Yamaha F80B manual

F75B F80B F90B O WNER’S MANU AL U .S.A.Edition LIT -18626-05-09 67F-9-16 hyoshi 4/18/02 6:04 PM Page 1 (2,1)[...]

67F-9-16 hyoshi 4/18/02 6:04 PM Page 2 (1,1)[...]

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,[...]

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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 67F-9-16-1 3/29/02 8:57 AM Page 3[...]

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E 2 3 4 5 6 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 .....[...]

E 1-1 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[...]

1-2 E 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 control info[...]

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[...]

1-4 E 8 This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symp- toms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets. 8 Check throttle, shift, and steering for proper operation before st[...]

1-5 E 8 When a swimmer is in the water near you shift into neutral and shut off the engine. 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[...]

1-6 E EMU00014* IMPORT ANT LABELS WARNING LABELS 1 q F1002 WARNING 8 Be sure shift control is in neutral before starting engine. (except 2HP) 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. 6A1-83625-41 67F-9-16-1 3/29/02 [...]

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 will clear one another if you continue on your set course and speed. Crossing When two power driven vessels are crossing each other’s path close enough to run the risk of collision, the vessel which has the other on the starboard (right) side must keep out of the way of the other. If the other vessel is on your right, you must keep out of i[...]

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 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 " &[...]

1-11 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- l[...]

1-12 E 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[...]

1-13 EMU01769 ENGINE OIL Recommended engine oil: 4-stroke motor oil with a combination of corresponding SAE and API as shown in the chart. c C All 4-stroke engines are shipped from the factory without engine oil. E Engine oil quantity: See Chapter 4, “Specifications.” 001162 SAE API SE SF SG SH SJ 10W-30 10W-40 67F-9-16-1 3/29/02 8:57 AM Page 1[...]

1-14 E 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[...]

1-15 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- tained. Conversely, a larger[...]

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. 67F-9-16-1 3/29/02 8:57 AM Page 21[...]

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EMU00037 Chapter 2 BASIC COMPONENTS MAIN COMPONENTS ..............................2-1 OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-2 Remote control .....................................2-2 Trim tab .................................................2-6 Power trim/tilt switch ...........................2-7 Digital tacho[...]

w !2 !3 o i u y t q w e r !0 !1 2-1 E EMU01206 MAIN COMPONENTS 1 Top cowling 2 Cowling lock lever 3 Oil drain bolt 4 Anti-cavitation plate 5 Trim tab (Anode) 6 Propeller 7 Cooling water inlet 8 Clamp bracket 9 Tilt support lever 0 Flushing device q Power trim and tilt switch w Remote control box e Digital tachometer * May not be exactly as shown; a[...]

2-2 E EMU00039 OPERA TIONS OF CONTROLS AND OTHER FUNCTIONS EMU00096 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 lanyard switch 6 Power [...]

2-3 E N 701033* q w ON START OFF 701045 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[...]

E 2-4 EMU00934 Engine Stop Lanyard Switch The lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 should be attached to a secure place on the operator’s cloth- ing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping igni- tion to [...]

E 2-5 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[...]

2-6 E 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 2-7 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. Push- ing 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 [...]

2-8 EMU00136 Tachometer This meter shows the engine speed. E q t w r 001081 e y u 001085 001058 EMU01617 DIGITAL TACHOMETER This gauge contains the tachometer, trim meter, hour meter, low oil pressure warn- ing indicator, and the overheat warning indicator. 1 Tachometer 2 Trim meter 3 Hour meter 4 Low oil pressure warning indicator 5 Overheat warni[...]

2-9 E EMU01109 Trim Meter This meter shows the trim angle of your outboard motor. NOTE: 8 Memorize the trim angles that work best for your boat under different condi- tions. Adjust the trim angle to the desired setting by operating the power trim and tilt switch. 8 If the trim angle of your motor exceeds the trim operating range, the top seg- ment [...]

2-10 E 001060 q 001061 q EMU01110 Low Oil Pressure Warning Indicator If oil pressure drops too low, the warning indicator will start to blink. Refer to the section “LOW OIL PRESSURE WARNING” for details. 1 Low oil pressure warning indicator c C 8 Do not operate the engine without oil. Serious engine damage will occur. 8 The low oil pressure war[...]

2-11 E F1008A F1008B EMU00163 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. F1009 EMU00157 TILT SUPPORT LEVER To keep the outboa[...]

2-12 E EMU00169* W ARNING SYSTEM c C Do not continue to operate the engine if the warning device has activated. Consult your Yamaha dealer if the problem can- not be located and corrected. EMU01017 OVERHEAT WARNING This engine has an overheat warning device. If the engine temperature rises too high, the warning device will activate. ( 1 ); Included[...]

001097 EMU01018 LOW OIL PRESSURE WARNING If oil pressure drops too low, the warning device will activate. ( 1 ):Included (—):N/A If the warning system has been activated, stop the engine as soon as it is safe to do so. Check oil level and add oil as needed. If the oil level is correct, consult your Yamaha dealer. c C Do not continue to run the en[...]

EMU00174 Chapter 3 OPERA TION INSTALLATION ........................................3-1 Mounting the outboard motor ............3-2 Filling fuel ..............................................3-4 PRE-OPERATION CHECKS ......................3-5 Checking the engine oil level ..............3-6 BREAKING IN (RUNNING IN) ENGINE ..3-7 STARTING ENGINE .......[...]

E 3-1 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 pres[...]

E 3-2 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 pos[...]

E 3-3 EMU01299 Mounting Height To run your boat at optimum efficiency, the water-resistance (drag) of the boat and outboard motor must be made as lit- tle as possible. The mounting-height of the outboard motor greatly affects the water-resistance. If the mounting-height is too high, cavitation tends to occur, thus reducing the propulsion; and if th[...]

3-4 EMU00187* 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. EMU00189* 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 [...]

E 3-5 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[...]

E 3-6 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[...]

E 3-7 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 [...]

E 3-8 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 vapors are fl[...]

E 3-9 N 701015 ON START OFF 701045 EMU00247* PROCEDURE FOR REMOTE CONTROL MODEL 4) Place the remote control lever in the Neutral position. NOTE: The start-in-gear protection device pre- vents the engine from starting except when in Neutral. 5) Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then, instal[...]

E 3-10 ON START OFF 701022 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 [...]

E 3-11 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 low oil [...]

E 3-12 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 equipped) and move the remo[...]

E 3-13 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 the fuel joints are provided, discon- nect the fuel line from the motor after stopping the engine. 3) Tighten the air ven[...]

E 3-14 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 [...]

E 3-15 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 watch for any signs[...]

E 3-16 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 3-17 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”. Never[...]

E 3-18 EMU01029 PROCEDURE FOR TILTING UP Power trim/tilt model 1) Remove the fuel-line connection from the motor. (If the fuel connector is provided on the motor.) 2 )Push the power trim/tilt switch “UP” until the outboard has tilted up com- pletely. UP DN F1006* UP DN 701034* UP DN F1009 3) Turn the tilt-support lever toward engine bracket and[...]

E 3-19 EMU00303 PROCEDURE FOR TILTING DOWN Power trim/tilt model 1) Push the power trim/tilt switch “UP” until the engine is supported by the tilt rod. 2) Release the tilt-support lever. 3) Push the power trim/tilt switch “DN” (Down) to lower the engine to the desired position. EMU00316* CRUISING IN OTHER CONDITIONS CRUISING IN SALT WATER A[...]

EMU00317 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 .........................[...]

4-1 E EMU00322* SPECIFICA TIONS Model Unit F75TRB Item 25 (2.5, 18) 35 (3.5, 25) 27 (2.7, 20) 18 (1.8, 13) 8 Spark plug 8 Propeller nut 8 Engine oil drain bolt 8 Engine oil filter N•m(kgf•m,lb•ft) N•m(kgf•m,lb•ft) N•m(kgf•m,lb•ft) N•m(kgf•m,lb•ft) DIMENSIONS PERFORMANCE 8 Overall Length 8 Overall Width 8 Overall Height L/X 8[...]

4-2 E F80TRB F90TRB — 4-stroke, DOHC, L4 1,596 (97.39) 79.0 × 81.4 (3.11 × 3.20) CDI system LFR5A-11 1.1 (0.043) Remote control Electric start 0.17 ~ 0.23 (0.007 ~ 0.009) 0.31 ~ 0.37 (0.012 ~ 0.015) 380 502 124 12-20 Prime start 25 (2.5, 18) 35 (3.5, 25) 27 (2.7, 20) 18 (1.8, 13) 817 (32.2) 479 (18.9) 1,582 (62.3) / 1,710 (67.3) 536 (21.1 ) / 6[...]

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 clearance[...]

E 4-4 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[...]

E 4-5 605014 903021* q 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 to[...]

E 4-6 NOTE: A flushing attachment is available from a Yamaha dealer. 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 PL[...]

E 4-7 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 4-8 EMU00913 PERIODIC MAINTENANCE w Be sure to turn off the engine when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other quali- fied mechanic. Maintenance, replacement, or repair of the emission control devices and systems may be performed[...]

E 4-9 Spark plug(s) Cleaning/Adjustment/ ●● 4-11 Replacement Greasing points Greasing ● 4-10 Gear oil Change ●● 4-25 Fuel system Inspection 1 4-13 Fuel filter Inspection/Replacement ●● 4-14 Fuel tank*1 Cleaning ● — Idling speed Inspection/Adjustment ●● 4-16 Anode(s) Inspection/Replacement 1 4-26 Outboard motor exterior Inspect[...]

E 4-10 EMU00366 GREASING Yamaha marine grease (Water resistant grease) F1017 67F-9-16-4 11/3/02 1:50 PM Page 11[...]

E 4-11 EMU01035 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 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 adjusted[...]

E 4-13 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. Checkin[...]

E 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. Keep away fr[...]

4-15 E 000137 000138 q e w r t EMU01577 NOTE: If any water is in the fuel, the float 5 will rise. If so, remove the cup and drain the water. 1) Remove the nut holding the fuel filter assembly if so equipped. 2) Unscrew the filter cup 1 , catching any spilled fuel in a rag. 3) Remove the filter element 2 , and wash it in solvent. Allow it to dry. In[...]

4-16 E 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 used. A dia[...]

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

4-19 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 F1025E t F1043 r e w q t w EMU01330 REPLACING FUSE If a fuse has blown, remove the electrical cover, open the fuse holder and remove the fuse with a fuse puller. Replace it with a spare one of proper amperage. w Be sure to use the specified fuse. An incorrect fuse or a piece of wire may allow excessive current flow. This could cause electric[...]

4-21 E 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 LEAKAGE Start the engine and check t[...]

4-22 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. [...]

4-23 E EMU00388* CHECKING PROPELLER 1) Remove the 5 screws and the cover. 2) Remove the spark plug caps from the spark plugs. 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 s[...]

4-24 E EMU00976 Removing the Propeller 1) Straighten the cotter-pin 1 and pull it out using a pair of pliers. 2) Remove the propeller nut 2 , washer 3 and spacer 4 . 3) Remove the propeller 5 and thrust washer 6 . EMU00397 Installing the Propeller c C 8 Be sure to install the thrust washer before installing propeller, otherwise, lower case and prop[...]

4-25 E 601015 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 falls. 1[...]

4-26 E 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: Refer to “SPECIFICATIONS,” page 4-1. EMU00831* INSPECTING AND REPLACING ANODE(S) Yamaha outboard motor is protected from corrosion by a sacrificial anode(s). Check the an[...]

4-27 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[...]

4-28 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[...]

4-29 E EMU01279 Connecting the Battery w Mount the battery holder securely in a dry, well-ventilated, vibration-free loca- tion in the boat. Install a fully charged battery in the holder. c C 8 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. [...]

E 4-30 EMU00408* CHECKING BOLTS AND NUTS 1) Check that bolts securing the engine and the nut securing the flywheel are tightened with their specified tighten- ing torque. 2) Check the tightening torque of other bolts and nuts. EMU01172 CLEANING COOLING-WATER PASSAGES Flushing device equipped model Perform this procedure right after opera- tion for [...]

4-31 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”. EMU00409 MOTOR EXTERIOR EMU00410 Cleaning the Outboard Motor After use, wash the exterior of [...]

4-32 E 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 paints[...]

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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 ......[...]

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

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

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

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

5-5 EMU00416 TEMPORARY ACTION IN EMERGENCY EMU01492 IMPACT DAMAGE w The outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the out- board motor unsafe to operate. If the outboard motor hits any object in the water, follow the procedure below. 1) Stop the engine immediately. 2) Inspect the control[...]

5-6 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 EMU00429* Emergency Starting Engine 1) Remove the top cowling. F1008A F1008B 2) Remove the two bolts holding the fly- wheel cover. 3) Lift up the rear of flywheel cover and pull it out forward. F1033 4) Prepare the engine for starting. See “STARTING ENGINE” for procedures. Be sure the engine is in Neutral and that the lock plate is attach[...]

5-8 E EMU00435* ENGINE FAILS TO OPERATE In the unlikely event of an ignition control system malfunction, the engine speed may become erratic or the engine may stop. In such a case, follow the procedure below. 1) Remove the electric cover 1 . 2) Disconnect the connection of the yel- low cord 2 (emergency circuit) to return to the nearest port. w Whe[...]

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 67F-9-16-6 3/29/02 9:03 AM Page 1[...]

6-1 E EMU00451 INDEX A Adjusting idling speed ..........................4-16 Adjusting trim angle ..............................3-15 B Basic boating rules ..................................1-7 Battery care...............................................4-7 Battery requirement ..............................1-14 Breaking in (running in) engine .......[...]

6-2 E Pre-operation checks ...............................3-5 Propeller selection .................................1-14 R Remote control .........................................2-2 Remote control lever ...............................2-2 Replacement parts ...................................4-8 Replacing fuse ........................................[...]

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 tim[...]

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

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

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

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Printed in Japan March 2002-0.2 × 1 ! 67F-28199-16 (F75AET, F80AET, F90AET) (E) Printed on recycled paper OW N 67F-9-16 hyoshi 4/18/02 6:04 PM Page 1 (1,1)[...]

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 ANTY DEP ARTMENT Warranty card 2/27/02 11:47 AM Page 2[...]