Yamaha 4 Stroke Owners Manual

							Operation
46
2. Hold the rear of the top cowling and
slightly tilt the outboard motor up until the
tilt support bar automatically locks. The
outboard motor can be operated in this
position for shallow water cruising. The
outboard motor is equipped with 3 shal-
low water cruising positions.
EMU40041Procedure for returning to normal cruising
1. To tilt the outboard motor down to the
normal running position, move the gear
shift lever to the neutral position.
2. Slightly tilt the outboard motor up, and
then slowly tilt the outboard motor down
while pulling the tilt support bar up.
EMU35391
Cruising in other conditions
Cruising in salt water
After operating in salt water, flush the cooling
water passages with fresh water to prevent
them from becoming clogged. Also rinse the
outside of the outboard motor with fresh wa-
ter.
Cruising in muddy, turbid, or acidic water
Water in some areas can be acidic or with a
lot of sediment in it, such as muddy or turbid
(cloudy) water. After operating in such water,
flush the cooling passages with fresh water to
prevent corrosion. Also rinse the outside of
the outboard motor with fresh water.
1. Shallow water cruising position
2. Tilt support bar
1. Neutral position
ZMU06760
2
1
1
ZMU06749
1. Tilt support bar
ZMU06881
1
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							Maintenance
47
EMU39901
Transporting and storing out-
board motor
WARNING
EWM00695

USE CARE when transporting a fuel
container, whether in a boat or car.

DO NOT exceed the specified capacity
of a fuel container. Gasoline will expand
considerably as it warms up and can
build up pressure in the fuel container.
This can cause fuel leakage and a poten-
tial fire hazard.

Leaking fuel is a fire hazard. When trans-
porting and storing the outboard motor,
close the fuel cock to prevent fuel from
leaking.
WARNING
EWM02330
Never get under the engine while it is tilt-
ed. Severe injury could occur if the out-
board motor accidentally falls.
NOTICE
ECM02190
Do not use the tilt support bar when traile-
ring the boat. The outboard motor could
shake loose from the tilt support and fall.
The outboard motor should be trailered and
stored in the fully tilted down position. If the
outboard motor cannot be trailered in the fully
tilted down position, consult a Yamaha dealer.
EMU39422Dismounting 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. Stop the engine and land the boat.2. Tighten the fuel tank cap and air vent
screw securely.
3. Align the fuel cock with the closed posi-
tion.
4. When using a portable fuel tank, discon-
nect the fuel hose from the fuel joint, 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. Air vent screw
2. Fuel tank cap
1. Closed position
ZMU06844
1
2
ZMU068711
1
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							Maintenance
48
5. To prevent steering movement, turn the
steering friction adjuster clockwise.
6. Turn the tiller handle 180° so that it is
pointing rearward.
7. Loosen the clamp screws.8. 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 to dismount it from the boat.
9. When transporting or storing the out-
board motor while removed from a boat,
use an outboard motor stand.
1. Fuel hose
2. Fuel joint cap
1. Steering friction adjuster
ZMU06753
2
1
ZMU06827
1
ZMU06836
1. Carrying handle
2. Handgrip
ZMU068211
2
ZMU06835
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							Maintenance
49
10. If transporting or storing the outboard mo-
tor horizontally cannot be avoided, tight-
en the clamp screws completely, place a
towel or something similar under the out-
board motor to protect it from damage,
and then place the outboard motor in the
attitude shown. If the front side of the out-
board motor is facing down, turn the
clamp bracket 90° so that it does not con-
tact the ground, and then turn the steer-
ing friction adjuster clockwise to secure
the bracket.
EMU39912Storing outboard motor
When storing your Yamaha outboard motor
for prolonged periods of time (2 months or
longer), several important procedures must
be performed to prevent excessive damage.
It is advisable to have your outboard motor
serviced by an authorized Yamaha dealer pri-
or to storage. However, the following proce-
dures can be performed by the owner.
NOTICE
ECM02212

Do not place the outboard motor on its
side before the cooling water has
drained from it completely. Otherwise,
water may enter the cylinder through the
exhaust valve and cause engine trouble.

Transport and store the outboard motor
as specified in “Dismounting the out-
board motor”.
ZMU06761
ZMU06806
ZMU06762
ZMU06807
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							Maintenance
50

Store the outboard motor in a dry, well-
ventilated place, not in direct sunlight.
EMU28305ProcedureEMU39602Flushing in a test tank
NOTICE
ECM00301
Before starting the engine, make sure to
supply water to the cooling water passag-
es. Otherwise, the engine could overheat
and be damaged.
Cooling system flushing is essential to pre-
vent the cooling system from clogging up with
salt, sand, or dirt. In addition, fogging of the
engine is mandatory to prevent excessive en-
gine damage due to rust. Perform the flushing
and fogging at the same time.
1. Wash the outboard motor body using
fresh water. NOTICE: Do not spray wa-
ter into the air intake.
 [ECM01840] For further
information, see page 52.
2. Fill the built-in fuel tank with fresh fuel and
add one ounce of “Yamaha Fuel Condi-
tioner and Stabilizer” to each gallon of fu-
el.
TIP:
The use of “Yamaha Fuel Conditioner and
Stabilizer” eliminates the need to drain the
fuel system. Consult a Yamaha dealer or oth-
er qualified mechanic if the fuel system is to
be drained instead.
3. When using a portable fuel tank, discon-
nect the fuel hose, install the fuel joint
cap, and then align the fuel cock with the
built-in fuel tank position.4. Remove the top cowling and fogging hole
cap.
5. Remove the propeller. For further infor-
mation, see page 61.
6. Install the outboard motor on the test
tank.
1. Closed position
1. Cap
1. Water surface
2. Lowest water level
3. Cooling water inlet
ZMU068711
1
1
ZMU06822
3
ZMU06862
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							Maintenance
51
7. Fill the test tank with fresh water to above
the level of the anti-cavitation plate.
NOTICE: If the fresh water level is be-
low the level of the anti-cavitation
plate, or if the water supply is insuffi-
cient, engine seizure may occur.
[ECM00291]
8. Start the engine, operate it for 10–15 min-
utes at engine idle speed. WARNING!
Do not touch or remove electrical
parts when starting or during opera-
tion. Keep hands, hair, and clothes
away from the flywheel and other ro-
tating parts while the engine is run-
ning.
 [EWM00091]
9. Quickly spray “Yamaha Stor-Rite Engine
Fogging Oil” into the fogging hole of the
silencer. When properly done, the engine
will smoke excessively and stop.
10. Remove the outboard motor from the test
tank.
11. Drain the cooling water completely out of
the outboard motor. Clean the body thor-
oughly.
12. Install the fogging hole cap and top cowl-
ing.
13. Align the fuel cock with the closed posi-
tion and tighten the air vent screw.
14. Install the propeller. For further informa-
tion, see page 62.
EMU39632Flushing with the water flush plug (option-
al)
NOTICE
ECM00301
Before starting the engine, make sure to
supply water to the cooling water passag-
es. Otherwise, the engine could overheat
and be damaged.
Cooling system flushing is essential to pre-
vent the cooling system from clogging up with
salt, sand, or dirt. In addition, fogging of the
engine is mandatory to prevent excessive en-
gine damage due to rust. Perform the flushing
and fogging at the same time.
1. Wash the outboard motor body using
fresh water. NOTICE: Do not spray wa-
ter into the air intake.
 [ECM01840] For further
information, see page 52.
2. Fill the built-in fuel tank with fresh fuel and
add “Yamaha Fuel Conditioner and Sta-
bilizer”. Remove the top cowling and fog-
ging hole cap. For further information,
see steps 2-4 in “Flushing in a test tank”.
3. Remove the propeller. For further infor-
mation, see page 61.
4. Remove the screw located beside the
“” (wash) mark on the lower case.
Install the water flush plug and connect it
to a fresh water tap.
5. Cover the cooling water inlet with tape.
ZMU06823
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							Maintenance
52
6. Turn on the water supply to the outboard
motor.
7. Start the engine, operate it for 10–15 min-
utes at engine idle speed, and then spray
“Yamaha Stor-Rite Engine Fogging Oil”
into the fogging hole of the silencer. For
further information, see steps 8-9 in
“Flushing in a test tank”.
8. Turn off the water supply to the outboard
motor, and then remove the water flush
plug and tape.
9. Install the fogging hole cap and top cowl-
ing. Align the fuel cock with the closed po-
sition and tighten the air vent screw.
10. Install the propeller. For further informa-
tion, see page 62.
EMU39280Lubrication
1. Install the spark plug and torque to proper
specification. For information on spark
plug installation, see page 58.
2. Change the gear oil. For instructions, see
page 62. Inspect the oil for the presence
of water that indicates a leaky seal. Seal
replacement should be performed by an
authorized Yamaha dealer prior to use.
3. Grease all grease fittings. For further de-
tails, see page 57.
TIP:
For long-term storage, fogging the engine
with oil is recommended. Contact your
Yamaha dealer for information about fogging
oil and procedures for your engine.
EMU28423Cleaning and anticorrosion measures
1. Wash down the exterior of the outboard
motor with fresh water and dry off com-
pletely. NOTICE: Do not spray water
into the air intake.
 [ECM01840]
2. Spray the outboard motor exterior with
“Yamaha Silicone Protectant”.
3. Wax the cowling with a non-abrasive wax
such as “Yamaha Silicone Wax”.
EMU28451Cleaning the outboard motor
After use, wash the exterior of the outboard
motor with fresh water. Flush the cooling sys-
tem with fresh water.
EMU28460Checking painted surface of motor
Check the motor for scratches, nicks, or flak-
ing paint. Areas with damaged paint are more
likely to corrode. If necessary, clean and paint
the areas. A touch-up paint is available from
your Yamaha dealer.
1. Water flush plug
1
ZMU02509
ZMU06763
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							Maintenance
53
EMU37081
Periodic maintenance
WARNING
EWM01981
These procedures require mechanical
skills, tools, and supplies. If you do not
have the proper skills, tools, or supplies to
perform a maintenance procedure, have a
Yamaha dealer or other qualified mechan-
ic do the work.
The procedures involve disassembling
the motor and exposing dangerous parts.
To reduce the risk of injury from moving,
hot, or electrical parts:

Turn off the engine and keep engine
shut-off cord (lanyard) with you when
you perform maintenance unless other-
wise specified.

Allow the engine to cool before handling
hot parts or fluids.

Always completely reassemble the mo-
tor before operation.
Maintenance, replacement, or repair of the
emission control devices and systems
may be performed by any marine engine
repair establishment or individual. All war-
ranty repairs, however, including those to
the emission control system, must be per-
formed by an authorized Yamaha marine
dealership.
A service manual is available for purchase
through your Yamaha dealer for owners who
have the mechanical skills, tools, and other
equipment necessary to perform mainte-
nance not covered by this owner’s manual.
EMU28511Replacement parts
If replacement parts are necessary, use only
genuine Yamaha parts or parts of equivalent
design and quality. Any part of inferior quality
may malfunction, and the resulting loss of
control could endanger the operator and pas-sengers. Yamaha genuine parts and acces-
sories are available from your Yamaha
dealer.
EMU35520Maintenance interval guidelines
The service intervals provided in the Mainte-
nance Chart were developed based upon
“typical” use that includes operating at varied
speeds, with sufficient time for engine warm
up and cool-down, a medium to light load, and
an average cruising speed near the 3000 to
4000 rpm range. As with any engine, howev-
er, if your normal operating conditions are dif-
ferent, you should consider service more
often than shown, especially how often you
change your engine and gear oil. Examples
might include extended wide-open-throttle
use or long periods of trolling or idling, carry-
ing heavy loads, or frequent starting and stop-
ping or shifting. More frequent maintenance
will often pay off many times over in increased
engine life and greater owner satisfaction.
Consult your Yamaha dealer for additional
maintenance recommendations.
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							Maintenance
54
EMU34446Maintenance chart 1
TIP:

Refer to the sections in this chapter for explanations of each owner-specific action.

The maintenance cycle on these charts assume usage of 100 hours per year and regular
flushing of the cooling water passages. Maintenance frequency should be adjusted when op-
erating the engine under adverse conditions such as extended trolling.

Disassembly or repairs may be necessary depending on the outcome of maintenance
checks.

Expendable or consumable parts and lubricants will lose their effectiveness over time and
through normal usage regardless of the warranty period.

When operating in salt water, muddy, other turbid (cloudy), acidic water, the engine should
be flushed with clean water after each use.
The “” symbol indicates the check-ups which you may carry out yourself.
The “” symbol indicates work to be carried out by your Yamaha dealer.
Item ActionsInitial Every
20 hours 
(3 months)100 hours 
(1 year)300 hours 
(3 years)500 hours 
(5 years)
Anode (external)Inspection or replace-
ment as necessary
Anode (thermostat 
cover)Inspection or replace-
ment as necessary
Cooling water leakageInspection or replace-
ment as necessary
Cowling lock lever Inspection
Engine starting condi-
tion/noiseInspection
Engine idle 
speed/noiseInspection
Engine oil Replacement
Engine oil filter (crank-
case)Inspection, cleaning or 
replacement as neces-
sary
Fuel filter (disposal 
type)Replacement
Fuel filter (inside built-
in fuel tank)Inspection and clean-
ing as necessary
Fuel line Inspection
Fuel lineInspection or replace-
ment as necessary
Fuel pumpInspection or replace-
ment as necessary
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							Maintenance
55
Fuel/engine oil leakage Inspection
Gear oil Replacement
Greasing points Greasing
Impeller/water pump 
housingInspection or replace-
ment as necessary
Impeller/water pump 
housingReplacement
Propeller/propeller 
nut/cotter pinInspection or replace-
ment as necessary
Shift linkInspection, adjustment 
or replacement as nec-
essary
Spark plugInspection or replace-
ment as necessary
Spark plug cap/spark 
plug wireInspection or replace-
ment as necessary
Water from the cooling 
water pilot holeInspection
Throttle link/throttle ca-
bleInspection, adjustment 
or replacement as nec-
essary
ThermostatInspection or replace-
ment as necessary
Valve clearanceInspection and adjust-
ment
Water inlet Inspection
Stop switchInspection or replace-
ment as necessary
Connector connec-
tions/lead connectionsInspection or replace-
ment as necessary
Fuel tank (optional 
Yamaha portable fuel 
tank)Inspection and clean-
ing as necessary
Fuel tank (built-in tank)Inspection and clean-
ing as necessary Item ActionsInitial Every
20 hours 
(3 months)100 hours 
(1 year)300 hours 
(3 years)500 hours 
(5 years)
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