OWNER'S MANUAL

outboard
motor
4 140HED
50DEO/5DDETD
A-989
[
- -IMPORTANT: --- -- ---
to Oil _
If the yellow all level warning lamp comes on during a cruise, add oil to the oil tank im-
mediately.
Should spare all be unavailable:
Proceed to the nearest port for oil refilling.
TA;lt !lIN
__.I". _U- t: .----
",IS wi' "
Avoid contln Ulng engine operation
seizure could occur.
with the red 011 level warning lamp on, or engine
A-510'
,----- -----
40HM/40HEO/50DEO/SODETO
OWNER'S MANUAL
1984 by Yamaha Motor Co., Ltd.
1st Edition, May 1984
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
A-ooo
TO THE OWNER
Thank you for choosing a Yamaha outboard motor This
manual cont"lJns the information required for proper mam-
tenance, care and operation A thorough understanding of
these simple Instructions will help you to obtain maximum
enjoyment 'from your new Yamaha
A300
-IMPORTANT.
Before operating this outboard motor. read this
Owner's Manual thoroughly and carefully It will
give you a good grasp of the engme's
tiCS and the technical information required for
safe operation
SpecIfIcatIons given In thIs manual may be subject to
change without pnor notice
Yamaha Motor Co , Ltd
PartIcularly Important informatIon lS dIstInguIshed In thIs
manual by the following notatIons
NOTE --- - ----- - ----
A NOTE prOVIdes key informatIon to make procedures
easier or clearer
A200
'1,';tNlN'- ----------
Before operating this outboard motor, famIliar-
ize yourself with the regulations set forth by
your state In relation to outboard motor opera-
tion
Gasoline is highly inflammable and explosive
Handle it with specIal care
Never attempt to modify this outboard motor
Be sure to wear life jackets on board.
Exercise speCial care to protect the environ-
ment
I
bj
followed to avoId damage to the outboard motor
- -- -------

- - - - -----J
A WARNING Indicates special procedures that
must be followed to avoid personal injury or dam-
8ge to the Unit
-- --------- -- ---- --- -- --- - - -----
CONTENTS
LOCATiON OF MAIN COMPONENTS
Accessory parts
SPECIFICATIONS .
-"
OUTBOARD MOTOR IDENTIFICATION
Outboard motor senal number
Engme senal number
ENGINE MOUNTING
Mounting position
Mounting height,
Clamp.
Remote control mounting
""I'dlim.ii,N".,....
Installing the steering gUide attachments
Ilu#l:t
et4iun
i,'h"'),it.
Battery mounting 1In:""+ili,J#nN"i'"
[nstalilng the meters
FUEL AND LUBRICATION OIL
OPERATIONAL INSTRUCTIONS
Starting .
Cranking the engine
Emergency starting In startIng system trouble
Engine w r ~ u p
Break-in
Gear selection (Forward and Reverse)
Shallowwater cruISing IEImmI
Stopping the engme ,
OperatIon In turbid water
Operation In salt water
. 1
7
9
.15
15
15
16
16
17
.16
.20
.29
.30
31
32
37
37
43
.. 45
47
48
50
52
53
54
54
ADJUSTMENTS
Steering friction adjustment IUI:@fiUllii_'
Adjustment of throttle tWist grip fnctlon ImDD
Adjusting the stiffness of the remote control lever
I,n;"8"I'&1"I"'"
Tnm angle adjustment
Trim tab adjustment
Idle speed adjustment
TILT-UP AND MOORING .
Tilt up.
PERIODIC MAINTENANCE
Fuel system.
Electrical system
Lower unit
Greasing pOInts
Coatmg of the bottomof a boat
Replacement parts .
OFF-SEASON STORAGE
Operation after a long time storage
Cleaning the water Intake passages
Storage of the battery '1"llluM_I,I'''''',i."",
PROPELLER SELECTION .
SUBMERGED MOTOR
TROUBLESHOOTING
WIRING.
55
55
55
56
56
56
59
50
60
63
64
66
66
69
70
70
.70
71
72
.73
73
.74
75
77
cooo
LOCATION OF MAIN COMPONENTS
3---/
4
7----
J

EiDiD


---(fj)
-'1$

10

-1-
Y-650 Y720 Y-360
CD Top cowling (j) Trim tab @ Steering handle/throttle control
Y-09O X-600 V-560
----"
CV ShIft handle Propeller (j}) Choke knob
V-905 Y-235
X-410
Emergency stop sWitch Splash board @ Overheat warning lamp
Y630 Y-590
Y-2BO
@ TIlt up lock TIlt Pin
@Recoil starter handle
Y-065 Y-560
Shallowwater lever q]) Transom clamp handle
V-09O X-960
Anti-cavitation plate @ Reverse lock
-2-
IIiIDm
--!j3J
\
I J2)
co
,
,
0D
1Ql
(9)
--(8)
C2)
3 ~ j --- :.:-r;;--
(5)--- "
-3--
-(6) 11---
Y-650
G) Top cowling
V260
Battery wire
V-560
(jJ) Choke knob
---'
Y-630
Tilt up lock
V-09O
Anti-cavitation plate
y-no
Tnmtab
X-600
@Propeller
Y-235
(j) Splash board
Y-590
nit pin
Y680
Transom clamp handle
X-960
@ Reverse lock
-4-
X-333
@ 011 level warning lamps
X-337
@ all tank cap
(3))------1-'fdl


r---P"'
: 6/)----'1__
-5-
JD



Y650
CD Top cowling
Y630
@TittuPlock
Y-590
@nltPln
v-09O
@ Anti-cavitation plate
Y720
Tnmtab
X-500
Propeller
V-260
(J) Battery wire
V-08O
@Anode
-6-
i1iJIiWI
X960
Reverse lock
V-560
Choke knob
X-333
QJ) 011 level warning lamps
X 337
Q?l 011 tan k cap
COlO
Accessory Parts
Fuel tank
Remote control box
3
-7-
f,I'I''
Tachometer
Y-Sl0
CD Fuel tank cap
W 165
Fuelhne
..,nl"It.
X561
Power tilt sWitch
X 900
Remote control lever
-----
X-210
Neutral throttle lever
X-OlD
Main sWitch
V-577
(j) Choke sWitch
v 905
Emergency stop sWitch
-8-
D 110'
SPECIFICATIONS
Item
DIMENSIONS
----,----- J
Model
-Overall length
-Overall wIdth
-Overall height
-Boat transom height
-Weight
f------
mm (In )
mm (In )
mm (In )
mm (In )
kg lib I
1,114143 91
37811491
S 1,203147 311L 1,324152 11
S 381 115 011L 508 120 01
S 6751148 51/L 69 5 1152 91
PERFORMANCE
---- -
-MaXimum output kW (HP1/mln I (RPM) 294(401/5,500
-Idle speed r/mln 750 - 850
- - -- - -------- - --- --
ENGINE
- -----r
-Type
-Number of cylinders
- Bore and stroke
-Total pIston displacement
-Cooling system
-Ignition system
-Spark plug
-Spark plug gap
mm (In )
em
J
(eu In )
NGK
mm(ln}
-9-
Two stroke
3
67
x
66126X261
69814261
Water
CDI
B-lHS1O
09- 1 010035 - 0 0391
-----
I
adel
Unit YAMAHA40HM
====-
-=
ForwardNeutral-Reverse
1 85124/131
Regular gasoline
Yamaha outboard motor 011
100' 1
L IUSgall 2416.341
cm
J
(ec) (US azl 350 111.81
-Fuel
-Recommended 011
- Fueloll ratio
-Fuel tank capacity
-Gear 011 capacity
Item
M
-Gear shIfting
-Gear ratio
DRIVE UNIT
FUEL AND OIL
f--------- -,,----
f----------------
f------- -----
-10-
0250"
SPECIFICATIONS

Model
Item
-- - ---
DIMENSIONS
Unl' __ - - -l -----1
'--
n
---- -
4,500 - 5,500
36 81501/5,500
750 - 850
r/mln --
kWIHPl/m,n-' (RPMI 2941401/5,500
r/mm (RPM) 750 - 850
-- --- -- - - -- ---
.Overall length
.Overalt wIdth
.Overall height
.Boat transom heIght
Welght
PERFORMANCE
.Full throttle operatIng range
.Maxlmum output
.ldle speed
ENGINE
mm (In )
mm(ln)
mm (In)
mm(ln)
kg lib I
542 (25 31
35011381
S 1,1721461J/L 1,29315091
S 381 (15 OI/L 508 (20 01
S 685(15071/L 705115511
54212531
350113 81
S 1,172146111L 1,29315091
S 38111501/L 50812001
S 745 (163 911L 765 (168 31
Type
.Number of cyhnders
.Bore and stroke
.Total piston displacement
.Cooling system
.Igmtlon system
.Spark plug
Spark plug gap
mm (In)
cm
J
(cu In )
NGK
mm (In)
Two stroke
3
67x66(2 6x2 6)
698 (4261
Water
COl
B-7HSlO
o9 - 1 0 (0 035 - 0 0391
-11-
Two stroke
3
67
X
66(26
X
26l
698 (42 61
Water
COl
B-8HS10
09-1010035-00391
-Gear shiftIng
-Gear ratio
FUEL AND OIL
-Fuel
- Recommended 011
-Oil tank capacity
-Fuel tank capacity
-Gear 011 capacIty
LlUS gall
LIUS gall
cm
J
(US OZ)
Regular gasoline
Yamaha outboard motor 011
131141
2416341
35011181
-12-
Regular gasoline
Yamaha outboard motor 011
1 311 41
2416341
350 11181
D200
SPECIFICATIONS
Model
Item
DIMENSIONS
Unit
_L
YAMAHA 50DETO
-Overall length
-Overall width
-Overall heIght
- Boat transom height
-Weigh
mm(ln)
mm (In )
mm(ln)
mm (In )
k9 lib 1
64212531
350 113 81
S 1,172(461)/L 1,29315091
S 381115011L 50812001
S 7601167 211L 7801171 61
PERFORMANCE
-FuJI throttle operatIng range
-MaxImum output
-Idle speed
ENGINE
I
---- - i
r/mln (RPM)
kW (HP)/mln '(RPM)
r/mln
-- -- -- ----
4,500 - 5,500
3681501/5,500
750 - 850
-Type
-Number of cylinders
-Sore and stroke
-Total piston displacement
-Cooling system
-'gnltlon system
-Spark plug
-Spark plug gap
NGK
mm(ln)
-13-
Two stroke
3
67x6612 6x2 61
69814261
Water
COl
B-8HS10
09-1010035-00391
Item
DRIVE UNIT
-Gear shlftmg
-Gear ratio
FUEL AND DIL

Model
-J ----=r-- Forward-Neutral-Reverse
1 85124/131
-- ----- -- - ------------j
1-------
-Fuel
-Recommended all
-all tank capacIty
- Fuel tank capacity
-Gear all capacity
LiUS gall
LIUS gall
cm
3
(ccl (US ozl
-14-
Regular gasoline
Yamaha outboard motor 011
1 311 41
2416341
35011181
--15-
EQ1Q
OUTBOARD MOTOR IDENTIFICATION
Outboard motor serial number
The outboard motor senal number IS stamped on the plate
attached to the port SIde of the clamp bracket
Engine serial number
The engine senal number IS stamped on the port side of the
cylinder body
NOTE - ------- ----
Both outboard motor and engine senal numbers are Impor-
tant when you want to have service performed or place an
order for parts Please take note of the numbers
p8 ,

=-

-
c05
-16-
'-000
ENGINE MOUNTING
Never equip a boat with an outboard motor whose
power exceeds the maximum rating shown on the
capacity plate. Over-powering the boat may cause
severe instabihty. If the boat has no capacity
plate, consult your Yamaha dealer or the boat
manufacturer
Mounting position
The outboard motor must be mounted on the boat center
hne (keel hne), and the boat must be well balanced so that
the drafts are on the same level both on the starboard and
the port side Otherwise, the boat will be very hard to steer
For boats without keel or which are asymmetrical, consult
your Yamaha dealer
0- 25mm (0-1
F 100
Mounting height
To run your boat with maxImum efficiency, water resist-
ance to the boat hull and outboard motor must be minimiZ-
ed The mounting height of the outboard motor greatly af-
fects the water resistance If the mounting height IS high,
cavItatIon tends to occur, thus reduclllg propulsion by the
engine If the propeller tiPS are too high, they cut the air
and the engine speed rises abnormally, thus cauSing the
engine to overheat If the mounting height IS too low,
splash resistance wIll Increase and thereby reduce engine
effiCiency The engIne should be mounted so that the antl-
cavitatIon plate IS between the bottom of the boat and a
level 25mm (1") belowIt
'Mk'iV"
t1
M ---
~
mounting height varies dependmg on the p ~ r
pose of the boat and the outboard motor The pro-
per height should thus be determmed by making
test-runs
--- - -----"---- --- ---
-17-
,--------------------,
I ~
'-------- - -- --- -----------'
-18-
F-210
Clam5! 11'!:huII.J:lj
1) Place the outboard on the transom so that It IS posItIon-
ed as close to the centre as possIble Tighten the clamp
screws evenly and securely
21 Make four holes ,n the transom board so that the holes
align with the clamp bracket holes, and secure the
clamp bracket wIth bolts
W ; Y ~ M I ~
AVOId using bolts, nuts or washers other than con-
tamed In the engme packing. If used, they must be
of the same or superior in the quality of material
and strength and must be tightened securely
After tightening. test-run the engine and check
their tightness
F 220
Clamp @ml'"f1nlJ!.it.
Make four holes In the transom board so that the holes
align with the clamp bracket holes, and secure the clamp
bracket with bolts (accessories) For details, consult your
Yamaha dealer
fu',;'m'MW
Avoid using bolts, nuts or washers other than con-
tained m the engine packing If used, they must be
of the same or supenor in the quality of matenal
and strength and must be tightened securely
After tightenmg. the engme and check
their tightness
e
,
122mm(051 I-
327mm(129)
2508mm(99 )
508mm(2)
69 3mm(2 7"1
87 8mm (3 5")
106 3mm 14 2")
254mm 110)
309 5mm (12 2)
-19-
-20-
F-400
Remote control mounting 11,IUg'Uin",,,.in.1iit.
@"iJNW,
Incorrect selection or installation of a remote o ~
trol may result in sudden and unexpected loss of
control, thus resulting 10 a serious accident
Please consult your Yamaha dealer.
For Installation of the steering system, see your nearest
Yamaha dealer. It IS also advisable to ask your Yamaha
dealer to Install the remote control box and cables The
remote control In this manual IS deSigned for starboard side
steering wheels
F 410
Remote control box positioning
The remote control box should be set In a posItion In which
It does not obstruct the operations of the remote control
lever Make sure there IS no obstruction In the path of the
remote control cables
CD Remote control box
Remote control lever
Remote control cable
F 420
Checking the remote control cable
Position the remote control cables and check If they are
long enough Connect the cables to the engine and make
sure they do not get tangled or bent when the steering
wheel IS turned

the cables
cables do not form a loop With a diameter of less than
406mm (16m)
--- --- ---. ----- ----- ---- -----
-21-
2) Loosen the two screws, and remove the lower back
panel.
Back panel
3) ScrewIn the cable JOInts (accessories) about 11 mm (0 4
In) over the ends of the remote control cables, and
tighten the lock nuts Before Installing the cable JOints,
apply the water-resistance grease (Yamaha Grease A)
to the threaded holes In the cable JOints
Remote control cable
@ Locknut
CableJomt
CD Wire cover
F 435
Remote control cable installation (On the remote control
box side)
1) PInch the wire cover with your fingers and pull It out to
remove
- -------------,
1 -
-22-
------ ----- ----,
r------ ---
-23-
4) Insert the femote control cable outer for shifting Into the
housing clamp so that the groove on Its end frts over the
ridge In the clamp Fit the cable Jomt over the pin on the
end of the shift arm, and lock It with the crrchp
5) Fit the grommet (accessory) In the clamp groove
CD Grommet
Clamp groove
Circhp
@ Sh,ftarm
6) Connect the remote control cable for the throttle to the
throttle arm In the same manner
Remote control cable for throttle
Remote control cable for shift
(J) errel,p
7) Secure the lower back panel with the two screws, and '---'
Install the wire cover
8) After connecting the remote control cables, Install the
remote control box In the prevIously determined pOSI-
tion uSing the accessory fittings (screws, nuts, washers,
and spacer)
CD

/'
CD Remote control box
Screw
Spacer
@Washer
Nut
Hull

-24-
_ . ~ _ .
L _ ~ ~ _
F ..,
Installing the remote control cables (on the motor side) and
wire harness
1) Remove the top cowling
2) Remove the upper and lower fittIng plates and the
grommet
CD Wire harness
@ Remote control cable for shift
Remote control cable for throttle
3) Pass the wire harness through the grommet, and Install
the grommet. then Install the lower frttlng plate on It
4) Connect the remote control cable& to the lower fitting
plate When connecting, align the groove In the remote
control outer with the ndge on the lower fitting plate,
and fit them together
5) LikewIse, fit the upper fItting plate to the groove In the
remote control cable outer
-25-
---------
---------,

0'
\__.-..L

-------------'

__ ___1
F468
Cable JOint installation
Shift side
1) Place the remote control lever In neutral (N), and also
set the gear shIft lever In neutral (Nl
2) Screw In the cable JOint over the end of the remote con-
trol cable so that the cable JOint hole aligns with the
cable JOint set pm, and lock It with the lock nut

the
cable Joint a minimum of 8 mm (O 3 10) and lock it
with the locknut
-- -------- ------- ----- --- -------

1
the lock nut
-- - --- - -- -- - --- --- -- ---
CD Locknut
3l Lock the cable JOint with the half pm
-26-
F 478
Throttle side
1) Turn the remote control lever downward 32 to the For-
ward Side, and place the neutral throttle lever In a
holrzontal position
NOTE, ----- ----
A click can be heard when the lever IS turned 32 Don't
turn beyond thIs pOInt
2) Set the throttle control lever In the full-closed POSition
CD Throttle control lever
3) Screw rn the cable Jornt over the end of the remote con-
trol cable so that the cable JOint hole alrgns with the
cable jornt set pIn, and lock It with the lock nut
the
cable Joint a minimum of 8 mm (03 m) and lock It
with the lock nut
---- - -- -- --
I
To cable from
the lock nut
--- --- ---- ----- --
Lock nut
-27-
\
'-- -0
;--------------------.,
'-- ---J
4) Lock the cable JOint wIth the half pin
5) Couple the Wire harnesses with the arrow and tnangle
aligned and lock them with the wire harness lock
Wire harness lock
-28-

-29-
F 620 'ltI:'g"piU.'j''+i''tl'it'
Installing the steermg guide attachments
Hold one end of the steering lInk rod to the steering hook
with the bolt and nut, and hold the other end to the steering
cable with the nut and washers
NOTE
For details, consult your Yamaha dealer
CD Steering hook
@ Steering link rod
Steering cable
_'"';-d-,
may result
2 If the battery connectiOns are reversed, the rectifier
Will be damaged

When removing
follows
Removal
Installation
or Installing the battery, proceed as
Disconnect the negative terminal Side
(black lead) first
Connect the posItive terminal SIde
(red lead) first
F-nD
Battery mounting IUlII#"#iU.J#.rijli.Ji,
N'';Y'h'MI --'-- --- -
When installing or removing electrical parts, be
U
ure to di.sconnect the battery Wires from the
tery termmals
--------- - -- - -- - - - - - --- ----- -----.
The battery should be securely mounted In a dry, vlbratlon-
free location tn the boat The battery should be a 12V, 252
kC 170AHI
To wire the battery, connect the red lead to the POSitive ter-
minal of the battery and the black lead to the negative ter-
mInal
-30-
t'Z"iN"NtI -------.-----
The battery fluid (electrolyte) is corrosive. If it gets
In your eyes or on your skin, immediately wash the
area with water and see your doctor. If the fluid
spills on or around the engine, thoroughly wash it
away. When the battery IS being charged,
ploslve hydrogen gas is produced. The battery
should therefore be charged In a
area
CD Redlead
Blacklead
Battery
o 0

"50
Installing the meters
Install the meters on the dashboard If no dashboard IS
available, Install them In a place free from water splashes
For wIring, refer to the "WIRING" section
o
Vll---(3)

o
-31-
liiu.lij,.
F-865
Tachometer
This meter Indicates the engme speed
NOTE
Before Installing the tachometer, make sure the terminal
plate IS set on the SIde If It IS set on the 12-pole side,
the tachometer will not show correct measurement
CD Black
Green
@ Dashboard
G 110
FUEL AND LUBRICATION OIL IDI MIxing ratio
Gasohne 0,1
Fuel tank capacity 24ltters (6 34 US gall
Gasoline IS highly inflammable and explosive.
When mlxmg gasoline wIth oil Or when refuell-
ing. refrain from smoking and keep away from
open flames Or sparks
When refuelling. be sure to stop the engine
Also take care not to spill gasoline or ad
Be sure to wipe off any gasoline or oil spilt on
board immediately and thoroughly with dry
rags
Never fill the fuel tank to more than the speci-
fied level. Safe filling level IS 5 mm (0 2 inch)
below bottom of filler neck
After filling, tighten the tank filler cap securely.
The mixing of fuel must be done offboard In a
well-ventilated area
Fuel Regular gasoline
Lubncatlon all YAMAHA outboard motor all or an
eqUIvalent two stroke outboard motor 011
whIch meets the BIA rating TC-W
-32-
Br eak-In penod
After break-In
25
lOQ
Mixture
1) First pour 011 Into the fuel tank, and then gasolrne
2) MIx the fuel thoroughly by shakIng the fuel tank
- CAUTION: - -- ~
AvoId USing any 011 other than that designated
Always use newgasoline
Use a thoroughly blended fuel,oll mixture
If the mixture IS not thorou!!hly blended or the mix-
Ing ratio IS incorrect, the following problems WIll oc-
cu,
Low 011 ratiO Due to lack of 011, major engine trou-
ble such as seizure will result
High oll ratio Fouled spark plugs, smoky exhaust,
or heavy carbon deposIts will result
CD 0,1
@ Gasoline
-33-
----------
,---------
----- - --- -------------'
G 570' 1't1;'j_Sin.JiI"."'"
FUEL AND LUBRICATION OIL
PrecIsion blend system
This engine uses the PrecIsIon Blend System whIch pro-
vides superior lubrication by ensuring the proper ad ratio for
all operating conditions, so no fuel premixing IS necessary
Simply pour gasoline Into the fuel tank and 011 Into the 011
tank
Recommended gasoline
Regular gasoline
Fuel tank capacIty 24 liters (6 34 US gall
Recommended 011
YAMAHA outboard motor all
If YAMAHA outboard motor olliS not available, another 2-
stroke engine all WIth BIAcertlfled ~ W may be used
Olltankcapaclty 1 311ter5(1 4USqtl
-34-
-35-
Gasoline is highly mflammable and explosive
When refuelling, refrain from smokmg and
keep away from open flames or sparks
When refuelling, be sure to !ltop the engme
Also take care not to spill gasoline or oil
Be sure to wipe off any gasoline or 011 spilt on
board immediately and thoroughly with dry
rags
Never fill the fuel tank to more than the specIfi-
ed level Safe fllhng level IS 5 mm (02 lnchl
below bottom of fdler neck
After fillmg. tighten the tank filler cap securely
Pour the engme oil (never gasoline) Into the 011
tank
, . - - - ~ . _ - - - - -
o
----------
WIll start sounding If the engine keeps on operation under
such conditions, the engine may seize up Avoid keep the
engine running with the red lamp beIng turned on
G-620' Ilti:'#'fjOin,J#"f'tl,l!ii"
011 level warning system
This engine IS equipped with an 011 level warning system to
warn the operator of the necesSlty of oll refilling to prevent
engine seizure
When the all tank IS full of 011, the green 011 level warning
lamp IS on When the 011 tank level decreases to 500 cc (0 5
US qtl, the yellow 011 level warning lamp will come on So
add all to the all tank
If no spare Ollis available, proceed to the nearest port for 011
refilling When the engine keeps on operation wIth the
yerrow lamp being turned on and the all tank level lowers to
300 cc (04 US qtl, the engine speed decreases automati-
cally to about 2,000 rpm, and the red 011 level warning lamp
Will hght In addition, the buzzer In the femote control box
NOTE. - ~ - - - - - - ~ - - - - - - - - - - - ._-
When the engine speed has dropped, you must stop
the engine by turning off the main sWitch, and add
011 to the 011 tank, then start the engine If ollis add-
ed without turning off the main sWitch, the engine
speed Will not rise to more than 2,000 rpm After ad-
ding oil, turn on the main sWitch, and make sure the
red all warning lamp comes off before starting the
engine
To operate the 011 level warning system, be sure to
Install the all level warnIng lamps
When the engine temperature rises too high, the
engine speed Will decrease and the buzzer In the
remote control box Will sound, as In the all level war
nlng system However, the red lamp will not come
on
CD Red lead
Yellow lamp
Green lamp
-36-
~
~
~ .;J
0lJm
~ I
I
o
~ ~ ~ ~
[]
-37-

<;AUTION: ---
Do not start the engme out of water , I
Make sure that there IS suffiCient fuel tn the tank
Make sure that there are suffiCient fuel and 011 In
each tank Im#ljtt#t".J"p",.IW
The fuel tank should be placed on a flat area In the
bottom of the boat
Prior to operation, check to see that the necessary
servIce tools and spare parts are on the boat
The fuel line should be routed In &uch a way as to
prevent any kinks or sharp bends and to allow full
steerrng movement Do not allow fuel line to contact
sharp objects or to become prnched
------ -- -- -- ----
Bleeding the 011 injectIon pump lIIi#l#niiJ"#,,,,'n.I'it'
Before operating the engIne for the first time or after a long
time of disuse, be sure to bleed the olllnJectlon pump To
bleed, loosen the air bleedIng screw attached to the all In-
Jection pump, and the all will flow to the olllnJectlon pump
due to a head, thus expelling the air In the pump After
making sure that the 011 starts overflOWing through the
screw hole, tighten the screw completely
CAUTION: -------------,
r;e sure to bleed the olllnJeetlon pump, otherwIse, It wIll
Impossible to supply oil, thus damaging the engine
-----------'
-38-
1) Firmly connect fuel hose connector 2 (positioned on the
tank mark sIde) to the fuel tank
When inserting the fuel JOint into the fuel tank.
vaporized gasoline will squirt out of the air bleed-
ing hole. Gasoline IS highly Inflammable and ex-
plosive under certain conditions Refrain from
smoking and keep away from open flames or
sparks when mserting the fuel joint
CD Fuel hose connector 2
2) Firmly connect fuel hose connector 2 to fuel hose con-
nector 1on the motor
Fuel hose connector 1
-39-
3) Squeeze the prtmer bulb until firm pressure IS felt
IDI
4-1) Place the shift handle In neutral (Nl
CAUTION: ---------J
The engme may only be started when the shift handle IS
In the "N" positIon
~ ------
4-2) Place the throttle gnp m the START posItIon (The
throttle openlng must be adjusted slightly according
to the engine temperature)
-40-
4-1) Place the remote control lever on the remote control
box In neutral (N)
CAUTION: ---
If the remote control lever IS not
motor cannot be turned
In "N," the
-41-
4-2) Turn the neutral throttle lever on the remote control
box upward (It IS necessary to change the throttle
opening slightly depending on the engine tempera-
ture )
START
,
,
,
,
IUI#lg"in,luijli.I,.,'
-42-
5l Install the lock plate fIrmly onto the emergency stop
sWitch
Tie the rope attached to the lock plate to your Wrist
CD Lock plate
NOTE -------- ---------------
The emergency stop sWitch IS provided for the safety of the
operator When the lock plate IS pulled out from the
emergency stop sWitch, the engine stops Immediately The
engine will not start when the lock plate IS removed
Should the operator fall off the boat or lean too far over one
sIde, the lock plate will pull out causmg the engine to stop
IIiDID
6) Pull the choke knob out completely
1"';'i
u
+1.
I

I
#"#".I,.,'
6) Turn the main sWitch to "ON," and turn the choke
sWitch lever upward (The remote choke sWitch lever
returns to ItS home position when It IS released There-
fore, keep the lever pressed upward.l
NOTE -----------------------
If the engine IS still warm do not use the choke
-43-
H 110
Cranking the engme
Il!DIiD
1) When the engIne IS ready for starting, slowly pull the
starter handle
2) When engagement of the mechanism IS felt, finish the ~ - . . , -
stroke with a strong pull and the engine wrll start
3) After the engine has started, allow the starter handle to
return slowly to ItS home positron without letting go
4) If the choke knob has been pulled OUl, return It slowly to
ItS home positIon so that the engine does not stop
NOTE
Should the engine fall to start on the first pull, repeat the
above procedure several times In the event that the engine
wrll not start, refer to the sectIon on TROUBLESHOOTING
\
-44-
,In#l:''tk'''.'ijttJ:j'',Ji'
1) Set the main sWitch to "START" and the starting motor
will turn
2) After making sure the engme has started, release the
main sWitch and remote choke lever
3) Slowly return the neutral throttle lever to Its home pOSI-
tion so that the engine does not stop
CAUTION: --------------
Never turn the main sWitch to the "STAAT" pOSI-
tion while the engme IS runnIng
2 Do not keep the starting motor turning for more
than five seconds with the main sWitch In
"START," If the engme will not start after five
seconds return the main sWitch to "ON" and crank
the engine again after waiting 10 seconds.
If the starting motor 15 turned continuously for more
than fIVe seconds, the battery will qUickly run dead
making .t Impossible to start the engme
r ~ _ _ _ _ _
tlll:'g"h"''#fijn,'ii,'
-45-
Emergency starting In startmg system trouble
If It IS Impossible to start the engine due to a dIscharged
battery or starting system trouble, the engme can be
started uSing the emergency starter rope
- tU";'#"N. ~
When the engine IS started with an emergency
rope, the start-In-gear protection system will not
work Be sure to check that the gear IS In Neutral
Otherwise the boat may lurch ahead or astern,
causmg seriOus damage or personal injury
1) Remove the top cowling by depressing the latch at the
rear of the cowling Lift up and back to remove
Il!miD
2) Remove the starter by removing the 3 bolts secunng
the rewind mechanism to the flywheel
,UJI!*,'pn,jje!#m,)i
2-1} Remove the flywheel cover by removIng the 3 bolts
22) Turn mam sWitch to "ON"
NOTE ----- - - ----
Without setting the main sWitch at "ON," It IS ImpossIble to
start the engine
6 ~
3) Wind emergency starter rope one or two turns around
flywheel rotor, then pull the starter rope to start
engine and, If reqUired, pull out choke knob to choke
manually
4) To release choke, push In choke knob
't""i'NNd
When starting or operating the engine, never
touch the Ignition coil. hightenslon wire, spark
plug cap or any other electrical parts to which high
voltage IS applied
When pulling the emergency starter rope, be sure
to keep loose clothing and other objects away
from the engme.
A rotating flywheel IS very dangerous Never a t ~
tempt to install the top cowling on the engme
when it is in operation
Proceed to the nearest port to get the starting
system repaired as quickly as possible Take care
that no water splashes onto the flywheel.
Iln#l#'*+i"I)#'W!"I)iie'
H 320
Engine warm-up
Before beglnnrng operation, the engine should be warmed
up at Idle speed for three minutes Failure to do so will
shorten the life of the engine
CAUTION' -- - - -
I
Make sure that water runs out from the cooling water J
pilot hole
- ------- - --- -- --
Overheat warning system
EliDIiD
ThIs engine has an overheat warning device Before the
engine becomes too hot, the engine speed will automatical-
ly reduce to a safe rpm and the overheat warning lamp on
the bottom cowling Will flash
Im:'ij'W'''I)j''fi,ll)i'''
Check that water runs out of the pilot hole If not, stop the
engine and check the water Inlet for clogging If clogged, It
should be cleaned, and If not clogged, operate to your
nearest port at low speed and consult a Yamaha dealer
Never run the engIne at high speed, otherWise, engine
seizure could occur, resulting In Irreparable damage
-47-

J

SLOW
,;:"
,<".
-.
"
--- --
3
I'',V

.,.START
W'UOW
I,",', I
H-430
Break-In EI!IIID
A penod of break-In IS required to allowthe matIng surfaces
of all moving parts to wear evenly when new This pro-
cedure will ensure proper performance and greater durabili-
ty
1) Break-In time
10 hours
2) MIxing ratio
Gasoline all 25 1
3) Procedure
a Run the engIne at trolling speeds (The lowest pOSSI-
ble speed) for the first 10 minutes.
b With an easy planing boat, bring It into the planmg
posItion; then, Immediately reduce the throttle to
approxImately 3,000 rpm (one-half throttle), con
tinue running at this throttle setting for 50 minutes
c Bring the boat Into the plamng state and reduce
throttle to 4,000 rpm or three-quarter throttle (ap-
proxImate) while maintaining planing. Continue run-
ning at this throttle setting for one (1 I hour
NOTE'
Run at full throttle for approximately one (11 out of every 10
minutes
d For the next eight (8) hours, avoid continuous full
throttle operation for more than fIve {51 minutes
e After the first 10 hours, return to 100 1 ratio

CAUTION: --------------:J
Failure to follow the break-In operation procedure may
result In severe engIne damage.
-48- --.---- --------------.---------
, }
-49-
H 420
Break-In '"I#I#''tin."nijl'I'''''
A penod of break-In IS required to allow the mating surfaces
of all moving parts to wear evenly when new This pro-
cedure will ensure maximum performance and engine life
1} Break-In time
10 hours
2) MIxIng ratio
Gasoline 0,1 50 1
3} Procedure
a Run the engine at trolling speeds (The lowest pOSSI-
ble speed) for the fIrst 10 mInutes
b With an easy plamng boat, bnng It Into the planing
posltlon, then, Immediately reduce the throttle to
approximately 3,000 rpm fone-half throttle), con-
tinue running at this throttle setting for 50 mrnutes
C Bring the boat Into the planing state and reduce
throttle to 4,000 rpm or three-quarter throttle (ap-
proximate) while maintaining planing Continue fun-
ning at th,s throttle setting for onE' (1) hour
NOTE
Run at full throttle for approximately one (1) out of every 10
minutes
d For the next eight (8) hours. avoid continuous full
throttle operation for more than five (5) minutes
e Afterthe first 10 hours, use straIght gasoline for nor-
mal operation of the precIsion blend system
CAUTION:
Failure to follow the break-In operatIon procedure may
result In severe engine damage
~ ~ ~
H-515
Gear Selection (Forward and Reversel
,O'*'''N. -
I
Should the engme hit an underwater obstacle, be I
sure to check the gear case and brackets for dam-
age
-------- .. ~ . _ -- ------_.-_.------ ----- ----
IlimI
A Forward (Fl
Turn the shift handle to "F" qUickly and firmly
B Reverse (Rl
1) Lock the reverse lock
-,.'iJN'N'- ~ ~ -- -- --
When operating in REVERSE, be sure to set the
reverse lock to LOCK and keep the throttle at
1/2 or less If this IS not done. the reverse lock
mechanism will not prevent the engme from lif-
ting out of the water and loss of control may oc-
cur. possibly causing injury to the passengers
2) Turn the shift handle to II R" qUickly and fIrmly
~ ~ CAUTION' - ~ - ~ ~ - ~ ~ -
To change the boat direction from forward to reverse or
vice versa, close the throttle first so that the engme Idles
lor runs at low speeds)
- ~ CAUTION' ~ - ~ ~ ~ ~ ~ ~ ~ ~ ~
For additional safety, the throttle IS deSigned not to
open more than 1/2 when the motor IS In NEUTRAL
Never attempt to force the throttle open more than 1/2
-50-
...--
F

PmtJi
l
"
A Forward (F)
Turn the remote control lever to "F "
B Reverse (R)
1) Lock the reverse lock 'U1Ud,WiIIIJm
-
When operating In REVERSE, be sure to set the
reverse lock to LOCK and keep the throttle at
1/2 or less If this IS not done, reverse lock
mechanism will not prevent the engine from IIf-
tlOg out of the water and loss of control may oc-
cur, possibly causing injury to the passengers
2) Turn the remote control lever to "A "
throttle 1$ designed
open more than 1/2 when operating In REVERSE
Never attempt to force the throttle to more than 1/2
--- -- -------
'-------- ----_----------'--'-------"
-51-
'-----------
-52-
H755
Shallow water cruising II!1IIiI
N"i'N'NtI
In shallows, run the boat at trolling speed or there-
abouts. The reverse lock will not operate and may
thus cause the engine to 11ft out of the water and
the boat to lose control when the lower casing hits
an underwater obstacle. Personal injury may ra
suit when the engine is operating in reverse, as it
can easily be lifted by the force of reverse thrust
To crUIse In shallows, proceed as follows
1) Place the shift handle In neutral.
2) Push the reverse lock down to release
3) Slightly tilt up the engine and pull the shallow water
lever toward you
4) When bTlnglng the engme from the shallow water pOSI-
tIon back to the home pOSition, tilt It up a httle, push the
shallow water lever downward. and tilt the engine down
slowly
--------- -
CD
H 618
Stopping the engine
II!ImiI
1-1) Turn the throttle gnp to the fully closed
1-2) Place the shlf handle In neutral
2) To stop the engine, push the emergency stop sWitch
button
t1t!:I#,@n'#'binnji.,
1} Place the remote control lever In neutral
2) Turn the main SWitch to OFF and the engIne will stop
Pull out the lock plate from the emergency stop sWitch
and the engine will stop
(1) Lock plate

It IS impossible to stop the engine by disconnec-
ting the wire harness Furthermore, when the wire
harness IS disconnected, the enuine cannot be
stopped by turnmg off the main sWitch or by
Ing out the emergency stop switch lock plate. Be
sure to keep the wire harness connected dUring
operation
3) After stopping the engine, remove the fuel hose
- CAUTION: 1
Before stopping the engine, reduce the engine tempera- '-/
ture by running It at Idle or low speeds for 2 or 3
minutes
L-
-53-
H900
Operation in turbid water
It IS strongly recommended that the optional chrome-plated
water pump kit be Installed If the outboard IS to be used In
turbId water conditions
H 910
Operation in salt water
After operating In salt water, wash out the cooling water
passage with fresh water Otherwise, the cooling water
passage may clog up wIth salt collections For washing,
refer to "Cleaning the water Intake passages" In the "OFF-
SEASON STORAGE" section
-54-
H-710
ADJUSTMENTS
adjustment II!Jliltn,m",.,
The tension of the steenng fnctlon can be adjusted by turn-
Ing the adjusting bolt attached to the sWivel bracket
To Increase tension
Turn the adjusting bolt clockwise
To decrease tenSion
Turn the adjusting bolt counterclockwise
H730
Adjustment of throttle twist gnp II!DmI
-55-
The throttle tWiSt grip has an adjustable fnctlon device The
fnctlon device IS located In the steering handle, and fnctlon
can be adjusted by tightening or loosening the fnctlon bolt
To Increase tension
Turn the fnctlon bolt clockWise
To decrease tension
Turn the fnctlon bolt counterclockwise
, /
CD
H 737 ,'el;II'PMt'!'E"'."'"
Adjusting the stiffness of the remote control lever
By turning In or out the throttle friction screw at the front of
the remote control box, the stIffness of the control lever
can be adjusted Turning the screw to the right makes the
control lever stIff to turn, and turning It to the left makes
the lever light
CD Makehght
Make stiff
F-330
Trim angle adjustment
To maintain steeTing stabilIty and good performance,
always maintain correct trim angle. The appropriate trim
angle vanes depending on the combination of the boat, en-
gIne, and propeller, as well as operating condItIon. but It IS
safe to say that when the tnm IS 3 to 5 by stern, the boat
IS In a stable tnm
If the tnm angle IS too large, the buoyancy center of the
boat Will shift toward the stern If this happens and the
stability moment at the bow IS great, the boat Will tend to
"porpoise," possibly causing the operator and passengers
to be thrown overboard If the tnm angle IS too small, the
bowWIll "plow," thus making the boat unstable
-56-
~
To adjust the trim angle, remove the tilt pin from the stern
bracket assembly and, whIle tIlting the motor, repositIon
the pin In the desIred hole
IW'iN"N. ---- -- - - - -
When mounting the outboard motOr on a boat, be J
sure to make a test-run and set the proper trim
angle
---- - ---
CD Tilt pIn
NOTE -----
To lower the bow, move pin towards the mountrng
plate To raise the bow, move pm towards the
engine
When operating against a strong wind, It IS ad-
vIsable to make the trim angle slightly smaller than
the standard for steering stability If the wind IS
favorable, the trim angle should be Increased for
better steenng stability
'M"''''
- CAUTION: --------- - --------
r
Never attempt to adjust the trim angle uSing the power
tilt sWitch dunng operation, or power tilt assembly trou-
ble could occur
----- --- - - - -
- 57-
H-8OO
Trim tab adjustmen_t
The tnm tab should be adjusted so that the steering handle
can be turned to either the nght or left by applying the Same
amount of force
An improperly adjusted trim tab will cause loss of
control. Test run to determine proper adjustment.
CD Trim tab
Trim tab screw
A When the boat tends to veer to port.
Turn the rear end of tnm tab to the left (port side)
"AN In the figure
B When the boat tends to veer to starboard
Turn the rear end of tnm tab to the nght (starboard side)
"B" In the figure
CAUTION: ,
The trim tab also serves as an anode to protect the
engine from electrochemical corrosion Never pamt the
trim tab as It will become ineffective as an anode
-58-
-59-
H850
Idle speed adjustment
1) Start the engIne, and warm It up for a few minutes
2) Set the Idle speed to the specifIed by adJustmg the
throttle stop screw (see "SPECIFICATIONS" prece-
dmg) '--'
To increase the Idle speed
Turn the throttle stop screw clockwise
To decrease the Idle speed
Turn the throttle stop screw cour1terclockwlse
" Throttle stop screw
40HM/40HEO/50DEO
'!n#lMI'n:""
---------
1015
TILT UP AND MOORING
If the engme will be stopped for some time, or If the boat IS
moored In shallows, the engine should be tilted up This
protects the propeller and lower casmg from damage by
rocks or any other underwater obstacle when the tide IS eb-
bIng, and from fast corrosIon by salt water
[r"""----------
When transporting the engine or keeping It tilted
up for more than a few minutes, be sure to discon
neet the fuel line hnking the engine to the fuel
tank Otherwise, fuel may leak out.
-------. - -
----,CAUTlON: - ----- --------- -------
1 Do not tilt up the engine by pushing the steering I
handle, you may breakl! off EDIIID
2 Make sure the power unIt IS kept hIgher than the
propeller at all times Otherwise, water may run Into
the engine and damage It
------ ---- -
Tilt up
1) Remove the fuel JOint from the engine
2) Release the reverse lock
3) Fully tilt up the engine, and lock It with the tilt up lock

-----
When the engIne IS not used for a long period of time,
the battery wires (pOSitIve and negative) should be
disconnected from the battery
------ -- -- ---
-60-
1055
TILT UP AND MOORING 1!m!I'im
If the engine will be stopped for some time, or If the boat 1$
moored In shallows, the engme should be tilted up This
protects the propeller and lower casing from damage by
rocks or any other underwater obstacle when the tide 1$ eb-
bing, and from fast corrosion by salt water
IW"dNN@I ---- ---
When transporting the engine or keeping It tilted
up for more than a few minutes, be sure to discon-
nect the fuel line linkmg the engme to the fuel
tank Otherwise. fuel may leak out
----- --- --- -------- ------- ---
l- -' -- CAUTION:
Make sure the power unit IS kept higher than the pro-
peller at all times Otherwise, water may run Into the
engine and damage It
Tilt-up
1) Push the upper portion of the power tilt sWitch on the
remote control lever until the power tilt motor nOise
changes And the engine trlts up completely
2) Turn the tilt up lock toward you and support the engIne
[
the engine, be to It
tilt up lock so that the engine will not ttlt down suddenly "-/
due to lack of orl pressure
---- ----- ------ -- --- ------ --

-62-
3) When tilting down the engine, release the tilt up lock,
and keep pushIng the lower portion of the power tilt
sWitch to tilt down the engine completely.
Manual operation
If It IS Impossible to tilt the engine up and down due to a
discharged battery or power tilt trouble, tighten the manu'al
valve screw counterclockwise until It stops
The engine can now be tilted up and down To lock the
engine In that posItion, turn the manual valve screw l o ~
wIse until It stops
CAUTION: -J
When the engine IS not used for a long penod of time,
the battery wires (pOSitive and negative) should be
disconnected from the battery
J-06O
PERIODIC MAINTENANCE
In the following check-up list, the mark le) Indicates the check-ups which may be done by yourself
The mark (O) Indicates work to be earned out by your Yamaha dealer
Grease
Check POint
Outboard motor body
Retighten bolts and nuts
-------
Time Interval
10 hours 50 hours lOa hours
Every 100 Off season
hours or (after the Procedure
0' 0' 0'
every 6 boating
, month 3 months 6 months
months season)
0 0 0 0 0
----------

Cleaning of filter
-----.
----

Checking for fuel leakage
-------- ---_.

Cleaning of tank Intenor
---

Cleaning of strainer
-----

Spark plug gap
09-10mrn(0035-0039'')
. ------
---
0 0 0 0
------- ----_.. --------
0 0 0 0 0 Check speCifiC gravity
_._-----
------
_.-

Checkmg for damage to blades
Replacement

Replacement
Checking for water leaks

---- .
---- -----

Checking for wear
----_. ----- ------
0 0 0 0
------ ------.-

Check for ddmage to extenor
------ ------ ---_..
==."r

Greasing
----_.. ._-_.
Gearoll
Spark plug
Fuel hose
Fuel tank
Trim tab (Zinc)
Ignition timing
Battery
Propeller
Fuel tank strainer
Carburetor settmg
Fuel filter
Lower Unit
Fuel system
Electric
system
NOTE. The time rntervals specIfied In thiS chart are based on general use and may vary depending on operatrng condItions
-63-
J 265
o Fuel system
Gasoline is highly inflammable and explosive
Handle it with speCial care.
Fuel line
Check the fuel line for leaks, cracks, foults. If any pro
blem IS found, do the necessary repalTlng or replacIng If
no cause can be found, ask your nearest Yamaha
dealer,
Checking points
1 Carburetor(s) leakage
2 Fuel pump fault or leakage
3. Fuel tank leakage.
4 Fuel hose JOlnt(s) leakage
5 Fuel hose(s) crack or any damage
6 Fuel filter leakage
7. Fuel connector(s) fault
8 Primer bulb fault or crack
-64-
r---- ----------,----,
-65-
J 275
Cleanmg the and
Fuel tank
Add a small quantity of SUItable cleaning solvent to the
fuel tank and thoroughly clean the tank Intenor by shak-
Ing the tank After cleaning, dram off the cleaning sol-
vent completely
Fuel tan k straIner
Thoroughly clean the strainer on the end of the suction
pipe with SUitable cleaning solvent
J 255
Cleaning the
Remove the filter cup, remove the filter and wash It In
sUItable cleanIng solvent
NOTE --
Be careful not to lose the O-ring Without the O-ring,
fuel leakage may occur
tU"i'NN'w-------- - ------ - - ---- -
When cleaning the fuel filter be sure to stop the
J
engme Also refrain from smokmg and keep away
from open flames or sparks
----- ------ ----- - ---- --- - -
IUI:@tli
ltl
:'8"
.'"''8'''''''''''
09-10mm
NGK B-7HS10
NGK B-8HSlO
J-305*
o Electrical system
U
While starting or operating the engine, never
touch the Ignition coil, wire, spark
plug cap. or any other electrical parts to which
high voltage is applied.
plug inspection
The spark plug IS an Important engine component and IS
easy to Inspect The condition of the spark plug can In-
dIcate somethIng of the COndItion of the englOe.
For example, If the center electrode porcelalO IS very
white, this could Indicate an Intake tract aIr leak or car-
buretlon problem for that cylinder
Do not attempt to diagnose any problems yourself In-
stead, take the outboard motor to a Yamaha dealer
You should penodlcally remove and Inspect the spark
plug because heat and deposits WIll cause the spark
plug to slowly break down and erode If electrode ero-
sIon becomes exceSSive, Or If carbon and other deposits
are exceSSive, you should replace the spark plug with a
proper type plug
40HM/40HEO
-66-
Standard spark plug'
'MJ#,n.1n.'#jI.,
NGK B-7HS10
NGK B-8HS10
Before installing the spark plug, measure the electrode
gap with a wire thickness gauge, adjust the gap to
specIfication as necessary
0 J
When Instalhng the plug, always clean the gasket sur-
face and use a new gasket Wipe off any grime from the
threads, and torque the spark plug properly
Ibl -]
NOTE' -- ------
If a torque wrench IS not available when you are installing a
spark plug, a good estimate of the correct torque IS 1/4 to
1/2 turns past finger tIght Have the spark plug torqued to
the correct value as soon as possIble with a torque wrench
tn'iV"NtI ---- ----- --
[:hen mstalling or removing a spark plug, be
careful not to damage the Insulator
---- --- ---
J 347
I
CAUTION: -- --- --------- ---
When Installing the spark plug, make sure the terminal
IS not loose If loose, be sure to tIghten completely
before installing the plug It IS adVIsable to use a spark
plug Integrated With the terminal
--- - --- ---- - - --- -----
J-380 tiU!:'#"AUlt'#,Uint'iie.
Battery maintenance and replenishing
A poorly maintained battery WIll deteriorate qUIckly The
battery flUid should be checked at least once amonth
1 The level should be between the upper and lower
level marks Use only distilled water If refilling IS '--"
necessary

whlC; are I
to a therefore, refll! __
2 Always make sure the battery IS charged suffiCIent-
ly It IS adVisable to Install a voltmeter for better bat-
tery maIntenance
J-360
stop
Keep the emergency stop sWitch In !)ood working order
Before starting the engine check the sWitch If faulty,
have It repaIred by your nearest Yamaha dealer
-67-
-J'----t2
J 810
o Lower Unit
Changing the gear 011
Place an empty all can under the lower casing and
remove the lower 011 drain plug uSing a slotted*head
screwdnver Next, remove the upper 011 level plug With
the outboard In an upnght posItion, uSing a flexible or
pressunzed fIlling device, Inject outboard motor hypOid
gear all SAE 90 Into the lower all drain plug hole When
the 011 begins to flow out of the upper 011 level plug hole,
Insert and tighten the plug Next, screw In the lower 011
drain plug
CAUTION: -----
Replace the gear all after the first 10 hours of opera-
tion and check the 011 every 100 hours thereafter
If the gear oil becomes "milky," consult a Yamaha
dealer.
~
NOTE: -----------------------
This engine has an advantage of gear all being replace
even In a tdtup state
CD 011 level plug
@ 011 drain plug
J 860
Trim tab (Zinc)
The lower unIt IS protected from corroSion WIth a tram
tab {Zinc) Installed
If the trim tab IS worn more than 2/3, replace It
-68-
J Greasing points
Iln:hU"":'j,1

: "'-11 ,
I
141.1.'#,*,,,.,,.,,
o
YAMAHA Grease A
-69-
YAMAHA Grease 0
J450
o Coating of the bottom of a boat
AVOId coating the boat bottom with anti-fouling paint
containing copper Such anti-fouling paint will corrode
the engine faster
J 500
o Replacement parts
Whenever the replacement of parts IS necessary, be
sure to use genuine Yamaha parts or eqUIvalents of the
same type and of equal strength and matenal Any 10-
fenor quality part can malfunction and the resulting loss
of control may endanger the operator and passengers
K-04O
OFF-SEASON STORAGE
When storing your engine for a long period of time (for ex-
ample, after the boating season IS over), we recommend
you have your engine checked by a Yamaha dealer
The follOWing check-ups and service you may perform
yourself
o Cooling system
Wash the cooling water passages With fresh water
o Fuel system
a Idle the engine until the carburetor IS drained off
b Wash the fuel filter In sUItable cleaning solvent
Refer to "Cleaning the fuel filter" In the "PERIODIC
MAINTENANCE" section
c Wash the fuel tank Intenor and strainer with sUItable
cleaning solvent
Refer to "Cleaning the fuel tank and strainer" In the
"PERIODIC MAINTENANCE" section
o Lubncatlon system
a Replace the gear 011
Refer to "Changmg the gear all" m the "PERIODIC
MAINTENANCE" section
b Add 5 to 10 cm
J
of outboard motor 011 through the
spark plug holes In the cylinders
c Apply grease to the specified places.
Refer to "Greasing POints" In the "PERIODIC
MAINTENANCE" section
o Electrical system In!#l#.f&ju.J#"#"'.Jiit'
Store the battery In a cool, dark place.
CAVnON;
For long penods of storage, the outboard motor should
be placed on a stand or with Its front faCing downward
AVOId direct sunlight and humidity
-70-
-71-
K 055 IUI#lj,@".'j"IM.','.'
Operation after a long time storage
When operating the engine after a long time (about 12
months) storage, proceed as follows
1) Use a 50 1gasOII mIxture to start the engine
2) Keep the engine running Idle '-.-"
3) Disconnect the 011 feed pipe connected to the top Intake
manifold on the port SIde
4) After making sure 011 runs out of the 011 feed pipe, con-
nect the pipe to Its onglnal POSition, and operate the
engine uSing the PrecIsion Blend System If no 011 flows
out of the 011 feed pipe after more than 10 minutes, con-
sult a Yamaha dealer
K-ll0
o Cleaning the water intake passages
a Install the outboard motor on the water tank and
add water up to above the anti-cavitatIon plate.
Next, shift rnto NEUTRAL, start the engine and run
at lowspeed for a few minutes

When the fresh water level IS below the anti-cavita-
tion plate or when water supply IS insuffiCient, en-
gine seizure may occur
11------,l-----l--iICD

v
CD Water surface
Lowest water level
L- .1 ...J
CD

@"iV"NM J
us.ng the water check plug, be sure to re-
move the propeller for safety
CD Water check plug
b. Remove the screw located beside the "WASH"
mark on the lower casing, Install the water check
plug (accessory), and connect It to a water faucet
Next, shift Into NEUTRAL, start the engine while
supplying water, then run at low speed for a few
minutes,

the engine even momentarily without

runmng cooling water. Either the water pump will
become damaged or the engme will overheat Before
startmg the engine, be sure to Install the water check
plug and feed water
=
=
=
-72-
K 410
o Storage of the battery IUllIg.W1".'getf1".';it.
1 When the outboard motor will not be used for month or
longer, remove the battery and store It In a cool, dark
place Completely recharge the battery before reusing
,t
2 If the battery Wilt be stored for a longer penod than the
above, check the specific gravity of the flUId at least
once a manth and recharge the battery when It IS too
low
NOTE
Follow the manufacturer's Instructions for battery details
-73-
L 110
PROPELLER SELECTION
The propeller IS one of the most cntlcal elements In the per-
formance of an outboard Selection of an Incorrect pro-
peller can adversely affect the performance, and It could
seriously damage the motor
A Yamaha outboard IS eqUIpped wIth a propeller that has
been selected to perform well In a variety of applications
There may be uses, however, where a propeller with a dif-
ferent diameter or pItch would work better For greater load
of operatron, a smaller-pitch propeller IS sUited because It
can maintain proper engine rpm LikeWise, a large-pitch
propeller IS sUited for smaller load of operation The engine
speed changes greatly depending on the propeller Size and
boat load If the engine speed IS extremely low or high, It
Will adversely affect the engine For thIS reason Yamaha
dealers stock a variety of propellers and can Install a SUIt-
able propeller on your outboard Consult your dealer when
selectIng a proper propeller for your particular application
1tiZ.'i'NlNtI -------- -
When removing or installing the propeller. shift in-
to NEUTRAL and remove the spark plug caps
Otherwise. the engme may start suddenly result-
Ing In a serious injury or aCCident It is a good prac-
tice to msert a piece of wood between the anti-
cavitation plate and the propeller to Jock the pro-
peller This protects your hands from the propeller
blades
-74-
M-020
SUBMERGED MOTOR
An accidentally submerged motor must be completely
overhauled as soon as possible If not, rust and corrosion
will develop. If your engine should be accidentally sub
merged, the following steps should be taken as emergency
measures
1) Bnng the engine up out of the water as qUickly as pOSSI"
ble
21 Wash It with fresh water All salt, mud and seaweed
should be completely removed.
3) Remove the spark plugs and drain the water from the
cylinders through the spark plug holes Also drain the
carburetors and fuel hnes
4) Pour engine 011 Into the motor through the spark plug
holes and carburetors while turnmg the engine over
repeatedly by operating the starter, so that 011 spreads
out over the surfaces of engme Inner parts
5) Have the engine overhauled by your Yamaha dealer as
soon as possIble
N 065
TROUBLESHOOTING
Problem Situations with your outboard motor can In most cases be prevented by ensuring proper, scheduled maintenance
Many problems result from careless handling and abuse The situations hsted and their possible causes dre Intended to assist
the operator In IdentifyIng and rectifyIng such problems Should you continue to experience any diffIculties after following
these procedures. please contact your Yamaha dealer
A The engine will not start
B The engIne runs Irregularly or stalls
C The engIne Idles roughly
D The engine runs too fast
E The engine runs too slow
F The boat speed IS too low
-75-
Spark plug ts fouled or defective
SpeCified olliS not used
o Cavitation takes place
Spark plug IS Incorrect In heat range
-- ---------'---- -- - ------
Possible Cause
Fuel hoses are connected Incorrectly
Fuel tank IS empty
Fuel hose IS flattened or kmked
F
o Propeller IS damaged
o Tnm angle IS Incorrect
Fuel filter IS clogged
--
all tank IS empty IIU#lj,@",'#.Will.I'it.
- -- - -- ------" - -------
B C 0 E
-----
0
0
0 0 0
0 0 0
0 0
0 0 0
0 0 0
0 0 0
0
0
0
o
A
o
o
o
o Loads on boat are Improperly distributed
o Transom 1$ too low
o
o o
o
o
Transom IS too hIgh
Propeller IS Incorrect In pitch Or diameter
o
o
o
o
o
Starter motor IS faulty Iln:'jtf'M,I'tfti"t'i'"
Solenoid IS faulty 1I,1:.#tfPUi,'t@u"ji,.
WIring or wire connections are faulty
SWitch IS faulty 1"':'lubin.II_Wi"elilt'
--- - -- -
Battery 1$ undercharged 'Itll'#"fint'"fi"t"ie'
-76-
0-000
WIRING
@
----0
(1) [-rr- , T
Gy Gray
'"1 "".,e!J'tll I" :I:"
- l=> .. w. ' - -6
'<W -.. WWM.
Y Yellow
a C?; <W____ _ _/
.J[J =_ := _
-77-
Y525
CD Thermo sWitch
W-505
IgnitIon cOil
X 660
Pulser COIl
V 535
@) Charge cOli
-78-
W82Q
LIghting cOil
V515
CDI unot
X41Q
(j) Overheat warning lamp
V-905
Emergency stop SWitch
----- -
Y-525 V 575 V-570
CD Thermo SWitch Choke solenoid @ Choke sWitch
W-505 Y-315 V-905
IgnitIon cOil Starting motor @ Emergency stop sWitch
X800 V-685 Y-500
Rectifier QD Control unIt (j]) Tachometer
W-235* X-333 V-235
@) Fuse (lOA) @ 011 level warning lamps Batte,y
X-660 X-334 Y-305
Pulser cOil @ 011 level sensor @ Starter relay
V-535 x 010
Charge COil @ MaIn sWitch
w""
v 395
(J) lighting COli @ Buzzer
v 515 X 205
@CDlumt @ Neutral SWitch
-80-
Y525
CD Thermo sWitch
w-505
1) Ignition cOil
~
X-800
Rectifier
W235"
@ Fuse (10A)
X-680
Pulser cOil
V 535
Charge COli
wW!
(j) Lighting cOil
V-515
CDlu""
V 575
Choke solenoid
Y-315
(j]l Starting motor
V 685
(jJ) Control umt
X-333
@ 011 level warnmg lamps
X 334
@ 011 level sensor
X-568
(j] Power tilt sWitch
X-OlD
@ MaIn SWitch
V 395
@ Buzzer
-82-
X-205
(jJ) Neutral sWitch
V-578
@ Choke sWitch
v-oo;
@ Emergency stop SWitch
Y500
@ Tachometer
X-562
@ Power tilt motor
V 235
@ Battery
Y 305
@ Starter relay
X-563
< ~ Power tilt relay
YAMAHA MOTOR CO.,LTD.
Pnnted In Japan
May 1984-0 3 x 1 til
6H4-28199-21