F6 F8 T8 OWNER’S MANUAL U.S.A.
U60R13E0.book Page 1 Thursday, April 6, 2006 10:29 AM ZMU01690 Read this owner’s manual carefully before operating your outboard motor.
U60R13E0.book Page 1 Thursday, April 6, 2006 10:29 AM Important manual information EMU31280 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer.
U60R13E0.book Page 1 Thursday, April 6, 2006 10:29 AM Table of contents General information .......................... 1 Identification numbers record .......... 1 Outboard motor serial number ........... 1 Key number ........................................ 1 Emission control information ........... 1 North American models...................... 1 Star labels .......................................... 2 Safety information ........................... 3 Important labels...............................
U60R13E0.book Page 2 Thursday, April 6, 2006 10:29 AM Table of contents Reverse (manual tilt and hydro tilt models) ......................................... 35 Stopping engine ............................ 36 Procedure......................................... 36 Procedure......................................... 37 Trimming outboard motor .............. 37 Adjusting trim angle for manual tilt models .......................................... 38 Adjusting trim angle (power tilt models)....................
U60R13E0.book Page 3 Thursday, April 6, 2006 10:29 AM Table of contents Consumer information.................... 76 Important warranty information for U.S.A. and Canada .................... 76 YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY ............... 78 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA .............
U60R13E0.book Page 1 Thursday, April 6, 2006 10:29 AM General information EMU25170 Identification numbers record EMU25183 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.
U60R13E0.book Page 2 Thursday, April 6, 2006 10:29 AM General information New Technology; (4-stroke/HPDI) EM Manufactured: ZMU04346 EMU25272 Star labels 1. Approval label location Your outboard motor is labeled with a California Air Resources Board (CARB) star label. See below for a description of your particular label. ZMU05159 EMU25262 Manufactured date label This label is attached to the clamp bracket or the swivel bracket. 1. Star labels location EMU25280 1.
U60R13E0.book Page 3 Thursday, April 6, 2006 10:29 AM General information ZMU01702 ZMU01704 EMU25290 EMU25362 Two Stars—Very Low Emission The two-star label identifies engines that meet the Air Resources Board’s 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low-Emission engines.
U60R13E0.book Page 4 Thursday, April 6, 2006 10:29 AM General information ● ● ● ● ● ● ● ● 4 ing. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating conditions. Gasoline is highly flammable, and its vapors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel before starting the engine.
U60R13E0.book Page 5 Thursday, April 6, 2006 10:29 AM General information EMU25382 EMU25465 Important labels Caution labels EMU25395 Warning labels EMU25473 Label EMU25401 Label EWM01260 WARNING ● ● ● Be sure shift control is in neutral before starting engine. (except 2HP) 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.
U60R13E0.book Page 6 Thursday, April 6, 2006 10:29 AM General information Several sets of rules prevail according to geographic location, but are all basically the same as the International Rules of the Road. The rules presented here in your Owner’s Manual are condensed, and have been provided for your convenience only. Consult your local U.S. Coast Guard Auxiliary or Department of Motor Vehicles for a complete set of rules governing the waters in which you will be using your boat.
U60R13E0.book Page 7 Thursday, April 6, 2006 10:29 AM General information Meeting If you are meeting another power vessel head on, and are close enough to run the risk of collision, neither of you has the right-of-way! Both of you should alter course to avoid an accident. You should keep the other vessel on your port (left) side. This rule doesn’t apply if both of you will clear one another if you continue on your set course and speed.
U60R13E0.book Page 8 Thursday, April 6, 2006 10:29 AM General information 1. When the sailing vessel is overtaking the power-driven vessel, the power-driven vessel has the right-of-way. 2. Sailing vessels should keep clear of any fishing vessel. 3. In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel which can navigate only in such a channel.
U60R13E0.book Page 9 Thursday, April 6, 2006 10:29 AM General information ZMU01708 EMU25540 Fueling instructions ● EWM00010 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.
U60R13E0.book Page 10 Thursday, April 6, 2006 10:29 AM General information ● ● ● ● ● ● Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Do not overfill the fuel tank. Tighten the filler cap securely after refueling. 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.
U60R13E0.book Page 11 Thursday, April 6, 2006 10:29 AM General information EMU25730 Without a rectifier or Rectifier Regulator ECM01090 CAUTION: A battery cannot be connected to models that do not have a rectifier or Rectifier Regulator. ZMU01710 EMU25690 Battery requirement ECM01060 CAUTION: Do not use a battery that does not meet the specified capacity. If a battery which does not meet specifications is used, the electric system could perform poorly or be overloaded, causing electric system damage.
U60R13E0.book Page 12 Thursday, April 6, 2006 10:29 AM General information 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. x 1 2 3 ZMU04606 1. Propeller diameter in inches 2. Propeller pitch in inches 3. Type of propeller (propeller mark) x 1 2 3 ZMU04604 1. Propeller diameter in inches 2. Propeller pitch in inches 3.
U60R13E0.book Page 13 Thursday, April 6, 2006 10:29 AM Basic components EMU25797 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all models. F6, F8 1. Top cowling 2. Top cowling lock lever 3. Anti-cavitation plate 4. Propeller* 5. Cooling water inlet 6. Drain screw 7. Trim rod 8. Clamp bracket 9. Manual starter handle 10.Warning indicator 11.Engine stop button/Engine stop lanyard switch 12.Gear shift lever 13.Tiller handle 14.
U60R13E0.book Page 14 Thursday, April 6, 2006 10:29 AM Basic components T8 1. Top cowling 2. Top cowling lock lever 3. Anti-cavitation plate 4. Propeller 5. Cooling water inlet 6. Drain screw 7. Trim rod 8. Clamp bracket 9. Power tilt switch* 10.Manual starter handle* 11.Warning indicator 12.Starter button* 13.Engine stop button/Engine stop lanyard switch* 14.Gear shift lever* 15.Tiller handle* 16.Steering friction lever* 17.Tilt lock lever* 18.Clamp screw 19.Rope attachment 20.Flushing device 14 21.
U60R13E0.book Page 15 Thursday, April 6, 2006 10:29 AM Basic components 3 4 1 2 ZMU01992 1. 2. 3. 4. Air vent screw Fuel gauge Fuel joint Fuel tank cap EMU25830 Fuel joint This joint is used to connect the fuel line. EMU25841 Fuel gauge This gauge is located on either the fuel tank cap or on the fuel joint base. It shows the approximate amount of fuel remaining in the tank. EMU25850 Fuel tank cap This cap seals the fuel tank. When removed, the tank can be filled with fuel.
U60R13E0.book Page 16 Thursday, April 6, 2006 10:29 AM Basic components EMU26201 EMU26221 Neutral interlock trigger Choke switch To shift out of neutral, first pull the neutral interlock trigger up. To activate the choke system, press in the main switch while the key is turned to the “ ” (on) or “ ” (start) position. The choke system will then supply the rich fuel mixture required to start the engine. When the key is released, the choke will switch off automatically. 1.
U60R13E0.book Page 17 Thursday, April 6, 2006 10:29 AM Basic components 1. Forward “ ” 2. Neutral “ ” 3. Reverse “ ” EMU25941 Throttle grip The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed. 1. Throttle indicator EMU25971 Throttle friction adjuster A friction device provides adjustable resistance to movement of the throttle grip or the remote control lever, and can be set according to operator preference.
U60R13E0.book Page 18 Thursday, April 6, 2006 10:29 AM Basic components NOTE: The engine cannot be started with the lock plate removed. When constant speed is desired, tighten the adjuster to maintain the desired throttle setting. EMU25990 Engine stop lanyard switch The lock plate must be attached to the engine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg.
U60R13E0.book Page 19 Thursday, April 6, 2006 10:29 AM Basic components EMU26011 Choke knob for pull type To supply the engine with the rich fuel mixture required to start, pull out this knob. EMU26090 Main switch EMU26070 Manual starter handle To start the engine, first gently pull the handle out until resistance is felt. From that position, then pull the handle straight out quickly to crank the engine. The main switch controls the ignition system; its operation is described below.
U60R13E0.book Page 20 Thursday, April 6, 2006 10:29 AM Basic components tor up. Pressing the switch “ ” (down) tilts the outboard motor down. When the switch is released, the outboard motor will stop in its current position. EMU31430 Steering friction adjuster A friction device provides adjustable resistance to the steering mechanism, and can be set according to operator preference. An adjuster lever is located on the bottom of the tiller handle bracket.
U60R13E0.book Page 21 Thursday, April 6, 2006 10:29 AM Basic components 1. Nut Nut tightening torque: 6.0 Nm (4.4 ft-lb) (0.61 kgf-m) 1. Tilt lock lever To lock it, set the tilt lock lever in the lock position. To release, push the tilt lock lever in the release position. EMU26320 NOTE: ● ● Check the tiller handle for smooth movement when the lever is turned to the starboard side “B”. Do not apply lubricants such as grease to the friction areas of the steering friction adjuster.
U60R13E0.book Page 22 Thursday, April 6, 2006 10:29 AM Basic components EMU26360 EMU26460 Power tilt unit Flushing device This unit tilts the outboard motor up and down and is controlled with the power tilt switch. This device is used to clean the cooling water passages of the motor using a garden hose and tap water. ECM00630 CAUTION: Do not step on or exert pressure on the power tilt motor. The power tilt unit could be damaged as a result. NOTE: For details on usage, see page 52. 1.
U60R13E0.book Page 23 Thursday, April 6, 2006 10:29 AM Basic components EMU26801 Warning system ECM00090 CAUTION: Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU30167 Low oil pressure warning 1. Warning indicator EMU26503 Low oil pressure warning indicator If oil pressure drops too low, this indicator will flash. For further information, see page 23.
U60R13E0.book Page 24 Thursday, April 6, 2006 10:29 AM Operation EMU26901 EWM00830 Installation ECM00110 CAUTION: Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat, or accessories such as transom ladders or depth finder 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.
U60R13E0.book Page 25 Thursday, April 6, 2006 10:29 AM Operation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the engine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the anti-cavitation plate is between the bottom of the boat and a level 25 mm (1 in.) below it. 0–25mm (0–1in.
U60R13E0.book Page 26 Thursday, April 6, 2006 10:29 AM Operation 3. Secure the clamp bracket to the transom using the bolts provided with the outboard (if packed). For details, consult your Yamaha dealer. 1. 2. EWM00650 WARNING Avoid using bolts, nuts or washers other than those contained in the engine packaging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tightening, test run the engine and check their tightness. 3. 4.
U60R13E0.book Page 27 Thursday, April 6, 2006 10:29 AM Operation EMU27130 Controls ● ● ● ● Check throttle, shift, and steering for proper operation before starting the engine. The controls should work smoothly, without binding or unusual free play. Look for loose or damaged connections. Check operation of the starter and stop switches when the outboard motor is in the water. EMU27140 Engine ● ● ● Check the engine and engine mounting. Look for loose or damaged fasteners.
U60R13E0.book Page 28 Thursday, April 6, 2006 10:29 AM Operation EMU27270 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 concerns about pollution and resulting emissions 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.
U60R13E0.book Page 29 Thursday, April 6, 2006 10:29 AM Operation ZMU02024 3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp. NOTE: During engine operation place the tank horizontally, otherwise fuel cannot be drawn from the fuel tank. 4. NOTE: The start-in-gear protection device prevents the engine from starting except when in neutral. 2. Squeeze the primer pump with the outlet end up until you feel it become firm.
U60R13E0.book Page 30 Thursday, April 6, 2006 10:29 AM Operation ● 3. Place the throttle grip in the “ (start) position. 5. Pull the manual starter handle slowly until you feel resistance. Then give a strong pull straight out to crank and start the engine. Repeat if necessary. 6. After the engine starts, slowly return the manual starter handle to its original position before releasing it. Slowly return the throttle grip to the fully closed position. ” 7. 4.
U60R13E0.book Page 31 Thursday, April 6, 2006 10:29 AM Operation boat could slow rapidly. This could cause people and objects in the boat to be thrown forward. again. Also if the engine is warm and fails to start, open the throttle a same amount and try to start the engine again. If the engine still fails to start, see page 68. EMU27562 Electric start models 1. Place the gear shift lever in neutral. 3. Place the throttle grip in the “ ” (start) position.
U60R13E0.book Page 32 Thursday, April 6, 2006 10:29 AM Operation NOTE: ● ● It is not necessary to use the choke when starting a warm engine. If the choke knob is left in the “ ” (start) position while the engine is running, the engine will run poorly or stall. 5. Push the starter button to start the motor. (Repeat if necessary.) ZMU02030 NOTE: ● ● 6. Immediately after the engine starts, release the starter button to allow it to return to its original position.
U60R13E0.book Page 33 Thursday, April 6, 2006 10:29 AM Operation 2. Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the engine stop switch. ON OFF EWM00120 WARNING ● ● ● Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating. Do not attach the lanyard to clothing that could tear loose.
U60R13E0.book Page 34 Thursday, April 6, 2006 10:29 AM Operation damaged. If the engine will not start after 5 seconds of cranking, return the main switch to “ ” (on), wait 10 seconds, then crank the engine again. EMU27670 Warming up engine EMU27732 Manual start models 1. NOTE: ● ● It is not necessary to use the choke when starting a warm engine. Push in the main switch fully, or the remote choke system will not operate. 6. Turn the main switch to “ ” (start), and hold it for a maximum of 5 seconds.
U60R13E0.book Page 35 Thursday, April 6, 2006 10:29 AM Operation EMU27740 Shifting EWM00180 WARNING Before shifting, make sure there are no swimmers or obstacles in the water near you. Remote control models Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward.
U60R13E0.book Page 36 Thursday, April 6, 2006 10:29 AM Operation ZMU02030 2. On models equipped with a tilt lock lever, check that it is in the lock/down position. 3. Move the gear shift lever quickly and firmly from neutral to reverse. 2. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to reverse. EMU27820 Stopping engine Before stopping the engine, first let it cool off for a few minutes at idle or low speed.
U60R13E0.book Page 37 Thursday, April 6, 2006 10:29 AM Operation NOTE: If the outboard motor is equipped with an engine stop switch lanyard, the engine can also be stopped by pulling the lanyard and removing the lock plate from the engine stop switch. EMU27852 Procedure 2. 1. Turn the main switch to “ 2. After stopping the engine, disconnect the fuel line or close the fuel cock if there is a fuel joint or a fuel cock on the boat. Tighten the air vent screw on the fuel tank cap (if equipped).
U60R13E0.book Page 38 Thursday, April 6, 2006 10:29 AM Operation engine, and propeller. Correct trim is also affected by variables such as the load in the boat, sea conditions, and running speed. EWM00740 WARNING Excessive trim for the operating conditions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This increases the possibility of an accident. If the boat begins to feel unstable or is hard to steer, slow down and/or readjust the trim angle. 1.
U60R13E0.book Page 39 Thursday, April 6, 2006 10:29 AM Operation EMU27902 Adjusting trim angle (power tilt models) EWM00751 WARNING ● ● ● Be sure all people are clear of the outboard 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 position for the first time. Increase speed gradually and watch for any signs of instability or control problems. Improper trim angle can cause loss of control.
U60R13E0.book Page 40 Thursday, April 6, 2006 10:29 AM Operation also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane. Bow Up Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag.
U60R13E0.book Page 41 Thursday, April 6, 2006 10:29 AM Operation ECM00241 CAUTION: ● ● Before tilting the outboard motor, stop the engine by following the procedure on page 36. Never tilt the outboard motor while the engine is running. Severe damage from overheating can result. Do not tilt up the engine by pushing the tiller handle (if equipped) because this could break the handle. EMU27978 4. Procedure for tilting up (manual tilt models) 5. 1. Place the gear shift lever in neutral. 6. 2.
U60R13E0.book Page 42 Thursday, April 6, 2006 10:29 AM Operation 2. Disconnect the fuel line from the outboard motor or close the fuel cock. 4. 3. Press the power trim and tilt switch / power tilt switch “ ” (up) until the outboard motor has tilted up completely. Push the tilt support knob into the clamp bracket or pull the tilt support lever toward you to support the engine. EWM00260 WARNING After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever.
U60R13E0.book Page 43 Thursday, April 6, 2006 10:29 AM Operation 5. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim and tilt switch / power tilt switch “ ” (down) to retract the trim rods. ECM00250 CAUTION: Be sure to retract the trim rods completely during mooring. This protects the rods from marine growth and corrosion which could damage the power trim and tilt mechanism. EMU30192 3.
U60R13E0.book Page 44 Thursday, April 6, 2006 10:29 AM Operation ECM00260 CAUTION: Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when setting up for and cruising in shallow water. Otherwise severe damage from overheating can result. EMU28060 Cruising in shallow water The outboard motor can be tilted up partially to allow operation in shallow water.
U60R13E0.book Page 45 Thursday, April 6, 2006 10:29 AM Operation 3. Slightly tilt the outboard motor up. The tilt support bar will lock automatically, supporting the outboard motor in a partially raised position. 5. 6. Slightly tilt the outboard motor up until the tilt support bar automatically returns to the free position. Slowly lower the outboard motor to the normal position.
U60R13E0.book Page 46 Thursday, April 6, 2006 10:29 AM Operation 2. Slightly tilt the outboard motor up to the desired position using the power trim and tilt switch / power tilt switch. 3. To return the outboard motor to the normal running position, press the power trim and tilt switch / power tilt switch and slowly tilt the outboard motor down.
U60R13E0.book Page 47 Thursday, April 6, 2006 10:29 AM Maintenance EMU31480 Specifications NOTE: “(AL)” stated in the specification data below represents the numerical value for the aluminum propeller installed. Likewise, “(SUS)” represents the value for stainless steel propeller installed and “(PL)” for plastic propeller installed. EMU28218 Dimension: Overall length: F6MH 1038 mm (40.9 in) F8MH 1038 mm (40.9 in) T8EH 1038 mm (40.9 in) T8PH 1038 mm (40.9 in) T8PR 552 mm (21.
U60R13E0.book Page 48 Thursday, April 6, 2006 10:29 AM Maintenance Spark plug gap: 0.9–1.0 mm (0.035–0.039 in) Control system: F6MH Tiller F8MH Tiller T8EH Tiller T8PH Tiller T8PR Remote control Starting system: F6MH Manual F8MH Manual T8EH Manual and electric T8PH Electric T8PR Electric Starting carburetion system: Choke valve Valve clearance (cold engine) IN: 0.15–0.20 mm (0.0059–0.0079 in) Valve clearance (cold engine) EX: 0.20–0.25 mm (0.0079–0.0098 in) Min. cold cranking amps (CCA/SAE): T8EH 245.
U60R13E0.book Page 49 Thursday, April 6, 2006 10:29 AM Maintenance Engine oil drain bolt: 24.0 Nm (17.7 ft-lb) (2.45 kgf-m) EMU28222 Transporting and storing outboard motor EWM00690 WARNING ● ● ● Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. USE CARE when transporting fuel tank, whether in a boat or car. DO NOT fill fuel container to maximum capacity.
U60R13E0.book Page 50 Thursday, April 6, 2006 10:29 AM Maintenance It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the following procedures. 4. Install the outboard motor on the test tank. 1 ECM01080 CAUTION: ● ● ● To prevent problems which can be caused by oil entering the cylinder from the sump, keep the outboard motor in the attitude shown when transporting and storing it.
U60R13E0.book Page 51 Thursday, April 6, 2006 10:29 AM Maintenance EWM00090 2. WARNING ● ● Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. 7. Run the engine at a fast idle for 10–15 minutes in neutral position. 8. Just prior to turning off the engine, quickly spray “Yamaha Stor-Rite Engine Fogging Oil” (Part No.
U60R13E0.book Page 52 Thursday, April 6, 2006 10:29 AM Maintenance Batteries vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery manufacturer’s instructions. Procedure 1. Disconnect and remove the battery from the boat. Always disconnect the black negative cable first to prevent the risk of shorting. 2. Clean the battery casing and terminals. Fill each cell to the upper level with distilled water. 3.
U60R13E0.book Page 53 Thursday, April 6, 2006 10:29 AM Maintenance 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 outboard motor until it is completely out of the water will achieve better results. For cooling system flushing instructions, see page 49.
U60R13E0.book Page 54 Thursday, April 6, 2006 10:29 AM Maintenance EMU28522 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use.
U60R13E0.book Page 55 Thursday, April 6, 2006 10:29 AM Maintenance Initial Item Oil filter (built into oil pan) Spark plug(s) Timing belt Valve clearance (OHC, OHV) Actions Every 10 hours 50 hours 100 hours 200 hours (1 month) (3 months) (6 months) (1 year) Inspection / cleaning / change Cleaning / adjustment / replacement Inspection / replacement Inspection / adjustment EMU28874 Maintenance chart (additional) Every Item Actions 500 hours (2.
U60R13E0.book Page 56 Thursday, April 6, 2006 10:29 AM Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) EMU28952 Cleaning and adjusting spark plug EWM00560 WARNING When removing or installing a spark plug, 56 be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire.
U60R13E0.book Page 57 Thursday, April 6, 2006 10:29 AM Maintenance The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer.
U60R13E0.book Page 58 Thursday, April 6, 2006 10:29 AM Maintenance EMU29041 Inspecting idling speed EWM00451 WARNING ● ● Do not touch or remove electrical parts when starting or during operation. Keep hands, hair, and clothes away from the flywheel and other rotating parts while the engine is running. ECM00490 CAUTION: This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be used.
U60R13E0.book Page 59 Thursday, April 6, 2006 10:29 AM Maintenance ● drain hole. Then remove the oil filler cap. Let the oil drain completely. Wipe up any spilled oil immediately. Be sure the outboard motor is securely fastened to the transom or a stable stand. ECM00970 CAUTION: ● ● Do not overfill the oil, and be sure the outboard motor is upright (not tilted) when checking and changing the engine oil.
U60R13E0.book Page 60 Thursday, April 6, 2006 10:29 AM Maintenance 7. Dispose of used oil according to local regulations. NOTE: ● ● For more information on the disposal of used oil, consult your Yamaha dealer. Change the oil more often when operating the engine under adverse conditions such as extended trolling. EMU29112 Checking wiring and connectors 1. Oil filler cap 5. Start the engine and watch to make sure the low oil pressure warning indicator (if equipped) turns off.
U60R13E0.book Page 61 Thursday, April 6, 2006 10:29 AM Maintenance EMU29163 EMU29171 Checking power trim and tilt / power tilt system Checking propeller EWM00430 WARNING ● ● 1. Never get under the lower unit while it is tilted, even when the tilt support lever is locked. Severe injury could occur if the outboard motor accidentally falls. Make sure no one is under the outboard motor before performing this test. Check the power trim and tilt unit / power tilt unit for any sign of oil leaks.
U60R13E0.book Page 62 Thursday, April 6, 2006 10:29 AM Maintenance ● ● ● ● ● Check each of the propeller blades for wear, erosion from cavitation or ventilation, or other damage. Check the propeller shaft for damage. Check the splines / shear pin for wear or damage. Check for fish line tangled around the propeller shaft. 1. 2. 3. 4. 5. Cotter pin Propeller nut Washer Propeller Thrust washer 1. 2. 3. 4. 5. 6.
U60R13E0.book Page 63 Thursday, April 6, 2006 10:29 AM Maintenance ● 1. 2. 3. 4. Be sure to use a new cotter pin and bend the ends over securely. Otherwise the propeller could come off during operation and be lost. Apply Yamaha marine grease or a corrosion resistant grease to the propeller shaft. Install the spacer (if equipped), thrust washer, and propeller on the propeller shaft. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque.
U60R13E0.book Page 64 Thursday, April 6, 2006 10:29 AM Maintenance EMU29302 NOTE: Cleaning fuel tank For disposal of used oil, consult your Yamaha dealer. EWM00920 5. With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole. Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: F6MH 150.0 cm³ (5.07 US oz) (5.29 Imp.oz) F8MH 150.0 cm³ (5.07 US oz) (5.29 Imp.oz) T8EH 370.0 cm³ (12.51 US oz) (13.
U60R13E0.book Page 65 Thursday, April 6, 2006 10:29 AM Maintenance 4. 5. Clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allow the filter to dry. Replace the gasket with a new one. Reinstall the fuel joint assembly and tighten the screws firmly. EMU29312 Inspecting and replacing anode(s) Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes.
U60R13E0.book Page 66 Thursday, April 6, 2006 10:29 AM Maintenance 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 hydrogen 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 (for example: welding equipment, lighted cigarettes, and so on.
U60R13E0.book Page 67 Thursday, April 6, 2006 10:29 AM Maintenance Connect the red battery cable to the POSITIVE (+) terminal first. Then connect the black battery cable to the NEGATIVE (-) terminal. 1. Red cable 2. Black cable 3. Battery tom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
U60R13E0.book Page 68 Thursday, April 6, 2006 10:29 AM Trouble Recovery EMU29424 Troubleshooting A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. This section describes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair, bring it to your Yamaha dealer.
U60R13E0.book Page 69 Thursday, April 6, 2006 10:29 AM Trouble Recovery A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer. Q. Has warning system activated? A. Find and correct cause of warning. Q. Is spark plug gap incorrect? A. Inspect and adjust as specified. Q.
U60R13E0.book Page 70 Thursday, April 6, 2006 10:29 AM Trouble Recovery Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. A. Remove foreign matter and clean lower unit. Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer. Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is there excess water in fuel filter cup? A. Drain filter cup. Q. Is fuel filter clogged? A.
U60R13E0.book Page 71 Thursday, April 6, 2006 10:29 AM Trouble Recovery A. Connect correctly. If the outboard motor hits an object in the water, follow the procedure below. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with recommended type. Q. Is high pressure fuel pump drive belt broken? A. Have serviced by a Yamaha dealer. Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer. 1. 2. Engine vibrates excessively. Q.
U60R13E0.book Page 72 Thursday, April 6, 2006 10:29 AM Trouble Recovery EMU29532 Starter will not operate If the starter mechanism does not operate (the engine cannot be cranked with the starter), the engine can be started with an emergency starter rope. EWM01021 WARNING ● 1. 2. 3. 4.
U60R13E0.book Page 73 Thursday, April 6, 2006 10:29 AM Trouble Recovery ● tached to the engine stop switch. The main switch must be “ ” (on), if equipped. engine is running. Do not install the starter mechanism or top cowling after the engine is running. Do not touch the ignition coil, spark plug wire, spark plug cap, or other electrical components when starting or operating the motor. You could get an electrical shock. ON OFF EMU29561 Emergency starting engine 1. 2. Remove the top cowling.
U60R13E0.book Page 74 Thursday, April 6, 2006 10:29 AM Trouble Recovery 1. Yellow cord EMU29670 Engine fails to operate EMU29691 Ignition system malfunction If the battery voltage is low or in the unlikely event of an ignition system malfunction, the engine speed may become erratic or the engine may stop. In such a situation, follow the procedure below. 1. Remove the CDI unit cover or electrical cover, if equipped. 2. Disconnect the yellow cord (emergency circuit) of the CDI unit to return to port.
U60R13E0.book Page 75 Thursday, April 6, 2006 10:29 AM Trouble Recovery ECM00400 CAUTION: Do not attempt to run the outboard motor until it has been completely inspected.
U60R13E0.book Page 76 Thursday, April 6, 2006 10:29 AM Consumer information EMU29811 Important warranty information for U.S.A.
U60R13E0.
U60R13E0.book Page 78 Thursday, April 6, 2006 10:29 AM Consumer information EMU29830 YAMAHA MOTOR CORPORATION, U.S.A.
U60R13E0.
U60R13E0.
U60R13E0.
YAMAHA MOTOR CORPORATION, USA Printed in France January 2006–0.
Warranty card 12/6/01 7:40 PM Page 1
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