Yamaha Z200A manuale d’uso

LIT -18626-04-63 Z150A LZ150A Z175A Z200A LZ200A OWNER’S MANUAL U.S.A.Edition[...]

USE STRAIGHT GASOLINE ONLY CAUTION • Do not use fuel mixed with oil both during break-in • Oil can damage fuel injectors. and during normal use. 000118[...]

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 CONTENTS GENERAL INFORMA TION BASIC COMPONENTS OPERA TION MAINTENANCE TROUBLE RECOVERY INDEX 1 2 3 4 5 6 READ THIS OWNER’S MANUAL CAREFULL Y BEFORE OPERA TING YOUR OUTBOARD MOTOR. EMU00003 68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 3[...]

E EMU00004 Chapter 1 GENERAL INFORMA TION IDENTIFICATION NUMBERS RECORD ..1-1 Outboard motor serial number...........1-1 Key number...........................................1-1 EMISSION CONTROL INFORMATION ...1-2 SAFETY INFORMATION ..........................1-4 IMPORTANT LABELS ..............................1-6 BASIC BOATING RULES ................[...]

1-1 E EMU00005 IDENTIFICA TION NUMBERS RECORD EMU00007 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[...]

E 1-2 108044 w q 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 cont[...]

E 1-3 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 hav[...]

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 operating. 8[...]

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 202036 w q e t 905011 r EMU00014 IMPORT ANT LABELS WARNING LABELS 2 3 WARNING 6K1-83623-41 YAMAHA Use only a counterclockwise rotation propeller with this engine. Counterclockwise propellers are marked with a letter "L" after the size indication. The wrong type of propeller could cause the boat to go in an unexpected direction, whic[...]

E 1-7 Stand-on vessel The vessel with the right-of-way has the duty to continue its course and speed, except to avoid an immediate collision. When you maintain your direction and speed, the other vessel will be able to determine how best to avoid you. Give-way vessel The vessel which does not have the right- of-way has the duty to take positive and[...]

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 traveling across the other vessel’s path) Overtaking (you are passing or being passed by ano[...]

E 1-9 the power-driven vessel, the power- driven vessel has the right-of-way. 2. Sailing vessels should keep clear of any fishing vessel. 3. In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel which can navigate only in such a channel. Reading buoys and other markers The waters of the United states are [...]

E 1-10 1 1 A 1 1 Proceeding toward head of navigation from seaward CAN BUOY Odd number. Leave to port. OR SECONDARY CHANNEL BUOYS STARTS NEW NUMBERING SYSTEM old new C " 1 " NUN BUOY Even number. Leave to starboard N " 2 " No change BUOY COLOR CODE BLACK RED GREEN " A " " 2 " " 1 " " 3 " &[...]

E 1-11 EMU00017 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- [...]

E 1-12 EMU00027 Gasohol There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if ethanol content does not exceed 10% and the fuel meets minimum octane ratings. Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or engine performan[...]

E 1-13 EMU00033 BA TTERY REQUIREMENT c C Do not use the battery that does not meet the specified capacity. If different battery from the specification is used, the electric system may perform poorly or be overloaded, causing electrical system damage. Choose battery which meets the following specifications. If any electrical accessories are used, us[...]

E 1-14 602022 14-1/2x17-M 12 3 Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For a greater operating load, a smaller-pitch propeller is more suitable as it enables the correct engine speed to be main- ta[...]

E 1-15 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. 68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 20[...]

E EMU00037 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS ..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-2 Remote control .....................................2-2 Trim tab .................................................2-7 Power trim/tilt switch ...........................2-8 Digital tac[...]

E EMU00038 MAIN COMPONENTS !4 !5 TRIP TIME BATT Km/h knot mph km mile SPEED YAMAHA set mode !3 !1 !2 !6 101083 q w e r o !0 i y t u 101084 w YAMAHA set mode P S mpg Km/L gph I/h ECON SYNC TTL FUEL MANAGEMENT !7 1 Top cowling 2 Top cowling lock levers 3 Trim tab (Anode) * 4 Propeller 5 Cooling water inlet 6 Anti-cavitation plate 7 Anode 8 Tilt suppo[...]

E EMU00039 OPERA TIONS OF CONTROLS AND OTHER FUNCTIONS EMU01273 REMOTE CONTROL Both the shifter and the throttle are actu- ated by the remote control lever. In addi- tion, the electrical switches are mounted on the remote control box. å Side mount remote control box ∫ Binnacle mount remote control box ç Switch panel (for use with ∫ ) 1 Remote[...]

E EMU00098 Remote Control Lever Moving the lever forward from the Neutral position engages Forward gear. Pulling the lever back from Neutral engages Reverse. The engine will contin- ue to run at idle until the lever is moved about 35° (a detent can be felt). Moving the lever farther opens the throttle, and the engine will begin to accelerate. 1 Ne[...]

E 2-4 EMU00101 Main switch The main switch controls the ignition sys- tem; its operation is described below. 8 OFF Electrical circuits switched off. (The key can be removed.) 8 ON Electrical circuits switched on. (The key cannot be removed.) 8 START Starter-motor will turn and start engine. (When the key is released, it returns auto- matically to ?[...]

E 2-5 NOTE: The engine cannot be started with the lock-plate removed. UP DN 701034 UP DN DN UP 702042** EMU01112 Power Trim/Tilt Switches The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the remote control lever grip. Individual- engine switches are also on the control cover. Pushing t[...]

E 2-6 EMU00106 Free Accelerator To open the throttle without shifting into either Forward or Reverse, push the free accelerator button and turn the remote control lever. NOTE: 8 The free accelerator button can be oper- ated only when the remote control lever is in the Neutral position. 8 After the button is pushed, the remote control lever must be [...]

E 2-7 EMU00113 TRIM TAB The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force. w An improperly adjusted trim tab may cause difficult steering. Always test run after the trim tab has been installed or replaced to be sure steering is correct. Be sure you have tighte[...]

E 2-8 302022 UP DN EMU01125 POWER TRIM/TILT SWITCH The power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the side of the bottom engine cowling. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the motor down[...]

E 2-9 001082 001049 EMU01614 DIGITAL TACHOMETER This gauge contains the tachometer, trim meter, hour meter, oil level indicator, and the overheat warning indicator. 1 Tachometer 2 Trim meter 3 Hour meter 4 Oil level indicator 5 Overheat warning indicator 6 Set button 7 Mode button NOTE: All segments of the display will light momentarily after the m[...]

E 2-10 001051 q 001087 EMU01620 Hour Meter This meter shows the number of hours the engine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off. 8 Changing the display format Pressing the MODE button changes the display format in the following circular p[...]

2-11 E 001052 q 802016* TRIP TIME BATT Km/h knot mph km mile SPEED YAMAHA set mode q w e r EMU00140 DIGITAL SPEEDOMETER This meter contains the speedometer, fuel meter with warning, trip meter, clock and voltmeter with warning. 1 Speedometer 2 Fuel meter 3 Trip meter/clock/voltmeter 4 Warning indicator NOTE: After the main switch is first turned on[...]

E 2-12 q w e 802023* EMU00141 Speedometer This meter shows the boat speed. NOTE: The speedometer displays km/h, mph, or knots, depending upon operator prefer- ence. Select the desired unit of measure- ment by setting the selector switch on the back of the meter. See the illustration for settings. 1 Cap 2 Selector switch (for speed unit) 3 Selector [...]

E 802025* TRIP TIME BATT Km/h knot mph km mile SPEED YAMAHA set mode 2-13 EMU00144 Fuel meter The fuel level is displayed by eight seg- ments. When all segments are showing, the fuel is full. c C The Yamaha fuel tank sensor is different from a conventional-type sensor. A wrong setting of the selector switch on the meter will give incorrect readings[...]

E PS mpg Km/L gph I/h ECON SYNC TTL FUEL MANAGEMENT 2-14 EMU00145 Warning indicator 8 Fuel warning If the fuel level decreases to one segment the fuel level warning segment 1 begins blinking. 8 Low battery voltage warning If battery voltage drops, the display 2 will be automatically turned on and it begins blinking. c C Do not continue to operate t[...]

E 2-15 YAMAHA PS gph I/h ECON SYNC TTL FUEL MANAGEMENT set mode 2 6 5 4 3 1 ON (liter) l/h (gallon) gph q EMU00147 Fuel Flow Meter The meter displays fuel flow within one hour, at the rate of current engine opera- tion. If twin engines are installed on your boat, the meter will display total fuel flow of Port and Starboard side engine. It also disp[...]

E 2-16 PS mpg Km/L gph I/h ECON SYNC TTL FUEL MANAGEMENT PS mp Km gph I/h ECON SYNC TTL FUEL MANAGEMENT /L g EMU01276 Fuel Consumption Meter This meter displays the total amount of fuel consumed since the meter was last reset. Repeatedly push and release the “mode” button until the indicator on the face of the meter points to total (“TTL”).[...]

E 2-17 NOTE: 8 Fuel consumption varies greatly with boat design, weight, propeller used, engine trim angle, sea conditions (including wind), and throttle position. Fuel consumption also varies slightly with the type of water (salt, fresh, and contaminate levels), air temperature and humidity, cleanliness of the boat bottom, engine mounting height, [...]

E 2-18 EMU01278 Twin Engine Speed Synchronizer This meter displays the difference in engine speed (r/min) between the Port and Starboard engines for reference pur- poses when synchronizing the two engines’ speeds. Repeatedly push and release the “mode” button until the indicator on the face of the meter points to “SYNC”. 1 Port side engin[...]

E 2-19 EMU01180* TOP COWLING LOCK LEVERS To remove the engine top cowling, pull up the front and rear lock levers. Then lift off the cowling. When replacing the cowl- ing, check to be sure it fits properly in the rubber seal. Then lock the cowling again by moving the levers downward. c C The air intake grills 1 on the top cowling are not designed a[...]

E 2-20 701054 001053 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. 703026 OFF START OFF START ON ON 605015 EMU00171 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too hi[...]

E 2-21 001094 703026 OFF START OFF START ON ON 213032 q 905012 q EMU00172 OIL LEVEL WARNING / OIL FILTER CLOGGING WARNING This engine has an oil level warning sys- tem. If oil level falls below lower limit, the warning device will activate. ( 1 ); Included (—); N/A If the warning system has been activated, stop the engine and check for the cause.[...]

E EMU00174 Chapter 3 OPERA TION INSTALLATION ........................................3-1 Mounting the outboard motor ............3-2 BREAKING IN (RUNNING IN) ENGINE ..3-4 PRE-OPERATION CHECKS ......................3-5 Operation after a long period of storage ...................................................3-7 FILLING FUEL AND ENGINE OIL ........[...]

E EMU00175 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 presence[...]

E EMU00176 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 possibl[...]

E w Overpowering a boat may cause severe instability. Do not install an outboard 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 manufac- turer. 104014 3-3 EMU01299 Mounting Height To run your boat at optimum efficiency, the water-resistance (drag) of[...]

E 3-4 EMU01192* 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 8 Failure to follow the break-in (running- in) procedure may result in reduced engine l[...]

E 3-5 2) Next 50 minutes: Do not exceed half throttle (approxi- mately 3,000 r/min). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 r/min or less. 3) Second hour: Accelerate at full throttle onto plane, then reduce engine speed to three- quarter[...]

E 3-6 EMU00206 Fuel 8 Check to be sure you have plenty of fuel for your trip. 8 Make sure there are no fuel leaks or gasoline fumes. 8 Check fuel line connections to be sure they are tight. 8 Be sure the fuel tank is positioned on a secure, flat surface, and that the fuel hose is not twisted or flattened, or likely to contact sharp objects. EMU0020[...]

E 3-7 EMU01184 OPERATION AFTER A LONG PERIOD OF STORAGE (for Yamaha oil injection system model) When operating the engine after a long period (12 months) of storage, proceed as follows: 1) Start the engine. Leave it idling. w 8 Do not touch or remove electrical parts when starting or during operation. 8 Keep hands, hair, and clothes away from flywh[...]

E 3-8 EMU00186 FILLING FUEL AND ENGINE OIL EMU01031 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. EMU01019 Ring Free Fuel Additive Gasoline is a precise blend of many differ- ent substances, each chosen to give cer- tain characteristics. Gasoline blend[...]

E 3-9 EMU01185 FILLING OIL (for Yamaha oil injection system model) This engine uses the Yamaha oil injection system, which provides superior lubrica- tion by ensuring the proper oil ratio for all operating conditions. No fuel pre-mixing is needed. Simply pour gasoline into the fuel tank and oil into the oil tank. Convenient indicators show the stat[...]

E 3-10 Yellow 1,500 cm 3 (1.6 US qt, 1.31 Imp qt) or less EMU00200* Oil Level Indicator The various oil level system functions are as follows: Remarks Oil level indicator (Digital tachometer) Oil level indicator(Analog tachometer) Engine oil tank Remote oil tank Green Red Green Red More than 300 cm 3 (0.32 US qt, 0.26 Imp qt) More than 300 cm 3 (0.[...]

E 3-11 902025 EMU01197 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 vapor[...]

E 3-12 EMU00248 PROCEDURE FOR REMOTE CONTROL MODEL 4) Place the remote control lever in the Neutral position. NOTE: The start-in-gear protection device per- mits the engine to be started only when it is in Neutral. N 702025 000293 ON START OFF ON START OFF 000714 5) Attach the engine stop switch lanyard to a secure place on your clothing, or your a[...]

E 3-13 ON START OFF 701022 703045 OFF START ON 6) Turn the main switch to “ON”. NOTE: In case of dual-engine operation, when the main switch is turned on, the buzzer operates for a few seconds and stops automatically. Should either of the dual engines stall, the buzzer operates. EMU00949 Electric Start Model 7 ) Turn the main switch to “START[...]

E 3-14 309034 EMU01198 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) Check for a steady flow of water from the cooling-water pilot hole. c C A continuous flow of water from the pilot hole shows that the water pump is pumping water throug[...]

E 3-15 701043 N F N R 701044 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). EMU00264 FORWARD Pull up the neutral interlock trigger (If equip[...]

E 3-16 OFF OFF ON ON 703046 ON START OFF 701023 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. EMU00276* 1) Turn the main switch to “OFF”. 2) If there is a fuel joint or a fuel cock on the boat, disconnect the fuel line or c[...]

E 3-17 000892 q 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[...]

E 3-18 UP DN 702014 q ADJUSTING TRIM ANGLE EMU01401 Power Trim/Tilt Model w 8 Be sure all people are clear of the out- board motor when adjusting the trim/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 watc[...]

E 3-19 EMU00282 Bow Up When the boat is on plane, a bow-up atti- tude result in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. When trimmed out, the boat may have more tendency to steer to one side or the other. Compensate for this as you steer. The trim tab can also be adju[...]

E 3-20 000895 EMU01200 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 Before tilting the motor, follow the proce- dures under “STOPPING ENGINE”[...]

E 3-21 UP DN UP DN 702014 403035* DN UP 702042** EMU00294* PROCEDURE FOR TILTING UP Power trim/tilt model 1) If there is a fuel joint or a fuel cock on the boat, disconnect the fuel line or close the fuel cock. 2) Push the power trim/tilt switch “UP” until the outboard has tilted up com- pletely. 3) Turn the tilt-support lever toward you and su[...]

E 3-22 EMU00316 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 s[...]

E – MEMO – 68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 24[...]

E EMU00317 Chapter 4 MAINTENANCE SPECIFICATION DATA .............................4-1 TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-4 Trailering outboard motor ...................4-4 Storing outboard motor ......................4-5 PERIODIC MAINTENANCE ......................4-9 Replacement parts ...........................[...]

Recommended fuel P.O.N. Fuel tank capacity l (US gal, Imp gal) Recommended engine oil Fuel/oil premix ratio Fuel : Oil Engine oil capacity (engine oil tank) l (US qt, Imp qt) (remote oil tank) l (US qt, Imp qt) Recommended gear oil Gear oil capacity cm 3 (US oz, Imp oz) Spark plug N•m(kgf•m,lb•ft) Propeller nut N•m(kgf•m,lb•ft) TIGHTENI[...]

2-stroke, 76°V6 2,596 (158.4) 90.0 × 68.0 (3.54 × 2.68) TCI BKR7EKU 1.5 - 1.6 (0.059 - 0.062) Remote control Electric start 12-100 - 120 512 182 12-45 Electronic Fuel Injection 2-stroke, 76°V6 2,596 (158.4) 90.0 × 68.0 (3.54 × 2.68) TCI BKR7EKU 1.5 - 1.6 (0.059 - 0.062) Remote control Electric start 12-100 - 120 512 182 12-45 Electronic Fuel [...]

E 4-3 Recommended fuel P.O.N. Fuel tank capacity l (US gal, Imp gal) Recommended engine oil Fuel/oil premix ratio Fuel : Oil Engine oil capacity (engine oil tank) l (US qt, Imp qt) (remote oil tank) l (US qt, Imp qt) Recommended gear oil Gear oil capacity cm 3 (US oz, Imp oz) Spark plug N•m(kgf•m,lb•ft) Propeller nut N•m(kgf•m,lb•ft) TI[...]

E 4-4 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. 000896 102074 EMU00326* TRAILERING OUTBOARD MOTOR The motor should be trailered and stored in the normal running position. If there is insuff[...]

E 4-5 EMU01187* 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. This is especially important for your Yamaha oil injection system- equipped outboard due to the lean oil ratios used at idle prior to shutting the e[...]

E 4-6 903021 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 remo[...]

E 4-7 EMU00350* Lubrication 1 ) Remove the spark plug(s). Spray a “Yamaha Stor-Rite Engine Fogging Oil” into each cylinder for 5 seconds. Grease the spark plug threads and reinstall the spark plug(s) and torque to proper specification. (Refer to “CLEANING AND ADJUSTING SPARK PLUG”.) 2 ) Turn the engine over with the stop lanyard disconnecte[...]

E 4-8 EMU00353 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[...]

E 4-9 901015 UPPER LEV EL LO WE RL E VE L EMU01569 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. 2) Clean the battery casing and termi- nals. Fill each cell [...]

E 4-10 EMU00362* MAINTENANCE CHART Frequency of maintenance operations may be adjusted according to the operating con- ditions, but the following table gives general guidelines. The mark ( 6 ) indicates the check-ups which you may carry out yourself. The mark ( 1 ) indicates work to be carried out by your Yamaha dealer. Spark plug(s) Cleaning/Adjus[...]

E 4-11 EMU00366 GREASING Yamaha marine grease (Water resistant grease) 103212 68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 12[...]

E 4-12 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[...]

E 4-13 q q w 000790 Spark plug torque: Refer to “SPECIFICATIONS”, page 4-1. Spark plug gap: Refer to “SPECIFICATIONS”, page 4-1. Initial of spark Plug wrench size plug I.D. mark B 21 mm (13/16 in.) C/BK 16 mm (5/8 in.) D 18.3 mm (23/32 in.) Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap [...]

E 4-14 106092 EMU00369* 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 a Yamaha dealer or other qualified mechan- i[...]

E 4-15 000629 r t e w u y EMU00370 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 f[...]

E 4-16 4) Reinstall the filter element. Make sure the O-ring is in position in the cup. Insert the cup and O-ring into the fil- ter housing 6 . Screw the ring nut onto the filter housing until the ring is lightly seated. 5) Tighten the ring nut approximately an additional 1/4 turn until ring nut is tight. Align one of the four larger ring nut tabs [...]

E 4-17 A diagnostic tachometer should be used for this procedure. 1) Start the engine and allow it to warm up fully in Neutral until it is running smoothly. If the outboard is mounted on a boat, be sure the boat is tightly moored. 2 ) Adjust the throttle stop-screw 1 to set the idling speed to specification (see “SPECIFICATIONS” on page 4-1) by[...]

E 4-18 206016 EMU01189 CHECKING HIGH PRESSURE FUEL PUMP DRIVE BELT Inspect the high pressure fuel pump drive belt and replace it if any of the following signs is observed: 8 Cracks in the back of the belt or in the base of belt teeth. 8 Excessive wear at the roots of cogs. 8 Rubber portion swollen by oil. 8 Belt surfaces roughened. 8 Signs of wear [...]

E 4-19 000500 r t w e r e q 000501 t EMU00383 CHECKING WIRING AND CONNECTORS 1 ) Check that each grounding wire is properly secured. 2) Check that each connector is engaged securely. EMU00384 EXHAUST LEAKAGE Start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head and crank case. EMU00385 WATER LEAKA[...]

E 4-20 EMU00993 CHECKING POWER TRIM AND TILT SYSTEM w 8 Never get under the lower unit while it is tilted, even when the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls. 8 Make sure no one is under the out- board before performing this test. 411046 q w 411044 e 411045 Recommended fluid; Yamaha power trim &[...]

E 4-21 210012 602051 602036 602074 w e r q y t EMU00388 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[...]

E 4-22 EMU00397 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 Corrosion[...]

E 4-23 601031* q w EMU00905 CHANGING GEAR OIL w 8 Be sure the outboard is securely fas- tened to the transom or a stable stand. You could be severely injured if the out- board falls on you. 8 Never get under the lower unit while it is tilted, even when the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls. 1[...]

E 4-24 5) With the outboard motor in an verti- cal position, using a flexible or pres- surized filling device, inject the gear oil into the oil drain plug 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 oil drain plug. 603024 405022 Gear oil grade/capacity: Refer [...]

E 4-25 EMU00404 CHECKING BATTERY (for Electric start model) 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 w[...]

E 4-26 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. 1 ) Check the electrolyte level at least once a month. Fill to the manufactur- er’s recommended level when neces- sary. Top up only with distilled water (or pure de-ionized water [...]

E 4-27 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[...]

E 4-28 EMU01280 Disconnecting the Battery Disconnect the BLACK lead from the NEG- ATIVE (-) terminal first. Then disconnect the RED lead from the POSITIVE (+) termi- nal. EMU00408 CHECKING BOLTS AND NUTS 1) Check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torque. [...]

E 4-29 000876 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 [...]

E 4-30 102025 EMU00413 COATING THE BOAT BOTTOM A clean hull improves boat performance. The boat bottom should be kept as clean of marine growths as possible. If neces- sary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These[...]

E – MEMO – 68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 32[...]

E EMU00414 Chapter 5 TROUBLE RECOVER Y TROUBLESHOOTING ..............................5-1 TEMPORARY ACTION IN EMERGENCY ............................................5-5 Impact damage .....................................5-5 Running single engine .........................5-5 Power trim/tilt will not operate ...........5-6 Starter will not operate ....[...]

E 5-1 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[...]

E 5-2 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[...]

E 5-3 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[...]

E 5-4 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. 21. High pressure fuel pump drive belt bro[...]

E EMU00416 TEMPORARY ACTION IN EMERGENCY EMU00417 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 control syste[...]

E 5-6 411025 q EMU00419 POWER TRIM/TILT WILL NOT OPERATE If the engine cannot be tilted up or down with the power trim and tilt because of a discharged battery or a failure with the power trim and tilt unit, the engine can be tilted manually. 1 Manual valve screw EMU00421 1) Loosen the manual valve screw coun- terclockwise until it stops. 2) Put th[...]

E 5-7 EMU00424 STARTER WILL NOT OPERATE If the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be manually start- ed with an emergency starter rope. However, the engine can not be manually started if the battery has low voltage. If the battery is discharged to 9 volts or below, the electrical fuel pump[...]

ON START OFF 701026 703043 ON ON E 5-8 301052 208083 208084 EMU01309 Emergency Starting Engine 1) Remove the top cowling. 2) Remove the flywheel cover. 3) Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in Neutral and that the lanyard is attached to the engine stop switch. 4) Turn the main switch to [...]

E 5-9 EMU01191 LOW OIL LEVEL WARNING ACTIVATES If the oil level is allowed to drop too low, the red segment will appear on the oil level indicator, the buzzer will sound, and engine speed will be limited to about 2,000 r/min. If this happens, a reserve amount of oil can be pumped from the remote oil tank 3 to the engine oil tank 2 using the emergen[...]

E 5-10 NOTE: 8 Reserve oil capacity is maximum 1,500 cm 3 (1.6 US qt, 1.31 Imp qt). 8 The oil feed pump will not operate if the engine is tilted more than 35°. Put the engine in the down position before operating the emergency switch. 68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 11[...]

E 5-11 EMU00446 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. EMU00449 1 ) Thoroughly wash away[...]

E EMU00450 Chapter 6 INDEX INDEX ........................................................6-1 1 2 3 4 5 6  ) QG!    30  3DJH [...]

E EMU00451 INDEX A Adjusting idling speed .......................... 4-16 Adjusting trim angle ..............................3-18 B Basic boating rules ..................................1-7 Battery care...............................................4-8 Battery requirement ..............................1-13 Bow down .................................[...]

E 6-2 Main switch ..............................................2-4 Maintenance chart .................................4-10 Motor exterior ........................................4-30 Mounting height ......................................3-3 Mounting the outboard motor ...............3-2 N Neutral interlock trigger ..........................2-3 Neu[...]

EMU01599 IMPORT ANT W ARRANTY 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 satisf[...]

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 o[...]

EMU00912* Y AMAHA MOTOR CORPORA TION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED W ARRANTY Yamaha Motor Corporation, U.S.A. is proud of its heritage and reputation for producing products with high standards of quality and workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Outboard Limited Wa[...]

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 Uni ted 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 [...]

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 2001—0.5 × 2 ! 68F-28199-13 (Z150PETO/LZ150PETO/Z175GETO/Z200NETO/LZ200NETO) (E) Printed on recycled paper[...]