Yamaha Owners Manual 40 50 HP

----~- ~~~-

-~-OWNER'S MANUAL

outboard

motor

4 140HED

50DEO/5DDETD

A-989

[

- -IMPORTANT:

---

--

---W~~_crUiSing,b~~ure

to

ca~1"Y s~are

Oil

_

If the yellow all level warning lamp comes on during a cruise, add oil to the oil tank

im-mediately.

Should spare all be unavailable:

Proceed to the nearest port for oil refilling.

TA;lt

_!lIN

__.I".

_U-

t:

.----",IS

w i ' "

Avoid contln Ulng engine operation

seizure could occur.

A-510'

, - - - - -

-40HM/40HEO/50DEO/SODETO

OWNER'S MANUAL

©1984 by Yamaha Motor Co., Ltd.

1st Edition, May 1984

All rights reserved. Any reprinting or

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

A-ooo

TO THE OWNER

Thank you for choosing a Yamaha outboard motor This

manual cont"lJns the information required for proper mam-tenance, care and operation A thorough understanding of these simple Instructionswill help you toobtainmaxim um

enjoyment 'from your new Yamaha

A 300

-IMPORTANT.

Before operating this outboard motor. read this

Owner's Manual thoroughly and carefully It

will

give

you

a

good

grasp

of the engme's

characteris~

tiCS and the technical information required for

safe operation

•

SpecIfIcatIons givenInthIs manual may be subject to change without pnor notice

Yamaha Motor Co , Ltd

PartIcularly Important informatIonlS dIstInguIshed In thIs man ualby

the

followingnotatIons

NOTE - - --~--- - -

-A NOTE prOVIdes key informatIon

to

make procedures easier or clearer

A·200

'1,·';tNlN'-

---• Before operating this outboard motor,

famIliar-ize yourself with the regulations set forth by

your state

In

relation to outboard motor

opera-tion

• Gasoline is highly inflammable andexplosive Handle

it

with specIal care

•

Never attempt to modify

this

outboard motor

• Be sure to wear life jackets on board.

•

Exercise speCial care to protect the

environ-ment

I

~- ~:~~~~~~dlcates specla~~~:e~:res t~~ mu~t

followed to avoId damage to the outboard motor

bj

-

--

- - - ~

-l

'>'t";j~"¢'. -~-

- - - -

~-

-

----J

A WARNING

Indicates special procedures

that must be followed

to avoid

personal injuryor

dam-8ge

to the Unit

-CONTENTS

LOCATiON OF MAIN COMPONENTS

Accessory parts

SPECIFICATIONS .

-"

_{OUTBOARD MOTOR IDENTIFICATION}

Outboard motor senal number

Engme senal number ENGINE MOUNTING

Mounting position Mounting height,

Clamp.

Remote control mounting

""I'd·lim.ii,N".,....

Installing the steering gUide attachments

Ilu#l:tet4iuni,'h"'·),it.

Battery mounting

1In:""+ili,J#n¥N"i'"

[nstalilng the meters

FUEL AND LUBRICATION OIL OPERATIONAL INSTRUCTIONS

Starting .

Cranking the engine

Emergency startingInstartIng system trouble Enginewarm~up

Break-in

Gear selection (Forward and Reverse) Shallow watercruISing

IEImmI

Stopping the engme , OperatIonInturbid water

OperationInsalt water

. 1 7 9

.15

15

15

16

16

17

.16

.20

.29

.30

31

32

37

37

43

.. 45

47

48

50

52

53

54 54 ADJUSTMENTS

Steering friction adjustment

IUI:@fiUllii_'

Adjustment of throttletWist grip fnctlon

ImDD

Adjusting the stiffness of the remotecontrol lever

I,n;"·8"·I'·&1"I"'"

Tnm angle adjustment Trim tab adjustment Idle speed adjustment

TILT-UP AND MOORING .

Tilt up. PERIODIC MAINTENANCE Fuel system. Electrical system Lower unit Greasing pOInts

Coatmg of the bottom of a boat Replacement parts .

OFF-SEASON STORAGE

Operation after a long time storage Cleaning the water Intake passages

Storage of the battery

'1"llluM_I,I'''''',i."",

PROPELLER SELECTION . SUBMERGED MOTOR TROUBLESHOOTING WIRING.

55

55

55

56

56

56

59

50

60

63

64

66

66

69

70

70

.70

71

72

.73

73

.74

75

77

c·ooo

LOCATION OF MAIN COMPONENTS

3 - - - /

4

· 7 - · - - -

J (8)~--·

EiDiD

---~\J"\.~\,\---~(i§J

~-~~-Q~

---(fj)

-'1$

~H!'l---JV

10

~-=YJ~-_·_---C~)

-1-Y-650 Y·720 Y-360

CD

Top cowling

(j)

Trim tab

@

Steering handle/throttle control

Y-09O X-600 V-560

----"

_CV

ShIft handle

®

Propeller

(j})

Choke knob

V-905 Y-235 X-410

®

Emergency stop sWitch

®

Splash board

@

Overheat warning lamp

Y630 Y-590 Y-2BO

@

TIltup lock

®

TIlt Pin

@

Recoil starter handle

Y-065 Y-560

®

Shallow water lever

q])

Transom clamp handle

V-09O X-960

®

Anti-cavitation plate

@

Reverse lock

-2-IIiIDm

--!j3J

\

I

J2)

co

_,,

0D

1Ql

(9)

--(8)

C2)

(3~j)

- - -

:.:-r;;--(5)---

"

-(6)

1 1

-Y-650

G)

Top cowling V·260

®

Battery wire V-560

(jJ)

Choke knob

---'

Y-630

®

Tilt up lock V-09O

®

Anti-cavitation plate

y-no

®

Tnmtab X-600

@

Propeller Y-235

(j)

Splash board Y-590

®

nit pin Y680

®

Transom clamp handle

X-960

@

Reverse lock

-4-X-333

@

011 level warning lamps

X-337

(3))---1-'fdl

(4)----~ 5\--~---/

r---P"'

: 6/)----'1__

JD

t----(9~ ~~--(8) \\\---~~7)

Y650

CD

Top cowling Y630 @TittuPlock Y-590 @nltPln v-09O

@

Anti-cavitation plate Y720

®

Tnmtab

X-500

®

Propeller V-260

(J)

Battery wire V-08O @Anode

i1iJIiWI

X·960

®

Reverse lock V-560

®

Choke knob X-333

QJ)

011 level warning lamps

X 337

COlO

Accessory Parts

Fuel tank

Remote control box

3

f,·I·'I'·'

Y-Sl0

CD

Fuel tank cap

W 165

®

Fuelhne

..,nl"It.

X·561

®

Power tilt sWitch

X 900

®

Remote control lever

--~~~~---

-X-210

®

Neutral throttle lever

X-OlD

®

Main sWitch

V-577

(j)

Choke sWitch

v905

®

Emergency stop sWitch

-8-D 110'

SPECIFICATIONS

Item

DIMENSIONS

----,--- J

Model

~_ ~ uni~

YAMABA40~-M--~

-Overall length

-Overall wIdth -Overall height -Boat transom height -Weight f - - - - ---~--~-mm(In ) mm(In ) mm(In ) mm(In ) kg lib I 1,114143 91 37811491 S 1,203147 311L 1,324152 11 S 381 115 011L 508 120 01 S 6751148 51/L 69 5 1152 91 PERFORMANCE

-FulI~h~tt1eoperatlngrange-E~~~~R~M) -D'5~-5'500

--MaXimum output kW (HP1/mln I(RPM) 294(401/5,500 -Idle speed r/mln 750 - 850 - - - -ENGINE ~ ----~---- - - r -Type -Number of cylinders - Bore and stroke

-Total pIston displacement -Cooling system

-Ignition system -Spark plug -Spark plug gap

mm(In ) emJ_{(eu In )} NGK mm(ln} Two stroke

3

67x66126X261 69814261 Water CDI B-lHS1O 09- 1 010035 - 0 0391

---I

adel Unit YAMAHA40HM

====--=

Forward·Neutral-Reverse

1 85124/131

Regular gasoline Yamaha outboard motor 011

100' 1

L IUS gall

2416.341

cmJ_{(ec) (US azl}

_{350 111.81}

-Fuel

-Recommended011

- Fuel·oll ratio -Fuel tank capacity -Gear011capacity Item M -Gear shIfting -Gear ratio DRIVE UNIT

FUEL AND OIL

f , , f

-f - - -

---0250"

SPECIFICATIONS

~-~-~--Model Item -- - -DIMENSIONS

Unl' _ _

I-~

-

YAMAH~40HEO

-

-l

~~AMAHA50DEO

---1

'

-n

4,500 - 5,500

---36 81501/5,500 750 - 850 r/mln

(RP~~--14'5~0-~,500

-kW IHPl/m,n-' (RPMI 2941401/5,500 r/mm (RPM) 750 - 850 - - -

-.Overall length .Overalt wIdth .Overall height .Boat transom heIght ·Welght

PERFORMANCE

.Full throttle operatIng range .Maxlmum output .ldle speed ENGINE mm(In ) mm(ln) mm(In) mm(ln) kg lib I 542 (25 31 35011381 S 1,1721461J/L 1,29315091 S 381 (15 OI/L 508 (20 01 S 685(15071/L 705115511 54212531 350113 81 S 1,172146111L 1,29315091 S 38111501/L 50812001 S 745 (163 911L 765 (168 31 ·Type .Number of cyhnders .Bore and stroke

.Total piston displacement .Cooling system

.Igmtlon system .Spark plug ·Spark plug gap

mm(In) cmJ (cu In ) NGK mm (In) Two stroke

3

67x66(2 6x2 6) 698 (4261 Water COl B-7HSlO

o

9 - 1 0 (0 035 - 0 0391 Two stroke

3

67X66(26X26l 698 (42 61 Water COl B-8HS10 09-1010035-00391

-Gear shiftIng -Gear ratio

FUEL AND OIL

-Fuel

- Recommended 011 -Oil tank capacity -Fuel tank capacity -Gear011capacIty

LlUS gall

L IUS gall

cmJ_(US OZ) Regular gasoline

Yamaha outboard motor011

131141

2416341

35011181

Regular gasoline

Yamaha outboard motor011

1 311 41

2416341

350 11181

D·200·

SPECIFICATIONS

Model Item

DIMENSIONS

Unit

_L

YAMAHA 50DETO

-Overall length

-Overall width -Overall heIght - Boat transom height -Weigh mm(ln) mm(In ) mm(ln) mm(In )

k9 lib 1

64212531

350 113 81

S 1,172(461)/L 1,29315091

S

381115011L 50812001

S 7601167 211L 7801171 61

PERFORMANCE

-FuJI throttle operatIng range -MaxImum output -Idle speed ENGINE

I

---- - i

r/mln (RPM) kW (HP)/mln '(RPM) r/mln - - -

-4,500 - 5,500

3681501/5,500

750 - 850

-Type -Number of cylinders -Sore and stroke

-Total piston displacement -Cooling system

-'gnltlon system -Spark plug -Spark plug gap

NGK mm(ln) Two stroke 3

67x6612 6x2 61

69814261

Water COl

B-8HS10

09-1010035-00391

Item

DRIVE UNIT

-Gear shlftmg -Gear ratio

FUEL AND DIL

~~~~---Model

-J ----

=r--

Forward-Neutral-Reverse

1 85124/131

-- --- - - - j

1

--Fuel -Recommended all -all tank capacIty - Fuel tan k capacity -Gear all capacity

LiUS gall L IUS gall cm3

(ccl (US ozl

Regular gasoline Yamaha outboard motor 011

1 311 41

2416341

35011181

E·Q1Q

OUTBOARD MOTOR IDENTIFICATION

Outboard motor serial number

The outboard motor senal numberISstamped on the plate attached to the port SIde of the clamp bracket

Engine serial number

The engine senal numberISstamped on the port side of the cylinder body

NOTE

-Both outboard motor and engine senal numbers are Impor-tant when you want to have service performed or place an order for parts Please take note of the numbers

p8

,

~

=-

~

-c

05

'-000

ENGINE MOUNTING

Never equip a boatwithan outboard motor whose

power exceeds the maximum rating shown on the

capacity plate. Over-powering the boat may cause

severe instabihty. If the boat has no capacity

plate, consult your Yamaha dealer or the boat

manufacturer

Mounting position

The outboard motor must be mounted on the boat center hne (keel hne), and the boat must be well balanced so that the drafts are on the same level both on the starboard and the port side Otherwise, the boat will be very hard to steer For boats without keel or which are asymmetrical, consult

0-25mm(0-1

F 100

Mounting height

To run your boat with maxImum efficiency, water resist-ance to the boat hull and outboard motor must be minimiZ-ed The mounting height of the outboard motor greatly af-fects the water resistance If the mounting height IS high, cavItatIon tends to occur, thus reduclllg propulsion by the engine If the propeller tiPS are too high, they cut the air and the engine speed rises abnormally, thus cauSing the engine to overheat If the mounting height IS too low, splash resistance wIll Increase and thereby reduce engine effiCiency The engIne should be mounted so that the antl-cavitatIon plate IS between the bottom of the boat and a level 25mm (1") below It

'Mk'iV"

t1

_M

---~

he

mounting height varies dependmg on the

p~r­

pose of the boat and the outboard motor The pro-per height should thus be determmed by making test-runs

-, - - - -,

I~

' - - - - -

- - -

- --

---

- - - '

F-210

Clam5!

11'!:huII.J:lj••

1) Place the outboard on the transom so that It IS

posItIon-ed as close to the centre as possIble Tighten the clamp

screwsevenly and securely

21 Make four holes ,n the transom board so that the holes align with the clamp bracket holes, and secure the

clamp bracket wIth bolts

'W'';Y''~MI-

---~--AVOId using bolts, nuts or washers other than

con-tamedInthe engme packing. If used, they must be of the same or superior in the quality of material

and strength and must be tightened securely

After tightening. test-run the engine and check

F 220

Clamp

@ml'¥"f1nlJ!.it.

Make four holes In the transom board so that the holes align with the clamp bracket holes, and secure the clamp bracket with bolts (accessories) For details, consult your Yamaha dealer

fu',;'m'MW

.---~

Avoid using bolts, nuts or washers other than con-tained m the engine packing If used, they must be of the same or supenor in the quality of matenal and strength and must be tightened securely After tightenmg. test~runthe engme and check their tightness e , 122mm(051 I-327mm(129) 2508mm(99 ) 508mm(2) 69 3mm(2 7"1 87 8mm (35") 1063mm 14 2") 254mm 110) 309 5mm (12 2)

F-400

Remote control mounting

11,IUg'Uin"§,,,.in.1iit.

@"iJNW,

Incorrect selection or installation of a remotecon~

trol may result in sudden and unexpected loss of control, thus resulting 10 a serious accident

Please consult your Yamaha dealer.

For Installation of the steering system, see your nearest Yamaha dealer. It IS also advisable to ask your Yamaha dealer to Install the remote control box and cables The remote controlInthis manualISdeSigned for starboard side steering wheels

F 410

Remote control box positioning

The remote control box should be setIna posItionInwhich It does not obstruct the operations of the remote control lever Make sure there IS no obstructionInthe path of the remote control cables

CD

Remote control box

®

Remote control lever

®

Remote control cable

F 420

Checking the remote control cablelen~lth

Position the remote control cables and check If they are long enough Connect the cables to the engine and make sure they do not get tangled or bent when the steering wheel IS turned

~

~v~:~:~~~~

the cables

sharPly-,-tha;~sl-ma~esu~~~;

cables do not form a loop With a diameter of less than 406mm (16m)

---2) Loosen the two screws, and remove the lower back

panel.

®

Back panel

3) ScrewInthe cableJOInts(accessories) about 11 mm (0 4

In) over the ends of the remote control cables, and tighten the lock nuts Before Installing the cable JOints,

apply the water-resistance grease (Yamaha Grease A) to the threaded holesInthe cable JOints

®

Remote control cable

@

Locknut

®

CableJomt

CD

Wire cover

F 435

Remote control cable installation (On the remote control

box side)

1) PInch the wire cover with your fingers and pullItout to

remove

-

- - - ,

1

-22-- -22-- -22-- -22-- -22-- -22-- -22-- -22-- -22-- -22-- -22--

- - - - ,

r - - -

---4) Insert the femote control cable outerforshifting Into the housing clamp so that the groove on Its end frts over the ridgeInthe clamp Fit the cable Jomt over the pin on the end of the shift arm, and lockItwith the crrchp

5) Fit the grommet (accessory)Inthe clamp groove

CD

Grommet

®

Clamp groove

®

Circhp

@

Sh,ftarm

6) Connect the remote control cable for the throttle to the

throttle armIn the same manner

®

Remote control cable for throttle

®

Remote control cable for shift

(J)

errel,p

7) Secure the lower back panel with the two screws, and '---' Install the wire cover

8) After connecting the remote control cables, Install the remote control boxIn the prevIously determined

pOSI-tion uSingtheaccessory fittings (screws, nuts,washers,

and spacer)

CD

®

®

/ '

CD

Remote control box

®

Screw

®

Spacer

@Washer

®

Nut

®

Hull

®

---_.~----_.-,

L-_~ ~ _

F ..,

Installing the remote control cables (on the motor side) and wire harness

1) Remove the top cowling

2) Remove the upper and lower fittIng plates and the grommet

CD

Wire harness

@

Remote control cable for shift

®

Remote control cable for throttle

3) Pass the wire harness through the grommet, and Install the grommet. then Install the lower frttlng plate onIt

4) Connect the remote control cable& to the lowerfitting

plate When connecting, align the grooveInthe remote control outer with the ndge on the lower fitting plate,

andfitthem together

5) LikewIse, fitthe upper fItting plate to the grooveInthe

-r---~---~ ~-~-- - - ,

~'Jy

,,-~---~

0'

\__.-..L

•

•

- - - ' ---~ _ _~ ~ ___1 F468

CableJOintinstallation Shift side

1) Place the remote control leverInneutral (N), and also set the gear shIft leverInneutral (Nl

2) ScrewInthe cableJOintover the end of the remote

con-trol cable so that the cable JOint hole aligns with the

cableJOintset pm, and lockItwith the lock nut

~

::::~:::n~TOf

the

r::'ot:;:-~;r~~~:~n~~~-h~

cable Joint a minimum of 8 mm (O 310)and lockit

with the locknut

- - - ~ . - - - ---

-[

~~~~e~:~~::e~-~~~~~~n~from~~~-In;~O-~~~,--t~~~;:n

1

the lock nut

--

- - - -- - ~ - - -- - ~ - --- --- - -

---CD

Locknut

F 478

Throttle side

1) Turn the remote control lever downward32°to the For-ward Side, and place the neutral throttle lever In a holrzontal position

NOTE, --~ - - - ~-

-Aclick can be heard when the lever IS turned 32° Don't turn beyond thIs pOInt

2) Set the throttle control lever In the full-closed POSition

CD

Throttle control lever

3)

Screw rn the cable Jornt over the end of the remote con-trol cable so that the cable JOint hole alrgns with the cable jornt set pIn, and lock It with the lock nut

-~clr~;~~::n~Tof

the

-:mote-~o~tr~~~a-~Iein;~~h:l

cable

Joint a minimum of 8 mm

(03

m)and lock It with the

lock

nut

- - - ~ - - - -- - -

-I

To

~~~:~?~~

cable

J~lnt

from

c~~;~-loose~;ht~~)

the lock nut

- - - ~ - - -

\

' - - -0

; - - - . ,

' - - ---J

4) Lock the cable JOint wIth the half pin

5) Couple the Wire harnesses with the arrow and tnangle aligned and lock them with the wire harness lock

®

Wire harness lock

-28-~--- ---~

F 620

'ltI:'g"piU.'j''+i''tl'it'

Installing the steermg guide attachments

Hold one end of the steering lInk rod to the steering hook with the bolt and nut, and hold the other end to the steering cable with the nut and washers

NOTE

For details, consult your Yamaha dealer

CD

Steering hook

@

Steering link rod

~ ~=:; ,;OO~"'

_'"';-d-,

-st-a-rt~n-g-fallu~:

may result

2 If the battery connectiOns are reversed, the rectifier Will be damaged ._~~-When removing follows Removal Installation

or Installing the battery, proceed as Disconnect the negative terminal Side (black lead) first

Connect the posItive terminal SIde (red lead) first

F-nD

Battery mounting

IUlII#"#iU.J#.rijli.Ji••,

N'';Y'h'MI

--'-- --- -

---~---J

When installing or removing electrical parts, be

U

ure to di.sconnect the battery Wires from the

bat~

tery termmals

---

-

--

- - - -

--- ---.

The battery should be securely mounted In a dry, vlbratlon-free location tn the boat The battery should be a 12V, 252

kC 170AHI

To wire the battery, connect the red lead to the POSitive minal of the battery and the black lead to the negative ter-mInal

-30-t'Z"iN"NtI

---.---The battery fluid (electrolyte) is corrosive. If it gets

Inyour eyes or on your skin, immediately wash the area with water and see your doctor. If the fluid spills on or around the engine, thoroughly wash it away. When the battery IS being charged, ex~

ploslve hydrogen gas is produced. The battery should therefore be charged In awell~ventllated

area

CD

Redlead

®

Blacklead

o

0

o~~

"50

Installing the meters

Install the meters on the dashboard If no dashboard IS

available, Install themIna place free from water splashes For wIring, refer to the "WIRING" section

o

Vll---(3)

YA~'H'

o

liiu.lij,.

F-865 Tachometer

This meter Indicates the engme speed

NOTE

Before Installing the tachometer, make sure the terminal

plateISset on the6~poreSIde If It IS set on the 12-pole side, the tachometer will not show correct measurement

CD

Black

®

Green

G 110

FUEL AND LUBRICATION OIL

IDI

MIxing ratio

Gasohne 0,1

Fuel tank capacity 24ltters (6 34 US gall • Gasoline IS highly inflammable and explosive.

When mlxmg gasoline wIth oil Or when refuell-ing. refrain from smoking and keep away from open flames Or sparks

• When refuelling. be sure to stop the engine Also take care not to spill gasoline or ad • Be sure to wipe off any gasoline or oil spilt on

board immediately and thoroughly with dry rags

• Never fill the fuel tank to more than the speci-fied level. Safe filling level IS 5 mm (0 2 inch)

below bottom of filler neck

• After filling, tighten the tank filler cap securely. • The mixing of fuel must be done offboardIna

well-ventilated area

Fuel Regular gasoline

Lubncatlon all YAMAHA outboard motor all or an eqUIvalent two stroke outboard motor 011 whIch meets the BIA rating TC-W

-32-Br eak-In penod

After break-In

25

Mixture

1) First pour011Into the fuel tank, and then gasolrne 2) MIx the fuel thoroughly by shakIng the fuel tank

-

CAUTION:

- - -

'-~

• AvoId USing any011other than that designated • Always use new gasoline

• Use a thoroughly blended fuel,oll mixture

• If the mixture IS not thorou!!hly blended or the mix-Ing ratio IS incorrect, the following problems WIll

oc-cu,

Low011ratiO Due to lack of011,major engine trou-ble such as seizure will result High oll ratio Fouled spark plugs, smoky exhaust,

or heavy carbon deposIts will result

CD

0,1

,

-- -- -- -- --

- - - -

- - - '

G 570'

1't1;'j_Sin.JiI••"."'"

FUEL AND LUBRICATION OIL

PrecIsionblend system

This engine uses the PrecIsIon Blend System whIch pro-vides superior lubrication by ensuring the proper ad ratio for all operating conditions, so no fuel premixingISnecessary Simply pour gasolineInto the fuel tank and 011 Into the 011 tank

Recommended gasoline Regular gasoline

Fuel tankcapacIty 24 liters (6 34 US gall

Recommended 011

YAMAHA outboard motor all

If YAMAHA outboard motor olliS not available, another

2-stroke engine all WIthBIAcertlfledTC~Wmay be used

• Gasoline ishighly mflammable andexplosive

When refuelling, refrain from smokmg and

keep away from open flames or sparks • When refuelling, be sure to !ltop the engme

Also take care not to spill gasoline or oil

Be sure to wipe off any gasoline or 011 spilt on

board immediately and thoroughly with dry

rags

• Neverfillthe fuel tank to more than the

specIfi-ed level Safe fllhng level IS 5 mm (02 lnchl

below bottom of fdler neck

After fillmg. tighten the tank filler cap securely • Pour the engme oil (never gasoline) Into the 011

,.---~._---o

-WIll start sounding If the engine keeps on operation under such conditions, the engine may seize up Avoid keep the engine running with the red lamp beIng turned on

G-620'

Ilti:'#'fjOin,J#"f'tl,l!ii"

011 level warning system

This engineISequipped with an 011 level warning system to warn the operator of the necesSlty of oll refilling to prevent engine seizure

When the all tankISfull of 011, the green 011 level warning

lampISon When the 011 tank level decreases to500cc(05 US qtl, the yellow 011 level warning lamp will come on So add all to the all tank

If no spare Ollis available, proceed to the nearest port for 011 refilling When the engine keeps on operation wIth the yerrow lamp being turned on and the all tank level lowers to 300

cc

(04 US

qtl,

the engine speed decreases automati-cally to about 2,000 rpm, and the red011level warning lamp Will hght In addition, the buzzer In the femote control box

NOTE. -~--'---"-~---

._-• When the engine speed has dropped, you must stop the engine by turning off the main sWitch, and add 011 to the 011 tank, then start the engine If ollis add-ed without turning off the main sWitch, the engine speed Will not rise to more than

2,000

rpm After ad-ding oil, turn on the main sWitch, and make sure the red all warning lamp comes off before starting the engine

• To operate the 011 level warning system, be sure to Install the all level warnIng lamps

• When the engine temperature rises too high, the engine speed Will decrease and the buzzer In the remote control box Will sound, as In the all level war· nlng system However, the red lamp will not come

on

CD

Red lead

®

Yellow lamp

®

Green lamp

-36-~

~

~:

.;J

0lJm

-~I

I

o

~~---~~-[]

•

•

•

•

•

<;AUTION:

-Do not start the engme out of water ,I

Make sure that thereIS suffiCientfuel tn the tank Make sure that there are suffiCient fuel and 011 In

each tank

Im#ljtt#t".J§"p",.IW

The fuel tank should be placed on a flat areaInthe

bottom of the boat

Prior to operation, check to see that the necessary servIcetools andspare parts are onthe boat

The fuel line should be routed In&uch a way as to prevent any kinks or sharp bends and to allow full steerrng movement Do not allow fuel line to contact sharp objects or to become prnched

- - - - -

-

-- - - --

-Bleeding the 011 injectIon pump

lIIi#l#ni§iJ"#,,,,'n.I'it'

Before operating theengInefor the first time or after a long time of disuse, be sure to bleed theolllnJectlonpump To bleed, loosen the air bleedIng screw attached to the all In-Jection pump, and the all will flow to the olllnJectlon pump

due to a head, thus expelling the air Inthe pump After making sure that the 011 starts overflOWing through the

screw hole, tighten the screw completely

CAUTION: - - - ,

r;e sure to bleed the

olllnJeetlon

pump, otherwIse,

It

wIll

I~

Impossible to supply oil, thus damaging the engine

- - - '

-38-1) Firmly connect fuel hose connector 2 (positioned on the tank mark sIde) to the fuel tank

When inserting the fuel JOint into the fuel tank. vaporized gasoline will squirt out of the air bleed-ing hole. Gasoline IShighly Inflammable and ex-plosive under certain conditions Refrain from smoking and keep away from open flames or sparks when mserting the fuel joint

CD

Fuel hose connector 2

2) Firmly connect fuel hose connector 2 to fuel hose con-nector 1 on the motor

3) Squeeze the prtmer bulb until firm pressure IS felt

IDI

4-1) Place the shift handle In neutral (Nl

CAUTION:

- - - -

--J

The engme may only be started when the shift handle IS In the "N" positIon

-.--~-

---4-2) Place the throttle gnp m the START posItIon (The throttle openlng must be adjusted slightly according to the engine temperature)

4-1) Place the remote control lever on the remote control box In neutral (N)

CAUTION:

-If the remote control lever IS not motor cannot be turned

In "N," the

4-2) Turn the neutral throttle lever on the remote control box upward (It IS necessary to change the throttle opening slightly depending on the engine tempera-ture )

START

_,

,

,

,

IUI#lg"in,l¥uijli.I,.,'

-42-5l Install the lock plate fIrmly onto the emergency stop sWitch

Tie the rope attached to the lock plate to your Wrist

CD

Lock plate

NOTE

-The emergency stop sWitch IS provided for the safety of the operator When the lock plate IS pulled out from the emergency stop sWitch, the engine stops Immediately The engine will not start when the lock plate IS removed Should the operator fall off the boat or lean too far over one sIde, the lock plate will pull out causmg the engine to stop

IIiDID

6) Pull the choke knob out completely

1"';'i

u

_{+1.I•I#"#".I,.,'}

6) Turn the main sWitch to "ON," and turn the choke sWitch lever upward (The remote choke sWitch lever returns to ItS home position when It IS released There-fore, keep the lever pressed upward.l

NOTE -If the engine IS still warm do not use the choke

H 110

Cranking the engme

Il!DIiD

1) When the engIne IS ready for starting, slowly pull the starter handle

2) When engagement of the mechanism IS felt, finish the ~'-..,-" stroke with a strong pull and the engine wrll start

3) After the engine has started, allow the starter handle to return slowly to ItS home positron without letting go 4) If the choke knob has been pulledOUl,return It slowly to

ItS home positIon so that the engine does not stop

NOTE

Should the engine fall to start on the first pull, repeat the above procedure several times In the event that the engine wrll not start, refer to the sectIon on TROUBLESHOOTING

\

,In#l:''tk'''.'ijttJ:j'',Ji··'

1) Set the main sWitch to "START" and the starting motor

will turn

2) After making sure the engme has started, release the main sWitch and remote choke lever

3) Slowly return the neutral throttle lever toItshome

pOSI-tion so that the engine does not stop

CAUTION:

-Never turn the main sWitch to the "STAAT"

pOSI-tion while the engmeISrunnIng

2 Do not keep the starting motor turning for more than five seconds with the main sWitch In "START," If the engme will not start after five

seconds return the main sWitch to "ON" and crank the engine again after waiting 10 seconds.

If the starting motor15turned continuously for more

than fIVeseconds, the battery will qUickly run dead making

.t

Impossible to start the engme

r---~---_____,

tlll:'g"h"'·'#·fijn,'ii,'

Emergency startingInstartmg system trouble If It IS Impossible to start the engine due to a dIscharged battery or starting system trouble, the engme can be started uSing the emergency starter rope

- tU";'#"N.

--~-When the engine IS started with an emergency

rope, the start-In-gear protection system will not

work Be sure to check that the gear

IS In

Neutral

Otherwise the boat may lurch ahead or astern, causmg seriOus damage or personal injury

1) Remove the top cowling by depressing the latch at the rear of the cowling Lift up and back to remove

Il!miD

2) Remove the starter by removing the 3 bolts secunng

the rewind mechanism to the flywheel

,UJI!*,'pn,jje!#m,)i•••

2-1} Remove the flywheel cover by removIng the 3 bolts 2·2) Turn mam sWitch to "ON"

NOTE - - -

-Without setting the main sWitch at "ON," It IS ImpossIble to start the engine

3) Wind emergency starter rope one or two turns around flywheel rotor, then pull the starter rope to start engine and, If reqUired, pull out choke knob to choke manually

4) To release choke, pushInchoke knob

't""i'NNd

When starting or operating the engine, never touch the Ignition coil. high·tenslon wire, spark plug cap or any other electrical parts to which high voltage IS applied

When pulling the emergency starter rope, be sure to keep loose clothing and other objects away from the eng me.

A rotating flywheel IS very dangerous Never at~

tempt to install the top cowling on the engme when it is in operation

Proceed to the nearest port to get the starting system repaired as quickly as possible Take care that no water splashes onto the flywheel.

Iln#l#'*+i"I)#'W!"I)iie'

H 320

Engine warm-up

Before beglnnrng operation, the engine should be warmed up at Idle speed for three minutes Failure to do so will shorten the life of the engine

~~-

CAUTION' - -

-

~----~-~

-

-

~--I

Make sure that water runs out from the cooling water

J

pilot hole

- - - --

-Overheat warning system

EliDIiD

ThIs engine has an overheat warning device Before the engine becomes too hot, the engine speed will automatical-ly reduce to a safe rpm and the overheat warning lamp on the bottom cowling Will flash

Im:'ij'W'''I)j''fi,ll)i'''

Check that water runs out of the pilot hole If not, stop the engine and check the water Inlet for clogging If clogged, It should be cleaned, and If not clogged, operate to your nearest port at low speed and consult a Yamaha dealer Never run the engIne at high speed, otherWise, engine seizure could occur, resultingInIrreparable damage

~.

J

I~:';'T

SLOW

C~~

,;:" _,<".

-.

"

- - -

-3

I'',V

~

.,.START

W'UOW

_I,",', ~,I H-430 Break-In

EI!IIID

A penod of break-In IS required to allow the matIng surfaces

of all moving parts to wear evenly when new This

pro-cedure will ensure proper performance and greater

durabili-ty 1) Break-In time 10 hours 2) MIxing ratio Gasoline all 25 1 3) Procedure

a Run theengIneat trolling speeds (The lowest

pOSSI-ble speed) for the first 10 minutes.

b With an easy planing boat, bringItinto the planmg

posItion;

then,

Immediately reduce the throttle to approxImately 3,000 rpm (one-half throttle), con·

tinue running at this throttle setting for 50 minutes c Bring the boat Into the plamng state and reduce

throttle to 4,000 rpm or three-quarter throttle

(ap-proxImate) while maintaining planing. Continue run-ning at this throttle setting for one (1

I

hour

NOTE'

Run at full throttle for approximately one (11 out of every 10 minutes

d For the next eight (8) hours, avoid continuous full throttle operation for more than fIve {51 minutes e After the first 10 hours, return to 100 1 ratio

~

CAUTION:

---:J

Failure to follow the break-In operation procedure may resultInsevere engIne damage.

-,

}

H 420

Break-In

'"I#I#''tin."nijl'I'''''

A penod of break-InISrequired to allow the mating surfaces of all moving parts to wear evenly when new This pro-cedure will ensure maximum performance and engine life 1} Break-In time

10 hours 2) MIxIng ratio

Gasoline 0,1 50 1

3} Procedure

a Run the engine at trolling speeds (The lowest pOSSI-ble speed) for the fIrst 10 mInutes

b With an easy plamng boat, bnng It Into the planing posltlon, then, Immediately reduce the throttle to approximately 3,000 rpm fone-half throttle), con-tinue running at this throttle setting for 50 mrnutes C Bring the boat Into the planing state and reduce

throttle to 4,000 rpm or three-quarter throttle (ap-proximate) while maintaining planing Continue fun-ning at th,s throttle setting for onE' (1) hour NOTE

Run at full throttle for approximately one (1) out of every 10 minutes

d For the next eight (8) hours. avoid continuous full throttle operation for more than five (5) minutes e Afterthe first 10 hours, use straIght gasoline for

nor-mal operation of the precIsion blend system

CAUTION: ~

Failure to follow the break-In operatIon procedure may result In severe engine damage

,---~----~---~

H-515

Gear Selection (Forward and Reversel

,O·'*'''N.

-I

Should the engme hit an underwater obstacle, be

I

sure to check the gear case and brackets for

dam-age

---

..-~----._--- --

---_.-_.---

---

-IlimI

A Forward (Fl

Turn the shift handle to "F" qUickly and firmly

B Reverse (R l 1) Lock the reverse lock

-£¢,.'iJN'N'-

-~---- ----~

--When operating in REVERSE, be sure to set the

reverse lock to

LOCK

and keep the throttle at

1/2 or less If this IS not done. the reverse lock mechanism will not prevent the engme from

lif-ting out of the water and loss of control may

oc-cur. possibly causing injury to the passengers

2) Turn the shift handle toI IR" qUickly and fIrmly

~ ~-

CAUTION'

-

~

-

-~-~

-

---~-~-

-To change the boat direction from forward to reverse or

vice versa,close the throttle first so that the engme Idles lor runs at low speeds)

-

~

CAUTION'

-~

-

~--~~ -~ ---~~ ~

-~~-For additional safety, the throttle IS deSigned not to open more than 1/2 when the motor IS In NEUTRAL

Neverattempt to force the throttle open more than 1/2

-50-~

...

--F

•

PmtJi

l "

A Forward (F)

Turn the remote control lever to "F " B Reverse (R)

1) Lock the reverse lock

'U1Ud,WiIIIJm

"4·';U!!~"CI

-When operating In REVERSE, be sure to set the

reverse lock to

LOCK

and keep the throttle at

1/2 or less If this IS not done, reverse lock mechanism will not prevent the engine from

IIf-tlOg out of the water and loss of control may oc-cur, possibly causing injury to the passengers 2) Turn the remote control lever to "A "

-F~~~~~~~n~f safety-,~~~e

throttle 1$ designed

-n:~-t~

open more than 1/2 when operating In REVERSE

Never attempt to force the throttle to more than 1/2

'

-H755

Shallow water cruising

II!1IIiI

N"i'N'NtI

In shallows, run the boat at trolling speed or

there-abouts. The reverse lockwillnot operate and may

thus cause the engine to 11ft out of the water and

the boat to lose control when the lower casing hits

an underwater obstacle. Personal injury may ra· suit when the engine is operating in reverse, as

it

can easily be lifted by the force of reverse thrust

TocrUIse Inshallows, proceed as follows 1) Place the shift handleInneutral. 2) Push the reverse lock down to release

3) Slightlytilt up the engine and pull the shallow water lever toward you

4) When bTlnglng the engme from the shallow water

pOSI-tIonback to the home pOSition,

tilt

It up ahttle, push the

shallow water lever downward. andtiltthe engine down slowly

---

-CD

H 618

Stopping the engine

II!ImiI

1-1) Turn the throttle gnp to the fully closed 1-2) Place the shlf handleInneutral

2) To stop the engine, push the emergency stop sWitch button

t1t!:I#,@n·'#·'binnji.,

1} Place the remote control leverInneutral

2) Turn the main SWitch to OFF and the engIne will stop Pull out the lock plate from the emergency stop sWitch and the engine will stop

(1)

Lock plate

In·!;'¢!!t~'.

ItIS impossible to stop the engine by disconnec-ting the wire harness Furthermore, when the wire harness IS disconnected, the enuine cannot be stopped by turnmg off the main sWitch or bypull~

Ing out the emergency stop switch lock plate. Be sure to keep the wire harness connected dUring operation

3) After stopping the engine, remove the fuel hose

- CAUTION:

1

Before stopping the engine, reduce the engine tempera- ' - / ture by running It at Idle or low speeds for 2 or 3 minutes

H900

Operation in turbid water

ItISstrongly recommended that the optional chrome-plated water pump kit be Installed If the outboard IS to be used In turbId water conditions

H 910

Operation in salt water

After operatingInsalt water, wash out the cooling water passage with fresh water Otherwise, the cooling water

passage may clog up wIth salt collections For washing,

refer to "Cleaning the water Intake passages" In the "OFF-SEASON STORAGE" section

-54-H-710

ADJUSTMENTS

S~~en~g ~nction

adjustment

II!Jliltn,m",.,

The tension of the steenng fnctlon can be adjusted by turn-Ing the adjusting bolt attached to the sWivel bracket To Increase tension

Turn the adjusting bolt clockwise To decrease tenSion

Turn the adjusting bolt counterclockwise

H730

Adjustment

of

throttle twist gnp

fnctio~

II!DmI

The throttle tWiSt grip has an adjustable fnctlon device The fnctlon device IS locatedInthe steering handle, and fnctlon can be adjusted by tightening or loosening the fnctlon bolt To Increase tension

Turn the fnctlon bolt clockWise To decrease tension

,

/

CD

H 737

,'el;II'PMt'!'E"'."'"

Adjusting the stiffness of the remote control lever

By

turning In or out

the throttle

friction screw at

the

front of the remote control box, the stIffness of the control lever

can be adjusted Turning the screw to the right makes the control leverstIffto turn, and turning Itto the left makes

the lever light

CD

Makehght

®

Makestiff

F-330

Trim angle adjustment

To maintain steeTing stabilIty and good performance, always maintain correct trim angle. The appropriate trim

angle vanes depending on the combination of the boat, en-gIne, and propeller, as well as operating condItIon. but It IS

safe to say that when the tnm

IS

3° to 5° by stern, the boat

ISIna stable tnm

If the tnm angle IStoo large, the buoyancy center of the

boat Will shift toward the stern Ifthis happens and the stability moment at the bowISgreat, the boat Will tend to "porpoise," possibly causing the operator and passengers to be thrown overboard Ifthe tnm angleIStoo small, the bow WIll "plow," thus making the boat unstable

-56-~---,

To adjust the trim angle, remove thetiltpin from the stern bracket assembly and, whIle tIlting the motor, repositIon the pinInthe desIred hole

IW·'iN"N. ----

-- -

-When mounting the outboard motOr on a boat, be

J

sure to make a test-run and set the proper trim

angle

- - -

-CD

TiltpIn

NOTE

-• To lower the bow, move pin towards the mountrng plate To raise the bow, move pm towards the engine

• When operating against a strong wind, It IS ad-vIsable to make the trim angle slightly smaller than the standard for steering stability If the wind IS

favorable, the trim angle should be Increased for better steenng stability

'M"''''

- CAUTION: ---

-

---r

Never attempt to adjust the trim angle uSing the power tilt sWitch dunng operation, or power tilt assembly trou-ble could occur

-H-8OO

Trim tab adjustmen_t

The tnm tab should be adjusted so that the steering handle can be turned to either the nght or left by applying the Same amount of force

An improperly adjusted trim tabwill cause loss of control. Test run to determine proper adjustment.

CD

Trim tab

®

Trim tab screw

A When the boat tends to veer to port.

Turn the rear end of tnm tab to the left (port side)

"ANInthe figure

B When the boat tends to veer to starboard

Turn the rear end of tnm tab to the nght (starboard side) "B"Inthe figure

CAUTION:

,

The trim tab also serves as an anode to protect the

engine from electrochemical corrosion Never pamt the trim tab as It will become ineffective as an anode

-58-H850

Idle

speed adjustment

1) Start the engIne, and warm It up for a few minutes 2) Set the Idle speed to the specifIed by adJustmg the

throttle stop screw (see "SPECIFICATIONS"

prece-dmg) '--'

To increase the Idle speed

Turn the throttle stop screw clockwise To decrease the Idle speed

Turn the throttle stop screwcour1terclockwlse

40HM/40HEO/50DEO

'!n#lMI'n:""

-1015

TILT UP AND MOORING

If the engme will be stopped for some time, orIfthe boatIS

mooredIn shallows, the engine should be tilted up This

protects the propeller and lower casmg from damage by

rocks or any other underwater obstacle when the tideIS

eb-bIng, and from fast corrosIon by salt water

[r"""---

When transporting the engine or keeping

It

tilted

up for more than a few minutes, be sure to discon·

neet the fuel line hnking the engine to the fuel

tank Otherwise, fuel may leak out.

- - - " - - - ~ - - - _ . _ - - - - -- - - . -

---,CAUTlON: - --- - - -

---1 Do not tilt up the engine by pushing the steering

I

handle, you maybreakl!off

EDIIID

2 Make sure the power unIt IS kept hIgher than the

propeller at all times Otherwise, water may run Into the engine and damage It

- - - -- - - ~ - - - - ~ - - - ---

-Tilt

up

1) Remove the fuel JOint from the engine 2) Release the reverse lock

3) Fully tilt up the engine, and lock It with the tilt up lock

~

';::~:!#.I

---

~

When the engIne IS not used for a long period of time, the battery wires (pOSitIve and negative) should be disconnected from the battery

---

- - - ~ - -

-- --

-

-60-1055

TILT UP AND MOORING

1!m!I'im

If the engine will be stopped for some time, orIfthe boat1$

moored In shallows, the engme should be tilted up This protects the propeller and lower casing from damage by

rocks or any other underwater obstacle when the tide1$

eb-bing, and from fast corrosion by salt water

IW"dNN@I

----

---~--

---

--~1

When transporting the engine or keeping

It

tilted

up for more than a few minutes, be sure to discon-nect the fuel line linkmg the engme to the fuel tank Otherwise. fuel may leak out

- - -

-l - ~ - '

-- CAUTION:

Make sure the power unit IS kept higher than the pro-peller at all times Otherwise, water may run Into the engine and damageIt

Tilt-up

1) Push the upper portion of the powertiltsWitch on the remote control lever until the power tilt motor nOise changes And the engine trlts up completely

2) Turn the tilt up lock toward you and support the engIne

[

~ft~~t~t~~~~

the engine, be

su~

to

~l:~POrt

It

w~~-th~

tilt up lock so that the engine will not ttlt down suddenly "-/ due to lack of orl pressure

-3) When tilting down the engine, release the tilt up lock, and keep pushIng the lower portion of the power tilt sWitch to tilt down the engine completely.

Manual operation

If It IS Impossible to tilt the engine up and down due to a discharged battery or power tilt trouble, tighten the manu'al valve screw counterclockwise until It stops

The engine can now be tilted up and down To lock the engine In that posItion, turn the manual valve screwclock~

wIse until It stops

CAUTION:

-J

When the engine IS not used for a long penod of time, the battery wires (pOSitive and negative) should be disconnected from the battery

J-06O

PERIODIC MAINTENANCE

In the following check-up list, the mark

le)

Indicates the check-ups which may be done by yourself The mark (O) Indicates work to be earned out by your Yamaha dealer

Grease

Check POint

Outboard motor body Retighten bolts and nuts

-Time Interval

10 hours 50 hours lOahours Every 100 Offseason

hours or (after the Procedure

0' 0' 0' _every6

boating , month 3 months 6 months

months season)

0 0 0 0 0

-•

•

•

•

•

Cleaning of filter

- - - .

-•

•

•

Checking for fuel leakage

- - - _ .

•

•

•

•

•

Cleaning of tank Intenor ~ ~ - - - -

-•

•

•

•

•

Cleaning of strainer

- - - - -

~

-•

•

•

•

•

Spark plug gap

09-10mrn(0035-0039'') . - - -

-0 0 0 0

- - -

----_

. .

-0 0 0 0 0 Check speCifiC gravity

_._--- --- _ .

-•

•

•

•

•

Checkmg for damage to blades Replacement

•

•

•

Replacement

Checking for water leaks

•

- - - - .

- - - -

- - - - -

•

•

•

•

•

•

Checking for wear

- - - - _ . - - -

-0 0 0 0

.

-•

•

•

•

•

Check for ddmage to extenor

- - -

- - - _

. .

==."r

•

•

•

•

Greasing - - - - _. . . _ - _ . Gearoll Spark plug Fuel hose Fuel tank

Trim tab (Zinc) Ignition timing

Battery

Propeller Fuel tank strainer Carburetor settmg Fuel filter Lower Unit Fuel system Electric system

J265

o

Fuel system

Gasoline is highly inflammable and explosive Handle it with speCial care.

Fuel line

Check the fuel line for leaks, cracks, foults. If any pro· blem IS found, do the necessary repalTlng or replacIng If no cause can be found, ask your nearest Yamaha dealer,

Checking points 1 Carburetor(s) leakage 2 Fuel pump fault or leakage 3. Fuel tank leakage. 4 Fuel hose JOlnt(s) leakage 5 Fuel hose(s) crack or any damage 6 Fuel filter leakage

7. Fuel connector(s) fault 8 Primer bulb fault or crack

-64-r - - - , - - - - ,

J275

Cleanmg thefu~l-.!ankand~!n~_irl~

Fuel tank

Add

a

small quantity of SUItable cleaning solvent to the fuel tank and thoroughly clean the tank Intenor by shak-Ing

the tank After

cleaning, dram off the cleaning sol-vent completely

Fuel tan kstraIner

Thoroughly clean the strainer on the end of the suction pipewithSUitable cleaning solvent

J255

Cleaning thefU~!}llter

Remove the filter cup, remove the filter and washIt In

sUItable cleanIng solvent

NOTE

-Be careful not to lose the O-ring Without the O-ring, fuel leakage may occur

tU"i'NN'w

-When cleaning the fuel filter be sure to stop the

J

engme Also refrain from smokmg and keep away from open flames or sparks

-IUI:@tli

ltl

_:'8"

.'"''8''''''·'''''

09-10mm

NGK B-7HS10 NGK B-8HSlO J-305*

o

Electrical system

U

While starting or operating the engine, never

touch the Ignition coil,

high~tension

wire, spark

plug cap. or any other electrical parts to which

high voltage is applied.

~park

plug inspection

The spark plug IS an Important engine component and IS easy to Inspect The condition of the spark plug can In-dIcate somethIng of the COndItion of the englOe. For example, If the center electrode porcelalO IS very white, this could Indicate an Intake tract aIr leak or car-buretlon problem for that cylinder

Do not attempt to diagnose any problems yourself In-stead, take the outboard motor to a Yamaha dealer You should penodlcally remove and Inspect the spark plug because heat and deposits WIll cause the spark plug to slowly break down and erode If electrode ero-sIon becomes exceSSive, Or If carbon and other deposits are exceSSive, you should replace the spark plug with a proper type plug

40HM/40HEO Standard spark plug'

Before installing the spark plug, measure the electrode gap with a wire thickness gauge, adjust the gap to specIfication as necessary

[!P~~k~~~~~~~_P_

0

-~=-;~m~ ~o 035--_0~_~391~-)

J

When Instalhng the plug, always clean the gasket sur-face and use a new gasket Wipe off any grime from the threads, and torque the spark plug properly

[s~a;-~~g(~o~;\g,14~

Ibl

- ]

NOTE' - -

-If a torque wrench IS not available when you are installing a spark plug, a good estimate of the correct torque IS 1/4 to 1/2 turns past finger tIght Have the spark plug torqued to the correct value as soon as possIble with a torque wrench

tn·'iV"NtI

----

-[:hen mstalling or removing a spark plug, be

careful not to damage the Insulator

- - -

-J347

I

~

CAUTION: -- - - - --- - - -

-~

When Installing the spark plug, make sure the terminal IS not loose If loose, be sure to tIghten completely before installing the plug It IS adVIsable to use a spark plug Integrated With the terminal

- - -

- - -

-J-380

tiU!:'#"AUlt'#,Uint'iie.

Battery maintenance andflUl~replenishing A poorly maintained battery WIll deteriorate qUIckly The battery flUid should be checked at least once amonth 1 The level should be between the upper and lower

level marks Use only distilled water If refilling IS '--" necessary

I

-;;o;:~;~~'::awcontaln~~;~e~a-'-;

whlC; are

;a~mful

I

to aba~tery,therefore, refll!o~~~~~ ~Istilled_~~~__ 2 Always make sure the battery IS charged

suffiCIent-ly It IS adVisable to Install a voltmeter for better bat-tery maIntenance

J-360

E:'!l~rgencystopsWjtc~

Keep the emergency stop sWitchIn!)ood working order Before starting the engine check the sWitch If faulty, have It repaIred by your nearest Yamaha dealer

-J'----t2

J810

o

LowerUnit

Changing the gear 011

Place an empty all can under the lower casing and

remove the lower 011 drain plug uSing a slotted*head screwdnver Next, remove the upper 011 level plug With

the outboardInan upnghtposItion, uSinga flexible or

pressunzed fIlling device, Inject outboard motor hypOid

gear all SAE 90 Into the loweralldrain plug hole When

the011begins to flow out of the upper 011 level plug hole,

Insert and tighten the plug Next, screw In the lower 011 drain plug

CAUTION:

-Replace the gearallafter the first 10 hours of opera-tion and check the 011 every 100 hours thereafter

If the gear oil becomes "milky," consult a Yamaha

dealer.

'~NOTE: -This engine has anadvantageof gear all being replace

evenIna tdt·up state

CD

011

level plug

@

011

drain plug

J860

Trim tab(Zinc)

The lower unIt IS protected from corroSion WIth a tram tab {Zinc) Installed

Ifthe trim tab IS worn more than 2/3, replace It

-68-J

~

Greasing points

Iln:hU"":'j,1

~-

: "'-11 ,

I

141.

1

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o

J450

o

Coating of the bottom of a boat

AVOId coating the boat bottom with anti-fouling paint containing copper Such anti-fouling paint will corrode the engine faster

J500

o

Replacement parts

Whenever the replacement of parts IS necessary, be sure to use genuine Yamaha parts or eqUIvalents of the

same type and of equal strength and matenal Any

10-fenor quality part can malfunction and the resulting loss of control may endanger the operator and passengers

K-04O

OFF-SEASON STORAGE

When storing your engine for a long period of time (for

ex-ample, after the boating season IS over), we recommend

you have your engine checked by a Yamaha dealer

The follOWing check-ups and service you may perform

yourself

o

Cooling

system

Wash the cooling water passages With freshwater

o

Fuel system

a Idle the engine until the carburetor IS drained off b Wash the fuel filterInsUItable cleaning

solvent

Refer to "Cleaning the fuel filter" In the "PERIODIC MAINTENANCE" section

c Wash the fuel tank Intenor and strainer with sUItable cleaning solvent

Refer to "Cleaning the fuel tank and strainer"Inthe "PERIODIC MAINTENANCE" section

o

Lubncatlon system a Replace the gear 011

Refer to "Changmg the gear all" m the "PERIODIC MAINTENANCE" section

b Add 5 to

10

cmJ_{of outboard motor 011 through the}

spark plug holesInthe cylinders c Apply grease to the specified places.

Refer to "Greasing POints" In the "PERIODIC MAINTENANCE" section

o

Electrical system

In!#l#.f&ju.J#"#"'.Jiit'

Store the battery In a cool, dark place.

CAVnON;

For long penods of storage, the outboard motor should be placed on a stand or with Its front faCing downward

AVOId direct sunlight and humidity

-70-K 055

IUI#lj,@".'j"IM.','.'

Operation after a long time storage

When operating the engine after a long time (about 12 months) storage, proceed as follows

1) Use a 50 1gas·OII mIxture to start the engine

2) Keep the engine running Idle '-.-"

3) Disconnect the011feed pipe connected to the top Intake manifold on the port SIde

4) After making sure011runs out of the011feed pipe, con-nect the pipe to Its onglnal POSition, and operate the engine uSing the PrecIsion Blend System If no011flows out of the011feed pipe after more than 10 minutes, con-sult a Yamaha dealer

K-ll0

o

Cleaning the water intake passages

a Install the outboard motor on the water tank and add water up to above the

anti-cavitatIon

plate. Next, shift rnto NEUTRAL, start the engine and run at low speed for a few minutes

.qAIJTlON:·~~~~~~~~~----, When the fresh water levelISbelow the anti-cavita-tion plate or when water supplyISinsuffiCient,

en-gine seizure may occur

11---,l---l--iICD

®

v

CD

Water surface

®

Lowest water level

L - .1 ...J

CD

r---~--,____--__,

@"iV"NM

J

~hen

us.ng the water check plug, be sure to re-move the propeller for safety

CD

Water check plug

b. Remove the screw located beside the "WASH" mark on the lower casing, Install the water check plug (accessory), and connectItto a water faucet

Next, shift Into NEUTRAL, start the engine while

supplying water, then run at low speed for a few minutes,

[

~e~:~;::~

the engine even momentarily without

runmng cooling water. Either the water pump will become damaged or the engme will overheat Before startmg the engine, be sure to Install the water check plug and feed water

=

=

=

-72-K 410

o

Storage of the battery

IUllIg.W1".'getf1".';it.

1 When the outboard motor will not be used for month or

longer, remove the battery and store It In a cool, dark place Completely recharge the battery before reusing

,t

2 If the battery Wilt be stored for a longer penod than the above, check the specific gravity of the flUId at least once a manth and recharge the battery when It IS too low

NOTE

Follow the manufacturer's Instructions for battery details

L 110

PROPELLER SELECTION

The propeller IS one of the most cntlcal elements In the per-formance of an outboard Selection of an Incorrect pro-peller can adversely affect the performance, and It could seriously damage the motor

A Yamaha outboard IS eqUIpped wIth a propeller that has been selected to perform well In a variety of applications There may be uses, however, where a propeller with a dif-ferent diameter or pItch would work better For greater load of operatron, a smaller-pitch propeller IS sUited because It can maintain proper engine rpm LikeWise, a large-pitch propeller IS sUited for smaller load of operation The engine speed changes greatly depending on the propeller Size and boat load If the engine speed IS extremely low or high, It Will adversely affect the engine For thIS reason Yamaha dealers stock a variety of propellers and can Install a SUIt-able propeller on your outboard Consult your dealer when selectIng a proper propeller for your particular application

1tiZ.'i'NlNtI

~---

-When removing or installing the propeller. shift in-to NEUTRAL and remove the spark plug caps Otherwise. the engme may start suddenly result-Ing In a serious injury or aCCident It is a good prac-tice to msert a piece of wood between the anti-cavitation plate and the propeller to Jock the pro-peller This protects your hands from the propro-peller blades