Yamaha F40A manual

F30A/F40A paper LIT -18626-04-71 F30A F40A OWNER’S MANUAL U.S.A.Edition 67C-9-12 01.5.2 9:00 AM y[W 1 (2,1)[...]

67C-9-12 01.5.2 9:00 AM y[W 2 (1,1)[...]

E 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 obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, ple[...]

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E GENERAL INFORMA TION BASIC COMPONENTS OPERA TION MAINTENANCE TROUBLE RECOVERY INDEX READ THIS OWNER’S MANUAL CAREFULL Y BEFORE OPERA TING YOUR OUTBOARD MOTOR. 1 2 3 4 5 6 EMU00003 CONTENTS 67C-9-12-1 5/1/01 5:24 PM Page 3[...]

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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 401015 q 904011* 123 YAMAHA q 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 [...]

1-2 E 108043 q w EMU01385 EMISSION CONTROL INFORMA TION EMU01387 NORTH AMERICAN MODELS This engine conforms to U.S. Environ- mental Protection Agency (EPA) regula- tions 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 c[...]

1-3 E EMU01389 STAR LABELS Your outboard motor is labeled with a California Air Resources Board (CARB) star label. See below for a description of your particular label. 1 Star label One Star - Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 exhaust emission standards. Engines meeting these standards 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 Be informed about boating safety. Addi- tional publications and information can be obtained from many organizations, including the following: United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647[...]

1-6 E 202083 w q e 202082 w e EMU00014 IMPORT ANT LABELS WARNING LABELS 1 2 CAUTION LABELS 3 WARNING This engine is equipped with a neutral starting device. The engine will not start unless the shift control is in neutral position. 6E0-83627-41 WARNING ● Be sure shift control is in neutral before starting engine. (except 2HP) ● Do not touch or [...]

1-7 E EMU00015 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 [...]

1-8 E RULES WHEN ENCOUNTERING VESSELS There are three main situations which you may encounter with other vessels which could lead to a collision unless the Steer- ing 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 a[...]

1-9 E its course and speed. You must stay out of its way until you are clear of it. Like- wise, 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. [...]

1-10 E tion. These markers are white with black letters and orange boarders. They signify speed zones, restricted areas, danger areas, and general information. Remember, markings may vary by geo- graphic location. Always consult local boating authorities before driving your boat in unfamiliar waters. 1 1 1 A 1 1 1 Proceeding toward head of navigati[...]

1-11 E 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- [...]

1-12 E EMU00025 GASOLINE (PETROL) If knocking or pinging occurs, use a differ- ent brand of gasoline or premium unlead- ed fuel. If unleaded gasoline is not avail- able, then leaded regular gasoline can be used. If leaded gasoline is usually used, engine valves and related parts should be inspected after every 300 hours of opera- tion. EMU00027 Gas[...]

1-13 E EMU01149 ENGINE OIL Recommended engine oil; Use a combination of corresponding SAE and API shown in the chart below; c C All four-stroke engines are shipped from the factory without engine oil. NOTE: If the recommended engine oil is not available, then a multigrade type engine oil such as SF-CC/CD,SG-CC/CD or SH-CD can be used. Engine oil qu[...]

1-14 E EMU01430¯ BA TTERY REQUIREMENT c C Do not use a battery that does not meet the specified capacity. If a battery which differs from the specification is used, the electrical system may perform poorly or be overloaded, causing electrical system damage. c C 8 A battery cannot be connected to mod- els which do not have a rectifier or rec- tifie[...]

1-15 E 602011 10-3/4 x 17 - G q w e 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 mai[...]

1-16 E 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. 67C-9-12-1 5/1/01 5:25 PM Page 21[...]

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EMU00037 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS ..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-2 Recoil starter handle .............................2-2 Multifunction tiller handle ....................2-2 Remote control ......................................2-5 Trim tab ............[...]

2-1 E EMU01206 MAIN COMPONENTS 101104 q w e r t o i u y 701016 801011 YAMAHA 801012 x1000 r/min 7 3 4 2 1 5 6 YAMAHA !7 !6 !8 !0 !1 !2 !3 !4 000707 !5 000708 !5 !4 1 Top cowling 2 Top cowling lock lever 3 Oil drain bolt 4 Anti-cavitation plate 5 Trim tab 6 Propeller 7 Cooling water inlet 8 Clamp bracket * 9 Power trim and tilt switch * 0 Recoil sta[...]

2-2 E 209022 501013 q e r t w y 501016 w q e 501046 EMU00039 OPERA TIONS OF CONTROLS AND OTHER FUNCTIONS EMU00059 RECOIL STARTER HANDLE (If equipped) Pull the handle gently until resistance is felt. Then vigorously pull the handle straight out to crank the engine to start it. EMU00075 MULTIFUNCTION TILLER HANDLE The tiller handle centralized most o[...]

2-3 E 501023 501023* q 501051 EMU00081 Throttle control grip The throttle control grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed. EMU00082 Throttle Indicator The fuel consumption curve on the throt- tle indicator shows the relative amount of fuel consumed for each throttle position. Ch[...]

2-4 E 000980 w q EMU00933 Engine Stop Lanyard Switch The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 should be attached to a secure place on the operator’s cloth- ing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ign[...]

2-5 E 501063 408026 701011 w q e r t y u EMU00085 Engine Stop Button Pushing this button opens the ignition cir- cuit and stops the engine. EMU01150 Steering Friction Adjusting Lever A friction device provides adjustable resistance to the steering mechanism, and can be set according to operator pref- erence. An adjusting lever is located on the bot[...]

2-6 E R N F q w e r t y u u t r y 701031 701034* UP DN EMU00098 Remote Control Lever Moving the lever forward from the Neu- tral 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 [...]

2-7 E N 701033* q w ON START OFF 701021 EMU00100 Neutral Throttle Lever To open the throttle without shifting into either Forward or Reverse, place the remote control lever in the Neutral posi- tion and lift the neutral throttle lever. NOTE: The neutral throttle lever will operate only when the remote control lever is in Neu- tral. The remote contr[...]

2-8 E 000569 q w EMU00934 Engine Stop Lanyard Switch The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 should be attached to a secure place on the operator’s cloth- ing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ign[...]

2-9 E 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[...]

2-10 E 603021 q w A B EM00113 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 [...]

2-11 E 302016 UP DN 303015 q 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. Push- ing the switch “UP” trims the motor up, then tilts the motor up. Pressing the switch “DN” tilts the motor down and trims th[...]

2-12 E 801012* x1000 r/min 7 3 4 2 1 5 6 YAMAHA q w e 801011 YAMAHA EMU00125 TACHOMETER This meter contains the following func- tions, 1 Tachometer 2 Low oil pressure warning lamp 3 Overheat warning lamp EMU00126 Tachometer This meter shows the engine speed. EMU00127 Low Oil Pressure Warning Lamp If oil pressure drops too low, this lamp will flash.[...]

2-13 E 402063 q 403064 301051 q EMU00154 TILT LOCK MECHANISM (for Hydro- tilt model) Tilt-lock mechanism is used to prevent reverse thrust from the propeller lifting the outboard motor when reversing. To lock it, set the tilt-lock lever in the Lock position. To release it, place the tilt-lock lever in the Tilt position. 1 Tilt-lock lever NOTE: The [...]

2-14 E 313023 q EMU01146 FLUSHING DEVICE This device 1 is used to clean the cooling water passages of the motor using a gar- den hose and tap water. NOTE: Refer to “Cleaning Cooling-water Pas- sages” in Chapter 4 for instructions on usage. 67C-9-12-2 5/1/01 5:25 PM Page 15[...]

2-15 E 303021 801014* x1000 r/min 7 6 5 4 3 1 0 605021 EMU00169 W ARNING SYSTEM c C Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem can- not be located and corrected. EMU00170 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, th[...]

2-16 E 303026 801013* x1000 r/min 7 6 5 4 3 1 0 EMU00173 LOW OIL PRESSURE WARNING If oil pressure drops too low, the warning device will activate. ( 1 ):Included (—):N/A If the warning system has been activated, stop the engine as soon as it is safe to do so. Check oil level and add oil as needed. If the oil level is correct, consult your Yamaha [...]

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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 CHECKING THE ENGINE OIL LEVEL ......3-6 FILLING FUEL ...........................................3-7 STARTING ENGINE ..................[...]

3-1 E 000701 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 t[...]

3-2 E 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 [...]

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

3-4 E EMU00224 BREAKING IN (RUNNING IN) ENGINE Your new engine requires a period of break-in (running-in) to allow mating sur- faces of moving parts to wear-in evenly. Correct break-in (running-in) will help ensure proper performance and longer engine life. c C Failure to follow the break-in (running-in) procedure may result in reduced engine life [...]

3-5 E EMU00204 PRE-OPERA TION CHECKS w If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the out- board motor. Otherwise, an accident could occur. c C Do not start the engine out of water. Overheating and serious engine damage can occur. EMU00206 Fuel 8 Check to be sure you have plenty o[...]

3-6 E EMU00209 Controls 8 Check throttle, shift, and steering for proper operation before starting the engine. 8 The controls should work smoothly, without binding or unusual free play. 8 Look for loose or damaged connec- tions. 8 Check operation of the starter and stop switches when the outboard motor is in the water. EMU00210 Engine 8 Check the e[...]

3-7 E 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. EMU00203 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 [...]

3-8 E EMU01147 ST ARTING ENGINE w 8 Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you. 8 When the air vent screw is loosened, gasoline (petrol) vapor will be released. Gasoline (petrol) is highly flammable, and its vapors are fl[...]

3-9 E EMU00854 PROCEDURE FOR TILLER CONTROL MODEL 4) Place the gear-shift lever in the neu- tral position. NOTE: The start-in-gear protection device pre- vents the engine from starting except when in Neutral. 5) Place the throttle control grip in the “START” position. 6) Attach the engine stop switch lanyard to a secure place on your clothing, [...]

3-10 E 209022 N 701015 000293 EMU01005 Manual Start Model 7) Pull the starter handle slowly until you feel resistance. Then, give a strong pull straight out to crank and start the engine. Repeat it, if neces- sary. NOTE: If the warm engine fails to start, open the throttle slightly and try to start the engine. 8) After the engine starts, return the[...]

3-11 E w 8 Attach the engine stop switch lanyard to a secure place on your clothing, your arm or leg while operating. 8 Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard where it could become entan- gled, preventing from functioning. 8 Avoid accidentally pulling the lanyard during normal operation. Loss of engine[...]

3-12 E 309015 EMU00258 W ARMING UP ENGINE 1) Before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (Failure to do this will shorten engine life.) 2) Be sure the low oil pressure warning indicator goes off after starting the engine. 3) Check for a steady flow of water from the cooling-water pilot hole. c C 8 If the l[...]

3-13 E EMU00261 SHIFTING w Before shifting, make sure there are no swimmers or obstacles in the water near you. c C To change the shifting position from for- ward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speeds). EMU00265 FORWARD Tiller control model 1) Place the throttle control grip in the fully [...]

3-14 E 501012 402065 501062 N R N R 701044 EMU01326 REVERSE w When operating in Reverse, go slowly. Do not open the throttle more than half. Oth- erwise, the boat may become unstable, which could result in loss of control and an accident. 1) Place the throttle control grip in the fully closed position (for Tiller control model). 2) Check that the t[...]

3-15 E EMU00273 STOPPING ENGINE Let it cool off for a few minutes at idle or low speed first. Stopping the engine immediately after operating at high speed is not recommended. EMU00277 1) Push and hold the engine stop button or turn the main switch to “OFF”. 2) If the fuel joints are provided, discon- nect the fuel line from the motor after sto[...]

3-16 E EMU01412 TRIMMING OUTBOARD MOTOR The trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel economy while reducing strain on the engine. The correct trim angle depends upon the combination of boat, engine, and propeller. Correct trim is [...]

3-17 E 402076 EMU01113* Hydro-tilt Model w 8 Stop the engine before adjusting the trim angle. 8 Be sure all people are clear of the out- board motor when adjusting the tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket. 8 Use caution when trying a trim position for the first time. Increase speed gradu- [...]

3-18 E EMU01116* 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 of instabili- ty or[...]

3-19 E 105011 q 105013 w 105015 e 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. Th[...]

3-20 E 105014 EMU00285 TIL TING UP/DOWN If the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion. c C 8 Before tilting the motor, follow the pro- cedures under “STOPPING ENGINE?[...]

3-21 E 304053 402076 403064 EMU01127 PROCEDURE FOR TILTING UP Hydro-tilt model 1) Remove the fuel-line connection from the motor. 2) Place the tilt-lock lever in the release position. 3) Hold the rear of the top cowling with one hand, tilt the engine up, push the tilt support knob into the clamp brack- et, and place the tilt-lock lever back into th[...]

3-22 E UP DN 701034* UP DN 403065 402076 411042 2) Push the power trim/tilt switch “UP” until the outboard has tilted up com- pletely. 3) Push the tilt support knob into the clamp bracket to support the engine. w After tilting the engine, be sure to sup- port it with the tilt support knob. Other- wise, the engine could fall back down suddenly i[...]

3-23 E 000702 EMU00307 CRUISING IN SHALLOW W A TER Hydro tilt model The engine can be tilted up partially to allow operation in shallow water. w 8 Place the gear shift in the Neutral posi- tion before setting for the shallow water cruising. 8 Return the engine to its normal posi- tion as soon as the boat is back in deeper water. c C Do not tilt up [...]

3-24 E 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[...]

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EMU00317 Chapter 4 MAINTENANCE SPECIFICATION DATA .............................4-1 TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-3 Trailering outboard motor ...................4-3 Storing outboard motor .......................4-4 PERIODIC MAINTENANCE ......................4-9 Replacement parts ............................[...]

Model Unit F30TRA Item 4-1 E 4-stroke, OHC, L3 747 (45.5) 65 × 75 (2.56 × 2.95) CDI system DPR6EA-9 0.9 (0.035) Remote control Electric start 0.15 ~ 0.25 (0.006 ~ 0.010) 0.25 ~ 0.35 (0.010 ~ 0.014) 12-70 ~ 100 380 124 12-15 Prime start EMU00322* SPECIFICA TION DA T A Spark plug Propeller nut Engine oil drain bolt Engine oil filter N•m(kgf•m,l[...]

4-2 E F40MHA F40ERA F40TRA 4-stroke, OHC, L3 747 (45.5) 65 × 75 (2.56 × 2.95) CDI system DPR6EA-9 0.9 (0.035) Remote control Electric start 0.15 ~ 0.25 (0.006 ~ 0.010) 0.25 ~ 0.35 (0.010 ~ 0.014) 12-70 ~ 100 380 124 12-15 Prime start 5,000 ~ 6,000 29.4 (40) @5,500 800 ~ 900 Forward-Neutral-Reverse 2.0 (26/13) Hydro tilt G Regular unleaded gasolin[...]

4-3 E 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. EMU00326 TRAILERING OUTBOARD MOTOR The motor should be trailered and stored in the normal running position. If there is insufficient road cle[...]

4-4 E EMU00330 STORING OUTBOARD MOTOR When storing your Yamaha outboard for prolonged periods of time, (2 months or longer), several important procedures must be performed to prevent expensive damage. It is advisable to have your outboard ser- viced by an authorized Yamaha dealer prior to storage. However, the following procedures can be performed [...]

4-5 E EMU00338 Flushing Cooling System and Fogging Engine Cooling system flushing is essential to prevent the cooling system from clogging up with salt, sand, or dirt. In addition, fog- ging of the engine is mandatory to pre- vent expensive engine damage due to rust. Perform the flushing and fogging at the same time. w 8 Do not touch or remove elec[...]

4-6 E 6) Remove the motor from the water tank. 7) Install the silencer cover and top cowling. 1 Water surface 2 Lowest water level 605024 q w 903021* q 605014 EMU00342 8 Flushing with the Flushing Attachment c C Avoid running the outboard at high speed while on the flushing attachment, or overheating could occur. 1) Remove the top cowling and the p[...]

4-7 E EMU00349 Lubrication 1) Remove the spark plug(s). Spray a Yamaha “Stor-Rite Engine Fogging Oil” into each cylinder for 10 seconds. Grease the spark plug threads and reinstall the spark plug(s) and torque to proper specification. (Refer to the “CLEANING AND ADJUSTING SPARK PLUG”). 2) Turn the engine over with the stop lanyard disconnec[...]

4-8 E 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[...]

4-9 E 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. Maintenance, replacement, or repair of the emission control devices and systems may be performed[...]

4-10 E Spark plug Cleaning/Adjustment/ ● ● ● 4-12 Replacement Greasing points Greasing ● 4-11 Gear oil Change ● ● 4-24 Fuel system Inspection ● 4-14 Fuel filter Inspection/Replacement ● ● ● 4-15 Fuel tank *1 Cleaning ● — Idling speed Adjustment ● ● 4-16 Anode Inspection/Replacement 1 1 4-25 Outboard motor exterior Inspec[...]

4-11 E EMU00366 GREASING Yamaha marine grease (Water resistant grease) 103211 67C-9-12-4 5/1/01 5:27 PM Page 12[...]

4-12 E EMU01202 CLEANING AND ADJUSTING SPARK PLUG w When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire. The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something a[...]

4-13 E When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque. NOTE: If a torque-wrench is not available when you are fitting a spark plug, a good esti- mate of the correct torque is 1/4 to 1/2 a turn past finger-tight. Have the spark plug adj[...]

4-14 E 106074 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 Yama- ha dealer or other qualified mechanic. [...]

4-15 E 207061 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 fuel filter. [...]

4-16 E 204062 q EMU00991 ADJUSTING IDLING SPEED w 8 Do not touch or remove electrical parts when starting or during operation. 8 Keep hands, hair and clothes away from flywheel and other rotating parts while engine is running. c C This procedure must be performed while the outboard motor is in the water. A flushing attachment or test tank can be us[...]

4-17 E EMU01415 CHANGING ENGINE OIL w 8 Avoid draining the engine oil immedi- ately after stopping the engine. The oil is hot and should be handled with care to avoid burns. 8 Be sure the outboard is securely fas- tened to the transom or a stable stand. c C 8 Change the engine oil after the first 10 hours of operation, and every 100 hours or at 6-m[...]

4-18 E 4) Remove the oil filler cap 2 . Add the correct amount of oil through the filler hole. Reinstall the filler cap. 5) Start the engine and watch to make sure the low oil pressure warning lamp turns off. Make sure that there are no oil leaks. c C If the oil lamp does not turn off, or if there are oil leaks, stop the engine and find the cause. [...]

4-19 E 6) Turn off the engine and wait 3 min- utes. Recheck the oil level using the dipstick to be sure the level falls between the upper and lower marks. Fill with oil if it is below the lower mark, or drain to the specified level if it is above the upper mark. 7) Dispose of used oil according to local regulations. NOTE: 8 For disposal of used oil[...]

4-20 E 205051* q w e r 205052 r 413013 EMU01015 REPLACING FUSE If the fuse has blown for Electric start model, open the fuse box and replace the fuse with a spare one of proper amper- age, using a fuse puller. w Be sure to use the specified fuse. A wrong fuse or a piece of wire may allow excessive current flow. This could cause electrical system da[...]

4-21 E EMU00992 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 of oil leaks. [...]

4-22 E 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 “OFF” posi- tion and remove the key[...]

4-23 E 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. Other- wise, the propeller could come off dur- ing operation and be lost. 1) Apply Yamaha Marine grease or Cor- r[...]

4-24 E 000701 w q 601016* 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 f[...]

4-25 E 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. EMU01037 INSPECTING AND REPLACING ANODE(S) Ya[...]

4-26 E 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[...]

4-27 E 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 s[...]

4-28 E EEMU01279 Connecting the Battery w Mount the battery holder securely in a dry, well-ventilated, vibration-free loca- tion in the boat. Install a fully charged battery in the holder. c C 8 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.[...]

4-29 E 000705 q w e 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. 2) Check the tightening torque of other bolts and nuts. EMU01172 CLEANING COOLING-WATER PASSAGES Flushing device equipped model Perform this procedure [...]

4-30 E NOTE: 8 When flushing the engine with the boat in the water, tilting up the engine until it is completely out of the water will achieve better results. 8 Refer to cooling system flushing instructions in “TRANSPORTING AND STORING OUTBOARD MOTOR”. EMU00412 Checking Painted Surface of Motor Check the motor for scratches, nicks, or flaking p[...]

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EMU00414 Chapter 5 TROUBLE RECOVER Y 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.....[...]

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

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

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

5-4 E Trouble Possible Cause Remedy 13. Poor connections or damaged ignition wiring. 14. Failed ignition parts. 15. Specified engine oil not used. 16. Thermostat faulty or clogged. 17. Air vent screw closed. 18. Fuel pump damaged. 19. Fuel joint connection incorrect. 20. Heat range of spark plug incorrect. 21. Engine not responding properly to shif[...]

5-5 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 s[...]

5-6 E EMU00423 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[...]

5-7 E EMU01130 Emergency Starting Engine 1) Remove the top cowling. 2) If the engine is equipped with a start- in-gear protection cable, remove it 1 by pulling it out from the starter. 3) Remove the starter/flywheel cover by removing the 4 bolts. 4) Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in [...]

5-8 E 5) Insert the knotted end of the emer- gency starter rope into the notch in the flywheel rotor and wind the rope several turns clockwise. 6) Pull the rope slowly until resistance is felt. 7) Give a strong pull straight out to crank and start the engine. Repeat if necessary. 208082 EMU00434 ENGINE FAILS TO OPERATE EMU00442 Cold Engine Fails to[...]

5-9 E EMU00446 TREATMENT OF SUBMERGED MOTOR If the outboard motor is submerged, immediately take it a Yamaha dealer. Oth- erwise, 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. EMU00448 1) Thoroughly wash away[...]

EMU00450 Chapter 6 INDEX INDEX ........................................................6-1 1 2 3 4 5 6 E 67C-9-12-6 5/2/01 9:06 AM Page 1[...]

6-1 E EMU00451 INDEX A Adjusting idling speed .......................... 4-16 Adjusting trim angle ..............................3-17 B Basic boating rules ..................................1-7 Battery care...............................................4-8 Battery requirement ..............................1-14 Breaking in (running in) engine ......[...]

6-2 E Outboard motor serial number ..............1-1 Overheat warning ..................................2-15 Overheat warning lamp ........................2-12 P Periodic maintenance ..............................4-9 Power trim/tilt switch .....................2-9, 2-11 Power trim/tilt will not operate ...............5-5 Pre-operation checks ......[...]

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[...]

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

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[...]

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F30A/F40A Printed in Japan April 2001—0.7 × 1 ! 67C-28199-12 (F30AET,F40BMHD,F40BED,F40BET) (E) Printed on recycled paper OW 67C-9-12 01.5.2 9:00 AM y[W 1 (1,1)[...]

F30A/F40A paper LIT -18626-04-71 F30A F40A OWNER’S MANUAL U.S.A.Edition 67C-9-12 01.5.2 9:00 AM y[W 1 (2,1)[...]