F40 Owner's Manual - Yamaha - Motorcycles, … manual information EMU31280 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains infor-mation

F40

OWNER’S MANUAL

67C-28199-18

U.S.A.EditionLIT-18626-07-10

67C-9-18-Hyoshi 06.3.3 10:15 AM ページ 1

EMU25060

ZMU01690

Read this owner’s manual carefully before operating your outboard motor.

67C-9-18-Hyoshi 06.3.3 10:15 AM ページ 2

Important manual information

EMU31280

To the owner

Thank you for choosing a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understandingof these simple instructions will help you ob-tain maximum enjoyment from your newYamaha. If you have any question about theoperation or maintenance of your outboardmotor, please consult a Yamaha dealer.In this Owner’s Manual particularly importantinformation is distinguished in the followingways.

The Safety Alert Symbol meansATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

WARNING

EWM00780

Failure to follow WARNING instructionscould result in severe injury or death tothe machine operator, a bystander, or aperson inspecting or repairing the out-

board motor.

CAUTION:

ECM00700

A CAUTION indicates special precautionsthat must be taken to avoid damage to the

outboard motor.

NOTE:

A NOTE provides key information to make

procedures easier or clearer.

Yamaha continually seeks advancements inproduct design and quality. Therefore, whilethis manual contains the most current prod-uct information available at the time of print-ing, there may be minor discrepanciesbetween your machine and this manual. Ifthere is any question concerning this manu-

al, please consult your Yamaha dealer.

NOTE:

The F40MH, F40ER, F40TR and the stan-dard accessories are used as a base for theexplanations and illustrations in this manual.Therefore some items may not apply to ev-

ery model.

EMU25110

F40OWNER’S MANUAL

©2006 by Yamaha Motor Corporation, USA1st edition, April 2006

All rights reserved.Any reprinting or unauthorized usewithout the written permission ofYamaha Motor Corporation, USA

is expressly prohibited.Printed in Japan

P/N LIT-18626-07-10

Table of contents

General information .......................... 1

Identification numbers record.......... 1

Outboard motor serial number .......... 1Key number....................................... 1

Emission control information ........... 1

North American models..................... 1Star labels ......................................... 2

Safety information ........................... 3Important labels............................... 4

Warning labels .................................. 4Caution labels ................................... 5

Basic boating rules (Rules of the road) .............................................. 5

Steering and sailing rules and sound signals.................................. 5

Rules when encountering vessels .... 6Other special situations..................... 7

Fueling instructions ......................... 9

Gasoline.......................................... 10Engine oil ........................................ 10

Battery requirement....................... 11

Battery specifications ...................... 11Without a rectifier or Rectifier

Regulator ...................................... 11

Propeller selection......................... 11Start-in-gear protection ................. 12

Basic components .......................... 13

Main components.......................... 13

Fuel tank ......................................... 13Fuel joint ......................................... 14Fuel gauge ...................................... 14Fuel tank cap .................................. 14Air vent screw ................................. 14Remote control................................ 14Remote control lever ....................... 14Neutral interlock trigger ................... 15Neutral throttle lever........................ 15Tiller handle .................................... 15Gear shift lever................................ 15Throttle grip ..................................... 16Throttle indicator ............................. 16Throttle friction adjuster................... 16Engine stop lanyard switch ............. 17Engine stop button .......................... 17Manual starter handle ..................... 18

Main switch .....................................18Steering friction adjuster .................18Steering friction adjuster .................19Power trim and tilt switch on remote

control or tiller handle....................19Power trim and tilt switch on bottom

engine cowling ..............................20Trim tab with anode.........................20Tilt lock mechanism.........................21Tilt support knob..............................21Top cowling lock lever(s)

(turn type)......................................21Flushing device ...............................21Warning indicator ............................22Tachometer .....................................22Digital tachometer ...........................22Low oil pressure warning

indicator ........................................23Low oil pressure warning

indicator ........................................23Overheat warning indicator .............23Overheat warning indicator (digital

type) ..............................................24Trim meter .......................................24Trim meter (digital type) ..................24Hour meter (digital type)..................24

Warning system ............................ 25

Overheat warning............................25Low oil pressure warning ................26

Operation ......................................... 27

Installation..................................... 27

Mounting the outboard motor ..........27

Breaking in engine ........................ 28

Procedure for 4-stroke models........28

Preoperation checks ..................... 28

Fuel .................................................28Controls...........................................29Engine .............................................29Checking the engine oil level ..........29

Filling fuel...................................... 29

Ring Free Fuel Additive...................30

Operating engine .......................... 30

Feeding fuel (portable tank) ............30Starting engine ................................31

Warming up engine....................... 35

Table of contents

Manual start and electric start models .......................................... 35

Shifting .......................................... 35

Forward (tiller handle and remote control models) ............................. 35

Reverse (automatic reverse lock and power trim and tilt models)..... 36

Reverse (manual tilt and hydro tilt models) ......................................... 37

Stopping engine ............................ 38

Procedure ....................................... 38

Trimming outboard motor.............. 39

Adjusting trim angle ........................ 40Adjusting trim angle for hydro tilt

models .......................................... 41Adjusting boat trim .......................... 41

Tilting up and down ....................... 42

Procedure for tilting up (hydro tilt models) ......................................... 42

Procedure for tilting up (power trim and tilt models / power tilt models) ......................................... 43

Procedure for tilting down (manual and hydro tilt models) ................... 45

Procedure for tilting down (power trim and tilt models / power tilt models) ......................................... 45

Cruising in shallow water .............. 46

Hydro tilt models ............................. 46Power trim and tilt models / power

tilt models...................................... 47

Cruising in other conditions........... 48

Maintenance..................................... 49

Specifications ................................ 49Transporting and storing outboard

motor ........................................... 50

Storing outboard motor ................... 50Procedure ....................................... 51Lubrication ...................................... 52Cleaning and anticorrosion

measures ...................................... 52Battery care..................................... 52Flushing power unit ......................... 53Cleaning the outboard motor .......... 54Checking painted surface of

motor.............................................54

Periodic maintenance ................... 54

Replacement parts ..........................54Maintenance chart...........................56Maintenance chart (additional) ........57Greasing..........................................58Cleaning and adjusting spark

plug ...............................................58Checking fuel system ......................59Checking fuel filter...........................60Inspecting idling speed....................60Changing engine oil ........................60Checking wiring and connectors .....62Exhaust leakage..............................62Water leakage .................................62Engine oil leakage...........................62Checking power trim and tilt /

power tilt system ...........................62Checking propeller ..........................63Removing the propeller ...................64Installing the Propeller.....................64Changing gear oil ............................65Cleaning fuel tank ...........................66Inspecting and replacing

anode(s)........................................66Checking battery (for electric start

models) .........................................67Connecting the battery ....................68Disconnecting the battery................68Checking top cowling ......................68Coating the boat bottom..................68

Trouble Recovery............................ 70

Troubleshooting ............................ 70Temporary action in emergency ... 73

Impact damage ...............................73Replacing fuse ................................73Power trim and tilt / power tilt will

not operate....................................74Starter will not operate ....................74Emergency starting engine .............75

Treatment of submerged motor .... 76

Procedure........................................76

Consumer information ................... 77

Important warranty information for U.S.A. and Canada ..................... 77

Table of contents

YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY ................................ 79

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA ...................... 81

1

General information

EMU25170

Identification numbers record

EMU25183

Outboard motor serial number

The outboard motor serial number isstamped on the label attached to the portside of the clamp bracket.Record your outboard motor serial number inthe spaces provided to assist you in orderingspare parts from your Yamaha dealer or forreference in case your outboard motor is sto-len.

EMU25190

Key number

If a main key switch is equipped with the mo-tor, the key identification number is stampedon your key as shown in the illustration.Record this number in the space provided forreference in case you need a new key.

EMU25221

Emission control information

EMU25230

North American models

This engine conforms to U.S. EnvironmentalProtection Agency (EPA) regulations for ma-rine SI engines. See the label affixed to yourengine for details.

EMU25242

Approval label of emission control certif-icate

This label is attached to the bottom cowling.New Technology; (4-stroke/HPDI) EM

1. Outboard motor serial number location

1

ZMU04028

1. Key number

1. Approval label location

ZMU04975

1

General information

2

EMU25262

Manufactured date label

This label is attached to the clamp bracket orthe swivel bracket.

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 thatmeet the Air Resources Board’s 2001 ex-haust emission standards. Engines meetingthese standards have 75% lower emissionsthan conventional carbureted two-stroke en-gines. These engines are equivalent to theU.S. EPA’s 2006 standards for marine en-gines.

EMU25290

Two Stars—Very Low Emission

The two-star label identifies engines thatmeet the Air Resources Board’s 2004 ex-haust emission standards. Engines meetingthese standards have 20% lower emissionsthan One Star-Low-Emission engines.

1. Manufactured date label location

ZMU05159

1

ZMU04029

1. Star labels location

1

ZMU04977

ZMU01702

General information

3

EMU25300

Three Stars—Ultra Low Emission

The three-star label identifies engines thatmeet the Air Resources Board’s 2008 ex-haust emission standards. Engines meetingthese standards have 65% lower emissionsthan One Star-Low-Emission engines.

EMU25362

Safety information

�

Before mounting or operating the outboardmotor, read this entire manual. Reading itshould give you an understanding of themotor and its operation.

�

Before operating the boat, read any own-er’s or operator’s manuals supplied with itand all labels. Be sure you understandeach item before operating.

�

Do not overpower the boat with this out-board motor. Overpowering the boat couldresult in loss of control. The rated power of

the outboard should be equal to or lessthan the rated horsepower capacity of theboat. If the rated horsepower capacity ofthe boat is unknown, consult the dealer orboat manufacturer.

�

Do not modify the outboard. Modificationscould make the motor unfit or unsafe touse.

�

Incorrect propeller selection and incorrectuse may not only cause engine damage,but also adversely affect fuel consumption.Consult your dealer for correct use.

�

Never operate after drinking alcohol or tak-ing drugs. About 50% of all boating fatali-ties involve intoxication.

�

Have an approved personal flotation de-vice (PFD) on board for every occupant. Itis a good idea to wear a PFD wheneverboating. At a minimum, children and non-swimmers should always wear PFDs, andeveryone should wear PFDs when thereare potentially hazardous boating condi-tions.

�

Gasoline is highly flammable, and its va-pors are flammable and explosive. Handleand store gasoline carefully. Make surethere are no gas fumes or leaking fuel be-fore starting the engine.

�

This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which may cause brain dam-age or death when inhaled. Symptoms in-clude nausea, dizziness, and drowsiness.Keep cockpit and cabin areas well ventilat-ed. Avoid blocking exhaust outlets.

�

Check throttle, shift, and steering for prop-er operation before starting the engine.

�

Attach the engine stop switch lanyard cordto a secure place on your clothing, or yourarm or leg while operating. If you acciden-tally leave the helm, the cord will pull from

ZMU01703

ZMU01704

General information

4

the switch, stopping the engine.

�

Know the marine laws and regulationswhere you will be boating—and obeythem. For basic boating rules, see “Rulesof the road” on page 5.

�

Stay informed about the weather. Checkweather forecasts before boating. Avoidboating in hazardous weather.

�

Tell someone where you are going: leavea Float Plan with a responsible person. Besure to cancel the Float Plan when you re-turn.

�

Use common sense and good judgmentwhen boating. Know your abilities, and besure you understand how your boat han-dles under the different boating conditionsyou may encounter. Operate within yourlimits, and the limits of your boat. Alwaysoperate at safe speeds, and keep a carefulwatch for obstacles and other traffic.

�

Always watch carefully for swimmers dur-ing the engine operation.

�

Stay away from swimming areas.

�

When a swimmer is in the water near youshift into neutral and shut off the engine.

�

Do not illegally discard empty containersused to replace or replenish oil. For thecorrect processing of empty containers,consult the dealer where you purchasedthe oil.

�

When replacing oils used to lubricate theproduct (engine or gear oil), be sure towipe away any spilt oil. Never pour oil with-out using a funnel or similar device. If nec-essary, verify the necessary replacementprocedure with the dealer.

�

Never illegally discard (dump) the product.Yamaha recommends consulting the deal-er on discarding the product.

Be informed about boating safety. Additionalpublications and information can be obtained

from many organizations, including the fol-lowing:

United States Coast Guard

Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Af-fairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647

National Marine Manufacturers Associa-tion (NMMA)

401 N. Michigan Ave. Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave. Chicago, Il 60601

EMU25382

Important labels

EMU25395

Warning labels

ZMU04033

ZMU05275

General information

5

EMU25401

Label

WARNING

EWM01260

�

Be sure shift control is in neutral beforestarting engine. (except 2HP)

�

Do not touch or remove electrical partswhen starting or during operation.

�

Keep hands, hair, and clothes awayfrom flywheel and other rotating parts

while engine is running.

EMU25431

Label

WARNING

EWM01300

�

This engine is equipped with a neutralstarting device.

�

The engine will not start unless the shift

control is in neutral position.

EMU25465

Caution labels

EMU25473

Label

CAUTION:

ECM01191

Transport and store the engine only asshown. Otherwise, engine damage could

result from leaking oil.

EMU25500

Basic boating rules (Rules of the road)

Just as there are rules which apply when youare driving on streets and high ways, thereare waterway rules which apply when youare driving your boat. These rules are usedinternationally, and are also enforced by theUnited States Coast Guard and local agen-cies. You should be aware of these rules,and follow them whenever you encounteranother vessel on the water.Several sets of rules prevail according togeographic location, but are all basically thesame as the International Rules of the Road.The rules presented here in your Owner’sManual are condensed, and have been pro-vided for your convenience only. Consultyour local U.S. Coast Guard Auxiliary or De-partment of Motor Vehicles for a completeset of rules governing the waters in whichyou will be using your boat.

EMU25510

Steering and sailing rules and sound signals

Whenever two vessels on the water meetone another, one vessel has the right-of-way; it is called the “stand-on” vessel. Thevessel which does not have the right-of-wayis called the “give-way” or “burdened” vessel.These rules determine which vessel has theright-of-way, and what each vessel shoulddo.

ZMU04101

ZMU05276

General information

6

Stand-on vessel

The vessel with the right-of-way has the dutyto continue its course and speed, except toavoid an immediate collision. When youmaintain your direction and speed, the othervessel will be able to determine how best toavoid you.

Give-way vessel

The vessel which does not have the right-of-way has the duty to take positive and timelyaction to stay out of the way of the Stand-Onvessel. Normally, you should not cross infront of the vessel with the right-of-way. Youshould slow down or change directions brief-ly and pass behind the other vessel. Youshould always move in such a way that theoperator of the other vessel can see whatyou are doing.

“The general prudential rule”

This rule is called Rule 2 in the InternationalRules and says,“In obeying and construing these rules dueregard shall be had to all dangers of naviga-tion and collision, and to any special circum-stances, which may render a departure fromthe above rules necessary in order to avoidimmediate danger.”In other words, follow the standard rules ex-cept when a collision will occur unless bothvessels try to avoid each other. If that is thecase, both vessels become “Give-Way” ves-sels.

EMU25520

Rules when encountering vessels

There are three main situations which youmay encounter with other vessels whichcould lead to a collision unless the SteeringRules are followed:

Meeting:

(you are approaching another ves-sel head-on)

Crossing:

(you are traveling across the oth-er vessel’s path)

Overtaking:

(you are passing or beingpassed by another vessel)In the following illustration, your boat is in thecenter. You should give the right-of-way toany vessels shown in white area (you are theGive-Way vessel). Any vessels in the shad-ed area must yield to you (they are the Give-Way vessels). Both you and the meetingvessel must alter course to avoid each other.

Meeting

If you are meeting another power vesselhead on, and are close enough to run the riskof collision, neither of you has the right-of-way! Both of you should alter course to avoidan accident. You should keep the other ves-sel on your port (left) side. This rule doesn’tapply if both of you will clear one another ifyou continue on your set course and speed.

Crossing

When two power driven vessels are crossingeach other’s path close enough to run the

General information

7

risk of collision, the vessel which has the oth-er on the starboard (right) side must keep outof the way of the other. If the other vessel ison your right, you must keep out of its way;you are the Give-Way vessel. If the othervessel is on your port (left) side, rememberthat you should maintain course and direc-tion, provided the other vessel gives you theright-of-way as it should.

Overtaking

If you are passing another vessel, you arethe “Give-Way” vessel. This means that theother vessel is expected to maintain itscourse and speed. You must stay out of itsway until you are clear of it. Likewise, if an-other vessel is passing you, you shouldmaintain your speed and direction so that theother vessel can steer itself around you.

EMU25530

Other special situations

There are three other rules you should beaware of when driving your boat around oth-er vessels.

Narrow channels and bends

When navigating in narrow channels, youshould keep to the right when it is safe andpractical to do so. If the operator of a power-driven vessel is preparing to go around abend that may obstruct the view of other wa-ter vessels, the operator should sound a pro-longed blast on the whistle (4 to 6 seconds).

If another vessel is around the bend, it tooshould sound the whistle. Even if no reply isheard, however, the vessel should still pro-ceed around the bend with caution. If younavigate such waters with your boat, you willneed to carry a portable air horn, availablefrom local marine supply stores.

Fishing vessel right-of-way

All vessels which are fishing with nets, linesor trawls are considered to be “fishing ves-sels” under the International Rules. Vesselswith trolling lines are not considered fishingvessels. Fishing vessels have the right-of-way regardless of position. Fishing vesselscannot, however, impede the passage ofother vessels in narrow channels.

Sailing vessel right-of-way

Sailing vessels should normally be given theright-of-way. The exceptions to this are:1. When the sailing vessel is overtaking

the power-driven vessel, the power-driv-en vessel has the right-of-way.

2. Sailing vessels should keep clear of anyfishing vessel.

3. In a narrow channel, a sailing vesselshould not hamper the safe passage ofa power-driven vessel which can navi-gate only in such a channel.

Reading buoys and other markers

The waters of the United states are markedfor safe navigation by the lateral system ofbuoyage. Simply put, buoys and markershave an arrangement of shapes, colors,numbers and lights to show which side of thebuoy a boater should pass on when navigat-ing in a particular direction. The markings onthese buoys are oriented from the perspec-tive of being entered from seaward (the boat-er is going towards the port). This means thatred buoys are passed on the starboard(right) side when proceeding from open wa-

General information

8

ter into port, and black buoys are to port (left)side. When navigating out of port, your posi-tion with respect to the buoys should be re-versed; red buoys should be to port andblack buoys to starboard.Many bodies of water used by boaters areentirely within the boundaries of a particularstate. The Uniform State Waterway MarkingSystem has been devised for these waters.This system uses buoys and signs with dis-tinctive shapes and colors to show regulato-ry or advisory information. These markersare white with black letters and orangeboarders. They signify speed zones, restrict-ed areas, danger areas, and general infor-mation.Remember, markings may vary by geo-graphic location. Always consult local boat-ing authorities before driving your boat inunfamiliar waters.

General information

9

EMU25540

Fueling instructions

WARNING

EWM00010

GASOLINE AND ITS VAPORS ARE HIGH-LY FLAMMABLE AND EXPLOSIVE!

�

Do not smoke when refueling, and keep

away from sparks, flames, or othersources of ignition.

�

Stop engine before refueling.

�

Refuel in a well-ventilated area. Refuelportable fuel tanks off the boat.

�

Take care not to spill gasoline. If gaso-line spills, wipe it up immediately with

ZMU01708

General information

10

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 getgasoline in your eyes, get immediatemedical attention.

�

If any gasoline spills onto your skin, im-mediately wash with soap and water.Change clothing if gasoline spills on it.

�

Touch the fuel nozzle to the filler open-ing or funnel to help prevent electro-

static sparks.

CAUTION:

ECM00010

Use only new clean gasoline which hasbeen stored in clean containers and is notcontaminated with water or foreign mat-

ter.

EMU25570

Gasoline

If knocking or pinging occurs, use a differentbrand of gasoline or premium unleaded fuel.

Gasohol

There are two types of gasohol: gasohol con-taining ethanol and that containing metha-nol. Gasohol containing ethanol can be usedif ethanol content does not exceed 10% andthe fuel meets minimum octane ratings.Yamaha does not recommended gasoholcontaining methanol because it can causefuel system damage or engine performanceproblems.

EMU31440

Engine oil

NOTE:

If the recommended engine oil grades arenot available, select an alternative from thefollowing chart according to the average

temperatures in your area.

CAUTION:

ECM01050

All 4-stroke engines are shipped from the

factory without engine oil.

Recommended gasoline:Regular unleaded gasoline with a min-imum octane rating of 86 (Pump Oc-tane Number) = (R+M)/2

Recommended engine oil:YAMALUBE 4-M FC-W oil or 4-stroke motor oil with a combination of the fol-lowing SAE and API oil classifications

Engine oil type SAE:10W-30 or 10W-40

Engine oil grade API:SE, SF, SG, SH, SJ, SL

Engine oil quantity (excluding oil filter):2.0 L (2.11 US qt) (1.76 Imp.qt)

General information

11

EMU25690

Battery requirement

CAUTION:

ECM01060

Do not use a battery that does not meetthe specified capacity. If a battery whichdoes not meet specifications is used, theelectric system could perform poorly orbe overloaded, causing electric system

damage.

For electric start models, choose a batterywhich meets the following specifications.

EMU25711

Battery specifications

EMU25730

Without a rectifier or Rectifier Regulator

CAUTION:

ECM01090

A battery cannot be connected to modelsthat do not have a rectifier or Rectifier

Regulator.

If you wish to use a battery with the modelswithout a rectifier or Rectifier Regulator, in-stall an optional Rectifier Regulator.Using a maintenance-free battery with theabove models can shorten the life of the bat-tery significantly.Install an optional Rectifier Regulator or useaccessories rated to withstand 18 volts orhigher with the above models. Consult yourYamaha dealer for details on installing anoptional Rectifier Regulator.

EMU25742

Propeller selection

The performance of your outboard motor willbe critically affected by your choice of propel-ler, as an incorrect choice could adverselyaffect performance and could also seriouslydamage the motor. Engine speed dependson the propeller size and boat load. If enginespeed is too high or too low for good engineperformance, this will have an adverse effecton the engine.Yamaha outboard motors are fitted with pro-pellers chosen to perform well over a rangeof applications, but there may be uses wherea propeller with a different pitch would bemore appropriate. For a greater operatingload, a smaller-pitch propeller is more suit-able as it enables the correct engine speedto be maintained. Conversely, a larger-pitchpropeller is more suitable for a smaller oper-ating load.Yamaha dealers stock a range of propellers,and can advise you and install a propeller onyour outboard that is best suited to your ap-plication.

Minimum cold cranking amps (CCA/SAE):

F40TR 380.0 AMinimum marine cranking amps (MCA/ABYC):

F40TR 502.0 AMinimum reserve capacity (RC/SAE):

F40TR 124 minutes

ZMU01710

General information

12

NOTE:

Select a propeller which will allow the engineto reach the middle or upper half of the oper-ating range at full throttle with the maximumboat load. If operating conditions such aslight boat loads then allow the engine r/min torise above the maximum recommendedrange, reduce the throttle setting to maintain

the engine in the proper operating range.

For instructions on propeller removal and in-stallation, see page 63.

EMU25770

Start-in-gear protection

Yamaha outboard motors or Yamaha-ap-proved remote control units are equippedwith start-in-gear protection device(s). Thisfeature permits the engine to be started onlywhen it is in neutral. Always select neutralbefore starting the engine.

1. Propeller diameter in inches2. Propeller pitch in inches3. Type of propeller (propeller mark)

ZMU04604

-x1 2 3

13

Basic components

EMU25799

Main componentsNOTE:

* May not be exactly as shown; also may not be included as standard equipment on all mod-

els.

F40

EMU25802

Fuel tank

If your model was equipped with a portablefuel tank, its function is as follows.

WARNING

EWM00020

The fuel tank supplied with this engine is

13

1

2

3

45

9

8

7

6

16 17 18

1315

14

1011

12

19 20

ZMU05026

1. Top cowling2. Top cowling lock lever3. Drain screw4. Anti-cavitation plate5. Trim tab (anode)6. Propeller*7. Cooling water inlet8. Clamp bracket9. Power trim and tilt switch*10. Manual starter handle*11. Warning indicator(s)*12. Steering friction adjuster*13. Tilt support knob14. Flushing device

15. Tiller handle*16. Fuel tank17. Tachometer*18. Trim meter*19. Digital tachometer*20. Remote control box (side mount type)*

Basic components

14

its dedicated fuel reservoir and must notbe used as a fuel storage container. Com-mercial users should conform to relevantlicensing or approval authority regula-

tions.

EMU25830

Fuel joint

This joint is used to connect the fuel line.

EMU25841

Fuel gauge

This gauge is located on either the fuel tankcap or on the fuel joint base. It shows the ap-proximate amount of fuel remaining in thetank.

EMU25850

Fuel tank cap

This cap seals the fuel tank. When removed,the tank can be filled with fuel. To remove thecap, turn it counterclockwise.

EMU25860

Air vent screw

This screw is on the fuel tank cap. To loosenthe screw, turn it counterclockwise.

EMU26180

Remote control

The remote control lever actuates both theshifter and the throttle. The electrical switch-

es are mounted on the remote control box.

EMU26190

Remote control lever

Moving the lever forward from the neutral po-sition engages forward gear. Pulling the le-ver back from neutral engages reverse. Theengine will continue to run at idle until the le-ver is moved about 35° (a detent can be felt).Moving the lever farther opens the throttle,and the engine will begin to accelerate.

1. Fuel joint2. Fuel gauge3. Fuel tank cap4. Air vent screw

1. Power trim and tilt switch2. Remote control lever3. Neutral interlock trigger4. Neutral throttle lever5. Main switch / choke switch6. Engine stop lanyard switch7. Throttle friction adjuster

1. Neutral “ ”

2. Forward “ ”

3. Reverse “ ”

Basic components

15

EMU26201

Neutral interlock trigger

To shift out of neutral, first pull the neutral in-terlock trigger up.

EMU26211

Neutral throttle lever

To open the throttle without shifting into ei-ther forward or reverse, put the remote con-trol lever in the neutral position and lift theneutral throttle lever.

NOTE:

The neutral throttle lever will operate onlywhen the remote control lever is in neutral.The remote control lever will operate onlywhen the neutral throttle lever is in the closed

position.

EMU25911

Tiller handle

To change direction, move the tiller handle tothe left or right as necessary.

EMU25922

Gear shift lever

Pulling the gear shift lever towards you putsthe engine in forward gear so that the boatmoves ahead. Pushing the lever away fromyou puts the engine in reverse gear so thatthe boat moves astern.

4. Shift5. Fully closed6. Throttle7. Fully open

1. Neutral interlock trigger

1. Fully open2. Fully closed

Basic components

16

EMU25941

Throttle grip

The throttle grip is on the tiller handle. Turnthe grip counterclockwise to increase speedand clockwise to decrease speed.

EMU25961

Throttle indicator

The fuel consumption curve on the throttleindicator shows the relative amount of fuelconsumed for each throttle position. Choosethe setting that offers the best performanceand fuel economy for the desired operation.

EMU25971

Throttle friction adjuster

A friction device provides adjustable resis-tance to movement of the throttle grip or theremote control lever, and can be set accord-ing to operator preference.To increase resistance, turn the adjusterclockwise. To decrease resistance, turn theadjuster counterclockwise.

WARNING

EWM00031

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to move the remote control leveror throttle grip, which could result in an

accident.

1. Forward “ ”

2. Neutral “ ”

3. Reverse “ ”

1. Throttle indicator

Basic components

17

When constant speed is desired, tighten theadjuster to maintain the desired throttle set-ting.

EMU25990

Engine stop lanyard switch

The lock plate must be attached to the en-gine stop switch for the engine to run. Thelanyard should be attached to a secure placeon the operator’s clothing, or arm or leg.Should the operator fall overboard or leavethe helm, the lanyard will pull out the lockplate, stopping ignition to the engine. Thiswill prevent the boat from running away un-der power.

WARNING

EWM00120

�

Attach the engine stop switch lanyardto a secure place on your clothing, oryour arm or leg while operating.

�

Do not attach the lanyard to clothingthat could tear loose. Do not route thelanyard where it could become entan-gled, preventing it from functioning.

�

Avoid accidentally pulling the lanyardduring normal operation. Loss of en-gine power means the loss of moststeering control. Also, without enginepower, the boat could slow rapidly. Thiscould cause people and objects in the

boat to be thrown forward.

NOTE:

The engine cannot be started with the lock

plate removed.

EMU26001

Engine stop button

To open the ignition circuit and stop the en-gine, push this button.

ZMU03169

1. Lanyard2. Lock plate

1. Lock plate2. Lanyard

1

2

ZMU03171

Basic components

18

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 quicklyto crank the engine.

EMU26090

Main switch

The main switch controls the ignition system;its operation is described below.

�

“ ”

(off)

With the main switch in the “ ” (off) posi-tion, the electrical circuits are off, and the keycan be removed.

�

“ ”

(on)

With the main switch in the “ ” (on) posi-tion, the electrical circuits are on, and the keycannot be removed.

�

“ ”

(start)

With the main switch in the “ ” (start) po-sition, the starter motor turns to start the en-

gine. When the key is released, it returnsautomatically to the “ ” (on) position.

EMU31430

Steering friction adjuster

A friction device provides adjustable resis-tance to the steering mechanism, and can beset according to operator preference. An ad-juster lever is located on the bottom of thetiller handle bracket.To increase resistance, turn the lever to theport side “A”.To decrease resistance, turn the lever to thestarboard side “B”.

WARNING

EWM00040

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to steer, which could result in an

accident.

ZMU04037

ONSTARTOFF

ZMU03590

Basic components

19

If the resistance does not increase evenwhen the lever is turned to the port side “A”,make sure that the nut is tightened to thespecified torque.

NOTE:

�

Check the tiller handle for smooth move-ment when the lever is turned to the star-board side “B”.

�

Do not apply lubricants such as grease tothe friction areas of the steering friction ad-

juster.

EMU26122

Steering friction adjuster

A friction device provides adjustable resis-tance to the steering mechanism, and can beset according to operator preference. An ad-

justing screw or bolt is located on the swivelbracket.

To increase resistance, turn the adjusterclockwise.To decrease resistance, turn the adjustercounterclockwise.

WARNING

EWM00040

Do not overtighten the friction adjuster. Ifthere is too much resistance, it could bedifficult to steer, which could result in an

accident.

EMU26141

Power trim and tilt switch on remote control or tiller handle

The power trim and tilt system adjusts theoutboard motor angle in relation to the tran-som. Pressing the switch “ ” (up) trims theoutboard motor up, then tilts it up. Pressingthe switch “ ” (down) tilts the outboard mo-tor down and trims it down. When the switchis released, the outboard motor will stop in itscurrent position.

NOTE:

For instructions on using the power trim and

tilt switch, see pages 39 and 42.

1. Nut

Nut tightening torque:3.7 Nm (2.7 ft-lb) (0.4 kgf-m)

ZMU02810

B

A

ZMU02908

Basic components

20

EMU26151

Power trim and tilt switch on bottom engine cowling

The power trim and tilt switch is located onthe side of the bottom engine cowling. Press-ing the switch “ ” (up) trims the outboardmotor up, then tilts it up. Pressing the switch“ ” (down) tilts the outboard motor downand trims it down. When the switch is re-leased, the outboard motor will stop in itscurrent position.

WARNING

EWM01030

Use the power trim and tilt switch locatedon the bottom engine cowling only whenthe boat is at a complete stop with the en-gine off. Attempting to use this switchwhile the boat is moving could increasethe risk of falling overboard and coulddistract the operator, increasing the riskof collision with another boat or an obsta-

cle.

NOTE:

For instructions on using the power trim and

tilt switch, see page 42.

EMU26241

Trim tab with anode

The trim tab should be adjusted so that thesteering control can be turned to either theright or left by applying the same amount offorce.

WARNING

EWM00840

An improperly adjusted trim tab couldcause difficult steering. Always test runafter the trim tab has been installed or re-placed to be sure steering is correct. Besure you have tightened the bolt after ad-

justing the trim tab.

If the boat tends to veer the left (port side),turn the trim tab rear end to the port side “A”in the figure. If the boat tends to veer the right(starboard side), turn the trim tab end to thestarboard side “B” in the figure.

CAUTION:

ECM00840

The trim tab also serves as an anode toprotect the engine from electrochemicalcorrosion. Never paint the trim tab as it

will become ineffective as an anode.

UP

DN

ZMU04038

Basic components

21

EMU26312

Tilt lock mechanism

The tilt lock mechanism is used to preventthe outboard motor from lifting out of the wa-ter when in reverse gear.

To lock it, set the tilt lock lever in the “ ”(lock) position. To release, push the tilt locklever in the “ ” (release) position.

EMU26320

Tilt support knob

To keep the outboard motor in the tilted upposition, push the tilt support knob under theswivel bracket.

EMU26372

Top cowling lock lever(s) (turn type)

To remove the engine top cowling, turn thelock lever(s) and lift off the cowling. When in-stalling the cowling, check to be sure it fitsproperly in the rubber seal. Then lock thecowling again by returning the lever(s) to thelock position.

EMU26460

Flushing device

This device is used to clean the cooling wa-ter passages of the motor using a gardenhose and tap water.

NOTE:

For details on usage, see page 53.

1. Trim tab2. Bolt

1. Tilt lock lever

ZMU02822

1

2

A

B

1 ZMU04039

1. Top cowling lock lever(s)

ZMU04040

1

ZMU04041

Basic components

22

EMU26302

Warning indicator

If the engine develops a condition which iscause for warning, the indicator lights up. Fordetails on how to read the warning indicator,see page 25.

EMU26470

Tachometer

This gauge shows the engine speed and hasthe following functions.

EMU26491

Digital tachometer

The tachometer shows the engine speedand has the following functions.

NOTE:

All segments of the display will light momen-tarily after the main switch is turned on and

will return to normal thereafter.

1. Flushing device

1. Warning indicator

1

ZMU04042

1

ZMU04043

1. Tachometer2. Warning indicator(s)

1. Tachometer2. Trim meter3. Hour meter4. Low oil pressure warning indicator5. Overheat warning indicator6. Water separator warning indicator7. Engine trouble warning indicator8. Set button9. Mode button

ZMU04578

1

2

1

5

2

4

3

76

8 9 ZMU04185

Basic components

23

NOTE:

The water separator and engine troublewarning indicators only operate when the en-gine is equipped with the appropriate func-

tions.

EMU26503

Low oil pressure warning indicator

If oil pressure drops too low, this indicator willflash. For further information, see page 25.

CAUTION:

ECM00020

�

Do not continue to run the engine if thelow oil pressure warning indicator is onand the engine oil level is lower. Seri-ous engine damage will occur.

�

The low oil pressure warning indicatordoes not indicate the engine oil level.Use the oil dipstick to check the re-maining oil quantity. For further infor-

mation, see page 29.

EMU26522

Low oil pressure warning indicator

If oil pressure drops too low, the warning in-dicator will start to blink. For further informa-tion, see page 25.

CAUTION:

ECM00020

�

Do not continue to run the engine if thelow oil pressure warning indicator is onand the engine oil level is lower. Seri-

ous engine damage will occur.

�

The low oil pressure warning indicatordoes not indicate the engine oil level.Use the oil dipstick to check the re-maining oil quantity. For further infor-

mation, see page 29.

EMU26572

Overheat warning indicator

If the engine temperature rises too high, thisindicator will flash. For further information onreading the indicator, see page 25.

CAUTION:

ECM00050

Do not continue to run the engine if theoverheat warning indicator is on. Serious

engine damage will occur.

ZMU04754

1. Low oil pressure warning indicator

ZMU017361

ZMU04715

Basic components

24

EMU26581

Overheat warning indicator (digital type)

If the engine temperature rises too high, thewarning indicator will start to blink. For fur-ther information on reading the indicator, seepage 25.

CAUTION:

ECM00050

Do not continue to run the engine if theoverheat warning indicator is on. Serious

engine damage will occur.

EMU26610

Trim meter

This gauge shows the trim angle of your out-board motor.

NOTE:

Memorize the trim angles that work best foryour boat under different conditions. Adjust

the trim angle to the desired setting with the

power trim and tilt switch.

EMU26620

Trim meter (digital type)

This meter shows the trim angle of your out-board motor.

NOTE:

�

Memorize the trim angles that work bestfor your boat under different conditions.Adjust the trim angle to the desired usingthe power trim and tilt switch.

�

If the trim angle of your motor exceeds thetrim operating range, the top segment on

the trim meter display will blink.

EMU26650

Hour meter (digital type)

This meter shows the number of hours theengine has been run. It can be set to showthe total number of hours or the number ofhours for the current trip. The display canalso be turned on and off.

1. Overheat warning indicator

ZMU01737

1

ZMU04581

ZMU01740

Basic components

25

�

Changing the display format

�

Pressing the “ ” (mode) button chang-es the display format in the following pat-tern:

�

Total hours

→

Trip hours

→

Display off

�

Resetting the trip hours

�

Simultaneously pressing the “ ” (set)and “ ” (mode) buttons for more than1 second while the trip hours are displayedresets the trip counter to 0 (zero).

NOTE:

The total number of hours the engine has

been run cannot be reset.

EMU26801

Warning system

CAUTION:

ECM00090

Do not continue to operate the engine if awarning device has activated. Consultyour Yamaha dealer if the problem can-

not be located and corrected.

EMU26816

Overheat warning

This engine has an overheat warning device.If the engine temperature rises too high, thewarning device will activate.

Activation of warning device

�

The engine speed will automatically de-crease to about 2000 r/min.

�

If equipped with an overheat warning indi-

cator, it will light or blink.

�

The buzzer will sound (if equipped on thetiller handle, remote control box, or mainswitch panel).

If the warning system has activated, stop theengine and check the cooling water inlet forclogging.

ZMU01741

ZMU05028

ZMU04044

Basic components

26

EMU30167

Low oil pressure warning

If the oil pressure drops too low, the warningdevice will activate.

Activation of warning device

�

The engine speed will automatically de-crease to about 2000 r/min.

�

If equipped with a low oil pressure warningindicator, it will light or blink.

�

The buzzer will sound (if equipped on thetiller handle, remote control box, or main

switch panel).

If the warning system has activated, stop theengine as soon as it is safe to do so. Checkthe oil level and add oil as needed. If the oillevel is correct and the warning device doesnot switch off, consult your Yamaha dealer.

CAUTION:

ECM00100

Do not continue to run the engine if thelow oil pressure warning indicator is on.

Serious engine damage could occur.

ZMU04994

ZMU04105

27

Operation

EMU26901

Installation

CAUTION:

ECM00110

Incorrect engine height or obstructionsto smooth water flow (such as the designor condition of the boat, or accessoriessuch as transom ladders or depth findertransducers) can create airborne waterspray while the boat is cruising. Severeengine damage may result if the motor isoperated continuously in the presence of

airborne water spray.

NOTE:

During water testing check the buoyancy ofthe boat, at rest, with its maximum load.Check that the static water level on the ex-haust housing is low enough to prevent wa-ter entry into the powerhead, when waterrises due to waves when the outboard is not

running.

EMU26910

Mounting the outboard motor

WARNING

EWM00820

�

Overpowering a boat could cause se-vere instability. Do not install an out-board motor with more horsepowerthan the maximum rating on the capac-ity plate of the boat. If the boat does nothave a capacity plate, consult the boatmanufacturer.

�

The information presented in this sec-tion is intended as reference only. It isnot possible to provide complete in-structions for every possible boat andmotor combination. Proper mountingdepends in part on experience and the

specific boat and motor combination.

WARNING

EWM00830

Improper mounting of the outboard mo-tor could result in hazardous conditionssuch as poor handling, loss of control, orfire hazards. Observe the following:

�

For permanently mounted models, yourdealer or other person experienced inproper rigging should mount the motor.If you are mounting the motor yourself,you should be trained by an experi-enced person.

�

For portable models, your dealer or oth-er person experienced in proper out-board motor mounting should show

you how to mount your motor.

Mount the outboard motor on the center line(keel line) of the boat, and ensure that theboat itself is well balanced. Otherwise theboat will be hard to steer. For boats withouta keel or which are asymmetrical, consultyour dealer.

EMU26930

Mounting height (boat bottom)

To run your boat at optimum efficiency, thewater resistance (drag) of the boat and out-board motor must be made as little as possi-ble. The mounting height of the outboard

1. Center line (keel line)

ZMU017601

Operation

28

motor greatly affects the water resistance. Ifthe mounting height is too high, cavitationtends to occur, thus reducing the propulsion;and if the propeller tips cut the air, the enginespeed will rise abnormally and cause the en-gine to overheat. If the mounting height is toolow, the water resistance will increase andthereby reduce engine efficiency. Mount theoutboard motor so that the anti-cavitationplate is in alignment with the bottom of theboat.

NOTE:

�

The optimum mounting height of the out-board motor is affected by the boat/motorcombination and the desired use. Testruns at different heights can help deter-mine the optimum mounting height. Con-sult your Yamaha dealer or boatmanufacturer for further information on de-termining the proper mounting height.

�

For instructions on setting the trim angle of

the outboard motor, see page 39.

EMU30173

Breaking in engine

Your new engine requires a period of break-in to allow mating surfaces of moving parts towear in evenly. Correct break-in will help en-sure proper performance and longer engine

life.

CAUTION:

ECM00800

Failure to follow the break-in procedurecould result in reduced engine life or

even severe engine damage.

EMU27081

Procedure for 4-stroke models

Run the engine under load (in gear with apropeller installed) for 10 hours as follows.1. First hour:

Run the engine at 2000 r/min or at ap-proximately half throttle.

2. Second hour:Run the engine at 3000 r/min or at ap-proximately three-quarter throttle.

3. Remaining eight hours:Run the engine at any speed. However,avoid operating at full throttle for morethan 5 minutes at a time.

4. After the first 10 hours:Operate the engine normally.

EMU27103

Preoperation checks

WARNING

EWM00080

If any item in the preoperation check isnot working properly, have it inspectedand repaired before operating the out-board motor. Otherwise an accident

could occur.

CAUTION:

ECM00120

Do not start the engine out of water. Over-heating and serious engine damage can

occur.

EMU27111

Fuel

�

Check to be sure you have plenty of fuelfor your trip.

�

Make sure there are no fuel leaks or gaso-

ZMU01762

Operation

29

line fumes.

�

Check fuel line connections to be sure theyare tight (if equipped Yamaha fuel tank orboat tank).

�

Be sure the fuel tank is positioned on a se-cure, flat surface, and that the fuel line isnot twisted or flattened, or likely to contactsharp objects (if equipped Yamaha fueltank or boat tank).

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 stopswitches when the outboard motor is in thewater.

EMU27140

Engine

�

Check the engine and engine mounting.

�

Look for loose or damaged fasteners.

�

Check the propeller for damage.

EMU27163

Checking the engine oil level

1. Put the outboard motor in an upright po-sition (not tilted).

2. Remove oil dipstick and wipe it clean.3. Completely insert the dipstick and re-

move it again.4. Check the oil level using the dipstick to

be sure the level falls between the upperand lower marks. Fill with oil if it is belowthe lower mark, or drain to the specifiedlevel if it is above the upper mark.

NOTE:

Be sure to completely insert the dipstick into

the dipstick guide.

EMU27433

Filling fuel

WARNING

EWM00060

Gasoline and its vapors are highly flam-mable and explosive. Keep away fromsparks, cigarettes, flames, or other

sources of ignition.

1. Remove the fuel tank cap.2. Carefully fill the fuel tank.3. Securely close the cap after filling the

1. Oil dipstick

1. Lower level mark2. Oil dipstick3. Upper level mark

1

ZMU04046

ZMU02082

13

2

Operation

30

tank. Wipe up any spilled fuel.

EMU27270

Ring Free Fuel Additive

Gasoline is a precise blend of many differentsubstances, each chosen to give certaincharacteristics. Gasoline blends have beenchanging in recent years in response to con-cerns about pollution and resulting emis-sions regulations. One of the most obviouschanges has been the elimination of leadfrom most fuels.As gasoline has changed, the amount of ad-ditives such as aromatics and oxygenateshas increased. These additives are impor-tant for the engines in passenger cars, butthey can have detrimental effects in marineengines, because of increased deposits inthe combustion chamber. When enough de-posits collect, piston rings begin sticking.Performance drops and engine wear in-creases dramatically.While many additives available may reducedeposits, Yamaha recommends the use of

Ring Free Fuel Additive

, available fromyour Yamaha dealer.

Ring Free Fuel Addi-tive

has repeatedly proven its ability to cleancombustion deposits from inside the engine,notably the critical piston-ring-land area, and

fuel system components. Follow product la-beling for use instructions.

EMU27450

Operating engine

EMU27461

Feeding fuel (portable tank)

WARNING

EWM00420

�

Before starting the engine, make surethat the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in thewater near you.

�

When the air vent screw is loosened,gasoline vapor will be released. Gaso-line is highly flammable, and its vaporsare flammable and explosive. Refrainfrom smoking, and keep away fromopen flames and sparks while loosen-ing the air vent screw.

�

This product emits exhaust gaseswhich contain carbon monoxide, a col-orless, odorless gas which could causebrain damage or death when inhaled.Symptoms include nausea, dizziness,and drowsiness. Keep cockpit and cab-in areas well ventilated. Avoid blocking

exhaust outlets.

1. If there is an air vent screw on the fueltank cap, loosen it 2 or 3 turns.

2. If there is a fuel joint on the motor, firmly

Fuel tank capacity:25 L (6.60 US gal) (5.50 Imp.gal)

ZMU04047

ZMU02022

Operation

31

connect the fuel line to the joint. Thenfirmly connect the other end of the fuelline to the joint on the fuel tank.

3. If a steering friction adjuster is providedon your outboard motor, securely attachthe fuel line to the fuel line clamp.

NOTE:

During engine operation place the tank hori-zontally, otherwise fuel cannot be drawn

from the fuel tank.

4. Squeeze the primer pump with the outletend up until you feel it become firm.

EMU27490

Starting engine

EMU27541

Starting engine

1. Place the gear shift lever in neutral.

NOTE:

The start-in-gear protection device preventsthe engine from starting except when in neu-

tral.

2. Attach the engine stop switch lanyard toa secure place on your clothing, or yourarm or leg. Then install the lock plate onthe other end of the lanyard into the en-gine stop switch.

WARNING

EWM00120

�


�

Do not attach the lanyard to clothingthat could tear loose. Do not route the

ZMU04048

ZMU02024

ZMU02025

Operation

32

lanyard where it could become entan-gled, preventing it from functioning.

�



3. Place the throttle grip in the “ ”(start) position.

4. Pull the manual starter handle slowly un-til you feel resistance. Then give astrong pull straight out to crank and startthe engine. Repeat if necessary.

5. After the engine starts, slowly return themanual starter handle to its original po-sition before releasing it.

NOTE:

�

When the engine is cold, it needs to bewarmed up. For further information, seepage 35.

�

If the engine is warm and fails to start,open the throttle slightly and try to start theengine again. If the engine still fails to

start, see page 70.

EMU27592

Electric start / prime start models


NOTE:


tral.

2. Attach the engine stop switch lanyard toa secure place on your clothing, or your

ZMU04050

Operation

33

arm or leg. Then install the lock plate onthe other end of the lanyard into the en-gine stop switch.

WARNING

EWM00120

�


�


�



3. Place the throttle grip in the “ ”(start) position. After the engine starts,return the throttle to the fully closed po-sition.

4. Turn the main switch to “ ” (start),and hold it for a maximum of 5 seconds.

5. Immediately after the engine starts, re-lease the main switch and allow it to re-turn to “ ” (on).

CAUTION:

ECM00191

�

Never turn the main switch to “ ”(start) while the engine is running.

�

Do not keep the starter motor turningfor more than 5 seconds. If the startermotor is turned continuously for morethan 5 seconds, the battery will bequickly discharged, thus making it im-possible to start the engine. The startercan also be damaged. If the engine willnot start after 5 seconds of cranking,return the main switch to “ ” (on), wait10 seconds, then crank the engine

again.

Operation

34

NOTE:

�


�


start, see page 70.

EMU27662

Electric start and remote control models

1. Place the remote control lever in neutral.

NOTE:


tral.

2. Attach the engine stop switch lanyard toa secure place on your clothing, or yourarm or leg. Then install the lock plate onthe other end of the lanyard into the en-gine stop switch.

WARNING

EWM00120

�


�


�

Avoid accidentally pulling the lanyard

during normal operation. Loss of en-gine power means the loss of moststeering control. Also, without enginepower, the boat could slow rapidly. Thiscould cause people and objects in the


3. Turn the main switch to “ ” (on).4. Turn the main switch to “ ” (start),

and hold it for a maximum of 5 seconds.

5. Immediately after the engine starts, re-lease the main switch and allow it to re-turn to “ ” (on).

CAUTION:

ECM00191

�

Never turn the main switch to “ ”(start) while the engine is running.

�

Do not keep the starter motor turningfor more than 5 seconds. If the startermotor is turned continuously for morethan 5 seconds, the battery will be

Operation

35

quickly discharged, thus making it im-possible to start the engine. The startercan also be damaged. If the engine willnot start after 5 seconds of cranking,return the main switch to “ ” (on), wait10 seconds, then crank the engine

again.

NOTE:

�


�


start, see page 70.

EMU27670

Warming up engine

EMU27710

Manual start and electric start models

1. After starting the engine, allow it to idlefor 3 minutes to warm up. Failure to doso will shorten engine life.

2. Be sure the low oil pressure warning in-dicator goes off after starting the engine.

3. Check for a steady flow of water from thecooling water pilot hole.

CAUTION:

ECM00210

�

If the low oil pressure warning indicatordoes not go off after the engine starts,stop the engine. Otherwise serious en-gine damage could occur. Check the oillevel and add oil if necessary. Consultyour Yamaha dealer if the cause for thelow oil pressure warning indicator can-not be found.

�

A continuous flow of water from the pi-lot hole shows that the water pump ispumping water through the cooling

passages. If water is not flowing out ofthe pilot hole at all times while the en-gine is running, overheating and seri-ous damage could occur. Stop theengine and check whether the coolingwater inlet on the lower case or thecooling water pilot hole is blocked.Consult your Yamaha dealer if the prob-

lem cannot be located and corrected.

EMU27740

Shifting

WARNING

EWM00180

Before shifting, make sure there are noswimmers or obstacles in the water near

you.

CAUTION:

ECM00220

To change the boat direction or shiftingposition from forward to reverse or vice-versa, first close the throttle so that the

engine idles (or runs at low speeds).

EMU27764

Forward (tiller handle and remote control models)

Tiller handle models1. Place the throttle grip in the fully closed

position.

ZMU04051

Operation

36

2. Move the gear shift lever quickly andfirmly from neutral to forward.

Remote control models1. Pull up the neutral interlock trigger (if

equipped) and move the remote controllever quickly and firmly from neutral toforward.

EMU27785

Reverse (automatic reverse lock and power trim and tilt models)

WARNING

EWM00190

When operating in reverse, go slowly. Donot open the throttle more than half. Oth-erwise the boat could become unstable,which could result in loss of control and

an accident.


position.

2. Move the gear shift lever quickly andfirmly from neutral to reverse.

ZMU03319

NF

ZMU03406

Operation

37

Remote control models1. Pull up the neutral interlock trigger (if

equipped) and move the remote controllever quickly and firmly from neutral toreverse.

EMU27796

Reverse (manual tilt and hydro tilt models)

WARNING

EWM00190

When operating in reverse, go slowly. Do

not open the throttle more than half. Oth-erwise the boat could become unstable,which could result in loss of control and

an accident.


position.

2. On models equipped with a tilt lock le-ver, check that it is in the lock/down po-sition.

3. Move the gear shift lever quickly andfirmly from neutral to reverse.

UP

DN

ZMU03909

N R

ZMU03407

ZMU04054

Operation

38

Remote control models1. Check that the tilt lock lever is in the lock

position.

2. Pull up the neutral interlock trigger (ifequipped) and move the remote controllever quickly and firmly from neutral toreverse.

EMU27820

Stopping engine

Before stopping the engine, first let it cool offfor a few minutes at idle or low speed. Stop-ping the engine immediately after operatingat high speed is not recommended.

EMU27844

Procedure

1. Push and hold the engine stop button orturn the main switch to “ ” (off).

ZMU04053

UP

DN

ZMU03909

N R

ZMU03627

ONSTARTOFF

ZMU03630

Operation

39

2. After stopping the engine, disconnectthe fuel line if there is a fuel joint on theoutboard motor.

3. Tighten the air vent screw on the fueltank cap (if equipped).

4. Remove the key if the boat will be leftunattended.

NOTE:

The engine can also be stopped by pullingthe lanyard and removing the lock plate from

the engine stop switch, then turning the main

switch to “ ” (off).

EMU27861

Trimming outboard motor

The trim angle of the outboard motor helpsdetermine the position of the bow of the boatin the water. Correct trim angle will help im-prove performance and fuel economy whilereducing strain on the engine. Correct trimangle depends upon the combination ofboat, engine, and propeller. Correct trim isalso affected by variables such as the load inthe boat, sea conditions, and running speed.

WARNING

EWM00740

Excessive trim for the operating condi-tions (either trim up or trim down) cancause boat instability and can makesteering the boat more difficult. This in-creases the possibility of an accident. Ifthe boat begins to feel unstable or is hardto steer, slow down and/or readjust the

trim angle.ZMU04057

ZMU04058

Operation

40

EMU27882

Adjusting trim angle

Power trim and tilt models

WARNING

EWM00751

�

Be sure all people are clear of the out-board motor when adjusting the tilt an-gle, also be careful not to pinch anybody parts between the drive unit andclamp bracket.

�

Use caution when trying a trim positionfor the first time. Increase speed gradu-ally and watch for any signs of instabil-ity or control problems. Improper trimangle can cause loss of control.

�

If equipped with a power trim and tiltswitch located on the bottom cowling,use the switch only when the boat is ata complete stop with the engine off. Donot adjust the trim angle with this

switch while the boat is moving.

Adjust the outboard motor trim angle usingthe power trim and tilt switch.

To raise the bow (trim-out), press the switch

1. Trim operating angle

1ZMU04059

1. Power trim and tilt switch



UP

DN

ZMU04060

1

Operation

41

“ ” (up).To lower the bow (trim-in), press the switch“ ” (down).Make test runs with the trim set to differentangles to find the position that works best foryour boat and operating conditions.

EMU27891

Adjusting trim angle for hydro tilt models

WARNING

EWM00490

�

Stop the engine before adjusting thetrim angle.

�

Be sure all people are clear of the out-board motor when adjusting the tilt an-gle, also be careful not to pinch anybody parts between the drive unit andclamp bracket.

�

Use caution when trying a trim positionfor the first time. Increase speed gradu-ally and watch for any signs of instabil-ity or control problems. Improper trim

angle can cause loss of control.

1. Stop the engine.2. Place the tilt lock lever in the release po-

sition.

3. Hold the rear of the top cowling with onehand and tilt the engine to the desiredangle.

4. Place the tilt lock lever back into the lockposition to support the engine.

To raise the bow (“trim-out”), tilt the engineup.To lower the bow (“trim-in”), tilt the enginedown.Make test runs with the trim set to differentangles to find the position that works best foryour boat and operating conditions.

EMU27911

Adjusting boat trim

When the boat is on plane, a bow-up attituderesults in less drag, greater stability and effi-ciency. This is generally when the keel line ofthe boat is up about 3 to 5 degrees. With thebow 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 canalso be adjusted to help offset this effect.When the bow of the boat is down, it is easierto accelerate from a standing start ontoplane.

Bow Up

Too much trim-out puts the bow of the boattoo high in the water. Performance and econ-omy are decreased because the hull of theboat is pushing the water and there is moreair drag. Excessive trim-out can also causethe propeller to ventilate, which reduces per-formance further, and the boat may “por-poise” (hop in the water), which could throwthe operator and passengers overboard.

ZMU04061

Operation

42

Bow Down

Too much trim-in causes the boat to “plow”through the water, decreasing fuel economyand making it hard to increase speed. Oper-ating with excessive trim-in at higher speedsalso makes the boat unstable. Resistance atthe bow is greatly increased, heightening thedanger of “bow steering” and making opera-tion difficult and dangerous.

NOTE:

Depending on the type of boat, the outboardmotor trim angle may have little effect on the

trim of the boat when operating.

EMU27933

Tilting up and down

If the engine will be stopped for some time orif the boat is moored in shallows, the out-board motor should be tilted up to protect thepropeller and casing from damage by colli-sion with obstructions, and also to reduce

salt corrosion.

WARNING

EWM00220

Be sure all people are clear of the out-board motor when tilting up and down,also be careful not to pinch any bodyparts between the drive unit and engine

bracket.

WARNING

EWM00250

Leaking fuel is a fire hazard. If there is afuel joint on the outboard motor, discon-nect the fuel line or close the fuel cock ifthe engine will be tilted for more than a

few minutes. Otherwise fuel may leak.

CAUTION:

ECM00241

�

Before tilting the outboard motor, stopthe engine by following the procedureon page 38. Never tilt the outboard mo-tor while the engine is running. Severedamage from overheating can result.

�

Do not tilt up the engine by pushing thetiller handle (if equipped) because this

could break the handle.

EMU27995

Procedure for tilting up (hydro tilt models)

1. Place the remote control lever / gearshift lever in neutral.

N

ZMU03087

Operation

43

2. Disconnect the fuel line from the out-board motor.

3. Place the tilt lock lever in the release po-sition.

4. Hold the rear of the top cowling with onehand, tilt the engine up, and turn the tiltsupport lever toward you or tilt supportknob into the clamp bracket, and thenplace the tilt lock lever back into the lockposition to support the outboard motor.

EMU28007

Procedure for tilting up (power trim and tilt models / power tilt models)


2. Disconnect the fuel line from the out-board motor or close the fuel cock.

ZMU04063

ZMU04064

ZMU04065

N

ZMU03196

Operation

44

3. Press the power trim and tilt switch /power tilt switch “ ” (up) until the out-board motor has tilted up completely.

4. Push the tilt support knob into the clampbracket or pull the tilt support lever to-ward you to support the engine.

WARNING

EWM00260

After tilting the outboard motor, be sureto support it with the tilt support knob ortilt support lever. Otherwise the outboardmotor could fall back down suddenly if oilin the power trim and tilt unit loses pres-

sure.

5. Models equipped with trim rods: Oncethe outboard motor is supported with thetilt support lever, press the power trimand tilt switch / power tilt switch “ ”(down) to retract the trim rods.

CAUTION:

ECM00250

Be sure to retract the trim rods complete-ly during mooring. This protects the rods

ZMU04066

UP

ZMU01935

UP

DN

UP

ZMU04067

ZMU04068

Operation

45

from marine growth and corrosion whichcould damage the power trim and tilt

mechanism.

EMU28041

Procedure for tilting down (manual and hydro tilt models)

1. Release the tilt lock lever.

2. Hold the rear of the top cowling with onehand, tilt the outboard motor up slightlyand pull out the tilt support knob or re-turn the tilt support lever.

3. Slowly tilt the outboard motor down.4. Place the tilt lock lever in the lock posi-

tion.

EMU28055

Procedure for tilting down (power trim and tilt models / power tilt models)

1. Push the power trim and tilt switch / pow-er tilt switch “ ” (up) until the outboardmotor is supported by the tilt rod and thetilt support lever / tilt support knob be-comes free.

2. Release the tilt support lever or pull outthe tilt support knob.

3. Push the power trim and tilt switch / pow-er tilt switch “ ” (down) to lower the out-board motor to the desired position.

ZMU04069

ZMU04070

ZMU04071

ZMU04072

Operation

46

EMU28060

Cruising in shallow water

The outboard motor can be tilted up partiallyto allow operation in shallow water.

EMU28080

Hydro tilt models


WARNING

EWM00270

�

Place the gear shift in neutral before us-

ing the shallow water cruising system.

�

Run the boat at the lowest possiblespeed when using the shallow watercruising system.

�

Use extra care when operating in re-verse. Too much reverse thrust cancause the outboard motor to lift out ofthe water, increasing the chance of ac-cident and personal injury.

�

Return the outboard motor to its normalposition as soon as the boat is back in

deeper water.

CAUTION:

ECM00260

Do not tilt the outboard motor up so thatthe cooling water inlet on the lower unit isabove the surface of the water when set-ting up for and cruising in shallow water.Otherwise severe damage from overheat-

ing can result.

EMU28174

Procedure for hydro tilt models


DN

ZMU01936

UP

DN

DN

ZMU04073

ZMU04074

Operation

47

2. Pull the tilt lock lever up to the releaseposition.

3. Slightly tilt the outboard motor up to thedesired position and push the tilt lock le-ver down to the lock position.

4. To return the outboard motor to the nor-mal running position, pull the tilt lock le-ver up to the release position and slowlytilt the outboard motor down.

5. Push the tilt lock lever down to the lockposition.

EMU28090

Power trim and tilt models / power tilt models


WARNING

EWM00660

�

Place the gear shift in neutral beforesetting up for shallow water cruising.

�

Return the outboard motor to its normalposition as soon as the boat is back in

deeper water.

CAUTION:

ECM00260

Do not tilt the outboard motor up so thatthe cooling water inlet on the lower unit isabove the surface of the water when set-ting up for and cruising in shallow water.Otherwise severe damage from overheat-

ing can result.

EMU28185

Procedure for power trim and tilt / powertilt models


N

ZMU03087

ZMU04075

ZMU04076

Operation

48

2. Slightly tilt the outboard motor up to thedesired position using the power trimand tilt switch / power tilt switch.

3. To return the outboard motor to the nor-mal running position, press the powertrim and tilt switch / power tilt switch andslowly tilt the outboard motor down.

EMU28192

Cruising in other conditions

Cruising in salt water

After operating in salt water, flush the coolingwater passages with fresh water to preventthem from becoming clogged with salt de-posits.

NOTE:

For cooling system flushing instructions, see

page 50.

Cruising in turbid water

Yamaha strongly recommends that you usethe optional chromium-plated water pump kit(not available for some models) if you usethe outboard motor in turbid or muddy waterconditions.

N

ZMU03525

UP

ZMU01935

UP

DN

UP

ZMU04077

49

Maintenance

EMU31480

SpecificationsNOTE:

“(AL)” stated in the specification data belowrepresents the numerical value for the alumi-num propeller installed.Likewise, “(SUS)” represents the value forstainless steel propeller installed and “(PL)”

for plastic propeller installed.

EMU28218

Dimension:

Overall length: F40MH 1332 mm (52.4 in)F40TR 700 mm (27.6 in)

Overall width: 378 mm (14.9 in)

Overall height S: 1217 mm (47.9 in)

Overall height L: 1340 mm (52.8 in)

Transom height S: 410 mm (16.1 in)

Transom height L: 533 mm (21.0 in)

Weight (without propeller) S: F40MH 83.0 kg (183 lb)

Weight (without propeller) L: F40MH 87.0 kg (192 lb)F40TR 89.0 kg (196 lb)

Performance:

Full throttle operating range: 5000–6000 r/min

Maximum output: 29.4 kW@5500 r/min (40 HP@5500 r/min)

Idling speed (in neutral): 850

±

50 r/min

Engine:

Type: 4-stroke L

Displacement: 747.0 cm

3

(45.58 cu.in)Bore

×

stroke: 65.0

×

75.0 mm (2.56

×

2.95 in)Ignition system:

CDISpark plug with resistor (NGK):

DPR6EA-9Spark plug gap:

0.8–0.9 mm (0.031–0.035 in)Control system:

F40MH TillerF40TR Remote control

Starting system: F40MH ManualF40TR Electric

Starting carburetion system: Prime start

Valve clearance (cold engine) IN: 0.15–0.25 mm (0.0059–0.0098 in)

Valve clearance (cold engine) EX: 0.25–0.35 mm (0.0098–0.0138 in)

Min. cold cranking amps (CCA/SAE): F40TR 380.0 A

Min. marine cranking amps (MCA/ABYC): F40TR 502.0 A

Min. reserve capacity (RC/SAE): F40TR 124 minutes

Alternator output for battery DC: 15.0 A

Drive unit:

Gear positions: Forward-neutral-reverse

Gear ratio: 2.00 (26/13)

Trim and tilt system: F40MH Hydro tiltF40TR Power trim and tilt

Propeller mark: G

Fuel and oil:

Maintenance

50

Recommended fuel: Regular unleaded gasoline

Min. pump octane: 86

Fuel tank capacity: 25 L (6.60 US gal) (5.50 Imp.gal)

Recommended engine oil: 4-stroke outboard motor oil

Engine oil grade API: API SE, SF, SG, SH, SJ, SL

Engine oil type SAE: SAE10W30 or SAE10W40

Lubrication: Wet sump

Engine oil quantity (excluding oil filter): 2.0 L (2.11 US qt) (1.76 Imp.qt)

Recommended gear oil: Hypoid gear oil SAE#90

Gear oil quantity: 430.0 cm

3

(14.54 US oz) (15.17 Imp.oz)

Tightening torque for engine:

Spark plug: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

Propeller nut: 40.0 Nm (29.5 ft-lb) (4.08 kgf-m)

Engine oil drain bolt: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

Engine oil filter: 18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

EMU28222

Transporting and storing outboard motor

WARNING

EWM00690

�

Leaking fuel is a fire hazard. Whentransporting and storing the outboardmotor, close the air vent screw and fuelcock to prevent fuel from leaking.

�

USE CARE when transporting fuel tank,

whether in a boat or car.

�

DO NOT fill fuel container to maximumcapacity. Gasoline will expand consid-erably as it warms up and can build uppressure in the fuel container. This cancause fuel leakage and a potential fire

hazard.

WARNING

EWM00700

Never get under the lower unit while it istilted, even if a motor support bar is used.Severe injury could occur if the outboard

motor accidentally falls.

CAUTION:

ECM00660

Do not use the tilt support lever or knobwhen trailering the boat. The outboardmotor could shake loose from the tilt sup-port and fall. If the motor cannot be trail-ered in the normal running position, usean additional support device to secure it

in the tilt position.

The outboard motor should be trailered andstored in the normal running position. If thereis insufficient road clearance in this position,then trailer the outboard motor in the tilt po-sition using a motor support device such asa transom saver bar. Consult your Yamahadealer for further details.

EMU28241

Storing outboard motor

When storing your Yamaha outboard motorfor prolonged periods of time (2 months orlonger), several important procedures mustbe performed to prevent excessive damage.It is advisable to have your outboard motorserviced by an authorized Yamaha dealerprior to storage. However, you, the owner,with a minimum of tools, can perform the fol-

Maintenance

51

lowing procedures.

CAUTION:

ECM01080

�

To prevent problems which can becaused by oil entering the cylinder fromthe sump, keep the outboard motor inthe attitude shown when transportingand storing it. If storing or transportingthe outboard motor on its side (not up-right), put it on a cushion after drainingthe engine oil.

�

Do not place the outboard motor on itsside before the cooling water hasdrained from it completely, otherwisewater may enter the cylinder throughthe exhaust port and cause engine trou-ble.

�

Store the outboard motor in a dry, well-

ventilated place, not in direct sunlight.

EMU28303

Procedure

EMU28372

Flushing in a test tank

1. Wash the outboard motor body usingfresh water. For further information, seepage 54.

2. Fill the fuel tank with fresh fuel and addone ounce of “Yamaha Fuel Conditionerand Stabilizer” (Part No. LUB-FUELC-12-00) to each gallon of fuel.

NOTE:

The use of “Yamaha Fuel Conditioner andStabilizer” eliminates the need to drain thefuel system. Consult your Yamaha dealer orother qualified mechanic if the fuel system is

to be drained instead.

3. Remove the engine top cowling and si-lencer cover.

4. Install the outboard motor on the testtank.

5. Fill the tank with fresh water to above thelevel of the anti-cavitation plate.

CAUTION:

ECM00300

Do not run the engine without supplyingit with cooling water. Either the enginewater pump will be damaged or the en-

ZMU04078

ZMU04079

1. Water surface2. Lowest water level

ZMU02051

1

2

Maintenance

52

gine will be damaged from overheating.Before starting the engine, be sure tosupply water to the cooling water passag-

es.

CAUTION:

ECM00290

If the fresh water level is below the levelof the anti-cavitation plate, or if the watersupply is insufficient, engine seizure may

occur.

6. Cooling system flushing is essential toprevent the cooling system from clog-ging up with salt, sand, or dirt. In addi-tion, fogging of the engine is mandatoryto prevent excessive engine damagedue to rust. Perform the flushing andfogging at the same time.

WARNING

EWM00090

�


�

Keep hands, hair, and clothes awayfrom the flywheel and other rotating

parts while the engine is running.

7. Run the engine at a fast idle for 10–15minutes in neutral position.

8. Just prior to turning off the engine, quick-ly spray “Yamaha Stor-Rite EngineFogging Oil” (Part No. LUB-STRRT-12-00) alternately into each carburetor orthe fogging hole of the silencer cover, ifequipped. When properly done, the en-gine will smoke excessively and almoststall.

9. Remove the outboard motor from thetest tank.

10. Drain the cooling water completely outof the motor. Clean the body thoroughly.

11. Install the silencer cover/cap and topcowling.

EMU28401

Lubrication

1. Grease the spark plug threads and in-stall the spark plug(s) and torque toproper specification. For information onspark plug installation, see page 58.

2. Change the gear oil. For instructions,see page 65. Inspect the oil for the pres-ence of water that indicates a leaky seal.Seal replacement should be performedby an authorized Yamaha dealer prior touse.

3. Grease all grease fittings. For further de-tails, see page 58.

EMU28421

Cleaning and anticorrosion measures

1. Wash down the exterior of the outboardmotor 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-abrasivewax such as “Yamaha Silicone Wax”(Part No. ACC-11000-15-02).

EMU28430

Battery care

WARNING

EWM00330

Battery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore ispoisonous and highly caustic.Always follow these preventive mea-sures:

�

Avoid bodily contact with electrolyticfluid as it can cause severe burns orpermanent eye injury.

�

Wear protective eye gear when han-

Maintenance

53

dling or working near batteries.Antidote (EXTERNAL):

�

SKIN - Flush with water.

�

EYES - Flush with water for 15 minutesand get immediate medical attention.

Antidote (INTERNAL):

�

Drink large quantities of water or milkfollowed by milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.

Batteries also generate explosive hydro-gen gas; therefore, you should alwaysfollow these preventive measures:

�

Charge batteries in a well-ventilated ar-ea.

�

Keep batteries away from fire, sparks,or open flames (for example: weldingequipment, lighted cigarettes, and soon.)

�

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

Batteries vary among manufacturers. There-fore the following procedures may not al-ways apply. Consult your batterymanufacturer’s instructions.Procedure1. Disconnect and remove the battery from

the boat. Always disconnect the blacknegative cable first to prevent the risk ofshorting.

2. Clean the battery casing and terminals.Fill each cell to the upper level with dis-tilled water.

3. Store the battery on a level surface in acool, dry, well-ventilated place out of di-rect sunlight.

4. Once a month, check the specific gravityof the electrolyte and recharge as re-quired to prolong battery life.

EMU28442

Flushing power unit

Perform this procedure right after operationfor the most thorough flushing.

CAUTION:

ECM01530

Do not perform this procedure while theengine is running. The water pump maybe damaged and severe damage from

overheating can result.

1. After shutting off the engine, unscrewthe garden hose connector from the fit-ting on the bottom cowling.

2. Screw the garden hose adapter onto agarden hose, which is connected to afresh water supply, and then connect itto the garden hose connector.

3. With the engine off, turn on the water tap

1. Fitting2. Garden hose connector3. Garden hose adapter

12

3

ZMU04080

Maintenance

54

and let the water flush through the cool-ing passages for about 15 minutes. Turnoff the water and disconnect the gardenhose adapter from the garden hose con-nector.

4. Reinstall the garden hose connectoronto the fitting on the bottom cowling.Tighten the connector securely.

CAUTION:

ECM00540

Do not leave the garden hose connectorloose on the bottom cowling fitting or letthe hose hang free during normal opera-tion. Water will leak out of the connectorinstead of cooling the engine, which cancause serious overheating. Be sure theconnector is tightened securely on the fit-

ting after flushing the engine.

NOTE:

�

When flushing the engine with the boat inthe water, tilting up the outboard motor un-til it is completely out of the water willachieve better results.

�

For cooling system flushing instructions,

see page 50.

EMU28450

Cleaning the outboard motor

After use, wash the exterior of the outboardmotor with fresh water. Flush the coolingsystem with fresh water.

NOTE:

For cooling system flushing instructions, see

page 50.

EMU28460

Checking painted surface of motor

Check the motor for scratches, nicks, or flak-ing paint. Areas with damaged paint aremore likely to corrode. If necessary, cleanand paint the areas. A touch-up paint is avail-able from your Yamaha dealer.

EMU28486

Periodic maintenance

WARNING

EWM01070

Be sure to turn off the engine when youperform maintenance unless otherwisespecified. If you or the owner is not famil-iar with machine servicing, this workshould be done by your Yamaha dealer or

other qualified mechanic.

Maintenance, replacement, or repair ofthe emission control devices and sys-tems may be performed by any marineengine repair establishment or individual.All warranty repairs, however, includingthose to the emission control system,must be performed by an authorizedYamaha marine dealership.

A service manual is available for purchasethrough your Yamaha dealer for owners whohave the mechanical skills, tools, and otherequipment necessary to perform mainte-nance not covered by this owner’s manual.

EMU28510

Replacement parts

If replacement parts are necessary, use onlygenuine Yamaha parts or parts of the sametype and of equivalent strength and materi-als. Any part of inferior quality may malfunc-tion, and the resulting loss of control couldendanger the operator and passengers.

ZMU02550

Maintenance

55

Yamaha genuine parts and accessories areavailable from your Yamaha dealer.

Maintenance

56

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 forexplanations of each owner-specific action.

NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushed with clean

water after each use.

The “ ” symbol indicates the check-ups which you may carry out yourself.The “ ” symbol indicates work to be carried out by your Yamaha dealer.

Item Actions

Initial Every

10 hours (1 month)

50 hours (3

months)

100 hours (6 months)

200 hours (1

year)

Anode(s) (external)Inspection / replace-ment

Anode(s) (internal)Inspection / replace-ment

Battery Inspection / charging

Cooling water pas-sages

Cleaning

Cowling clamp Inspection

Fuel filter (disposable)Inspection / replace-ment

Fuel system Inspection

Fuel tank (Yamaha por-table tank)

Inspection / cleaning

Gear oil Change

Greasing points Greasing

Idling speed (carbure-tor models)

Inspection

Power trim and tilt unit Inspection

Propeller and cotter pinInspection / replace-ment

Shift link / shift cable Inspection / adjustment

ThermostatInspection / replace-ment

Throttle link / throttle cable / throttle pick-up timing

Inspection / adjustment

Maintenance

57

EMU28874

Maintenance chart (additional)

EMU28910

NOTE:

When using lead or high-sulfur gasoline, inspecting valve clearance may be required more

frequently than every 500 hours.

Water pumpInspection / replace-ment

Engine oil Inspection / change

Oil filter (cartridge) Change

Spark plug(s)Cleaning / adjustment / replacement

Timing beltInspection / replace-ment

Valve clearance (OHC, OHV)

Inspection / adjustment

Item ActionsEvery

500 hours (2.5 years) 1000 hours (5 years)

Timing belt Replacement

Exhaust guide, exhaust manifold

Inspection / replace-ment

Item Actions

Initial Every

10 hours (1 month)

50 hours (3

months)

100 hours (6 months)

200 hours (1

year)

Maintenance

58

EMU28931

Greasing

Yamaha marine grease (Water resistant grease)

F40

EMU28952

Cleaning and adjusting spark plug

WARNING

EWM00560

When removing or installing a spark plug,be careful not to damage the insulator. Adamaged insulator could allow externalsparks, which could lead to explosion or

fire.

The spark plug is an important engine com-ponent and is easy to inspect. The conditionof the spark plug can indicate somethingabout the condition of the engine. For exam-ple, if the center electrode porcelain is verywhite, this could indicate an intake air leak orcarburetion problem in that cylinder. Do not

attempt to diagnose any problems yourself.Instead, take the outboard motor to aYamaha dealer. You should periodically re-move and inspect the spark plug becauseheat and deposits will cause the spark plugto slowly break down and erode. If electrodeerosion becomes excessive, or if carbon andother deposits are excessive, you should re-place the spark plug with another of the cor-rect type.

Before fitting the spark plug, measure theelectrode gap with a wire thickness gauge;

ZMU04081

Standard spark plug:DPR6EA-9

Maintenance

59

adjust the gap to specification if necessary.

When fitting the plug, always clean the gas-ket surface and use a new gasket. Wipe offany dirt from the threads and screw in thespark plug to the correct torque.

NOTE:

If a torque-wrench is not available when youare fitting a spark plug, a good estimate ofthe correct torque is 1/4 to 1/2 a turn past fin-ger-tight. Have the spark plug adjusted to thecorrect torque as soon as possible with a

torque-wrench.

EMU28962

Checking fuel system

WARNING

EWM00060

Gasoline and its vapors are highly flam-mable and explosive. Keep away fromsparks, cigarettes, flames, or other

sources of ignition.

WARNING

EWM00910

Leaking fuel can result in fire or explo-sion.

�

Check for fuel leakage regularly.

�

If any fuel leakage is found, the fuelsystem must be repaired by a qualifiedmechanic. Improper repairs can make

the outboard unsafe to operate.

Check the fuel lines for leaks, crack, or mal-function. If a problem is found, your Yamahadealer or other qualified mechanic should re-pair it immediately.

Checkpoints

�

Fuel system parts leakage

�

Fuel line joint leakage

�

Fuel line cracks or other damage

�

Fuel connector leakage

1. Spark plug gap2. Spark plug I.D. mark (NGK)

Spark plug gap:0.8–0.9 mm (0.031–0.035 in)

Spark plug torque:18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

ZMU04082

Maintenance

60

EMU28990

Checking fuel filter

Check the fuel filter periodically. The fuel fil-ter is a one piece, disposable type. If foreignmatter is found in the filter, replace it. For re-placement of the fuel filter, consult yourYamaha dealer.

EMU29041

Inspecting idling speed

WARNING

EWM00451

�


�

Keep hands, hair, and clothes awayfrom the flywheel and other rotating

parts while the engine is running.

CAUTION:

ECM00490

This procedure must be performed whilethe outboard motor is in the water. Aflushing attachment or test tank can be

used.

A diagnostic tachometer should be used forthis procedure. Results may vary dependingon whether testing is conducted with theflushing attachment, in a test tank, or with theoutboard motor in the water.1. Start the engine and allow it to warm up

fully in neutral until it is running smooth-ly.

NOTE:

Correct idling speed inspection is only possi-ble if the engine is fully warmed up. If notwarmed up fully, the idle speed will measurehigher than normal. If you have difficulty ver-ifying the idle speed, or the idle speed re-quires adjustment, consult a Yamaha dealer

or other qualified mechanic.

2. Verify whether the idle speed is set tospecification. For idle speed specifica-tions, see page 49.

EMU29073

Changing engine oil

WARNING

EWM00760

�

Avoid draining the engine oil immedi-ately after stopping the engine. The oilis hot and should be handled with careto avoid burns.

�

Be sure the outboard motor is securelyfastened to the transom or a stable

stand.

CAUTION:

ECM00970

�

Do not overfill the oil, and be sure theoutboard motor is upright (not tilted)when checking and changing the en-gine oil.

�

If the oil level is above the upper levelmark, drain until the level meets thespecified capacity. Overfilling the oil

could cause leakage or damage.

CAUTION:

ECM01240

Change the engine oil after the first 10hours of operation, and every 100 hoursor at 6-month intervals thereafter. Other-

wise the engine will wear quickly.

ZMU04083

Maintenance

61

NOTE:

Change the engine oil when the oil is still

warm.

1. Put the outboard motor in an upright po-sition (not tilted).

2. Prepare a suitable container that holds alarger amount than the engine oil capac-ity. Loosen and remove the drain screwwhile holding the container under thedrain hole. Then remove the oil filler cap.Let the oil drain completely. Wipe up anyspilled oil immediately.

3. Put a new gasket on the oil drain screw.Apply a light coat of oil to the gasket andinstall the drain screw.

NOTE:

If a torque wrench is not available when youare installing the drain screw, finger tightenthe screw just until the gasket comes intocontact with the surface of the drain hole.Then tighten 1/4 to 1/2 turn more. Tightenthe drain screw to the correct torque with a

torque wrench as soon as possible.

4. Add the correct amount of oil through thefiller hole. Install the filler cap.

5. Start the engine and watch to make surethe low oil pressure warning indicator (ifequipped) turns off. Make sure thatthere are no oil leaks.

CAUTION:

ECM00680

If the low oil pressure warning indicatordoes not turn off or if there are oil leaks,stop the engine and find the cause. Con-tinued operation with a problem couldcause severe engine damage. Consultyour Yamaha dealer if the problem can-

1. Drain screw

Drain screw tightening torque:18.0 Nm (13.3 ft-lb) (1.84 kgf-m)

ZMU04084

1

ZMU04085

Recommended engine oil:4-stroke outboard motor oil

Engine oil quantity (excluding oil filter):2.0 L (2.11 US qt) (1.76 Imp.qt)

1. Oil filler cap

1

ZMU04086

Maintenance

62

not be located and corrected.

6. Turn off the engine and wait 3 minutes.Recheck the oil level using the dipstickto be sure the level falls between the up-per and lower marks. Fill with oil if it isbelow the lower mark, or drain to thespecified level if it is above the uppermark.

7. Dispose of used oil according to localregulations.

NOTE:

�

For more information on the disposal ofused oil, consult your Yamaha dealer.

�

Change the oil more often when operatingthe engine under adverse conditions such

as extended trolling.

EMU29112

Checking wiring and connectors

�

Check that each grounding wire is properlysecured.

�

Check that each connector is engaged se-curely.

EMU29120

Exhaust leakage

Start the engine and check that no exhaustleaks from the joints between the exhaustcover, cylinder head, and body cylinder.

EMU29130

Water leakage

Start the engine and check that no waterleaks from the joints between the exhaustcover, cylinder head, and body cylinder.

EMU29140

Engine oil leakage

Check for oil leaks on the around the engine.

NOTE:

If any leaks are found, consult your Yamaha

dealer.

EMU29163

Checking power trim and tilt / power tilt system

WARNING

EWM00430

�

Never get under the lower unit while itis tilted, even when the tilt support leveris locked. Severe injury could occur ifthe outboard motor accidentally falls.

�

Make sure no one is under the outboard

motor before performing this test.

1. Check the power trim and tilt unit / powertilt unit for any sign of oil leaks.

ZMU02058

ZMU04087

Maintenance

63

2. Operate each of the power trim and tiltswitches / power tilt switches to checkthat all switches work.

3. Tilt the outboard motor up and checkthat the trim and tilt rod / the tilt rod ispushed out completely.

4. Check that the trim and tilt rod / the tiltrod is free of corrosion or other flaws.

5. Tilt the outboard motor down. Checkthat the trim and tilt rod / the tilt rod oper-ates smoothly.

NOTE:

Consult your Yamaha dealer if any operation

is abnormal.

EMU29171

Checking propeller

WARNING

EWM00321

You could be seriously injured if the en-gine accidentally starts when you arenear the propeller.

�

Before inspecting, removing, or install-ing the propeller, remove the sparkplug caps from the spark plugs. Also,place the shift control in neutral, turnthe main switch to “ ” (off) and re-move the key, and remove the lanyardfrom the engine stop switch. Turn offthe battery cut-off switch if your boat

has one.

�

Do not use your hand to hold the pro-peller when loosening or tightening thepropeller nut. Put a wood block be-tween the anti-cavitation plate and thepropeller to prevent the propeller from

turning.

Checkpoints

�

Check each of the propeller blades forwear, erosion from cavitation or ventila-tion, or other damage.

�

Check the propeller shaft for damage.

�

Check the splines / shear pin for wear ordamage.

�

Check for fish line tangled around the pro-peller shaft.

1. Trim and tilt rod

1

ZMU04088

ZMU04089

ZMU01897

Maintenance

64

�

Check the propeller shaft oil seal for dam-age.

NOTE:

If the shear pin equipped: it is designed tobreak if the propeller hits a hard underwaterobstacle to help protect the propeller anddrive mechanism. The propeller will thenspin freely on the shaft. If this happens, the

shear pin must be replaced.

EMU30660

Removing the propeller

EMU29194

Spline models

1. Straighten the cotter pin and pull it outusing a pair of pliers.

2. Remove the propeller nut, washer, andspacer (if equipped).

3. Remove the propeller and thrust wash-er.

EMU30670

Installing the Propeller

EMU29231

Spline models

CAUTION:

ECM00340

�

Be sure to install the thrust washer be-fore installing the propeller, otherwisethe lower case and propeller bosscould be damaged.

�

Be sure to use a new cotter pin andbend the ends over securely. Otherwisethe propeller could come off during op-

eration and be lost.

1. Apply Yamaha marine grease or a cor-rosion resistant grease to the propellershaft.

2. Install the spacer (if equipped), thrustwasher, and propeller on the propellershaft.

3. Install the spacer (if equipped) and thewasher. Tighten the propeller nut to thespecified torque.

4. Align the propeller nut with the propellershaft hole. Insert a new cotter pin in thehole and bend the cotter pin ends.

1. Cotter pin2. Propeller nut3. Washer4. Spacer

5. Propeller6. Thrust washer

ZMU02063

Maintenance

65

NOTE:

If the propeller nut does not align with thepropeller shaft hole after tightening to thespecified torque, tighten the nut further to

align it with the hole.

EMU29282

Changing gear oil

WARNING

EWM00800

�

Be sure the outboard motor is securelyfastened to the transom or a stablestand. You could be severely injured ifthe outboard motor falls on you.

�

Never get under the lower unit while itis tilted, even when the tilt support leveror knob is locked. Severe injury couldoccur if the outboard motor accidental-

ly falls.

1. Tilt the outboard motor so that the gearoil drain screw is at the lowest point pos-sible.

2. Place a suitable container under thegear case.

3. Remove the gear oil drain screw andgasket.

NOTE:

�

If a magnetic gear oil drain screw is

equipped, remove all metal particles fromthe screw before installing it.

�

Always use new gaskets. Do not reuse the

removed gaskets.

4. Remove the oil level plug and gasket toallow the oil to drain completely.

CAUTION:

ECM00710

Inspect the used oil after it has beendrained. If the oil is milky, water is gettinginto the gear case which can cause geardamage. Consult a Yamaha dealer for re-

pair of the lower unit seals.

NOTE:

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 intothe gear oil drain screw hole.

6. Put a new gasket on the oil level plug.When the oil begins to flow out of the oillevel plug hole, insert and tighten the oil

1. Gear oil drain screw2. Oil level plug

1

2

ZMU04090

Recommended gear oil:Hypoid gear oil SAE#90

Gear oil quantity:430.0 cm

3

(14.54 US oz) (15.17 Imp.oz)

ZMU04091

Maintenance

66

level plug.7. Put a new gasket on the gear oil drain

screw. Insert and tighten the gear oildrain screw.

EMU29302

Cleaning fuel tank

WARNING

EWM00920

Gasoline is highly flammable, and its va-pors are flammable and explosive.

�

If you have any question about properlydoing this procedure, consult yourYamaha dealer.

�

Keep away from sparks, cigarettes,flames, or other sources of ignitionwhen cleaning the fuel tank.

�

Remove the fuel tank from the boat be-fore cleaning it. Work only outdoors inan area with good ventilation.

�

Wipe up any spilled fuel immediately.

�

Reassemble the fuel tank carefully. Im-proper assembly can result in a fuelleak, which could result in a fire or ex-plosion hazard.

�

Dispose of old gasoline according to lo-

cal regulations.

1. Empty the fuel tank into an approvedcontainer.

2. Pour a small amount of suitable solventinto the tank. Install the cap and shakethe tank. Drain the solvent completely.

3. Remove the screws holding the fuel jointassembly. Pull the assembly out of thetank.

4. Clean the filter (located on the end of thesuction pipe) in a suitable cleaning sol-vent. Allow the filter to dry.

5. Replace the gasket with a new one. Re-install the fuel joint assembly and tightenthe screws firmly.

EMU29312

Inspecting and replacing anode(s)

Yamaha outboard motors are protected fromcorrosion by sacrificial anodes. Inspect theexternal anodes periodically. Remove scalesfrom the surfaces of the anodes. Consult aYamaha dealer for replacement of externalanodes.

CAUTION:

ECM00720

Do not paint anodes, as this would render

them ineffective.

NOTE:

Inspect ground leads attached to externalanodes on equipped models. Consult aYamaha dealer for inspection and replace-ment of internal anodes attached to the pow-

er unit.

ZMU02066

Maintenance

67

EMU29320

Checking battery (for electric start models)

WARNING

EWM00330

Battery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore ispoisonous and highly caustic.Always follow these preventive mea-sures:

�

Avoid bodily contact with electrolyticfluid as it can cause severe burns orpermanent eye injury.

�

Wear protective eye gear when han-dling or working near batteries.

Antidote (EXTERNAL):

�

SKIN - Flush with water.

�

EYES - Flush with water for 15 minutesand get immediate medical attention.

Antidote (INTERNAL):

�

Drink large quantities of water or milk

followed by milk of magnesia, beatenegg, or vegetable oil. Get immediatemedical attention.

Batteries also generate explosive hydro-gen gas; therefore, you should alwaysfollow these preventive measures:

�

Charge batteries in a well-ventilated ar-ea.

�

Keep batteries away from fire, sparks,or open flames (for example: weldingequipment, lighted cigarettes, and soon.)

�

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

CAUTION:

ECM00360

�

A poorly maintained battery will quicklydeteriorate.

�

Ordinary tap water contains mineralsharmful to a battery, and should not be

used for topping up.

1. Check the electrolyte level at least oncea month. Fill to the manufacturer’s rec-ommended level when necessary. Topup only with distilled water (or pure de-ionized water suitable to use in batter-ies).

2. Always keep the battery in a good state

ZMU02820

ZMU04092

Maintenance

68

of charge. Installing a voltmeter will helpyou monitor your battery. If you will notuse the boat for a month or more, re-move the battery from the boat and storeit in a cool, dark place. Completely re-charge the battery before using it.

3. If the battery will be stored for longerthan a month, check the specific gravityof the fluid at least once a month and re-charge the battery when it is low.

NOTE:

Consult a Yamaha dealer when charging or

re-charging batteries.

EMU29331

Connecting the battery

WARNING

EWM00570

Mount the battery holder securely in adry, well-ventilated, vibration-free loca-tion in the boat. Install a fully charged bat-

tery in the holder.

CAUTION:

ECM01121

�

Make sure the main switch (on applica-ble models) is “ ” (off) before work-ing on the battery.

�

Reversal of the battery cables will dam-age the electrical parts.

�

Connect the red battery cable firstwhen installing the battery and discon-nect the black battery cable first whenremoving it. Otherwise, the electricalparts can be damaged.

�

The electrical contacts of the batteryand cables must be clean and properlyconnected, or the battery will not start

the engine.

Connect the red battery cable to the POSI-TIVE (+) terminal first. Then connect theblack battery cable to the NEGATIVE (-) ter-

minal.

EMU29370

Disconnecting the battery

Disconnect the BLACK cable from the NEG-ATIVE (-) terminal first. Then disconnect theRED cable from the POSITIVE (+) terminal.

EMU29390

Checking top cowling

Check the fitting of the top cowling by push-ing it with both hands. If it is loose have it re-paired by your Yamaha dealer.

EMU29400

Coating the boat bottom

A clean hull improves boat performance. Theboat bottom should be kept as clean of ma-rine growth as possible. If necessary, theboat bottom can be coated with an anti-foul-ing paint approved for your area to inhibit

1. Red cable2. Black cable3. Battery

ZMU02068

Maintenance

69

marine growth.Do not use anti-fouling paint which includescopper or graphite. These paints can causemore rapid engine corrosion.

ZMU01943

70

Trouble Recovery

EMU29424

Troubleshooting

A problem in the fuel, compression, or igni-tion systems can cause poor starting, loss ofpower, 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 yourmodel.If your outboard motor requires repair, bringit to your Yamaha dealer.If the engine trouble warning indicator isflashing, consult your Yamaha dealer.

Starter will not operate.

Q. Is battery capacity weak or low?A. Check battery condition. Use battery ofrecommended capacity.

Q. Are battery connections loose or corrod-ed?A. Tighten battery cables and clean batteryterminals.

Q. Is fuse for electric start relay or electric cir-cuit blown?A. Check for cause of electric overload andrepair. Replace fuse with one of correct am-perage.

Q. Are starter components faulty?A. Have serviced by a Yamaha dealer.

Q. Is shift lever in gear?A. Shift to neutral.

Engine will not start (starter operates).

Q. Is fuel tank empty?A. Fill tank with clean, fresh fuel.

Q. Is fuel contaminated or stale?

A. Fill tank with clean, fresh fuel.

Q. Is fuel filter clogged?A. Clean or replace filter.

Q. Is starting procedure incorrect?A. See page 31.

Q. Has fuel pump malfunctioned?A. Have serviced by a Yamaha dealer.

Q. Are spark plug(s) fouled or of incorrecttype?A. Inspect spark plug(s). Clean or replacewith recommended type.

Q. Are spark plug cap(s) fitted incorrectly?A. Check and re-fit cap(s).

Q. Is ignition wiring damaged or poorly con-nected?A. Check wires for wear or breaks. Tightenall loose connections. Replace worn or bro-ken wires.

Q. Are ignition parts faulty?A. Have serviced by a Yamaha dealer.

Q. Is engine stop switch lanyard not at-tached?A. Attach lanyard.

Q. Are engine inner parts damaged?A. Have serviced by a Yamaha dealer.

Engine idles irregularly or stalls.


Trouble Recovery

71

Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line orother obstructions in fuel system.

Q. Is fuel contaminated or stale?A. Fill tank with clean, fresh fuel.


Q. Have ignition parts failed?A. Have serviced by a Yamaha dealer.

Q. Has warning system activated?A. Find and correct cause of warning.

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


Q. Is specified engine oil not being used?A. Check and replace oil as specified.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Are carburetor adjustments incorrect?A. Have serviced by a Yamaha dealer.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw on fuel tank closed?A. Open air vent screw.

Q. Is choke knob pulled out?

A. Return to home position.

Q. Is motor angle too high?A. Return to normal operating position. Q. Is carburetor clogged?A. Have serviced by a Yamaha dealer.

Q. Is fuel joint connection incorrect?A. Connect correctly.

Q. Is throttle valve adjustment incorrect?A. Have serviced by a Yamaha dealer.

Q. Is battery cable disconnected?A. Connect securely.

Warning buzzer sounds or indicatorlights.

Q. Is cooling system clogged?A. Check water intake for restriction.

Q. Is engine oil level low?A. Fill oil tank with specified engine oil.

Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is engine oil contaminated or deteriorat-ed?A. Replace oil with fresh, specified type.

Q. Is oil filter clogged?A. Have serviced by a Yamaha dealer.

Q. Has oil feed/injection pump malfunc-tioned?

Trouble Recovery

72

A. Have serviced by a Yamaha dealer.

Q. Is load on boat improperly distributed?A. Distribute load to place boat on an evenplane.

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 propeller repaired or replaced.

Q. Is propeller pitch or diameter incorrect?A. Install correct propeller to operate out-board at its recommended speed (r/min)range.

Q. Is trim angle incorrect?A. Adjust trim angle to achieve most efficientoperation.

Q. Is motor mounted at incorrect height ontransom?A. Have motor adjusted to proper transomheight.

Q. Has warning system activated?A. Find and correct cause of warning.

Q. Is boat bottom fouled with marine growth?A. Clean boat bottom.


Q. Are weeds or other foreign matter tangledon gear housing?A. Remove foreign matter and clean lowerunit.

Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line orother obstructions in fuel system.


Q. Is fuel contaminated or stale?A. Fill tank with clean, fresh fuel.

Q. Is spark plug gap incorrect?A. Inspect and adjust as specified.


Q. Have electrical parts failed?A. Have serviced by a Yamaha dealer.

Q. Is specified fuel not being used?A. Replace fuel with specified type.

Q. Is specified engine oil not being used?A. Check and replace oil with specified type.

Q. Is thermostat faulty or clogged?A. Have serviced by a Yamaha dealer.

Q. Is air vent screw closed?A. Open the air vent screw.

Q. Is fuel pump damaged?A. Have serviced by a Yamaha dealer.

Trouble Recovery

73

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 shiftlever position?A. Have serviced by a Yamaha dealer.

Engine vibrates excessively.

Q. Is propeller damaged?A. Have propeller repaired or replaced.

Q. Is propeller shaft damaged?A. Have serviced by a Yamaha dealer.

Q. Are weeds or other foreign matter tangledon propeller?A. Remove and clean propeller.

Q. Is motor mounting bolt loose?A. Tighten bolt.

Q. Is steering pivot loose or damaged?A. Tighten or have serviced by a Yamahadealer.

EMU29433

Temporary action in emergency

EMU29440

Impact damage

WARNING

EWM00870

The outboard motor can be seriously

damaged by a collision while operating ortrailering. Damage could make the out-

board motor unsafe to operate.

If the outboard motor hits an object in the wa-ter, follow the procedure below.

1. Stop the engine immediately.2. Inspect the control system and all com-

ponents for damage. Also inspect theboat for damage.

3. Whether damage is found or not, returnto the nearest harbor slowly and careful-ly.

4. Have a Yamaha dealer inspect the out-board motor before operating it again.

EMU29471

Replacing fuse

If a fuse has blown, remove the electricalcover, open the fuse holder and remove thefuse with a fuse puller (if equipped). Replaceit with a spare one of the proper amperage.

WARNING

EWM00630

Be sure to use the specified fuse. An in-correct fuse or a piece of wire could allowexcessive current flow. This could cause

electric system damage and a fire hazard.

NOTE:

Consult your Yamaha dealer if the new fuse

immediately blows again.

Trouble Recovery

74

EMU29511

Power trim and tilt / power tilt will not operate

If the engine cannot be tilted up or down withthe power trim and tilt / the power tilt becauseof a discharged battery or a failure with thepower trim and tilt unit / the power tilt unit, theengine can be tilted manually.1. Loosen the manual valve screw by turn-

ing it clockwise until it stops.

2. Put the engine in the desired position,then tighten the manual valve screw byturning it counterclockwise.

EMU29532

Starter will not operate

If the starter mechanism does not operate(the engine cannot be cranked with the start-er), the engine can be started with an emer-gency starter rope.

WARNING

EWM01021

�

Use this procedure only in an emergen-cy to return to the nearest port for re-pairs.

�

When the emergency starter rope isused to start the engine, the start-in-gear protection device does not oper-ate. Make sure the remote control leveris in neutral. Otherwise the boat couldunexpectedly start to move, whichcould result in an accident.

�

Attach the engine stop switch lanyardto a secure place on your clothing, oryour arm or leg while operating theboat.

�

Do not attach the lanyard to clothingthat could tear loose. Do not route thecord where it could become entangled,

1. Fuse box2. Fuse (20 A)3. Spare fuse (20 A)4. Fuse puller

1. Fuse puller

12

3

4

ZMU04094

1

ZMU04093

1. Manual valve screw

1

ZMU04095

Trouble Recovery

75

preventing it from functioning.

�

Avoid accidentally pulling the lanyardduring normal operation. Loss of en-gine power means the loss of moststeering control. Also, without enginepower, the boat could slow rapidly. Thiscould cause people and objects in theboat to be thrown forward.

�

Make sure no one is standing behindyou when pulling the starter rope. Itcould whip behind you and injuresomeone.

�

An unguarded, rotating flywheel is verydangerous. Keep loose clothing andother objects away when starting theengine. Use the emergency starter ropeonly as instructed. Do not touch the fly-wheel or other moving parts when theengine is running. Do not install thestarter mechanism or top cowling afterthe engine is running.

�

Do not touch the ignition coil, sparkplug wire, spark plug cap, or other elec-trical components when starting or op-erating the motor. You could get an

electrical shock.

EMU30361

Emergency starting engine

1. Remove the top cowling.2. Disconnect the start-in-gear protection

cable from the starter, if equipped.

3. Remove the starter/flywheel cover afterremoving the bolt(s).

4. Prepare the engine for starting. For fur-ther information, see page 31. Be surethe engine is in neutral and that the en-gine stop switch lanyard lock plate is at-tached to the engine stop switch. Themain switch must be “ ” (on), ifequipped.

ZMU04096

ZMU04097

ZMU04098

Trouble Recovery

76

5. Insert the knotted end of the emergencystarter rope into the notch in the flywheelrotor and wind the rope several turnsaround the flywheel clockwise.

6. Pull the rope slowly until resistance isfelt.

7. Give a strong pull straight out to crankand start the engine. Repeat if neces-sary.

EMU29760

Treatment of submerged motor

If the outboard motor is submerged, immedi-ately take it to a Yamaha dealer. Otherwisesome corrosion may begin almost immedi-ately.If you cannot immediately take the outboardmotor to a Yamaha dealer, follow the proce-dure below in order to minimize engine dam-age.

EMU29783

Procedure

1. Thoroughly wash away mud, salt, sea-weed, and so on, with fresh water.

2. Remove the spark plug(s), then face thespark plug holes downward to allow anywater, mud, or contaminants to drain.

3. Drain the fuel from the carburetor, fuelfilter, and fuel line. Drain the engine oilcompletely.

4. Fill the sump with the fresh engine oil.

5. Feed engine fogging oil or engine oilthrough the carburetor(s) and spark plugholes while cranking the engine with themanual starter or emergency starterrope.

6. Take the outboard motor to a Yamahadealer as soon as possible.

CAUTION:

ECM00400

Do not attempt to run the outboard motor

until it has been completely inspected.

ZMU02334

ON STARTOFF

ZMU01906

ZMU04100

Engine oil capacity:2.0 L (2.11 US qt) (1.76 Imp.qt)

77

Consumer information

EMU29811

Important warranty information for U.S.A. and Canada


78


79

EMU29830

YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY


80


81

EMU29841

IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA

67C-9-18-Hyoshi 06.3.3 10:15 AM ページ 3

Printed in JapanApril 2006–0.6 × 1 ! Printed on recycled paper

67C-9-18-Hyoshi 06.3.3 10:15 AM ページ 4

YAMAHA MOTOR CO., LTD.MADE IN JAPANPAYS D'ORIGINE JAPON

OUTBOARD MOTOR WARRANTY REGISTRATION

ENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORD

Please complete and mail this card. This information is necessary to accurately register your unit for warranty.Veuillez signer ci-dessous pour attester que le montage et l’inspection ont été faits dans le respect des directives d’inspection et

que la marche à suivre pour la garantie et l’entretien a été expliquée à l’acheteur au détail.

OUTBOARD MOTOR MODEL AND SERIAL NUMBER (From I.D. label on clamp bracket)MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation)

(For Dealer Use Only)(A l’usage du concessionnaire)YAMAHA DEALER NUMBERNO. DU CONCESSIONNAIRE YAMAHA

DEALER NAMENOM DU CONCESSIONNAIRE

DATE SOLDDATE DELIVRAISON

OWNER’S NAMENOM DUPROPRIÉTAIRE

ADDRESSADRESSE

PHONE NUMBER ( )NUMÉRO DE TÉLÉPHONE

USAGE(Check One)UTILISATION(En cocher un.)

PLEASURELOISIRCOMMERCIALCOMMERCIAL

MONTH DAY YEARMOIS JOUR ANNÉE

FIRST LASTPRÉNOM NOM DE FAMILLE

STREETRUE

CITY STATE/PROVINCE ZIPVILLE PROVINCE CODE POSTAL

Warranty card-04 2/17/03 2:41 PM Page 1

PLACEPOSTAGEHERE

ATTN: WARRANTY DEPARTMENT

Warranty card-04 2/17/03 2:41 PM Page 2

Documents

F40 Owner's Manual - Yamaha - Motorcycles, … manual information EMU31280 To the owner Thank you for choosing a Yamaha outboard motor. This Owner’s Manual contains infor-mation