Printed in JapanMarch 2003-0.6 1 !6H3-28199-1N(60FETO, 70BETO, 90AETO)(E)

Printed on recycled paper

60C70C90C

OWNERS MANUALU.S.A.Edition

LIT-18626-05-50

6H3-9-1N Hyoshi 2/11/03 9:05 Page 1

6H3-9-1N Hyoshi 2/11/03 9:05 Page 2

EThank you for choosing a Yamaha out-board motor. This Owners manual con-tains information needed for proper oper-ation, maintenance and care. A thoroughunderstanding of these simple instruc-tions will help you obtain maximumenjoyment from your new Yamaha. If youhave any question about the operation ormaintenance of your outboard motor,please consult a Yamaha dealer.

In this Owners Manual particularlyimportant information is distinguished inthe following ways.

QThe Safety Alert Symbol meansATTENTION! BECOME ALERT!YOUR SAFETY IS INVOLVED!

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

cCA CAUTION indicates special precautionsthat must be taken to avoid damage tothe outboard motor.

NOTE:

A NOTE provides key information to makeprocedures easier or clearer.

* Yamaha continually seeks advance-ments in product design and quality.Therefore, while this manual containsthe most current product informationavailable at the time of printing, theremay be minor discrepancies betweenyour machine and this manual. If thereis any question concerning this manual,please consult your Yamaha dealer.

NOTE:

The 70TR, 90TR and their standard acces-sories are used as a base for the explana-tions and illustrations in this manual.Therefore, some items may not apply toevery model.

EMU01449

TO THE OWNER

EMU01446

60C, 70C, 90COWNER'S MANUAL

2003 by Yamaha Motor Corporation, USA 1st Edition, March 2003

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-18626-05-50

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3

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ECONTENTS

GENERAL INFORMATION

BASIC COMPONENTS

OPERATION

MAINTENANCE

TROUBLE RECOVERY

INDEX

READ THIS OWNERS MANUAL CAREFULLYBEFORE OPERATING YOUR OUTBOARD MOTOR.

EMA20010

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EEMB00010

Chapter 1

GENERALINFORMATION

IDENTIFICATION NUMBERS RECORD ....................................................1-1

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

EMISSION CONTROL INFORMATION...1-2

SAFETY INFORMATION..........................1-3

IMPORTANT LABELS ..............................1-5

BASIC BOATING RULES .........................1-6

FUELING INSTRUCTIONS.....................1-10Gasoline ..............................................1-11Engine oil ............................................1-11

BATTERY REQUIREMENT ....................1-12

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

START-IN-GEAR PROTECTION ............1-14

1

2

3

4

5

6

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EMU00008

KEY NUMBER

If a main key switch is equipped with themotor, the key identification number isstamped on your key as shown in theillustration. Record this number in thespace provided for reference in case youneed a new key.

1 Key number

1-1

E

1

401012

904011*

123YAMAHA

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EMU00005

IDENTIFICATION NUMBERSRECORD

EMU00007

OUTBOARD MOTOR SERIAL NUMBER

The outboard motor serial number isstamped on the label attached to the portside of the clamp-bracket.Record your outboard motor serial num-ber in the spaces provided to assist you inordering spare parts from your Yamahadealer or for reference in case your out-board motor is stolen.

1 Outboard motor serial number

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

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EMU01385

EMISSION CONTROLINFORMATION

EMU01386

NORTH AMERICAN MODELSThis engine conforms to U.S.Environmental Protection Agency (EPA)regulations for marine SI engines. See thelabel affixed to your engine for details.

Approval label of Emission control certificateThis label is attached to the bottom cowl-ing.

1 Emission control information label

Existing Technology ; N/A

Manufactured date labelThis label is attached to the clamp bracketor the swivel bracket.

2 Manufactured date label

EMISSION CONTROL INFORMATIONENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.FELs :SPARK PLUG :DISPLACEMENT :ADVERTISED POWER :

IDLE SPEED :SPARK PLUG GAP (mm) :FUEL : GASOLINEVALVE LASH (mm) : IN EX

cmkw

g/kw-hr rpm IN NEUTRAL

3

Manufactured:

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EMU00917

SAFETY INFORMATION

8 Before 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.8 Before operating the boat, read any

owners or operators manuals suppliedwith it and all labels. Be sure you under-stand each item before operating.8 Do not overpower the boat with this

outboard motor. Overpowering theboat could result in loss of control. Therated power of the outboard should beequal to or less than the rated horse-power capacity of the boat. If the ratedhorsepower capacity of the boat isunknown, consult the dealer or boatmanufacturer.8 Do not modify the outboard.

Modifications could make the motorunfit or unsafe to use.8 Never operate after drinking alcohol or

taking drugs. About 50% of all boatingfatalities involve intoxication.8 Have an approved personal flotation

device (PFD) on board for every occu-pant. It is a good idea to wear a PFDwhenever boating. At a minimum, chil-dren and non-swimmers should alwayswear PFDs, and everyone should wearPFDs when there are potentially haz-ardous boating conditions.8 Gasoline is highly flammable, and its

vapors are flammable and explosive.Handle and store gasoline carefully.Make sure there are no gas fumes orleaking fuel before starting the engine.

8 This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which may cause braindamage or death when inhaled.Symptoms include nausea, dizziness,and drowsiness. Keep cockpit and cabinareas well ventilated. Avoid blockingexhaust outlets.8 Check throttle, shift, and steering for

proper operation before starting theengine.8 Attach the engine stop switch lanyard

to a secure place on your clothing, oryour arm or leg while operating. If youaccidentally leave the helm, the lanyardwill pull from the switch, stopping theengine.8 Know the marine laws and regulations

where you will be boating - and obeythem. Refer to the RULES OF THEROAD section for basic boating rules.8 Stay informed about the weather.

Check weather forecasts before boating.Avoid boating in hazardous weather.8 Tell someone where you are going:

leave a Float Plan with a responsibleperson. Be sure to cancel the Float Planwhen you return.8 Use common sense and good judgment

when boating. Know your abilities, andbe sure you understand how your boathandles under the different boatingconditions you may encounter. Operatewithin your limits, and the limits of yourboat. Always operate at safe speeds,and keep a careful watch for obstaclesand other traffic.8 Always watch carefully for swimmers

during the engine operation.8 Stay away from swimming areas.

Q

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8When a swimmer is in the water nearyou shift into neutral and shut off theengine.8 Be informed about boating safety.

Additional publications and informationcan be obtained from many organiza-tions, including the following:

United States Coast Guard

Consumer Affairs Staff (G-BC)Office of Boating, Public, and ConsumerAffairsU.S. Coast Guard HeadquartersWashington, D.C. 20593-0001Boating 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

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202021

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EMB30010

IMPORTANT LABELS

WARNING LABELS

WARNING 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.

6A1-83625-41

1

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EMB40010

BASIC BOATING RULES(Rules of the road)

Just as there are rules which apply whenyou are driving on streets and high ways,there are waterway rules which applywhen you are driving your boat. Theserules are used internationally, and arealso enforced by the United States CoastGuard and local agencies. You should beaware of these rules, and follow themwhenever you encounter another vesselon the water.

Several sets of rules prevail according togeographic location, but are all basicallythe same as the International Rules of theRoad. The rules presented here in yourOwners Manual are condensed, and havebeen provided for your convenience only.Consult your local U.S. Coast GuardAuxiliary or Department of MotorVehicles for a complete set of rules gov-erning the waters in which you will beusing your boat.

STEERING AND SAILING RULES ANDSOUND SIGNALS

Whenever two vessels on the water meetone 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 determinewhich vessel has the right-of-way, andwhat each vessel should do.

Stand-on VesselThe vessel with the right-of-way has theduty to continue its course and speed,except to avoid an immediate collision.When you maintain your direction andspeed, the other vessel will be able todetermine how best to avoid you.

Give-way VesselThe vessel which does not have the right-of-way has the duty to take positive andtimely action to stay out of the way of theStand-On vessel. Normally, you shouldnot cross in front of the vessel with theright-of-way. You should slow down orchange directions briefly and pass behindthe other vessel. You should always movein such a way that the operator of theother vessel can see what you are doing.

The general prudential ruleThis rule is called Rule 2 in the Inter-national Rules and says,

In obeying and construing these rulesdue regard shall be had to all dangersof navigation and collision, and to anyspecial circumstances, which may ren-der a departure from the above rulesnecessary in order to avoid immediatedanger.

In other words, follow the standard rulesexcept when a collision will occur unlessboth vessels try to avoid each other. Ifthat is the case, both vessels becomeGive-Way vessels.

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RULES WHEN ENCOUNTERINGVESSELSThere are three main situations which youmay encounter with other vessels whichcould lead to a collision unless theSteering Rules are followed:Meeting

(you are approaching another vesselhead-on)

Crossing(you are travelling across the other ves-sels path)

Overtaking(you are passing or being passed byanother vessel)

In the following illustration, your boat isin 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 youand the meeting vessel must alter courseto avoid each other.

MeetingIf you are meeting another power vesselhead on, and are close enough to run therisk of collision, neither of you has theright-of-way! Both of you should altercourse to avoid an accident. You should

keep the other vessel on your port (left)side. This rule doesnt apply if both of youwill clear one another if you continue onyour set course and speed.

CrossingWhen two power driven vessels arecrossing each others path close enoughto run the risk of collision, the vesselwhich has the other on the starboard(right) side must keep out of the way ofthe other. If the other vessel is on yourright, you must keep out of its way; youare the Give-Way vessel. If the other ves-sel is on your port (left) side, rememberthat you should maintain course anddirection, provided the other vessel givesyou the right-of-way as it should.

OvertakingIf you are passing another vessel, you arethe Give-Way vessel. This means thatthe other vessel is expected to maintain

102045

102046

102044

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its course and speed. You must stay outof its way until you are clear of it.Likewise, if another vessel is passing you,you should maintain your speed anddirection so that the other vessel can steeritself around you.OTHER SPECIAL SITUATIONSThere are three other rules you should beaware of when driving your boat aroundother vessels.

Narrow Channels and BendsWhen navigating in narrow channels, youshould keep to the right when it is safeand practical to do so. If the operator of apower-driven vessel is preparing to goaround a bend that may obstruct the viewof other water vessels, the operatorshould sound a prolonged blast on thewhistle (4 to 6 seconds). If another vesselis around the bend, it too should soundthe whistle. Even if no reply is heard,however, the vessel should still proceedaround the bend with caution. If you navi-gate such waters with your boat, you willneed to carry a portable air horn, avail-able from local marine supply stores.

Fishing Vessel Right-of-wayAll vessels which are fishing with nets,lines or trawls are considered to befish-ing vessels under the InternationalRules. Vessels with trolling lines are notconsidered fishing vessels. Fishing ves-sels have the right-of-way regardless ofposition. Fishing vessels cannot, howev-er, impede the passage of other vessels innarrow channels.

Sailing Vessel Right-of-waySailing vessels should normally be giventhe right-of-way. The exceptions to thisare:

1. When the sailing vessel is overtakingthe power-driven vessel, the power-driven vessel has the right-of-way.

2. Sailing vessels should keep clear ofany fishing vessel.

3. In a narrow channel, a sailing vesselshould not hamper the safe passageof a power-driven vessel which cannavigate only in such a channel.

Reading Buoys and Other MarkersThe waters of the United states aremarked for safe navigation by the lateralsystem of buoyage. Simply put, buoysand markers have an arrangement ofshapes, colors, numbers and lights toshow which side of the buoy a boatershould pass on when navigating in a par-ticular direction. The markings on thesebuoys are oriented from the perspectiveof being entered from seaward (theboater is going towards the port). Thismeans that red buoys are passed on thestarboard (right) side when proceedingfrom open water into port, and blackbuoys are to port (left) side. When navi-gating out of port, your position withrespect to the buoys should be reversed;red buoys should be to port and blackbuoys to starboard.Many bodies of water used by boaters areentirely within the boundaries of a partic-ular state. The Uniform State WaterwayMarking System has been devised forthese waters. This system uses buoys andsigns with distinctive shapes and colorsto show regulatory or advisory informa-tion. These markers are white with blackletters and orange boarders. They signifyspeed zones, restricted areas, dangerareas, and general information.

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Remember, markings may vary by geo-graphic location. Always consult localboating authorities before driving yourboat in unfamiliar waters.

1 1

A

1 1

Proceeding toward headof navigation from seaward

CAN BUOYOdd number. Leave to port.

OR

SECONDARY CHANNEL BUOYSSTARTS NEW NUMBERING SYSTEM

old new

C " 1"

NUN BUOYEven number. Leave to starboard

N " 2"

No change

BUOYCOLOR CODE

BLACK

RED

GREEN

" A"

" 2"

" 1"

" 3"

" 4"

" 5"

" 7"

N " 2"" 6"

C " 1"

RB " L"

RG " L"or

SECO

NDAR

YCH

ANNE

L

MAINCHANNEL

old new

2

2 2

A

LL

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 eitherside. Letter has no lateral significance, used for

No number . Topmost band red - prefer red

Top MarkWhite LightWhite 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 lateralsignificance, used for identification and locationpurposes.

Red LightRed orWhite Light

OR

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EMU00016

FUELING INSTRUCTIONS

wGASOLINE AND ITS VAPORS ARE HIGH-LY FLAMMABLE AND EXPLOSIVE!8 Do not smoke when refueling, and

keep away from sparks, flames, orother sources of ignition.8 Stop engine before refueling.8 Refuel in a well-ventilated area. Refuel

portable fuel tanks off the boat.8 Take care not to spill gasoline. If gaso-

line spills, wipe it up immediately withdry rags.8 Do not overfill the fuel tank.8 Tighten the filler cap securely after

refueling.8 If you should swallow some gasoline

inhale a lot of gasoline vapor, or getgasoline in your eyes, get immediatemedical attention.8 If any gasoline spills onto your skin,

immediately wash with soap andwater. Change clothing if gasoline spillson it.8 Touch the fuel nozzle to the filler open-

ing or funnel to help prevent electrosta-tic sparks.

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

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EMU01804

GASOLINE

If knocking or pinging occurs, use a differ-ent brand of gasoline or premium unlead-ed fuel.

EMU00027

GasoholThere are two types of gasohol: gasoholcontaining ethanol and that containingmethanol. Gasohol containing ethanolcan be used if ethanol content does notexceed 10% and the fuel meets minimumoctane ratings. Gasohol containingmethanol is not recommended byYamaha because it can cause fuel systemdamage or engine performance prob-lems.

EMU00858

ENGINE OIL

If the recommended engine oil is notavailable, another 2-stroke engine oil witha NMMA-certified TC-W3 rating may beused.

Recommended engine oil:YAMALUBE 2 STROKE OUTBOARDOIL

Recommended gasoline:Regular unleaded gasoline with a minimum octane rating of 86 (Pump Octane Number) = (R+M)/2

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EMU01775

BATTERY REQUIREMENT

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

For electric start models, choose a batterywhich meets the following specifications.EMU01860

Minimum cold cranking amps(CCA/SAE): 380 amps at -18C (-0.4F)Minimum marine cranking amps(MCA/ABYC): 502 amps at 0C (32F)Minimum reserve capacity (RC/SAE):

124 minutes

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EMU01395

PROPELLER SELECTION

The performance of your outboard motorwill be critically affected by your choice ofpropeller, as an incorrect choice couldadversely affect performance and couldalso seriously damage the motor. Enginespeed depends on the propeller size andboat load. If engine speed is too high ortoo low for good engine performance,this will have an adverse effect on theengine.

Yamaha outboard motors are fitted withpropellers chosen to perform well over arange of applications, but there may beuses where a propeller with a differentpitch would be more appropriate. For agreater operating load, a smaller-pitchpropeller is more suitable as it enablesthe 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 apropeller on your outboard that is bestsuited to your application.NOTE:

At full throttle and under a maximumboat load, the engines rpm should bewithin the upper half of the full throttleoperating range, as listed in SPECIFICA-TIONS on page 4-1. Select a propellerwhich fulfills this requirement.If operating under conditions which allowthe engines rpm to rise above the maxi-mum recommended range (such as lightboat loads), reduce the throttle setting tomaintain the rpm in the proper operatingrange.

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1 Propeller diameter (in inches)2 Propeller pitch (in inches)3 Type of propeller (propeller mark)

Refer to the section CHECKING PRO-PELLER for instructions on propellerremoval and installation.

EMU01209

START-IN-GEAR PROTECTION

Yamaha outboard motors or Yamahaapproved remote control units areequipped with start-in-gear protectiondevice(s). This feature permits the engineto be started only when it is Neutral.Always select Neutral before starting theengine.

13 x 17 - Kq w e

000933

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EMEMO

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EEMC00010

Chapter 2

BASIC COMPONENTS

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

OPERATIONS OF CONTROLS AND OTHER FUNCTIONS ................................2-2

Fuel tank.................................................2-2Remote control......................................2-3Power trim/tilt switch............................2-7Trim tab..................................................2-8Digital tachometer ................................2-9Tilt support lever.................................2-12Top cowling lock levers......................2-12Flushing device ...................................2-12

WARNING SYSTEM ..............................2-13Overheat warning ...............................2-13Oil level warning/oil filter cloggingwarning ................................................2-14

1

2

3

4

5

6

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EMU01206

MAIN COMPONENTS

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1 Top cowling2 Top cowling lock lever3 Anti-cavitation plate4 Trim tab (Anode)

*5 Propeller6 Cooling water inlet7 Anode8 Trim angle adjusting rod9 Clamp bracket

0 Tilt support leverq Power trim and tilt switch

*w Flushing device*e Remote control box*r Digital tachometer

* May not be exactly as shown; also may notbe included as standard equipment on allmodels.

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902051

EMC20010

OPERATIONS OF CONTROLSAND

OTHER FUNCTIONS

EMC21012

FUEL TANKIf your model was equipped with aportable fuel tank, its function is as fol-lows.

1 Fuel hose joint2 Fuel meter(If equipped)3 Fuel tank cap4 Air vent screw(If equipped)

Fuel hose jointThis connector is provided for connectingor disconnecting fuel hose.

Fuel meterThis meter is on the fuel tank cap. Itshows current fuel quantity in the fueltank approximately.

Fuel tank capThis cap is for filling fuel. To remove it,turn it counterclockwise.

Air Vent screwThis screw is on the fuel tank cap. Toloosen it, turn it counterclockwise.

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000323

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EMC80612

REMOTE CONTROLBoth the shifter and the throttle are actu-ated by the remote control lever. In addi-tion, this control also has the electricalswitches.

1 Remote control lever2 Neutral interlock trigger3 Neutral throttle lever4 Main switch5 Engine stop lanyard switch6 Power trim and tilt switch7 Throttle friction adjusting screw

Remote control leverMoving the lever forward from theNeutral position engages Forward gear.Pulling the lever back from Neutralengages Reverse. The engine will contin-ue to run at idle until the lever is movedabout 35 (a detent can be felt). Movingthe lever farther opens the throttle, andthe engine will begin to accelerate.

1 Neutral2 Forward3 Reverse4 Shift5 Fully closed6 Throttle7 Fully open

Neutral interlock triggerTo shift out of Neutral, the neutral inter-lock trigger of the remote control levermust first be pulled up.

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N

701033*

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ON STARTOFF

701045

Neutral throttle leverTo open the throttle without shifting intoeither Forward or Reverse, place theremote control lever in the Neutral posi-tion and lift the neutral throttle lever.NOTE:

The neutral throttle lever will operate onlywhen the remote control lever is inNeutral. The remote control lever willoperate only when the neutral throttlelever is in the closed position.

1 Fully open2 Fully closed

Main switchThe main switch controls the ignition sys-tem; its operation is described below.

8 OFFElectrical circuits switched off. (The keycan be removed.)

8 ONElectrical circuits switched on. (The keycannot be removed.)

8 STARTStarter-motor will turn and start engine.(When the key is released, it returns auto-matically to ON.)

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EMC28210

Engine stop lanyard switchThe lock-plate on the end of the lanyardmust be attached to the engine stopswitch for the engine to run. The lanyardshould be attached to a secure place onthe operators clothing, or arm or leg.Should the operator fall overboard orleave the helm, the lanyard will pull outthe lock plate, stopping ignition to theengine. This will prevent the boat fromrunning away under power.

w8 Attach the engine stop switch lanyard

to a secure place on your clothing, yourarm or leg while operating.8 Do not attach the lanyard to clothing

that could tear loose. Do not route thelanyard in such a way that it couldbecome entangled, preventing it fromfunctioning.8 Avoid accidentally pulling the lanyard

during normal operation. Loss ofengine power means the loss of moststeering control. Also, without enginepower, the boat could slow rapidly.This could cause people and objects inthe boat to be thrown forward.

NOTE:

The engine cannot be started with thelock-plate removed.

1 Lock-plate2 Lanyard

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UPDN

701034*

UPDN

701035

EMU01331

Power Trim/Tilt SwitchThe power trim/tilt adjusts the motorangle in relation to the transom. Thepower trim/tilt switch is located on theremote control lever grip. Pushing theswitch UP trims the motor up, then tiltsthe motor up. Pressing the switch DNtilts the motor down and trims the motordown. When the switch button isreleased, the motor will stop in its currentposition.NOTE:

Refer to the sections ADJUSTING TRIMANGLE and TILTING UP/DOWN inChapter 3 for instructions on usage.

EMU01155

Throttle Friction Adjusting ScrewA friction device in the remote control boxprovides adjustable resistance to move-ment of the remote control lever, and canbe set according to operator preference.An adjusting screw is located on the frontof the remote control box.

wDo not overtighten the friction adjustingscrew. If there is too much resistance, itmay be difficult to move the lever, whichcould result in an accident.

Resistance Screw

Increase Turn clockwise

Decrease Turn counterclockwise

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EMU01125

POWER TRIM/TILT SWITCHThe power trim/tilt adjusts the motorangle in relation to the transom. Thepower trim/tilt switch is located on theside of the bottom engine cowling.Pushing the switch UP trims the motorup, then tilts the motor up. Pressing theswitch DN tilts the motor down andtrims the motor down. When the switchbutton is released, the motor will stop inits current position.

wUse the power trim/tilt switch located onthe bottom engine cowling only whenthe boat is at a complete stop with theengine off. Attempting to use the cowl-ing-mounted power trim/tilt switch whilethe boat is moving could increase the riskof falling overboard and could distractthe operator, increasing the risk of colli-sion with another boat or an obstacle.

NOTE:

Refer to the section Adjusting TrimAngle and Tilting Up/Down for instruc-tions on usage.

302021

DN

UP

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EMD04011

TRIM TABThe trim tab should be adjusted so thatthe steering control can be turned toeither the right or left by applying thesame amount of force.

wAn improperly adjusted trim tab maycause difficult steering. Always test runafter the trim tab has been installed orreplaced to be sure steering is correct. Besure you have tightened the bolt afteradjusting the trim tab.

1 Trim tab2 Bolt3 Cap

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

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603014

603012

A

BBoat tends to veer The rear end of

trim tab

To the left Turn the left(port side) (port side), A

in the figure

To the right Turn the right(starboard side) (starboard side),

B in the figure

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001078

001082

001049

EMU01614

DIGITAL TACHOMETERThis gauge contains the tachometer, trimmeter, hour meter, oil level indicator, andthe overheat warning indicator.

1 Tachometer2 Trim meter3 Hour meter4 Oil level indicator5 Overheat warning indicator6 Set button7 Mode button

NOTE:

All segments of the display will lightmomentarily after the main switch isturned on and will return to normal there-after.

EMU00136

TachometerThis meter shows the engine speed.

6H3-9-1N 2 2/6/03 11:09 Page 10

E2-10

001087

EMU01620

Hour MeterThis meter shows the number of hoursthe engine has been run. It can be set toshow the total number of hours or thenumber of hours for the current trip. Thedisplay can also be turned on and off.8 Changing the display format

Pressing the MODE button changes thedisplay format in the following circularpattern:Total hours - Trip hours - Display off8 Resetting the trip hours

Simultaneously pressing the SET andMODE buttons for more than 1 secondwhile the trip hours are displayed resetsthe trip counter to 0 (zero).

NOTE:

The total number of hours the engine hasbeen run cannot be reset.

EMU01109

Trim MeterThis meter shows the trim angle of youroutboard motor.NOTE:

8 Memorize the trim angles that workbest for your boat under different condi-tions. Adjust the trim angle to thedesired setting by operating the powertrim and tilt switch.8 If the trim angle of your motor exceeds

the trim operating range, the top seg-ment on the trim meter display will startto blink.

001050

6H3-9-1N 2 2/6/03 11:09 Page 11

E2-11

001052

q

EMU01553

Overheat Warning IndicatorIf the engine temperature rises too high,the warning indicator will start to blink.Refer to OVERHEAT WARNING fordetails.

1 Overheat warning indicator

cCDo not continue to operate the engine if awarning device has activated. If neces-sary, refer to the TROUBLESHOOTINGsection in this manual. Consult your deal-er if the problem cannot be located andcorrected.

EMU00138

Oil-Level IndicatorThis 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 andOIL LEVEL WARNING for details.

1 Oil-level indicator

cCDo not operate the engine without oil.Serious engine damage will occur.

001051q

6H3-9-1N 2 2/6/03 11:09 Page 12

E2-12

403011*

q 301041*

000945

q

EMD60010

TILT SUPPORT LEVERTo keep the outboard motor in the tilted-up position, lock the tilt support lever tothe clamp bracket.

q

301042*

EMD63111

TOP COWLING LOCK LEVERSTo remove the engine top cowling, turnthe front lock lever and rear lock lever(s).Then lift off the cowling. When replacingthe cowling, check to be sure it fits prop-erly in the rubber seal. Then lock thecowling again by returning the levers tothe locked position.

1 Top cowling lock lever

EMU01146

FLUSHING DEVICEThis device 1 is used to clean the coolingwater passages of the motor using a gar-den hose and tap water.NOTE:

Refer to Cleaning Cooling-waterPassages in Chapter 4 for instructions onusage.

6H3-9-1N 2 2/6/03 11:09 Page 13

E2-13

701054

605015

EMD80010

WARNING SYSTEM

cCDo not continue to operate the engine ifthe warning device has activated. Consultyour Yamaha dealer if the problem can-not be located and corrected.

EMD82012

OVERHEAT WARNINGThis engine has an overheat warningdevice.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 inletfor clogging.

Warning device Tiller Remote activation control control

model model

The engine speed will automatically

1decrease to about 2,000 r/min.

The overheat warning indicator 1will come on.

The buzzer will sound. 1

001053

6H3-9-1N 2 2/6/03 11:09 Page 14

E2-14

001054

701054

213025

q

EMD84012

OIL LEVEL WARNING / OIL FILTER CLOGGING WARNINGThis engine has an oil level warning sys-tem.If oil level falls below lower limit, thewarning 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 andoverheating.For easy troubleshooting, it is advisableto check for engine overheating first, thenoil level and finally oil filter clogging.

1 Oil filter

Warning device Tiller Remoteactivation control control

model model

The engine speed will automatically

1decrease to about 2,000 r/min.

The oil level warning indicator 1will come on.

The buzzer will sound. 1

6H3-9-1N 2 2/6/03 11:09 Page 15

E2-15

Oil level warning systemThe various oil-level warning system functions are as follows:

Oil level warningindicator (Digital

tachometer)

No refilling necessary.more than 770 cm3(0.81 US qt, 0.68 Imp qt)

Buzzer sounds in remotecontrol box and engine speed islimited to about 2,000 r/min tohelp conserve oil.Check oil filter for clogging.

Oil level warninglamp (Analogtachometer)

Engine oil tank Remarks

Green

Yellow from 770 cm3(0.81 US qt, 0.68 Imp qt)down to 280 cm3(0.30 US qt, 0.25 Imp qt)

Add oil, refer to oil filling.

Red 280 cm3 (0.30 US qt,

0.25 Imp qt) or less

90

Oil level warningindicator (Digital

tachometer)

No refilling necessary.more than 1,130 cm3(1.19 US qt, 0.99 Imp qt)

Buzzer sounds in remotecontrol box and engine speed islimited to about 2,000 r/min tohelp conserve oil.Check oil filter for clogging.

Oil level warninglamp (Analogtachometer)

Engine oil tank Remarks

Green

Yellow from 1,130 cm3(1.19 US qt, 0.99 Imp qt)down to 310 cm3(0.33 US qt, 0.27 Imp qt)

Add oil, refer to oil filling.

Red 310 cm3 (0.33 US qt,

0.27 Imp qt) or less

60/70

6H3-9-1N 2 2/6/03 11:09 Page 16

EEMF00010

Chapter 3

OPERATION

INSTALLATION ........................................3-1Mounting the outboard motor ............3-2

FILLING FUEL AND ENGINE OIL ............3-4Filling fuel ..............................................3-4Filling oil.................................................3-5

PRE-OPERATION CHECKS ......................3-6Operation after a long period ofstorage ...................................................3-7

BREAKING IN ENGINE ............................3-8

STARTING ENGINE ...............................3-10

WARMING UP ENGINE .........................3-13

SHIFTING ................................................3-14Forward................................................3-14Reverse ................................................3-14

STOPPING ENGINE ...............................3-15

TRIMMING OUTBOARD MOTOR.........3-16Adjusting trim angle...........................3-17

TILTING UP/DOWN ...............................3-19

CRUISING IN OTHER CONDITIONS.....3-21Cruising in salt water..........................3-21Cruising in turbid water .....................3-21

1

2

3

4

5

6

6H3-9-1N 3 2/6/03 11:19 Page 1

E3-1

EMF10010

INSTALLATION

cCIncorrect engine height or obstructions tosmooth water flow (such as the design orcondition of the boat or accessories suchas transom ladders/depth finder trans-ducers) can create airborne water spraywhile the boat is cruising. Severe enginedamage may result if the motor is operat-ed continuously in the presence of air-borne water spray.

NOTE:

During water testing check the buoyancyof the boat, at rest, with its maximumload. Check that the static water level onthe exhaust housing is low enough to pre-vent water entry into the powerhead,when water rises due to waves when theoutboard is not running.

6H3-9-1N 3 2/6/03 11:19 Page 2

E3-2

104011q

EMU00176

MOUNTING THE OUTBOARDMOTOR

wImproper mounting of the outboardmotor could result in hazardous condi-tions such as poor handling, loss of con-trol, or fire hazards. Observe the follow-ing:8 The information presented in this sec-

tion is intended as reference only. It isnot possible to provide completeinstructions for every possibleboat/motor combination. Propermounting depends in part on experi-ence and the specific boat/motor com-bination.8 Your dealer or other person experi-

enced in proper rigging should mountthe motor. If you are mounting themotor yourself, you should be trainedby an experienced person. [permanentmounted type]8 Your dealer or other person experi-

enced in proper outboard motormounting should show you how tomount your motor. [portable type]

Mount the outboard motor on the centerline (keel line) of the boat, and ensure thatthe boat itself is well balanced. Otherwise,the boat will be hard to steer. For boatswithout a keel or which are asymmetrical,consult your dealer.

1 Center line (keel line)

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E3-3

104014

wOverpowering a boat may cause severeinstability. Do not install an outboardmotor with more horsepower than themaximum rating on the capacity plate ofthe boat. If the boat does not have acapacity plate, consult the boat manufac-turer.

EMU01299

Mounting HeightTo run your boat at optimum efficiency,the water-resistance (drag) of the boatand outboard motor must be made as lit-tle as possible. The mounting-height ofthe outboard motor greatly affects thewater-resistance. If the mounting-heightis too high, cavitation tends to occur, thusreducing the propulsion; and if the pro-peller tips cut the air, the engine speedwill rise abnormally and cause the engineto overheat. If the mounting-height is toolow, the water-resistance will increaseand thereby reduce engine efficiency.Mount the engine so that the anti-cavita-tion plate is in alignment with the bottomof the boat .NOTE:

8 The optimum mounting height of theoutboard motor is affected by theboat/motor combination. Test runs atdifferent heights can help determine theoptimum mounting height.8 Refer to the section TRIMMING OUT-

BOARD MOTOR for instructions onsetting the trim angle of the outboard.

6H3-9-1N 3 2/6/03 11:19 Page 4

E3-4

902055

EMU01031

FILLING FUEL1) Remove the fuel tank cap.2) Fill the fuel tank carefully.3) Close the cap securely after refueling.

Wipe up any spilled fuel.Ring Free Fuel Additive

Gasoline is a precise blend of many differ-ent substances, each chosen to give cer-tain characteristics. Gasoline blends havebeen changing in recent years inresponse to concerns about pollution andresulting emissions regulations. One ofthe most obvious changes has been theelimination of lead from most fuels.As gasoline has changed, the amount ofadditives such as aromatics and oxy-genates has increased. These additivesare important for the engines in passen-ger cars, but they can have detrimentaleffects in marine engines, particularly 2-cycle outboards because of increaseddeposits in the combustion chamber.When enough deposits collect, pistonrings begin sticking. Performance dropsand engine wear increases dramatically.

EMU00186

FILLING FUEL AND ENGINE OIL

EMU00188

FILLING FUEL1) Put the outboard in the tilt-down posi-

tion. Remove the fuel tank cap.2) Use a funnel if the nozzle on the fuel

can or pump is not small enough orlong enough to fit into the mouth ofthe fuel tank.

3) Fill the fuel tank carefully.4) Close the cap securely after refueling.

Wipe up any spilled fuel.

Fuel tank capacity:Refer to SPECIFICATIONS, page 4-1.

6H3-9-1N 3 2/6/03 11:19 Page 5

E3-5

EMU01800*

FILLING OILThis engine uses the oil injection system,which provides superior lubrication byensuring the proper oil ratio for all operat-ing conditions. No fuel premixing is need-ed (except during break-in). Simply pourgasoline into the fuel tank and oil into theoil tank. Convenient indicator segmentsindicate the status of the oil supply. Fordetails on reading the indicator segments,see Oil level indicator in this chapter.To fill the engine oil tank, proceed as fol-lows:

wDo not add gasoline into the oil tank. Fireor explosion could result.

1) Turn the oil filler access cap on top ofthe top cowling counterclockwise andopen it.

2) Open the oil tank filler cap by pullinga tab on the cap.

While many additives available mayreduce deposits, Yamaha recommendsthe use of Ring Free Fuel Additive, avail-able from your Yamaha dealer. Ring Freehas repeatedly proven its ability to cleancombustion deposits from inside theengine, notably the critical piston-ring-land area, and fuel system components.Follow product labeling for use instruc-tions.

203014

203015

Engine oil tank capacity:See Chapter 4, Specifications.

6H3-9-1N 3 2/6/03 11:19 Page 6

E3-6

203016

q w

EMF40110

PRE-OPERATION CHECKS

wIf any item in the pre-operation check isnot working properly, have it inspectedand repaired before operating the out-board motor. Otherwise, an accidentcould occur.

FuelCheck to be sure you have plenty of fuelfor your trip. Make sure there are no fuelleaks or gasoline fumes.Be sure the fuel hose is not being flat-tened or kinked by objects in the boat,and that there are no sharp objects nearit.

OilCheck to be sure you have plenty of oil foryour trip.

ControlsCheck throttle, shift, and steering forproper operation before starting theengine.The controls should work smoothly, with-out binding or unusual free play. Look forloose or damaged connections.Check operation of the starter and stopswitches when the outboard moter is inthe water.

3) Slowly fill the engine oil into theengine oil tank.

4) After filling, replace the all capssecurely.

1 Oil filler access cap2 Oil tank filler cap

6H3-9-1N 3 2/6/03 11:19 Page 7

E3-7

212011*

EngineCheck the engine and engine mounting.Look for loose or damaged fasteners.Check the propeller for damage.

cCDo not start the engine out of water.Overheating and serious engine damagecan occur.

EMU01790

OPERATION AFTER A LONG PERIODOF STORAGEWhen operating the engine after a longperiod (12 months) of storage, proceed asfollows:1) Use a 50:1 gasoline-oil mixture to

start the engine.2) Start the engine. Leave it idling.

w8 Do not touch or remove electrical parts

when starting or during operation.8 Keep hands, hair, and clothes away

from the flywheel and other rotatingparts while the engine is running.

3) Watch for oil flowing through the oilfeed pipes. After any air in the oillines has been expelled, the oil injec-tion system should supply oil normal-ly. If no oil is flowing after 10 minutesof idling, consult your Yamaha dealer.

cCBe sure to take the above steps whenoperating the engine after a long periodof storage. Otherwise engine seizurecould occur.

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E3-8

EMU01776

BREAKING IN ENGINE

Your new engine requires a period ofbreak-in to allow mating surfaces of mov-ing parts to wear in evenly. Correct break-in will help ensure proper performanceand longer engine life.

cC8 Failure to follow the break-in procedure

could result in reduced engine life oreven severe engine damage.8 Premix fuel must be used during break-

in, in addition to oil in the oil injectionsystem.

EMF52010

Gasoline (Petrol)/ Engine oil mixing chart

cCMake sure to mix gasoline (petrol) and oilcompletely, otherwise your outboardmotor may be damaged.

Mixingratio

50 : 1

Gasoline(Petrol)

1 L

(0.26 US gal,

0.22 Imp gal)

12 L

(3.2 US gal,

2.6 Imp gal)

14 L

(3.7 US gal,

3.1 Imp gal)

24 L

(6.3 US gal,

5.3 Imp gal)

0.02 L

(0.02 US qt,

0.02 Imp ql)

0.24 L

(0.25 US qt,

0.21 Imp qt)

0.28 L

(0.30 US qt,

0.25 Imp qt)

0.48 L

(0.51 US qt,

0.42 Imp qt)

Engine oil

Break-in time: 10 hours

Gasoline to engine oil premix ratioduring break-in: 50:1

6H3-9-1N 3 2/6/03 11:19 Page 9

E3-9

EMU01784

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

Run the engine at the lowest possi-ble-speed. A fast idle in neutral isbest.

2) Next 50 minutes:Do not exceed half throttle (approxi-mately 3,000 r/min). Vary enginespeed occasionally. If you have aneasy-planing boat, accelerate at fullthrottle onto plane, then immediatelyreduce the throttle to 3,000 r/min orless.

3) Second hour:Accelerate at full throttle onto plane,then reduce engine speed to three-quarter throttle (approximately 4,000r/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 tolet the engine cool.

4) Third through tenth hours:Avoid operating at full throttle formore than 5 minutes at a time. Let theengine cool between full-throttle runs.Vary engine speed occasionally.

5) After the first 10 hours:Operate the engine normally. Useonly straight gasoline in the fuel tank.The oil injection system providesproper lubrication for normal opera-tion.

6H3-9-1N 3 2/6/03 11:19 Page 10

E3-10

304034*

902053

EMU01147

STARTING ENGINE

w8 Before starting the engine, make sure

that the boat is tightly moored and thatyou can steer clear of any obstructions.Be sure there are no swimmers in thewater 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 andexplosive. Refrain from smoking, andkeep away from open flames andsparks while loosening the air ventscrew.8 This product emits exhaust gases

which contain carbon monoxide, a col-orless, odorless gas which may causebrain damage or death when inhaled.Symptoms include nausea, dizziness,and drowsiness. Keep cockpit andcabin areas well ventilated. Avoidblocking exhaust outlets.

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

2) If there is a fuel joint on the motor,firmly connect the fuel line to thejoint. Then firmly connect the otherend of the fuel line to the joint on thefuel tank.

NOTE:

During engine operation place the tankhorizontally, or fuel cannot be drawn intothe engine.

3) Squeeze the primer bulb with the out-let end up until you feel it becomefirm.

902061

001671

6H3-9-1N 3 2/6/03 11:19 Page 11

E3-11

000293

EMF65010

PROCEDURE FOR REMOTECONTROL MODEL 4) Place the remote control lever in the

Neutral position.NOTE:

8 The start-in-gear protection device pre-vents the engine from starting exceptwhen in Neutral.8 It is not necessary to open the free

accelerator lever or Neutral throttlelever while starting.

5) Attach the engine stop switch lanyardto a secure place on your clothing, oryour arm or leg. Then, install the lockplate on the other end of the lanyardin the engine stop switch.

w8 Attach the engine stop switch lanyard

to a secure place on your clothing, yourarm or leg while operating.8 Do not attach the lanyard to clothing

that could tear loose. Do not route thelanyard where it could become entan-gled, preventing from functioning.8 Avoid accidentally pulling the lanyard

during normal operation. Loss ofengine power means the loss of moststeering control. Also, without enginepower, the boat could slow rapidly.This could cause people and objects inthe boat to be thrown forward.

6) Turn the main switch to ON.

N

701015

6H3-9-1N 3 2/6/03 11:19 Page 12

E3-12

EMU00949

Electric Start Model7) 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 toON.

cC8 Do not turn the main switch to

START when the engine is running.8 Do not keep the starter-motor turning

for more than 5 seconds. The batterywill rapidly become exhausted and itwill be impossible for it to start theengine. If the engine does not startwithin 5 seconds, return the mainswitch to ON, wait 10 seconds, andthen crank the engine again.

ON STARTOFF

701022

6H3-9-1N 3 2/6/03 11:19 Page 13

E3-13

309014

EMG00210

WARMING UP ENGINE

1) Before beginning operation, allow theengine to warm up at idling speed for3 minutes. (Failure to do this willshorten engine life.)

2) Check for a steady flow of water fromthe cooling-water pilot hole.

cCA continuous flow of water from the pilothole shows that the water pump ispumping water through the cooling pas-sages. If water is not flowing out of thepilot hole at all times while the engine isrunning, do not continue to run theengine. Overheating and serious damagecould occur. Stop the engine and checkto see if the water inlet on the lower cas-ing is blocked. If the problem cannot befound and corrected, consult yourYamaha dealer.

NOTE:

After the engine starts, warm-up opera-tion is automatically controlled by thePrime Start system. Automatic control iscancelled if the throttle is opened morethan halfway.

6H3-9-1N 3 2/6/03 11:19 Page 14

E3-14

701043

NF

EMU00261

SHIFTING

wBefore shifting, make sure there are noswimmers or obstacles in the water nearyou.

cCTo change the shifting position from for-ward to reverse or vice-versa, close thethrottle first so that the engine idles (orruns at low speeds).

N R

701044

EMU00264

FORWARDPull up the neutral interlock trigger (Ifequipped) and move the remote controllever quickly and firmly from Neutral toForward.

EMU00269

REVERSE

wWhen operating in Reverse, go slowly. Donot open the throttle more than half.Otherwise, the boat may become unsta-ble, which could result in loss of controland an accident.

Pull up the neutral interlock trigger (Ifequipped) and move the remote controllever quickly and firmly from Neutral toReverse.

6H3-9-1N 3 2/6/03 11:19 Page 15

E3-15

ONSTARTOFF

701023

304034*

902052

EMG38010

STOPPING ENGINE

Let it cool off for a few minutes at idle orlow speed first. Stopping the engineimmediately after operating at high speedis not recommended.

EMG41211

PROCEDURE1) Turn the main switch to OFF.

NOTE:

The engine can also be stopped bypulling the lanyard from the engine stopswitch (then turning the main switch toOFF).

2) If the fuel joints are provided, discon-nect the fuel line from the motor afterstopping the engine.

3) Tighten the air vent screw on the fueltank cap after stopping the engine, ifit is equipped.

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

6H3-9-1N 3 2/6/03 11:19 Page 16

E3-16

000862

q

EMU01412

TRIMMING OUTBOARDMOTOR

The trim angle of the outboard motorhelps determine the position of the bowof the boat in the water. The correct trimangle will help improve performance andfuel economy while reducing strain on theengine. The correct trim angle dependsupon the combination of boat, engine,and propeller. Correct trim is also affectedby variables such as the load in the boat,sea conditions, and running speed.

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

NOTE:

Refer to the section ADJUSTING TRIMANGLE for instructions on usage.

1 Trim operating angle

6H3-9-1N 3 2/6/03 11:19 Page 17

E3-17

UPDN

701034

UPDN

q

EMU01401

Power Trim/Tilt Model

w8 Be sure all people are clear of the out-

board motor when adjusting thetrim/tilt angle, also be careful not topinch any body parts between the driveunit and clamp bracket.8 Use 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.8 Use the power trim/tilt switch located

on the bottom engine cowling (ifequipped) only when the boat is at acomplete stop with the engine off.

The outboard motor trim angle can beadjusted operating the power trim/tiltswitch 1.

To raise the bow (trim-out), push theswitch UP.

To lower the bow (trim-in), push theswitch DN.

Make test runs with the trim set to differ-ent angles to find the position that worksbest for your boat and operating condi-tions.

NOTE:

To adjust the trim angle while the boat ismoving, use the power trim and tiltswitch located on the remote controldevice or tiller handle, if so equipped.

ADJUSTING TRIM ANGLE

6H3-9-1N 3 2/6/03 11:19 Page 18

E3-18

001672

q

001673

w

001674

e

EMU19160

Trim angle settings and boat handlingWhen the boat is on plane, a bow-up atti-tude results in less drag, greater stabilityand efficiency. This is generally when thekeel line of the boat is up about 3 to 5degrees. With the bow up, the boat mayhave a greater tendency to steer to oneside or the other. Compensate for this asyou steer. The trim tab can also be adjust-ed to help offset this effect.

1 Optimum angle (level keel line)2 Bow up3 Bow down

Bow UpToo much trim-out puts the bow of theboat too high in the water. Performanceand economy are decreased because thehull of the boat is pushing the water andthere is more air drag. Excessive trim-outcan also cause the propeller to ventilate,which reduces performance further, andthe boat may porpoise (hop in thewater), which could throw the operatorand passengers overboard.

Bow DownWhen the bow of the boat is down, it iseasier to accelerate from a standing startonto plane. Too much trim-in causes theboat to plow through the water,decreasing fuel economy and making ithard to increase speed. Operating withexcessive trim-in at higher speeds alsomakes the boat unstable. Resistance atthe bow is greatly increased, heighteningthe danger of bow steering and makingoperation difficult and dangerous.

6H3-9-1N 3 2/6/03 11:19 Page 19

E3-19

000817

EMU01200

TILTING UP/DOWN

If the engine will be stopped for sometime, or if the boat is moored in shallows,the engine should be tilted up to protectthe propeller and casing from damage bycollision with obstructions, and also toreduce salt corrosion.

cCBefore tilting the motor, follow the proce-dures under STOPPING ENGINE. Nevertilt the motor while the engine is running.Severe damage from overheating canresult.

wBe sure all people are clear of the out-board motor when adjusting the tiltangle, also be careful not to pinch anybody parts between the drive unit andengine bracket.

wLeaking fuel is a fire hazard. Disconnectthe fuel line or close the fuel cock if theengine will be tilted for more than a fewminutes. Otherwise, fuel may leak. (If thefuel connector is provided on the motor.)

NOTE:

Depending on the type of boat, the out-board motor trim angle may have littleeffect on the trim of the boat when oper-ating.

6H3-9-1N 3 2/6/03 11:19 Page 20

E3-20

UPDN

701034*

UPDN

302021*

DN

UP

403011*

411014

EMU00295

PROCEDURE FOR TILTING UPPower tilt / Power trim/tilt model

1) Remove the fuel-line connection fromthe motor. (If the connector is provid-ed on the motor.)

2) Push the power tilt / power trim/tiltswitch UP until the outboard hastilted up completely.

3) Turn the tilt-support lever toward youand support the engine.

wAfter tilting the engine, be sure to sup-port it with the tilt-support lever.Otherwise, the engine could fall backdown suddenly if oil in the power tilt /power trim/tilt unit should lose pressure.

Power trim/tilt model

4) Once the engine is supported with thetilt-support lever, push the powertrim/tilt switch DOWN to retract thetrim rods.

6H3-9-1N 3 2/6/03 11:19 Page 21

E3-21

411021

cCBe sure to retract the trim rods complete-ly during mooring. This protects the rodsfrom marine growths and corrosionwhich could damage the power trim/tiltmechanism.

EMH60010

CRUISING IN OTHERCONDITIONS

CRUISING IN SALT WATERAfter operating in salt water, wash out thecooling-water passages with fresh waterto prevent them from becoming clogged-up with salt deposits.NOTE:

Refer to cooling system flushing instruc-tions in TRANSPORTING AND STORINGOUTBOARD MOTOR.

CRUISING IN TURBID WATERIt is strongly recommended that theoptional chromium-plated water-pump kitbe installed if the outboard is to be usedin turbid (muddy) water conditions.

EMU00304

PROCEDURE FOR TILTING DOWNPower tilt / Power trim/tilt model

1) Push the power tilt / power trim/tiltswitch UP until the engine is sup-ported by the tilt rod.

2) Release the tilt-support lever.3) Push the power tilt / power trim/tilt

switch DN(Down) to lower theengine to the desired position.

6H3-9-1N 3 2/6/03 11:19 Page 22

EEMK00010

Chapter 4

MAINTENANCE

SPECIFICATIONS .....................................4-1

TRANSPORTING AND STORING OUTBOARD MOTOR ...............................4-3

Trailering outboard motor ...................4-3Storing outboard motor .......................4-4

PERIODIC MAINTENANCE......................4-8Replacement parts ................................4-8Maintenance chart ................................4-9Cleaning and adjusting spark plug ...4-10Checking top cowling .........................4-11Checking fuel system .........................4-12Cleaning fuel filter...............................4-13Inspecting idling speed ......................4-14Checking water in engine oil tank.....4-15Replacing fuse.....................................4-16Checking wiring and connectors.......4-16Exhaust leakage ..................................4-16Water leakage......................................4-16Greasing...............................................4-17Checking power trim and tilt system..................................................4-18Checking propeller..............................4-19Changing gear oil................................4-21Inspecting and replacing anode(s)....4-22Checking battery .................................4-23Checking bolts and nuts.....................4-26Motor exterior .....................................4-26Cleaning cooling-water passages .....4-26Coating the boat bottom....................4-27

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EMK10011*

SPECIFICATIONSModel

Unit 60TRCItem

25 (2.5, 18)35 (3.5, 25)

8Spark plug Nm (kgfm, lbft)8Propeller nut Nm (kgfm, lbft)

DIMENSIONS

PERFORMANCE

8Overall Length mm (in.)8Overall Width mm (in.)8Overall Height L mm (in.)8Transom height L mm (in.)8Weight kg (lb.)

713 (28.1)364 (14.3)1,374 (54.1)521 (20.5)104 (229)

8Full throttle operating range r/min8Maximum output kW (HP)8Idling speed r/min

4,500~5,50044.1 (60) at 5,000 r/min700~800

ENGINE

8TypeDisplacement cm3 (cu.in.)Bore stroke mm (in.)8Ignition system8Spark plug NGK

Spark plug gap mm (in.)8Control system8Starting system8Battery

Min. cold cranking amps (CCA/SAE) amps at -18C (-0.4F)Min. marine cranking amps (MCA/ABYC) amps at 0C (32F)Min. reserve capacity (RC/SAE) minutes8Alternator output V-Amp (W)8Starting carburetion system

2-stroke, L3849 (51.8)72.0 69.5 (2.8 2.7)C.D.I systemB8HS-100.9~1.0 (0.035~0.039)Remote controlElectric start

38050212412-6Prime start system

DRIVE UNIT

8Gear positionsGear ratio8Trim/tilt system8Propeller mark

Forward-Neutral-Reverse2.33 (28/12)Power trim/tiltK

FUEL AND OIL

TIGHTENING TORQUE

8Fuel

Fuel tank capacity L (US gal, Imp gal)8Recommended engine oil

LubricationEngine oil capacity (engine oil tank) L (US qt, Imp qt)8Recommended gearcase oil

Gear oil capacity cm3 (US oz, Imp oz)

Regular unleaded gasoline (P.O.N.: minimum 86)YAMALUBE 2 STROKE OUTBOARD OIL, or an equivalentTC-W3 certified outboard oiloil injection system2.8 (3.0, 2.5)Hypoid gear oil (SAE 90)610 (20.6, 21.5)

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70TRC 90TRC

713 (28.1)364 (14.3)1,374 (54.1)521 (20.5)104 (229)

5,000~6,00051.5 (70) at 5,500 r/min750~850

2-stroke, L3849 (51.8)72.0 69.5 (2.8 2.7)C.D.I systemB8HS-100.9~1.0 (0.035~0.039)Remote controlElectric start

38050212412-6Prime start system

Forward-Neutral-Reverse2.33 (28/12)Power trim/tiltK

Regular unleaded gasoline (P.O.N.: minimum 86)YAMALUBE 2 STROKE OUTBOARD OIL, or anequivalent TC-W3 certified outboard oiloil injection system2.8 (3.0, 2.5)Hypoid gear oil (SAE 90)610 (20.6, 21.5)

25 (2.5, 18)35 (3.5, 25)

726 (28.6)374 (14.7)1,413 (55.6)520 (20.5)119 (262)

4,500~5,50066.2 (90) at 5,000 r/min750~850

2-stroke, L31,140 (69.6)82.0 72.0 (3.2 2.8)C.D.I systemB8HS-100.9~1.0 (0.035~0.039)Remote controlElectric start

38050212412-10Prime start system

Forward-Neutral-Reverse2.00 (26/13)Power trim/tiltK

Regular unleaded gasoline (P.O.N.: minimum 86)YAMALUBE 2 STROKE OUTBOARD OIL, or anequivalent TC-W3 certified outboard oiloil injection system3.3 (3.5, 2.9)Hypoid gear oil (SAE 90)610 (20.6, 21.5)

25 (2.5, 18)35 (3.5, 25)

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EMU01369

TRANSPORTING ANDSTORING OUTBOARD MOTORwLeaking fuel is a fire hazard. When trans-porting and storing the outboard motor,close the air vent screw and fuel cock toprevent fuel from leaking.000940

EMU00326

TRAILERING OUTBOARD MOTORThe motor should be trailered and storedin the normal running position. If there isinsufficient road clearance in this position,then trailer the motor in the tilt positionusing a motor support device such as atransom saver bar.For further details, consult your Yamahadealer.

w8 Never get under the lower unit while it

is tilted, even if a motor support bar isused. Severe injury could occur if theoutboard accidentally falls.8 USE CARE when transporting fuel tank,

whether in a boat or car.8 DO NOT fill fuel container to maximum

capacity. Gasoline will expand consid-erably as it warms up and can build uppressure in the fuel container. This cancause fuel leakage and a potential firehazard.

cCDo not use the tilt support lever/knobwhen trailering the boat. The outboardmotor could shake loose from the tiltsupport and fall. If the motor can not betrailered in the down position, use anadditional support device to secure it inthe up position.

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EMU01796

STORING OUTBOARD MOTORWhen storing your Yamaha outboardmotor for prolonged periods of time (2months or longer), several important pro-cedures must be performed to preventexcessive damage. This is especiallyimportant for your oil injection-equippedoutboard motor due to the lean oil ratiosused at idle prior to shutting the engineoff for the season. It is advisable to haveyour outboard motor serviced by anauthorized Yamaha dealer prior to stor-age. However, the following procedurescan be performed by you, the owner, witha minimum of tools.

EMK21010

Filling Fuel TankFill the fuel tank with fresh fuel and addone ounce of Yamaha Fuel Conditionerand Stabilizer (Part No. LUB-FUELC-12-00) to each gallon of fuel.NOTE:

The use of Yamaha Fuel Conditioner andStabilizer eliminates the need to drainthe fuel system. Consult your Yamahadealer or other qualified mechanic if thefuel system is to be drained instead.

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605014

EMK22111

Flushing Cooling System and FoggingEngineCooling system flushing is essential toprevent the cooling system from cloggingup with salt, sand, or dirt. In addition, fog-ging of the engine is mandatory to pre-vent expensive engine damage due torust. Perform the flushing and fogging atthe same time.1) Remove the top cowling and silencer

cover. Remove the propeller.2) Install a flushing attachment to the

lower unit. (Flushing attachmentavailable from your Yamaha dealer).

cCAvoid running the outboard at highspeed while on the flushing attachment,or overheating could occur.

w8 Do not touch or remove electrical parts

when starting or during operation.8 Keep hands, hair and clothes away

from flywheel and other rotating partswhile engine is running.

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

4) Just prior to turning off the engine,quickly spray Yamaha Stor-RiteEngine Fogging Oil (Part No. LUB-STRRT-12-00) alternately into eachcarburetor. When properly done, theengine will smoke excessively andalmost stall.

5) Remove the flushing attachment andwipe off any excess water.

6) Install the silencer cover and topcowling. Install the propeller.

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EMK26111

Lubrication1) Remove the spark plugs, and spray a

10 second spray of Yamaha Stor-Rite Engine Fogging Oil into eachcylinder. Grease the spark plugthreads and reinstall the spark plugsand torque to proper specification.(Refer to CLEANING AND ADJUST-ING SPARK PLUG.)

2) Turn the engine over with the stoplanyard disconnected to work the fog-ging oil into the piston rings.

3) Fill the oil tanks. This prevents the for-mation of condensation. For modelswith a remote tank, it may be neces-sary to manually override the controlunit to completely fill the engine maintank. (Refer to TEMPORARY ACTIONIN EMERGENCY).

4) Change the lower unit oil. (Refer toCHANGING GEAR OIL). Inspect theoil for the presence of water whichindicates a leaky seal. Seal replace-ment should be performed by anauthorized Yamaha dealership priorto use.

5) Grease all grease fittings. (Refer toGREASING)

EMK27011

Cleaning and Anti-corrosion Measure1) Wash down the exterior of the out-

board with fresh water and dry offcompletely.

2) Spray the engines exterior withYamaha Silicone Protectant (PartNo. LUB-SILCNE-13-00).

3) Wax the cowling with a non-abrasivewax such as Yamaha Silicone Wax(Part No. ACC-11000-15-02).

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EMK29010

Battery Care

wBattery electrolyte is poisonous and dan-gerous, causing severe burns, etc. It con-tains sulfuric acid. Avoid contact withskin, eyes, or clothing.Antidote:EXTERNAL; Flush with water.INTERNAL; Drink large quantities ofwater or milk. Follow with milk of mag-nesia, beaten egg, or vegetable oil. Callphysician immediately.EYES; Flush with water for 15 minutesand get prompt medical attention.Batteries produce explosive gases: Keepsparks, flame, cigarettes, etc. away.Ventilate when charging or using in aclosed space. Always wear eye protectionwhen working near batteries.KEEP OUT OF REACH OF CHILDREN.

NOTE:

Batteries vary among manufacturers.Therefore the following procedures maynot always apply. Consult your batterymanufacturers instructions.

1) Disconnect and remove the batteryfrom the boat. Always disconnect theblack negative lead first to prevent therisk of shorting.

2) Clean the battery casing and termi-nals. Fill each cell to the upper levelwith distilled water.

3) Store the battery on a level surface ina cool, dry, well-ventilated place outof direct sunlight.

4) Once a month, check the specificgravity of the electrolyte and rechargeas required to prolong battery life.

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EMK32110

PERIODIC MAINTENANCE

wBe sure to turn off the engine when youperform maintenance unless otherwisespecified. If the owner is not familiar withmachine servicing, this work should bedone by a Yamaha dealer or other quali-fied mechanic.

A service manual is available for purchasethrough a Yamaha dealer for owners whohave the mechanical skills, tools, andother equipment necessary to performmaintenance not covered by this ownersmanual.EMK33011

REPLACEMENT PARTSIf replacement parts are necessary, useonly genuine Yamaha parts or equiva-lents of the same type and of equivalentstrength and materials. Any part of inferi-or quality may malfunction, and theresulting loss of control could endangerthe operator and passengers.Yamaha genuine parts and accessoriesare available from a Yamaha dealer.

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EMU19470

MAINTENANCE CHARTFrequency of maintenance operations may be adjusted according to the operating con-ditions, but the following table gives general guidelines. Refer to the sections in thischapter for explanations of each owner-specific action.The mark () indicates the check-ups which you may carry out yourself.The mark (1) indicates work to be carried out by your Yamaha dealer.

NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushedwith clean water after each use.

10 hours 50 hours 100 hours 200 hours(1 month) (3 months) (6 months) (1 year)

Spark plug(s) Cleaning / adjustment /replacement

Greasing points Greasing Gear oil Change Fuel system Inspection Fuel filter (can bedisassembled) Inspection / cleaning Fuel tank (Yamahaportable tank) Inspection / cleaning Idling speed (carburetormodels) Inspection / adjustment /1 /1Anode(s) (external) Inspection / replacement /1 /1Anode(s) (internal) Inspection / replacement 1Cooling water passages Cleaning Propeller and cotter pin Inspection / replacement Battery Inspection / charging /1Throttle link / throttle cable/ throttle pick-up timing Inspection / adjustment 1Shift link / shift cable Inspection / adjustment 1Oil tank water drain Inspection / cleaning /1 /1 /1Oil pump Inspection / adjustment 1Thermostat Inspection 1PCV (Pressure ControlValve) Inspection 1Power trim and tilt unit Inspection 1Water pump Inspection 1Cowling clamp Inspection

Item ActionsInitial Every

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EMU01202

CLEANING AND ADJUSTING SPARKPLUG

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

The spark plug is an important enginecomponent and is easy to inspect. Thecondition of the spark plug can indicatesomething about the condition of theengine. For example, if the center elec-trode porcelain is very white, this couldindicate an intake air leak or carburetionproblem in that cylinder. Do not attemptto diagnose any problems yourself.Instead, take the outboard motor to aYamaha dealer. You should periodicallyremove and inspect the spark plugbecause heat and deposits will cause thespark plug to slowly break down anderode. If electrode erosion becomesexcessive, or if carbon and other depositsare excessive, you should replace thespark plug with another of the correcttype.

Before fitting the spark plug, measure theelectrode gap with a wire thicknessgauge; adjust the gap to specification ifnecessary.

Standard spark plug:Refer to SPECIFICATIONS, page 4-1.

Spark plug gap:Refer to SPECIFICATIONS, page 4-1.

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903022

qw

When fitting the plug, always clean thegasket surface and use a new gasket.Wipe off any dirt from the threads andscrew in the spark plug to the correcttorque.

NOTE:

If a torque-wrench is not available whenyou are fitting a spark plug, a good esti-mate of the correct torque is 1/4 to 1/2 aturn past finger-tight. Have the spark plugadjusted to the correct torque as soon aspossible with a torque-wrench.

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

Initial of spark Plug wrench sizeplug I.D. mark

B 21 mm (13/16 in.)

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

D 18.3 mm (23/32 in.)

Spark plug torque:Refer to SPECIFICATIONS, page 4-1.

EMU16350

CHECKING TOP COWLINGCheck the fitting of the top cowling bypushing it with both hands.If the fitting is loose have it repaired by aYamaha dealer.

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EMK38010

CHECKING FUEL SYSTEM

wGasoline (petrol) and its vapors are highlyflammable and explosive. Keep awayfrom sparks, cigarettes, flames or othersources of ignition.

Check the fuel line for leaks, cracks, ormalfunctions. If any problem is found, itshould be repaired immediately byYamaha dealer or other qualified mechan-ic.

Checking points8 Fuel system parts leakage.8 Fuel hose joint leakage.8 Fuel hose cracks or other damage.8 Fuel connector leakage.

wLeaking fuel can result in fire or explo-sion.8 Check for fuel leakage regularly.8 If any fuel leakage is found, the fuel

system must be repaired by a qualifiedmechanic. Improper repairs can makethe outboard unsafe to operate.

106071

6H3-9-1N 4 2/21/03 10:26 Page 13

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000983

q

w

er

207016

EMK50011

CLEANING FUEL FILTER

wGasoline (petrol) is highly flammable, andits vapors are flammable and explosive.8 If you have any question about properly

doing this procedure, consult yourYamaha dealer.8 Do not perform this procedure on a hot

or running engine. Allow the engine tocool.8 There will be fuel in the fuel filter. Keep

away from sparks, cigarettes, flames orother sources of ignition.8 This procedure will allow some fuel to

spill. Catch fuel in a rag. Wipe up anyspilled fuel immediately.8 The fuel filter must be reassembled

carefully with O-ring, filter cup, andhoses in place. Improper assembly canresult in a fuel leak, which could resultin a fire or explosion hazard.

EMU09782

1) Remove the nut holding the fuel filterassembly if equipped.

2) Unscrew the filter cup 1, catchingany spilled fuel in a rag.

3) Remove the filter element 2, andwash it in solvent. Allow it to dry.Inspect the filter element and O-ring3 to make sure they are in good con-dition. Replace them if necessary. Ifany water is found in the fuel, theYamaha portable fuel tank or otherfuel tanks should be checked andcleaned.

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4) Reinstall the filter element in the cup.Make sure the O-ring is in position inthe cup. Firmly screw the cup ontothe filter housing 4.

5) Attach the filter assembly to thebracket so that the fuel hoses areattached to the filter assembly.

6) Run the engine and check the filterand lines for leaks.

EMU09912

INSPECTING IDLING SPEED

w8 Do not touch or remove electrical parts

when starting or during operation.8 Keep hands, hair and clothes away

from flywheel and other rotating partswhile engine is running.

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

A diagnostic tachometer should be usedfor this procedure. Results may varydepending on whether testing is conduct-ed with the flushing attachment, in a testtank, or with the outboard motor in thewater.1) Start the engine and allow it to warm

up fully in neutral until it is runningsmoothly. If the outboard motor ismounted on a boat, be sure the boatis tightly moored.

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213013

q

w

213014

q

w

2) Verify whether the idle speed is set tospecification. For idle speed specifica-tions, see Specifications in thischapter.

NOTE:

Correct idling speed inspection is onlypossible if the engine is fully warmed up.If not warmed up fully, the idle speed willmeasure higher than normal. If you havedifficulty verifying the idle speed, or theidle speed requires adjustment, consult aYamaha dealer or other qualified mechan-ic.

EMU03782

CHECKING WATER IN ENGINE OILTANKA translucent water drain hose is connect-ed from the bottom of the oil tank to thefiller neck. If water or foreign matter col-lects in this hose, consult a Yamaha deal-er.

1 Drain hose2 Filler neck side

60/70

90

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205016

q

w

413011

EMU01329

REPLACING FUSEIf the fuse has blown on an Electric startmodel, open the fuse holder and replacethe fuse with a new one of proper amper-age.

wBe sure to use the specified fuse. Anincorrect fuse or a piece of wire mayallow excessive current flow. This couldcause electrical system damage and a firehazard.

NOTE:

If the new fuse blows again immediately,consult a Yamaha dealer.

1 Fuse holder2 Fuse (20A)

EMK78010

CHECKING WIRING ANDCONNECTORS1) Check that each grounding wire is

properly secured.2) Check that each connector is engaged

securely.

EXHAUST LEAKAGEStart the engine and check that noexhaust leaks from the joints between theexhaust cover, cylinder head and crankcase.

WATER LEAKAGEStart the engine and check that no waterleaks from the joints between the exhaustcover, cylinder head and crank case.

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EMU00366

GREASINGYamaha marine grease(Water resistant grease)

103031*

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411015

411016

EML02011

CHECKING POWER TRIM AND TILTSYSTEM

w8 Never get under the lower unit while it

is tilted, even when the tilt-supportlever is locked. Severe injury couldoccur if the outboard accidentally falls.8 Make sure no one is under the out-

board before performing this test.

1) Check the power trim and tilt unit forany sign of oil leaks.

2) Operate each of the power trim andtilt switches on remote control andengine bottom cowling (If equipped)to check that all switches work.

3) Tilt up the motor and check that thetilt rod and trim rods are pushed outcompletely.

4) Use the tilt-support lever to lock themotor in the UP position. Operate thetilt down switch briefly so the motoris supported the tilt-support lever.

5) Check that the tilt rod and trim rodsare free of corrosion or other flaws.

6) Activate the tilt-down switch until thetrim rods have gone completely intothe cylinders.

7) Activate the trim-up switch until thetilt rod is fully extended. Unlock thetilt-support lever.

8) Operate the motor to tilt down. Checkthat the tilt rod and trim rods operatesmoothly.

NOTE:

If any operation is abnormal, consult aYamaha dealer.

Recommended fluid; Yamaha power trim & tilt fluid or ATF (DEXRON-II).

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210012

602051

602054

EML08011*

CHECKING PROPELLER

wYou could be seriously injured if theengine accidentally starts while you arenear the propeller.8 Before inspecting, removing or

installing the propeller, remove thespark 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 removethe lanyard from the engine stopswitch. Turn off the battery cut-offswitch if your boat has one.8 Do not use your hand to hold the pro-

peller when loosening or tightening thepropeller nut. Put a wood blockbetween the cavitation plate and thepropeller to prevent the propeller fromturning.

1) Check each of the propeller blades forwear, erosion from cavitation or ven-tilation, or other damage.

2) Check the splines for wear and dam-age.

3) Check for fish line winding around thepropeller shaft. Check the propellershaft oil seal for damage.

602073

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e

r

t

y

EMU00976

Removing the Propeller1) Straighten the cotter-pin 1 and pull it

out using a pair of pliers.2) Remove the propeller nut 2, washer

3 and spacer 4.3) Remove the propeller 5 and thrust

washer 6.

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602053

EMU00397

Installing the Propeller

cC8 Be sure to install the thrust washer

before installing propeller, otherwise,lower case and propeller boss may bedamaged.8 Be sure to use a new cotter pin and

bend the ends over securely.Otherwise, the propeller could come offduring operation and be lost.

1) Apply Yamaha Marine grease orCorrosion resistant grease to the pro-peller-shaft.

2) Install the thrust washer and propelleron the propeller-shaft.

3) Install the spacer and washer. Tightenthe propeller nut to the specifiedtorque.

4) Align the propeller nut with the pro-peller shaft hole. Insert a new cotterpin in the hole and bend the cotter pinends.

NOTE:

If the propeller nut does not align with thepropeller shaft hole after tightening to thespecified torque, then tighten the nut fur-ther to align it with the hole.

Tightening torque:Refer to SPECIFICATIONS page 4-1.

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000565

w

q

EMU01460

CHANGING GEAR OIL

w8 Be 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.8 Never get under the lower unit while it

is tilted, even when the tilt-supportlever/knob is locked. Severe injurycould occur if the outboard accidentallyfalls.

1) Tilt the outboard motor so that the oildrain plug is at the lowest point possi-ble.

2) Place a suitable container under thegear-case.

3) Remove the oil drain plug 1.NOTE:

The oil drain plug is magnetic. Remove allmetal particles from the plug before rein-stalling it.

4) Remove the oil level plug 2 to allowthe oil to drain completely.

cCInspect the used oil after it has beendrained. If the oil is milky, water is get-ting into the gear-case which can causegear damage. Consult a Yamaha dealerfor repair of the lower unit seals.

NOTE:

For disposal of used oil consult yourYamaha dealer.

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000377

603024

405012

5) With the outboard motor in a verticalposition, and using a flexible or pres-surized filling device, inject the gearoil into the oil drain plug hole.

6) When the oil begins to flow out of theoil level plug hole, insert and tightenthe oil level plug.

7) Insert and tighten the oil drain plug.

Gear oil grade/capacity:Refer to SPECIFICATIONS, page 4-1.

EMU14622

INSPECTING AND REPLACINGANODE(S)Yamaha outboard motors are protectedfrom corrosion by sacrificial anodes.Inspect the external anodes periodically.Remove scales from the surfaces of theanodes. Consult a Yamaha dealer forreplacement of external anodes.

cCDo not paint anodes, as this would ren-der them ineffective.

NOTE:

Inspect ground leads attached to externalanodes on equipped models. Consult aYamaha dealer for inspection andreplacement of internal anodes attachedto the power unit.

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EMU04041

CHECKING BATTERY (for Electricstart models)

wBattery electrolytic fluid is dangerous; itcontains sulfuric acid and therefore is poi-sonous and highly caustic.Always follow these preventive mea-sures:8 Avoid bodily contact with electrolytic

fluid as it can cause severe burns orpermanent eye injury.8Wear protective eye gear when han-

dling or working near batteries.Antidote (EXTERNAL):8 SKIN - Flush with water.8 EYES - Flush with water for 15 minutes

and get immediate medical attention.Antidote (INTERNAL):8 Drink large quantities of water or milk

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

Batteries also generate explosive hydro-gen gas; therefore, you should always fol-low these preventive measures:8 Charge batteries in a well-ventilated

area.8 Keep batteries away from fire, sparks,

or open flames (e.g., welding equip-ment, lighted cigarettes, etc.).8 DO NOT SMOKE when charging or han-

dling batteries.8 KEEP BATTERIES AND ELECTROLYTIC

FLUID OUT OF REACH OF CHILDREN.

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cC8 A poorly maintained battery will quick-

ly deteriorate.8 Ordinary tap-water contains minerals

harmful to a battery, and should not beused for topping-up.

1) Check the electrolyte level at leastonce a month. Fill to the manufactur-ers recommended level when neces-sary. Top up only with distilled water(or pure de-ionized water suitable touse in batteries).

2) Always keep the battery in