Yamaha Z200A Z150A, LZ150A, Z175A, Z200A, LZ200A User Manual To The 02502dc5 B207 4054 9893 24dc61727dbe

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LIT-18626-04-63

Z150A

LZ150A

Z175A

Z200A

LZ200A

OWNER’S MANUAL

U.S.A.Edition

USE STRAIGHT GASOLINE ONLY

CAUTION

• Do not use fuel mixed with oil both during break-in

• Oil can damage fuel injectors.

and during normal use.

000118

E

Thank you for choosing a Yamaha out-

board motor. This Owner’s manual con-

tains information needed for proper oper-

ation, maintenance and care. A thorough

understanding of these simple instruc-

tions will help you obtain maximum

enjoyment from your new Yamaha. If you

have any question about the operation or

maintenance of your outboard motor,

please consult a Yamaha dealer.

In this Owner’s Manual particularly

important information is distinguished in

the following ways.

QThe Safety Alert Symbol means

ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

w

Failure to follow WARNING instructions

could result in severe injury or death to

the machine operator, a bystander, or a

person inspecting or repairing the out-

board motor.

cC

A CAUTION indicates special precautions

that 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 advance-

ments in product design and quality.

Therefore, while this manual contains

the most current product information

available at the time of printing, there

may be minor discrepancies between

your machine and this manual. If there

is any question concerning this manual,

please consult your Yamaha dealer.

NOTE:

The Z200TR, LZ200TR and their standard

accessories are used as a base for the

explanations and illustrations in this man-

ual. Therefore, some items may not apply

to every model.

EMU01449

TO THE OWNER

EMU01446

Z150A/LZ150A/Z175A/Z200A/LZ200A

OWNER'S MANUAL

©2001 by Yamaha Motor Corporation, USA

2nd Edition, April 2001

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in Japan

P/N LIT-18626-04-63

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 1

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CONTENTS

GENERAL INFORMATION

BASIC COMPONENTS

OPERATION

MAINTENANCE

TROUBLE RECOVERY

INDEX

1

2

3

4

5

6

READ THIS OWNER’S MANUAL CAREFULLY

BEFORE OPERATING YOUR OUTBOARD MOTOR.

EMU00003

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 3

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EMU00004

Chapter 1

GENERAL

INFORMATION

IDENTIFICATION NUMBERS RECORD ..1-1

Outboard motor serial number...........1-1

Key number...........................................1-1

EMISSION CONTROL INFORMATION...1-2

SAFETY INFORMATION..........................1-4

IMPORTANT LABELS ..............................1-6

BASIC BOATING RULES .........................1-7

FUELING INSTRUCTIONS.....................1-11

Gasoline ..............................................1-12

Engine oil ............................................1-12

BATTERY REQUIREMENT ....................1-13

PROPELLER SELECTION .......................1-13

START-IN-GEAR PROTECTION ............1-15

1

2

3

4

5

6

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 5

1-1

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EMU00005

IDENTIFICATION NUMBERS

RECORD

EMU00007

OUTBOARD MOTOR SERIAL

NUMBER

The outboard motor serial number is

stamped on the label attached to the port

side of the clamp-bracket.

Record your outboard motor serial num-

ber in the spaces provided to assist you in

ordering spare parts from your Yamaha

dealer or for reference in case your out-

board motor is stolen.

1Outboard motor serial number

EMU00008

KEY NUMBER

If a main key switch is equipped with the

motor, the key identification number is

stamped on your key as shown in the

illustration. Record this number in the

space provided for reference in case you

need a new key.

1Key number

q401016

904011*

123

YAMAHA

q

YAMAHA MOTOR CO., LTD.

MADE IN JAPAN

PAYS D'ORIGINE JAPON

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 6

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1-2

108044

w

q

EMU01385

EMISSION CONTROL

INFORMATION

EMU01387*

NORTH AMERICAN MODELS

This engine conforms to U.S.

Environmental Protection Agency (EPA)

regulations for marine SI engines. See the

label affixed to your engine for details.

Approval label of Emission control

certificate

This label is attached to the bottom cowl-

ing.

1Emission control information label

New Technology ; (4-stroke/HPDI) EM

Manufactured date label

This label is attached to the clamp brack-

et.

2Manufactured date label

EMISSION CONTROL INFORMATION

ENGINE FAMILY :

THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.

THIS ENGINE CONFORMS TO 2001 CALIFORNIA EMISSION REGULATIONS FOR SI MARINE ENGINES.

REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.

FELs :

SPARK PLUG :

DISPLACEMENT :

ADVERTISED POWER :

IDLE SPEED :

SPARK PLUG GAP (mm) :

FUEL : GASOLINE

VALVE LASH (mm) : IN EX

cm

kw

g/kw-hr rpm IN NEUTRAL

3

EM

Manufactured:

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 7

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1-3

EMU01389

STAR LABELS

Your outboard motor is labeled with a

California Air Resources Board (CARB)

star label. See below for a description of

your particular label.

1Star label

One Star - Low Emission

The one-star label identifies engines that

meet the Air Resources Board’s 2001

exhaust emission standards. Engines

meeting these standards have 75% lower

emissions than conventional carbureted

two-stroke engines. These engines are

equivalent to the U.S. EPA’s 2006 stan-

dards for marine engines.

Two Stars - Very Low Emission

The two-star label identifies engines that

meet the Air Resources Board’s 2004

exhaust emission standards. Engines

meeting these standards have 20% lower

emissions than One Star-Low-Emission

engines.

Three Stars - Ultra Low Emission

The three-star label identifies engines that

meet the Air Resources Board’s 2008

exhaust emission standards. Engines

meeting these standards have 65% lower

emissions than One Star-Low-Emission

engines.

000849

q

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 8

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1-4

EMU00917

SAFETY

INFORMATION

8Before mounting or operating the out-

board motor, read this entire manual.

Reading it should give you an under-

standing of the motor and its operation.

8Before operating the boat, read any

owner’s or operator’s manuals supplied

with it and all labels. Be sure you under-

stand each item before operating.

8Do not overpower the boat with this

outboard motor. Overpowering the

boat could result in loss of control. The

rated power of the outboard should be

equal to or less than the rated horse-

power capacity of the boat. If the rated

horsepower capacity of the boat is

unknown, consult the dealer or boat

manufacturer.

8Do not modify the outboard.

Modifications could make the motor

unfit or unsafe to use.

8Never operate after drinking alcohol or

taking drugs. About 50% of all boating

fatalities involve intoxication.

8Have an approved personal flotation

device (PFD) on board for every occu-

pant. It is a good idea to wear a PFD

whenever boating. At a minimum, chil-

dren and non-swimmers should always

wear PFDs, and everyone should wear

PFDs when there are potentially haz-

ardous boating conditions.

8Gasoline is highly flammable, and its

vapors are flammable and explosive.

Handle and store gasoline carefully.

Make sure there are no gas fumes or

leaking fuel before starting the engine.

8This product emits exhaust gases which

contain carbon monoxide, a colorless,

odorless gas which may cause brain

damage or death when inhaled.

Symptoms include nausea, dizziness,

and drowsiness. Keep cockpit and cabin

areas well ventilated. Avoid blocking

exhaust outlets.

8Check throttle, shift, and steering for

proper operation before starting the

engine.

8Attach the engine stop switch lanyard

to a secure place on your clothing, or

your arm or leg while operating. If you

accidentally leave the helm, the lanyard

will pull from the switch, stopping the

engine.

8Know the marine laws and regulations

where you will be boating - and obey

them. Refer to the “RULES OF THE

ROAD” section for basic boating rules.

8Stay informed about the weather.

Check weather forecasts before boating.

Avoid boating in hazardous weather.

8Tell someone where you are going:

leave a Float Plan with a responsible

person. Be sure to cancel the Float Plan

when you return.

8Use common sense and good judgment

when boating. Know your abilities, and

be sure you understand how your boat

handles under the different boating

conditions you may encounter. Operate

within your limits, and the limits of your

boat. Always operate at safe speeds,

and keep a careful watch for obstacles

and other traffic.

8Always watch carefully for swimmers

during the engine operation.

8Stay away from swimming areas.

Q

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1-5

8When a swimmer is in the water near

you shift into neutral and shut off the

engine.

8Be informed about boating safety.

Additional publications and information

can be obtained from many organiza-

tions, including the following:

United States Coast Guard

Consumer Affairs Staff (G-BC)

Office of Boating, Public, and Consumer

Affairs

U.S. Coast Guard Headquarters

Washington, D.C. 20593-0001

Boating Safety Hotline: 1-800-368-5647

National Marine Manufacturers

Association (NMMA)

401 N. Michigan Ave.

Chicago, Il 60611

Marine Retailers Association of America

155 N. Michigan Ave.

Chicago, Il 60601

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 10

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1-6

202036

w

q

e

t

905011

r

EMU00014

IMPORTANT LABELS

WARNING LABELS

2

3

WARNING

6K1-83623-41

YAMAHA

Use only a counterclockwise rotation propeller with this engine.

Counterclockwise propellers are marked with a letter "L"

after the size indication.

The wrong type of propeller could cause the boat to go

in an unexpected direction, which could lead to an accident.

WARNING

6Be sure shift control is in neutral

6before starting engine. (except 2HP)

6Do not touch or remove electrical parts

6when starting or during operation.

6Keep hands,hair,and clothes away from flywheel

6and other rotating parts while engine is running.

6A1-83625-41

WARNING

Hot surface under this cover

during and after operation.

To avoid burns, do not touch

finned resistor with bare hands.

65L-83625-40

YAMAHA

4

ENGINE OIL ONLY

WARNING

6E5-13437-43

Pour the engine oil into this oil tank, not gasoline.

RECOMMENDED OIL:

YAMALUBE 2 STROKE OUTBOARD OIL or an equivalent TC-W3 certified outborad oil.

Do not add gasoline to the oil tank.

Fire or explosion could result.

OIL TANK

CAPACITY:10.5 LITERS

11.1 U.S. qt.

9.2 IMP. qt.

USE UNLEADED STRAIGHT GASOLINE ONLY

CAUTION

• Gasoline containing lead can cause performance loss and engine damage.

• Do not use gasoline mixed with oil (premix).

• Use YAMALUBE 2-stroke outboard oil or another 2-stroke engine oil with a

BIA-certified TC-W3 rate.

• Refer to Owner's manual.

68F-2415E-40

YAMAHA

CAUTION LABELS

1

5

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 11

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1-7

Stand-on vessel

The vessel with the right-of-way has the

duty to continue its course and speed,

except to avoid an immediate collision.

When you maintain your direction and

speed, the other vessel will be able to

determine how best to avoid you.

Give-way vessel

The vessel which does not have the right-

of-way has the duty to take positive and

timely action to stay out of the way of the

Stand-On vessel. Normally, you should

not cross in front of the vessel with the

right-of-way. You should slow down or

change directions briefly and pass behind

the other vessel. You should always move

in such a way that the operator of the

other vessel can see what you are doing.

“The general prudential rule”

This rule is called Rule 2 in the

International Rules and says,

‘In obeying and construing these

rules due regard shall be had to all

dangers of navigation and collision,

and to any special circumstances,

which may render a departure from

the above rules necessary in order to

avoid immediate danger.’

In other words, follow the standard rules

except when a collision will occur unless

both vessels try to avoid each other. If

that is the case, both vessels become

“Give-Way” vessels.

EMU00015

BASIC BOATING RULES

(Rules of the road)

Just as there are rules which apply when

you are driving on streets and high ways,

there are waterway rules which apply

when you are driving your boat. These

rules are used internationally, and are

also enforced by the United States Coast

Guard and local agencies. You should be

aware of these rules, and follow them

whenever you encounter another vessel

on the water.

Several sets of rules prevail according to

geographic location, but are all basically

the same as the International Rules of the

Road. The rules presented here in your

Owner’s Manual are condensed, and have

been provided for your convenience only.

Consult your local U.S. Coast Guard

Auxiliary or Department of Motor

Vehicles for a complete set of rules gov-

erning the waters in which you will be

using your boat.

STEERING AND SAILING RULES AND

SOUND SIGNALS

Whenever two vessels on the water meet

one another, one vessel has the right-of-

way; it is called the “stand-on” vessel.

The vessel which does not have the right-

of-way is called the “give-way” or “bur-

dened” vessel. These rules determine

which vessel has the right-of-way, and

what each vessel should do.

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 12

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1-8

RULES WHEN ENCOUNTERING

VESSELS

There are three main situations which you

may encounter with other vessels which

could lead to a collision unless the

Steering Rules are followed:

Meeting

(you are approaching another vessel

head-on)

Crossing

(you are traveling across the other

vessel’s path)

Overtaking

(you are passing or being passed by

another vessel)

In the following illustration, your boat is

in the center. You should give the right-of-

way to any vessels shown in white area

(you are the Give-Way vessel). Any ves-

sels in the shaded area must yield to you

(they are the Give-Way vessels). Both you

and the meeting vessel must alter course

to avoid each other.

Meeting

If you are meeting another power vessel

head on, and are close enough to run the

risk of collision, neither of you has the

right-of-way! Both of you should alter

course to avoid an accident. You should

keep the other vessel on your port (left)

102045

side. This rule doesn’t apply if both of you

will clear one another if you continue on

your set course and speed.

Crossing

When two power driven vessels are

crossing each other’s path close enough

to run the risk of collision, the vessel

which has the other on the starboard

(right) side must keep out of the way of

the other. If the other vessel is on your

right, you must keep out of its way; you

are the Give-Way vessel. If the other ves-

sel is on your port (left) side, remember

that you should maintain course and

direction, provided the other vessel gives

you the right-of-way as it should.

Overtaking

If you are passing another vessel, you are

the “Give-Way” vessel. This means that

the other vessel is expected to maintain

its course and speed. You must stay out

102046

102044

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 13

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1-9

the power-driven vessel, the power-

driven vessel has the right-of-way.

2. Sailing vessels should keep clear of

any fishing vessel.

3. In a narrow channel, a sailing vessel

should not hamper the safe passage

of a power-driven vessel which can

navigate only in such a channel.

Reading buoys and other markers

The waters of the United states are

marked for safe navigation by the lateral

system of buoyage. Simply put, buoys

and markers have an arrangement of

shapes, colors, numbers and lights to

show which side of the buoy a boater

should pass on when navigating in a par-

ticular direction. The markings on these

buoys are oriented from the perspective

of being entered from seaward (the

boater is going towards the port). This

means that red buoys are passed on the

starboard (right) side when proceeding

from open water into port, and black

buoys are to port (left) side. When navi-

gating out of port, your position with

respect to the buoys should be reversed;

red buoys should be to port and black

buoys to starboard.

Many bodies of water used by boaters are

entirely within the boundaries of a partic-

ular state. The Uniform State Waterway

Marking System has been devised for

these waters. This system uses buoys and

signs with distinctive shapes and colors

to show regulatory or advisory informa-

tion. These markers are white with black

letters and orange boarders. They signify

speed zones, restricted areas, danger

areas, and general information.

of its way until you are clear of it.

Likewise, if another vessel is passing you,

you should maintain your speed and

direction so that the other vessel can steer

itself around you.

OTHER SPECIAL SITUATIONS

There are three other rules you should be

aware of when driving your boat around

other vessels.

Narrow channels and bends

When navigating in narrow channels, you

should keep to the right when it is safe

and practical to do so. If the operator of a

power-driven vessel is preparing to go

around a bend that may obstruct the view

of other water vessels, the operator

should sound a prolonged blast on the

whistle (4 to 6 seconds). If another vessel

is around the bend, it too should sound

the whistle. Even if no reply is heard,

however, the vessel should still proceed

around the bend with caution. If you navi-

gate such waters with your boat, you will

need to carry a portable air horn, avail-

able from local marine supply stores.

Fishing vessel right-of-way

All vessels which are fishing with nets,

lines or trawls are considered to be “fish-

ing vessels” under the International

Rules. Vessels with trolling lines are not

considered fishing vessels. Fishing ves-

sels have the right-of-way regardless of

position. Fishing vessels cannot, howev-

er, impede the passage of other vessels in

narrow channels.

Sailing vessel right-of-way

Sailing vessels should normally be given

the right-of-way. The exceptions to this

are:

1. When the sailing vessel is overtaking

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1-10

11

A

11

Proceeding toward head

of navigation from seaward

CAN BUOY

Odd number. Leave to port.

OR

SECONDARY CHANNEL BUOYS

STARTS NEW NUMBERING SYSTEM

old new

C

"

1

"

NUN BUOY

Even number. Leave to starboard

N

"

2

"

No change

BUOY

COLOR CODE

BLACK

RED

GREEN

"

A

"

"

2

"

"

1

"

"

3

"

"

4

"

"

5

"

"

7

"

N

"

2

"

"

6

"

C

"

1

"

RB

"

L

"

RG

"

L

"

or

SECONDARY CHANNEL

MAIN CHANNEL

old new

2

22

A

L

L

Odd number. increasing toward head of naviga-

MAIN CHANNEL BUOYS

"

1

""

3

""

5

""

7

"

tion.Leave to port (left) proceeding upstream.

LIGHTED BUOY (Port Hand)`

White Light Green Light

old new

old new

old new

LIGHTED BUOY (Starboard Hand)`

"

2

""

4

""

6

"

Even number,increasing toward head of naviga-

tion. Leave to starboard (right) proceeding up-

stream.

White Light Red Light

"

A

"

LIGHTED SAFE WATER BUOY

No number. Marks midchannel, pass on either

side. Letter has no lateral significance, used for

No number. Topmost band red

-

preferred

Top Mark

White Light

White Light

OR

OR

LIGHTED PREFERRED CHANNEL TO

RB

"

L

"

RG

"

L

"

PORT BUOY

identification and location purposes.

channel is to left of buoy. Letter has no lateral

significance, used for identification and location

purposes.

Red Light

Red or

White Light

OR

102052

Remember, markings may vary by geo-

graphic location. Always consult local

boating authorities before driving your

boat in unfamiliar waters.

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1-11

EMU00017

FUELING INSTRUCTIONS

w

GASOLINE AND ITS VAPORS ARE HIGH-

LY FLAMMABLE AND EXPLOSIVE!

8Do not smoke when refueling, and

keep away from sparks, flames, or

other sources of ignition.

8Stop engine before refueling.

8Refuel in a well-ventilated area. Refuel

portable fuel tanks off the boat.

8Take care not to spill gasoline. If gaso-

line spills, wipe it up immediately with

dry rags.

8Do not overfill the fuel tank.

8Tighten the filler cap securely after

refueling.

8If you should swallow some gasoline

inhale a lot of gasoline vapor, or get

gasoline in your eyes, get immediate

medical attention.

8If any gasoline spills onto your skin,

immediately wash with soap and

water. Change clothing if gasoline spills

on it.

8Touch the fuel nozzle to the filler open-

ing or funnel to help prevent electrosta-

tic sparks.

cC

8Use only new clean gasoline which has

been stored in clean containers and is

not contaminated with water or foreign

matter.

8Do not use leaded gasoline(petrol).

Leaded gasoline will cause damage to

the oxygen sensor for Electronic Fuel

Injection system.

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1-12

EMU00027

Gasohol

There are two types of gasohol: gasohol

containing ethanol and that containing

methanol. Gasohol containing ethanol

can be used if ethanol content does not

exceed 10% and the fuel meets minimum

octane ratings. Gasohol containing

methanol is not recommended by

Yamaha because it can cause fuel system

damage or engine performance prob-

lems.

EMU00858

ENGINE OIL

If the recommended engine oil is not

available, another 2-stroke engine oil with

a NMMA-certified TC-W3 rating may be

used.

EMU00019

GASOLINE (PETROL)

If knocking or pinging occurs, use a differ-

ent brand of gasoline or premium unlead-

ed fuel.

Recommended engine oil:

YAMALUBE 2 STROKE OUTBOARD

OIL

Recommended gasoline:

Regular unleaded gasoline with a mini-

mum octane rating of 86 (Pump

Octane Number) = (R+M)/2

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1-13

EMU00033

BATTERY REQUIREMENT

cC

Do not use the battery that does not

meet the specified capacity. If different

battery from the specification is used, the

electric system may perform poorly or be

overloaded, causing electrical system

damage.

Choose battery which meets the following

specifications.

If any electrical accessories are used, use

a second battery to power them. Choose

a battery with the same capacity as the

one for the engine. If the engine’s battery

voltage drops approximately 9 volts or

below during operation or while starting,

the electric fuel pump for Electronic Fuel

Injection system will not operate. The

engine can not be started if battery volt-

age is too low.

Minimum cold crank performance

512 Amps at -17.8°C (0°F)

Minimum reserve capacity

182 Minutes at 26.7°C (80°F)

EMU01395

PROPELLER SELECTION

The performance of your outboard motor

will be critically affected by your choice of

propeller, as an incorrect choice could

adversely affect performance and could

also seriously damage the motor. Engine

speed depends on the propeller size and

boat load. If engine speed is too high or

too low for good engine performance,

this will have an adverse effect on the

engine.

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1-14

602022

14-1/2x17-M

123

Yamaha outboard motors are fitted with

propellers chosen to perform well over a

range of applications, but there may be

uses where a propeller with a different

pitch would be more appropriate. For a

greater operating load, a smaller-pitch

propeller is more suitable as it enables

the correct engine speed to be main-

tained. Conversely, a larger-pitch pro-

peller is more suitable for a smaller oper-

ating load.

Yamaha dealers stock a range of pro-

pellers, and can advise you and install a

propeller on your outboard that is best

suited to your application.

NOTE:

At full throttle and under a maximum

boat load, the engine’s rpm should be

within the upper half of the full throttle

operating range, as listed in “SPECIFICA-

TIONS” on page 4-1. Select a propeller

which fulfills this requirement.

If operating under conditions which allow

the engine’s rpm to rise above the maxi-

mum recommended range (such as light

boat loads), reduce the throttle setting to

maintain the rpm in the proper operating

range.

1Propeller diameter (in inches)

2Propeller pitch (in inches)

3Type of propeller (propeller mark)

Refer to the section “CHECKING PRO-

PELLER” for instructions on propeller

removal and installation.

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1-15

EMU01209

START-IN-GEAR PROTECTION

Yamaha outboard motors or Yamaha

approved remote control units are

equipped with start-in-gear protection

device(s). This feature permits the engine

to be started only when it is Neutral.

Always select Neutral before starting the

engine.

68F-9-13-1 <2nd> 4/23/01 11:45 AM Page 20

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EMU00037

Chapter 2

BASIC COMPONENTS

MAIN COMPONENTS..............................2-1

OPERATIONS OF CONTROLS AND

OTHER FUNCTIONS ................................2-2

Remote control .....................................2-2

Trim tab .................................................2-7

Power trim/tilt switch ...........................2-8

Digital tachometer................................2-9

Digital speedometer...........................2-11

Fuel management meter ...................2-14

Tilt support lever ................................2-19

Top cowling lock levers .....................2-19

Flushing device...................................2-19

WARNING SYSTEM ..............................2-20

Overheat warning...............................2-20

Oil level warning /

oil filter clogging warning .................2-21

1

2

3

4

5

6

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 1

E

EMU00038

MAIN COMPONENTS

!4 !5

TRIP TIME BATT

Km/h

knot

mph

km

mile

SPEED

YAMAHA

set mode

!3

!1 !2

!6

101083

q

w

e

r

o

!0

i

y

t

u

101084

w

YAMAHA

set mode

P S

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

!7

1Top cowling

2Top cowling lock levers

3Trim tab (Anode)

*4Propeller

5Cooling water inlet

6Anti-cavitation plate

7Anode

8Tilt support lever

9Flushing device

0Power trim and tilt switch

*qRemote control box (Side mount type)

*w

Remote control box (Binnacle mount type)

*eSwitch panel (for use with w)

*rDigital tachometer

*tDigital speedometer

*yFuel management meter

*uRemote oil tank

* May not be exactly as shown; also may not

be included as standard equipment on all

models.

2-1

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 2

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EMU00039

OPERATIONS OF CONTROLS

AND

OTHER FUNCTIONS

EMU01273

REMOTE CONTROL

Both the shifter and the throttle are actu-

ated by the remote control lever. In addi-

tion, the electrical switches are mounted

on the remote control box.

åSide mount remote control box

∫Binnacle mount remote control box

çSwitch panel (for use with ∫)

1Remote control lever

2Neutral interlock trigger

3Neutral throttle lever

4Free accelerator

5Main switch

6Engine stop lanyard switch

7Power trim/tilt switch

8Throttle friction adjusting screw

701011*

w

q

e

t

y

u

i

2-2

q

r

u

u

702051

i

ON

STARTOFF ON

STARTOFF

t

y

703022

A

B

C

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 3

E

EMU00098

Remote Control Lever

Moving the lever forward from the

Neutral position engages Forward gear.

Pulling the lever back from Neutral

engages Reverse. The engine will contin-

ue to run at idle until the lever is moved

about 35° (a detent can be felt). Moving

the lever farther opens the throttle, and

the engine will begin to accelerate.

1Neutral

2Forward

3Reverse

4Shift

5Fully closed

6Throttle

7Fully open

R

N

F

q

we

r

ty

u

u

t

r

y

701031

701034*

N

701033

w

q

2-3

702032

q

we

rr

ttyy

u

u

EMU00099

Neutral Interlock Trigger

To shift out of Neutral, the neutral inter-

lock trigger of the remote control lever

must first be pulled up.

EMU00100

Neutral Throttle Lever

To open the throttle without shifting into

either Forward or Reverse, place the

remote control lever in the Neutral posi-

tion and lift the neutral throttle lever.

NOTE:

The neutral throttle lever will operate only

when the remote control lever is in

Neutral. The remote control lever will

operate only when the neutral throttle

lever is in the closed position.

1Fully open

2Fully closed

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 4

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2-4

EMU00101

Main switch

The main switch controls the ignition sys-

tem; its operation is described below.

8OFF

Electrical circuits switched off.

(The key can be removed.)

8ON

Electrical circuits switched on.

(The key cannot be removed.)

8START

Starter-motor will turn and start engine.

(When the key is released, it returns auto-

matically to “ON”.)

ON

STARTOFF ON

STARTOFF

000569

q

w

ON

STARTOFF ON

STARTOFF

q

w

000715

EMU00934

Engine Stop Lanyard Switch

The lock-plate 1must be attached to the

engine stop lanyard switch for the engine

to run. The lanyard 2should be attached

to a secure place on the operator’s cloth-

ing, or arm or leg. Should the operator fall

overboard or leave the helm, the lanyard

will pull out the lock plate, stopping igni-

tion to the engine. This will prevent the

boat from running away under power.

w

8Attach the lanyard to a secure place on

your clothing, your arm or leg while

operating.

8Do not attach the lanyard to clothing

that could tear loose. Do not route the

lanyard in such a way that it could

become entangled, preventing it from

functioning.

8Avoid accidentally pulling the lanyard

during normal operation. Loss of

engine power means the loss of most

steering control. Also, without engine

power, the boat could slow rapidly.

This could cause people and objects in

the boat to be thrown forward.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 5

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2-5

NOTE:

The engine cannot be started with the

lock-plate removed.

UP

DN

701034

UP

DN

DN

UP

702042**

EMU01112

Power Trim/Tilt Switches

The power trim/tilt adjusts the motor

angle in relation to the transom. The

power trim/tilt switch is located on the

remote control lever grip. Individual-

engine switches are also on the control

cover. Pushing the switch “UP” trims the

motor up, then tilts the motor up.

Pressing the switch “DN” tilts the motor

down and trims the motor down. When

the switch button is released, the motor

will stop in its current position.

NOTE:

8On the dual engine control, the switch

on the remote control grip controls both

engines at the same time.

8Refer to the sections “Adjusting Trim

Angle” and “Tilting Up/Down” in

Chapter 3 for instructions on usage.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 6

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2-6

EMU00106

Free Accelerator

To open the throttle without shifting into

either Forward or Reverse, push the free

accelerator button and turn the remote

control lever.

NOTE:

8The free accelerator button can be oper-

ated only when the remote control lever

is in the Neutral position.

8After the button is pushed, the remote

control lever must be moved at least

35° to begin opening the throttle.

8After operating the free accelerator,

return the remote control lever to the

Neutral position. The free accelerator

button will return automatically to its

set position. The remote control will

then engage Forward and Reverse nor-

mally.

1Fully-open

2Fully-closed

3Free accelerator

702043

35°

q

w

e

701035

EMU01155

Throttle Friction Adjusting Screw

A friction device in the remote control box

provides adjustable resistance to move-

ment of the remote control lever, and can

be set according to operator preference.

An adjusting screw is located on the front

of the remote control box.

w

Do not overtighten the friction adjusting

screw. If there is too much resistance, it

may be difficult to move the lever, which

could result in an accident.

Resistance Screw

Increase Turn clockwise

Decrease Turn counterclockwise

702035

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 7

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2-7

EMU00113

TRIM TAB

The trim tab should be adjusted so that

the steering control can be turned to

either the right or left by applying the

same amount of force.

w

An improperly adjusted trim tab may

cause difficult steering. Always test run

after the trim tab has been installed or

replaced to be sure steering is correct. Be

sure you have tightened the bolt after

adjusting the trim tab.

1Trim tab

2Bolt

3Cap (If equipped)

cC

The trim tab also serves as an anode to

protect the engine from electrochemical

corrosion. Never paint the trim tab as it

will become ineffective as an anode.

A

B603012*

q

w

e

603014

Boat tends to veer

To the left

(port side)

To the right

(starboard side)

The fin of trim tab

Turn to the left

(A in the figure)

Turn to the right

(B in the figure)

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 8

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2-8

302022

UP

DN

EMU01125

POWER TRIM/TILT SWITCH

The power trim/tilt adjusts the motor

angle in relation to the transom. The

power trim/tilt switch is located on the

side of the bottom engine cowling.

Pushing the switch “UP” trims the motor

up, then tilts the motor up. Pressing the

switch “DN” tilts the motor down and

trims the motor down. When the switch

button is released, the motor will stop in

its current position.

w

Use the power trim/tilt switch located on

the bottom engine cowling only when

the boat is at a complete stop with the

engine off. Attempting to use the cowl-

ing-mounted power trim/tilt switch while

the boat is moving could increase the risk

of falling overboard and could distract

the operator, increasing the risk of colli-

sion with another boat or an obstacle.

NOTE:

Refer to the section “Adjusting Trim

Angle” and “Tilting Up/Down” for instruc-

tions on usage.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 9

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2-9

001082

001049

EMU01614

DIGITAL TACHOMETER

This gauge contains the tachometer, trim

meter, hour meter, oil level indicator, and

the overheat warning indicator.

1Tachometer

2Trim meter

3Hour meter

4Oil level indicator

5Overheat warning indicator

6Set button

7Mode button

NOTE:

All segments of the display will light

momentarily after the main switch is

turned on and will return to normal there-

after.

q

t

w

u

y

e

r

001078

001050

EMU00136

Tachometer

This meter shows the engine speed.

EMU01109

Trim Meter

This meter shows the trim angle of your

outboard motor.

NOTE:

8Memorize the trim angles that work

best for your boat under different condi-

tions. Adjust the trim angle to the

desired setting by operating the power

trim and tilt switch.

8If the trim angle of your motor exceeds

the trim operating range, the top seg-

ment on the trim meter display will start

to blink.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 10

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2-10

001051

q

001087

EMU01620

Hour Meter

This meter shows the number of hours

the engine has been run. It can be set to

show the total number of hours or the

number of hours for the current trip. The

display can also be turned on and off.

8Changing the display format

Pressing the MODE button changes the

display format in the following circular

pattern:

Total hours - Trip hours - Display off

8Resetting the trip hours

Simultaneously pressing the SET and

MODE buttons for more than 1 second

while the trip hours are displayed resets

the trip counter to 0 (zero).

NOTE:

The total number of hours the engine has

been run cannot be reset.

EMU00138

Oil-Level Indicator

This indicator shows the engine oil level.

If the oil level falls below the lower limit,

the warning indicator will start to blink.

Refer to the sections “FILLING OIL” and

“OIL LEVEL WARNING” for details.

1Oil-level indicator

cC

Do not operate the engine without oil.

Serious engine damage will occur.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 11

2-11

E

001052

q

802016*

TRIP TIME BATT

Km/h

knot

mph

km

mile

SPEED

YAMAHA

set mode

qw

e

r

EMU00140

DIGITAL SPEEDOMETER

This meter contains the speedometer, fuel

meter with warning, trip meter, clock and

voltmeter with warning.

1Speedometer

2Fuel meter

3Trip meter/clock/voltmeter

4Warning indicator

NOTE:

After the main switch is first turned on, all

portions of the meter come on as a check.

After a few seconds, the meters will

change to normal operation. Watch the

meter when turning on the main switch to

make sure all segments come on.

EMU01553

Overheat Warning Indicator

If the engine temperature rises too high,

the warning indicator will start to blink.

Refer to “OVERHEAT WARNING” for

details.

1Overheat warning indicator

cC

Do not continue to operate the engine if a

warning device has activated. If neces-

sary, refer to the “TROUBLESHOOTING”

section in this manual. Consult your deal-

er if the problem cannot be located and

corrected.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 12

E

2-12

q

w

e

802023*

EMU00141

Speedometer

This meter shows the boat speed.

NOTE:

The speedometer displays km/h, mph, or

knots, depending upon operator prefer-

ence. Select the desired unit of measure-

ment by setting the selector switch on the

back of the meter. See the illustration for

settings.

1Cap

2Selector switch (for speed unit)

3Selector switch (for fuel sender)

802024*

TRIP TIME BATT

Km/h

knot

mph

km

mile

SPEED

YAMAHA

set mode

EMU01274

Trip Meter

This meter displays the distance the boat

has traveled since the meter was last

reset.

Repeatedly push and release the “mode”

button until the indicator on the face of

the meter points to “TRIP”. To reset the

trip meter to “0”, press the “set” and

“mode” button together.

NOTE:

8The trip distance is shown in kilometers

or miles depending upon the unit of

measurement selected for the

speedometer.

8The trip distance is kept in memory by

battery power. The stored data will be

lost if the battery is disconnected.

802034

TRIP TIME BATT

Km/h

knot

mph

km

mile

SPEED

YAMAHA

set mode

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 13

E

802025*

TRIP TIME BATT

Km/h

knot

mph

km

mile

SPEED

YAMAHA

set mode

2-13

EMU00144

Fuel meter

The fuel level is displayed by eight seg-

ments. When all segments are showing,

the fuel is full.

cC

The Yamaha fuel tank sensor is different

from a conventional-type sensor. A

wrong setting of the selector switch on

the meter will give incorrect readings.

Consult Yamaha dealer for correct set-

ting.

NOTE:

The fuel reading can be affected by the

position of the sensor in the fuel tank and

the attitude of the boat in the water.

Operation with bow-up trim or continu-

ous turning can give false readings.

802032TRIP TIME BATT

Km/h

knot

mph

km

mile

SPEED

EMU01275

Clock

This meter shows the current time.

Repeatedly push and release the “mode”

button until the indicator on the face of

the meter points to “TIME.” To set the

clock, be sure the meter is in the “TIME”

mode. Press the “set” button; the hour

display will begin blinking. Press the

“mode” button until the desired hour is

displayed. Press the “set” button again,

the minute display will begin blinking.

Press the “mode” button until the desired

minute is displayed. Press the “set” but-

ton again to start the clock.

NOTE:

The clock operates on battery power.

Disconnecting the battery will stop the

clock. Reset the clock after connecting the

battery.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 14

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PS

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

2-14

EMU00145

Warning indicator

8Fuel warning

If the fuel level decreases to one segment

the fuel level warning segment 1begins

blinking.

8Low battery voltage warning

If battery voltage drops, the display 2will

be automatically turned on and it begins

blinking.

cC

Do not continue to operate the engine if a

warning device has activated. Refer to

the TROUBLESHOOTING section in this

manual. Consult a Yamaha dealer if the

problem cannot be located and corrected.

802031

TRIP TIME BATT

Km/h

knot

mph

km

mile

SPEED

YAMAHA

set mode

q

w

YAMAHA

set mode

PS

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

q

w

e

EMU00146

FUEL MANAGEMENT METER

Optional Equipment

The meter contains the fuel flow meter,

fuel consumption meter, fuel economy

meter, twin engine speed synchronizer,

water separator warning indicator.

1Fuel flow meter

2Fuel consumption / Fuel economy meter /

Twin engine speed synchronizer

3Water separator warning indicator

(Operates only if the sensor has been

installed.)

NOTE:

After the main switch is first turned on, all

portions of the meter come on as a check.

After a few seconds, the meters will

change to normal operation. Watch the

meter when turning on the main switch to

make sure all segments come on.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 15

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2-15

YAMAHA

PS

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

set mode

2 65431

ON

(liter)

l/h

(gallon)

gph

q

EMU00147

Fuel Flow Meter

The meter displays fuel flow within one

hour, at the rate of current engine opera-

tion.

If twin engines are installed on your boat,

the meter will display total fuel flow of

Port and Starboard side engine. It also

displays PS indication at the same time.

By pressing “set” button, the meter will

display fuel flow of starboard side engine

and S indication.

By pressing “set” button again, the meter

will display fuel flow of port side engine

and P indication.

By pressing “set” button again, the meter

will display total fuel flow.

NOTE:

8The meter displays gallon/hour and liter

depending upon operator preference.

Select the desired unit of measurement

by setting the selector switch 1on the

back of the meter during installation.

8Fuel consumption meter and Fuel econ-

omy meter will indicate same unit of

measurement.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 16

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2-16

PS

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

PS

mp

Km

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

/L

g

EMU01276

Fuel Consumption Meter

This meter displays the total amount of

fuel consumed since the meter was last

reset.

Repeatedly push and release the “mode”

button until the indicator on the face of

the meter points to total (“TTL”). To reset

the total fuel consumption to “0”, press

the “set” and “mode” buttons together.

EMU01277

Fuel Economy

This meter displays the distance per liter

or gallon when cruising for reference use

by the operator.

Repeatedly push and release the “mode”

button until the indicator on the face of

the meter points to “ECON.”

NOTE:

If twin engines are installed on your boat,

the meter will display only the total fuel

economy of both engines.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 17

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2-17

NOTE:

8Fuel consumption varies greatly with

boat design, weight, propeller used,

engine trim angle, sea conditions

(including wind), and throttle position.

Fuel consumption also varies slightly

with the type of water (salt, fresh, and

contaminate levels), air temperature

and humidity, cleanliness of the boat

bottom, engine mounting height, skill of

the operator, and individual gasoline

formulation (winter or summer fuel and

amount of additives).

8The Yamaha digital speedometer and

fuel management meter calculates

speed, miles traveled, and fuel econo-

my by water movement at the stern of

the boat. This distance can vary greatly

from the actual distance traveled

because of water currents, sea swells,

and the condition of the water speed

sensor (partially plugged or damaged).

8Individual engines may slightly vary in

their fuel consumption due to manufac-

turing variations. These variations can

be even greater if the engines are of dif-

ferent year models. In addition, varia-

tions in propellers, even of the same

basic dimensions of the same design,

can also cause a slight variation in fuel

consumption.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 18

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2-18

EMU01278

Twin Engine Speed Synchronizer

This meter displays the difference in

engine speed (r/min) between the Port

and Starboard engines for reference pur-

poses when synchronizing the two

engines’ speeds.

Repeatedly push and release the “mode”

button until the indicator on the face of

the meter points to “SYNC”.

1Port side engine speed is higher

2Port side engine speed is slightly higher

3Engine speed is synchronized evenly

between Port and Starboard side engines

4Starboard side engine speed is slightly

higher

5Starboard side engine speed is higher

NOTE:

If the two engines’ speeds are not syn-

chronized while cruising, they can be syn-

chronized by adjusting trim angle or

throttle.

PS

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

q

w

e

r

t

PS

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

EMU01207

Water Separator Warning Indicator

If the water which has been separated

from fuel in the water trap exceeds a spe-

cific volume, the indicator will blink show-

ing the need for water to be drained.

NOTE:

This indicator only operates when a water

separator sensor is equipped.

PS

mpg

Km/L

gph

I/h

ECON SYNCTTL

FUEL MANAGEMENT

802**9

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 19

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2-19

EMU01180*

TOP COWLING LOCK LEVERS

To remove the engine top cowling, pull

up the front and rear lock levers. Then lift

off the cowling. When replacing the cowl-

ing, check to be sure it fits properly in the

rubber seal. Then lock the cowling again

by moving the levers downward.

cC

The air intake grills 1on the top cowling

are not designed as handles and may

break if used as such.

301052

301053*

qq

EMU00157

TILT SUPPORT LEVER

To keep the outboard motor in the tilted-

up position, lock the tilt support lever to

the clamp bracket.

403033

313024

q

EMU01146

FLUSHING DEVICE

This device 1is used to clean the cooling

water passages of the motor using a gar-

den hose and tap water.

NOTE:

Refer to “Cleaning Cooling-water

Passages” in Chapter 4 for instructions on

usage.

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 20

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2-20

701054

001053

EMU00169

WARNING SYSTEM

cC

Do not continue to operate the engine if

the warning device has activated. Consult

your Yamaha dealer if the problem can-

not be located and corrected.

703026

OFF START OFF START

ON ON

605015

EMU00171

OVERHEAT WARNING

This engine has an overheat warning

device. If the engine temperature rises too

high, the warning device will activate.

(1); Included (—); N/A

If the warning system has been activated,

stop the engine and check the water inlet

for clogging.

NOTE:

In case of dual engine drive;

Should the overheat warning system of

one engine operate, it slows down and

the buzzer sounds. This will cause the

other engine to slow down and the buzzer

to sound. For the other engine, the warn-

ing system can be released by shifting the

remote control lever into the neutral.

Warning device Tiller Remote

activation control control

model model

The engine speed

will automatically 1

decrease to about

2,000 r/min.

The overheat warning

1

indicator will come on.

The buzzer will sound.

1

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 21

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2-21

001094

703026

OFF START OFF START

ON ON

213032

q

905012

q

EMU00172

OIL LEVEL WARNING / OIL FILTER

CLOGGING WARNING

This engine has an oil level warning sys-

tem. If oil level falls below lower limit, the

warning device will activate.

(1); Included (—); N/A

If the warning system has been activated,

stop the engine and check for the cause.

NOTE:

The warning for oil filter clogging is simi-

lar to the warnings for low oil level and

overheating. For easy troubleshooting, it

is advisable to check for engine overheat-

ing first, then oil level and finally oil filter

clogging.

1Oil filter

Warning device Tiller Remote

activation control control

model model

The engine speed

will automatically 1

decrease to about

2,000 r/min.

The oil level warning

1

indicator will come on.

The buzzer will sound.

1

68F-9-13-2 <2nd> 4/23/01 11:53 AM Page 22

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EMU00174

Chapter 3

OPERATION

INSTALLATION ........................................3-1

Mounting the outboard motor............3-2

BREAKING IN (RUNNING IN) ENGINE ..3-4

PRE-OPERATION CHECKS......................3-5

Operation after a long period of

storage...................................................3-7

FILLING FUEL AND ENGINE OIL ............3-8

Filling fuel..............................................3-8

Filling oil ................................................3-9

STARTING ENGINE ...............................3-11

WARMING UP ENGINE .........................3-14

SHIFTING ................................................3-15

Forward ...............................................3-15

Reverse................................................3-15

STOPPING ENGINE ...............................3-16

TRIMMING OUTBOARD MOTOR.........3-17

Adjusting trim angle ..........................3-18

TILTING UP/DOWN ...............................3-20

CRUISING IN OTHER CONDITIONS.....3-22

Cruising in salt water .........................3-22

Cruising in turbid water.....................3-22

1

2

3

4

5

6

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 1

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EMU00175

INSTALLATION

cC

Incorrect engine height or obstructions to

smooth water flow (such as the design or

condition of the boat or accessories such

as transom ladders/depth finder trans-

ducers) can create airborne water spray

while the boat is cruising. Severe engine

damage may result if the motor is operat-

ed continuously in the presence of air-

borne water spray.

NOTE:

During water testing check the buoyancy

of the boat, at rest, with its maximum

load. Check that the static water level on

the exhaust housing is low enough to pre-

vent water entry into the powerhead,

when water rises due to waves when the

outboard is not running.

3-1

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 2

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EMU00176

MOUNTING THE OUTBOARD

MOTOR

w

Improper mounting of the outboard

motor could result in hazardous condi-

tions such as poor handling, loss of con-

trol, or fire hazards. Observe the follow-

ing:

8The information presented in this sec-

tion is intended as reference only. It is

not possible to provide complete

instructions for every possible

boat/motor combination. Proper

mounting depends in part on experi-

ence and the specific boat/motor com-

bination.

8Your dealer or other person experi-

enced in proper rigging should mount

the motor. If you are mounting the

motor yourself, you should be trained

by an experienced person. [permanent

mounted type]

8Your dealer or other person experi-

enced in proper outboard motor

mounting should show you how to

mount your motor. [portable type]

Mount the outboard motor on the center

line (keel line) of the boat, and ensure that

the boat itself is well balanced. Otherwise,

the boat will be hard to steer. For boats

without a keel or which are asymmetrical,

consult your dealer.

1Center line (keel line)

3-2

000371

q

q104016

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 3

E

w

Overpowering a boat may cause severe

instability. Do not install an outboard

motor with more horsepower than the

maximum rating on the capacity plate of

the boat. If the boat does not have a

capacity plate, consult the boat manufac-

turer.

104014

3-3

EMU01299

Mounting Height

To run your boat at optimum efficiency,

the water-resistance (drag) of the boat

and outboard motor must be made as lit-

tle as possible. The mounting-height of

the outboard motor greatly affects the

water-resistance. If the mounting-height

is too high, cavitation tends to occur, thus

reducing the propulsion; and if the pro-

peller tips cut the air, the engine speed

will rise abnormally and cause the engine

to overheat. If the mounting-height is too

low, the water-resistance will increase

and thereby reduce engine efficiency.

Mount the engine so that the anti-cavita-

tion plate is in alignment with the bottom

of the boat .

NOTE:

8The optimum mounting height of the

outboard motor is affected by the

boat/motor combination. Test runs at

different heights can help determine the

optimum mounting height.

8Refer to the section “TRIMMING OUT-

BOARD MOTOR” for instructions on

setting the trim angle of the outboard.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 4

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3-4

EMU01192*

BREAKING IN (RUNNING IN)

ENGINE

Your new engine requires a period of

break-in (running-in) to allow mating sur-

faces of moving parts to wear-in evenly.

Correct break-in (running-in) will help

ensure proper performance and longer

engine life.

cC

8Failure to follow the break-in (running-

in) procedure may result in reduced

engine life or even severe engine dam-

age.

8Do not use pre-mixed fuel in this

engine as it may cause carbon deposits

on the fuel injector thereby causing

engine trouble.

8Follow the instructions for breaking-

in/running-in carefully.

NOTE:

The label pictured at left is to be left on

the top cowling until the break-in (run-

ning-in) procedure has been completed

and may be removed afterwards.

Break-in (running-in) time: 10 hours

EMU01183*

Run the engine under load (in gear with a

propeller installed) as follows.

1) First 10 minutes:

Run the engine at the lowest possi-

ble-speed. A fast idle in neutral is

best.

000106

Do not use fuel mixed

with oil during break-in

or under any circum-

stances.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 5

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3-5

2) Next 50 minutes:

Do not exceed half throttle (approxi-

mately 3,000 r/min). Vary engine

speed occasionally. If you have an

easy-planing boat, accelerate at full

throttle onto plane, then immediately

reduce the throttle to 3,000 r/min or

less.

3) Second hour:

Accelerate at full throttle onto plane,

then reduce engine speed to three-

quarter throttle (approximately 4,000

r/min). Vary engine speed occasional-

ly. Run at full throttle for one minute,

then allow about 10 minutes of opera-

tion at three-quarter throttle or less to

let the engine cool.

4) Third through tenth hours:

Avoid operating at full throttle for

more than 5 minutes at a time. Let the

engine cool between full-throttle runs.

Vary engine speed occasionally.

5) After the first 10 hours:

Operate the engine normally.

EMU00204

PRE-OPERATION CHECKS

w

If any item in the pre-operation check is

not working properly, have it inspected

and repaired before operating the out-

board motor. Otherwise, an accident

could occur.

cC

Do not start the engine out of water.

Overheating and serious engine damage

can occur.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 6

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3-6

EMU00206

Fuel

8Check to be sure you have plenty of fuel

for your trip.

8Make sure there are no fuel leaks or

gasoline fumes.

8Check fuel line connections to be sure

they are tight.

8Be sure the fuel tank is positioned on a

secure, flat surface, and that the fuel

hose is not twisted or flattened, or likely

to contact sharp objects.

EMU00207

Oil

8Check to be sure you have plenty of oil

for your trip.

EMU00209

Controls

8Check throttle, shift, and steering for

proper operation before starting the

engine.

8The controls should work smoothly,

without binding or unusual free play.

8Look for loose or damaged connec-

tions.

8Check operation of the starter and stop

switches when the outboard motor is in

the water.

EMU00211

Engine

8Check the engine and engine mounting.

8Look for loose or damaged fasteners.

8Check the propeller for damage.

8Check that the battery is in good condi-

tion and battery connections are secure.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 7

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3-7

EMU01184

OPERATION AFTER A LONG PERIOD

OF STORAGE (for Yamaha oil

injection system model)

When operating the engine after a long

period (12 months) of storage, proceed as

follows:

1) Start the engine. Leave it idling.

w

8Do not touch or remove electrical parts

when starting or during operation.

8Keep hands, hair, and clothes away

from flywheel and other rotating parts

while engine is running.

2) Watch for oil flowing through the oil

feed pipes. After any air in the oil

lines has been expelled, the Yamaha

oil injection system should supply oil

normally. If no oil has begun flowing

after 10 minutes of idling, consult

your Yamaha dealer.

cC

8When operating the engine after a long

period of storage, be sure to take the

above steps; otherwise, engine seizure

may occur.

8Use straight gasoline (petrol) only. If

pre-mixed fuel is used, the fuel injector

could be damaged.

212023

212024

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 8

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3-8

EMU00186

FILLING FUEL

AND ENGINE OIL

EMU01031

FILLING FUEL

1) Remove the fuel tank cap.

2) Fill the fuel tank carefully.

3) Close the cap securely after refueling.

Wipe up any spilled fuel.

EMU01019

Ring Free Fuel Additive

Gasoline is a precise blend of many differ-

ent substances, each chosen to give cer-

tain characteristics. Gasoline blends have

been changing in recent years in

response to concerns about pollution and

resulting emissions regulations. One of

the most obvious changes has been the

elimination of lead from most fuels.

As gasoline has changed, the amount of

additives such as aromatics and oxy-

genates has increased. These additives

are important for the engines in passen-

ger cars, but they can have detrimental

effects in marine engines, because of

increased deposits in the combustion

chamber. When enough deposits collect,

piston rings begin sticking. Performance

drops and engine wear increases dramati-

cally.

While many additives available may

reduce deposits, Yamaha recommends

the use of Ring Free Fuel Additive, avail-

able from your Yamaha dealer. Ring Free

has repeatedly proven its ability to clean

combustion deposits from inside the

engine, notably the critical piston-ring-

land area, and fuel system components.

Follow product labeling for use instruc-

tions.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 9

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3-9

EMU01185

FILLING OIL (for Yamaha oil injection

system model)

This engine uses the Yamaha oil injection

system, which provides superior lubrica-

tion by ensuring the proper oil ratio for all

operating conditions. No fuel pre-mixing

is needed. Simply pour gasoline into the

fuel tank and oil into the oil tank.

Convenient indicators show the status of

the oil supply. Refer to the section “OIL

LEVEL INDICATOR” for details.

To fill the engine oil tank, proceed as fol-

lows:

w

Do not add gasoline (Petrol) into the oil

tank. Fire or explosion could result.

905015

ON STARTOFF

701024

Engine oil tank capacity:

Refer to “SPECIFICATIONS”, page 4-1.

EMU01186*

When remote oil tank is used

1) Pour the engine oil into the remote oil

tank.

2) Turn the main switch to “ON” to feed

the oil automatically from the remote

oil tank to the engine oil tank by the

YAMAHA oil injection system.

3) Operate the engine normally.

cC

When the engine is operated for the first

time or stored for a period of time, a min-

imum of 5 liters (5.3 US qt, 4.4 Imp qt) of

oil should be kept in the remote oil tank.

Otherwise, the oil-feed pump chamber

will not be filled with oil, and no oil will

be supplied.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 10

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3-10

Yellow

1,500 cm3

(1.6 US qt, 1.31

Imp qt) or less

EMU00200*

Oil Level Indicator

The various oil level system functions are as follows:

Remarks

Oil level

indicator (Digital

tachometer)

Oil level

indicator(Analog

tachometer)

Engine oil

tank

Remote oil

tank

Green

Red Green

Red

More than

300 cm3

(0.32 US qt,

0.26 Imp qt)

More than

300 cm3

(0.32 US qt,

0.26 Imp qt)

300 cm3

(0.32 US qt,

0.26 Imp qt)

or less

300 cm3

(0.32 US qt,

0.26 Imp qt)

or less

More than

1,500 cm3

(1.6 US qt,

1.31 Imp qt)

1,500 cm3(1.6

US qt, 1.31

Imp qt) or less

More than

1,500 cm3

(1.6 US qt,

1.31 Imp qt)

• No refilling necessary.

• Add oil, refer to oil

filling.

• Check oil filter for

clogging.

• Check battery cable

connection.

• Buzzer will sound.

• Engine speed is

automatically reduced

to about 2,000 r/min.

• Oil has not been added.

• Buzzer will sound.

• Engine speed is

automatically reduced

to about 2,000 r/min.

• Refer to Chapter 5.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 11

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3-11

902025

EMU01197

STARTING ENGINE

w

8Before starting the engine, make sure

that the boat is tightly moored and that

you can steer clear of any obstructions.

Be sure there are no swimmers in the

water near you.

8When the air vent screw is loosened,

gasoline (petrol) vapor will be released.

Gasoline (petrol) is highly flammable,

and its vapors are flammable and

explosive. Refrain from smoking, and

keep away from open flames and

sparks while loosening the air vent

screw.

8This product emits exhaust gases

which contain carbon monoxide, a col-

orless, odorless gas which may cause

brain damage or death when inhaled.

Symptoms include nausea, dizziness,

and drowsiness. Keep cockpit and

cabin areas well ventilated. Avoid

blocking exhaust outlets.

1) If there is an air vent screw on the fuel

tank cap, loosen it 2 or 3 turns.

2) If there is a fuel joint or a fuel cock on

the boat, firmly connect the fuel line

to the joint or open the fuel cock.

3) Squeeze the primer bulb with the out-

let end up until you feel it become

firm.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 12

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3-12

EMU00248

PROCEDURE FOR REMOTE

CONTROL MODEL

4) Place the remote control lever in the

Neutral position.

NOTE:

The start-in-gear protection device per-

mits the engine to be started only when it

is in Neutral.

N

702025

000293

ON

STARTOFF ON

STARTOFF

000714

5) Attach the engine stop switch lanyard

to a secure place on your clothing, or

your arm or leg. Then, install the lock

plate on the other end of the lanyard

in the engine stop switch.

w

8Attach the engine stop switch lanyard

to a secure place on your clothing, your

arm or leg while operating.

8Do not attach the lanyard to clothing

that could tear loose. Do not route the

lanyard where it could become entan-

gled, preventing it from functioning.

8Avoid accidentally pulling the lanyard

during normal operation. Loss of

engine power means the loss of most

steering control. Also, without engine

power, the boat could slow rapidly.

This could cause people and objects in

the boat to be thrown forward.

N

701015

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 13

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3-13

ON START

OFF

701022

703045

OFF START

ON

6) Turn the main switch to “ON”.

NOTE:

In case of dual-engine operation, when

the main switch is turned on, the buzzer

operates for a few seconds and stops

automatically. Should either of the dual

engines stall, the buzzer operates.

EMU00949

Electric Start Model

7) Turn the main switch to “START”,

and hold it for a maximum of 5 sec-

onds.

8) Immediately after the engine starts,

release the main switch to return it to

“ON”.

cC

8Do not turn the main switch to

“START” when the engine is running.

8Do not keep the starter-motor turning

for more than 5 seconds. The battery

will rapidly become exhausted and it

will be impossible for it to start the

engine. If the engine does not start

within 5 seconds, return the main

switch to “ON”, wait 10 seconds, and

then crank the engine again.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 14

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3-14

309034

EMU01198

WARMING UP ENGINE

1) Before beginning operation, allow the

engine to warm up at idling speed for

3 minutes. (Failure to do this will

shorten engine life.)

2) Check for a steady flow of water from

the cooling-water pilot hole.

cC

A continuous flow of water from the pilot

hole shows that the water pump is

pumping water through the cooling pas-

sages. If water is not flowing out of the

pilot hole at all times while the engine is

running, do not continue to run the

engine. Overheating and serious damage

could occur. Stop the engine and check

to see if the water inlet on the lower cas-

ing is blocked. If the problem cannot be

found and corrected, consult your

Yamaha dealer.

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 15

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3-15

701043

N

F

NR

701044

EMU00261

SHIFTING

w

Before shifting, make sure there are no

swimmers or obstacles in the water near

you.

cC

To change the shifting position from for-

ward to reverse or vice-versa, close the

throttle first so that the engine idles (or

runs at low speeds).

EMU00264

FORWARD

Pull up the neutral interlock trigger (If

equipped) and move the remote control

lever quickly and firmly from Neutral to

Forward.

EMU00269

REVERSE

w

When operating in Reverse, go slowly. Do

not open the throttle more than half.

Otherwise, the boat may become unsta-

ble, which could result in loss of control

and an accident.

Pull up the neutral interlock trigger (If

equipped) and move the remote control

lever quickly and firmly from Neutral to

Reverse.

N

F

702015

NR

702016

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 16

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3-16

OFF OFF

ON ON

703046

ON

START

OFF

701023

EMU00273

STOPPING ENGINE

Let it cool off for a few minutes at idle or

low speed first. Stopping the engine

immediately after operating at high speed

is not recommended.

EMU00276*

1) Turn the main switch to “OFF”.

2) If there is a fuel joint or a fuel cock on

the boat, disconnect the fuel line or

close the fuel cock after stopping the

engine.

3) Tighten the air vent screw on the fuel

tank cap after stopping the engine, if

it is equipped.

4) Remove the key if the boat will be left

unattended.

NOTE:

The engine can also be stopped by

pulling the lanyard and removing the lock

plate from the engine stop lanyard switch

(then turning the main switch to “OFF”).

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 17

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3-17

000892

q

EMU01412

TRIMMING OUTBOARD

MOTOR

The trim angle of the outboard motor

helps determine the position of the bow

of the boat in the water. The correct trim

angle will help improve performance and

fuel economy while reducing strain on the

engine. The correct trim angle depends

upon the combination of boat, engine,

and propeller. Correct trim is also affected

by variables such as the load in the boat,

sea conditions, and running speed.

w

Excessive trim for the operating condi-

tions (either trim up or trim down) can

cause boat instability and can make

steering the boat more difficult. This

increases the possibility of an accident. If

the boat begins to feel unstable or is hard

to steer, slow down and/or readjust the

trim angle.

NOTE:

Refer to the section “ADJUSTING TRIM

ANGLE” for instructions on usage.

1Trim operating angle

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 18

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3-18

UP

DN

702014

q

ADJUSTING TRIM ANGLE

EMU01401

Power Trim/Tilt Model

w

8Be sure all people are clear of the out-

board motor when adjusting the

trim/tilt angle, also be careful not to

pinch any body parts between the drive

unit and clamp bracket.

8Use caution when trying a trim position

for the first time. Increase speed gradu-

ally and watch for any signs of instabili-

ty or control problems.

8Use the power trim/tilt switch located

on the bottom engine cowling (if

equipped) only when the boat is at a

complete stop with the engine off.

The outboard motor trim angle can be

adjusted operating the power trim/tilt

switch 1.

To raise the bow (“trim-out”), push the

switch UP.

To lower the bow (“trim-in”), push the

switch DN.

Make test runs with the trim set to differ-

ent angles to find the position that works

best for your boat and operating condi-

tions.

NOTE:

To adjust the trim angle while the boat is

moving, use the power trim and tilt

switch located on the remote control

device or tiller handle, if so equipped.

DN

UP

702042*

q

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 19

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3-19

EMU00282

Bow Up

When the boat is on plane, a bow-up atti-

tude result in less drag, greater stability

and efficiency. This is generally when the

keel line of the boat is up about 3 to 5

degrees. When trimmed out, the boat

may have more tendency to steer to one

side or the other. Compensate for this as

you steer. The trim tab can also be adjust-

ed to help offset this effect.

Too much trim-out puts the bow of the

boat too high in the water. Performance

and economy are decreased because the

hull of the boat is pushing the water and

there is more air drag.

Excessive trim-up can cause the propeller

to ventilate, which reduces performance

further. When trimmed-out too much, a

boat may “porpoise” (hop in the water),

which could throw the operator and pas-

sengers overboard.

EMU00283

Bow Down

When the bow of the boat is down, it is

easier to accelerate from a standing start

onto plane.

Too much trim-in causes the boat to

“plow” through the water, decreasing

fuel economy and making in hard to

increase speed.

Operating with excessive trim-in at higher

speeds also makes the boat unstable.

Resistance at the bow is greatly

increased, heightening the danger of

“bow steering” and making operation dif-

ficult and dangerous.

1Bow up

2Bow down

3Optimum angle

105011

q

105013

w

105015

e

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 20

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3-20

000895

EMU01200

TILTING UP/DOWN

If the engine will be stopped for some

time, or if the boat is moored in shallows,

the engine should be tilted up to protect

the propeller and casing from damage by

collision with obstructions, and also to

reduce salt corrosion.

cC

Before tilting the motor, follow the proce-

dures under “STOPPING ENGINE”. Never

tilt the motor while the engine is running.

Severe damage from overheating can

result.

w

Be sure all people are clear of the out-

board motor when adjusting the tilt

angle, also be careful not to pinch any

body parts between the drive unit and

engine bracket.

w

Leaking fuel is a fire hazard. Disconnect

the fuel line or close the fuel cock if the

engine will be tilted for more than a few

minutes. Otherwise, fuel may leak. (If the

fuel connector is provided on the motor.)

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 21

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3-21

UP

DN

UP

DN

702014

403035*

DN

UP

702042**

EMU00294*

PROCEDURE FOR TILTING UP

Power trim/tilt model

1) If there is a fuel joint or a fuel cock on

the boat, disconnect the fuel line or

close the fuel cock.

2) Push the power trim/tilt switch “UP”

until the outboard has tilted up com-

pletely.

3) Turn the tilt-support lever toward you

and support the engine.

w

After tilting the engine, be sure to sup-

port it with the tilt-support lever.

Otherwise, the engine could fall back

down suddenly if oil in the power

trim/tilt unit should lose pressure.

4) Once the engine is supported with the

tilt-support lever, push the power

trim/tilt switch DOWN to retract the

trim rods.

cC

Be sure to retract the trim rods complete-

ly during mooring. This protects the rods

from marine growths and corrosion

which could damage the power trim/tilt

mechanism.

411043

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 22

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3-22

EMU00316

CRUISING IN OTHER

CONDITIONS

CRUISING IN SALT WATER

After operating in salt water, wash out the

cooling-water passages with fresh water

to prevent them from becoming clogged-

up with salt deposits.

NOTE:

Refer to cooling system flushing instruc-

tions in “TRANSPORTING AND STORING

OUTBOARD MOTOR”.

CRUISING IN TURBID WATER

It is strongly recommended that the

optional chromium-plated water-pump kit

be installed if the outboard is to be used

in turbid (muddy) water conditions.

EMU00303

PROCEDURE FOR TILTING DOWN

Power trim/tilt model

1) Push the power trim/tilt switch “UP”

until the engine is supported by the

tilt rod.

2) Release the tilt-support lever.

3) Push the power trim/tilt switch “DN”

(Down) to lower the engine to the

desired position.

411045

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 23

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– MEMO –

68F-9-13-3 <2nd> 4/23/01 11:59 AM Page 24

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EMU00317

Chapter 4

MAINTENANCE

SPECIFICATION DATA.............................4-1

TRANSPORTING AND STORING

OUTBOARD MOTOR ...............................4-4

Trailering outboard motor...................4-4

Storing outboard motor ......................4-5

PERIODIC MAINTENANCE......................4-9

Replacement parts ...............................4-9

Maintenance chart..............................4-10

Greasing ..............................................4-11

Cleaning and adjusting spark plug...4-12

Checking fuel system.........................4-14

Inspecting fuel filter ...........................4-15

Adjusting idling speed.......................4-16

Checking water in engine oil tank ....4-17

Checking high pressure fuel pump

drive belt..............................................4-18

Replacing fuse ....................................4-19

Checking wiring and connectors ......4-19

Exhaust leakage..................................4-19

Water leakage .....................................4-19

Checking power trim and tilt

system .................................................4-20

Checking propeller .............................4-21

Changing gear oil ...............................4-23

Inspecting and replacing anode(s) ...4-24

Checking battery.................................4-25

Checking bolts and nuts ....................4-28

Cleaning cooling-water passages.....4-29

Motor exterior.....................................4-30

Coating the boat bottom ...................4-30

1

2

3

4

5

6

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 1

Recommended fuel

P.O.N.

Fuel tank capacity l (US gal, Imp gal)

Recommended engine oil

Fuel/oil premix ratio Fuel : Oil

Engine oil capacity (engine oil tank) l (US qt, Imp qt)

(remote oil tank) l (US qt, Imp qt)

Recommended gear oil

Gear oil capacity cm3(US oz, Imp oz)

Spark plug N•m(kgf•m,lb•ft)

Propeller nut N•m(kgf•m,lb•ft)

TIGHTENING TORQUE

E

4-1

25 (2.5, 18)

55 (5.5, 40)

EMU00318*

SPECIFICATION DATA

Model Unit Z150TRA

Item

DIMENSIONS

PERFORMANCE

Overall Length mm (in.)

Overall Width mm (in.)

Overall Height L/X mm (in.)

Transom height L/X mm (in.)

Weight L/X kg (lb.)

792 (31.2)

554 (21.8)

1,655 (65.2) / 1,782 (70.2)

516 (20.3) / 643 (25.3)

216 (476) / 222 (490)

Full throttle operating range r/min

Maximum output kW (HP) @ r/min

Idling speed (Neutral) r/min

4,500 - 5,500

110.3 (150.0) @ 5,000

670 - 730

ENGINE

Type

Displacement cm3(cu.in.)

Bore ×stroke mm (in.)

Ignition system

Spark plug NGK

Spark plug gap mm (in.)

Control system

Starting system

Battery capacity V-AH

Minimum cold crank performance Amps at –17.8°C (0°F)

Minimum reserve capacity Minutes at 26.7°C (80°F)

Alternator output V-A (W)

Starting carburetion system

2-stroke, 76°V6

2,596 (158.4)

90.0 ×68.0 (3.54 ×2.68)

TCI

BKR6EKU

1.5 - 1.6 (0.059 - 0.062)

Remote control

Electric start

12-100 - 120

512

182

12-45

Electronic Fuel Injection

DRIVE UNIT

Gear positions

Gear ratio

Trim/tilt system

Propeller mark

Forward-Neutral-Reverse

1.86 (26 / 14)

Power trim & tilt

M

FUEL AND OIL

Regular unleaded gasoline

(Minimum 86)

—

YAMALUBE 2 STROKE OUTBOARD OIL

or an equivalent TCW3 certified outboard oil

YAMAHA oil injection system

0.9 (0.95, 0.79)

10.5 (11.1, 9.24), / 18.0 (19.1, 15.9)

Hypoid gear oil (SAE90)

980 (33.1, 34.5)

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 2

2-stroke, 76°V6

2,596 (158.4)

90.0 ×68.0 (3.54 ×2.68)

TCI

BKR7EKU

1.5 - 1.6 (0.059 - 0.062)

Remote control

Electric start

12-100 - 120

512

182

12-45

Electronic Fuel Injection

2-stroke, 76°V6

2,596 (158.4)

90.0 ×68.0 (3.54 ×2.68)

TCI

BKR7EKU

1.5 - 1.6 (0.059 - 0.062)

Remote control

Electric start

12-100 - 120

512

182

12-45

Electronic Fuel Injection

792 (31.2)

554 (21.8)

— / 1,782 (70.2)

— /643 (25.3)

— / 222 (490)

4,500 - 5,500

110.3 (150.0) @ 5,000

670 - 730

2-stroke, 76°V6

2,596 (158.4)

90.0 ×68.0 (3.54 ×2.68)

TCI

BKR6EKU

1.5 - 1.6 (0.059 - 0.062)

Remote control

Electric start

12-100 - 120

512

182

12-45

Electronic Fuel Injection

792 (31.2)

554 (21.8)

1,655 (65.2) / 1,782 (70.2)

516 (20.3) / 643 (25.3)

216 (476) / 222 (490)

4,500 - 5,500

147.1 (200) @ 5,000

670 - 730

792 (31.2)

554 (21.8)

— / 1,782 (70.2)

— /643 (25.3)

— / 222 (490)

4,500 - 5,500

128.7 (175) @ 5,000

670 - 730

E

4-2

Regular unleaded gasoline

(Minimum 86)

—

YAMALUBE 2 STROKE OUTBOARD OIL

or an equivalent TCW3 certified outboard oil

YAMAHA oil injection system

0.9 (0.95, 0.79)

10.5 (11.1, 9.24), / 18.0 (19.1, 15.9)

Hypoid gear oil (SAE90)

980 (33.1, 34.5)

Forward-Neutral-Reverse

1.86 (26 / 14)

Power trim & tilt

M

Regular unleaded gasoline

(Minimum 86)

—

YAMALUBE 2 STROKE OUTBOARD OIL

or an equivalent TCW3 certified outboard oil

YAMAHA oil injection system

0.9 (0.95, 0.79)

10.5 (11.1, 9.24), / 18.0 (19.1, 15.9)

Hypoid gear oil (SAE90)

870 (29.4, 30.6)

25 (2.5, 18)

55 (5.5, 40)

Forward-Neutral-Reverse

1.86 (26 / 14)

Power trim & tilt

M

Forward-Neutral-Reverse

1.86 (26 / 14)

Power trim & tilt

ML

25 (2.5, 18)

55 (5.5, 40)

Regular unleaded gasoline

(Minimum 86)

—

YAMALUBE 2 STROKE OUTBOARD OIL

or an equivalent TCW3 certified outboard oil

YAMAHA oil injection system

0.9 (0.95, 0.79)

10.5 (11.1, 9.24), / 18.0 (19.1, 15.9)

Hypoid gear oil (SAE90)

980 (33.1, 34.5)

25 (2.5, 18)

55 (5.5, 40)

LZ150TRA Z175TRA Z200TRA

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 3

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4-3

Recommended fuel

P.O.N.

Fuel tank capacity l (US gal, Imp gal)

Recommended engine oil

Fuel/oil premix ratio Fuel : Oil

Engine oil capacity (engine oil tank) l (US qt, Imp qt)

(remote oil tank) l (US qt, Imp qt)

Recommended gear oil

Gear oil capacity cm3(US oz, Imp oz)

Spark plug N•m(kgf•m,lb•ft)

Propeller nut N•m(kgf•m,lb•ft)

TIGHTENING TORQUE

EMU00318*

SPECIFICATION DATA

Model Unit LZ200TRA

Item

DIMENSIONS

PERFORMANCE

Overall Length mm (in.)

Overall Width mm (in.)

Overall Height L/X mm (in.)

Transom height L/X mm (in.)

Weight L/X kg (lb.)

Full throttle operating range r/min

Maximum output kW (HP) @ r/min

Idling speed (Neutral) r/min

ENGINE

Type

Displacement cm3(cu.in.)

Bore ×stroke mm (in.)

Ignition system

Spark plug NGK

Spark plug gap mm (in.)

Control system

Starting system

Battery capacity V-AH

Minimum cold crank performance Amps at –17.8°C (0°F)

Minimum reserve capacity Minutes at 26.7°C (80°F)

Alternator output V-A (W)

Starting carburetion system

DRIVE UNIT

Gear positions

Gear ratio

Trim/tilt system

Propeller mark

FUEL AND OIL

2-stroke, 76°V6

2,596 (158.4)

90.0 ×68.0 (3.54 ×2.68)

TCI

BKR7EKU

1.5 - 1.6 (0.059 - 0.062)

Remote control

Electric start

12-100 - 120

512

182

12-45

Electronic Fuel Injection

792 (31.2)

554 (21.8)

— / 1,782 (70.2)

— /643 (25.3)

— / 222 (490)

4,500 - 5,500

147.1 (200.0) @ 5,000

670 - 730

Forward-Neutral-Reverse

1.86 (26 / 14)

Power trim & tilt

ML

Regular unleaded gasoline

(Minimum 86)

—

YAMALUBE 2 STROKE OUTBOARD OIL

or an equivalent TCW3 certified outboard oil

YAMAHA oil injection system

0.9 (0.95, 0.79)

10.5 (11.1, 9.24), / 18.0 (19.1, 15.9)

Hypoid gear oil (SAE90)

870 (29.4, 30.6)

25 (2.5, 18)

55 (5.5, 40)

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 4

E

4-4

EMU01369

TRANSPORTING AND

STORING OUTBOARD MOTOR

w

Leaking fuel is a fire hazard. When trans-

porting and storing the outboard motor,

close the air vent screw and fuel cock to

prevent fuel from leaking.

000896

102074

EMU00326*

TRAILERING OUTBOARD MOTOR

The motor should be trailered and stored

in the normal running position. If there is

insufficient road clearance in this position,

then trailer the motor in the tilt position

using a motor support device such as a

transom saver bar.

For further details, consult your Yamaha

dealer.

w

8Never get under the lower unit while it

is tilted, even if a motor support bar is

used. Severe injury could occur if the

outboard accidentally falls.

8USE CARE when transporting fuel tank,

whether in a boat or car.

8DO NOT fill fuel container to maximum

capacity. Gasoline will expand consid-

erably as it warms up and can build up

pressure in the fuel container. This can

cause fuel leakage and a potential fire

hazard.

cC

Do not use the tilt support lever/knob

when trailering the boat. The outboard

motor could shake loose from the tilt

support and fall. If the motor can not be

trailered in the down position, use an

additional support device to secure it in

the up position.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 5

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4-5

EMU01187*

STORING OUTBOARD MOTOR

When storing your Yamaha outboard for

prolonged periods of time, (2 months or

longer), several important procedures

must be performed to prevent expensive

damage. This is especially important for

your Yamaha oil injection system-

equipped outboard due to the lean oil

ratios used at idle prior to shutting the

engine off for the season.

It is advisable to have your outboard ser-

viced by an authorized Yamaha dealer

prior to storage. However, the following

procedures can be performed by you, the

owner, with a minimum of tools.

cC

8Do not use any chemical goods con-

taining Silicon, Phosphorus or Lead.

Otherwise, the oxygen sensor for

Electronic Fuel Injection system could

be damaged. For the detail, consult

your Yamaha dealer to use chemical

goods for storage.

8Drain the remaining gasoline from the

vapor separator. Gasoline left in the

vapor separator 1for a prolonged peri-

od of time will break down and possi-

bly cause damage to the fuel line.

EMU00335

Filling Fuel Tank

Fill the fuel tank with fresh fuel and add

one ounce of “Yamaha Fuel Conditioner

and Stabilizer” (Part No. LUB-FUELC-12-

00) to each gallon of fuel.

NOTE:

The use of “Yamaha Fuel Conditioner and

Stabilizer” eliminates the need to drain

the fuel system. Consult your Yamaha

dealer or other qualified mechanic if the

fuel system is to be drained instead.

000100

q

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 6

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4-6

903021

EMU00338

Flushing Cooling System and Fogging

Engine

Cooling system flushing is essential to

prevent the cooling system from clogging

up with salt, sand, or dirt. In addition, fog-

ging of the engine is mandatory to pre-

vent expensive engine damage due to

rust. Perform the flushing and fogging at

the same time.

w

8Do not touch or remove electrical parts

when starting or during operation.

8Keep hands, hair and clothes away

from flywheel and other rotating parts

while engine is running.

EMU00343

Flushing with the Flushing Attachment

cC

Avoid running the outboard at high

speed while on the flushing attachment,

or overheating could occur.

1) Remove the top cowling and silencer

cover. Remove the propeller.

2) Install a flushing attachment to the

lower unit. (A flushing attachment is

available from a Yamaha dealer).

3) Run the engine at a fast idle for 10~15

minutes supplying water.

4) Just prior to turning off the engine,

quickly spray “Yamaha Stor-Rite

Engine Fogging Oil” (Part No. LUB-

STRRT-12-00) alternately into each

intake manifold. When properly done,

the engine will smoke excessively

and almost stall.

5) Remove the flushing attachment and

wipe off any excess water.

6) Install the silencer cover and top

cowling. Install the propeller.

605014

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 7

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4-7

EMU00350*

Lubrication

1) Remove the spark plug(s). Spray a

“Yamaha Stor-Rite Engine Fogging

Oil” into each cylinder for 5 seconds.

Grease the spark plug threads and

reinstall the spark plug(s) and torque

to proper specification. (Refer to

“CLEANING AND ADJUSTING

SPARK PLUG”.)

2) Turn the engine over with the stop

lanyard disconnected to work the fog-

ging oil into the piston rings.

3) Fill the oil tanks. This prevents the for-

mation of condensation. For models

with a remote tank, it may be neces-

sary to manually override the control

unit to completely fill the engine main

tank. (Refer to Filling Oil section).

4) Change the gear-case oil. (Refer to

“CHANGING GEAR OIL”). Inspect the

oil for the presence of water which

indicates a leaky seal. Seal replace-

ment should be performed by an

authorized Yamaha dealership prior

to use.

5) Grease all grease fittings. (Refer to

“GREASING”)

EMU00352

Cleaning and Anti-corrosion Measure

1) Wash down the exterior of the out-

board with fresh water and dry off

completely.

2) Spray the engine’s exterior with

“Yamaha Silicone Protectant” (Part

No. LUB-SILCNE-13-00).

cC

Do not spray when the engine is running.

Also, do not spray near the silencer and

oxygen sensor cover or into the engine.

Otherwise, the oxygen sensor for

Electronic Fuel Injection system could be

damaged.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 8

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4-8

EMU00353

Battery Care

w

Battery electrolyte is poisonous and dan-

gerous, causing severe burns, etc. It con-

tains sulfuric acid. Avoid contact with

skin, eyes, or clothing.

Antidote:

EXTERNAL; Flush with water.

INTERNAL; Drink large quantities of

water or milk. Follow with milk of mag-

nesia, beaten egg, or vegetable oil. Call

physician immediately.

EYES; Flush with water for 15 minutes

and get prompt medical attention.

Batteries produce explosive gases: Keep

sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in a

closed space. Always wear eye protection

when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

Batteries vary among manufacturers.

Therefore the following procedures may

not always apply. Consult your battery

manufacturer’s instructions.

1) Disconnect and remove the battery

from the boat. Always disconnect the

black negative lead first to prevent the

risk of shorting.

3) Wax the cowling with a non-abrasive

wax such as “Yamaha Silicone Wax”

(Part No. ACC-11000-15-02).

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 9

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4-9

901015

UPPER LEVEL

LOWERLE

VEL

EMU01569

PERIODIC MAINTENANCE

w

Be sure to turn off the engine when you

perform maintenance unless otherwise

specified. If the owner is not familiar with

machine servicing, this work should be

done by a Yamaha dealer or other quali-

fied mechanic.

2) Clean the battery casing and termi-

nals. Fill each cell to the upper level

with distilled water.

3) Store the battery on a level surface in

a cool, dry, well-ventilated place out

of direct sunlight.

4) Once a month, check the specific

gravity of the electrolyte and recharge

as required to prolong battery life.

Maintenance, replacement, or repair of

the emission control devices and systems

may be performed by any marine engine

repair establishment or individual. All

warranty repairs, however, including

those to the emission control system,

must be performed by an authorized

Yamaha marine dealership.

A service manual is available for purchase

through a Yamaha dealer for owners who

have the mechanical skills, tools, and

other equipment necessary to perform

maintenance not covered by this owner’s

manual.

EMU00356

REPLACEMENT PARTS

If replacement parts are necessary, use

only genuine Yamaha parts or equiva-

lents of the same type and of equivalent

strength and materials. Any part of inferi-

or quality may malfunction, and the

resulting loss of control could endanger

the operator and passengers.

Yamaha genuine parts and accessories

are available from a Yamaha dealer.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 10

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4-10

EMU00362*

MAINTENANCE CHART

Frequency of maintenance operations may be adjusted according to the operating con-

ditions, but the following table gives general guidelines.

The mark (6) indicates the check-ups which you may carry out yourself.

The mark (1) indicates work to be carried out by your Yamaha dealer.

Spark plug(s) Cleaning/Adjustment/ ●●● 4-12

Replacement

Greasing points Greasing ●4-11

Gear oil Change ●●4-23

Fuel system Inspection ●●● 4-14

Fuel filter (Water separator)

Cleaning/Inspection ●●● 4-15

Fuel tank Cleaning ●—

High pressure fuel pump Inspection 14-18

drive belt*2

High pressure fuel pump oil

*3Inspection 1—

Idling speed Inspection/Adjustment ●●4-16

Anode(s)

Inspection/Replacement

●/1●/14-24

Outboard motor exterior Inspection ●●● 4-30

Cooling water passage*1Cleaning ●● 4-29

Propeller/Cotter pin

Inspection/Replacement

●●● 4-21

Battery Inspection/Charge ●4-25

(every month)

Throttle pick-up timing Inspection/Adjustment 1—

Bolts/Nuts Retightening ●●● 4-28

Oil tank water drain Cleaning ●●● 4-17

Oil pump Inspection/Adjustment 1—

Power trim/tilt unit Inspection ●4-20

Power trim/tilt operation Inspection ●●● 4-20

Exhaust leakage Inspection ●●● 4-19

Water leakage Inspection ●●● 4-19

Cowling clamp Inspection ●—

Throttle link Inspection/Adjustment 1—

Throttle sensor Inspection/Adjustment 1—

Wiring/Connector(s) Inspection/Reconnect ●●● 4-19

Interval

Item

Initial Every

Refer

page

10 hours

(1 month)

50 hours

(3 months)

100 hours

(6 months)

200 hours

(1 year)

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

water after each use.

*2. Be sure to replace the high pressure fuel pump drive belt after every 1,000 hours or 5 years

(whichever comes first) of operation.

*3. Be sure to replace the high pressure fuel pump oil after every 1,000 hours or 5 years (whichev-

er comes first) of operation.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 11

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4-11

EMU00366

GREASING

Yamaha marine grease

(Water resistant grease)

103212

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 12

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4-12

EMU01202

CLEANING AND ADJUSTING SPARK

PLUG

w

When removing or installing a spark plug,

be careful not to damage the insulator. A

damaged insulator could allow external

sparks, which could lead to explosion or

fire.

The spark plug is an important engine

component and is easy to inspect. The

condition of the spark plug can indicate

something about the condition of the

engine. For example, if the center elec-

trode porcelain is very white, this could

indicate an intake air leak or carburetion

problem in that cylinder. Do not attempt

to diagnose any problems yourself.

Instead, take the outboard motor to a

Yamaha dealer. You should periodically

remove and inspect the spark plug

because heat and deposits will cause the

spark plug to slowly break down and

erode. If electrode erosion becomes

excessive, or if carbon and other deposits

are excessive, you should replace the

spark plug with another of the correct

type.

Standard spark plug:

Refer to “SPECIFICATIONS”, page 4-1

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 13

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4-13

q

qw

000790

Spark plug torque:

Refer to “SPECIFICATIONS”, page 4-1.

Spark plug gap:

Refer to “SPECIFICATIONS”, page 4-1.

Initial of spark Plug wrench size

plug I.D. mark

B 21 mm (13/16 in.)

C/BK 16 mm (5/8 in.)

D 18.3 mm (23/32 in.)

Before fitting the spark plug, measure the

electrode gap with a wire thickness

gauge; adjust the gap to specification if

necessary.

When fitting the plug, always clean the

gasket surface and use a new gasket.

Wipe off any dirt from the threads and

screw in the spark plug to the correct

torque.

NOTE:

If a torque-wrench is not available when

you are fitting a spark plug, a good esti-

mate of the correct torque is 1/4 to 1/2 a

turn past finger-tight. Have the spark plug

adjusted to the correct torque as soon as

possible with a torque-wrench.

1Spark plug gap

2Spark plug I.D. mark (NGK)

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 14

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4-14

106092

EMU00369*

CHECKING FUEL SYSTEM

w

Gasoline (petrol) and its vapors are highly

flammable and explosive. Keep away

from sparks, cigarettes, flames or other

sources of ignition.

Check the fuel line for leaks, cracks, or

malfunctions. If any problem is found, it

should be repaired immediately by a

Yamaha dealer or other qualified mechan-

ic.

Checking points

8Fuel system parts leakage.

8Fuel hose joint leakage.

8Fuel hose cracks or other damage.

8Fuel connector leakage.

w

Leaking fuel can result in fire or explo-

sion.

8Check for fuel leakage regularly.

8If any fuel leakage is found, the fuel

system must be repaired by a qualified

mechanic. Improper repairs can make

the outboard unsafe to operate.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 15

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4-15

000629

r

t

e

w

u

y

EMU00370

INSPECTING FUEL FILTER

w

Gasoline (petrol) is highly flammable, and

its vapors are flammable and explosive.

8If you have any question about properly

doing this procedure, consult your

Yamaha dealer.

8Do not perform this procedure on a hot

or running engine. Allow the engine to

cool.

8There will be fuel in the fuel filter. Keep

away from sparks, cigarettes, flames or

other sources of ignition.

8This procedure will allow some fuel to

spill. Catch fuel in a rag. Wipe up any

spilled fuel immediately.

8The fuel filter must be reassembled

carefully with O-ring, filter cup, and

hoses in place. Improper assembly or

replacement can result in a fuel leak,

which could result in a fire or explosion

hazard.

001224

q

EMU01308

NOTE:

If any water is in the fuel, the float 7will

rise. If so, remove the cup and drain the

water.

1) Loosen and remove the locking tab

bolt and tab 1. Slightly loosen the fil-

ter cup ring nut 2.

2) Remove the filter cup 3, catching any

spilled fuel in a rag.

3) Remove the filter element 4, and

wash it in solvent.

Allow it to dry. Inspect the filter ele-

ment and O-ring 5to make sure they

are in good condition. Replace them if

necessary.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 16

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4-16

4) Reinstall the filter element. Make sure

the O-ring is in position in the cup.

Insert the cup and O-ring into the fil-

ter housing 6. Screw the ring nut

onto the filter housing until the ring is

lightly seated.

5) Tighten the ring nut approximately an

additional 1/4 turn until ring nut is

tight. Align one of the four larger ring

nut tabs into the slot of the locking

tab. Install the locking tab bolt and

tighten.

6) Run the engine and check the filter

and lines for leaks.

EMU00991

ADJUSTING IDLING SPEED

w

8Do not touch or remove electrical parts

when starting or during operation.

8Keep hands, hair and clothes away

from flywheel and other rotating parts

while engine is running.

cC

This procedure must be performed while

the outboard motor is in the water. A

flushing attachment or test tank can be

used.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 17

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4-17

A diagnostic tachometer should be used

for this procedure.

1) Start the engine and allow it to warm

up fully in Neutral until it is running

smoothly. If the outboard is mounted

on a boat, be sure the boat is tightly

moored.

2) Adjust the throttle stop-screw 1to

set the idling speed to specification

(see “SPECIFICATIONS” on page 4-1)

by turning the stop-screw clockwise

to increase the idling speed, and turn-

ing it counterclockwise to decrease

the idling speed.

NOTE:

Correct idling-speed adjustment is only

possible if the engine is fully warmed-up.

If not warmed up fully, the speed setting

will tend to be too high. If you have diffi-

culty obtaining the specified idle, consult

a Yamaha dealer or other qualified

mechanic.

204063

q

213033

q

w

EMU00377

CHECKING WATER IN ENGINE OIL

TANK

There is a trap at the bottom of the engine

oil tank. If water or foreign matter is visi-

ble in this trap, consult a Yamaha dealer.

1Trap

2Engine oil tank

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 18

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4-18

206016

EMU01189

CHECKING HIGH PRESSURE FUEL

PUMP DRIVE BELT

Inspect the high pressure fuel pump drive

belt and replace it if any of the following

signs is observed:

8Cracks in the back of the belt or in the

base of belt teeth.

8Excessive wear at the roots of cogs.

8Rubber portion swollen by oil.

8Belt surfaces roughened.

8Signs of wear on edges or outer surface

of belt.

cC

Consult your Yamaha dealer when replac-

ing or adjusting the high pressure fuel

pump drive belt.

NOTE:

If the high pressure fuel pump drive belt

can be stretched by 10 mm (0.39 in) or

more by pushing with your finger in the

middle between the pulleys, the belt ten-

sion needs adjustment.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 19

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4-19

000500

r

t

w

e

r

e

q

000501

t

EMU00383

CHECKING WIRING AND

CONNECTORS

1) Check that each grounding wire is

properly secured.

2) Check that each connector is engaged

securely.

EMU00384

EXHAUST LEAKAGE

Start the engine and check that no

exhaust leaks from the joints between the

exhaust cover, cylinder head and crank

case.

EMU00385

WATER LEAKAGE

Start the engine and check that no water

leaks from the joints between the exhaust

cover, cylinder head and crank case.

413016

EMU01310

REPLACING FUSE

If a fuse has blown, remove the electrical

cover, open the fuse holder and remove

the fuse with a fuse puller. Replace it with

a spare one of proper amperage.

w

Be sure to use the specified fuse. An

incorrect fuse or a piece of wire may

allow excessive current flow. This could

cause electrical system damage and a fire

hazard.

NOTE:

If the new fuse blows again immediately,

consult a Yamaha dealer.

1Electrical cover

2Fuse holder

3Fuse (20A ×3, 30A ×1, 80A ×2)

4Spare fuse (20A, 30A, 80A)

5Fuse puller

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 20

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4-20

EMU00993

CHECKING POWER TRIM AND TILT

SYSTEM

w

8Never get under the lower unit while it

is tilted, even when the tilt-support

lever is locked. Severe injury could

occur if the outboard accidentally falls.

8Make sure no one is under the out-

board before performing this test.

411046

q

w

411044

e

411045 Recommended fluid;

Yamaha power trim & tilt fluid or ATF

(DEXRONII).

1) Check the power trim and tilt unit for

any sign of oil leaks.

2) Operate each of the power trim and

tilt switches on remote control and

engine bottom cowling (If equipped)

to check that all switches work.

3) Tilt up the motor and check that the

tilt rod 1and trim rods 2are pushed

out completely.

4) Use the tilt support lever 3to lock

the motor in the UP position. Operate

the tilt down switch briefly so the

motor is supported the tilt support

lever.

5) Check that the tilt rod and trim rods

are free of corrosion or other flaws.

6) Activate the tilt-down switch until the

trim rods have gone completely into

the cylinders.

7) Activate the trim-up switch until the

tilt rod is fully extended. Unlock the

tilt support lever.

8) Operate the motor to tilt down. Check

that the tilt rod and trim rods operate

smoothly.

NOTE:

If any operation is abnormal, consult a

Yamaha dealer.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 21

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4-21

210012

602051

602036

602074

w

e

r

q

yt

EMU00388

CHECKING PROPELLER

w

You could be seriously injured if the

engine accidentally starts while you are

near the propeller.

8Before inspecting, removing or

installing the propeller, remove the

spark plug caps from the spark plugs.

Also, put the shift control in Neutral,

put the main switch in the “OFF” posi-

tion and remove the key, and remove

the lanyard from the engine stop

switch. Turn off the battery cut-off

switch if your boat has one.

8Do not use your hand to hold the pro-

peller when loosening or tightening the

propeller nut. Put a wood block

between the cavitation plate and the

propeller to prevent the propeller from

turning.

EMU00390

Propeller Checking Point

8Check each of the propeller blades for

wear, erosion from cavitation or ventila-

tion, or other damage.

8Check the splines for wear and damage.

8Check for fish line winding around the

propeller shaft.

8Check the propeller shaft oil seal for

damage.

EMU00976

Removing the Propeller

1) Straighten the cotter-pin 1and pull it

out using a pair of pliers.

2) Remove the propeller nut 2, washer

3and spacer 4.

3) Remove the propeller 5and thrust

washer 6.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 22

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4-22

EMU00397

Installing the Propeller

cC

8Be sure to install the thrust washer

before installing propeller, otherwise,

lower case and propeller boss may be

damaged.

8Be sure to use a new cotter pin and

bend the ends over securely.

Otherwise, the propeller could come off

during operation and be lost.

1) Apply Yamaha Marine grease or

Corrosion resistant grease to the pro-

peller-shaft.

2) Install the thrust washer and propeller

on the propeller-shaft.

3) Install the spacer and washer. Tighten

the propeller nut to the specified

torque.

4) Align the propeller nut with the pro-

peller shaft hole. Insert a new cotter

pin in the hole and bend the cotter pin

ends.

NOTE:

If the propeller nut does not align with the

propeller shaft hole after tightening to the

specified torque, then tighten the nut fur-

ther to align it with the hole.

602053

Tightening torque:

Refer to “SPECIFICATIONS” page 4-1.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 23

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4-23

601031*

q

w

EMU00905

CHANGING GEAR OIL

w

8Be sure the outboard is securely fas-

tened to the transom or a stable stand.

You could be severely injured if the out-

board falls on you.

8Never get under the lower unit while it

is tilted, even when the tilt-support

lever is locked. Severe injury could

occur if the outboard accidentally falls.

1) Put the outboard in a vertical position

(not tilted).

2) Place a suitable container under the

gear-case.

3) Remove the oil drain plug 1.

NOTE:

The oil drain plug is magnetic. Remove all

metal particles from the plug before rein-

stalling it.

4) Remove the oil level plug 2to allow

the oil to drain completely.

cC

Inspect the used oil after it has been

drained. If the oil is milky, water is get-

ting into the gear-case which can cause

gear damage. Consult a Yamaha dealer

for repair of the lower unit seals.

NOTE:

For disposal of used oil consult your

Yamaha dealer.

000896

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 24

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4-24

5) With the outboard motor in an verti-

cal position, using a flexible or pres-

surized filling device, inject the gear

oil into the oil drain plug hole.

6) When the oil begins to flow out of the

oil level plug hole, insert and tighten

the oil level plug.

7) Insert and tighten the oil drain plug.

603024

405022

Gear oil grade/capacity:

Refer to SPECIFICATIONS on page 4-1.

EMU00831

INSPECTING AND REPLACING

ANODE(S)

Yamaha outboard motor is protected

from corrosion by a sacrificial anode(s).

Check the anode(s) periodically. Remove

the scales from surfaces of the anode(s).

For the inspection and replacement of the

anode(s), consult a Yamaha dealer.

cC

Do not paint the anode(s), for this would

render it ineffective

601033

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 25

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4-25

EMU00404

CHECKING BATTERY

(for Electric start model)

w

Battery electrolytic fluid is dangerous; it

contains sulfuric acid and therefore is poi-

sonous and highly caustic.

Always follow these preventive mea-

sures:

8Avoid bodily contact with electrolytic

fluid as it can cause severe burns or

permanent eye injury.

8Wear protective eye gear when han-

dling or working near batteries.

Antidote (EXTERNAL):

8SKIN - Flush with water.

8EYES - Flush with water for 15 minutes

and get immediate medical attention.

Antidote (INTERNAL):

8Drink large quantities of water or milk

followed by milk of magnesia, beaten

egg, or vegetable oil. Get immediate

medical attention.

Batteries also generate explosive

hydrogen gas; therefore, you should

always follow these preventive mea-

sures:

8Charge batteries in a well-ventilated

area.

8Keep batteries away from fire, sparks,

or open flames (e.g., welding equip-

ment, lighted cigarettes, etc.).

8DO NOT SMOKE when charging or han-

dling batteries.

8KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 26

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4-26

cC

8A poorly maintained battery will quick-

ly deteriorate.

8Ordinary tap-water contains minerals

harmful to a battery, and should not be

used for topping-up.

1) Check the electrolyte level at least

once a month. Fill to the manufactur-

er’s recommended level when neces-

sary. Top up only with distilled water

(or pure de-ionized water suitable to

use in batteries).

2) Keep the battery always in a good

state of charge. Installing a voltmeter

will help you monitor your battery. If

you will not use the boat for a month

or more, remove the battery from the

boat and store it in a cool, dark place.

Completely recharge the battery

before using it.

3) If the battery will be stored for longer

than a month, check the specific grav-

ity of the fluid at least once a month

and recharge the battery when it is

low.

EMU01304*

Connecting the Battery

w

Mount the battery holder securely in a

dry, well-ventilated, vibration-free loca-

tion in the boat. Install the fully charged

battery in the holder.

UPPERLEVE

L

LOWER LEVEL

901012*

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 27

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4-27

cC

8Make sure the main switch (on applica-

ble models) is “OFF” before working on

the battery.

8Reversal of the battery leads will dam-

age the rectifier.

8Connect the RED lead first when

installing the battery and disconnect

the RED lead last when removing it.

Otherwise, the electrical system can be

damaged.

8The electrical contacts of the battery

and cables must be clean and properly

connected, or the battery will not start

the engine.

Connect the RED lead to the POSITIVE (+)

terminal first. Then connect the BLACK

lead to the NEGATIVE (-) terminal.

8Using a single battery

Connect both red cables 1and 2to the

(+) terminal.

w

Do not leave cable 2unconnected. If it

accidentally contacts the NEGATIVE (-)

terminal of the battery, there will be a

short circuit. Electrical system damage

and a fire could result.

1Large red lead for starting battery

2Small red lead for accessory battery charg-

ing (optional part)

3Large black lead

4Battery

8Using an accessory battery

Use a connecting cable between the (-)

terminals of the starting battery and

accessory battery. See the illustrations of

the wiring connections. This cable must

be made from wire equivalent to the start-

ing battery cable 3.

q

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901013

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 28

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4-28

EMU01280

Disconnecting the Battery

Disconnect the BLACK lead from the NEG-

ATIVE (-) terminal first. Then disconnect

the RED lead from the POSITIVE (+) termi-

nal.

EMU00408

CHECKING BOLTS AND NUTS

1) Check that bolts securing the cylinder

head and engine and the nut securing

the flywheel are tightened with their

specified tightening torque.

2) Check the tightening torque of other

bolts and nuts.

901014*

w

erty

q

w

Use of smaller wire could lead to a fire.

1Battery for starting

2Battery for accessories

3Large red lead for starting battery

4Small red lead for accessory battery charg-

ing (optional part)

5Large black lead

6Negative connecting cable

NOTE:

If a battery selector switch is desired, con-

sult your YAMAHA dealer about correct

wiring.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 29

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4-29

000876

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EMU01172

CLEANING COOLING-WATER

PASSAGES

Flushing device equipped model

Perform this procedure right after opera-

tion for the most thorough flushing.

1) After shutting off the engine, unscrew

the garden-hose connector 2from

the fitting 1on the bottom cowling.

2) Screw the garden-hose connector 2

onto a garden hose 3which is con-

nected to a fresh-water supply.

3) With the engine off, turn on the water

tap and let the water flush through

the cooling passages for about 15

minutes. Turn off the water and dis-

connect the garden hose 3.

4) When flushing is complete, reinstall

the garden-hose connector 2on the

fitting 1on the bottom cowling.

Tighten the connector securely.

cC

Do not leave the garden-hose connector

loose on the bottom cowling fitting or let

the hose hang free during normal opera-

tion. Water will leak out of the connector

instead of cooling the engine, which can

cause serious overheating. Be sure the

connector is tightened securely on the fit-

ting after flushing the engine.

NOTE:

8When flushing the engine with the boat

in the water, tilting up the engine until it

is completely out of the water will

achieve better results.

8Refer to cooling system flushing

instructions in “TRANSPORTING AND

STORING OUTBOARD MOTOR”.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 30

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4-30

102025

EMU00413

COATING THE BOAT BOTTOM

A clean hull improves boat performance.

The boat bottom should be kept as clean

of marine growths as possible. If neces-

sary, the boat bottom can be coated with

an anti-fouling paint approved for your

area to inhibit marine growth.

Do not use anti-fouling paint which

includes copper or graphite. These paints

can cause more rapid engine corrosion.

EMU00409

MOTOR EXTERIOR

EMU00410

Cleaning the Outboard Motor

After use, wash the exterior of the out-

board with fresh water.

Flush the cooling system with fresh

water.

NOTE:

Refer to Flushing Cooling System instruc-

tions in “TRANSPORTING AND STORING

OUTBOARD MOTOR”.

EMU00412

Checking Painted Surface of Motor

Check the motor for scratches, nicks, or

flaking paint. Areas with damaged paint

are more likely to corrode. If necessary,

clean and paint the areas. A touch-up

paint is available from a Yamaha dealer.

68F-9-13-4 <2nd> 4/23/01 1:12 PM Page 31

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– MEMO –

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EMU00414

Chapter 5

TROUBLE RECOVERY

TROUBLESHOOTING ..............................5-1

TEMPORARY ACTION IN

EMERGENCY ............................................5-5

Impact damage.....................................5-5

Running single engine.........................5-5

Power trim/tilt will not operate ...........5-6

Starter will not operate ........................5-7

Low oil level warning activates...........5-9

Treatment of submerged motor.......5-11

1

2

3

4

5

6

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 1

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5-1

EMU01204¯

TROUBLESHOOTING

A problem in the fuel, compression, or ignition systems can cause poor starting, loss of

power, or other problems. The troubleshooting chart describes basic checks and possi-

ble remedies. (This chart covers all Yamaha outboard motors. Therefore, some items

may not apply to your model.)

If your outboard motor requires repair, bring it to a Yamaha dealer.

A. Starter will not

operate.

Trouble Possible Cause Remedy

1. Battery capacity weak or low.

2. Battery connections loose or

corroded.

3. Fuse for electric start circuit blown.

4. Starter components faulty.

5. Engine stop switch lanyard not

attached.

6. Shift lever in gear.

1. Check battery condition. Use

battery of recommended capacity.

2. Tighten battery cables and clean

battery terminals.

3. Check for cause of electric

overload and repair. Replace fuse

with one of correct amperage.

4. Have serviced by a Yamaha

dealer.

5. Attach lanyard.

6. Shift to neutral.

B. Engine will not

start (Starter

operates).

1. Fuel tank empty.

2. Fuel contaminated or stale.

3. Fuel filter clogged.

4. Starting procedure incorrect.

5. Fuel pump malfunctions.

6. Spark plug(s) fouled or incorrect

type.

7. Spark plug cap(s) fitted incorrectly.

8. Poor connections or damaged

ignition wiring.

9. Ignition parts faulty.

10. Engine stop switch lanyard not

attached.

11. Shift lever in gear.

12. Engine inner parts damaged.

1. Fill tank with clean, fresh fuel.

2. Fill tank with clean, fresh fuel.

3. Clean or replace filter.

4. Read "STARTING ENGINE"

section.

5. Have serviced by a Yamaha

dealer.

6. Inspect spark plug(s). Clean or

replace with recommended type.

7. Check and re-fit cap(s).

8. Check wires for wear or breaks.

Tighten all loose connections.

Replace worn or broken wires.

9. Have serviced by a Yamaha

dealer.

10. Attach lanyard.

11. Shift to neutral.

12. Have serviced by a Yamaha

dealer.

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 2

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5-2

C. Engine idles

irregularly or stalls.

Trouble Possible Cause Remedy

1. Spark plug(s) fouled or incorrect

type.

2. Fuel system obstructed.

3. Fuel contaminated or stale.

4. Fuel filter clogged.

5. Failed ignition parts.

6. Warning system activated.

7. Spark plug gap incorrect.

8. Poor connections or damaged

ignition wiring.

9. Specified engine oil not used.

10. Thermostat faulty or clogged.

11. Fuel pump damaged.

12. Air vent screw on the fuel tank

closed.

13. Choke knob pulled out.

14. Motor angle too high.

15. Fuel joint connection incorrect.

16. Throttle valve adjustment incorrect.

17. Battery lead disconnected.

1. Inspect spark plug(s). Clean or

replace with recommended type.

2. Check for pinched or kinked fuel

line or other obstructions in fuel

system.

3. Fill tank with clean, fresh fuel.

4. Clean or replace filter.

5. Have serviced by a Yamaha

dealer.

6. Find and correct cause of warning.

7. Inspect and adjust as specified.

8. Check wires for wear or breaks.

Tighten all loose connections.

Replace worn or broken wires.

9. Check and replace oil as specified.

10. Have serviced by a Yamaha

dealer.

11. Have serviced by a Yamaha

dealer.

12. Open the air vent screw.

13. Return to home position.

14. Return to normal operating

position.

15. Connect correctly.

16. Have serviced by a Yamaha

dealer.

17. Connect securely.

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 3

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5-3

D. Warning buzzer

sounds or

indicator lamp

lights.

Trouble Possible Cause Remedy

1. Cooling system clogged.

2. Engine oil level low.

3. Heat range of spark plug incorrect.

4. Specified engine oil not used.

5. Engine oil contaminated or

deteriorated.

6. Oil filter clogged.

7. Oil feed/injection pump

malfunctions.

8. Load on boat improperly distributed.

9. Water pump/thermostat faulty.

1. Check water intake for restriction.

2. Fill oil tank with specified engine

oil.

3. Inspect spark plug and replace it

with recommended type.

4. Check and replace oil with

specified type.

5. Replace oil with fresh, specified

type.

6. Have serviced by a Yamaha

dealer.

7. Have serviced by a Yamaha

dealer.

8. Distribute load to place boat on an

even plane.

9. Have serviced by a Yamaha

dealer.

1. Propeller damaged.

2. Propeller pitch or diameter incorrect.

3. Trim angle incorrect.

4. Motor mounted at incorrect height

on transom.

5. Warning system activated.

6. Boat bottom fouled with marine

growth.

7. Spark plug(s) fouled or incorrect

type.

8. Weeds or other foreign matter

tangled on gear housing.

9. Fuel system obstructed.

10. Fuel filter clogged.

11. Fuel contaminated or stale.

12. Spark plug gap incorrect.

1. Have propeller repaired or

replaced.

2. Install correct propeller to operate

outboard at its recommended

speed (r/min) range.

3. Adjust trim angle to achieve most

efficient operation.

4. Have motor adjusted to proper

transom height.

5. Find and correct cause of warning.

6. Clean boat bottom.

7. Inspect spark plug(s). Clean or

replace with recommended type.

8. Remove foreign matter and clean

lower unit.

9. Check for pinched or kinked fuel

line or other obstructions in fuel

system.

10. Clean or replace filter.

11. Fill tank with clean, fresh fuel.

12. Inspect and adjust as specified.

E. Engine power loss.

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 4

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5-4

Trouble Possible Cause Remedy

13. Poor connections or damaged

ignition wiring.

14. Failed ignition parts.

15. Specified engine oil not used.

16. Thermostat faulty or clogged.

17. Air vent screw closed.

18. Fuel pump damaged.

19. Fuel joint connection incorrect.

20. Heat range of spark plug incorrect.

21. High pressure fuel pump drive belt

broken.

22. Engine not responding properly to

shift lever position.

13. Check wires for wear or breaks.

Tighten all loose connections.

Replace worn or broken wires.

14. Have serviced by a Yamaha

dealer.

15. Check and replace oil with

specified type.

16. Have serviced by a Yamaha

dealer.

17. Open the air vent screw.

18. Have serviced by a Yamaha

dealer.

19. Connect correctly.

20. Inspect spark plug and replace it

with recommended type.

21. Have serviced by a Yamaha

dealer.

22. Have serviced by a Yamaha

dealer.

E. Engine power loss.

F. Engine vibrates

excessively.

1. Propeller damaged.

2. Propeller shaft damaged.

3. Weeds or other foreign matter

tangled on propeller.

4. Motor mounting bolt loose.

5. Steering pivot loose or damaged.

1. Have propeller repaired or

replaced.

2. Have serviced by a Yamaha

dealer.

3. Remove and clean propeller.

4. Tighten bolt.

5. Tighten or have serviced by a

Yamaha dealer.

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 5

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EMU00416

TEMPORARY ACTION IN

EMERGENCY

EMU00417

IMPACT DAMAGE

w

The outboard motor can be seriously

damaged by a collision while operating

or trailering. Damage could make the out-

board motor unsafe to operate.

If the outboard motor hits any object in

the water, follow the procedure below.

1) Stop the engine immediately.

2) Inspect control system and all compo-

nents for damage. Also, inspect the

boat damage.

3) However damage is found or not

found, go back to a nearest harbor

slowly and carefully.

4) Have a Yamaha dealer inspection of

the outboard motor, before operating

it again.

607011

5-5

102043

EMU00418

RUNNING SINGLE ENGINE

Using only one of the engines in case of

an emergency, be sure to keep the

unused one tilted up and operate the

other engine at low speed.

cC

If the boat is operated with one engine in

the water but not running, water may run

into the exhaust pipe due to wave action,

causing engine trouble.

NOTE:

When you are maneuvering at low speed,

such as near a dock, it is recommended

that both engines be running with one in

neutral gear if possible.

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 6

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5-6

411025

q

EMU00419

POWER TRIM/TILT WILL NOT

OPERATE

If the engine cannot be tilted up or down

with the power trim and tilt because of a

discharged battery or a failure with the

power trim and tilt unit, the engine can be

tilted manually.

1Manual valve screw

EMU00421

1) Loosen the manual valve screw coun-

terclockwise until it stops.

2) Put the engine in the desired position,

then tighten the manual valve screw

clockwise.

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5-7

EMU00424

STARTER WILL NOT OPERATE

If the starter mechanism does not operate

(engine cannot be cranked with the

starter), the engine can be manually start-

ed with an emergency starter rope.

However, the engine can not be manually

started if the battery has low voltage. If

the battery is discharged to 9 volts or

below, the electrical fuel pump will not

operate.

w

8Use this procedure only in an emer-

gency and only to return to port for

repairs.

8When the emergency starter rope is

used to start the engine, the start-in-

gear protection device does not oper-

ate. Make sure the remote control lever

is in neutral. Otherwise, the boat could

unexpectedly start to move, which

could result in an accident.

8Be sure no one is standing behind you

when pulling the starter rope. It could

whip behind you and injure someone.

8An unguarded rotating flywheel is very

dangerous. Keep loose clothing and

other objects away when starting the

engine. Use the emergency starter rope

only as instructed. Do not touch the fly-

wheel or other moving parts when the

engine is running. Do not install the

starter mechanism or top cowling after

the engine is running.

8Do not touch the ignition coil, high

voltage wire, spark plug cap or other

electrical components when starting of

operating the motor. You could be

shocked.

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 8

ON STARTOFF

701026

703043

ON

ON

E

5-8

301052

208083

208084

EMU01309

Emergency Starting Engine

1) Remove the top cowling.

2) Remove the flywheel cover.

3) Prepare the engine for starting. See

“STARTING ENGINE” for procedures.

Be sure the engine is in Neutral and

that the lanyard is attached to the

engine stop switch.

4) Turn the main switch to the ON posi-

tion.

5) Insert the knotted end of the emer-

gency starter rope into the notch in

the flywheel rotor and wind the rope

several turns clockwise.

6) Give a strong pull straight out to

crank the engine. Repeat if necessary.

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 9

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5-9

EMU01191

LOW OIL LEVEL WARNING

ACTIVATES

If the oil level is allowed to drop too low,

the red segment will appear on the oil

level indicator, the buzzer will sound, and

engine speed will be limited to about

2,000 r/min. If this happens, a reserve

amount of oil can be pumped from the

remote oil tank 3to the engine oil tank 2

using the emergency switch 1.

w

Be sure to stop the engine before per-

forming this procedure.

cC

8If the emergency switch is held up too

long, too much oil will be pumped into

the engine tank, overflowing it. Release

the switch when oil reaches the upper

level line on the engine oil tank.

8Do not use this emergency procedure

unless the oil level warning lamps are

installed and working.

1) Remove the top cowling.

2) Turn the main switch to the “ON”

position.

3) Lift the emergency switch to pump

reserve oil in remote oil tank into the

engine oil tank.

4) After using the emergency switch,

turn off the main switch, then turn it

back on. This resets the warning sys-

tem for normal operation. Yellow seg-

ment will remain appearing on oil

level indicator at this time.

5) Start the engine and return to the

nearest port for more oil.

905013

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218013

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68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 10

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5-10

NOTE:

8Reserve oil capacity is maximum 1,500

cm3(1.6 US qt, 1.31 Imp qt).

8The oil feed pump will not operate if the

engine is tilted more than 35°. Put the

engine in the down position before

operating the emergency switch.

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 11

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5-11

EMU00446

TREATMENT OF SUBMERGED

MOTOR

If the outboard motor is submerged,

immediately take it a Yamaha dealer.

Otherwise, some corrosion may begin

almost immediately.

If you cannot immediately take the out-

board motor to a Yamaha dealer, follow

the procedure bellow for taking care to

minimize engine damage.

EMU00449

1) Thoroughly wash away mud, salt,

seaweed, etc. with fresh water.

2) Remove the spark plugs and face the

spark plug holes downward to allow

any water, mud or contaminants to

drain.

3) Drain the fuel from the vapor separa-

tor, fuel filter and fuel line.

4) Feed fogging oil or engine oil through

the intake manifold and spark plug

holes while cranking with the emer-

gency starter rope.

5) Take the outboard motor to a Yamaha

dealer as soon as possible.

cC

Do not attempt to run the motor until it

has been completely inspected.

107012

107013

107014

68F-9-13-5 <2nd> 4/23/01 1:06 PM Page 12

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EMU00450

Chapter 6

INDEX

INDEX........................................................6-1

1

2

3

4

5

6

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E

EMU00451

INDEX

A

Adjusting idling speed ..........................4-16

Adjusting trim angle..............................3-18

B

Basic boating rules ..................................1-7

Battery care...............................................4-8

Battery requirement ..............................1-13

Bow down...............................................3-19

Bow up ....................................................3-19

Breaking in (running in) engine..............3-4

C

Changing gear oil...................................4-23

Checking battery ................................... 4-25

Checking bolts and nuts........................4-28

Checking fuel system ............................4-14

Checking high pressure fuel pump

drive belt .................................................4-18

Checking painted surface of motor......4-30

Checking power trim and tilt system...4-20

Checking propeller.................................4-21

Checking water in engine oil tank........4-17

Checking wiring and connectors..........4-19

Cleaning and adjusting spark plug ......4-12

Cleaning and anti-corrosion measure ...4-7

Cleaning cooling-water passages ........4-29

Cleaning the outboard motor ...............4-30

Clock........................................................2-13

Coating the boat bottom.......................4-30

Connecting the battery..........................4-26

Cruising in other conditions .................3-22

Cruising in salt water.............................3-22

Cruising in turbid water ........................3-22

D

Digital speedometer ..............................2-11

Digital tachometer ...................................2-9

Disconnecting the battery.....................4-28

E

Emergency starting engine.....................5-8

Emission control information.................1-2

Engine oil ................................................1-12

Engine stop lanyard switch.....................2-4

Exhaust leakage .....................................4-19

F

Filling fuel .................................................3-8

Filling fuel and engine oil........................3-8

Filling fuel tank .........................................4-5

Filling oil....................................................3-9

Flushing cooling system and

fogging engine .........................................4-6

Flushing device ......................................2-19

Flushing with the flushing

attachment................................................4-6

Forward...................................................3-15

Free accelerator........................................2-6

Fuel consumption meter.......................2-16

Fuel economy.........................................2-16

Fuel flow meter ......................................2-15

Fuel management meter.......................2-14

Fuel meter...............................................2-13

Fueling instructions ...............................1-11

G

Gasohol...................................................1-12

Gasoline (petrol) ....................................1-12

Greasing..................................................4-11

H

Hour meter..............................................2-10

I

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

Impact damage ........................................5-5

Important labels .......................................1-6

Inspecting and replacing anode(s).......4-24

Inspecting fuel filter ...............................4-15

Installation ................................................3-1

K

Key number ..............................................1-1

L

Low oil level warning activates ..............5-9

Lubrication................................................4-7

M

Main components....................................2-1

6-1

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E

6-2

Main switch ..............................................2-4

Maintenance chart .................................4-10

Motor exterior ........................................4-30

Mounting height ......................................3-3

Mounting the outboard motor ...............3-2

N

Neutral interlock trigger ..........................2-3

Neutral throttle lever ...............................2-3

O

Oil level indicator..........................2-10, 3-10

Oil level warning/

oil filter clogging warning.....................2-21

Operation after a long period of

storage ......................................................3-7

Operations of controls and other

functions ...................................................2-2

Outboard motor serial number ..............1-1

Overheat warning ..................................2-20

Overheat warning indicator..................2-11

P

Periodic maintenance..............................4-9

Power trim/tilt switches ...................2-5, 2-8

Power trim/tilt will not operate...............5-6

Pre-operation checks ...............................3-5

Propeller selection .................................1-13

R

Remote control.........................................2-2

Remote control lever ...............................2-3

Replacement parts...................................4-9

Replacing fuse........................................4-19

Reverse ...................................................3-15

Ring free fuel additive .............................3-8

Running single engine ........................... 5-5

S

Safety information ...................................1-4

Shifting....................................................3-15

Specification data ....................................4-1

Speedometer..........................................2-12

Star labels .................................................1-3

Start-in-gear protection.........................1-15

Starter will not operate............................5-7

Starting engine.......................................3-11

Stopping engine.....................................3-16

Storing outboard motor ..........................4-5

T

Tachometer...............................................2-9

Temporary action in emergency............5-5

Throttle friction adjusting screw ............2-6

Tilt support lever....................................2-19

Tilting up/down ......................................3-20

Top cowling lock levers.........................2-19

Trailering outboard motor ......................4-4

Transporting and storing outboard

motor.........................................................4-4

Treatment of submerged motor ..........5-11

Trim meter ................................................2-9

Trim tab.....................................................2-7

Trimming outboard motor....................3-17

Trip meter ...............................................2-12

Troubleshooting.......................................5-1

Twin engine speed synchronizer .........2-18

U

Using a single battery ...........................4-27

Using an accessory battery ..................4-27

W

Warming up engine...............................3-14

Warning indicator ..................................2-14

Warning system.....................................2-20

Warranty information .................Next page

Water leakage.........................................4-19

Water separator warning indicator......2-18

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EMU01599

IMPORTANT WARRANTY INFORMATION FOR U.S.A. AND

CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is commit-

ted to exceptional customer satisfaction, and we want your ownership experience to be

a satisfying one. Please read the following warranty information to help ensure satisfac-

tion with your Yamaha.

Yamaha is ready to stand behind your purchase with strong warranty coverage. To be sure

you receive all the benefits of warranty, please take the following steps:

1. Be sure your new Yamaha is registered for warranty. Your boat dealer should do this at

the time of sale. Make sure your dealer gives you a copy of the completed Yamaha regis-

tration card for your records. If you are unsure whether or not your Yamaha is registered,

complete the Warranty Registration card found inside the cover of the Owner's Manual.

Mail it to the distributor for the country in which you live (see step 6 for the correct

address). If your Yamaha is not properly registered, a warranty repair could be unneces-

sarily delayed while registration records are checked.

2. Read the Limited Warranty statement which follows these instructions. This warranty

applies to Yamaha outboard motors sold in the United States, whether purchased sepa-

rately or when supplied as original equipment by a boat builder. The terms also apply to

original equipment packages sold in Canada, with coverage provided by Yamaha Motor

Canada (see ``Warranty Guide'' for Canadian models). This warranty explains the condi-

tions of the warranty, including the obligations that your dealer and you as the owner

have under the warranty. For example, your Yamaha outboard must receive a proper

pre-delivery inspection (PDI) by the selling dealer. Failure to take this important step

could jeopardize warranty coverage!

3. If you need warranty repairs, you must take your Yamaha outboard to an authorized

Yamaha outboard dealer. Be aware that not all selling boat dealers are authorized

Yamaha dealers. Only authorized dealers have the factory training, special tools, and

Yamaha support needed to perform warranty repairs.

4. If you are away from home, or your selling dealer is not an authorized Yamaha dealer,

use the following toll-free numbers to find the nearest Yamaha dealer.

United States Dealer Locations: 1-800-692-6242

Canada Dealer Locations: 1-800-267-8577

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5. Your warranty applies specifically to repairs made in the country of purchase. If your

U.S.-purchased Yamaha needs warranty service while in Canada, or your Canadian pur-

chased Yamaha needs service while in the United States, Yamaha will assist the local

dealer whenever possible. However, some products available in one country may not be

sold or serviced in the other.

6. If you need any additional information about your Yamaha or warranty coverage which

your dealer cannot provide, please contact us directly.

Yamaha Motor Corporation, U.S.A.

P.O. Box 6555

Cypress, CA 90630

Attention: Customer Relations Department

Telephone No. (714) 761-7439

Fax No. (714) 761-7559

Yamaha Motor Canada Ltd.

480 Gordon Baker Road

Toronto, Ontario

M2H 3B4

Attention: Customer Relations Department

Telephone No. (416) 498-1911

Fax No. (416) 491-3122

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EMU00912*

YAMAHA MOTOR CORPORATION, U.S.A.

OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. is proud of its heritage and reputation for producing products with high standards of quality and

workmanship. Product excellence provides the cornerstone for our commitment to customer satisfaction. The Yamaha Outboard

Limited Warranty is your assurance of this commitment.

This warranty provides you with protection against the expense of repairs for your outboard motor that are required as a result of

defects in materials or workmanship. When maintained and utilized in the prescribed manner, you can count on your Yamaha outboard

to provide reliable service.

This warranty provides you with specific coverage and notes your responsibilities in maintaining and operating your outboard. Please

take the time to read and become familiar with this warranty.

PERIOD OF WARRANTY. Any new Yamaha outboard motor purchased and registered with Yamaha Motor Corporation, U.S.A. for plea-

sure use in the United States, will be warranted against defects in material or workmanship for a period of two (2) years from date of

purchase, subject to exclusions noted herein. Any Yamaha outboard motor purchased and utilized for commercial applications will be

warranted for a period of one (1) year from the date of purchase, subject to exclusions noted herein. Yamaha peripheral equipment

included with the motor, such as gauges, fuel tanks and hoses, remote control boxes, propellers, and wiring external from the motor

unit, will be warranted for one (1) year from the date of purchase for either pleasure or commercial use. Replacement parts used in war-

ranty repairs will be warranted for the balance of the applicable warranty period.

The second year of warranty (if applicable) shall be limited to covering the cost of parts and labor for major components only. The major

components covered are:

Power Unit Section

8Power Head

8Intake Manifold and Reed Valve Assembly

8Carburetor Assembly and its Related Components

8Fuel and Oil Pump Assemblies

8Ignition System (Standard and Microcomputer)

8Precision Blend ® System

Bracket Section

8Bracket System

8Power Trim and Tilt Assembly

Lower Unit Section

8Exhaust System

8Upper Casing

8Lower Unit Assembly

The warranty described here applies to outboard motor purchased and registered for use in the United States only excluding its territo-

ries. For warranty provisions outside the United States, contact the particular country’s local Yamaha distributor.

WARRANTY REGISTRATION. To be eligible for warranty coverage, the outboard motor must first be registered with Yamaha Motor

Corporation, U.S.A. A warranty registration form is provided in the Owner`s Manual with each outboard. This form must be completed

and mailed to Yamaha by either the selling dealer or the purchaser. Warranty registration can also be accomplished by any authorized

Yamaha outboard dealer. Upon receipt of the registration, an Owner`s Warranty Card will be sent by Yamaha to the registered purchas-

er.

OBTAINING REPAIRS UNDER WARRANTY. To receive repairs under this warranty, a valid Owner`s Warranty Card must be presented to

an authorized Yamaha outboard dealer.

During the period of warranty, any authorized Yamaha outboard dealer will, free of charge, repair or replace, at Yamaha`s option, any

parts adjudged defective by Yamaha due to faulty workmanship or material from the factory. All replaced parts will become the property

of Yamaha Motor Corporation, U.S.A.

CUSTOMER`S RESPONSIBILITY. Under the terms of this warranty, the customer will be responsible for ensuring that the outboard

motor is properly operated, maintained and stored as specified in the applicable Owner’s Manual.

The owner of the outboard motor shall give notice to an authorized Yamaha marine dealer of any and all apparent defects within ten

(10) days of discovery and make the motor available at that time for inspection and repairs at the dealer’s place of business.

GENERAL EXCLUSIONS FROM WARRANTY. This warranty will not cover the repair of damage if the damage is a result of abuse or

neglect of the product. Examples of abuse and neglect include, but are not limited to:

1. Racing or competition use, modification of original parts, abnormal strain.

2. Lack of proper maintenance and off-season storage as described in the Owner`s Manual, improper mounting of the motor, installa-

tion of parts or accessories that are not equivalent in design and quality to genuine Yamaha parts.

3. Operation of the motor at an rpm other than specified, improper propeller selection, use of lubricants, oils, and fuel/oil mixtures

that are not suitable for outboard motor use.

4. Damage as a result of accidents, collisions, contact with foreign materials, or submersion.

5. Growth of marine organisms on motor surfaces.

6. Normal deterioration.

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SPECIFIC PARTS EXCLUDED FROM WARRANTY. Parts replaced due to normal wear or routine maintenance such as oil, spark plugs,

shear pins, propellers, hubs, fuel and oil filters, brushes for the starter motor and power tilt motor, water pump impellers, and anodes

are not covered by warranty. Charges for removal of the motor from a boat and transporting the motor to and from an authorized

Yamaha outboard dealer are excluded from warranty coverage.

Specific parts excluded from the second year of warranty (if applicable) are:

8Top and Bottom Cowling

8Electric Components (other than ignition system)

8Rubber Components (such as hoses, tubes, rubber seals, fittings, and clamps)

TRANSFER OF WARRANTY. Transfer of the warranty from the original purchaser to any subsequent purchaser is possible by having the

motor inspected by an authorized Yamaha outboard dealer and requesting the dealer to submit a change of registration to Yamaha

Motor Corporation, U.S.A. within ten (10) days of the transfer.

EMISSION CONTROL SYSTEM WARRANTY. Yamaha warrants to the ultimate purchaser and each subsequent purchaser, that this

engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean

Air Act and this engine is free from defects in materials and workmanship which cause said engine to fail to conform with applicable

regulations for one (1) year from date of purchase.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND

TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND

EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION

MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUEN-

TIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE

TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A.

Post Office Box 6555

Cypress, California 90630

WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty period?

A. The customer`s responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision dam-

ages.

Q. What are some examples of ``abnormal’’ strain, neglect, or abuse?

A. These terms are general and overlap each other in areas. Specific examples include:

Running the machine out of oil, operating the machine with a broken or damaged part which causes another part to fail, damage or

failure due to improper or careless transportation, and/or tie down. If you have any specific questions on operation or mainte-

nance, please contact your Yamaha outboard dealer for advice.

Q. Does the warranty cover incidental costs such as towing or transportation due to a failure?

A. No. The warranty is limited to repair of the machine itself.

Q. May I perform any or all of the recommended maintenance shown in the Owner’s Manual instead of having the dealer do them?

A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s and Service Manuals. We do recommend,

however, that items requiring special tools or equipment be done by a Yamaha outboard dealer.

Q. Will the warranty be void or canceled if I do not operate or maintain my new outboard exactly as specified in the Owner’s Manual?

A. No. The warranty on a new outboard cannot be ’’voided`` or ’’canceled``. However, if a particular failure is caused by operation or

maintenance other than as shown in the Owner’s Manual, that failure may not be covered under warranty.

Q. What responsibility does a Yamaha outboard dealer have under this warranty?

A. Each Yamaha outboard dealer is expected to:

1. Completely set up each outboard he sells prior to delivery.

2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request

at any later date.

In addition, each Yamaha outboard dealer is held responsible for his setup, service and warranty repair work.

Q. Is the warranty transferable to second owners?

A. Yes. The remainder of any existing warranty can be transferred upon request. The unit has to be inspected and re-registered by an

authorized Yamaha outboard dealer for the policy to remain effective.

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CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha outboard dealer within the continental United

States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or

problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level,

this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A.

CUSTOMER RELATIONS DEPARTMENT

P.O.Box 6555

Cypress, California 90630

When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include any important information such as names, addresses,

model, engine serial number, dates, and receipts.

CHANGE OF ADDRESS

The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers

against the possibility of a safety-related defect and recall. This list is complied from the purchase registrations sent to Yamaha Motor

Corporation, U.S.A. by the selling dealer at the time of your purchase.

If you should move after you have purchased your new outboard, please advise us of your new address by sending a postcard listing

your outboard model name, engine serial number, dealer number (or dealer’s name) as it is shown on your warranty identification, your

name and new mailing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A.

WARRANTY DEPARTMENT

P.O.Box 6555

Cypress, California 90630

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

)QG!303DJH

EMU01178

IMPORTANT WARRANTY INFORMATION

IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA

Welcome to the Yamaha Family!

Congratulations on the purchase of your new Yamaha marine power. Yamaha is com-

mitted to exceptional customer satisfaction, and we want your ownership experience

to be a satisfying one. Please read the following warranty information to help ensure

satisfaction with your Yamaha.

This model was manufactured as a U.S.A. specification model, and the warranty state-

ment shown in this manual is for market. To receive the benefits of the warranty that

applies to the country in which you use your Yamaha, please note the following infor-

mation.

1. The warranty on this model is the same as equivalent models sold in the country

where you will receive service. If you need more information about your warranty

coverage or your Yamaha outside the U.S.A. or Canada, please contact an autho-

rized Yamaha dealer in your country.

2. Keep a copy of your sales contract or invoice for the purchase of your Yamaha and

present it if you need warranty repairs. This document should show the date of

purchase, which is important evidence the repairing dealer will need to be sure

your Yamaha is covered by warranty.

3. If your Yamaha needs warranty repairs, contact an authorized Yamaha dealer in

the country where you are. He will explain how to get warranty service in that

country.

4. This Yamaha model may not be sold in some countries. Therefore, in some cases

your local dealer may not have all the parts or service information he may need,

which may unavoidably delay repairs. If this happens, we thank you for your

understanding and assure you we will attempt to resolve the situation as quickly as

possible.

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Printed in Japan

April 2001—0.5 ×2!

68F-28199-13

(Z150PETO/LZ150PETO/Z175GETO/Z200NETO/LZ200NETO)

(E)

Printed on recycled paper