use this procedure only in an emer-


gency and only to return to port for
repairs.
● When the emergency starter rope is
used to start the engine, the start-in-
gear protection device does not oper-
ate. Make sure the gear shift lever/
remote control lever is in neutral. Oth-
erwise, the boat could unexpectedly
start to move, which could result in an
accident.
● Be sure no one is standing behind you
when pulling the starter rope. It could
whip behind you and injure someone.
● An unguarded rotating flywheel is very
dangerous. Keep loose clothing and
other objects away when starting the
engine. Use the emergency starter
rope only as instructed. Do not touch
the flywheel or other moving parts
when the engine is running. Do not
install the starter mechanism or top
cowling after the engine is running.
● Do not touch the ignition coil, high
voltage wire, spark plug cap or other
electrical components when starting
of operating the motor. You could be
shocked.
@

5-5
U68T15.book Page 6 Thursday, March 20, 2003 11:28 AM

E
EMU01513¯

Emergency Starting Engine


1) Remove the top cowling.
2) Remove the start-in-gear protection
cable from the starter if equipped.

3) Remove the starter/flywheel cover after


removing the bolt(s).

4) Prepare the engine for starting. Refer to


“STARTING ENGINE” for details. Be
sure the engine is in Neutral and that
the lock plate is attached to the engine
stop lanyard switch. The main switch
must be “ON” if equipped.

5-6
U68T15.book Page 7 Thursday, March 20, 2003 11:28 AM

E
5) Insert the knotted end of the emergency
starter rope into the notch in the fly-
wheel rotor and wind the rope 1 or 2
turns clockwise.
6) Give a strong pull straight out to crank
and start the engine. Repeat if neces-
sary.

5-7
U68T15.book Page 8 Thursday, March 20, 2003 11:28 AM

E
EMU01363

ENGINE FAILS TO OPERATE


If the engine stops unexpectedly, or if the
engine does not start, you may attempt to
use the following emergency circuit proce-
dure. Before using this procedure, be sure to
check the “TROUBLESHOOTING” section
to eliminate causes such as low fuel or over-
heating.
CAUTION:
@

● This emergency circuit should only be


used to return to the nearest harbor for
repairs in an emergency. Do not use it
again without getting repairs.
● When using the emergency circuit the
engine control systems will not make
the proper adjustments for operating
conditions. Operate only at low speed
(less than one-quarter throttle). Higher
engine speeds could result in damage
to the engine.
@

To start the engine


1) Adjust the trim so that the engine is ver-
tical.
2) Remove the top cowling and locate the
yellow wire in the harness.
3) Disconnect the connector for the yellow
wire. (The control circuit for the CDI unit
will be connected directly.)
4) Install the top cowling.
5) Start the engine using the procedures
under “STARTING THE ENGINE.”

1 Yellow cord

5-8
U68T15.book Page 9 Thursday, March 20, 2003 11:28 AM

E
EMU01511

TREATMENT OF SUBMERGED
MOTOR
If the outboard motor is submerged, immedi-
ately take it a Yamaha dealer. Otherwise,
some corrosion may begin almost immedi-
ately.
If you cannot immediately take the outboard
motor to a Yamaha dealer, follow the proce-
dure below in order to minimize engine dam-
age.

EMU00448

1) Thoroughly wash away mud, salt, sea-


weed, etc. with fresh water.
2) Remove the spark plug(s), then face the
spark plug holes downward to allow any
water, mud or contaminants to drain.
3) Drain the fuel from the carburetor, fuel
filter and fuel line. Drain the engine oil
completely.
4) Fill the sump with the fresh engine oil as
the same quantity as the engine oil
capacity.

Engine oil capacity:


Refer to SPECIFICATIONS, Page 4-1.

5) Feed engine fogging oil or engine oil


through the carburetor(s) and spark plug
hole(s) while cranking the engine with
the manual starter or emergency starter
rope.
6) Take the outboard motor to a Yamaha
dealer as soon as possible.
CAUTION:
@

Do not attempt to run the motor until it


has been completely inspected.
@

5-9
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

EMU00450

Chapter 6
INDEX

INDEX ..........................................................6-1

6
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

E
EMU00451 E
INDEX Electric start models ...................................... 3-12
Electric start models ...................................... 3-14
Emergency starting engine.............................. 5-6
A Emission control information ........................... 1-2
Adjusting trim angle ....................................... 3-20
Engine ............................................................. 3-7
Air vent screw .................................................. 2-3
Engine fails to operate..................................... 5-8
Approval label of emission control certificate... 1-2 Engine oil....................................................... 1-13
B
Engine stop button........................................... 2-7
Basic boating rules (rules of the road) ............. 1-7
Engine stop lanyard switch..................... 2-7, 2-11
Battery care ..................................................... 4-9 Exhaust leakage ............................................ 4-20
Battery requirement ....................................... 1-14 F
Breaking in (running in) engine........................ 3-5
Filling fuel ........................................................ 3-8
C Filling fuel tank................................................. 4-6
Caution labels .................................................. 1-6
Fishing vessel right-of-way .............................. 1-9
Changing engine oil ....................................... 4-18
Flushing cooling system and fogging engine... 4-6
Changing gear oil........................................... 4-24 Flushing device.............................................. 2-16
Checking battery (for electric start models) ... 4-28
Forward ......................................................... 3-16
Checking bolts and nuts ................................ 4-31
Fuel.................................................................. 3-6
Checking fuel system..................................... 4-15 Fuel hose joint ................................................. 2-3
Checking painted surface of motor ................ 4-33
Fueling instructions........................................ 1-11
Checking points after starting engine ............ 3-15
Fuel meter ....................................................... 2-3
Checking power tilt system ............................ 4-21 Fuel tank.......................................................... 2-3
Checking propeller......................................... 4-22
Fuel tank cap ................................................... 2-3
Checking the engine oil level ........................... 3-7 G
Checking top cowling..................................... 4-33 Gasohol ......................................................... 1-12
Checking wiring and connectors.................... 4-20
Gasoline ........................................................ 1-12
Checkpoints ................................................... 4-15
Gear shift lever ................................................ 2-5
Choke knob...................................................... 2-4 Give-way vessel .............................................. 1-7
Choke switch ................................................. 2-11
Greasing ........................................................ 4-12
Clamping the outboard motor .......................... 3-4 I
Cleaning and adjusting spark plug................. 4-13 Identification numbers record .......................... 1-1
Cleaning and anti-corrosion measure.............. 4-8
Impact damage................................................ 5-4
Cleaning cooling-water passages.................. 4-32
Important labels ............................................... 1-6
Cleaning fuel tank .......................................... 4-26 Inspecting and replacing anode(s) ................ 4-27
Cleaning the fuel filter .................................... 4-26
Inspecting fuel filter........................................ 4-16
Cleaning the outboard motor ......................... 4-33
Inspecting idling speed .................................. 4-17
Coating the boat bottom ................................ 4-33 Installation ....................................................... 3-1
Connecting the battery................................... 4-30
Installing the propeller ................................... 4-23
Controls ........................................................... 3-7 K
Crossing........................................................... 1-8 Key number ..................................................... 1-1
Cruising in other conditions ........................... 3-32 L
Cruising in salt water ..................................... 3-32
Low oil pressure warning............................... 2-17
Cruising in shallow water ...................... 3-28, 3-30 Lubrication ....................................................... 4-8
Cruising in turbid water .................................. 3-32 M
D
Main components ............................................ 2-1
Disconnecting the battery .............................. 4-30 Main switch.................................................... 2-10
Maintenance chart ......................................... 4-11
Manual start models ...................................... 3-11

6-1
U68T15.book Page 2 Thursday, March 20, 2003 11:28 AM

E
Manual tilt model............................................ 3-20 S
Manufactured date label .................................. 1-2 Safety information............................................ 1-4
Meeting ............................................................ 1-8 Sailing vessel right-of-way............................... 1-9
Motor exterior................................................. 4-33 Shifting........................................................... 3-16
Mounting height ............................................... 3-3 Specifications .................................................. 4-1
Mounting the outboard motor........................... 3-2 Stand-on vessel............................................... 1-7
Multifunction tiller handle ................................. 2-5 Star labels........................................................ 1-3
N Starter button (for tiller control model) ............. 2-4
Narrow channels and bends ............................ 1-9 Starter will not operate..................................... 5-5
Neutral interlock trigger.................................... 2-9 Start-in-gear protection.................................. 1-16
Neutral throttle lever ...................................... 2-10 Starting engine ................................................ 3-9
New technology ; (4-stroke/HPDI) EM............. 1-2 Steering and sailing rules and sound
North american models.................................... 1-2 signals ............................................................. 1-7
O Steering friction adjusting lever ..................... 2-13
Oil .................................................................... 3-6 Stopping engine............................................. 3-18
One star - low emission ................................... 1-3 Storing outboard motor.................................... 4-5
Operations of controls and other functions ...... 2-3 T
Other special situations ................................... 1-9 Temporary action in emergency ...................... 5-4
Outboard motor serial number......................... 1-1 Three stars - ultra low emission....................... 1-3
Overtaking ....................................................... 1-8 Throttle control grip.......................................... 2-6
P Throttle friction adjusting knob......................... 2-6
Periodic maintenance .................................... 4-10 Throttle friction adjusting screw ..................... 2-12
Power tilt switch ...................................... 2-8, 2-12 Throttle indicator.............................................. 2-6
Power tilt unit ................................................. 2-15 Tiller handle ..................................................... 2-5
Power tilt will not operate................................. 5-4 Tilting up/down .............................................. 3-24
Power trim/tilt switch ...................................... 2-14 Tilt lock mechanism (for manual tilt model) ... 2-14
Pre-operation checks....................................... 3-6 Tilt support bar............................................... 2-15
Procedure ............................................. 3-29, 3-30 Tilt support knob ............................................ 2-15
Procedure for remote control model .............. 3-13 Top cowling lock lever ................................... 2-16
Procedure for tiller control model................... 3-10 Trailering outboard motor ................................ 4-4
Procedure for tilting down ..................... 3-25, 3-27 Transporting and storing outboard motor ........ 4-4
Procedure for tilting up.......................... 3-25, 3-26 Transporting outboard when unmounted......... 4-5
Propeller checking point ................................ 4-22 Treatment of submerged motor ....................... 5-9
Propeller selection ......................................... 1-15 Trim angle adjusting rod ................................ 2-13
R Trim angle settings and boat handling........... 3-23
Reading buoys and other markers................... 1-9 Trimming outboard motor .............................. 3-19
Recoil starter handle (if equipped)................... 2-4 Troubleshooting............................................... 5-1
Remote control ................................................ 2-8 Two stars - very low emission ......................... 1-3
Remote control lever........................................ 2-9 W
Removing the propeller.................................. 4-23 Warming up engine ....................................... 3-15
Replacement parts......................................... 4-10 Warning indicator(s) ...................................... 2-16
Replacing fuse ............................................... 4-20 Warning labels................................................. 1-6
Returning to original position ......................... 3-29 Warning system............................................. 2-17
Reverse ......................................................... 3-17 Water leakage ............................................... 4-20
Ring free fuel additive ...................................... 3-8
Rules when encountering vessels ................... 1-8

6-2
U68T15.book Page 1 Thursday, March 20, 2003 11:28 AM

EMU01599

IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND


CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is com-
mitted to exceptional customer satisfaction, and we want your ownership experience
to be a satisfying one. Please read the following warranty information to help ensure
satisfaction with your Yamaha.

Yamaha is ready to stand behind your purchase with strong warranty coverage. To be sure
you receive all the benefits of warranty, please take the following steps:

1. Be sure your new Yamaha is registered for warranty. Your boat dealer should do this at
the time of sale. Make sure your dealer gives you a copy of the completed Yamaha reg-
istration card for your records. If you are unsure whether or not your Yamaha is regis-
tered, complete the Warranty Registration card found inside the cover of the Owner’s
Manual. Mail it to the distributor for the country in which you live (see step 6 for the cor-
rect address). If your Yamaha is not properly registered, a warranty repair could be
unnecessarily delayed while registration records are checked.

2. Read the Limited Warranty statement which follows these instructions. This warranty
applies to Yamaha outboard motors sold in the United States, whether purchased sepa-
rately or when supplied as original equipment by a boat builder. The terms also apply to
original equipment packages sold in Canada, with coverage provided by Yamaha Motor
Canada (see ‘‘Warranty Guide’’ for Canadian models). This warranty explains the condi-
tions of the warranty, including the obligations that your dealer and you as the owner
have under the warranty. For example, your Yamaha outboard must receive a proper
pre-delivery inspection (PDI) by the selling dealer. Failure to take this important step
could jeopardize warranty coverage!

3. If you need warranty repairs, you must take your Yamaha outboard to an authorized
Yamaha outboard dealer. Be aware that not all selling boat dealers are authorized
Yamaha dealers. Only authorized dealers have the factory training, special tools, and
Yamaha support needed to perform warranty repairs.

4. If you are away from home, or your selling dealer is not an authorized Yamaha dealer,
use the following toll-free numbers to find the nearest Yamaha dealer.

United States Dealer Locations: 1-800-692-6242


Canada Dealer Locations: 1-800-267-8577
U68T15.book Page 2 Thursday, March 20, 2003 11:28 AM

5. Your warranty applies specifically to repairs made in the country of purchase. If your
U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian
purchased Yamaha needs service while in the United States, Yamaha will assist the
local dealer whenever possible. However, some products available in one country may
not be sold or serviced in the other.

6. If you need any additional information about your Yamaha or warranty coverage which
your dealer cannot provide, please contact us directly.

Yamaha Motor Corporation, U.S.A.


P.O. Box 6555
Cypress, CA 90630
Attention: Customer Relations Department

Telephone No. (714) 761-7439


Fax No. (714) 761-7559

Yamaha Motor Canada Ltd.


480 Gordon Baker Road
Toronto, Ontario
M2H 3B4
Attention: Customer Relations Department

Telephone No. (416) 498-1911


Fax No. (416) 491-3122
U68T15.book Page 3 Thursday, March 20, 2003 11:28 AM

EMU01404

YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE


OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY
Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha 1999-or-later model four-stroke outboard motors originally distrib-
uted by Yamaha Motor Corporation, U.S.A. will be free from defects in material and workmanship for the period of time stated herein, sub-
ject to certain stated limitations. Warranty coverage for outboards distributed by non-US Yamaha affiliated companies may be different.

PERIOD OF WARRANTY. Any new Yamaha 1999-or-later model four-stroke outboard motor purchased and registered with Yamaha
Motor Corporation, U.S.A. for pleasure use in the United States, will be warranted against defects in material or workmanship for a period
of three (3) years from the date of purchase, subject to exclusions noted herein. Any Yamaha outboard motor purchased and utilized for
commercial applications will be warranted for a period of one (1) year from the date of purchase, subject to exclusions noted herein.
Yamaha peripheral equipment included with the motor, such as gauges, fuel tanks, and hoses, remote control boxes, and wiring external
from the motor unit, will be warranted for one (1) year from the date of purchase of either pleasure or commercial use. Replacement parts
used in warranty repairs will be warranted for the balance of the applicable warranty period.

The second and third year of warranty (if applicable) shall be limited to covering the cost of parts and labor for major components only. The
major components covered are:

Power Unit Section


● Power Head
● Intake Manifold
● Carburetor Assembly and its Related Components
● Fuel Injection System and its Related Components
● Fuel and Oil Pump Assemblies
● Ignition System (Standard and Microcomputer)

Lower Unit Section


● Exhaust System
● Upper Casing
● Lower Unit Assembly

Bracket Section
● Bracket System
● Power Trim and Tilt Assembly

WARRANTY REGISTRATION. To be eligible for warranty coverage, the outboard motor must be registered with Yamaha Motor Corpora-
tion, U.S.A. Warranty registration can be accomplished by any authorized Yamaha Outboard Motor Dealer. Upon receipt of the registra-
tion, an Owner’s Warranty Card will be sent by Yamaha to the registered purchaser.

OBTAINING REPAIRS UNDER WARRANTY. To receive repairs under this warranty, a valid Owner’s Warranty Card must be presented to
an authorized Yamaha Outboard Motor Dealer.

During the period of warranty, any authorized Yamaha outboard dealer will, free of charge, repair or replace, at Yamaha’s option, any parts
adjudged defective by Yamaha due to faulty workmanship or material from the factory. All replaced parts will become the property of
Yamaha Motor Corporation, U.S.A.

CUSTOMER’S RESPONSIBILITY. Under the terms of this warranty, the customer will be responsible for ensuring that the outboard motor
is properly operated, maintained, and stored as specified in the applicable Owner’s Manual.

The owner of the outboard motor shall give notice to an authorized Yamaha Outboard Motor Dealer of any and all apparent defects within
ten (10) days of discovery and make the motor available at that time for inspection and repairs at the dealer’s place of business.

GENERAL EXCLUSIONS FROM WARRANTY. This warranty will not cover the repair of damage if the damage is a result of abuse or
neglect of the product. Examples of abuse and neglect include, but are not limited to:

1. Racing or competition use, modification of original parts, abnormal strain.


2. Lack of proper maintenance and off season storage as described in the Owner’s Manual, installation of parts or accessories that are
not equivalent in design and quality genuine Yamaha parts.
3. Operation of the motor at an rpm other than specified, use of lubricants or oils that are not suitable for outboard motor use.
4. Damage as a result of accidents, collisions, contact with foreign materials, or submersion.
5. Growth of marine organism on motor surfaces.
6. Normal deterioration.
U68T15.book Page 4 Thursday, March 20, 2003 11:28 AM

SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs,
shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes, are
not covered by warranty.

Charges for removal of the motor from a boat and transporting the motor to and from an authorized Yamaha Outboard Motor Dealer are
excluded from warranty coverage.
Specific parts excluded from the second and third year of warranty (if applicable) are:
● Top and Bottom Cowling
● Electric Components (other than ignition system)
● Rubber Components (such as hoses, tubes, rubber seals, fittings, and clamps)

TRANSFER OF WARRANTY. Transfer of the warranty from the original purchaser to any subsequent purchaser is possible by having the
motor inspected by an authorized Yamaha Outboard Motor Dealer and requesting the dealer to submit a change of registration to Yamaha
Motor Corporation, U.S.A. within ten (10) days of the transfer.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGA-
TIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A.
AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS
MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUEN-
TIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM
STATE TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A.


Post Office Box 6555
Cypress, California 90630
U68T15.book Page 5 Thursday, March 20, 2003 11:28 AM

EMU01178

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR


YAMAHA OUTSIDE U.S.A. OR CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is com-
mitted to exceptional customer satisfaction, and we want your ownership experience
to be a satisfying one. Please read the following warranty information to help ensure
satisfaction with your Yamaha.

This model was manufactured as a U.S.A. specification model, and the warranty statement
shown in this manual is for market. To receive the benefits of the warranty that applies to the
country in which you use your Yamaha, please note the following information.

1. The warranty on this model is the same as equivalent models sold in the country where
you will receive service. If you need more information about your warranty coverage or
your Yamaha outside the U.S.A. or Canada, please contact an authorized Yamaha
dealer in your country.

2. Keep a copy of your sales contract or invoice for the purchase of your Yamaha and
present it if you need warranty repairs. This document should show the date of pur-
chase, which is important evidence the repairing dealer will need to be sure your
Yamaha is covered by warranty.

3. If your Yamaha needs warranty repairs, contact an authorized Yamaha dealer in the
country where you are. He will explain how to get warranty service in that country.

4. This Yamaha model may not be sold in some countries. Therefore, in some cases your
local dealer may not have all the parts or service information he may need, which may
unavoidably delay repairs. If this happens, we thank you for your understanding and
assure you we will attempt to resolve the situation as quickly as possible.
F6C
F8C
T8C

YAMAHA MOTOR CORPORATION, USA


Printed in Japan
OWNER’S MANUAL
March 2003–3.0 × 1 CR
68T-28199-15
(F6AMH, F8CMH, FT8DEHP, FT8DWH, FT8DEP)
U.S.A.Edition
(E)
LIT-18626-05-31
Printed on recycled paper
Warranty card 2/27/02 11:47 AM Page 1

OUTBOARD MOTOR WARRANTY REGISTRATION


ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD
Please complete and mail this card. This information is necessary to accurately register your unit for warranty.
Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et
que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.
OUTBOARD MOTOR MODEL AND SERIAL NUMBER (From I.D. label on clamp bracket) (For Dealer Use Only)
MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation) (A l’usage du concessionnaire)
YAMAHA DEALER NUMBER
NO. DU CONCESSIONNAIRE
YAMAHA

YAMAHA MOTOR CO., LTD. DEALER NAME


NOM DU
MADE IN JAPAN CONCESSIONNAIRE
PAYS D'ORIGINE JAPON

USAGE PLEASURE
DATE SOLD (Check One) LOISIR
DATE DE UTILISATION COMMERCIAL
LIVRAISON (En cocher un.) COMMERCIAL
MONTH DAY YEAR
OWNER’S NAME MOIS JOUR ANNÉE
NOM DU
PROPRIÉTAIRE
FIRST LAST
ADDRESS PRÉNOM NOM DE FAMILLE
ADRESSE
STREET
RUE

CITY STATE/PROVINCE ZIP


PHONE NUMBER ( )
VILLE PROVINCE CODE POSTAL
NUMÉRO DE TÉLÉPHONE
Warranty card 2/27/02 11:47 AM Page 2
PLACE
POSTAGE
HERE
ATTN: WARRANTY DEPARTMENT

You might also like