Yamaha 4 Stroke Owners Manual

							Installation
26
EMU39731
Installation
The information presented in this section is in-
tended as reference only. It is not possible to
provide complete instructions for every possi-
ble boat and motor combination. Proper
mounting depends in part on experience and
the specific boat and motor combination.
WARNING
EWM02341

Overpowering a boat could cause se-
vere instability. Do not mount an out-
board motor with more horsepower than
the maximum rating on the capacity
plate of the boat. If the boat does not
have a capacity plate, consult the boat
manufacturer.

Improper mounting of the outboard mo-
tor could result in hazardous conditions,
such as poor handling, loss of control,
or fire hazards. If you are not able to
mount the outboard motor properly,
consult a Yamaha dealer.
EMU39562Mounting the outboard motor
WARNING
EWM02300
Do not hold the top cowling or tiller handle
when mounting or dismounting the out-
board motor. Otherwise, the outboard mo-
tor could fall.
1. Be sure to mount the outboard motor
while the boat is on land. If the boat is on
the water, move it to an area on land.
2. To prevent steering movement, turn the
steering friction adjuster clockwise.3. Turn the tiller handle 180° so that it is
pointing rearward.
4. Hold the carrying handle and the hand-
grip on the front side of the bottom cowl-
ing and lift up the outboard motor using
two people.
1. Steering friction adjuster
1. Carrying handle
2. Handgrip
ZMU06827
1
ZMU06836
ZMU068211
2
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							Installation
27
5. Mount the outboard motor on the center
line (keel line) of the boat, and ensure
that the boat itself is well balanced. Oth-
erwise the boat will be hard to steer. For
boats without a keel or which are asym-
metrical, consult your dealer.
6. Turn the steering friction adjuster coun-
terclockwise to set the steering friction
according to operator preference.
WARNING! If there is too much resis-
tance it could be difficult to steer,
which could result in an accident.
[EWM00721]EMU39740
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 en-
gine to overheat. If the mounting height is too
low, the water resistance will increase and
thereby reduce engine efficiency. Mount the
outboard motor so that the anti-cavitation
plate is between the bottom of the boat and a
level 25 mm (1 in) below it.
1. Center line (keel line)
ZMU06835
ZMU017601
1. Steering friction adjuster
1. Idle hole
2. Anti-cavitation plate
ZMU06834
1
ZMU06796
0-25 mm
(0-1 in)
2
1
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							Installation
28
NOTICE
ECM02170

Check that the idle hole stays high
enough to keep out water getting inside
engine even if the boat is in stationary
with maximum load.

Incorrect engine height or obstructions
to the smooth flow of water (such as the
design or condition of the boat) can cre-
ate airborne water spray while the boat
is cruising. If the motor is operated con-
tinuously in the presence of airborne
water spray, enough water could enter
the engine through the intake opening
on the top cowling to cause severe en-
gine damage. Eliminate the cause of the
airborne water spray.
TIP:

The optimum mounting height of the out-
board motor is affected by the boat and mo-
tor combination and the desired use. Test
runs at different heights can help determine
the optimum mounting height. Consult your
Yamaha dealer or boat manufacturer for
further information on determining the prop-
er mounting height.

For instructions on setting the trim angle of
the outboard motor, see page 41.
EMU39751Clamping the outboard motor
1. Place the outboard motor on the transom
so that it is positioned as close to the cen-
ter as possible. Tighten the clamp screws
evenly and securely. Occasionally check
the clamp screws for tightness during op-
eration of the outboard motor because
they could become loose due to engine
vibration. WARNING! Loose clamp
screws could allow the outboard mo-
tor to fall off or move on the transom.
This could cause loss of control andserious injury. Make sure the clamp
screws are tightened securely. Occa-
sionally check the screws for tight-
ness during operation.
 [EWM00642]
2. Attach one end to the restraint cable at-
tachment 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.
1. Clamp screw
1. Restraint cable attachment
ZMU068111
ZMU06812
1
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							Operation
29
EMU36381
First-time operationEMU36391Fill engine oil
The engine is shipped from the factory without
engine oil. If your dealer did not fill the oil, you
must fill it before starting the engine. NOTICE:
Check that the engine is filled with oil be-
fore first-time operation to avoid severe
engine damage.
 [ECM01781]
The engine is shipped with the following stick-
er, which should be removed after engine oil
is filled for the first time. For more information
on checking the engine oil level, see page 31.
EMU30174Breaking in engine
Your new engine requires a period of break-in
to allow mating surfaces of moving parts to
wear in evenly. Correct break-in will help en-
sure proper performance and longer engine
life. NOTICE: Failure to follow the break-in
procedure could result in reduced engine
life or even severe engine damage.
 [ECM00801]
EMU40060
Procedure for 4-stroke models
Your new engine requires a period of 10
hours break-in to allow mating surfaces of
moving parts to wear in evenly.
TIP:
Run the engine in the water, under load (in
gear with a propeller installed) as follows. For
10 hours for breaking in engine avoid extend-
ed idling, rough water and crowded areas.1. For the first hour of operation:
Run the engine at varying speeds up to
2000 r/min or approximately half throttle.
2. For the second hour of operation:
Run the engine at 3000 r/min or at ap-
proximately three-quarter throttle.
3. Remaining 8 hours:
Run the engine at any speed. However,
avoid operating at full throttle for more
than 5 minutes at a time.
4. After the first 10 hours:
Operate the engine normally.
EMU36400Getting to know your boat
Different boats handle differently. Operate
cautiously while you learn how your boat han-
dles under different conditions and with differ-
ent trim angles (see page 41).
EMU36412
Checks before starting engine
WARNING
EWM01920
If any item in the checks before starting
engine is not working properly, have it in-
spected and repaired before operating the
outboard motor. Otherwise an accident
could occur.
NOTICE
ECM00120
Do not start the engine out of water. Over-
heating and serious engine damage can
occur.
EMU36560Fuel level
Be sure you have plenty of fuel for your trip. A
good rule is to use 1/3 of your fuel to get to the
destination, 1/3 to return, and to keep 1/3 as
an emergency reserve. With the boat level on
a trailer or in the water, check the fuel level.
For fuel filling instructions, see page 32.
ZMU01710
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							Operation
30
EMU39840Removing top cowling
For the following checks, remove the top
cowling from the bottom cowling.
To remove the top cowling, pull the cowling
lock lever up and lift up the top cowling.
EMU36442Fuel system
WARNING
EWM00060
Gasoline and its vapors are highly flam-
mable and explosive. Keep away from
sparks, cigarettes, flames, or other sourc-
es of ignition.
WARNING
EWM00910
Leaking fuel can result in fire or explosion.

Check for fuel leakage regularly.

If any fuel leakage is found, the fuel sys-
tem must be repaired by a qualified me-
chanic. Improper repairs can make the
outboard unsafe to operate.
EMU36451Check for fuel leaks

Check for fuel leaks or gasoline fumes in
the boat.

Check for fuel leakage from the fuel system.

Check the fuel tank and fuel lines for
cracks, swellings, or other damages.
EMU39851Controls

Move the tiller handle fully to the left and
right to check that operation is smooth.

Turn the throttle grip from the fully closed
position to the fully open position. Check
that the throttle grip turns smoothly and that
it completely returns to the fully closed posi-
tion.

Check the throttle cable and throttle link for
loose or damaged connections.

Check the shift link and start-in-gear protec-
tion cable for loose or damaged connec-
tions.
1. Cowling lock lever
ZMU06732
1
ZMU06851
ZMU06852
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							Operation
31
EMU36483Engine shut-off cord (lanyard)
Inspect the engine shut-off cord and clip for
damage, such as cuts, breaks, and wear.
EMU39383Engine oil
1. Place the outboard motor in an upright
position (not tilted). NOTICE: If the mo-
tor is not level, the oil level indicated
on the dipstick may not be accurate.
[ECM01790]
2. Remove the oil filler cap and wipe the at-
tached oil dipstick clean.
TIP:
The oil lubrication check window does not in-
dicate the engine oil level. Use the oil lubrica-
tion check window to make sure that the
engine is being lubricated with oil while it is
running.
3. Install the oil filler cap and tighten it com-
pletely.
4. Remove the oil filler cap again and check
that the oil level on the dipstick is be-
tween the upper and lower marks. If the
oil level is not at the proper level, add or
extract oil until the oil is between the up-
per and lower marks.
5. Install the oil filler cap and tighten it com-
pletely.
1. Clip
2. Cord
ZMU06874
ZMU06873
1
2
1. Oil filler cap
2. Oil lubrication check window
1. Oil dipstick
2. Upper mark
3. Lower mark
ZMU06769
12
1
2
3
ZMU06737
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							Operation
32
EMU27153Engine

Check the engine and engine mounting.

Look for loose or damaged fasteners.

Check the propeller for damage.

Check for engine oil leaks.EMU39861Installing top cowling
1. Check the rubber seal for damage. If the
rubber seal is damaged, have it replaced
by a Yamaha dealer.
2. Align the fuel tank cap and manual starter
handle with their respective holes in the
top cowling.
3. Hook the top cowling hook onto the bot-
tom cowling, and then make sure that the
fuel tank cap and manual starter handle
fit properly into their respective holes.4. Check to be sure the rubber seal is seat-
ed correctly between the top cowling and
the bottom cowling.
5. Pull the cowling lock lever down to secure
the top cowling.
6. Check the fitting of the top cowling by
pushing it with both hands. NOTICE: If
the top cowling is not installed cor-
rectly, water spray under the top cowl-
ing can damage the engine, or the top
cowling can blow off at high speeds.
[ECM01991]
EMU39871
Filling fuel
WARNING
EWM01950
Be sure the outboard motor is securely
fastened to the transom or a stable stand.
1. Fuel tank cap
2. Manual starter handle
3. Rubber seal
1. Hook
ZMU06856
1
2
3
ZMU06857
1
1. Cowling lock lever
ZMU06738
1
ZMU06739
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							Operation
33
WARNING
EWM01830

Gasoline and its vapors are highly flam-
mable and explosive. Always refuel ac-
cording to this procedure to reduce the
risk of fire and explosion.

Gasoline is poisonous and can cause in-
jury or death. Handle gasoline with care.
Never siphon gasoline by mouth. If you
should swallow some gasoline or inhale
a lot of gasoline vapor, or get some gas-
oline in your eyes, see your doctor im-
mediately. If gasoline spills on your
skin, wash with soap and water. If gaso-
line spills on your clothing, change your
clothes.
Before refueling, check the following points:

Securely moor the boat in a well-ventilated
area and stop the engine. If the boat is trail-
ered, make sure that it is stable.

Do not smoke and keep away from sparks,
flames, static electric discharge, or other
sources of ignition.

If you use a portable container to store and
dispense fuel, only use a locally approved
GASOLINE container.

To prevent electrostatic sparks, discharge
any built-up static electricity from your body
before refueling.
Filling fuel for built-in fuel tank
1. Remove the fuel tank cap.2. Fill the fuel tank, but do not overfill it. Fuel
can expand and overflow if the tempera-
ture increases.
3. Tighten the fuel tank cap securely.
4. Wipe up any spilled gasoline immediately
with dry rags. Dispose of rags properly
according to local laws or regulations. If
you use a portable container to store and
dispense fuel, only use a locally ap-
proved GASOLINE container.
Filling fuel for portable fuel tank (optional)
1. Disconnect the fuel hose, and then install
the fuel joint cap. WARNING! When not
using a portable fuel tank, make sure
to install the fuel joint cap. Otherwise,
injury could result from striking the
fuel joint accidentally.
 [EWM02411]
1. Fuel tank cap
Fuel tank capacity (built in type):
1.1 L (0.29 US gal, 0.24 Imp.gal)
ZMU06875
1
ZMU06810
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							Operation
34
2. Remove the portable fuel tank from the
boat.
3. Remove the fuel tank cap.
4. Fill the fuel tank, but do not overfill it. Fuel
can expand and overflow if the tempera-
ture increases.
5. Tighten the fuel tank cap securely.6. Wipe up any spilled gasoline immediately
with dry rags. Dispose of rags properly
according to local laws or regulations. If
you use a portable container to store and
dispense fuel, only use a locally ap-
proved GASOLINE container.
EMU27452
Operating engine
WARNING
EWM00420

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

When the air vent screw is loosened,
gasoline vapor will be released. Gaso-
line is highly flammable, and its vapors
are flammable and explosive. Refrain
from smoking, and keep away from
open flames and sparks while loosening
the air vent screw.

This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which could cause brain
damage or death when inhaled. Symp-
toms include nausea, dizziness, and
drowsiness. Keep cockpit and cabin ar-
eas well ventilated. Avoid blocking ex-
haust outlets.
EMU39394Sending fuel
Sending fuel for built-in fuel tank
1. Loosen the air vent screw by 1 or 2 turns.
1. Fuel hose
2. Fuel joint cap
1. Fuel tank cap
ZMU06753
2
1
ZMU06832
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							Operation
35
2. Align the fuel cock with the built-in fuel
tank position.
3. Remove the top cowling, and then
squeeze the primer pump in the bottom
cowling repeatedly until you feel it be-
come slightly firm.
4. Install the top cowling.Sending fuel for portable fuel tank (optional)
1. Loosen the air vent screw on the portable
fuel tank by 2 or 3 turns.
2. If there is fuel in the built-in fuel tank, loos-
en the air vent screw by 1 or 2 turns to
prevent pressure from increasing inside
the tank due to fuel expansion.
3. Remove the fuel joint cap. Connect the
fuel hose securely between the tank and
the outboard motor so that the primer
pump arrow is pointing toward the out-
board motor.
1. Air vent screw
1. Built-in fuel tank position
1. Primer pump
ZMU06740
1
ZMU06720
11
ZMU068261
1. Air vent screw
1. Air vent screw
ZMU06740
1
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