Yamaha E8D User manual

OWNER’S MANUAL
E8D
677-28199-20-E0
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM

Read this owner’s manual carefully before operating your outboard motor.
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM

Important manual information
EMU25100
To the owner
Thank you for choosing a Yamaha outboard
motor. This Owner’s Manual contains infor-
mation needed for proper operation, mainte-
nance and care. A thorough understanding of
these simple instructions will help you 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.
The Safety Alert Symbol means AT-
TENTION! BECOME ALERT! YOUR SAFE-
TY IS INVOLVED!
WARNING
EWM00780
Failure to follow WARNING instructions
could result in severe injury or death to the
machine operator, a bystander, or a per-
son inspecting or repairing the outboard
motor.
CAUTION:
ECM00700
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 advancements 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 con-
sult your Yamaha dealer.
NOTE:
The E8DMH and the standard accessories
are used as a base for the explanations and
illustrations in this manual. Therefore some
items may not apply to every model.
EMU25120
E8D
OWNER’S MANUAL
©2004 by Yamaha Motor Co., Ltd.
1st Edition, February 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM

Table of contents
General information ......................1
Identification numbers record...... 1
Outboard motor serial number ....... 1
EC label....................................... 1
Safety information ....................... 1
Important labels........................... 2
Warning labels................................ 2
Fueling instructions ..................... 3
Gasoline ......................................... 3
Engine oil........................................ 3
Propeller selection....................... 3
Start-in-gear protection ............... 4
Basic components ........................5
Main components........................ 5
Fuel tank......................................... 5
Fuel joint......................................... 6
Fuel tank cap.................................. 6
Air vent screw................................. 6
Tiller handle.................................... 6
Gear shift lever............................... 6
Throttle grip .................................... 6
Throttle indicator............................. 6
Throttle friction adjuster.................. 7
Engine stop lanyard switch............. 7
Engine stop button ......................... 8
Choke knob for pull type................. 8
Manual starter handle..................... 8
Steering friction adjuster................. 8
Trim rod (tilt pin) ............................. 8
Tilt lock mechanism........................ 9
Tilt support bar ............................... 9
Top cowling lock lever(s)
(turn type).................................... 9
Operation ..................................... 10
Installation ................................. 10
Mounting the outboard motor ....... 10
Clamping the outboard motor....... 11
Breaking in engine .................... 12
Gasoline and engine oil mixing
chart (25:1)................................ 12
Procedure for pre-mixed
models ...................................... 12
Preoperation checks ................. 13
Fuel .............................................. 13
Oil ................................................. 13
Controls ........................................ 13
Engine .......................................... 13
Filling fuel and engine oil .......... 13
Filling fuel for portable tank .......... 13
Gasoline and oil mixing ................ 13
Operating engine ...................... 14
Feeding fuel (portable tank) ......... 14
Starting engine ............................. 15
Warming up engine................... 17
Choke start models ...................... 17
Shifting ...................................... 18
Forward (tiller handle and
remote control models) ............. 18
Reverse (manual tilt and
hydro tilt models)....................... 18
Stopping engine........................ 19
Procedure..................................... 19
Trimming outboard motor.......... 19
Adjusting trim angle for
manual tilt models ..................... 20
Adjusting boat trim........................ 20
Tilting up and down................... 21
Procedure for tilting up
(manual tilt models)................... 22
Procedure for tilting down
(manual tilt models)................... 23
Cruising in shallow water .......... 23
Cruising in shallow water
(manual tilt models)................... 23
Cruising in other conditions....... 24
Maintenance ................................ 26
Specifications............................ 26
Transporting and storing
outboard motor ...................... 26
Clamp screw mounting models .... 27
Storing outboard motor................. 27
Procedure..................................... 28
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM

Table of contents
Lubrication
(except oil injection models)...... 29
Cleaning the outboard motor........ 29
Checking painted
surface of motor ........................ 29
Periodic maintenance................ 29
Replacement parts ....................... 29
Maintenance chart........................ 30
Greasing....................................... 31
Cleaning and adjusting
spark plug ................................. 31
Checking fuel system ................... 32
Inspecting fuel filter ...................... 33
Cleaning fuel filter......................... 33
Inspecting idling speed................. 33
Checking wiring and
connectors ................................ 34
Exhaust leakage........................... 34
Water leakage .............................. 34
Checking propeller ....................... 34
Removing the propeller ................ 35
Installing the Propeller.................. 35
Changing gear oil ......................... 36
Cleaning fuel tank......................... 37
Inspecting and replacing
anode(s).................................... 37
Checking top cowling ................... 38
Coating the boat bottom............... 38
Trouble Recovery ........................ 39
Troubleshooting ........................ 39
Temporary action in
emergency ............................. 42
Impact damage............................. 42
Starter will not operate ................. 42
Emergency starting engine........... 43
Treatment of
submerged motor ................... 44
Procedure..................................... 44
U67720E0.book Page 2 Friday, March 26, 2004 10:36 AM

General information
1
EMU25170
Identification numbers record
EMU25182
Outboard motor serial number
The outboard motor serial number is stamped
on the label attached to the port side of the
clamp bracket or the upper part of the swivel
bracket.
Record your outboard motor serial number in
the spaces provided to assist you in ordering
spare parts from your Yamaha dealer or for
reference in case your outboard motor is sto-
len.
EMU25202
EC label
Engines affixed with this label conform to cer-
tain portions of the European Parliament di-
rective relating to machinery. Refer to the
label and the EC Declaration of Conformity for
more details.
EMU25370
Safety information
●Before mounting or operating the outboard
motor, read this entire manual. Reading it
should give you an understanding of the
motor and its operation.
●Before operating the boat, read any own-
er’s or operator’s manuals supplied with it
and all labels. Be sure you understand each
item before operating.
●Do not overpower the boat with this out-
board 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 horsepower capacity of the boat.
If the rated horsepower capacity of the boat
is unknown, consult the dealer or boat man-
ufacturer.
1. Outboard motor serial number location
1. EC label location
ZMU01696
U67720E0.book Page 1 Friday, March 26, 2004 10:36 AM

General information
2
●Do not modify the outboard. Modifications
could make the motor unfit or unsafe to use.
●Never operate after drinking alcohol or tak-
ing drugs. About 50% of all boating fatalities
involve intoxication.
●Have an approved personal flotation device
(PFD) on board for every occupant. It is a
good idea to wear a PFD whenever boat-
ing. At a minimum, children and non-swim-
mers should always wear PFDs, and
everyone should wear PFDs when there
are potentially hazardous boating condi-
tions.
●Gasoline is highly flammable, and its va-
pors are flammable and explosive. Handle
and store gasoline carefully. Make sure
there are no gas fumes or leaking fuel be-
fore starting the engine.
●This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which may cause brain dam-
age or death when inhaled. Symptoms in-
clude nausea, dizziness, and drowsiness.
Keep cockpit and cabin areas well ventilat-
ed. Avoid blocking exhaust outlets.
●Check throttle, shift, and steering for proper
operation before starting the engine.
●Attach 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.
●Know the marine laws and regulations
where you will be boating - and obey them.
●Stay informed about the weather. Check
weather forecasts before boating. Avoid
boating in hazardous weather.
●Tell someone where you are going: leave a
Float Plan with a responsible person. Be
sure to cancel the Float Plan when you re-
turn.
●Use common sense and good judgment
when boating. Know your abilities, and be
sure you understand how your boat han-
dles under the different boating conditions
you may encounter. Operate within your
limits, and the limits of your boat. Always
operate at safe speeds, and keep a careful
watch for obstacles and other traffic.
●Always watch carefully for swimmers during
the engine operation.
●Stay away from swimming areas.
●When a swimmer is in the water near you
shift into neutral and shut off the engine.
EMU25380
Important labels
EMU25395
Warning labels
EMU25401
Label
WARNING
EWM01260
●Be sure shift control is in neutral before
starting engine. (except 2HP)
●Do not touch or remove electrical parts
when starting or during operation.
●Keep hands, hair, and clothes away from
flywheel and other rotating parts while
engine is running.
U67720E0.book Page 2 Friday, March 26, 2004 10:36 AM

General information
3
EMU25431
Label
WARNING
EWM01300
●This engine is equipped with a neutral
starting device.
●The engine will not start unless the shift
control is in neutral position.
EMU25540
Fueling instructions
WARNING
EWM00010
GASOLINE AND ITS VAPORS ARE HIGH-
LY FLAMMABLE AND EXPLOSIVE!
●Do not smoke when refueling, and keep
away from sparks, flames, or other
sources of ignition.
●Stop engine before refueling.
●Refuel in a well-ventilated area. Refuel
portable fuel tanks off the boat.
●Take care not to spill gasoline. If gaso-
line spills, wipe it up immediately with
dry rags.
●Do not overfill the fuel tank.
●Tighten the filler cap securely after refu-
eling.
●If you should swallow some gasoline, in-
hale a lot of gasoline vapor, or get gaso-
line in your eyes, get immediate medical
attention.
●If any gasoline spills onto your skin, im-
mediately wash with soap and water.
Change clothing if gasoline spills on it.
●Touch the fuel nozzle to the filler open-
ing or funnel to help prevent electrostat-
ic sparks.
CAUTION:
ECM00010
Use only new clean gasoline which has
been stored in clean containers and is not
contaminated with water or foreign matter.
EMU30330
Gasoline
If knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel. If
unleaded gasoline is not available, then pre-
mium gasoline can be used.
EMU25650
Engine oil
If the recommended engine oil is not avail-
able, another 2-stroke engine oil with an
NMMA-certified TC-W3 rating may be used.
EMU25741
Propeller selection
The performance of your outboard motor will
be critically affected by your choice of propel-
ler, as an incorrect choice could adversely af-
fect 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.
Yamaha outboard motors are fitted with pro-
pellers 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 propeller is
more suitable for a smaller operating load.
Yamaha dealers stock a range of propellers,
and can advise you and install a propeller on
your outboard that is best suited to your appli-
cation.
Recommended gasoline:
Regular unleaded gasoline
Recommended engine oil:
YAMALUBE 2-stroke outboard motor
oil
U67720E0.book Page 3 Friday, March 26, 2004 10:36 AM

General information
4
NOTE:
Select a propeller which will allow the engine
to reach the middle or upper half of the oper-
ating range at full throttle with the maximum
boat load. If operating conditions such as light
boat loads then allow the engine r/min to rise
above the maximum recommended range, re-
duce the throttle setting to maintain the en-
gine in the proper operating range.
For instructions on propeller removal and in-
stallation, see page 34.
EMU25760
Start-in-gear protection
Yamaha outboard motors affixed with the pic-
tured label or Yamaha-approved remote con-
trol units are equipped with start-in-gear
protection device(s). This feature permits the
engine to be started only when it is in neutral.
Always select neutral before starting the en-
gine.
1. Propeller diameter in inches
2. Propeller pitch in inches
3. Type of propeller (propeller mark)
ZMU04604
-
x
123
1. Start-in-gear protection label
ZMU01713
1
U67720E0.book Page 4 Friday, March 26, 2004 10:36 AM

Basic components
5
EMU25795
Main components
NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all models.
EMU25802
Fuel tank
If your model was equipped with a portable
fuel tank, its function is as follows.
WARNING
EWM00020
The fuel tank supplied with this engine is
its dedicated fuel reservoir and must not
be used as a fuel storage container. Com-
mercial users should conform to relevant
licensing or approval authority regula-
tions.
1. Manual starter handle
2. Tiller handle
3. Choke knob
4. Engine stop button/Engine stop lanyard
switch
5. Tilt lock lever
6. Clamp screw
7. Trim rod
8. Propeller
9. Cooling water inlet
10.Anti-cavitation plate
11.Clamp bracket
12.Rope attachment
13.Gear shift lever
14.Top cowling
15.Fuel tank
U67720E0.book Page 5 Friday, March 26, 2004 10:36 AM