. F150 LF150 OWNER’S MANUAL U.S.A.Edition LIT-18626-07-14 63P-28199-15. ZMU01690 Read this owner’s manual carefully before operating your outboard motor. EMU31280 your machine and this manual.

• Yamaha 40 Hp 4-stroke Service Manual

Yamaha Outboard Manuals by Seloc 1984-2014. Seloc manual 1707 (book) covers 2005-2010 Yamaha 4-stroke outboard 2.5-350 HP, 1- to 4-cylinder. Outboard Motor Yamaha 40 Installation Manual. Yamaha recom. Specifications 246.0 cm³ Bore × stroke: TIP.

If there is any To the owner question concerning this manual, please con- Thank you for choosing a Yamaha outboard sult your Yamaha dealer. This Owner’s Manual contains infor- NOTE: mation needed for proper operation, mainte- The F150TR, LF150TR and the standard ac- nance and care. Table of contents Top cowling lock lever General information.1 (pull up type). 19 Identification numbers record.1 Flushing device. 19 Outboard motor serial number.

1 Water separator. 20 Key number.1 Digital tachometer.20 Emission control information. Table of contents Filling fuel.38 Greasing. 57 Cleaning and adjusting spark plug. 57 Ring Free Fuel Additive.38 Checking fuel system. 58 Operating engine.38 Changing engine oil.59 Feeding fuel.38 Checking wiring and connectors.61 Starting engine.

Yamaha 40 Hp 4-stroke Service Manual

Table of contents Consumer information.77 Important warranty information for U.S.A. And Canada.77 YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY.79 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto- 1. Key number len.

General information 1. Star labels location EMU25262 Manufactured date label EMU25280 This label is attached to the clamp bracket or One Star—Low Emission The one-star label identifies engines that the swivel bracket. Meet the Air Resources Board’s 2001 ex- haust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke en- gines. General information the rated horsepower capacity of the boat.

If the rated horsepower capacity of the boat is unknown, consult the dealer or boat man- ufacturer. Do not modify the outboard. Modifications could make the motor unfit or unsafe to use.

Incorrect propeller selection and incorrect use may not only cause engine damage, but also adversely affect fuel consumption. Never illegally discard (dump) the product.

Keep hands, hair, and clothes away from Yamaha recommends consulting the deal- flywheel and other rotating parts while er on discarding the product. Engine is running.

General information EMU25413 the “give-way” or “burdened” vessel. These Label (counter rotation models) rules determine which vessel has the right-of- EWM01281 way, and what each vessel should do. WARNING Stand-on vessel Use only a counterclockwise rotation pro- The vessel with the right-of-way has the duty peller with this engine. General information Crossing: (you are traveling across the other Crossing When two power driven vessels are crossing vessel’s path) each other’s path close enough to run the risk Overtaking: (you are passing or being of collision, the vessel which has the other on passed by another vessel) the starboard (right) side must keep out of the In the following illustration, your boat is in the. General information vessels, the operator should sound a pro- proceeding from open water into port, and longed blast on the whistle (4 to 6 seconds). If black buoys are to port (left) side. When navi- another vessel is around the bend, it too gating out of port, your position with respect to should sound the whistle.

General information ZMU01708 EMU25540 Do not smoke when refueling, and keep Fueling instructions away from sparks, flames, or other EWM00010 sources of ignition. WARNING Stop engine before refueling.

GASOLINE AND ITS VAPORS ARE HIGH- Refuel in a well-ventilated area. Refuel LY FLAMMABLE AND EXPLOSIVE! Portable fuel tanks off the boat. All 4-stroke engines are shipped from the ethanol content does not exceed 10% and the factory without engine oil. Fuel meets minimum octane ratings.

Yamaha does not recommended gasohol containing methanol because it can cause fuel system damage or engine performance problems. Yamaha outboard motors are fitted with pro- pellers chosen to perform well over a range of applications, but there may be uses where a propeller with a different pitch would be more appropriate. For instructions on propeller removal and in- stallation, see page 62. EMU25770 Start-in-gear protection Yamaha outboard motors or Yamaha-ap- proved remote control units are equipped with start-in-gear protection device(s). This feature permits the engine to be started only when it is in neutral. Basic components EMU25799 Main components NOTE:. May not be exactly as shown; also may not be included as standard equipment on all models.

Top cowling 2. Top cowling lock lever(s) 3. Anti-cavitation plate 4. Trim tab (anode) 5. Propeller. 6.

Basic components ZMU05429 1. Tachometer unit (Square type). 2. Tachometer unit (Round type).

3. Speedometer unit (Square type). 4.

Speed & fuel meter unit (Square type). 5. Speed & fuel meter unit (Round type).

6. Fuel management meter (Square type). EMU26180 Remote control The remote control lever actuates both the. Basic components ZMU04569 ZMU04573 1. Remote control lever 1. Neutral “ ” 2. Power trim and tilt switch 2.

Forward “ ” 3. Free accelerator 3. Reverse “ ” 4.

Throttle friction adjuster 4. Fully closed EMU26190 Remote control lever 6. Basic components After the button is pushed, the throttle be- NOTE: gins to open after the remote control lever is The neutral throttle lever will operate only moved at least 35°. When the remote control lever is in neutral. After using the free accelerator, return the The remote control lever will operate only remote control lever to the neutral position.

Basic components NOTE: The engine cannot be started with the lock plate removed. ZMU04646 When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting. EMU25990 Engine stop lanyard switch 1. Lock plate The lock plate must be attached to the engine stop switch for the engine to run. Basic components With the main switch in the “ ” (start) po- sition, the starter motor turns to start the en- gine. When the key is released, it returns automatically to the “ ” (on) position.

EMU26151 Power trim and tilt switch on bottom engine cowling The power trim and tilt switch is located on the side of the bottom engine cowling. Basic components For instructions on using the power trim and tilt switches, see pages 43 and 45. EMU26241 Trim tab with anode The trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force.

Basic components 1. Tilt support lever EMU26382 Top cowling lock lever (pull up type) To remove the engine top cowling, pull up the lock lever(s) and lift off the cowling. When in- stalling the cowling, check to be sure it fits properly in the rubber seal. ECM00020 If the warning system has activated, stop CAUTION: the engine and consult a Yamaha dealer Do not continue to run the engine if the immediately. Low oil pressure warning indicator is on EMU31410 and the engine oil level is lower. Basic components The low oil pressure warning indicator EMU26600 Speedometer (digital type) does not indicate the engine oil level. This gauge shows the boat speed.

Use the oil dipstick to check the remain- ing oil quantity. For further information, see page 37.

Basic components EMU26650 Hour meter (digital type) This meter shows the number of hours the en- gine has been run. It can be set to show the total number of hours or the number of hours for the current trip. The display can also be turned on and off. When all segments are showing, the fuel tank is full. ECM00860 CAUTION: NOTE: The Yamaha fuel tank sensor differs from The trip distance is shown in kilometers or conventional sensors. Incorrectly setting miles depending upon the unit of measure- the selector switch on the gauge will give ment selected for the speedometer.

Get back to the port soon if a warning de- mal operation. Watch the gauge when turning vice has activated.

For charging the bat- on the main switch to make sure all segments tery, consult your Yamaha dealer. EMU26750 Fuel flow meter.

Basic components The fuel consumption meter and fuel econ- omy meter will indicate the same unit of measurement. EMU26760 Fuel consumption meter This gauge displays the total amount of fuel consumed since the gauge was last reset. Press the “ ”. (winter or summer fuel and amount of addi- tives). The Yamaha digital speedometer and fuel management meter calculates speed, miles traveled, and fuel economy by water movement at the stern of the boat. Basic components your Yamaha dealer.

The tachometer unit is NOTE: available in round or square types. Check This indicator only operates when a water your tachometer unit type. Separator sensor is equipped.

Set button ZMU01755 2. If the buzzer sounds and the water separator warning indicator blinks, consult your Yamaha dealer immediately. NOTE: ZMU05417 To stop the buzzer, press the “. Consult vated.

Serious engine damage will occur. Your Yamaha dealer if the problem can- not be located and corrected. Overheat warning If the engine temperature rises too high while. Yamaha dealer.

Damage to the engine. Engine trouble warning This indicator will blink when the engine mal- functions while cruising. Get back to the port soon and consult a Yamaha dealer immedi- ately. ZMU05427 ZMU05425 ZMU05428 EMU31610 Speed &. If optional sensors are connected to the unit, trip display, water surface temperature display, depth display, and clock will be avail- able. For the optional sensor, consult your Yamaha dealer. Set button 2.

Basic components EMU31630 Fuel management meter This meter has functions of fuel flow meter, to- tal consumption display, fuel economy dis- play, and remaining fuel display. Set button 2. Mode button ZMU05438 1. Set button 2. Mode button ZMU05437 1. CAUTION: Do not continue to operate the engine if a START START warning device has activated.

Consult your Yamaha dealer if the problem cannot be located and corrected. EMU26824 Overheat warning (twin engines) ZMU04584 This engine has an overheat warning device. Check the oil level and add oil as needed. If the oil level is correct and the warning device does not switch off, consult your Yamaha dealer. ECM00100 CAUTION: Do not continue to run the engine if the low oil pressure warning indicator is on. Operation EMU26901 EWM00830 Installation WARNING ECM00110 Improper mounting of the outboard motor CAUTION: could result in hazardous conditions such Incorrect engine height or obstructions to as poor handling, loss of control, or fire smooth water flow (such as the design or hazards.

Test runs at different heights can help determine the optimum mounting height. Consult your Yamaha dealer or boat manufacturer for further information on determining the prop- er mounting height. For instructions on setting the trim angle of 1.

Remove oil dipstick and wipe it clean. Check fuel line connections to be sure they Completely insert the dipstick and re- are tight (if equipped Yamaha fuel tank or move it again. Check the oil level using the dipstick to be. Squeeze the primer pump, with the arrow pointing up, until you feel it become firm. While many additives available may reduce deposits, Yamaha recommends the use of Ring Free Fuel Additive, available from your Yamaha dealer.

Ring Free Fuel Additive. Operation Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the en- gine stop switch. EWM00120 WARNING Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating. START engine. Otherwise serious engine dam- age could occur.

Check the oil level and add oil if necessary. Consult your Yamaha dealer if the cause for the low oil pressure warning indicator cannot be found. ZMU04590 A continuous flow of water from the pilot. Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked. Consult your Yamaha dealer if the problem cannot be located and corrected. If the cooling passage is frozen, it may take awhile for water to start flowing out of the pilot hole. Operation To shift from in gear (forward/reverse) to neu- tral Close the throttle so that the engine slows to idle speed.

ZMU04588 EMU31741 Braking EWM01510 WARNING Do not use the reverse function to slow down or stop the boat as it could cause you to lose control, be ejected, or impact the steering wheel or other parts of the boat. Operation engine, and propeller. Correct trim is also af- fected by variables such as the load in the boat, sea conditions, and running speed. EWM00740 WARNING Excessive trim for the operating condi- tions (either trim up or trim down) can cause boat instability and can make steer- ing the boat more difficult.

Operation complete stop with the engine off. Do cy to steer to one side or the other.

Compen- not adjust the trim angle with this switch sate for this as you steer. The trim tab can while the boat is moving.

Also be adjusted to help offset this effect. Operation the bow is greatly increased, heightening the ECM00241 CAUTION: danger of “bow steering” and making opera- Before tilting the outboard motor, stop tion difficult and dangerous. The engine by following the procedure on page 42. Never tilt the outboard mo- tor while the engine is running. Operation EWM00260 WARNING After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever. Otherwise the outboard mo- tor could fall back down suddenly if oil in the power trim and tilt unit loses pressure. Models equipped with trim rods: Once the outboard motor is supported with the tilt ZMU04602.

Operation EMU28055 Procedure for tilting down (power trim and tilt models / power tilt models) Push the power trim and tilt switch / pow- er tilt switch “ ” (up) until the outboard motor is supported by the tilt rod and the tilt support lever / tilt support knob be- comes free. For cooling system flushing instructions, see page 50. Cruising in turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (not available for some models) if you use the outboard motor in turbid or muddy water con- ditions. Maintenance EMU31480 Spark plug gap: Specifications 1.0–1.1 mm (0.039–0.043 in) Control system: NOTE: Remote control “(AL)” stated in the specification data below Starting system: represents the numerical value for the alumi- Electric Starting carburetion system: num propeller installed.

Electronic fuel injection Likewise, “(SUS)”. WARNING is advisable to have your outboard motor ser- Leaking fuel is a fire hazard. When trans- viced by an authorized Yamaha dealer prior to porting and storing the outboard motor, storage. However, you, the owner, with a min- close the air vent screw and fuel cock to imum of tools, can perform the following pro- prevent fuel from leaking.

NOTE: ry to prevent excessive engine damage The use of “Yamaha Fuel Conditioner and due to rust. Perform the flushing and fog- Stabilizer” eliminates the need to drain the ging at the same time. Run the engine at a fast idle for a few Wax the cowling with a non-abrasive wax minutes in neutral position while supply- such as “Yamaha Silicone Wax” (Part No. Ing fresh water. Just prior to turning off the engine, quickly.

Maintenance Batteries vary among manufacturers. There- fore the following procedures may not always apply. Consult your battery manufacturer’s in- structions.

Procedure Disconnect and remove the battery from the boat. Always disconnect the black negative cable first to prevent the risk of shorting.

When flushing the engine with the boat in iar with machine servicing, this work the water, tilting up the outboard motor until should be done by your Yamaha dealer or it is completely out of the water will achieve other qualified mechanic. When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer. Initial Every Item Actions.

Maintenance Initial Every Item Actions 10 hours 50 hours 100 hours 200 hours (1 month) (3 months) (6 months) (1 year) Throttle link / throttle cable / throttle pick-up Inspection / adjustment timing Inspection / replace- Water pump ment Engine oil Inspection / change Oil filter (cartridge) Change. Do not attempt to di- sparks, which could lead to explosion or agnose any problems yourself. Instead, take fire.

The outboard motor to a Yamaha dealer. You should periodically remove and inspect the. Improper repairs can make the outboard unsafe to operate. Check the fuel lines for leaks, crack, or mal- function. If a problem is found, your Yamaha 1. Spark plug gap dealer or other qualified mechanic should re- 2.

Spark plug part number pair it immediately. Maintenance If the oil level is above the upper level mark, drain until the level meets the specified capacity. Overfilling the oil could cause leakage or damage. ECM01240 CAUTION: Change the engine oil after the first 10 hours of operation, and every 100 hours or at 6-month intervals thereafter.

Consult tact with the surface of the drain hole. Then your Yamaha dealer if the problem cannot tighten 1/4 to 1/2 turn more. Tighten the drain be located and corrected. Check that the tilt rod and trim rods are NOTE: free of corrosion or other flaws. If any leaks are found, consult your Yamaha Activate the tilt-down switch until the trim dealer. Rods have retracted completely into the EMU29153 cylinders. Activate the trim-up switch until the tilt rod is fully extended.

Unlock the tilt support lever. Tilt the outboard motor down. Check that the tilt rod and trim rods operate smooth- NOTE: Consult your Yamaha dealer if any operation is abnormal.

ZMU01897 EMU29171 Checkpoints Checking propeller. Remove the propeller nut, washer, and spacer (if equipped). Apply Yamaha marine grease or a corro- sion resistant grease to the propeller shaft. Install the thrust washer and propeller on the propeller shaft.

Tilt the outboard motor so that the gear oil NOTE: drain screw is at the lowest point possi- For disposal of used oil, consult your Yamaha ble. Place a suitable container under the gear With the outboard motor in a vertical po- case. Inspect ground leads attached to external an- manent eye injury. Odes on equipped models.

Consult a Yamaha Wear protective eye gear when handling dealer for inspection and replacement of inter- or working near batteries. (for example: welding the battery when it is low. Equipment, lighted cigarettes, and so NOTE: on.) Consult a Yamaha dealer when charging or DO NOT SMOKE when charging or han- re-charging batteries.

Dling batteries. KEEP BATTERIES AND ELECTROLYTIC. NOTE: Remove the accessory battery coupler If connecting an accessory battery, consult cover from the outboard motor. Your Yamaha dealer about correct wiring.

Connect the accessory battery coupler to the coupler of the accessory battery ca- EMU29370 Disconnecting the battery ble (optional). Maintenance EMU29400 Coating the boat bottom A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bot- tom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Yamaha outboard motors.

Has fuel pump malfunctioned? Some items may not apply to your model.

Have serviced by a Yamaha dealer. If your outboard motor requires repair, bring it to your Yamaha dealer. Are spark plug(s) fouled or of incorrect. Return to normal operating position. Fill tank with clean, fresh fuel.

Is carburetor clogged? Is fuel filter clogged? Have serviced by a Yamaha dealer. Clean or replace filter.

Is fuel joint connection incorrect? Have ignition parts failed? Is fuel system obstructed? Is water pump or thermostat faulty?

Check for pinched or kinked fuel line or oth- A. Have serviced by a Yamaha dealer. Er obstructions in fuel system. Is there excess water in fuel filter cup?. If the boat is operated with one engine in Q. Is steering pivot loose or damaged?

The water but not running, water may run A. Tighten or have serviced by a Yamaha into the exhaust pipe due to wave action, dealer. Main fuse (50 A) NOTE: 5. Main switch / trim switch fuse (20 A) Consult your Yamaha dealer if the new fuse 6. Engine control unit / ignition coil / electric immediately blows again.

Fuel pump / fuel injector / ISC (idle speed control) fuse (20 A) 7. Trouble Recovery 1. Manual valve screw 1. Water separator warning indicator Put the engine in the desired position, Stop the engine. Then tighten the manual valve screw by Remove the top cowling.

Turning it clockwise. Remove the plastic tie. EMU31601 Water separator warning indicator blinks while cruising EWM01500.

Trouble Recovery ECM01570 NOTE: CAUTION: Properly dispose of the rag. Be careful not to get any water on the wa- ter detection switch coupler, otherwise a Firmly screw the filter cup onto the filter malfunction could occur. NOTE: Be careful not to twist the water detection switch lead when screwing the filter cup onto the filter housing. EMU29760 Treatment of submerged motor If the outboard motor is submerged, immedi- ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immediate- If you cannot immediately take the outboard motor to a Yamaha dealer, follow the proce- dure below in order to minimize engine dam- age. Consumer information EMU29811 Important warranty information for U.S.A. Consumer information.

Consumer information EMU29830 YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY.

Consumer information. Consumer information EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA. YAMAHA MOTOR CORPORATION, USA Printed in Japan March 2006–4.0 × 1 CR Printed on recycled paper.