Yamaha 90C manual

Printed in Japan March 2003-0.6 × 1 ! 6H3-28199-1N (60FETO , 70BETO , 90AETO) (E) Printed on recycled paper 60C 70C 90C O WNER’S MANU AL U .S.A.Edition LIT -18626-05-50 6H3-9-1N Hyoshi 2/11/03 9:05 Page 1[...]

6H3-9-1N Hyoshi 2/11/03 9:05 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,[...]

1 2 3 4 5 6 E CONTENTS GENERAL INFORMA TION BASIC COMPONENTS OPERA TION MAINTENANCE TROUBLE RECOVERY INDEX READ THIS OWNER’S MANUAL CAREFULL Y BEFORE OPERA TING YOUR OUTBOARD MOTOR. EMA20010 6H3-9-1N 1 2/6/03 11:07 Page 3[...]

E EMB00010 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 ..........................1-3 IMPORTANT LABELS ...................[...]

EMU00008 KEY NUMBER If a main key switch is equipped with the motor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key. 1 Key number 1-1 E 1 401012 904011* 123 YAMAHA q EMU00005 IDENTIFICA TION NUMBERS RECORD EMU00007 OUTBOARD MOTOR SE[...]

1-2 E q w EMU01385 EMISSION CONTROL INFORMA TION EMU01386 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 control info[...]

E 1-3 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 1-4 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 1-5 202021 q 202022 q 90 EMB30010 IMPORT ANT LABELS WARNING LABELS WARNING Be sure shift control is in neutral before starting engine. (except 2HP) Do not touch or remove electrical parts when starting or during operation. Keep hands,hair,and clothes away from flywheel and other rotating parts while engine is running. 6A1-83625-41 1 6H3-9-1N 1 2/[...]

E 1-6 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 1-7 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 ves- sel ’ s path) Overtaking (you are passing or being passed b[...]

E 1-8 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 1-9 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 port. OR SECONDARY CHANNEL BUOYS STARTS NEW NUMBERING SYSTEM old new C " 1 " NUN BUOY Even number. Lea[...]

E 1-10 EMU00016 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 1-11 EMU01804 GASOLINE If knocking or pinging occurs, use a differ- ent brand of gasoline or premium unlead- ed fuel. 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. Gas[...]

E 1-12 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, the electric system could perform poorly or be overloaded, causing electric system damage. For electric start models, choose a battery which meets the following specifications. EMU01860 Mi[...]

E 1-13 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 1-14 1 Propeller diameter (in inches) 2 Propeller pitch (in inches) 3 Type of propeller (propeller mark) Refer to the section “ CHECKING PRO- PELLER ” for instructions on propeller removal and installation. EMU01209 ST ART -IN-GEAR PROTECTION Yamaha outboard motors or Yamaha approved remote control units are equipped with start-in-gear protec[...]

E — MEMO — 6H3-9-1N 1 2/6/03 11:07 Page 20[...]

E EMC00010 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS ..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-2 Fuel tank .................................................2-2 Remote control ......................................2-3 Power trim/tilt switch ............................2-7 Trim tab[...]

E 2-1 EMU01206 MAIN COMPONENTS q !0 w !3 !4 e r t y u i o !2 !1 1 Top cowling 2 Top cowling lock lever 3 Anti-cavitation plate 4 Trim tab (Anode) * 5 Propeller 6 Cooling water inlet 7 Anode 8 Trim angle adjusting rod 9 Clamp bracket 0 Tilt support lever q Power trim and tilt switch * w Flushing device * e Remote control box * r Digital tachometer *[...]

E 2-2 q w e r 902051 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) Fuel hose joint This connector is provided for connecting or disconnecting fuel hos[...]

E 2-3 701011* w q e r t y u R N F q w e r t y u u t r y 701031 000323 UP DN EMC80612 REMOTE CONTROL Both the shifter and the throttle are actu- ated by the remote control lever. In addi- tion, this control also has the electrical switches. 1 Remote control lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Main switch 5 Engine stop lanyar[...]

E 2-4 N 701033* q w ON START OFF 701045 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 throttle lever. NOTE: The neutral throttle lever will operate only when the remote control lever is in Neutral. The remote control lever wi[...]

E 2-5 000569 q w EMC28210 Engine stop lanyard switch The lock-plate on the end of the lanyard must be attached to the engine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, [...]

E 2-6 UP DN 701034* UP DN 701035 EMU01331 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 remote control lever grip. Pushing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims the moto[...]

E 2-7 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. When the sw[...]

E 2-8 EMD04011 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 2-9 q t w u y e r 001078 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 mo[...]

E 2-10 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 pattern: T[...]

E 2-11 001052 q EMU01553 Overheat Warning Indicator If the engine temperature rises too high, the warning indicator will start to blink. Refer to “ OVERHEAT WARNING ” for details. 1 Overheat warning indicator c C Do not continue to operate the engine if a warning device has activated. If neces- sary, refer to the “TROUBLESHOOTING” section i[...]

E 2-12 403011* q 301041* 000945 q EMD60010 TILT SUPPORT LEVER To keep the outboard motor in the tilted- up position, lock the tilt support lever to the clamp bracket. q 301042* EMD63111 TOP COWLING LOCK LEVERS To remove the engine top cowling, turn the front lock lever and rear lock lever(s). Then lift off the cowling. When replacing the cowling, c[...]

E 2-13 701054 605015 EMD80010 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. EMD82012 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate. ( [...]

E 2-14 001054 701054 213025 q EMD84012 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. NOTE: The warning for oil filter[...]

E 2-15 Oil level warning system The various oil-level warning system functions are as follows: Oil level warning indicator (Digital tachometer) No refilling necessary. more than 770 cm 3 (0.81 US qt, 0.68 Imp qt) Buzzer sounds in remote control box and engine speed is limited to about 2,000 r/min to help conserve oil. Check oil filter for clogging.[...]

E EMF00010 Chapter 3 OPERA TION INSTALLATION ........................................3-1 Mounting the outboard motor ............3-2 FILLING FUEL AND ENGINE OIL ............3-4 Filling fuel ..............................................3-4 Filling oil.................................................3-5 PRE-OPERATION CHECKS ......................3-6[...]

E 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 pres[...]

E 3-2 104011 q 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 [...]

E 3-3 104014 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. EMU01299 Mounting Height To run your boat at optimum efficiency, the water-resistance (drag) of[...]

E 3-4 902055 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. 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 years in[...]

E 3-5 EMU01800* FILLING OIL This engine uses the oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operat- ing conditions. No fuel premixing is need- ed (except during break-in). Simply pour gasoline into the fuel tank and oil into the oil tank. Convenient indicator segments indicate the status of th[...]

E 3-6 203016 q w EMF40110 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. Fuel Check to be sure you have plenty of fuel for your trip. Make sure there are no fuel leaks or gasoline fumes. Be sure the fuel[...]

E 3-7 212011* Engine Check the engine and engine mounting. Look for loose or damaged fasteners. Check the propeller for damage. c C Do not start the engine out of water. Overheating and serious engine damage can occur. EMU01790 OPERATION AFTER A LONG PERIOD OF STORAGE When operating the engine after a long period (12 months) of storage, proceed as [...]

E 3-8 EMU01776 BREAKING IN ENGINE Your new engine requires a period of break-in to allow mating surfaces of mov- ing parts to wear in evenly. Correct break- in will help ensure proper performance and longer engine life. c C 8 Failure to follow the break-in procedure could result in reduced engine life or even severe engine damage. 8 Premix fuel mus[...]

E 3-9 EMU01784 Run the engine under load (in gear with a propeller installed) as follows. 1) First 10 minutes: Run the engine at the lowest possi- ble-speed. A fast idle in neutral is best. 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 f[...]

E 3-10 304034* 902053 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 i[...]

E 3-11 000293 EMF65010 PROCEDURE FOR REMOTE CONTROL MODEL 4) Place the remote control lever in the Neutral position. NOTE: 8 The start-in-gear protection device pre- vents the engine from starting except when in Neutral. 8 It is not necessary to open the free accelerator lever or Neutral throttle lever while starting. 5) Attach the engine stop swit[...]

E 3-12 EMU00949 Electric Start Model 7 ) Turn the main switch to “ START ” , and hold it for a maximum of 5 sec- onds. 8) Immediately after the engine starts, release the main switch to return it to “ ON ” . 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 s[...]

E 3-13 309014 EMG00210 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 3-14 701043 N F 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). N R 701044 EMU00264 FORWARD Pull up the neutral interlock trigger (If equip[...]

E 3-15 ON START OFF 701023 304034* 902052 EMG38010 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. EMG41211 PROCEDURE 1) Turn the main switch to “ OFF ” . NOTE: The engine can also be stopped by pulling the lanyard from the engine sto[...]

E 3-16 000862 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 3-17 UP DN 701034 UP DN q 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 watch for any signs[...]

E 3-18 001672 q 001673 w 001674 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. [...]

E 3-19 000817 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 3-20 UP DN 701034* UP DN 302021* DN UP 403011* 411014 EMU00295 PROCEDURE FOR TILTING UP Power tilt / Power trim/tilt model 1) Remove the fuel-line connection from the motor. (If the connector is provid- ed on the motor.) 2) Push the power tilt / power trim/tilt switch “ UP ” until the outboard has tilted up completely. 3) Turn the tilt-suppor[...]

E 3-21 411021 c C Be sure to retract the trim rods complete- ly during mooring. This protects the rods from marine growths and corrosion which could damage the power trim/tilt mechanism. 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 fr[...]

E EMK00010 Chapter 4 MAINTENANCE SPECIFICATIONS .....................................4-1 TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-3 Trailering outboard motor ...................4-3 Storing outboard motor .......................4-4 PERIODIC MAINTENANCE ......................4-8 Replacement parts ......................[...]

E 4-1 EMK10011* SPECIFICA TIONS Model Unit 60TRC Item 25 (2.5, 18) 35 (3.5, 25) 8 Spark plug N•m (kgf•m, lb•ft) 8 Propeller nut N•m (kgf•m, lb•ft) DIMENSIONS PERFORMANCE 8 Overall Length mm (in.) 8 Overall Width mm (in.) 8 Overall Height L mm (in.) 8 Transom height L mm (in.) 8 Weight kg (lb.) 713 (28.1) 364 (14.3) 1,374 (54.1) 521 (20.[...]

E 4-2 70TRC 90TRC — 713 (28.1) 364 (14.3) 1,374 (54.1) 521 (20.5) 104 (229) 5,000~6,000 51.5 (70) at 5,500 r/min 750~850 2-stroke, L3 849 (51.8) 72.0 × 69.5 (2.8 × 2.7) C.D.I system B8HS-10 0.9~1.0 (0.035~0.039) Remote control Electric start 380 502 124 12-6 Prime start system Forward-Neutral-Reverse 2.33 (28/12) Power trim/tilt K Regular unlea[...]

E 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. 000940 EMU00326 TRAILERING OUTBOARD MOTOR The motor should be trailered and stored in the normal running position. If there is insufficient r[...]

E 4-4 EMU01796 STORING OUTBOARD MOTOR When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important pro- cedures must be performed to prevent excessive damage. This is especially important for your oil injection-equipped outboard motor due to the lean oil ratios used at idle prior to shutting the engi[...]

E 4-5 605014 EMK22111 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. 1) Remove the top cowlin[...]

E 4-6 EMK26111 Lubrication 1) Remove the spark plugs, and spray a 10 second spray of “Yamaha Stor- Rite Engine Fogging Oil” into each cylinder. Grease the spark plug threads and reinstall the spark plugs and torque to proper specification. (Refer to “CLEANING AND ADJUST- ING SPARK PLUG”.) 2 ) Turn the engine over with the stop lanyard disco[...]

E 4-7 EMK29010 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 4-8 EMK32110 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. A service manual is available for purchase through a Yamaha dealer for owners who have the mecha[...]

E 4-9 EMU19470 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 [...]

E 4-10 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 4-11 903022 q w 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 spa[...]

E 4-12 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[...]

E 4-13 000983 q w e r 207016 EMK50011 CLEANING 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 [...]

E 4-14 4) Reinstall the filter element in the cup. Make sure the O-ring is in position in the cup. Firmly screw the cup onto the filter housing 4 . 5 ) Attach the filter assembly to the bracket so that the fuel hoses are attached to the filter assembly. 6 ) Run the engine and check the filter and lines for leaks. EMU09912 INSPECTING IDLING SPEED w [...]

E 4-15 213013 q w 213014 q w 2) Verify whether the idle speed is set to specification. For idle speed specifica- tions, see “Specifications” in this chapter. NOTE: Correct idling speed inspection is only possible if the engine is fully warmed up. If not warmed up fully, the idle speed will measure higher than normal. If you have difficulty veri[...]

E 4-16 205016 q w 413011 EMU01329 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. NOT[...]

E 4-17 EMU00366 GREASING Yamaha marine grease (Water resistant grease) 103031* 6H3-9-1N 4 2/21/03 10:26 Page 18[...]

E 4-18 411015 411016 EML02011 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. 1) Check the power trim and tilt unit for any sign [...]

E 4-19 210012 602051 602054 EML08011* 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- t[...]

E 4-20 602053 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 Co[...]

E 4-21 000565 w q EMU01460 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/knob is locked. Severe injury could occur if the outboard accidentally fall[...]

E 4-22 000377 603024 405012 5) With the outboard motor in a vertical position, and 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. Gear oil grade/capacity[...]

E 4-23 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 [...]

E 4-24 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 wate[...]

E 4-25 EMU01280 Disconnecting the Battery Disconnect the BLACK lead from the NEG- ATIVE (-) terminal first. Then disconnect the RED lead from the POSITIVE (+) termi- nal. 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[...]

E 4-26 q w e 000841 EML40010 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 torques. 2) Check the tightening torques of other bolts and nuts. EMU00409 MOTOR EXTERIOR EMU00410 Cleaning the Outboard Motor After use, wash the exterior of [...]

E 4-27 102025 c C Do not leave the garden-hose connector loose on the bottom cowling fitting or let the hose hang free during normal opera- tion. Water will leak out of the connector instead of cooling the engine, which can cause serious overheating. Be sure the connector is tightened securely on the fit- ting after flushing the engine. NOTE: 8 Whe[...]

E EMN00010 Chapter 5 TROUBLE RECOVERY TROUBLESHOOTING ..............................5-1 TEMPORARY ACTION IN EMERGENCY ............................................5-5 Impact damage .....................................5-5 Power trim/tilt will not operate ............5-5 Starter will not operate.........................5-6 Engine fails to 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. 13. Check wires for wear or breaks. Tighte[...]

E 5-5 607011 411012 q 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 ) [...]

E 5-6 EMN30410 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- ge[...]

E 5-7 208022 ON START OFF 701026 208016 Procedure 1) Remove the top cowling. 2) Remove the flywheel cover by remov- ing the bolts. 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. The main switch must be on if the main switch [...]

E 5-8 216012 q w EMN32311 ENGINE FAILS TO OPERATE If battery voltage is low or in the unlikely event of an ignition system malfunction, the engine speed may become erratic or the engine may stop. In such a case, dis- connect the connection on the yellow cord (emergency circuit) to return to port. w When the connection is disconnected, the idling an[...]

E 5-9 001671 N 701014 1) Adjust the trim angle so that the drive shaft is at right angles to the water surface or is trimmed in. 2 ) Open the emergency starter valve located behind the silencer cover on the front side. 214013 OPEN CLOSE 3 ) Squeeze the priming pump two or three times to feed fuel. 4 ) Open the throttle slightly without shifting usi[...]

E 5-10 OPEN CLOSE 214014 7 ) After the engine starts, return the emergency starter valve (if used) to “ CLOSE ” . NOTE: When the starter mechanism malfunc- tions, refer to “ STARTER WILL NOT OPERATE ” . 6H3-9-1N 5 2/6/03 11:50 Page 11[...]

E 5-11 107012 107013 107014 EMN50011 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 imme- diately take the outboard motor to a Yamaha dealer, follow the procedure bel- low for taking care to minimize engine damage. 1 ) Thorou[...]

E EMP00010 Chapter 6 INDEX INDEX ........................................................6-1 1 2 3 4 5 6 6H3-9-1N 6 2/18/03 9:19 Page 1[...]

E 6-1 F Filling fuel .................................................3-4 Filling fuel and engine oil ........................3-4 Filling fuel tank .........................................4-4 Filling oil....................................................3-5 Flushing cooling system and fogging engine .........................................4-5 Fl[...]

E 6-2 N Neutral interlock trigger ..........................2-3 Neutral throttle lever ...............................2-4 O Oil-level indicator ...................................2-11 Oil level warning/oil filter clogging warning ...................................................2-14 Oil level warning system.......................2-15 Operation af[...]

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 [...]

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 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 March 2003-0.6 × 1 ! 6H3-28199-1N (60FETO , 70BETO , 90AETO) (E) Printed on recycled paper 60C 70C 90C O WNER’S MANU AL U .S.A.Edition LIT -18626-05-50 6H3-9-1N Hyoshi 2/11/03 9:05 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[...]