Yamaha F4 manual

F4 O WNER’S MANU AL 68D-F8199-17 U .S.A.Edition LIT -18626-07-05 U68D17MC 06.2.9 15:41 Page 1[...]

EMU25060 ZMU01690 Read this owner ’ s manual carefully before operating your outboard motor. U68D17MC 06.2.9 15:41 Page 2[...]

Important manual information EMU31280 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains infor- mation needed for proper operation, mainte- nance and care. A thorough understanding of these simple instructions will help you ob- tain maximum enjoyment from your new Yamaha. If you have any question about the o[...]

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

Table of contents Lubrication (except oil injection models) ......................................... 37 Cleaning and anticorrosion measures ...................................... 38 Cleaning the outboard motor .......... 38 Checking painted surface of motor ............................................. 38 Periodic maintenance .................... [...]

1 General information EMU25170 Identification numbers record EMU25183 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 number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in [...]

General information 2 EMU25272 Star labels Your outboard motor is labeled with a Cali- fornia Air Resources Board (CARB) star la- bel. See below for a description of your particular label. EMU25280 One Star—Low Emission The one-star label identifies engines that meet the Air Resources Board’s 2001 ex- haust emission standards. Engines meeting t[...]

General information 3 these standards have 65% lower emissions than One Star-Low-Emission engines. EMU25362 Safety information ● Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation. ● Before operating the boat, read any own- er ’ s or operator ’[...]

General information 4 dles under the different boating conditions you may encounter. Operate within your limits, and the limits of your boat. Always operate at safe speeds, and keep a careful watch for obstacles and other traffic. ● Always watch carefully for swimmers dur- ing the engine operation. ● Stay away from swimming areas. ● When a sw[...]

General information 5 tion. ● Tighten the air-vent screw on the fuel tank cap. EMU25465 Caution labels EMU25482 Label CAUTION: ECM01201 Store the engine only as shown. Otherwise, engine damage could result from leaking oil. EMU25500 Basic boating rules (Rules of the road) Just as there are rules which apply when you are driving on streets and hig[...]

General information 6 cept when a collision will occur unless both vessels try to avoid each other. If that is the case, both vessels become “ Give-Way ” ves- sels. EMU25520 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 fol[...]

General information 7 other vessel can steer itself around you. EMU25530 Other special situations There are three other rules you should be aware of when driving your boat around oth- er vessels. Narrow channels and bends When navigating in narrow channels, you should keep to the right when it is safe and practical to do so. If the operator of a po[...]

General information 8 EMU25540 Fueling instructions W ARNING EWM00010 GASOLINE AND ITS VAPORS ARE HIGH- LY FLAMMABLE AND EXPLOSIVE! ● Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. ● Stop engine before refueling. ● Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat. ● Tak[...]

General information 9 dry rags. ● Do not overfill the fuel tank. ● Tighten the filler cap securely after re- fueling. ● If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention. ● If any gasoline spills onto your skin, im- mediately wash with soap and water. Change cl[...]

General information 10 EMU25742 Propeller selection The performance of your outboard motor will be critically affected by your choice of propel- ler, 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 fo[...]

11 Basic components EMU25797 Main components NO TE: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. F4 EMU25802 Fuel tank If your model was equipped with a portable fuel tank, its function is as follows. W ARNING EWM00020 The fuel tank supplied with this engine is 1 2 4 8 7 6 9 3 5 10 2 11 14 18 17 16 [...]

Basic components 12 its dedicated fuel reservoir and must not be used as a fuel storage container. Com- mercial users should conform to relevant licensing or approval authority regula- tions. EMU25821 Fuel tank If your model included a fuel tank, its parts and functions are as follows. EMU25830 Fuel joint This joint is used to connect the fuel line[...]

Basic components 13 EMU25901 Open The fuel cock has two open positions, one for selecting fuel flow from the built-in fuel tank, and one for an external tank. Fuel flows to the carburetor with the lever or knob in either open position. These are the normal running positions. EMU25911 Tiller handle To change direction, move the tiller handle to the [...]

Basic components 14 EMU25941 Throttle grip The throttle grip is on the tiller handle. Turn the grip counterclockwise to increase speed and clockwise to decrease speed. EMU25961 Throttle indicator The fuel consumption curve on the throttle indicator shows the relative amount of fuel consumed for each throttle position. Choose the setting that offers[...]

Basic components 15 EMU25990 Engine stop lanyard switch The lock plate must be attached to the en- gine 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, stopping ignition t[...]

Basic components 16 EMU26070 Manual starter handle To start the engine, first gently pull the han- dle out until resistance is felt. From that posi- tion, then pull the handle straight out quickly to crank the engine. EMU26122 Steering friction adjuster A friction device provides adjustable resis- tance to the steering mechanism, and can be set acc[...]

Basic components 17 EMU26382 Top cowling lock lever (pull up type) To remove the engine top cowling, pull up the lock lever(s) and lift off the cowling. When installing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling by moving the lever(s) down- ward. EMU26450 Carrying handle A carrying handle is provided on[...]

18 Operation EMU26901 Installation CAUTION: ECM00110 Incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat, or accessories such as transom ladders or depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if the motor is operated conti[...]

Operation 19 motor greatly affects the water resistance. If the mounting height is too high, cavitation tends to occur, thus reducing the propulsion; and if the propeller tips cut the air, the engine speed will rise abnormally and cause the en- gine to overheat. If the mounting height is too low, the water resistance will increase and thereby reduc[...]

Operation 20 board (if packed). For details, consult your Yamaha dealer. W ARNING EWM00650 Avoid using bolts, nuts or washers other than those contained in the engine pack- aging. If used, they must be of at least the same quality of material and strength and must be tightened securely. After tighten- ing, test run the engine and check their tightn[...]

Operation 21 EMU27130 Controls ● Check throttle, shift, and steering for prop- er operation before starting the engine. ● The controls should work smoothly, with- out binding or unusual free play. ● Look for loose or damaged connections. ● Check operation of the starter and stop switches when the outboard motor is in the water. EMU27140 Eng[...]

Operation 22 3. Securely close the cap after filling the tank. Wipe up any spilled fuel. NO TE: The upper fuel level mark is indicated on the built-in fuel tank. EMU27450 Operating engine EMU27472 Feeding fuel W ARNING EWM00420 ● Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions[...]

Operation 23 3. If you are using an external fuel tank, connect the fuel joints securely and squeeze the primer pump with the outlet end up until you feel it become firm (if equipped the fuel joint). EMU27490 Starting engine EMU30860 Manual start models (tiller control) 1. Place the gear shift lever in neutral. NO TE: The start-in-gear protection d[...]

Operation 24 lanyard where it could become entan- gled, preventing it from functioning. ● Avoid accidentally pulling the lanyard during normal operation. Loss of en- gine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward. 3. [...]

Operation 25 NO TE: ● When the engine is cold, it needs to be warmed up. For further information, see page 25. ● If the engine does not start on the first try, repeat the procedure. If the engine fails to start after 4 or 5 tries, see page 50. Also, if the engine is warm and fails to start, open the throttle halfway and try to start the en- gin[...]

Operation 26 EMU27764 Forward (tiller handle and remote control models) Tiller handle models 1. Place the throttle grip in the fully closed position. 2. Move the gear shift lever quickly and firmly from neutral to forward. Remote control models 1. Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firm[...]

Operation 27 until the engine comes to a complete stop. 2. After stopping the engine, tighten the air vent screw on the fuel tank cap and set the fuel cock lever or knob to the closed position, if equipped. 3. Disconnect the fuel line if you are using an external fuel tank. NO TE: If the outboard motor is equipped with an en- gine stop switch lanya[...]

Operation 28 EMU27872 Adjusting trim angle for manual tilt models There are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim an- gle. 1. Stop the engine. 2. Tilt the outboard motor up, and then re- move the trim rod from the clamp brack- et. 3. Reposition the rod in the desired hole. To raise the bow ( “ trim-out ” )[...]

Operation 29 the boat is up about 3 to 5 degrees. With the bow up, the boat may have a greater tenden- cy to steer to one side or the other. Compen- sate for this as you steer. The trim tab can also be adjusted to help offset this effect. When the bow of the boat is down, it is easier to accelerate from a standing start onto plane. Bow Up Too much [...]

Operation 30 W ARNING EWM00220 Be sure all people are clear of the out- board motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket. W ARNING EWM00230 Leaking fuel is a fire hazard. Tighten the air vent screw and place the fuel cock in the closed position if the outboard motor will be [...]

Operation 31 4. Close the fuel cock. 5. Tilt support bar equipped models: Hold the rear of the top cowling or the rear handle (if equipped) with one hand and tilt the outboard motor up fully until the tilt support bar automatically locks. 6. Tilt support knob equipped models: Hold the rear of the top cowling with one hand, fully tilt the outboard m[...]

Operation 32 3. If equipped with the tilt support knob: Pull the knob out, and then slowly tilt the outboard motor down. 4. If equipped with the tilt support lever: Slowly tilt the outboard motor down while pulling the tilt support lever up. 5. Loosen the steering friction adjuster by turning it counterclockwise, and adjust the steering friction ac[...]

Operation 33 EMU28101 Procedure 1. Place the gear shift lever in neutral and face the outboard motor forward. 2. Slightly tilt the outboard motor up until the tilt support bar automatically turns to the lock position to support the engine. 3. To lower the outboard motor to the nor- mal running position, first slightly tilt the outboard motor up. Th[...]

34 Maintenance EMU31480 Specifications NO TE: “ (AL) ” stated in the specification data below represents the numerical value for the alumi- num propeller installed. Likewise, “ (SUS) ” represents the value for stainless steel propeller installed and “ (PL) ” for plastic propeller installed. EMU28218 Dimension: Overall length: 717 mm (28[...]

Maintenance 35 Engine oil quantity (excluding oil filter): 0.5 L (0.53 US qt) (0.44 Imp.qt) Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: 100.0 cm 3 (3.38 US oz) (3.53 Imp.oz) Tightening torque for engine: Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) Engine oil drain bolt: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m) EMU28222 Transporting a[...]

Maintenance 36 NO TE: Place a towel or something similar under the outboard motor to protect it from damage. EMU28241 Storing outboard motor When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard mot[...]

Maintenance 37 4. Install the outboard motor on the test tank. 5. Fill the tank with fresh water to above the level of the anti-cavitation plate. CAUTION: ECM00300 Do not run the engine without supplying it with cooling water. Either the engine water pump will be damaged or the en- gine will be damaged from overheating. Before starting the engine, [...]

Maintenance 38 EMU28421 Cleaning and anticorrosion measures 1. Wash down the exterior of the outboard motor with fresh water and dry off com- pletely. 2. Spray the outboard motor exterior with “ Yamaha Silicone Protectant ” (Part No. LUB-SILCNE-13-00). 3. Wax the cowling with a non-abrasive wax such as “ Yamaha Silicone Wax ” (Part No. ACC-[...]

Maintenance 39 EMU28522 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating condi- tions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. NO TE: When operating in salt water, turbid or muddy water, the engine should b[...]

Maintenance 40 EMU28874 Maintenance chart (additional) Engine oil Inspection / change Spark plug(s) Cleaning / adjustment / replacement V alve clearance (OHC , OHV) Inspection / adjustment Item Actions Every 500 hours (2.5 year s) 1000 hours (5 year s) Exhaust guide, e xhaust manifold Inspection / replace- ment Item Actions Initial Every 10 hours ([...]

Maintenance 41 EMU28931 Greasing Yamaha marine grease (Water resistant grease) F4 EMU28952 Cleaning and adjusting spark plug W ARNING EWM00560 When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire. The spark plug is an important engine[...]

Maintenance 42 attempt to diagnose any problems yourself. Instead, take the outboard motor to a Yamaha dealer. You should periodically re- move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you shou[...]

Maintenance 43 Checkpoints ● Fuel system parts leakage ● Fuel line joint leakage ● Fuel line cracks or other damage ● Fuel connector leakage EMU28990 Checking fuel filter Check the fuel filter periodically. The fuel fil- ter is a one piece, disposable type. If foreign matter is found in the filter, replace it. For re- placement of the fuel [...]

Maintenance 44 is hot and should be handled with care to avoid burns. ● Be sure the outboard motor is securely fastened to the transom or a stable stand. CAUTION: ECM00970 ● Do not overfill the oil, and be sure the outboard motor is upright (not tilted) when checking and changing the en- gine oil. ● If the oil level is above the upper level m[...]

Maintenance 45 5. Start the engine and make sure that there are no oil leaks. 6. Turn off the engine and wait 3 minutes. Recheck the oil level using the dipstick to be sure the level falls between the up- per 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. NO TE: ● For d[...]

Maintenance 46 Checkpoints ● Check each of the propeller blades for wear, erosion from cavitation or ventila- tion, or other damage. ● Check the propeller shaft for damage. ● Check the splines / shear pin for wear or damage. ● Check for fish line tangled around the pro- peller shaft. ● Check the propeller shaft oil seal for dam- age. NO T[...]

Maintenance 47 could be damaged. ● Be sure to use a new cotter pin and bend the ends over securely. Otherwise the propeller could come off during op- eration and be lost. 1. Apply Yamaha marine grease or a cor- rosion resistant grease to the propeller shaft. 2. Install the spacer (if equipped), thrust washer, and propeller on the propeller shaft.[...]

Maintenance 48 pair of the lower unit seals. NO TE: For disposal of used oil, consult your Yamaha dealer. 5. With the outboard motor in a vertical po- sition, and using a flexible or pressur- ized filling device, inject the gear oil into the gear oil drain screw hole. 6. Put a new gasket on the oil level plug. When the oil begins to flow out of the[...]

Maintenance 49 from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes. CAUTION: ECM00720 Do not paint anodes, as this would render them ineffective. NO TE: Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replace- ment of internal anodes attached to [...]

50 Trouble Recovery EMU29424 Troubleshooting A problem in the fuel, compression, or igni- tion systems can cause poor starting, loss of power, or other problems. This section de- scribes basic checks and possible remedies, and covers all Yamaha outboard motors. Therefore some items may not apply to your model. If your outboard motor requires repair[...]

Trouble Recovery 51 Q. Is fuel system obstructed? A. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Have ignition parts failed? A. Have serviced by a Yamaha dealer. Q. Has warning system activ[...]

Trouble Recovery 52 A. Have serviced by a Yamaha dealer. Q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. Q. Is water pump or thermostat faulty? A. Have serviced by a Yamaha dealer. Q. Is there excess water in fuel filter cup? A. Drain filter cup. Engine power loss. Q. Is propeller damaged? A. Have prope[...]

Trouble Recovery 53 Q. Is fuel joint connection incorrect? A. Connect correctly. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec- ommended type. Q. Is high pressure fuel pump drive belt bro- ken? A. Have serviced by a Yamaha dealer. Q. Is engine not responding properly to shift lever position? A. Have service[...]

Trouble Recovery 54 could result in an accident. ● Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating the boat. ● Do not attach the lanyard to clothing that could tear loose. Do not route the cord where it could become entangled, preventing it from functioning. ● Avoid accidentally pul[...]

Trouble Recovery 55 tank. 6. Prepare the engine for starting. For fur- ther information, see page 23. Be sure the engine is in neutral and that the en- gine stop switch lanyard lock plate is at- tached to the engine stop switch. 7. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several tu[...]

Trouble Recovery 56 3. Drain the fuel from the carburetor, fuel filter, and fuel line. Drain the engine oil completely. 4. Fill the sump with the fresh engine oil. 5. Feed engine fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking the engine with the manual starter or emergency starter rope. 6. Take the outboard [...]

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

Consumer information 58[...]

Consumer information 59 EMU29830 YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY[...]

Consumer information 60[...]

Consumer information 61 EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA[...]

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