Yamaha f15c manual

Printed in Japan April 2003-0.5 × 1 ! 66M-28199-17 (F15AMH, F15AEH, F15AEP , F15AEHP) (E) Printed on recycled paper F1 5C O WNER’S MANU AL U .S.A.Edition LIT -18626-05-47 66M-9-17-hyoshi 2/27/03 9:40 AM Page 1[...]

66M-9-17-hyoshi 2/27/03 9:40 AM Page 2[...]

E Thank you for choosing a Yamaha out- board motor. This Owner’s manual con- tains information needed for proper oper- ation, maintenance and care. A thorough understanding of these simple instruc- tions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor,[...]

E GENERAL INFORMA TION BASIC COMPONENTS OPERA TION MAINTENANCE TROUBLE RECOVERY INDEX READ THIS OWNER’S MANUAL CAREFULL Y BEFORE OPERA TING YOUR OUTBOARD MOTOR. 1 2 3 4 5 6 EMA20010 CONTENTS 66M-9-17-1 2/27/03 9:53 AM Page 3[...]

EMB00010 Chapter 1 GENERAL INFORMA TION IDENTIFICATION NUMBERS RECORD ..1-1 Outboard motor serial number ...........1-1 EMISSION CONTROL INFORMATION ...1-2 Star labels ..............................................1-3 SAFETY INFORMATION ..........................1-4 IMPORTANT LABELS ..............................1-6 BASIC BOATING RULES ............[...]

1-1 EMB10011 IDENTIFICA TION NUMBERS RECORD EMB10210 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 num- ber in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your out- [...]

1-2 E 504**2 q w EMU01385 EMISSION CONTROL INFORMA TION EMU01387 NORTH AMERICAN MODELS This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details. Approval label of Emission control certificate This label is attached to the bottom cowl- ing. 1 Emission contr[...]

1-3 E EMU01389 STAR LABELS Your outboard motor is labeled with a California Air Resources Board (CARB) star label. See below for a description of your particular label. 1 Star label One Star - Low Emission The one-star label identifies engines that meet the Air Resources Board ’ s 2001 exhaust emission standards. Engines meeting these standards h[...]

E 1-4 EMU00917 SAFETY INFORMA TION 8 Before mounting or operating the out- board motor, read this entire manual. Reading it should give you an under- standing of the motor and its operation. 8 Before operating the boat, read any owner ’ s or operator ’ s manuals supplied with it and all labels. Be sure you under- stand each item before operatin[...]

E 1-5 8 When a swimmer is in the water near you shift into neutral and shut off the engine. 8 Be informed about boating safety. Additional publications and information can be obtained from many organiza- tions, including the following: United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast[...]

E 1-6 EMB30011 IMPORT ANT LABELS WARNING LABELS 1 2 CAUTION LABELS 3 202**1 q w e WARNING This engine is equipped with a neutral starting device. The engine will not start unless the shift control is in neutral position. 6E0-83627-41 WARNING ● Be sure shift control is in neutral before starting engine. (except 2HP) ● Do not touch or remove elec[...]

E 1-7 EMB40010 BASIC BOA TING RULES (Rules of the road) Just as there are rules which apply when you are driving on streets and high ways, there are waterway rules which apply when you are driving your boat. These rules are used internationally, and are also enforced by the United States Coast Guard and local agencies. You should be aware of these [...]

E 1-8 RULES WHEN ENCOUNTERING VESSELS There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steering Rules are followed: Meeting (you are approaching another vessel head-on) Crossing (you are travelling across the other vessel ’ s path) Overtaking (you are passing or being passed by [...]

E 1-9 its course and speed. You must stay out of its way until you are clear of it. Likewise, if another vessel is passing you, you should maintain your speed and direction so that the other vessel can steer itself around you. OTHER SPECIAL SITUATIONS There are three other rules you should be aware of when driving your boat around other vessels. Na[...]

E 1-10 letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geo- graphic location. Always consult local boating authorities before driving your boat in unfamiliar waters. 1 1 A 1 1 Proceeding toward head of navigation from seaward CAN BUOY Odd number. Leave to[...]

E 1-11 EMB01010 FUELING INSTRUCTIONS w GASOLINE AND ITS VAPORS ARE HIGH- LY FLAMMABLE AND EXPLOSIVE! 8 Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. 8 Stop engine before refueling. 8 Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. 8 Take care not to spill gasoline. If gaso- [...]

EMU01804 GASOLINE If knocking or pinging occurs, use a differ- ent brand of gasoline or premium unlead- ed fuel. E 1-12 Recommended gasoline: Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2 EMB50610 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol co[...]

EMU01769 ENGINE OIL Recommended engine oil: 4-stroke motor oil with a combination of corresponding SAE and API as shown in the chart. c C All 4-stroke engines are shipped from the factory without engine oil. E 1-13 Engine oil quantity: See Chapter 4, “ Specifications. ” 001162 SAE API SE SF SG SH SJ 10W-30 10W-40 66M-9-17-1 2/27/03 9:53 AM Page[...]

E 1-14 Minimum cold cranking amps (CCA/SAE): 245 amps at -18 ° C (-0.4 ° F) Minimum marine cranking amps (MCA/ABYC): 323 amps at 0 ° C (32 ° F) Minimum reserve capacity (RC/SAE): 52 minutes EMU01775 BA TTERY REQUIREMENT c C Do not use a battery that does not meet the specified capacity. If a battery which does not meet specifications is used, t[...]

E 1-15 EMU01395 PROPELLER SELECTION The performance of your outboard motor will be critically affected by your choice of propeller, as an incorrect choice could adversely affect performance and could also seriously damage the motor. Engine speed depends on the propeller size and boat load. If engine speed is too high or too low for good engine perf[...]

E 1-16 EMU01209 ST ART -IN-GEAR PROTECTION Yamaha outboard motors or Yamaha approved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is Neutral. Always select Neutral before starting the engine. 9-1/4x9-3/4-J 1 23 602021 NOTE: At full throttle and under a maximum [...]

E -MEMO- 66M-9-17-1 2/27/03 9:53 AM Page 22[...]

EMC00010 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS ..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-2 Fuel tank .................................................2-2 Gear shift lever ......................................2-3 Choke knob ............................................2-3 Reco[...]

2-1 E 101121 q w r i u y e t 701061 !6 000934 !0 !2 !3 !4 !1 !5 !7 !8 !9 o @2 @1 @0 000944 EMU01206 MAIN COMPONENTS 1 Top cowling 2 Top cowling lock lever 3 Oil drain bolt 4 Anti-cavitation plate 5 Propeller 6 Cooling water inlet 7 Trim angle adjusting rod 8 Clamp bracket * 9 Recoil starter handle 0 Choke knob q Warning indicator * w Gear shift lev[...]

E 2-2 EMC20010 OPERA TIONS OF CONTROLS AND OTHER FUNCTIONS EMC21012 FUEL TANK If your model was equipped with a portable fuel tank, its function is as fol- lows. 1 Fuel hose joint 2 Fuel meter(If equipped) 3 Fuel tank cap 4 Air vent screw(If equipped) EMC31010 Fuel hose joint This connector is provided for connecting or disconnecting fuel hose. EMC[...]

2-3 EMC25010 GEAR SHIFT LEVER (for Tiller control model) Turning the gear-shift lever towards you engages the clutch with the forward gear so that the boat moves ahead. Turning the lever away from you engages the reverse gear so that the boat moves astern. 1 Neutral 2 Forward 3 Reverse E 406023 w q e 226011 209014 225011 EMC42210 CHOKE KNOB Pulling[...]

2-4 E EMU01317 TILLER HANDLE (for tiller control models) Moving the tiller handle from side to side changes the steering direction. In addi- tion, this handle has the following func- tions. 1 Throttle control grip 2 Throttle indicator 3 Throttle friction adjusting knob/screw 4 Engine stop button / Engine stop lanyard switch 5 Power tilt switch (if [...]

2-5 EMU01294 Throttle Friction Adjusting Knob A friction device in the tiller handle pro- vides resistance to movement of the throttle grip. This is adjustable for opera- tor preference. When constant speed is desired, tighten the adjusting knob to maintain the desired throttle setting. w Do not overtighten the friction adjusting knob. If there is [...]

2-6 E w 8 Attach the engine stop switch lanyard to a secure place on your clothing, your arm or leg while operating. 8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard in such a way that it could become entangled, preventing it from functioning. 8 Avoid accidentally pulling the lanyard during normal operation. L[...]

2-7 E EMU00094 REMOTE CONTROL Both the shifter and the throttle are actu- ated by the remote control lever. In addi- tion, this remote control also has the elec- trical switches. 1 Remote control lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Main switch / Choke switch 5 Engine stop lanyard switch 6 Power tilt switch 7 Throttle fricti[...]

2-8 E EMU00099 Neutral Interlock Trigger To shift out of Neutral, the neutral inter- lock trigger of the remote control lever must first be pulled up. 701036 N 000324 q w EMU00100 Neutral Throttle Lever To open the throttle without shifting into either Forward or Reverse, place the remote control lever in the Neutral posi- tion and lift the neutral[...]

2-9 E EMU00934 Engine Stop Lanyard Switch The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 should be attached to a secure place on the operator’s cloth- ing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping igni- tion to [...]

2-10 E EMU01316 Power Tilt Switch The power tilt adjusts the motor angle in relation to the transom. The power tilt switch is located on the remote control lever grip. Pushing the switch “UP” tilts the motor up. Pressing the switch “DN” tilts the motor down. When the switch button is released, the motor will stop in its current position. NO[...]

2-11 EMU01295 STEERING FRICTION ADJUSTING LEVER A friction device provides resistance to steering movement. This is adjustable according to operator preference. w Do not overtighten the friction adjusting lever. If there is too much resistance, it may be difficult to steer, which could result in an accident. E 408033 001776 223013* q EMU01297 TRIM [...]

2-12 E 402013 q 403**2 q EMD44110 TILT LOCK MECHANISM (for Manual tilt model) The tilt-lock mechanism is used to pre- vent reverse thrust from the propeller lift- ing the outboard motor when reversing. To lock it, set the tilt-lock lever in the Lock position. To release it, place the tilt-lock lever in the Tilt position. 1 Tilt-lock lever EMD48010*[...]

2-13 E EMD62011 TOP COWLING LOCK LEVER To remove the engine top cowling, turn the lock lever. Then lift off the cowling. When replacing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by moving the lever upward. 1 Top cowling lock lever 301045 q q 000935 EMU01146 FLUSHING DEVICE This device 1 is used t[...]

2-14 E EMU00169 W ARNING SYSTEM c C Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem can- not be located and corrected. EMU00170 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate. ( 1 ); Included [...]

2-15 EMD86112 LOW OIL PRESSURE WARNING If oil pressure drops too low, the warning device will activate. ( 1 ):Included (—):N/A If the warning system has been activated, stop the engine as soon as it is safe to do so. Check oil level and add oil as needed. If the oil level is correct, consult your Yamaha dealer. c C Do not continue to run the engi[...]

EMF00010 Chapter 3 OPERA TION INSTALLATION ........................................3-1 Mounting the outboard motor ............3-2 Clamping the outboard motor .............3-4 BREAKING IN (RUNNING IN) ENGINE ..3-5 PRE-OPERATION CHECKS ......................3-6 Checking the engine oil level ...............3-7 FILLING FUEL ...........................[...]

3-1 EMF10010 INST ALLA TION c C Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat or accessories such as transom ladders/depth finder trans- ducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operat- ed continuously in the presen[...]

3-2 EMF12012 MOUNTING THE OUTBOARD MOTOR w Improper mounting of the outboard motor could result in hazardous condi- tions such as poor handling, loss of con- trol, or fire hazards. Observe the follow- ing: 8 The information presented in this sec- tion is intended as reference only. It is not possible to provide complete instructions for every possi[...]

3-3 EMU01298 Mounting Height To run your boat at optimum efficiency, the water-resistance (drag) of the boat and outboard motor must be made as lit- tle as possible. 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 [...]

3-4 EMU01318 CLAMPING THE OUTBOARD MOTOR 1) Place the outboard on the transom so that it is positioned as close to the center as possible. Tighten the tran- som clamp screws evenly and secure- ly. Check the clamp-screws for tight- ness occasionally during operation of the motor as they can work loose due to engine vibration. w Loose clamp screws co[...]

3-5 E EMF50312 BREAKING IN (RUNNING IN) ENGINE Your new engine requires a period of break-in (running-in) to allow mating sur- faces of moving parts to wear-in evenly. Correct break-in (running-in) will help ensure proper performance and longer engine life. c C Failure to follow the break-in (running-in) procedure may result in reduced engine life [...]

3-6 EMF40013 PRE-OPERA TION CHECKS w If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the out- board motor. Otherwise, an accident could occur. c C Do not start the engine out of water. Overheating and serious engine damage can occur. EMF41110 Fuel 8 Check to be sure you have plenty of [...]

3-7 EMF43010 Controls 8 Check throttle, shift, and steering for proper operation before starting the engine. 8 The controls should work smoothly, without binding or unusual free play. 8 Look for loose or damaged connec- tions. 8 Check operation of the starter and stop switches when the outboard motor is in the water. EMF43511 Engine 8 Check the eng[...]

3-8 E EMF30211 FILLING FUEL 1) Remove the fuel tank cap. 2) Fill the fuel tank carefully. 3) Close the cap securely after refueling. Wipe up any spilled fuel. 902055 EMF21110 Ring Free Fuel Additive Gasoline is a precise blend of many differ- ent substances, each chosen to give cer- tain characteristics. Gasoline blends have been changing in recent[...]

3-9 EMU01147 ST ARTING ENGINE w 8 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. 8 When the air vent screw is loosened, gasoline (petrol) vapor will be released. Gasoline (petrol) is highly flammable, and its vapors are flam[...]

3-10 EMU01497 PROCEDURE FOR TILLER CONTROL MODEL 4) Place the gear-shift lever in the neu- tral position. NOTE: The start-in-gear protection device pre- vents the engine from starting except when in Neutral. E 406023* N 508014 000648 5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the l[...]

3-11 EMF63112* Manual start model 7) Pull out the choke knob completely. After the engine starts, return the knob to the original position. NOTE: 8 It is not necessary to use the choke when restarting a warm engine. 8 If the choke knob is left pulled out after the engine starts, the engine will stall. 8) Pull the starter handle slowly until you fee[...]

3-12 EMF63511* Electric start model 7) Pull out the choke knob completely. After the engine starts, return the choke knob to the original position. NOTE: 8 It is not necessary to use the choke when restarting a warm engine. 8 If the choke knob is left pulled out, the engine will stall. 8) Push the starter-button to start the starting motor. 9) Imme[...]

3-13 E N 701015 000293 EMU00247 PROCEDURE FOR REMOTE CONTROL MODEL 4) Place the remote control lever in the Neutral position. NOTE: The start-in-gear protection device pre- vents the engine from starting except when in Neutral. 5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, install the lock pl[...]

3-14 E EMU00945 Electric Start Model 7) Open the throttle slightly lifting the neutral throttle lever upwards partial- ly. You may need to change the throt- tle opening slightly depending on engine temperature. After the engine starts, return the throttle to the original position. NOTE: 8 As a starting point, lift the lever just until you feel resi[...]

3-15 E c C 8 Do not turn the main switch to “START” when the engine is running. 8 Do not keep the starter-motor turning for more than 5 seconds. The battery will rapidly become exhausted and it will be impossible for it to start the engine. If the engine does not start within 5 seconds, return the main switch to “ON”, wait 10 seconds, and t[...]

3-16 E EMG00411 W ARMING UP ENGINE 1) Before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (Failure to do this will shorten engine life.) 2) Be sure the low oil pressure warning indicator goes off after starting the engine. 3) Check for a steady flow of water from the cooling-water pilot hole. c C 8 If the low oil [...]

3-17 E EMU00261 SHIFTING w Before shifting, make sure there are no swimmers or obstacles in the water near you. c C To change the shifting position from for- ward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speeds). 503012 406024 N F 701043 N F EMU00265 FORWARD Tiller control model 1) Place the thrott[...]

3-18 E EMU01326 REVERSE w When operating in Reverse, go slowly. Do not open the throttle more than half. Otherwise, the boat may become unsta- ble, which could result in loss of control and an accident. 402013* 406025 N R N R 701044 1) Place the throttle control grip in the fully closed position (for Tiller control model). 2) Check that the tilt-lo[...]

3-19 E EMU00273 STOPPING ENGINE Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended. ON START OFF 701023 506021 304045 902052 2) If the fuel joints are provided, discon- nect the fuel line from the motor after stopping the engine. 3) Tighten the air vent scre[...]

3-20 E EMU01412 TRIMMING OUTBOARD MOTOR The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is [...]

EMU00951 Manual tilt model There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim angle. 1) Stop the engine. 2) Remove the trim angle adjusting rod 1 from the clamp bracket while tilting the motor up slightly. 3) Reposition the rod in the desired hole. To raise the bow ( “ trim-out ” ), move the rod away from the[...]

3-22 E UP DN 701034 UP DN 000610 DN UP EMU01414 Power Tilt Model w 8 Be sure all people are clear of the out- board motor when adjusting the tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket. 8 Use caution when trying a trim position for the first time. Increase speed gradu- ally and watch for any sign[...]

3-23 E EMU19160 Trim angle settings and boat handling When the boat is on plane, a bow-up atti- tude results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tendency to steer to one side or the other. Compensate for this as you [...]

3-24 E EMH10111 TIL TING UP/DOWN If the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion. c C 8 Before tilting the motor, follow the pro- cedures under “ STOPPING ENGINE ” . [...]

3-25 E EMU00290 PROCEDURE FOR TILTING UP Manual tilt model 1) Place the gear shift lever in Neutral. 2) Remove the fuel line connection from the motor. 3) Place the tilt lock lever in the release position. 4) Hold the rear of the top cowling with one hand and fully tilt the engine up. 5) The tilt support bar turns to the locked position automatical[...]

3-26 E 304045 UP DN 701034 UP DN 000610 DN UP 000603 EMU01312 PROCEDURE FOR TILTING UP Power tilt model 1) Remove the fuel-line connection from the motor. 2) Push the power tilt switch “ UP ” until the outboard has tilted up completely. 3) Push the tilt support knob into the clamp bracket to support the engine. w After tilting the engine, be su[...]

3-27 E EMU01313 PROCEDURE FOR TILTING DOWN Power tilt model 1) Push the power tilt switch “ UP ” until the engine is supported by the tilt rod. 2) Pull out the tilt support knob. 3) Push the power tilt switch “ DN ” (Down) to lower the engine to the desired position. 66M-9-17-3 2/27/03 10:30 AM Page 28[...]

3-28 E EMG70011 CRUISING IN SHALLOW W A TER Manual tilt model The outboard motor can be tilted up par- tially to allow operation in shallow water. w 8 Place the gear shift in the Neutral posi- tion before using the shallow water cruising system. 8 Run the boat at the lowest possible speed when using the shallow water cruising system. The tilt-lock [...]

E 3-29 EMG71211 PROCEDURE Manual tilt model 1) Place the gear shift lever in the neu- tral position. 402016 403056 402022 406023* N 2) Place the tilt lock lever in the release position. 3) Slightly tilt up the engine. The tilt- support bar will lock automatically, supporting the engine in a partially raised position. NOTE: This motor has 2 position[...]

E 3-30 000922 EMU01319 CRUISING IN SHALLOW W A TER Power tilt model The engine can be tilted up partially to allow operation in shallow water. w 8 Place the gear shift in the Neutral posi- tion before setting for shallow water cruising. 8 Return the engine to its normal posi- tion as soon as the boat is back in deeper water. c C Do not tilt up the [...]

E EMH60010 CRUISING IN OTHER CONDITIONS CRUISING IN SALT WATER After operating in salt water, wash out the cooling-water passages with fresh water to prevent them from becoming clogged- up with salt deposits. NOTE: Refer to cooling system flushing instruc- tions in “ TRANSPORTING AND STORING OUTBOARD MOTOR ” . CRUISING IN TURBID WATER It is str[...]

EMK00010 Chapter 4 MAINTENANCE SPECIFICATIONS .....................................4-1 TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-3 Trailering outboard motor ...................4-3 Storing outboard motor .......................4-5 PERIODIC MAINTENANCE ......................4-9 Replacement parts ........................[...]

4-1 E EMK10111* SPECIFICA TIONS Model Unit F15MHC Item 18 (1.8, 13) 35 (3.5, 25) 28 (2.8, 20) 18 (1.8, 13) Spark plug N•m (kgf•m, lb•ft) Propeller nut N•m (kgf•m, lb•ft) Engine oil drain bolt N•m (kgf•m, lb•ft) Engine oil filter N•m (kgf•m, lb•ft) DIMENSIONS PERFORMANCE Overall Length mm (in.) Overall Width mm (in.) Overall [...]

F15EHC F15PRC F15PHC 4-2 E 1,001 (39.4) 427 (16.8) 1,080 (42.5)/1,207 (47.5) 440 (17.3)/567 (22.3) 48 (106)/50 (110) 4,500–5,500 11.0 (15.0) @5,000 900–1000 4-stroke, OHC, L2 323 (19.71) 59.0 × 59.0 (2.32 × 2.32) CDI system DPR6EA-9 0.8–0.9 (0.031–0.035) Tiller control Electric start 0.15–0.25 (0.006–0.010) 0.20–0.30 (0.008–0.012)[...]

4-3 EMU01369 TRANSPORTING AND STORING OUTBOARD MOTOR w Leaking fuel is a fire hazard. When trans- porting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. EMK20210* TRAILERING OUTBOARD MOTOR The motor should be trailered and stored in the normal running position. If there is insufficient road clea[...]

4-4 E EMU00327 Clamp handle mounting model When transporting or storing the out- board motor while removed from a boat, fold the tiller handle and lean the motor on the tiller handle to keep in a horizontal position. c C Keep the power unit higher than the pro- peller at all times. Otherwise, cooling water can run into the cylinder, which could res[...]

4-5 E EMK16210* STORING OUTBOARD MOTOR When storing your Yamaha outboard for prolonged periods of time, (2 months or longer), several important procedures must be performed to prevent expensive damage. It is advisable to have your outboard ser- viced by an authorized Yamaha dealer prior to storage. However, the following procedures can be performed[...]

4-6 E EMU00338 Flushing Cooling System and Fogging Engine Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fog- ging of the engine is mandatory to pre- vent expensive engine damage due to rust. Perform the flushing and fogging at the same time. w 8 Do not touch or remove elec[...]

EMK26011 Lubrication 1) Remove the spark plug(s). Spray a Yamaha “Stor-Rite Engine Fogging Oil” into each cylinder for 10 seconds. Grease the spark plug threads and reinstall the spark plug(s) and torque to proper specification. (Refer to the “CLEANING AND ADJUSTING SPARK PLUG”). 2) Turn the engine over with the stop lanyard disconnected to[...]

4-8 E EMK29011 Battery Care w Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. It con- tains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL; Flush with water. INTERNAL; Drink large quantities of water or milk. Follow with milk of mag- nesia, beaten egg, or vegetable oil. Call physician imme[...]

EMU00913 PERIODIC MAINTENANCE w Be sure to turn off the engine when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other quali- fied mechanic. Maintenance, replacement, or repair of the emission control devices and systems may be performed by an[...]

E 4-10 EMU19361 MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating con- ditions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. The mark ( ● ) indicates the check-ups which you may carry out yourself. The mark ( 1[...]

4-11 E 500 hours 1000 hours (2.5 years) (5 years) Timing belt Replacement 1 Item Actions Every 66M-9-17-4 3/13/03 9:35 AM Page 12[...]

4-12 E 103192 EML00011 GREASING Yamaha marine grease (Water resistant grease) 66M-9-17-4 3/13/03 9:35 AM Page 13[...]

4-13 E EMU01202 CLEANING AND ADJUSTING SPARK PLUG w When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire. The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something a[...]

4-14 E When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque. NOTE: If a torque-wrench is not available when you are fitting a spark plug, a good esti- mate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adj[...]

4-15 E EMK38010 CHECKING FUEL SYSTEM w Gasoline (petrol) and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition. Check the fuel line for leaks, cracks, or malfunctions. If any problem is found, it should be repaired immediately by Yamaha dealer or other qualified mechan- ic. Checkin[...]

4-16 E EMK50001* INSPECTING FUEL FILTER w Gasoline (petrol) is highly flammable, and its vapors are flammable and explosive. 8 If you have any question about properly doing this procedure, consult your Yamaha dealer. 8 Do not perform this procedure on a hot or running engine. Allow the engine to cool. 8 There will be fuel in the fuel filter. Keep a[...]

4-17 E EMU09912 INSPECTING IDLING SPEED w 8 Do not touch or remove electrical parts when starting or during operation. 8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running. c C This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can also be used.[...]

4-18 E EMU01415 CHANGING ENGINE OIL w 8 Avoid draining the engine oil immedi- ately after stopping the engine. The oil is hot and should be handled with care to avoid burns. 8 Be sure the outboard is securely fas- tened to the transom or a stable stand. c C 8 Change the engine oil after the first 10 hours of operation, and every 100 hours or at 6-m[...]

4-19 E NOTE: If a torque wrench is not available when you are installing the drain plug, finger tighten the bolt just until the gasket comes into contact with the surface of the drain hole. Then tighten 1/4 - 1/2 turn. Have the drain plug torqued to the correct value with a torque wrench as soon as possible. 4) Remove the oil filler cap 2 . Add the[...]

4-20 E 001552 w q e EMU01463 REPLACING FUSE If the fuse has blown on an Electric start model, open the fuse holder and replace the fuse with a new one of proper amper- age. w Be sure to use the specified fuse. An incorrect fuse or a piece of wire may allow excessive current flow. This could cause electrical system damage and a fire hazard. NOTE: If[...]

4-21 E EMK78011 CHECKING WIRING AND CONNECTORS 1) Check that each grounding wire is properly secured. 2) Check that each connector is engaged securely. EMK78110 EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head and crank case. EMK78210 WATER LEAKAGE Start the engine and check t[...]

4-22 E q 000604 EMU01322 CHECKING POWER TILT SYSTEM w 8 Never get under the lower unit while it is tilted, even when the tilt-support knob is locked. Severe injury could occur if the outboard accidentally falls. 8 Make sure no one is under the out- board before performing this test. 1) Check the power tilt unit for any sign of oil leaks. 2) Operate[...]

4-23 E 210014* 602051 EML08013 CHECKING PROPELLER w You could be seriously injured if the engine accidentally starts while you are near the propeller. 8 Before inspecting, removing or installing the propeller, remove the spark plug caps from the spark plugs. Also, put the shift control in Neutral, put the main switch in the “OFF” posi- tion and[...]

4-24 E EML19010 Installing the Propeller c C 8 Be sure to install the thrust washer before installing propeller, otherwise, lower case and propeller boss may be damaged. 8 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. 1) Apply Yamaha Marine grease or a corrosio[...]

4-25 E EMU01773 CHANGING GEAR OIL w 8 Be sure the outboard motor is securely fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you. 8 Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor acci- denta[...]

4-26 E 601022 5) With the outboard motor in a vertical position, and using a flexible or pres- surized filling device, inject the gear oil into the gear oil drain screw hole. 6) When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. 7) Insert and tighten the gear oil drain screw. Gear oil grade and capaci[...]

4-27 E EML22110 Cleaning the Fuel Filter 1) Remove the screws holding the fuel hose joint assembly . Pull the assem- bly out of the tank. 2) Clean the filter (located on the end of the suction pipe) in a suitable clean- ing solvent. Allow the filter to dry. 3) Replace the gasket with a new one. Reinstall the fuel hose joint assembly and tighten the[...]

4-28 E EMU04041 CHECKING BATTERY (for Electric start models) w Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poi- sonous and highly caustic. Always follow these preventive mea- sures: 8 Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury. 8 Wear protective eye gear [...]

4-29 E EMU01279 Connecting the Battery w Mount the battery holder securely in a dry, well-ventilated, vibration-free loca- tion in the boat. Install a fully charged battery in the holder. c C 8 A poorly maintained battery will quick- ly deteriorate. 8 Ordinary tap-water contains minerals harmful to a battery, and should not be used for topping-up. [...]

4-30 E c C 8 Make sure the main switch (on applica- ble models) is “OFF” before working on the battery. 8 Reversal of the battery leads will dam- age the rectifier. 8 Connect the RED lead first when installing the battery and disconnect the RED lead last when removing it. Otherwise, the electrical system can be damaged. 8 The electrical contact[...]

4-31 E 000936 q w e EMU01172 CLEANING COOLING-WATER PASSAGES Flushing device equipped model Perform this procedure right after opera- tion for the most thorough flushing. 1) After shutting off the engine, unscrew the garden-hose connector 2 from the fitting 1 on the bottom cowling. 2) Screw the garden-hose connector 2 onto a garden hose 3 which is [...]

4-32 E 001187 102025 EML42012 MOTOR EXTERIOR EML42511 Cleaning the Outboard Motor After use, wash the exterior of the out- board with fresh water. Flush the cooling system with fresh water. NOTE: Refer to Flushing Cooling System instruc- tions in “ TRANSPORTING AND STORING OUTBOARD MOTOR ” . EML42810 Checking Painted Surface of Motor Check the [...]

E -MEMO- 66M-9-17-4 3/13/03 9:35 AM Page 34[...]

EMN00010 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING ..............................5-1 TEMPORARY ACTION IN EMERGENCY ............................................5-5 Impact damage .....................................5-5 Power tilt will not operate ....................5-5 Starter will not operate.........................5-6 Treatment of submerged mot[...]

5-1 E EMU01204¯ TROUBLESHOOTING A problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possi- ble remedies. (This chart covers all Yamaha outboard motors. Therefore, some items may not apply to your model.) If your outboard motor requir[...]

5-2 E C. Engine idles irregularly or stalls. Trouble Possible Cause Remedy 1. Spark plug(s) fouled or incorrect type. 2. Fuel system obstructed. 3. Fuel contaminated or stale. 4. Fuel filter clogged. 5. Failed ignition parts. 6. Warning system activated. 7. Spark plug gap incorrect. 8. Poor connections or damaged ignition wiring. 9. Specified engin[...]

5-3 E D. Warning buzzer sounds or indicator lamp lights. Trouble Possible Cause Remedy 1. Cooling system clogged. 2. Engine oil level low. 3. Heat range of spark plug incorrect. 4. Specified engine oil not used. 5. Engine oil contaminated or deteriorated. 6. Oil filter clogged. 7. Oil feed/injection pump malfunctions. 8. Load on boat improperly dis[...]

5-4 E Trouble Possible Cause Remedy 13. Poor connections or damaged ignition wiring. 14. Failed ignition parts. 15. Specified engine oil not used. 16. Thermostat faulty or clogged. 17. Air vent screw closed. 18. Fuel pump damaged. 19. Fuel joint connection incorrect. 20. Heat range of spark plug incorrect. 13. Check wires for wear or breaks. Tighte[...]

5-5 EMN20010 TEMPORARY ACTION IN EMERGENCY EMU01492 IMPACT DAMAGE w The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the out- board motor unsafe to operate. If the outboard motor hits any object in the water, follow the procedure below. 1) Stop the engine immediately. 2) Inspect the control[...]

5-6 EMN30111 STARTER WILL NOT OPERATE If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be started with an emergency starter rope. w 8 Use this procedure only in an emer- gency and only to return to port for repairs. 8 When the emergency starter rope is used to start the engine, the start-in- gear[...]

5-7 EMN34810 Emergency Starting Engine 1) Remove the top cowling. 2) Remove the cable 1 by pulling out it from the starter if equipped. E 208065* q 204053** w 208066 e 204054 3) Remove both ends of the choke rink rod 2 . 6) Pull up the lever 3 on the carburetor to operate the choke system when the engine is cold. After the engine starts, return the[...]

5-8 E 208072 7) Insert the knotted end of the emer- gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise. 8) Pull the rope slowly until resistance is felt. 9) Give a strong pull straight out to crank and start the engine. Repeat if necessary. 66M-9-17-5 2/27/03 1:37 PM Page 9[...]

5-9 E EMN50012 TREATMENT OF SUBMERGED MOTOR If the outboard motor is submerged, immediately take it a Yamaha dealer. Otherwise, some corrosion may begin almost immediately. If you cannot immediately take the out- board motor to a Yamaha dealer, follow the procedure bellow for taking care to minimize engine damage. EMN50611 1) Thoroughly wash away m[...]

EMP00010 Chapter 6 INDEX INDEX ........................................................6-1 1 2 3 4 5 6 E 66M-9-17-6 2/27/03 1:51 PM Page 1[...]

6-1 E EMP10010 INDEX A Adjusting trim angle ..............................3-21 Air vent screw...........................................2-2 B Basic boating rules ..................................1-7 Battery care...............................................4-8 Battery requirement ..............................1-14 Breaking in (running in) engine [...]

6-2 E Mounting height ......................................3-3 Mounting the outboard motor ...............3-2 N Neutral interlock trigger ..........................2-8 Neutral throttle lever ...............................2-8 O Operations of controls and other functions ...................................................2-2 Outboard motor serial n[...]

EMU01599 IMPORT ANT WARRANTY INFORMA TION FOR U.S.A. AND CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is commit- ted to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty information to help ensure satisfa[...]

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

EMU01404 Y AMAHA MOTOR CORPORA TION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED W ARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha 1999-or-later model four-stroke outboard motors originally dis - tributed by Yamaha Motor Corporation, U.S.A. will be free from defects in material and workmanship for the period of tim[...]

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

CUSTOMER SERVICE If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of t[...]

EMU01178 IMPORT ANT W ARRANTY INFORMA TION IF YOU USE YOUR Y AMAHA OUTSIDE U.S.A. OR CANADA Welcome to the Yamaha Family! Congratulations on the purchase of your new Yamaha marine power. Yamaha is com- mitted to exceptional customer satisfaction, and we want your ownership experience to be a satisfying one. Please read the following warranty inform[...]

Printed in Japan April 2003-0.5 × 1 ! 66M-28199-17 (F15AMH, F15AEH, F15AEP , F15AEHP) (E) Printed on recycled paper F1 5C O WNER’S MANU AL U .S.A.Edition LIT -18626-05-47 66M-9-17-hyoshi 2/27/03 9:40 AM Page 1[...]

YAMAHA MOTOR CO., LTD. MADE IN JAPAN PAYS D'ORIGINE JAPON OUTBOARD MOTOR W ARRANTY REGISTRA TION ENREGISTREMENT DE LA GARANTIE DU MO TEUR HORS-BORD Please complete and mail this card. This information is necessary to accurately register your unit for warranty . V euillez signer ci-dessous pour attester que le montage et l’inspection ont ét?[...]

PLACE POST AGE HERE A T TN: W ARR ANT Y DEP ARTMENT Warranty card 2/27/02 11:47 AM Page 2[...]