60D 70D OWNER'S MANUAL U.S.A.Edition LIT-18626-05-85 6H3-28199-1P EMU25060 ZMU01690 Read this owner's manual carefully before operating your outboard motor. Important manual information EMU25100 To the owner Thank you for choosing a Yamaha outboard motor. This Owner's Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner's Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! EWM00780 al, please consult your Yamaha dealer. NOTE: The 60TR, 70TR and the standard accessories are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model. EMU25110 WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. ECM00700 60D, 70D OWNER'S MANUAL ©2004 by Yamaha Motor Corporation, USA 1st edition, March 2004 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-18626-05-85 CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If there is any question concerning this manu- Table of contents General information .......................... 1 Identification numbers record.......... 1 Outboard motor serial number .......... 1 Key number....................................... 1 (turn type)...................................... 15 Tachometer ..................................... 16 Digital tachometer ........................... 16 Oil level indicators (three indicators 2) ........................ 16 Oil level indicator (digital type) ........ 16 Overheat warning indicator (digital type) .................................. 17 Trim meter ....................................... 17 Trim meter (digital type) .................. 17 Hour meter (digital type).................. 17 Emission control information ........... 1 North American models..................... 1 Safety information ........................... 2 Important labels............................... 3 Warning labels .................................. 3 Basic boating rules (Rules of the road) .............................................. 3 Steering and sailing rules and sound signals.................................. 4 Rules when encountering vessels .... 4 Other special situations..................... 5 Warning system ............................ 18 Overheat warning ............................ 18 Oil level warning and oil filter clogging warning ........................... 19 Fueling instructions ......................... 7 Gasoline ............................................ 8 Engine oil .......................................... 8 Operation ......................................... 20 Installation..................................... 20 Mounting the outboard motor .......... 20 Clamping the outboard motor.......... 21 Battery requirement......................... 8 Battery specifications ........................ 8 Breaking in engine ........................ 22 Gasoline and engine oil mixing chart (50:1).................................... 22 Procedure for oil injection models ... 22 Propeller selection........................... 8 Start-in-gear protection ................... 9 Basic components .......................... 10 Main components.......................... 10 Fuel tank ......................................... 10 Fuel joint ......................................... 11 Fuel gauge ...................................... 11 Fuel tank cap .................................. 11 Air vent screw ................................. 11 Remote control................................ 11 Remote control lever ....................... 11 Neutral interlock trigger ................... 12 Neutral throttle lever........................ 12 Throttle friction adjuster................... 12 Engine stop lanyard switch ............. 13 Main switch ..................................... 13 Power trim and tilt switch on remote control or tiller handle ....... 14 Power trim and tilt switch on bottom engine cowling .................. 14 Trim tab with anode ........................ 14 Trim rod (tilt pin) .............................. 15 Tilt support lever for power trim and tilt or hydro tilt model..................... 15 Top cowling lock lever(s) Preoperation checks ..................... 23 Fuel ................................................. 23 Oil .................................................... 23 Controls ........................................... 23 Engine ............................................. 23 Operation after a long period of storage .......................................... 23 Filling fuel and engine oil .............. 24 Filling fuel for portable tank ............. 24 Ring Free Fuel Additive................... 24 Filling oil for electric start models .... 25 Oil level indicator operation ............. 26 Operating engine .......................... 26 Feeding fuel (portable tank) ............ 26 Starting engine ................................ 27 Warming up engine....................... 28 Electric start and prime start models .......................................... 28 Shifting .......................................... 29 Forward (tiller handle and remote control models) ............................. 29 Reverse (automatic reverse lock Table of contents and power trim and tilt models)..... 29 Stopping engine ............................ 30 Procedure ....................................... 30 Trimming outboard motor.............. 30 Adjusting trim angle ........................ 31 Adjusting boat trim .......................... 32 Tilting up and down ....................... 32 Procedure for tilting up .................... 33 Procedure for tilting down ............... 34 Changing gear oil ............................ 50 Cleaning fuel tank ........................... 51 Inspecting and replacing anode(s) .. 51 Checking battery (for electric start models) ......................................... 52 Connecting the battery .................... 53 Disconnecting the battery................ 53 Checking top cowling ...................... 53 Coating the boat bottom .................. 54 Cruising in shallow water .............. 35 Power trim and tilt models / power tilt models...................................... 35 Trouble Recovery............................ 55 Troubleshooting ............................ 55 Temporary action in emergency ... 58 Impact damage ............................... 58 Replacing fuse ................................ 58 Power trim and tilt will not operate .. 59 Starter will not operate .................... 59 Emergency starting engine ............. 60 Cruising in other conditions........... 35 Maintenance..................................... 37 Specifications ................................ 37 Transporting and storing outboard motor ........................................... 38 Clamp screw mounting models ....... 38 Storing outboard motor ................... 38 Procedure ....................................... 39 Lubrication (oil injection models)..... 40 Cleaning and anticorrosion measures ...................................... 40 Battery care..................................... 40 Cleaning the outboard motor .......... 41 Checking painted surface of motor............................................. 41 Engine fails to operate .................. 60 Ignition system malfunction ............. 60 Cold engine fails to start.................. 61 Treatment of submerged motor .... 62 Procedure........................................ 62 Periodic maintenance.................... 41 Replacement parts .......................... 41 Maintenance chart .......................... 42 Greasing ......................................... 43 Cleaning and adjusting spark plug .. 44 Checking fuel system ...................... 44 Inspecting fuel filter ......................... 45 Cleaning fuel filter ........................... 45 Inspecting idling speed ................... 46 Checking water in engine oil tank ... 46 Checking wiring and connectors ..... 47 Exhaust leakage ............................. 47 Water leakage ................................. 47 Checking power trim and tilt system .......................................... 47 Checking propeller .......................... 48 Removing the propeller ................... 49 Installing the propeller ..................... 49 Consumer information ................... 64 Important warranty information for U.S.A. and Canada ..................... 64 YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY ..... 66 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA ................... 69 General information EMU25170 Identification numbers record EMU25182 reference in case you need a new key. Outboard motor serial number The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket or the upper part of the swivel bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen. 1. Key number EMU25220 1 Emission control information EMU25230 North American models ZMU02931 1. Outboard motor serial number location This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details. EMU30390 Approval label of emission control certificate This label is attached to the bottom cowling. Existing Technology; N/A 1 EMU25190 Key number If a main key switch is equipped with the motor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for ZMU04898 1. Approval label location 1 General information G EMISSION CONTROL INFORMATION ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES. REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. g/kw-hr FELs : IDLE SPEED : rpm IN NEUTRAL SPARK PLUG : SPARK PLUG GAP (mm) : DISPLACEMENT : cm 3 FUEL : GASOLINE ADVERTISED POWER : EX VALVE LASH (mm) : IN kw G ZMU04304 EMU25261 Manufactured date label This label is attached to the clamp bracket or the swivel bracket. G G G 1 1. Manufactured date label location ZMU04893 G G EMU25361 Safety information G Before mounting or operating the outboard motor, read this entire manual. Reading it G should give you an understanding of the motor and its operation. Before operating the boat, read any owner's or operator's manuals supplied with it and all labels. Be sure you understand each item before operating. Do not overpower the boat with this outboard motor. Overpowering the boat could result in loss of control. The rated power of the outboard should be equal to or less than the rated horsepower capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer. Do not modify the outboard. Modifications could make the motor unfit or unsafe to use. Never operate after drinking alcohol or taking drugs. About 50% of all boating fatalities involve intoxication. Have an approved personal flotation device (PFD) on board for every occupant. It is a good idea to wear a PFD whenever boating. At a minimum, children and nonswimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating conditions. Gasoline is highly flammable, and its vapors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel before starting the engine. This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets. Check throttle, shift, and steering for prop- 2 General information er operation before starting the engine. Attach the engine stop switch lanyard cord to a secure p ...