Yamaha LIT-18626-05-81 manual

8D O WNER’S MANU AL 6M8-F8199-18 U .S.A.Edition LIT -18626-05-81 6M8-9-18 Hyoshi 1/21/04 6:49 PM Page 1[...]

EMU25060 ZMU01690 Read this owner ’ s manual carefully before operating your outboard motor. 6M8-9-18 Hyoshi 1/21/04 6:49 PM Page 2[...]

Important manual information EMU25100 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains infor- mation needed for proper operation, mainte- nance and care. A thorough understanding of these simple instructions will help you ob- tain maximum enjoyment from your new Yamaha. If you have any question about the o[...]

Table of contents General information .......................... 1 Identification numbers record .......... 1 Outboard motor serial number .......... 1 Emission control information ........... 1 North American models..................... 1 Safety information ........................... 2 Important labels ............................... 3 Warning la[...]

Table of contents models) ......................................... 34 Cleaning and anticorrosion measures ...................................... 34 Cleaning the outboard motor .......... 34 Checking painted surface of motor ............................................. 34 Periodic maintenance .................... 34 Replacement parts .............[...]

1 General information EMU25170 Identification numbers record EMU25182 Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket or the upper part of the swivel bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from[...]

General information 2 EMU25360 Safety information ● Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation ● Before operating the boat, read any own- er ’ s or operator ’ s manuals supplied with it and all labels. Be sure you understand each item b[...]

General information 3 a Float Plan with a responsible person. Be sure to cancel the Float Plan when you re- turn. ● Use common sense and good judgment when boating. Know your abilities, and be sure you understand how your boat han- dles under the different boating conditions you may encounter. Operate within your limits, and the limits of your bo[...]

General information 4 starting device. ● The engine will not start unless the shift control is in neutral position. EMU25500 Basic boating 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 internatio[...]

General information 5 Give-Way vessel). Any vessels in the shad- ed area must yield to you (they are the Give- Way vessels). Both you and the meeting vessel must alter course to avoid each other. 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 [...]

General information 6 need to carry a portable air horn, available from local marine supply stores. Fishing vessel right-of-way All vessels which are fishing with nets, lines or trawls are considered to be “ fishing ves- sels ” under the International Rules. Vessels with trolling lines are not considered fishing vessels. Fishing vessels have th[...]

General information 7 EMU25540 Fueling instructions W ARNING EWM00010 GASOLINE AND ITS VAPORS ARE HIGH- LY 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. ● Tak[...]

General information 8 dry rags. ● Do not overfill the fuel tank. ● Tighten the filler cap securely after re- fueling. ● 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, im- mediately wash with soap and water. Change cl[...]

General information 9 NO TE: Select a propeller which will allow the engine to reach the middle or upper half of the oper- ating range at full throttle with the maximum boat load. If operating conditions such as light boat loads then allow the engine r/min to rise above the maximum recommended range, reduce the throttle setting to maintain the engi[...]

10 Basic components EMU25795 Main components NO TE: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. 8D EMU25802 Fuel tank If your model was equipped with a portable fuel tank, its function is as follows. W ARNING EWM00020 The fuel tank supplied with this engine is its dedicated fuel reservoir and must [...]

Basic components 11 tions. 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 ap- proximate 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 f[...]

Basic components 12 EMU25961 Throttle indicator The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers the best performance and fuel economy for the desired operation. EMU25970 Throttle friction adjuster A friction device provides adjustable resis- t[...]

Basic components 13 could cause people and objects in the boat to be thrown forward. NO TE: The engine cannot be started with the lock plate removed. EMU26001 Engine stop button To open the ignition circuit and stop the en- gine, push this button. EMU26011 Choke knob for pull type To supply the engine with the rich fuel mix- ture required to start,[...]

Basic components 14 To increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. W ARNING EWM00040 Do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident. EMU26261 Trim rod (tilt pin) The position of the trim rod[...]

Basic components 15 1. T op co wling lock lev er(s) ZMU02862 1[...]

16 Operation EMU26901 Installation CAUTION: ECM00110 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 conti[...]

Operation 17 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 reduc[...]

Operation 18 board (if packed). For details, consult your Yamaha dealer. W ARNING EWM00650 Avoid using bolts, nuts or washers other than those contained in the engine pack- aging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tighten- ing, test run the engine and check their tightn[...]

Operation 19 cool. 4. Third through tenth hours: Avoid operating at full throttle for more than 5 minutes at a time. Let the engine cool between full-throttle runs. Vary en- gine speed occasionally. 5. After the first 10 hours: Operate the engine normally. Use the standard premix ratio of gasoline and oil. For details on mixing fuel and oil, see pa[...]

Operation 20 EMU27402 Gasoline and oil mixing (100:1) If equipped with a portable fuel tank 1. Pour oil into the portable fuel tank, and then add gasoline. 2. Replace the fuel tank cap and close tightly. 3. Shake the fuel tank to mix the fuel thor- oughly. 4. Make sure that the oil and gasoline are mixed. If equipped with a built-in fuel tank 1. Po[...]

Operation 21 2. If there is a fuel joint on the motor, firmly connect the fuel line to the joint. Then firmly connect the other end of the fuel line to the joint on the fuel tank. 3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp. NO TE: During engine operation place the tank[...]

Operation 22 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. Do not route the lanyard where it could become entan- gled, preventing it from functioning. ● Avoid accidentally pulling the lanyard during normal operation. Loss of en- gine power means the loss of[...]

Operation 23 NO TE: ● When the engine is cold, it needs to be warmed up. For further information, see page 23. ● If the engine does not start on the first try, repeat the procedure. If the engine fails to start after 4 or 5 tries, open the throttle a small amount (between 1/8 and 1/4) and try again. Also if the engine is warm and fails to start[...]

Operation 24 2. Move the gear shift lever quickly and firmly from neutral to forward. Remote control models 1. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward. EMU27795 Reverse (manual tilt and hydro tilt models) W ARNING EWM00190 When operating in reverse, go slowly. [...]

Operation 25 until the engine comes to a complete stop. 2. After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to the closed position, if equipped. 3. Disconnect the fuel line if you are using an external fuel tank. NO TE: If the outboard motor is equipped with an en- gine stop switch lanya[...]

Operation 26 EMU27871 Adjusting trim angle for manual tilt models There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim an- gle. 1. Stop the engine. 2. Remove the trim rod from the clamp bracket while slightly tilting the outboard motor up. 3. Reposition the rod in the desired hole. To raise the bow ( “ trim-out ?[...]

Operation 27 the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden- cy to steer to one side or the other. Compen- sate for this as you steer. The trim tab can 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 [...]

Operation 28 will be tilted for more than a few minutes. Otherwise fuel may leak. CAUTION: ECM00230 ● Before tilting the outboard motor, fol- low the procedure under “ Stopping en- gine ” in this chapter. Never tilt the outboard motor while the engine is run- ning. Severe damage from overheating can result. ● Do not tilt up the engine by pu[...]

Operation 29 EMU28013 Procedure for tilting down (manual tilt models) 1. Slightly tilt the engine up. 2. On models equipped with a tilt support knob, pull it out. 3. Slowly tilt the engine down. EMU28060 Cruising in shallow water The outboard motor can be tilted up partially to allow operation in shallow water. EMU28071 Cruising in shallow water (m[...]

Operation 30 3. The shallow water lever will lock, sup- porting the outboard motor in a partially raised position. 4. When lowering the outboard motor, slightly tilt it up and push the shallow wa- ter lever down. Slowly lower the out- board motor to the normal position. EMU28190 Cruising in other conditions Cruising in salt water After operating in[...]

31 Maintenance EMU28214 Specifications Dimension: Overall length: 802 mm (31.6 in) Overall width: 343 mm (13.5 in) Overall height S: 977 mm (38.5 in) Transom height S: 436 mm (17.2 in) Weight (AL) S: 27.0 kg (60 lb) Performance: Full throttle operating range: 4500 – 5500 r/min Maximum output: 5.9 kW@5000 r/min (8 HP@5000 r/min) Idling speed (in n[...]

Maintenance 32 whether in a boat or car. ● DO NOT fill fuel container to maximum capacity. Gasoline will expand consid- erably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard. W ARNING EWM00700 Never get under the lower unit while it is tilted, even if a motor support bar is [...]

Maintenance 33 EMU28301 Procedure EMU28372 Flushing in a test tank 1. Wash the outboard motor body using fresh water. For further information, see page 34. 2. Fill the fuel tank with fresh fuel and add one ounce of “ Yamaha Fuel Conditioner and Stabilizer ” (Part No. LUB-FUELC- 12-00) to each gallon of fuel. NO TE: The use of “ Yamaha Fuel Co[...]

Maintenance 34 EMU28400 Lubrication (except oil injection models) 1. Grease the spark plug threads and in- stall the spark plug(s) and torque to proper specification. For information on spark plug installation, see page 37. 2. Change the gear oil. For instructions, see page 42. Inspect the oil for the pres- ence of water that indicates a leaky seal[...]

Maintenance 35 have the mechanical skills, tools, and other equipment necessary to perform mainte- nance not covered by this owner ’ s manual. EMU28510 Replacement parts If replacement parts are necessary, use only genuine Yamaha parts or parts of the same type and of equivalent strength and materi- als. Any part of inferior quality may malfunc- [...]

Maintenance 36 EMU28521 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating condi- tions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. The “” symbol indicates the check-ups which you may carry out yourself. The[...]

Maintenance 37 EMU28931 Greasing Yamaha marine grease (Water resistant grease) 8D EMU28950 Cleaning and adjusting spark plug W ARNING EWM00560 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[...]

Maintenance 38 attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically re- move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you shou[...]

Maintenance 39 Checkpoints ● Fuel system parts leakage ● Fuel line joint leakage ● Fuel line cracks or other damage ● Fuel connector leakage EMU28990 Checking fuel filter Check the fuel filter periodically. The fuel fil- ter is a one piece, disposable type. If foreign matter is found in the filter, replace it. For re- placement of the fuel [...]

Maintenance 40 or other qualified mechanic. 2. Verify whether the idle speed is set to specification. For idle speed specifica- tions, see page 31. EMU29111 Checking wiring and connectors ● Check that each grounding wire is properly secured. ● Check that each connector is engaged se- curely. EMU29120 Exhaust leakage Start the engine and check t[...]

Maintenance 41 ● Check the propeller shaft oil seal for dam- age. NO TE: If the shear pin equipped: it is designed to break if the propeller hits a hard underwater obstacle to help protect the propeller and drive mechanism. The propeller will then spin freely on the shaft. If this happens, the shear pin must be replaced. EMU29193 Removing the pro[...]

Maintenance 42 align it with the hole. EMU29280 Changing gear oil W ARNING EWM00800 ● 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. ● Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe [...]

Maintenance 43 pors are flammable and explosive. ● If you have any question about properly doing this procedure, consult your Yamaha dealer. ● Keep away from sparks, cigarettes, flames, or other sources of ignition when cleaning the fuel tank. ● Remove the fuel tank from the boat be- fore cleaning it. Work only outdoors in an area with good v[...]

Maintenance 44 EMU29400 Coating the boat bottom A clean hull improves boat performance. The boat bottom should be kept as clean of ma- rine growth as possible. If necessary, the boat bottom can be coated with an anti-foul- ing paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. The[...]

45 Trouble Recovery EMU29422 Troubleshooting A problem in the fuel, compression, or igni- tion systems can cause poor starting, loss of power, or other problems. This section de- scribes 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[...]

Trouble Recovery 46 Q. Is fuel system obstructed? 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 activ[...]

Trouble Recovery 47 A. Have serviced by a Yamaha dealer. Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer. Q. Is there excess water in fuel filter cup? A. Drain filter cup. Engine power loss. Q. Is propeller damaged? A. Have prope[...]

Trouble Recovery 48 Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec- ommended type. Q. Is high pressure fuel pump drive belt bro- ken? A. Have serviced by a Yamaha dealer. Q. Is engine not responding properly to shift lever position? A. Have serviced by a Yamaha dealer. Engine vibrates excessively. Q. Is prop[...]

Trouble Recovery 49 your arm or leg while operating. ● Do not attach the lanyard to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. ● Avoid accidentally pulling the lanyard during normal operation. Loss of en- gine power means the loss of most steering control. Also, without[...]

Trouble Recovery 50 up. 6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise. 7. Give a strong pull straight out to crank and start the engine. Repeat if neces- sary. EMU29760 Treatment of submerged motor If the outboard motor is submerged, immedi-[...]

Trouble Recovery 51 5. Take the outboard motor to a Yamaha dealer as soon as possible. CAUTION: ECM00400 Do not attempt to run the outboard motor until it has been completely inspected.[...]

52 Consumer information EMU29811 Important warranty information for U.S.A. and Canada[...]

Consumer information 53[...]

Consumer information 54 EMU29820 YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY[...]

Consumer information 55[...]

Consumer information 56[...]

Consumer information 57 EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA[...]

Printed in Fr ance April 2004–0.5 × 1 ! 6M8-9-18 Hyoshi 1/21/04 6:49 PM Page 4[...]

Warranty card 12/6/01 7:40 PM Page 1[...]

Warranty card 12/6/01 7:40 PM Page 2[...]