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

Basic components
6
EMU25830
Fuel joint
This joint is used to connect the fuel line.
EMU25850
Fuel tank cap
This cap seals the fuel tank. When removed,
the tank can be filled with fuel. To remove the
cap, turn it counterclockwise.
EMU25860
Air vent screw
This screw is on the fuel tank cap. To loosen
the screw, turn it counterclockwise.
EMU25911
Tiller handle
To change direction, move the tiller handle to
the left or right as necessary.
EMU25922
Gear shift lever
Pulling the gear shift lever towards you puts
the engine in forward gear so that the boat
moves ahead. Pushing the lever away from
you puts the engine in reverse gear so that the
boat moves astern.
EMU25941
Throttle grip
The throttle grip is on the tiller handle. Turn
the grip counterclockwise to increase speed
and clockwise to decrease speed.
EMU25961
Throttle indicator
The fuel consumption curve on the throttle in-
dicator shows the relative amount of fuel con-
sumed for each throttle position. Choose the
setting that offers the best performance and
fuel economy for the desired operation.
1. Fuel joint
2. Fuel tank cap
3. Air vent screw
1. Forward “”
2. Neutral “”
3. Reverse “”
U67720E0.book Page 6 Friday, March 26, 2004 10:36 AM

Basic components
7
EMU25970
Throttle friction adjuster
A friction device provides adjustable resis-
tance to movement of the throttle grip or the
remote control lever, and can be set accord-
ing to operator preference.
To increase resistance, turn the adjuster
clockwise. To decrease resistance, turn the
adjuster counterclockwise.
WARNING
EWM00030
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to move throttle lever or grip,
which could result in an accident.
When constant speed is desired, tighten the
adjuster to maintain the desired throttle set-
ting.
EMU25990
Engine stop lanyard switch
The lock plate must be attached to the engine
stop switch for the engine to run. The lanyard
should be attached to a secure place on the
operator’s clothing, or arm or leg. Should the
operator fall overboard or leave the helm, the
lanyard will pull out the lock plate, stopping ig-
nition to the engine. This will prevent the boat
from running away under power.
WARNING
EWM00120
●Attach the engine stop switch lanyard to
a secure place on your clothing, or your
arm or leg while operating.
●Do 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.
●Avoid 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
O
TE:
The engine cannot be started with the lock
plate removed.
1. Throttle indicator
1. Lock plate
2. Lanyard
U67720E0.book Page 7 Friday, March 26, 2004 10:36 AM

Basic components
8
EMU26001
Engine stop button
To open the ignition circuit and stop the en-
gine, push this button.
EMU26011
Choke knob for pull type
To supply the engine with the rich fuel mixture
required to start, pull out this knob.
EMU26070
Manual starter handle
To start the engine, first gently pull the handle
out until resistance is felt. From that position,
then pull the handle straight out quickly to
crank the engine.
EMU26122
Steering friction adjuster
A friction device provides adjustable resis-
tance to the steering mechanism, and can be
set according to operator preference. An ad-
justing screw or bolt is located on the swivel
bracket.
To increase resistance, turn the adjuster
clockwise.
To decrease resistance, turn the adjuster
counterclockwise.
WARNING
EWM00040
Do not overtighten the friction adjuster. If
there is too much resistance, it could be
difficult to steer, which could result in an
accident.
EMU26261
Trim rod (tilt pin)
The position of the trim rod determines the
minimum trim angle of the outboard motor in
relation to the transom.
U67720E0.book Page 8 Friday, March 26, 2004 10:36 AM

Basic components
9
EMU30460
Tilt lock mechanism
The tilt lock mechanism is used to prevent the
outboard motor from lifting out of the water
when in reverse gear.
To lock it, set the tilt lock lever in the “”
(lock) position. To release, push the tilt lock le-
ver in the “”(release) position.
EMU26330
Tilt support bar
The tilt support bar keeps the outboard motor
in the tilted up position.
EMU26372
Top cowling lock lever(s) (turn type)
To remove the engine top cowling, turn the
lock lever(s) and lift off the cowling. When in-
stalling the cowling, check to be sure it fits
properly in the rubber seal. Then lock the
cowling again by returning the lever(s) to the
lock position.
1. Tilt lock lever
1. Top cowling lock lever(s)
U67720E0.book Page 9 Friday, March 26, 2004 10:36 AM

Operation
10
EMU26901
Installation
CAUTION:
ECM00110
Incorrect engine height or obstructions to
smooth water flow (such as the design or
condition of the boat, or accessories such
as transom ladders or depth finder 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 ex-
haust housing is low enough to prevent water
entry into the powerhead, when water rises
due to waves when the outboard is not run-
ning.
EMU26910
Mounting the outboard motor
WARNING
EWM00820
●Overpowering a boat could cause se-
vere instability. Do not install an out-
board 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
manufacturer.
●The information presented in this sec-
tion is intended as reference only. It is
not possible to provide complete in-
structions for every possible boat and
motor combination. Proper mounting
depends in part on experience and the
specific boat and motor combination.
WARNING
EWM00830
Improper mounting of the outboard motor
could result in hazardous conditions such
as poor handling, loss of control, or fire
hazards. Observe the following:
●For permanently mounted models, your
dealer or other person experienced in
proper rigging should mount the motor.
If you are mounting the motor yourself,
you should be trained by an experienced
person.
●For portable models, your dealer or oth-
er person experienced in proper out-
board motor mounting should show you
how to mount your motor.
Mount the outboard motor on the center line
(keel line) of the boat, and ensure that 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.
EMU26920
Mounting height
To run your boat at optimum efficiency, the
water resistance (drag) of the boat and out-
board motor must be made as little as possi-
ble. The mounting height of the outboard
motor greatly affects the water resistance. If
the mounting height is too high, cavitation
1. Center line (keel line)
ZMU01760
1
U67720E0.book Page 10 Friday, March 26, 2004 10:36 AM

Operation
11
tends to occur, thus reducing the propulsion;
and if the propeller tips cut the air, the engine
speed will rise abnormally and cause the en-
gine to overheat. If the mounting height is too
low, the water resistance will increase and
thereby reduce engine efficiency. Mount the
outboard motor so that the anti-cavitation
plate is between the bottom of the boat and a
level 25 mm (1 in.) below it.
NOTE:
●The optimum mounting height of the out-
board motor is affected by the boat and mo-
tor combination and the desired use. Test
runs at different heights can help determine
the optimum mounting height. Consult your
Yamaha dealer or boat manufacturer for
further information on determining the prop-
er mounting height.
●For instructions on setting the trim angle of
the outboard motor, see page 19.
EMU26970
Clamping the outboard motor
1. Place the outboard motor on the transom
so that it is positioned as close to the cen-
ter as possible. Tighten the transom
clamp screws evenly and securely. Oc-
casionally check the clamp screws for
tightness during operation of the out-
board motor because they could become
loose due to engine vibration.
WARNING
EWM00640
Loose clamp screws could allow the out-
board motor to fall off or move on the tran-
som. This could cause loss of control and
serious injury. Make sure the transom
screws are tightened securely. Occasion-
ally check the screws for tightness during
operation.
2. If the engine restraint cable attachment is
equipped on your engine, an engine re-
straint cable or chain should be used. At-
tach one end to the engine restraint cable
attachment and the other to a secure
mounting point on the boat. Otherwise
the engine could be completely lost if it
accidentally falls off the transom.
ZMU02011
0–25mm
(0–1in.)
ZMU02012
ZMU02013
U67720E0.book Page 11 Friday, March 26, 2004 10:36 AM

Operation
12
3. Secure the clamp bracket to the transom
using the bolts provided with the out-
board (if packed). For details, consult
your Yamaha dealer.
WARNING
EWM00650
Avoid using bolts, nuts or washers other
than those contained in the engine pack-
aging. If used, they must be of at least the
same quality of material and strength and
must be tightened securely. After tighten-
ing, test run the engine and check their
tightness.
EMU30172
Breaking in engine
Your new engine requires a period of break-in
to allow mating surfaces of moving parts to
wear in evenly. Correct break-in will help en-
sure proper performance and longer engine
life.
CAUTION:
ECM00800
Failure to follow the break-in procedure
could result in reduced engine life or even
severe engine damage.
EMU27050
Gasoline and engine oil mixing chart
(25:1)
CAUTION:
ECM00150
Be sure to mix gasoline and oil complete-
ly, otherwise the engine may be damaged.
EMU27073
Procedure for pre-mixed models
Run the engine under load (in gear with a pro-
peller installed) as follows.
1. First 10 minutes:
Run the engine at the lowest possible
speed. A fast idle in neutral is best.
2. Next 50 minutes:
Do not exceed half throttle (approximate-
ly 3000 r/min). Vary engine speed occa-
sionally. If you have an easy-planing
boat, accelerate at full throttle onto plane,
then immediately reduce the throttle to
3000 r/min or less.
3. Second hour:
Accelerate at full throttle onto plane, then
reduce engine speed to three-quarter
throttle (approximately 4000 r/min). Vary
engine speed occasionally. Run at full
throttle for one minute, then allow about
10 minutes of operation 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 en-
gine speed occasionally.
5. After the first 10 hours:
Operate the engine normally. Use the
standard premix ratio of gasoline and oil.
For details on mixing fuel and oil, see
page 13.
1. : Gasoline
2. : Engine oil
U67720E0.book Page 12 Friday, March 26, 2004 10:36 AM

Operation
13
EMU27101
Preoperation checks
WARNING
EWM00080
If any item in the preoperation check is not
working properly, have it inspected and
repaired before operating the outboard
motor. Otherwise an accident could occur.
CAUTION:
ECM00120
Do not start the engine out of water. Over-
heating and serious engine damage can
occur.
EMU27110
Fuel
●Check to be sure you have plenty of fuel for
your trip.
●Make sure there are no fuel leaks or gaso-
line fumes.
●Check fuel line connections to be sure they
are tight (if equipped Yamaha fuel tank or
boat tank).
●Be sure the fuel tank is positioned on a se-
cure, flat surface, and that the fuel line is not
twisted or flattened, or likely to contact
sharp objects (if equipped Yamaha fuel
tank or boat tank).
EMU27120
Oil
●Check to be sure you have plenty of oil for
your trip.
EMU27130
Controls
●Check throttle, shift, and steering for proper
operation before starting the engine.
●The controls should work smoothly, without
binding or unusual free play.
●Look for loose or damaged connections.
●Check operation of the starter and stop
switches when the outboard motor is in the
water.
EMU27140
Engine
●Check the engine and engine mounting.
●Look for loose or damaged fasteners.
●Check the propeller for damage.
EMU27233
Filling fuel and engine oil
EMU27242
Filling fuel for portable tank
WARNING
EWM00060
Gasoline and its vapors are highly flam-
mable and explosive. Keep away from
sparks, cigarettes, flames, or other sourc-
es of ignition.
1. Remove the fuel tank cap.
2. Fill the fuel tank carefully.
3. Close the cap securely after refueling.
Wipe up any spilled fuel.
EMU27392
Gasoline and oil mixing
If equipped with a portable fuel tank
1. Pour oil into the portable fuel tank, and
then add gasoline.
Fuel tank capacity (if equipped Yamaha
fuel tank):
24.0 L (6.34 US gal) (5.28 Imp.gal)
Gasoline to engine oil
ratio
Break-in period 25:1
After break-in 50:1
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Operation
14
2. Replace the fuel tank cap and close tight-
ly.
3. Shake the fuel tank to mix the fuel thor-
oughly.
4. Make sure that the oil and gasoline are
mixed.
If equipped with a built-in fuel tank
1. Pour oil into a clean fuel can, and then
add gasoline.
2. Replace the fuel can cap and close tight-
ly.
3. Shake the fuel can to mix the fuel thor-
oughly.
4. Make sure that the oil and gasoline are
mixed.
5. Pour the gasoline and oil mixture into the
built-in fuel tank.
CAUTION:
ECM00810
●Avoid using any oil other than the spec-
ified type.
●Use a thoroughly blended fuel-oil mix-
ture.
●If the mixture is not thoroughly mixed, or
if the mixing ratio is incorrect, the fol-
lowing problems could occur. Low oil
ratio: Lack of oil could cause major en-
gine trouble, such as piston seizure.
●High oil ratio: Too much oil could cause
fouled spark plugs, smoky exhaust, and
heavy carbon deposits.
N
O
TE:
If using a permanently installed tank, pour the
oil gradually as the gasoline is being added to
the tank.
EMU27450
Operating engine
EMU27461
Feeding fuel (portable tank)
WARNING
EWM00420
●Before starting the engine, make sure
that the boat is tightly moored and that
you can steer clear of any obstructions.
Be sure there are no swimmers in the
water near you.
●When the air vent screw is loosened,
gasoline vapor will be released. Gaso-
line 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.
●This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which could cause brain
damage or death when inhaled. Symp-
toms include nausea, dizziness, and
1. Engine oil
2. Gasoline
U67720E0.book Page 14 Friday, March 26, 2004 10:36 AM

Operation
15
drowsiness. Keep cockpit and cabin ar-
eas well ventilated. Avoid blocking ex-
haust 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 on the motor, firmly
connect the fuel line to the joint. Then
firmly connect the other end of the fuel
line to the joint on the fuel tank.
3. If a steering friction adjuster is provided
on your outboard motor, securely attach
the fuel line to the fuel line clamp.
NOTE:
During engine operation place the tank hori-
zontally, otherwise fuel cannot be drawn from
the fuel tank.
4. Squeeze the primer pump with the outlet
end up until you feel it become firm.
EMU27490
Starting engine
EMU27505
Manual start models (tiller control)
1. Place the gear shift lever in neutral.
NOTE:
The start-in-gear protection device prevents
the engine from starting except when in neu-
tral.
ZMU02295
ZMU02024
ZMU02025
U67720E0.book Page 15 Friday, March 26, 2004 10:36 AM