ELECTRONICGAY ELECTRIGIDAD PARAVEHIGULOSYe Ee Outboards 148 SERVICE MANUAL LIT-18616-01-65NOTICE This manual has been prepared by the Yamaha Motor Company primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could ren- der it unsafe or unfit for use. Because the Yamaha Motor Company Ltd. has a policy of continuously improving its prod- ucts, models may differ in detail from the descriptions and illustrations given in this publica- tion. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. 9.9F, 15F SERVICE MANUAL ©1996 Yamaha Motor Co., Ltd. ‘1st Edition, May 1996 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of the copyright holder. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. P/N LIT-18616-01-65HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection opera- tions. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., * Bearings Pitting/Damage — Replace. To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page. On the first page of each Section is an Index of that section's contents. MODEL INDICATION Multiple models are shown in this manual. These indications are noted as follows. Modstrame | 89F usaana | SaMt cawaonname | S964: ineion | 88 ‘THE ILLUSTRATIONS Some illustrations in this manual may differ from the model you have. This is because a procedure described may relate to several models, though only one may be illustrated. (The name of model described will be mentioned in the description). REFERENCES These have been kept to a minimum; however, when you are referred to another section of the manual, you are told the page number to go to.HOW TO READ DESCRIPTIONS 1. A disassembly installation job mainly consists of the exploded diagram@. 2. The numerical figures represented by the number @) indicates the order of the job steps. 3. The symbols represented by the number @) indicates the contents and notes of the job. For the meanings of the symbols, refer to the next page(s). 4. The REMOVAL AND INSTALLATION CHART @ is attached to the exploded diagram and explains the job steps, part names, notes for the jobs, etc. 5. The SERVICE POINTS, other than the exploded diagram, explains in detail the items difficult to explain in the exploded diagram or REMOVAL AND INSTALLATION CHART, the Service points requiring the detailed description © ,etc.WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish important information in this manual in the following ways. LN The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! AWARNING 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. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: ANOTE provides key information to make procedures easier or clearer.‘SYMBOLS Symbols () to @ are designed as thumb-tabs to indicate the content of a chapter: @ General information ® Specifications @ Periodic Inspection and Adjustment @ Fuel system © Power unit © Lower unit © Bracket unit @© Electrical system @ Trouble-analysis Symbols @ to (@ indicate specific data: © Special tool @ Specified quid @ Specified engine sp2ed @ Specified torque @ Specified measurement ® Specified electrical valve [Resistance (21, Voltage (V), Electric current wi ‘Symbol { to @ in an exploded diagram indicate grade of lubricant and location of lubrication point: ® Apply Yamaha 2-stroke outboard motor oil ® Apply water resistant grease (Yamaha grease A, Yamaha marine grease) ® Apply molybdenum disulfide grease ‘Symbols (@ to @ in an exploded diagram indicate grade of sealing or locking agent, and location of application point: @ Apply Gasket Maker® @ Apply Yamabond #4 (Yamaha bond No. 4) @ Apply LOCTITE® No. 271 (Red LOCTITE) @ Apply LOCTITE* No. 242 (Blue LOCTITE) @ Apply LOCTITE® No. 572 @ Apply Silicon sealant NOTE: In this manual, the above symbols may not be used in every case.INDEX | GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT ee LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEM TROUBLE-ANALYSISset CHAPTER 1 GENERAL INFORMATION IDENTIFICATION. SERIAL NUMBER ccs STARTING SERIAL NUMBER .. ‘SAFETY WHILE WORKING FIRE PREVENTION... VENTILATION .. SELF-PROTECTION .rrsvssrnnsstene OILS, GREASES AND SEALING FLUIDS ... GOOD WORKING PRACTICES. DISASSEMBLY AND ASSEMBLY. ‘SPECIAL TOOLS MEASURING ... REMOVAL AND INSTALLATION ..GEN INFO IDENTIFICATION IDENTIFICATION ‘SERIAL NUMBER The serial number of the outboard motor is stamped on the label attached to the port side of the clamp bracket. NOTE: For USA model: As an antitheft measure, a special label on which the outboard motor serial number is stamped is bonded to the port side of the clamp. bracket. The label is specially treated so that peeling it off causes cracks across the serial number. ® Model name ® Approved model No, @ Transom height ® Serial number STARTING SERIAL NUMBERS. The starting serial number blocks are as fol- lows: Mode World | USA, wide [CANADA s.9rmH | 9.9MH Li 455181- [SuL: 250196- 'S: 700301~ goremH | 99H | ea2c | L:600791~ | SUL: 900141~ 8: 630246~ SareMHn) 1: 660183- SFEMR | 9.9ER L: 690256~ 'S: 405497 1: 153352~ WWSAFETY WHILE WORKING SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline (petrol), and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapor is heavier than air and if in- haled in large quantities will not support life. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation, ‘SELF-PROTECTION Protect your eyes with suitable safety spec- tacles or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing. OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha. 12GEN INFO! [? SAFETY WHILE WORKING 13 Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all- important, and by adopting good safety prac- tices, any risk is minimized. A summary of the most important precautions is as follows: 1 While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before fur- ther use. 3, Avoid skin contact with lubricants; do not, for example, place a soiled wiping-rag in one's pocket. 4, Hands, and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable. 5. To protect the skin, the application of @ suitable barrier cream to the hands before working is recommended. 6. A supply of clean lint-free cloths should be available for wiping purposes. GOOD WORKING PRACTICES 1. The right tools Use the special tools that are advised to protect parts from damage. Use the right tool in the right manner ~ don’t improvise. 2. Tightening torque Follow the torque tightening instructions. When tightening bolts, nuts and screws, tighten the larger sizes first, and tighten inner-positioned fixings before outer-posi- tioned ones.SAFETY WHILE WORKING 3. Nonreusable items Always use new gaskets, packings, O-rings, oil seals, split-pins and circlips etc. on reas- sembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed-air on disas- sembling them, 2. Oil the contact surfaces of moving parts on assembly. 3. After assembly, check that moving parts ‘operate normally. 4. Install bearings with the manufacturer's markings on the side exposed to view, and liberally oil the bearings. Do not use compressed air to spin the bear- ings dry. This causes damage to the bearing surfaces 5. When installing oil seals, apply a light coat- ing of water-resistant grease to the outside diameter. 14a SPECIAL TOOLS Worse a AS Ag 2 —® @ 15 SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accu- rate assembly and tune-up. Improvisations and Use of improper tools can cause damage to the equipment. NOTE: *For U.S.A. and Canada, use part number starting with “J-", "YB-", “YM-", “YU-" or “For others, use part number starting with “9089 MEASURING 1. Dial gauge and stand PIN. YU-03097, YU-01256 90890-01252 2. Tachometer PIN. YU-08036-A 90890-06760 3. Pressure tester PIN. YB-03595 90890-06762 4, Mity vac PIN. YB-35956 90890-08756 5. Cylinder gauge set PIN. YU-03017 90890-06759 6. Digital caliper P/N. 90890-06704 7. Magnet base PIN. YU-34481 90890-06705 8. Digital multi meter PIN. J-39299 90890-06752 9. Compression gauge PIN. YU-33223 90890-06751GEN SPECIAL TOOLS 16 REMOVAL AND INSTALLATION 1. Flywheel holder PIN. YB-06139 90890-06522 2. Flywheel puller PIN. YB-06117 90890-06521 3. Bearing separator PIN, YB-06219 90890-06534 4, Small end bearing needle installer PIN. YB-06104 90890-06543 5. Bearing housing puller PIN. YB-06234 90890-06503 6. Stopper guide plate (Propeller shaft housing, Reverse gear bearing) P/N. 90890-06501 7. Center bolt (Propeller shaft hou: PIN. 90890-06504 8. Slide hammer set (Reverse gear bearing) PIN. YB-06096 9, Bearing puller (Reverse gear bearing) PIN. 90890-06535 ‘Stopper guide stand (Reverse gear bearing) PIN, 90890-06538 11. Driver rod PIN. YB-06071, YB-06229 90890-06602, 90890-06604, 90890-06605, 90890-06652 19) 10.GEN INFO: ‘Dye-ovoss veces SPECIAL TOOLS 12, 20. 21. 22. 23. 24, WW Needle bearing attachment (Propeller shaft) PIN. YB-06081 90890-06616 Oil seal installer (Propeller shaft) P/N. YB-06168 90890-06613, |. Bearing installer PIN. YB-06015, (Reverse gear) YB-06085 (Forward gear) 90890-08625 (Forward gear) Drive shaft holder PIN. YB-06228 90890-06515, Pinion nut holder PIN. YB-06078 Bushing attachment (Drive shaft housing) PIN. YB-06028 90890-06649 Needle bearing attachment (Drive shaft) PIN. YB-06230 90890-06617 . Driver shaft needle bearing depth stop PIN. YB-06231 Bearing depth plate 90890-06603 Bearing installer PIN. YB-06022 (Drive shaft oil seal) 90980-06644 (Forward gear) Pinion height gauge PIN. YB-34232 Shimming plate P/N. 90890-06701 Backlash indicator PIN. YB-06265, 90890-06706 Backlash adjusting plate PIN. YB-07003,CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS... MAINTENANCE SPECIFICATIONS. ENGINE LOWER ELECTRICAL .. DIMENSION .. TIGHTENING TORQUE. SPECIFIED TORQUE ... GENERAL TORQUE ..GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS. Tem Unit 29 15 DIMENSION: Overall Length mm (n) 873 (34.4) Overall With ‘mm (1) 332 (13.1) Overall Height s ‘mm (in) 1040 (40.9) L ‘mm (in) 1167 (45.9) SUL mm (in) 1309 (61.5) WEIGHT: Weight (Al) s ig (bo) 36 (79.4) ic g (Io) 87.5 (82.7) SUL gb) 39 (86.0) PERFORMANCE: Full Throttle Operating Range tlmin 4500-5500 Output (180) Jew (hoy at mil 7-4 (8) 75000 112 (15) 75000 bend faye im | 5:1 1.95.1.12) at $500 | 7.9 (1.99.1.64) at $500 ENGINE: Type 2 stroke -L Cylinders 2 Total Displacement em? (cu. in) 246 (15.01) Bore X Stroke mm fn) 56.0 x 50.0 (2.20 x 1.97) Compression Ratio 6.80 Carburetor Quantity 1 Intake System Reed Valve Induction System Loop Charge Starting System WH EMH (EH), EMF, EMA ER) Manual Manual & Electric Control system 14H, EMH (EH) ] Ewan EWR (ER) Tle controt_[raer 8 Remoteconval] Remote control Ignition System Cor Alternator Output WH EMH (ER) EMA 12-80W 12-68 Enrichment System Chaxe Vane Advance Type Mecanical Spark Plug (Nek) 87HS-10 BRTHS-10 Exhaust System Through Prop Boss Cooling System Water Lubrication System Pre-Mixed Fuel & Oil FUEL AND OI: Fuel Type Reguler Gasoline Engine Oi Type / Grade 2 stroke outboard motor oil/ TC-W/3 Gear Oi Type Hypold Gear Oil SAE#90 Gear Oil Quantity ee 250 (8.45,8.80) Mixing Ratio 100:1(JPNIGEN 50:1 24GENERAL SPECIFICATIONS Unit BRACKET: Tit Angle degrees Titt-up Angle degrees Shallow Water Crushing Angle degrees degrees Steering Angle (oneright DRIVE UNIT: Gear Shift Position Gear Ratio Gear Type Clutch Type Propeller Direction Propeller Drive System Propeller Series Mark 8,12,16,20 67 30,36 45+40 ENR 2.08 (27/13) Spiral Bevel Gear Dog clutch Clockwise Spline J ELECTRICAL: Battery Capacity Cold Cranking 22 EMA (EH), EMHA, EMA (ER) 49 (144) 210MAINTENANCE SPECIFICATIONS. MAINTENANCE SPECIFICATIONS. ENGINE item Unit 99 15 [CYLINDER HEAD: Warpage limit mm (in) 0.1 (0.004) |CYLINDER: Bore size mm (in) 56.00~56.02 (2.205~2.206) Wear it mm (i) 56.1 (2.21) Taper limit mm (in) 0.08 (0.003) Out of round fimit mmr) 0.05 (0.002) PISTON: Piston clearance mm) 0.035-0.040 (0.0014-0.0016) Limit Lat | mi 0.090 (0.0035) Diameter Loy 9] mein 55.940-55.985 (2.2024-2.2041) ‘Measuring point 5. HI mm (in) 10 (0.39) Pin boss inside diameter men (o) 14,004~14.018 (0.5513-0.5518) Ring groove clearance top] mma) 0.02-0,08 (0.001-0.002) 2nd} mm (in) 0.04~0.08 (0.002-0.003) Over size diameter 1st'i]—mmén) 56.25 (2.215) 2nd] mm (in) 56.50 (2.224) PISTON PIN: Diameter, mm (in) 13.996-14.000_(0.5510-0.5512) PISTON RING: 1st Type Tra Keystone Dimensions ye (BxT) mm (in) 2.0x2.5 (0.08x0.10) End gap SVE Ginstalied)| mm (in) 0.15~0.35 (0.006~0.014) Limit mm (in) 0.55 (0.022) PISTON RING: 2nd Type Ty Barrel Dimensions iss 8 BxT| amir) 2.0%2.5 (0.08x0.10) End gap 7 (installed)} mm (in) 0.15-0.35 (0.006~0.014) Limit man (in) 0.55 (0.022) JSONNECTING ROD: ‘Small end diameter som 18.000~18.011 (0.7087-0.7091) [RANK SHAFT: 7 Crank with A) min 46,90-46.95 (1.846~1.848) £4 Ae 8] mmén) 25.90~26.10 (1.020-1.028) Ae Runout limit SWI? 0} mm ny 0.03 (0.001) Big end side clearance °° Emm in) 0.30~0.80 (0.012~0.031) ‘Maximum small end axial play _F]_—_mmiin) 2.0 (0.08) HERMOSTAT: Opening temperature “cen 48-52 (118-126) Full-opening temperature “cer 60 (140) Valve lift mm (in) 3 (0.12) REED VALVE: 7 ‘Valve stopper height mm (in) 0,740.1 (0.0340.00)"2 | 6,940.1 (0240.00) 1,340.1 (0.05+0.00)"3. Valve warpage limit CL ae 2 (0.0) “1: Except for USA *2: Except for Europe *3: For EuropeQ™ | MAINTENANCE SPECIFICATIONS tem CARBURETOR: Identitication mark. Float height Valve seat size Main jot Main nozzle Main air jet Pilot jet Pilot air jot Pilot screw ’ ’ ’ ‘ tums out 63V00 14.041.5 (0.5540.06) 1.2 (0.05) 110 3.0 (0.12) 120 48 75 s1241/4 ENGINE SPEED: Idle speed Trolling speed RECOIL STARTER: Starter rope length LOWER Item rimin elmin rm (in) 750250 650350 1800 (70.9) GEAR BACKLASH: Pinion - Forward Pinion - Revers Pinion shims Forward shims Reverse shims 0.19-0.86 (0.007-0.034) 0.95~1.65 (0.037~-0.065) 1.1312 0.10,0.12,0.15,0.18,0.30,0.40,0.50 0.1,0.2,0.3,0.4,0.5 PROPELLER: Material Blade x Diameter x Pitch ‘Aluminium Dual thrust SxS4x8 J Bx94/4 x9 -J 8x9-1/4 9-9/4 -J Bx 9-1/4 x 10-1/2-J Bx9-44 x12 +d 8x9-4/2 x6-1/2 - 683-45947-12 00 3x934 x8 -J 683-45949-12 01 8x9-9/4 x6-172 -J Test propeller (except for USA and Canada} (for USA and Canada) 90880-01619 5000-5200 5200-5400 YB-01619MAINTENANCE SPECIFICATIONS ELECTRICAL item Unit TGNITION SYSTEM Ignition timing (til retard} degrees AT.DC. 5:1 (til aavanced}] degrees BT.D.C. 30s1 Piston position (ull etars)] mm (ry AT.D.C. 0.1220.04 (0.00520.002) (jul advanced)} mm (n) | B.T.0.C. 4.22 +0.28 -0.27 (0.166 +0.011 -0.011) Pulser col resistance (color) 352-528 (WIR-B) ‘Charge coll resistance (coer 248-372 (Br-L) Ignition col resistance primary coil Q{eoler) 0.05-0.07 (B/W-B) secondarily col 2{cotor) 1.68-2.52 (BIW-High tension cord) Spark plug gap ‘mm (r) 0.9-1.0 (0.035~0.039) Charging current (einimum)| at min 1,9~4.9/9000 (maximum)| A at rimin 4.7-7.718500 [STARTING SYSTEM WA [EMH (EH), MAR, EMR (ER) Fuse vA 12-20 Neutral switch mm (a) 185-195 (0.73-0.77) mm) 19.5-20.5 (0.7-0.81) [STARTER MOTOR: EMH (EH), EMR, EMA ER) Type Bendix Output Kw o.4 Brush length sei) 7.5 (0.30) Wear imit mm (er) 4.5 (0.18) Commutator diameter mm fr) 20.0 (0.79) Limit mm in) 19.4 (0.76) Clutch type lover running Rating Sec. 30 [GRARGING SYSTEM Lighting coil resistance (e010) 0.16-0.24 (6-6) Lighting vottage (minimum) Vat rimin 11,5/3000 Vat vein 14-17.5/5500 Me 219 DIMENSION Ra 440 (17.3) 567 (22.3) 709 (27.9) 134 (5.3) 133.5 (5.3) 31 (1.2) 64 (2.5)TIGHTENING TORQUE TIGHTENING TORQUE ‘SPECIFIED TORQUE Part to tightened Tightening torque um [ mekg | tteo ENGINE: Flywheel 10.5 | 75 [Spark plug 26 | 18 (Cylinder head 08 47 58 12 [Exhaust cover 0.6 12 43 a7. (Crank case 1.5 3.0 W 22 LOWER: Propeller erat Pinion nut MB 26 | 19 [BRACKET: [Ciamp bracket 718 UNF 1.3 | 9.4 Upper rubber mounting MB 21 [15 Lower front rubber mountin General torque Nut ® | Bot @ | specifications Nm | mkg|_ftib 8mm ms | 50] 05 | 36 tomm | M6 | 80} 08 | 58 jamm | me | 18 | 18] 13 14mm | mio | 36 | 36 | 25 17mm | _mi2_| 43 | 43 | 31 oS [@r M6 13 [94 GENERAL TORQUE This chart specifies the torques for tightening standard fasteners with standard clean dry ISO threads at room temperature. Torque specifications for special components or as- semblies are given in applicable sections of this manual. To avoid causing warpage, tighten multifastener assemblies in crisscross fashion, in progressive stages until the speci- fied torque is reached.INSP ADJ CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .. : sestunsnsnene OM PERIODIC SERVICE ... FUEL SYSTEM .. Fuel tine .. CONTROL SYSTEM .. Ignition timing adjustment Throttle link adjustment : Start-in-gear protection adjustment Idle speed adjustment LOWER UNTT...... Gear oil . Lower unit leakage check... GENERAL Anode Battery Spark plug .. we 39 Greasing point ... 3-10aa MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. Tnitiat Every TO hours | SOhours | 100 hours [200 hours (Break-in) | (3 months) | (6 months) |_(1 year) [Cowling clamp Inspection ° FUEL SYSTEM: Fuel fine Inspection ° Fuel filter Cleaning Carburetor [Cleaning POWER UNIT: Water leakage inspection Motor exterior Inspection Exhaust leakage inspection Cooling water passage |Cleaning [CONTROL SYSTEM: Ignition timing inspection/Adjustment Throttle fink Inspection/Adjustment Throttle cable Inspection/Adjustment Start-in-gear protection |Inspection/Adjustment Idle speed Inspection/Adjustment LOWER UNIT: (Gear oil [Change Lower unit leakage —_| Inspection Inspection Inspection Inspection [Cleaning/Adjustment/ Replacement |Wiring and connector |Adjustment/Reconnect Bolts and nuts Retightening Grease points (Greasing a4INSP’ ADJ FUEL SYSTEM/CONTROL SYSTEM PERIODIC SERVICE FUEL SYSTEM Fuel line 1. Inspect * Fuel line Break/Leak/Damage -> Replace. CONTROL SYSTEM Ignition timing adjustment 1. Check: ‘* Fully advanced ignition timing Incorrect > Adjust. Checking steps: * Turn the flywheel clockwise so that its specified marking @ aligns with the starter cover marking ©. Fully advanced posi 30° BTOC ‘* Turn the magneto control lever @ so that it contacts the fully advanced stopper @. * Check the timing indicator © so that it aligns with the marking @ on the flywheel. 2. Adjust: © Link joint ‘Adjustment steps: # Loosen the lock nut ®. * Disconnect the link joint from the magneto control lever. ‘* Remove the spark plug of No. 1 cylinder * Attach the dial gauge to the spark plug hole. Dial gauge: #& YU-03097 / 90890-01252 Dial gauge stand: YU-01256 * Slowly turn the flywheel clockwise until the piston reaches top dead center (TDC).al Q CONTROL SYSTEM ‘© Set the dial gauge to zero at TDC. ‘+ Tum the flywheel counterclockwise until the dial gauge indicates that the piston position is at a specified distance from ToC. ‘& [Piston positior 4.22 mm (0.166 in) BTDC ‘* Turn the magneto control lever @ so that it contacts the fully advanced stopper @. © Adjust the link joint length so that the timing indicator aligns with the marking @ on the flywheel. # Tighten the lock nut. 3. Check: © Fully retard ignition timing Incorrect -> Adjust. Checking steps: * Turn the flywheel clockwise so thatthe its ‘specified marking @ aligns with the starter cover marking ©) Fully retard positi 5° ATDC * Tur the magneto control lever so that the fully retard screw @ contacts the fully reterd stopper @. * Check the timing indicator © so that it aligns with the marking @ on the flywheel. 4. Adjust: © Fully retard screw Adjustment steps: ‘* Turn the flywheel clockwise until the dial gauge indicates that the piston position is at soecified distance from TDC. Piston position: 0.12 mm (0.005 in) ATDCCONTROL SYSTEM 34 * Turn the magneto control lever so that the fully retard screw contacts the fully retard stopper. © Adjust the fully retard screw © so that the timing indicator aligns with the marking @ on the flywheel. Throttle link adjustment NOTE: Before adjusting the throttle link, the ignition timing should be adjusted. 1. Inspect: * Fully closed position Incorrect —» Adjust. Checking steps: * Close the throttle grip fully. ‘© Check the fully retard screw @ so that it contacts the fully retard stopper @. 2. Adjust: * Throttle cable adjuster ‘Adjustment steps: * Loosen the lock nuts O,@. * Turn the magneto control lever until the fully retard screw contacts the fully retard stopper. * Adjust the throttle cable adjuster until there is specified free play between the stoppers of the pulley @ and free acceleration lever @. 4 Free play: ‘Lmm (0.04 in) * Tighten the lock nut ®.a CONTROL SYSTEM © Adjust the throttle cable adjuster until there is specified free play on the throttle cable. Free play: ‘1mm (0.04 in) * Tighten the lock nut @. 3. Check: © Throttle operation Rough operation + Repair. Start-in-gear protection adjustment 1. Check: © Start-in-gear protection operation Incorrect —> Adjust. 2. Adjust: * Start-in-gear protection wire Adjustment steps: * Set the shift lever in neutral. * Loosen the lock nut . ‘+ Adjust the start-in-gear protection wire adjuster so that the end of the stopper @ aligns with the marking @ of the starter case. # Tighten the lock nut. Idle speed adjustment NOTE: Before adjusting the idle speed, be sure to ad- just the throttle link. 1. Measure: * Idle speed Out of specification > Adjust. oO 750 + 50 rpm Measuring steps: * Start the engine and allow it to warm up for a few minutes. * Attach the tachometer to the high tension lead of the cylinder #1. Z| Tachometer: %, ‘YU-08036-A / 90890-067602. Adjust * Idle speed ‘Adjustment steps: * Loosen the screw @ of the carburetor throttle lever. ‘+ Tum in the pilot screw @ unt seated. + Turn out the pilot screw to specification. Pilot screw (turns out): 1/24 © Adjust the throttle stop screw @ in or out until specified idle speed is obtained. is lightly ‘Turning in — Idle speed becomes higher. ‘Turning out — Idle speed becomes lower. # Pull the acceleration rod @ until the fully retard screw contacts the fully retard stopper. * Tighten the screw@. ‘Screw: 1.Nm (0.1 mekg, 0.7 ftelb) LOWER UNIT Gear oil 1. Check: * Gear oil Milky oil + Replace the oil seal Slag oil > Check the gear, bearing and dog. 2. Check: * Gear oil level Oil level is low — Add oil to proper level 3. Replace: * Gear oil Replacement steps: * Tilt up the motor. * Place a pan under the drain plug ®. ‘+ Remove the drain plug, then the oil level plug @and drain the oil thoroughly. ‘* Place the outboard motor in an upright position.ipa LOWER UNIT/GENERAL * Fill the gear oil through the drain hole until it overflows at the level hole. Vp Recommended oil: GEAR CASE LUBE (USA) or Hypoid gear oil, SAE #90 Oil capacity: 250 cm? (8.45 US oz, 8.80Imp oz] ‘* Refit the oil level plug and then oil drain plug. Lower unit leakage check 1. Check: * Pressure holding Pressure falls + Inspect seals and compo- nent parts. Checking steps: * Attach the tester to the d YB-03595/90890-06762 © Apply the speci 1d pressure Pressur 100 kPa (1.0 kg/cm, 14.2 psi) © Check that the pressure is held as specified for 10 seconds. NOTE: Do not over-pressurize. Excess pressure may ‘cause the air to leak out. GENERAL Anode 1. Inspect: * Anode Scale > Clean. Oil/grease — Clean. Wear/Excessively consumed — Replace. the anode, or the function of the sacrificial anode will be spoiled.GENERAL 38 Battery Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It skin, eyes, or clothing. Antidote: EXTERNAL; Flush with wi INTERNAL; Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg. or vegetable oil. Call physician immediately. EYES; Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases: Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in a closed space. Always wear eye protection when working near batteries. KEEP OUT OF REACH OF CHILDREN. Note: — * Batteries vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery manufacturer's instructions. * Disconnect the black negative lead first to prevent the risk of shorting. 1. Inspect: © Battery fluid level © Battery fluid specific gravityGENERAL Spark plug 1. Inspect: * Electrode @ Wear/Damage —> Replace. * Insulator color @ Distinctly different color -» Check the en- gine condition. x Color guide Medium to light tan color: Normal Whitish color:Lean fuel mixture Plugged fuel mixture Air leak Wrong settings Blackish color:Overly rich mixture Electrical malfunction Excess oil used Defective spark plug 2. Clean: © Spark plug Clean the spark plug with a spark plug cleaner or wire brush. 3. Measure: * Spark plug gap @ Out of specification + Alter gap. Use a wire gauge. Spark plug gap: 0.9 ~ 1.0 mm (0.035 ~ 0.039 in) 4, Tighten: * Spark plug Spark plug: 25 Nm (2.5 m+ kg, 18 ft « Ib) NOTE: ‘* Before installing a spark plug, clean the gasket surface and plug surface. Also itis suggested to apply a thin film of Anti Seize Compound to the spark plug threads to prevent future thread seizure. * Ifa torque wrench is not available, a good estimate of the correct torque is a further 1/4 to 1/2 turns ©) on finger tightened @ spark plug.a GENERAL Greasing point 1. Apply: © Water resistant grease 310‘ABs|[ro] CHAPTER 4 FUEL SYSTEM FUEL JOINT AND FUEL FILTER ..... EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART.. SERVICE POINTS 42 Fuel joint inspection 42 Fuel filter inspectior 42 CARBURETOR REMOVAL. 43 EXPLODED DIAGRAM. 43 REMOVAL AND INSTALLATION CHART... CARBURETOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART... SERVICE POINTS Carburetor inspection Fuel pump inspection Carburetor assembly . soe AB 45FEL B FUEL JOINT AND FUEL FILTER FUEL JOINT AND FUEL FILTER EXPLODED DIAGRAM 44FUEL FUEL JOINT AND FUEL FILTER REMOVAL AND INSTALLATION CHART Step Procedure/Part name Tov] Service points FUEL JOINT AND FUEL FILTER | Follow the left “Step” for removal. REMOVAL | | | | | | Clip | Fuet hose (joint - fitter Bolt (with washer) | Fuel joint | Clip Fuel hose (joint - filter) Fuel hose (filter - carburetor) Nut elfiter _ FUEL FILTER DISASSEMBLY Filter cup O-ring Filter element | Ja \4 Ja Ja Body cover eo Reverse the removal steps for installation, SERVICE POINTS Fuel joint inspection 1. Inspect: © Fuel joint Crack/Leak/Damage ~> Replace. 2. Measure: * Fuel joint operation Impossible to maintain the specified pres- sure for 10 sec. -» Replace. Measuring step’ © Attach the Mity vac. Mity vac: ‘YB-35956/90890-06756 * Apply the specified pressure. “<] Specified pressure: 50 kPa (0.5 kg/om, 7.1 psi Fuel filter inspection 1. Inspect: * Filter element * Filter cup Crack/Leak/Clog — Replace. Contamination -> Clean. 42FUEL, Bw CARBURETOR REMOVAL CARBURETOR REMOVAL EXPLODED DIAGRAM Thin (0.1 mekg, 0.7 felby SNm (GS mag, 2.1 feb) 43CARBURETOR REMOVAL REMOVAL AND INSTALLATION CHART Procedure/Part name Service points ‘CARBURETOR REMOVAL 1 | Choke rod 2 | Screw 3. | Acceleration rod 4 | Choke knob rod 5 | Clip 6 | Fuel hose 7 | Bolt (with washer) 8 | Silencer assembly 9 | Collar 10 | O-ring 11_| Carburetor assembly Follow the left “Step” for removal. SILENCER DISASSEMBLY Tapping screw Plane washer Choke lever joint, Spring pin Choke lever Fogging hole grommet Silencer Reverse the removal steps for installation. 44FUEL BRB CARBURETOR CARBURETOR EXPLODED DIAGRAMFUEL CARBURETOR REMOVAL AND INSTALLATION CHART Step Procedure/Part name ary] Service points CARBURETOR DISASSEMBLY Carburetor assembly Drain screw Washer Follow the left “Step” for removal. Refer to the “CARBURETOR REMOVAL” section in chapter 4. 1 1 2 1 3 | Screw (with washer) 4 | 4x14mm 4 | Float chamber 1] 5 | Float chamber packing 1 6 | Screw 1 7 | Arm pin a | 8 | Float 1] 9 | Clip 1 10 | Needle valve 1 11 | Cap 1 12 | Pilot jot 1 13 | Main jet 1 14 | Main nozzle 1 15 | Screw (with washer) 4 | 4x10mm 16 | Plate 1 17 | Packing 1 18 | Stopping screw 1 19 | Spring Hea 20 | Pilot adjusting screw ja 21 | Spring 1 22 | Carburetor body \1 FUEL PUMP DISASSEMBLY 1 ® | Screw (with washer) 4 @® | Pump cover 1 @ | Diaphragm 1 @ | Pump body 1 © | Screw 2 © | Seat valve 2 @ | nut 2 | Diaphragm 1 | © | Diaphragm gasket 1 46 | Reverse the removal steps for installation.FUEL CARBURETOR SERVICE POINTS NOTE: Do not use steetwire for cleaning the jets as this may enlarge the jet diameters and seriously affect performance. Carburetor inspection 1. Inspect: * Carburetor body Crack/Damage — Replace. Contamination — Clean. 2. Inspect: © Pilot screw BendWear —> Replace. 3. Inspect: © Main jet © Pilot jet © Main nozzle Contamination — Replace. 4. Inspect: © Needle valve Grooved wear -> Replace. 5. Inspect: © Float Crack/Damage — Replace. Fuel pump inspection Crack/Leak/Damage — Replace. 2. Inspect: © Seat valve Crack/Distortion + Replace. 3. Inspect: © Diaphragm Damage — Replace.CARBURETOR 48 Carburetor assembly 1. Install Needle valve Float ® Float pin @ Screw @ NOTE: * The float pin should be fit in the slit the carburetor and locted with the screw. ‘* After installing, check the smooth movement of the float. 2. Measure: * Float height @ Out of specification — Replace. [A Float height ©: (Ax 14.0 + 1.5mm (0.55 + 0.06 in) NOTE: * The float should be resting on the needle valve, but not compressing the needle valve. ‘* Take measurement at the end surface of the float opposite to its pivoted side. 3. Adjust: © Pilot screw ‘Adjustment steps: © Screw in the pilot screw until it seated lightly * Back out by the specified number of turns. Pilot screw: 1-1/2 + 1/4 (turns out)FUEL| fh)ron POWER UNIT REMOVAL ..... EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART. CHAPTER 5 POWER UNIT RECOIL STARTER .. EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART SERVICE POINTS .. Sheave drum removal Spiral spring removal Starter stopping plunger inspection ... Drive pawl and spring inspection Bushing inspection Sheave drum inspection Spiral spring inspection .. Starter rope inspection.. Recoil starter checking .. FLYWHEEL MAGNETO AND MAGNETO BASE .. EXPLODED DIAGRAM .. REMOVAL AND INSTALLATION CHART. SERVICE POINTS... Flywheel magneto removal .. ELECTRICAL UNIT EXPLODED DIAGRAM... REMOVAL AND INSTALLATION CHART. CONTROL UNIT... EXPLODED DIAGRAM... REMOVAL AND INSTALLATION CHART... REED VALVE EXPLODED DIAGRAM. REMOVAL AND INSTALLATION CHART. SERVICE POINTS «ce Reed valve inspection CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART. SERVICE POINTS .. Cylinder head inspection .. Thermostat inspectionCRANKCASE AND CYLINDER BODY. EXPLODED DIAGRAM. REMOVAL AND INSTALLATION CHART. SERVICE POINTS... Cylinder body inspection Piston to cylinder clearance Cylinder body and crankcase install 5-19 519 5-20 5-21 5-21 5-22 6-22 5-23 5-23 CRANK SHAFT AND PISTON .. EXPLODED DIAGRAM... REMOVAL AND INSTALLATION CHART 5-24 ‘SERVICE POINTS 5-25 Bearing removal... = ome _ 5-25 fon inspection ... 5-25 Piston pin and small end bearing inspection.. seo B25, fon ring inspection. comer eeennnees 5-26 Crankshaft inspection 5-27 Piston and piston ring installation 5-28 Crankshaft and piston installation 5-28PowR| @} POWER UNIT REMOVAL POWER UNIT REMOVAL EXPLODED DIAGRAM 54POWR POWER UNIT REMOVAL REMOVAL AND INSTALLATION CHART Procedure/Partname ‘(Q'ty | POWER UNITREMOVAL 1_| Screw (with washer) 2 | Shift lever link 3. | Bushing 4 | Nut 5 | Throttle lever link 6 7 8 9 “Follow the left “Step” for removal. for remote model Plane washer ‘Wave washer | Bushing Choke link rod | 10 | Screw 11 | Acceleration rod | 12. | Link joint | 13 | Choke knob rod 14 | Bolt (with washer) 15 | Bolt (with washer) 16 | Control pulley bracket assembly 17 | Bolt (with washer) 18 | Engine stop switch lead | Wire harness ground lead Except for remote model for remote model for 2P connector model 2P connector lead 21 | Wire harness rectifier lead | 22 | Wire harness starter relay lead =| 23. | Bolt (with washer) | 24 | Nut 25 | Spring washer 26 | Battery cable 27 | Pilot water hose 28 | Fuel hose 29 | Bolt (with washer) 30 | Clip 31 | Plane washer 32. | Shift lever rod 33. | Engine unit 34 35 36 for remote model Electrical starter model. 8x30mm Upper case gasket Dowel pin Collar Reverse the removal steps for installation.POWR| @} | REcoI staRTER RECOIL STARTER EXPLODED DIAGRAMPOwR| @} | Recon staRTER REMOVAL AND INSTALLATION CHART Step Procedure/Part name ty) Service points BSSS©HRD9@QOOUE RECOIL STARTER REMOVAL Start-in-gear protection wire Bolt (with washer) Collar Recoil starter assembly __ RECOIL STARTER DISASSEMBLY Cotter pin Plane washor Reel stopper ‘Stopper arm Spring Screw Cover Starter handle Starter rope Bolt (with washer) Drive plate Drive pawl spring Sheave drum assembly Bushing Spiral spring | Starter case a wos Follow the left “Step” for removal. for start-in-gear protection model 6x 20mm NOTE: ‘ Position the inner end of the spiral spring on the retainer post of the sheave drum, © Wind up the spring 2-1/2 turns counter- clockwise with the starter rope. 8Seees O98 8 ‘SHEAVE DRUM DISASSEMBLY Circlip Drive pawl Spring Return spring Rope guide Starter rope Sheave drum NOTE: Wind the rope 2 turns around the sheave drum. Reverse the removal steps for installationSERVICE POINTS ‘Sheave drum removal 1. Turn: * Sheave drum @ Turn the sheave drum clockwise until the spiral spring is free. NOTE: + Turn the sheave drum so that the cutaway on the outer surface of the sheave drum faces toward the starter handle. * Pass the starter rope through the cut. 2. Remove: * Sheave drum AWARNING When removing the sheave drum, be sure to turn the sheave drum upside down to prevent the spiral spring from popping up at you. Spiral spring removal 1. Remove: * Spiral spring PNG Be careful so that the spiral spring does not pop ‘out when removing it. Remove it by allowing it ‘out one turn of the winding each time. Starter stopping plunger inspection 1. Inspect * Starter stopping plunger CrackWear/Damage - Replace. Drive pawl and spring inspection 1. Inspect: © Drive pawl CrackWear/Damage ~> Replace. * Drive pawl spring Broken/Bent/Damage — Replace. Bushing inspection 1. Inspect: © Bushing Crack/Damage ~ Replace.RECOIL STARTER Sheave drum inspection 1. Inspect: © Sheave drum Crack/Damage — Replace. Spiral spring inspection 1. Inspect: * Spiral spring Broken/Bent/Damage — Replace. Starter rope inspection 1. Inspect: © Starter rope FrayWear/Damage — Replace. NOTE: When replacing the rope, cut it to the specified length and burn the rope end so that it will not travel. Starter rope length: 1,800 mm (70.9 in) Recoil starter checking 1. Check: * Starter operation Rough operation + Repair. 56FLYWHEEL MAGNETO AND MAGNETO BASE EXPLODED DIAGRAM FLYWHEEL MAGNETO AND MAGNETO BASE 57REMOVAL AND INSTALLATION CHART FLYWHEEL MAGNETO AND MAGNETO BASE Step Procedure/Part name ary Service points FLYWHEEL MAGNETO AND MAGNETO BASE REMOVAL Recoil starter assembly 1 | Nut 2. | Plane washer 3 | Flywheel 4 | Woodruff key 5. | Bolt (with washer) 6 | Charge coil 7 | Collar 8 | Bolt (with washer) 9 | Lighting coit 10 | Collar 11 | Magneto base plate 12 | Pulser coil assembly Follow the left “Step” for removal. Refer to the “RECOIL STARTER” section, Reverse the removal steps for installation. SERVICE POINTS Flywheel magneto removal 1, Remove and install: * Flywheel nut Flywheel hold ‘YB-06139/90890-06522 A For USA and CANADA {B]_ Except for USA and CANADA The major load should be carried in the direc- tion of the arrows. If not, the holder may easily slip off.FLYWHEEL MAGNETO AND MAGNETO BASE 2. Remove: ‘© Flywheel magneto Flywheel puller: ‘YB-06117/90890-06521 [For USA and CANADA [B) Except for USA and CANADA _ CAUTION: * Keep the nut side flush with the crank- shaft end until the flywheel comes off the tapered portion of the crankshaft. * To prevent damage to the engine or tools, ‘screw in the flywheel magneto- puller set- bolts evenly and completely so that the puller plate is parallel to the flywheel. 59ELECTRICAL UNIT ELECTRICAL UNIT EXPLODED DIAGRAMELECTRICAL UNIT REMOVAL AND INSTALLATION CHART ‘Step Procedure/Part name ory ‘Service points ELECTRICAL UNIT REMOVAL Follow the left “Step” for removal. 1 | Starter relay lead 2 |rfor electrical starter model 2 | Bolt (with washer) | 1 }6x30mm 3 | Nut 1 4 | Spring washer ja1 5 | Battery cable }1 4 6 | Bolt (with washer) Jah 7 | Cylinder head ground lead \1q 8 | Bolt (with washer) 11 46x25mm 9 | Bolt (with washer) | 2 |[6x20mm 10 | Electrical unit 1 11. | Bolt (with washer) {1b for 2P connector model: 6 x 16 mm 12 | Rectifier regulator Ja 13. | Screw (with washer) | 1 | for electrical starter mode! 14 | Rectifier 1 15 | Bolt (with washer) 2 | 6x20mm 16 | Clamp 1 a7 | cDtunit 1 18 | Bolt (with washer) 2 | 6x18mm 19_| Ignition coil 2 |_| ELECTRICAL UNIT DISASSEMBLY ® | Nut 1 ® | Spring washer 1 @ | Lead wire 1 @ | Starter relay 1 © | Bolt (with washer) 2 | 8x 14mm © | Starter relay bracket 1 @® | Bolt (with washer) 2 ® | Starter motor 1 @ | Starter motor bracket 1 | Reverse the removal steps for installation. 5-11CONTROL UNIT EXPLODED DIAGRAM Powr! @% | contro unitCONTROL UNIT REMOVAL AND INSTALLATION CHART ‘Step Procedure/Part name Ory] Service points ‘CONTROL UNIT DISASSEMBLY Control pully bracket assembly Follow the left “Step” for removal Refer to the “POWER UNIT REMOVAL” section, Ut 1 | Throttle cable lock nut 2 2. | Bolt (with washer) 1 3. | Plate 1 | for over revolution limit model 4. | Control pully bracket 1 5 | Throttle cable 2 6 | Collar 1 7 | Controt pully assembly 1 8 | Accelerator lever 1 9. | Accelerator lever spring 1 10 | Magneto contro! lever 1 11 | Magneto control lever spring 1 12 | Start-in-gear lever rod 1 13 | Bolt (with washer) 1 | 6x 20mm 14 | Stertin-gear lever 1 15 | Startin-gear lever spring 1 16 _| Colter 1 ‘CONTROL PULLY DISASSEMBLY @® | Cotter pin 2 @ | Plane washer 2 ® | Control pully rod 1 @ | Controt pully lever 1 © | Contro! pully 1 Reverse the removal steps for installation. 5-13Thm Ot mkg 0.7 by Powe] & | peep vate REED VALVE EXPLODED DIAGRAM 5-14POWR REED VALVE REMOVAL AND INSTALLATION CHART Procedure/Part name REED VALVE REMOVAL 1. | Bolt (with washer) 2_| Reed valve assembly REED VALVE DISASSEMBLY Screw (with washer) Valve stopper Reed valve Reed valve body ©6680 oy Carburetor assembly LE | Service points “Follow the left “Step” for removal. Refer to the “CARBURETOR REMOVAL” section in chapter 4. 6x20 mm Reverse the removal steps for installation. SERVICE POINTS Reed valve inspection 1. Inspect: * Reed valve Crack/Damage — Replace. 2. Measure: * Valve bending © Out of specification — Replace. 3. Measure: * Valve stopper height © Out of specification > Replace. Valve stopper height: 99: except for Europe 0.7 + 0.1 mm (0.03 + 0.004 in} for Europe 1.3 + 0.1 mm (0.05 + 0.004 in) 15: 6.0 + 0.1 mm (0.24 + 0.004 in)CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER EXPLODED DIAGRAM ENme5m-kg, TRI] 8 Nm (0.8 mekg, 5.8 fib) 6.Nm (0.6 mekg, 4.3 fib) 42 Nm (1.2 akg, 8.7 ftlb) 5-16CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER REMOVAL AND INSTALLATION CHART REMOVAL AND INSTALLATION CHART Step | Procedure/Part name ory ‘Service points | CYLINDER HEAD, THERMOSTAT |_| ‘Follow the left “Step” for removal. AND EXHAUST COVER REMOVAL 1 | Bolt (with washer) 1 | 6x 12mm 2 | Cylinder head ground lead 1 3. | Spark plug 2 4. | Flange bolt 11 | NOTE: 5 | Cylinder head assembly 1_ | Tighten the bolts in sequence and in two 6 | Cylinder hoad gasket 1 | 888 of torque. (Refer to fig. 1) 7 | Pilot water hose 1 8 | Bolt (with washer) 13 | NOTE: 9 | Exhaust outer cover 1 | Tighten the bolts in sequence and in two 40 | Exhaust cover gasket 2. | steps of torque. (Refer to fig.2) 11_ | Exhaust inner cover 1} | CYLINDER HEAD DISASSEMBLY @® | Bolt (with washer) 4 | 6x20mm @® | Thermostat cover 1 @ | Thermostat cover gasket 1 @ | Plane washer 1 © | Thermostat \1 © | Screw \1 @ | Anode | 1 ® | Cylinder head 1 | | Reverse the removal steps for installation. SERVICE POINTS Cylinder head inspection 1. Inspe © Water jacket Material deposiCorrosion -> Clean. * Cylinder inner surface Score marks ~ Clean. Use #600 ~ 800 grit wet sandpaper. CAUTION: Do not scratch the fitting surfaces of the cylin- der and cylinder cover.CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER 2. Measure: ‘* Cylinder head warpage Use a straightedge and thickness gauge. Out of specification + Resurface or re- place. Resurfacing steps: © Place a 400 ~ 600 grit wet sandpaper on the surface plate. ‘* Resurface the head using a figure-eight sanding pattern. * Thermostat Stick/Damage -> Replace. 2. Measure: * Valve opening temperature * Valve lift Out of specification + Replace. Water temperature | Below 48~82°C _(18 ~ 126 °F) Above 60°C (140 °F) (0.12 in) Measuring steps: * Suspend thermostat in a vessel. * Place reliable thermometer in a water. * Heat water slowly. * Observe thermometer, while stirring water continually. 518own] & | crankcase Ap cvLinDER BODY CRANKCASE AND CYLINDER BODY EXPLODED DIAGRAM 1st |15 Nm (1.5 mekg, 11 ftelb)} | 2nd [30 Nm (3.0 mekg, 22 Felb) a5 €) 13 (A aeCRANKCASE AND CYLINDER BODY REMOVAL AND INSTALLATION CHART Step Procedure/Part name ey Service points Yonsene S@S9SO080090 ©0808 a “Step” for removal. BODY REMOVAL | Clip Hose Clip 0 ‘CRANK CASE AND CYLINDER | J2 ha 2 Hose 1 1 1 6 6x 16mm. Oil seal housing Bolt (with washer) | | Bolt (with washer) | | NOTE: | Tighten the bolts in sequence and in two | steps of torque. (Refer to fig.1) \ | | | | Neutral switch bracket | Cylinder body Dowel pin Crank case assembly Crank shaft assembly | | | | Toreleceal sarer model Plate Plane washer Oil seal Plate ‘OIL SEAL HOUSING DISASSEMBLY O-ring Oil seal Oil seal Oil seal housing ‘CRANK CASE DISASSEMBLY | Screw (with washer) | snittever busing 5x 12mm | Screw (with washer) 5x 12mm 1 1 2 | cam plate 1 1 1 1 1 Ball Spring Shaft rod lever | | Shift arm shaft | | I | Reverse the removal steps for installation. 5-20powr!| & | crankcase anp CYLINDER BODY SERVICE POINTS Cylinder body inspection 1. Inspect: © Water jacket Material deposit/Corrosion — Clean. * Cylinder inner surface Score marks -> Clean. Use #600 ~ 800 grit wet sandpaper. Note: —___ Do not scratch the fitting surfaces of the crank case and cylinder head 2. Inspect: © Exhaust wall Crack/Damage — Replace. Carbon deposit — Clean. Use a round scraper. NOTE: Do not scratch the fitting surfaces of the cylinder and exhaust cover. 3, Measure: * Cylinder bore “D" Use cylinder gauge. Out of specification — Rebore or replace. NOTE: Measure the cylinder bore “D” in parallel. Then, find the average of the measurement. Standard | Wear limit Cylinder |56.00~56.02mm | 6.1mm bore “D” _|(2.205 ~ 2.206 in) | (2.21 in) 0.08 mm {0.003 (maximum D1 or D2) - (minimum DS or D6) A: 10 mm (0.4 in) below the cylinder top 5 mm (0.2 in} above the exhaust port 5 mm (0.2 in) below the scavenging port 521CRANKCASE AND CYLINDER BODY Piston to cylinder cle 1, Calculate: * Piston clearance Out of specification —> Replace piston and piston ring and/or cylinder. Piston clearance: 0.035 ~ 0.040 mm. {0.0014 ~ 0.0016 in) Cylinder body and crankcase installation 1. Install * Cylinder body * Crankshaft and piston NOTE: — * Align the piston ring end gaps with the respective locating pins. * Fit the bearing locating pins in the cylinder body. 2. Apply: * Gasket maker Onto the connecting surfaces of the crank- case and cylinder body. Nove: —___ * Clean the connecting surfaces of the crankcase and cylinder body before applying the Gasket maker. * Gasket maker should be so applied that it does not overflow the contacting surface, 5-22POwR] @&} | CRANK SHAFT AND PISTON CRANK SHAFT AND PISTON EXPLODED DIAGRAM. 5-23REMOVAL AND INSTALLATION CHART. CRANK SHAFT AND PISTON Procedure/Part name RANK SHAFT AND PISTON DISASSEMBLY Crank shaft asembly Piston pin clip | Piston pin | | { | Piston pin washer ‘Small end bearing needle | Piston | Top piston ring 2nd piston ring | Bearing Crank shaft jov B24 ‘Service points Follow the left “Step” for removal. Refer to the “CRANKCASE AND CYLINDER BODY” section. CE —————— Take care not to damage piston pin hole CAUTION: Always use the new cli NOTE: ‘When the piston pins, pistons, and small end needle bearings are reused, they should be marked with No. 1 and 2 so that they are not confused. ‘The washer should be placed with their con- vex sides facing the piston. Do not a mixture of new and used bearing needles in the same small end. NOTE: Mold mark ® the “UP” mark on the piston. NoTe: ——___ Remove the piston ring from the piston by opening the ring to the least possible width. Reverse the removal steps for installation.CRANK SHAFT AND PISTON SERVICE POINTS Bearing removal 1, Remove: * Bearing NOTE: Hold the bearing with the bearing separator, and forth out the crankshaft with a press. se Bearing separator: YB-06219/90890-06534 1, Measure: © Piston diameter Use a micrometer. Qut of specification —» Replace. | Meas As | | Piston diameter point “H” Standerd) 32mm | §5:940~56.985 mm | (0.4in) (2.2024 ~ 2.2041 in) Over size piston diamet. 1%: 56.25 mm (2.215 in) 2:56.50 mm (2.224 in) *: Except for U.S.A. 2, Measure: * Piston pin boss inside diameter Use a micrometer. Out of specification —> Replace. 14.004 ~ 14.015 mm {0.5513 ~ 0.5518 in) Piston pin and small end bearing inspection 1. Inspect * Piston pin ‘* Small end bearing Signs of heat discoloration — Replace. Soratch/Damage = Replace. 5-25POWR CRANK SHAFT AND PISTON 2. Measure: * Piston pin diameter Use a micrometer. Out of specification > Replace. Piston pin diameter: 13.996 ~ 14.000 mm (0.5510 ~ 0.5512 in) 3. Check: * Free play (when the piston pin i in the piston.) There should be no noticeable for the play. Free play exists — Replace the pin and/or piston. inserted Piston ring inspection 1. Inspect: * Piston ring Breakage/Demage — Replace. 2. Measure’ * End gap Use a feeler gauge. Out of specification ~ Replace. End gap: Top: 0.15 ~ 0.35 mm (0.006 ~ 0.014 in} 2nd: 0.15 ~ 0.35 mm {0.006 ~ 0.014 in) End gap limit: Top: 0.55 mm (0.022 in) 2nd: 0.55 mm (0.022 in) Measuring point 20 mm (0.8 in) NoTe: — Install the piston ring into the cylinder. Push the ring with the piston crown. 3. Measure: * Side clearance Use a thickness gauge. Out of specification —> Replace piston and/ orring. Top Al: 0.02 ~ 0.06 mm (0.001 ~ 0.002 in) 2nd @): 0.04 ~ 0.08 mm (0.002 ~ 0.003 in) 5.26CRANK SHAFT AND PISTON Crankshaft inspection 1. Measure: * Crank width @ * Crank width ® Out of specification + Replace. Crank width @: 46.90 ~ 46.95 mm (1.846 ~ 1.848 in) Crank width ®: 25.90 ~ 26.10 mm (1.020 ~ 1.028 in) 2, Measure: © Runout Use a V-blocks and dial gauge. Out of specification — Replace. (AAS Runout timi kA 0.03 mm (0.001 in) 3. Measure: © Axial play Out of specification + Replace. ‘Axial play 2.0 mm (0.08 in) 4, Inspect: * Crankshaft bearing Pitting/Rumbling — Replace. * Do not spin bearing with damage the bearing. © Also take care not to scratch the bearing balls when cleaning. ir blow; this can 5:27CRANK SHAFT AND PISTON Piston and piston ring installation 1. Insta * Piston 1g (2nd) * Piston ring (top) * Take care not to scratch the piston or break piston rings. locating pins. Alter fitting the rings, check that they move smoothly. NOTE: Piston rings should be repiaced as a set. Crankshaft and piston installation 1. Install: Small end bearing needle Needles per piston: 25 pieces ‘Small end bearing needle instal ‘YB-06104/90890-06543 5-28LOWR’ LOWER UNIT REMOVAL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART SERVICE POINTS. Propeller inspection Lower unit installation . CHAPTER 6 LOWER UNIT WATER PUMP. EXPLODED DIAGRAM .. REMOVAL AND INSTALLATION CHART ‘SERVICE POINTS Water pump housing inspection Impeller and insert cartridge inspection. PROPELLER SHAFT AND REVERSE GEAR EXPLOCED DIAGRAM .... REMOVAL AND INSTALLATION CHART .. SERVICE POINTS. Propeller shaft housing removal Propeller shaft housing disassembly 67 Reverse gear inspection... Bearing inspection Propeller shaft housing inspection Dog clutch inspection Propeller shaft inspection Propeller shaft housing assembly . DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD EXPLODED DIAGRAM . REMOVAL AND INSTALLATION CHART 611 SERVICE POINTS. Pinion nut removal and installation . Forward gear disassembly. Bearing housing disassembly and assembly. Lower case disassembly Pinion and forward gear inspection Drive shaft inspection Shift cam inspection Bearing inspection Sleeve inspection Lower case inspection Lower case assembly Drive shaft oil seal housing assembly Forward gear assembly..SHIMMING.... EXPLODED DIAGRAM ..00- SHIM SELECTION (FOR USA AND CANADA) Pinion gear shim... SHIM SELECTION (EXCEPT FOR USA AND CANADA) Pinion gear shim Forward gear shim.. Reverse gear shim... BACKLASH MEASUREMENT... Forward gear Reverse gear...LOWR LOWER UNIT REMOVAL LOWER UNIT REMOVAL EXPLODED DIAGRAM hi » Cm] a)LOWER UNIT REMOVAL REMOVAL AND INSTALLATION CHART Procedure/Part name Sarvies points LOWER UNIT REMOVAL Follow the left “Step” for removal. Cotter pin Propeller nut NOTE: Plane washer H the propeller nut does not align with the Deflection ring propeller shaft hole when the nut is tightened Propeller to specification, turn it in further so that they Spacer align. Adjusting nut NOTE: Locknut ‘When connecting the adjusting nut, set the Bolt (with washer) 4 | shift lever and shift cam to reverse position. Lower unit NOTE: Seal rubber Ingert the drive shaft into the crankshaft. f the Pin splines will not come in complete mesh, Bolt (with washer) rotate the propeller shaft a little so that they Extension are in mesh correctly. Pin ‘Seal rubber Circlip Damper Bushing Reverse the removal steps for installation. {8 : For super long model : For dual thrust model SERVICE POINTS Propeller inspection 1, Inspect: © Blade © Spline ‘Wear/CrackDamage ~ Replace. Lower unit installation 1. Install: © Adjusting nut PRG The adjusting nut should be screwed in more than 8 mm (0.31 in).WATER PUMP LOWR' ‘WATER PUMP EXPLODED DIA \GRAMLOWR, WATER PUMP REMOVAL AND INSTALLATION CHART ‘Step Procedura/Part name ay Service paints WATER PUMP REMOVAL Follow the left “Step” for removal Lower unit assembly Refer to the “LOWER UNIT REMOVAL” sec- | tion. 1 | Bolt a] 2 | Plate 2 3. | Water pump housing 1 | NOTE: 4 | o-ing | 1 [When instalting the water pump housing, 5 | | turn the drive shaft clockwise. 6 | Woodruff key \1 7 | Bolt | 2 | 8x25mm 8 | Pin 2 9 | Cartridge plate 1 10 | Water seal rubber 1 | Reverse the removal steps for installation. SERVICE POINTS Water pump housing inspection 1, Inspect: ‘* Water pump housing Crack/Damage -> Replace. Impeller and insert cartridge inspection 1. Inspect: © Impeller © Insert cartridge Crack/Damage -» Replace.LOWR € PROPELLER SHAFT AND REVERSE GEAR PROPELLER SHAFT AND REVERSE GEAR EXPLODED DIAGRAMLOWR’ t PROPELLER SHAFT AND REVERSE GEAR REMOVAL AND INSTALLATION CHART Procedure/Part name ay Service points PROPELLER SHAFT AND REVERSE ~~] Follow the left “Step” for removal. GEAR REMOVAL Gear oil Refer to the “LOWER UNIT” section in chapter 3. Propeller Refer to the “LOWER UNIT REMOVAL" section. Bolt (with washer) 6x 20mm Propeller shaft housing assembly Plate washer Propeller shaft } Cross pin ring | NOTE: By pushing the shift plunger, bring the cross pin hole in the dog clutch with the hole in the | | shift slider. Cross pin Dog clutch | 1 | NOTE: Install the clutch with “F” mark toward the forward gear side. Shift plunger 1 Spring 1 PROPELLER SHAFT HOUSING DISASSEMBLY O-ring O-ring Reverse gear Reverse gear shim Ball bearing Oit-seal Needle housing Propeller Shaft housing @29Ge@6009 Reverse the removal steps for installation. As required 66LOWR' t PROPELLER SHAFT AND REVERSE GEAR SERVICE POINTS Propeller shaft housing removal 1. Remove: * Propeller shaft housing assembly Bearing housing puller: 90890-06504 ... For USA and CANADA Except for USA and CANADA @ 5) Propeller shaft housing disassembly 1. Remove: * Ball bearing For USA and CANADA Except for USA and CANADA a B 2. Remove: * Needle bearing Va Driver rod: ‘YB-06071/90890-06604 Needle bearing attachment: ‘YB-06081/90890-06615 67PROPELLER SHAFT AND REVERSE GEAR Reverse gear inspection 1. Inspect: * Tooth * Dog Wear/Damage — Replace. Bearing inspection 1. Inspect: * Bearing Pitting/Rumbling —> Replace. Propeller shaft housing inspection 1. Clean: * Propeller shaft housing Use a soft brush and solvent. 2. Inspect: * Propeller shaft housing Crack/Damage — Replace. Dog clutch inspection 1. Inspect: © Dog clutch Wear/Damage — Replace. Propeller shaft inspection 1, Inspect: * Propeller shaft Wear/Damage -> Replace. Propeller shaft housing assembly 1. Install: * Needle bearing Depth@: O mm (0in} Driver rod: YB-06071/90890-06604 Needle bearing attachment: YB-06081/90890-06616 68LOWR € PROPELLER SHAFT AND REVERSE GEAR 2. Install: 69 Driver rod: ‘YB-06071 3, Install © Ball bearing Bearing installer: ‘YB-06015 Driver rod: ‘YB-06071LOWR| € DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD EXPLODED DIAGRAM ZoNm 6 mkg, 19 elo)REMOVAL AND INSTALLATION CHART LOWR: DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD i Step Procedure/Part name ay Service points 7 DRIVE SHAFT, FORWARD GEAR =| _—|_ Follow the left “Step” for removal. — AND SHIFT ROD REMOVAL | Propeller shaft Rofer to the “PROPELLER SHAFT AND RE- | | VERSE GEAR” section. Impeller Refer to the “WATER PUMP” section. 1 | Pinion nut 1] 2 | Pinion gear }4 3. | Shim j4 4 | Thrust bearing | 1| 5 | Drive shaft 1 | Forward gear assembly 11 7 | Bearing housing 1 8 | Shiftrod 1 9 | o-ring 1 10 | Bearing housing gasket \1 11 | Sleeve ) 1 | NOTE: | Install the sleeve with its hole frontward. ~~) BEARING HOUSING DISASSEMBLY | - — © | Oilseal \2 ® | Bushing 14 @ | Bearing housing |1 ~ | LOWER CASE DISASSEMBLY i } =e @ | Forward gear bearing outer race 1| @ | Forward gear shim \+ © | Noodle bearing Ja @ | Bolt [1 | 8x30mm Toothed washer 1 @ | Anode 1 @ | Screw {1 @ | Water inlet cover }2 ® | Nut | 1 | | Reverse the removal steps for installation. L__t 1 *:As required 611> LOWR| DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD ‘SERVICE POINTS Pinion nut removal and installation 1. Remove and install: * Pinion nut Drive shaft holde ‘YB-06228/90890-06515 Pinion nut holder: YB-06078 Forward gear disassembly 1. Remove: * Taper roller bearing * Forward gear Vea Bearing separator: YB-06219/90890-06534 Bearing housing disassembly and assembly 1. Remove and install: * Bushing 5 Bushing attachm: ‘YB-06028/90890-06649 Driver rod: ‘YB-06229/90890-06652 Lower case disassembly 1. Remove: shaft needle be ing Needl 9 attachment: ‘YB-06230/0890-0661 Driver rod: YB-06229/90890-06602, 6-12DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD 2. Remove: * Forward gear bearing outer rece {For USA and CANADA (8) Except for USA and CANADA Pinion and forward gear inspection 1. Inspect: * Tooth * Dog Wear/Damage — Replace. Drive shaft inspection 1. Inspect © Drive shaft Wear/Damage — Replace. Shift cam inspection 1. Inspect: © Shift cam Wear/Damage -+ Replace. Bearing inspection 1. Inspect: * Bearing Pitting/Rumbling — Replace. Sleeve inspection 1. Inspect: * Sleeve Wear/Damage —> Replace. 613Lown et DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD Lower case inspection 1. Clean: + Gear case Use a soft brush and solvent, 2. Inspect: © Water passage * Lower case Crack/Damage ~» Replace. Lower case assembly 1. Install: * Forward gear shim@® ‘* Forward gear bearing outer race@ Ls] Bearing installer: ‘YB-06085/90890-06625 Driver rod: YB-06071/90890-06605 2. Install: © Drive shaft needle bearing Depth @: 17.8 mm (0.70 in) Depth ©: 172,7-173.2 mm (6.80~6.82 in} Bearing attachment: ‘YB-0623¢ 90890-06617 Driver rod: Bearing depth plate: 90890-06603 ... 614 For USA and CANADA Except for USA and CANADA weDRIVE SHAFT, FORWARD GEAR AND SHIFT ROD Drive shaft oil seal housing assembly 1. Install: * Oil seal ® Driver rod: ‘YB-06071 Forward gear assembly 1. Install: * Forward gear * Taper roller bearing 6-15Lown| © | stmmine SHIMMING EXPLODED DIAGRAM a | al ye Tu[B.Bt.es10.18|__ Bs As ASHIMMING NOTE: Shim selection requirement guide: ‘© Not required when; reassembling with original case and inner parts. * Numeric calculation is required when; reassembling with original inner parts and the new case. (Difference between original and new case) * Measurement and adjustment is required when; replacing the inner part(s). SHIM SELECTION (FOR USA AND CANADA) Pinion gear shim 1, Measure: * Pinion gear clearance : Out of specification — Adjust. Yeas | Measuring steps: ‘* Install the drive shaft components and tighten the pinion nut. Pinion nut: 26 Nm (2.6 m + kg, 19 ft - Ib) * Attach the shimming tool into the gear case. Pinion height gauge: YB-34232 ‘¢ Measure the clearance and determine the shim thickness. Less than | Tobe decreased by 1.15mm_ | (1.20- measurement) More than | To be increased by 1.25mm_— | (measurement - 1.20) 6-17LOWR ‘SHIMMING Example: If measurement = 1.02 mm decrease shim thickness by .20- 1.02 1.18 mm If measurement = 1.32 mm increase shim thickness by .32- 1.20 = 0.12 mm Note: Find forward and reverse gear shim thickness by backlash measurement. 6-18Lowe € SHIMMING SHIM SELECTION (EXCEPT FOR USA AND CANADA) i shim ing shims until the specified measurement is obtained with the special tool 1, Measure: © Measurement (M) > Digital caliper: 90890-06704 NOTE: Measure the thicknesses (Mv3) of be washer. ing and 2. Calculate: inion gear shim thickness (T3) (A&] Pinion gear shim thickness (A (73) =6.05 - Mv3 mm. 3. Select: * Pinion gear shim Calculated numeral more than 1.13 Using shim 1.20 443 | 1.20 ‘Available shim thickness: 1.13 and 1.20 mm 6-19LOWR' € SHIMMING Forward gear shim Note: — Find forward gear shim thickness (T1) by select- ing shims until the specified measurement (M) obtained with the special to 1. Measure: Me © Measurement (M) ‘Shimming pl 90890-06701 Digital caliper: 90890-06704 NOTE: Measure the length between the shimming plate and the bearing outer race after turning the outer race 2 to 3 times. 2. Calculate: © Forward gear si thickness (T1) [ZA] Forward gear shim thickness (AN (11) = 16.60-Mivt 3. Select: * Forward gear shim Calculated numeral at 1/100th place more than_| Rounded numeral Available shim thickness: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm Example: HTT is “0.44 mm”, then forward gear shim = 0.42 mm WT1 is “0.45 mm", then forward gear shim = 0.45 mm 620LOWR SHIMMING Reverse gear shim Nore: —— Find reverse gear shim thickness (T2) by select- ing shims until the specified measurement (M) is obtained with the special tool. 1. Measure: ‘© Measurement (M) Shimming plate: ‘90890-06701 Digital caliper: 90890-06704 NOTE: Remove the shim(s) before measurement. 2. Calculate: ‘© Reverse gear shim thickness (T2) [ASX] Reverse gear shim thickness (AX| tra) = 8057 - ve 3. Select: * Reverse gear shim Calculated numeral pas Using shim 0.30 0.60 Available shim thickness: 0.10, 0.20, 0.30, 0.40 and 0.50 mm| 621LOWR SHIMMING BACKLASH MEASUREMENT NoTt ‘© Do not install the water pump components when measuring the backlash ‘© Both forward and reverse gear backlashes should be measured. * If both the forward and reverse gear backlashes are large than specified, the pinion may be too high. © If both forward and reverse gear backlashes are smaller than specified, the pinion may be too low. * Ifeither of these conditions exists, then check the pinion shim selection Forward gi a 1. Measure: * Forward gear backlash Out of specification > Adjust. Backlash: 0.19 ~ 0.86 mm (0.007 ~ 0.034 in) ‘* Set the shift shaft in the forward position. ‘* Set the bearing housing puller for pushing the propeller shaft. Bearing housing puller ‘YB-06234/90890-06503 Universal puller: ‘YB-06117 ‘Stopper guide plate: ‘90890-06501 Center bolt: 90890-06504 Center bolt: 5 Nm (0.5 m+ kg, 3.6ft + Ib) © Set the lower unit upside down. ‘© Attach the backlash indicator on the drive shaft (12.8 mm in diameter). Backlash indicator: ‘YB-06265/90890-06706SHIMMING Dial gauge: YU-03097 /90890-01252 Q Magnet base: YU-34481/90890-06705 * Attach the dial gauge on the lower case, and make the dial gauge stem contact the mark on the indicator. xt a ‘YB-07003 Ne + ‘© While pulling the drive shaft, slowly turn the drive shaft clockwise and counterclockwise; then, measure the backlash when the drive shaft stops in each direction. 2. Adjust * Forward gear shim(s) NOTE: Adjust the shim(s) to be added or removed according to specification. Forward gearbacklash Shim thickness To be decreased by 0.53 measurement) poof To be increased by (measurement - 0.53) 21 Less than 0.19 mm More than 0.86mm Available shim thickness: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50mm_ Reverse gear 1. Measure: * Reverse gear backlash Out of specification ~> Adjust. AS ssn na ex 6-23[Lowa] t€ SHIMMING Measuring steps: ‘* Set the shift shaft in the reverse position. * Load the reverse gear by installing the propeller with the front side facing backward, and tighten the propeller nut. 5 Nm (0.5 m+ kg, 3.6 ft - Ib) ‘* Attach the backlash indicator on the drive shaft (12.8 mm in diameter) aa Backlash indicator: ‘YB-06265/90890-06706 ‘* Attach the dial gauge on the lowercase, and make the dial gauge stem contact the mark on the indicator. Backlash adjusting plat: YB-07003 Dial gauge: ‘YU-03097/90890-01252 Magnet base: ‘YU-34481/90890-06705 © While pulling the drive shaft, slowly turn the drive shaft clockwise and counterclockwise; then, measure the backlash when the drive shaft stops at each direction. 2. Adjust: * Reverse gear shimi(s) NOTE: Adjust the shim(s) to be added or removed according to specification. Reverse gear backlash | Shim thickness To be decreased by Less than 0.95 mm ) Available shim thickness: 0.10, 0.20, 0.30, 0.40 and 0.50 mi 6-24BRKT CHAPTER 7 BRACKET UNIT ‘STEERING HANDLE AND SHIFT LEVER.. EXPLODED DIAGRAM . REMOVAL AND INSTALLATION CHART ‘SERVICE POINTS. Control cable inspection Bushing inspection Friction piece inspection Steering handle inspection .. Throttle shaft inspection wn BOTTOM COWLING EXPLODED DIAGRAM ..... REMOVAL AND INSTALLATION CHART UPPER CASE AND EXHAUST MANIFOLD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART : TT SERVICE POINTS... Rubber mount inspection Mount bolt inspection .. CLAMP BRACKET EXPLODED DIAGRAM .. REMOVAL AND INSTALLATION CHART ... ‘STEERING AND SWIVEL BRACKET. EXPLODED DIAGRAM ne : REMOVAL AND INSTALLATION CHARTBRKT T STEERING HANDLE AND SHIFT LEVER STEERING HANDLE AND SHIFT LEVER EXPLODED DIAGRAM SS “ Thm (akg, 29 eb) 7ABRKT ‘STEERING HANDLE AND SHIFT LEVER REMOVAL AND INSTALLATION CHART AND SHIFT LEVER [Step Procedure/Part name Qty Service points ‘STEERING HANDLE REMOVAL Follow the left “Step” for removal. Control pulley bracket assembly Refer to the “POWER UNIT REMOVAL" sec- tion in chapter 5. 1 | Bot 1 | 6X16mm 2 | Plate 1 3. | Bushing 1 4. | Plane washer 1 5. | Wave washer 1 6 | Bushing 1 7_| Steering handle assembly lel ‘SHIFT LEVER REMOVAL 8 | Clip 1 9 | Plane washer 1 10 | Bott 1 | 6x12mm 11 | Shift lever || 12 | Wave washer | 1| 13. | Shift link rod 1 ‘Screw Plate Clip Friction adjusting screw Screw Steering Plane washer Spring Bushing Throttle shaft Friction piece Throttle cable BSS@©GDGeGS8O000 Reverse the removal steps for installation. 72STEERING HANDLE AND SHIFT LEVER SERVICE POINTS Control cable inspection 1. Inspect © Throttle cable Kink/Fray/Stick + Replace. Bushing inspection 1. Inspect: * Bushing Wear/Crack/Damage ~» Replace. Friction piece inspection 1. Inspect: * Friction piece WeariCrack/Damage -> Replace. 1. Inspect: © Steering handle Wear/Crack/Damage — Replace. Throttle shaft inspection 1. Inspect: © Throttle shaft Wear/Bent/Damage —> Replace. 73BRKT, TY BOTTOM COWLING BOTTOM COWLING EXPLODED DIAGRAMBRKT BOTTOM COWLING REMOVAL AND INSTALLATION CHART Procedure/Part name Service points BOTTOM COWLING REMOVAL Power unit Bolt (with washer) Bottom cowling assembly Seal rubber Follow the left “Step” for removal. Refer to the “POWER UNIT REMOVAL" sec- tion in chapter 5. 6x 25mm BOTTOM COWLING DISASSEMBLY Collar Grommet Hose nipple Nut Plane washer Clamp hook Bushing Bolt Clamp lever Wave washer Bushing Fitting plate Grommet Grommet Grommet Grommet Bolt (with washer! Nut Remote bracket Grommet Grommet Nut Cop 2P connector Nut Plane washer Starter switch ® @ @ @ ® © @ ® ® @ ® @ 8 ® ® ® @ ®@ ®@ @ @ ® @ @ ® ® @ except for remote model for remote model: 6 x 16 mm. except for electrical starter model for 2P connector for starter switch model Reverse the removal steps for installation.BRKT i) UPPER CASE AND EXHAUST MANIFOLD UPPER CASE AND EXHAUST MANIFOLD EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART BRKT UPPER CASE AND EXHAUST MANIFOLD Step, Procedure/Part name Service points UPPER CASE REMOVAL Follow the left “Step” for removal. Bottom cowling assembly Refer to the “BOTTOM COWLING REMOVAL” section. Lower unit Refer to the “LOWER UNIT REMOVAL" sec- tion in chapter 6. 1 | Screw 1 2 | Nipple 1 3. | Nut 2 4 | Bolt (with washer) 2 | 6x55mm 5 | Nur 2 6 | Bolt (with washer) 2 | 6x75mm 7 | Lower mount rubber housing 2 8 | Front mount rubber 1 9 | Side mount rubber 2 10 | Water tube 1 11. | Seal rubber 1 12 | Nut 2 13. | Plate 1 14 | Bracket unit assembly 1 15 | Bolt (with washer) 3 | 6x18mm 16 | Upper rubber mount 1 17 | Water rubber seal 1 18 | Upper casing gasket 1 19. | Water rubber seal 1 20 | Plane rubber 1 21_| Upper case 1 EXHAUST MANIFOLD REMOVAL Power unit Refer to the “POWER UNIT REMOVAL" sec- tion in chapter 5. 22. | Bolt (with washer) 5 | 6x20mm 23, | Exhaust manifold 1 24 | Exhaust manifold gasket 1 25. | Exhaust manifold packing 1 26 | O-ring 1 Reverse the removal steps for installation. 1UPPER CASE AND EXHAUST MANIFOLD SERVICE POINTS Rubber mount inspection 1. Inspect: * Rubber mount Wear/Crack/Damage — Replace. Mount bolt inspection 1. Inspect: ‘* Mount bolt Wear/Bent/Damage — Replace. 78BRKT a CLAMP BRACKET CLAMP BRACKET EXPLODED DIAGRAMCLAMP BRACKET REMOVAL AND INSTALLATION CHART Procedure/Part name Service points CLAMP BRACKET REMOVAL Follow the left “Step” for removal. 1 | Screw 2 2 | Lead wire 1 3 | Tiitpin 1 4 | Nut 1 5. | Plane washer 1 6 | Coltar 1 7 | Bott 1 8 | Bolt 2 9 | Nut 1 10 | Clamp bracket plate 1 11 | Clamp bracket assembly 1 1 12 | Plane washer 1 13. | Bushing 1 14 | Clamp bracket bolt 1 15 | Bushing 1} Carrying handle model 16 | Carrying handle assembly 1 17 | Bushing 1 18 | O-ring 1 19 | Bushing 1 20 | Plane washer 1 21 | Clamp bracket assembly 2 1 22_| Nut 1 CLAMP BRACKET DISASSEMBLY ® | Bott 2 ® | Tilt stop tever 2 @_| Clamp bracket 2 CARRYING HANDLE DISASSEMBLY @ | Screw 1 | Carrying handle model © | Nut 1 ® | Hook 1 ® | Wave washer 1 © | Colter 1 @® | Carrying handle 1 Reverse the removal steps for installation. 7-10BRKT| A | steric ano swivet BRAckeT STEERING AND SWIVEL BRACKET EXPLODED DIAGRAMBRKT STEERING AND SWIVEL BRACKET REMOVAL AND INSTALLATION CHART Step Procedure/Part name ay Service points ~ | STEERING BRACKET REMOVAL Follow the left “Step” for removal. | Clamp bracket assembly Refer to the “BOTTOM COWLING* section. section. 1. | Flange bolt 1] 2. | Seal rubber 1 3. | Bushing 1| 4 | O-ing 1 5. | Bushing 1 6 | Steering bracket 1 7 | Bushing 1 8_| Friction piece 1 ‘SWIVEL BRACKET DISASSEMBLY 9 | Spring Nea) 10 | Clip \0 11 | Tilt lock shaft vy 12 | Tilt lock rod 1} 13 | Tilt lock arm 7 | 14 | Clip 1 15 | Tilt lock plate shaft 1 16 | Shallow water drive lever 1 17 | Spring 1 18 | Pin 1 19 | Tilt ever 1 20 | clip 2 21 | Shaft pin 1 22 | Bushing }2] 23 | Control! lever 1 24 | Bushing 1 25 | Swivel bracket 1 Reverse the removal steps for installation. 712CHAPTER 8 ELECTRICAL UNIT ELECTRICAL COMPONENTS MANUAL STARTER MODEL. ELECTRICAL STARTER MODEL .. REMOTE CONTROL MODEL........ ELECTRICAL ANALYSIS. INSPECTION. Peak voltage measurement .. IGNITION SYSTEM..... WIRING DIAGRAM IGNITION SPARK GAP : CDI SYSTEM PEAK VOLTAGE SPARK PLUG... SPARK PLUG CAP . ENGINE STOP SWITCH... MAIN SWITCH ‘STARTING SYSTEM WIRING DIAGRAM ...... BATTERY .. FUSE WIRING HARNESS .. WIRING CONNECTION... ENGINE STOP SWITCH MAIN SWITCH ..... STARTER SWITC NEUTRAL SWITCH .. STARTER RELAY STARTER MOTOR... EXPLODED DIAGRAM... REMOVAL AND INSTALLATION CHART..... SERVICE POINTS Pinion removal Pinion inspection Armature inspection Brush holder inspection Cover inspection CHARGING SYSTEM... WIRING DIAGRAM . CHARGING SYSTEM PEAK VOLTAGE FUSE BATTERY ..ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS MANUAL STARTER MODEL @ 2Peonnector* —_—*-Eyrope model B : Black @ Lighting coi Aro Br: Brown @ Charge coil 1O.® 8/0 : Black/Orange @ Ignition eoit © To pulser coil BIW: BlackAWhite © col unit De® G :Green © Rectifier regulator” fel to GM: GreenWhite © Engine stop switch Li Blue Ww: White WIR: White/RedELECTRICAL COMPONENTS, ELECTRICAL STARTER MODEL © Battery cable @ Rectifier HO @ Starter relay @® Engine stop switch Wr® @ Starter motor ® Starter switch D0®.®@ @® Lighting coit Ato® Kto@ © Charge coil B® [To pulser coit © Ignition coil {C) To battery ® CDi unit DTo@ © Fuse HTo® © Neutral switch Hm® (6) To spark plug B : Black Br_: Brown BJO : Black/Orange BIW: Black/White G :Green GM: GreenWhite L :Blue Ro :Red W_ : White WIR: White/RedREMOTE CONTROL MODEL @ Wire harness @ Battery cable @ Starter relay @ Starter motor @ Lighting coil © Charge coil @ Ignition coi © CDi unit © Fuse @ Rectifier Ar® To battery [E] To spark plug Fl To® To pulser coil ELECTRICAL COMPONENTS. B : Black Br_ : Brown 8/0 : Black/Orange B/W: BlackWhite Green /W: Green/White BlueELECTRICAL ANALYSIS ELECTRICAL ANALYSIS INSPECTION All measuring instruments should be handled with special care, or the correct measurement is impossible. ‘On an instrument powered by dry batteries, they should be checked for voltage periodically and replaced, if necessary. NOTE: “O-C" indicates the termin: there is a continuity of electri circuit at the respective between which ity; i.e., a closed switeh position. Peak voltage measurement NOTE: * The coil output veries greatly cranking speed. ‘* Cranking the cold engine with the plugs in and a weak battery cannot be found proper readings. Digital tester: J-39299 Peak volt adapter Yu-39991fevec|e3] IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM © Spark plug Br: Brown @ Ignition coit L Blue ® Charge coil WIR: White/Red @ Pulser coil 8/0 : Black/Orange © Main switch BIW: BlackWhite © Engine stop switch Wo: White ® 10P coupler B Black © 7P coupler ® COI unit {A except for remote control model for remote control model 85ELEC IGNITION SYSTEM IGNITION SPARK GAP —_____ ‘* While taking spark check be careful not to touch any connection of lead wires of the “Ignition spark gap tester”. ‘* When doing the spark test, take spe care not to allow leakage from the removed plug cap. * This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity. 1. Check: * Ignition spark gap Out of specification > Peak voltage mea- surement, [A] spark gap: ZAMS Checking steps: '* Adjust the spark gap to specification by turning the adjusting knob. ‘Spark gap tester: YM-34487/90890-06754 ‘© Connect the spark-plug cap to the spark gap tester. '* Remove the spark plugs from the engine. '* Cranking the engine and check sparks of ignition system seen through discharge window.IGNITION SYSTEM CDI SYSTEM PEAK VOLTAGE AWARNING While taking CDI unit check be careful not to touch any connection of lead wires. NOTE: © If there is no spark, or the spark is weak, continue with the CDI test. * Ifa good sparkis obtained, the problem is not with the CDI system, but possibly the spark plug or other component is defective. 1. Measui © CDI unit output (test #1) Below specification — Replace ignition coil. Repeat checking two times. CDI output: 170 V at cranking 215 V at 1500 r/min Measurement steps: * Connect the tester @ to the CDI unit @ as shown. * Set the tester dial to specification. wil Range: * Cranking or starting the engine.2. Measure: © Charge coil output (test #2) Below specification + Replace charge coil. Charge coil output: 200 V at cranking 250 V at 1500 r/ Measurement steps: * Connect the tester @ to the charge coil @ as shown. * Set the tester dial to specification. wil Rangi 7 * Cranking or starting the engine. 3, Measure: * Pulser coil output (test #3) Beyond specification — Replace CDI unit. Below specification —» Replace pulser coil. Pulser coil output: 5 Vat cranking 5 Vat 1500 r/min ‘Measurement steps: * Connect the tester @ to the pulser coil @ as shown. * Set the tester dial to specification. * Cranking or starting the engine. ‘SPARK PLUG Refer to the “GENERAL” section in chapter 3. 88ELEC IGNITION SYSTEM ‘SPARK PLUG CAP 1. Inspect: ‘© Spark plug cap Loosen + Tighten. Crack/Damage — Replace. 2, Measure: (For Canada and Europe) * Spark plug cap resistance Out of specification — Replace. wll Replacement steps: (Except for Canada and Europe) * Remove the spark-plug cap by pulling the spark-plug cap. ‘* Remove the plug-cap spring. © Strip the insulation cover 5 mm (0. and spread the core wires outward. Fit the plug-cap spring close to the spread core wires and bend the spring end for clamping. ‘* Install the plug-cap spring into the spark- plug cap. Spark plug cap resistance: 4.0 ~6.0kQ ® —> 89 Replacement steps: (For Canada and Europe) ‘* Remove the spark-plug cap by turning the cap counterclockwise. * Install the spark-plug cap by turning the cap clockwise until it stops.IGNITION SYSTEM ENGINE STOP SWITCH 1. Check: * Continuity Out of specification > Replace. Remove the button [C) MAIN SWITCH 1. Check: * Continuity Out of specification + Replace. Leads color White] Btack Red Yellow |Brown [O=FS | {| O--0 OOO 8-10STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM © Fuse Bl Except for remote céntrol model @ 10P coupler Remote control model @ 7P coupler B Black @ Main switch Br : Brown © Starter motor R :Red © Battory @ Starter switch ® Neutral switch @ Starter relayELEC STARTING SYSTEM BATTERY Refer to the “GENERAL” section in chapter 3. FUSE 1. Check: * Fuse 8-12 Blown ~ Replace. Fuse rating: 12V-20A WIRING HARNESS 1, Check: * Continuity iscontinuity — Replace. WIRING CONNECTION 1. Check: * Wiring connection Poor connection -» Correct. ENGINE STOP SWITCH Refer to the "IGNITION SYSTEM" section. MAIN SWITCH Refer to the "IGNITION SYSTEM" section. STARTER SWITCH 1. Check: * Continuity Out of specification —» Replace. Leads color Brown _| eaare) NEUTRAL SWITCH 4. Check * Continuity Out of specification ~ Replace. Length Leads color Brown | Brown 195 ~205mm (0.77 ~ 0.81 in) 18.5 ~ 19.5 mm © ‘lor ~0.77 in)| O-ELEC STARTING SYSTEM \ 8-13 STARTER RELAY 1. Inspect: © Brown lead terminal ‘* Black lead terminal Loose — Tighten. 2. Check: * Rolay operation Does not function > Replace. Checking steps: * Connect the tester between the terminals of the starter relay as shown. * Connect a 12 V battery. Brown lead (1) — Positive terminal Black lead @ —> Negative termi © Check that there is continuity between the starter relay terminals.ELEC STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM 10—ELEC STARTER MOTOR REMOVAL AND INSTALLATION CHART. Procedure/Part name Q'ty Service points STARTER MOTOR DISASSEMBLY Follow the left “Step” for removal. Starter motor assembly | Refer to the “ELECTRICAL UNIT RE- | MOVAL" section in chapter 5. Clip }1 Pinion stopper [1 Spring \1 Pinion 1 Through bolt 2 | Front cover 1 Washer 2 | 05mm Washer 3 | 0.25mm cirelin 1 Starter assembly 7 Armature assembly 1 Washer 1 1.0mm Nut 1 ‘Spring washer 7 Rear cover 1 Brush holder 1 Brush 1 18 | spring a 19 | owing 2 | Reverse the removal stops for istalation SERVICE POINTS: Pinion removal “Remove: * Clip@ Nore: Using a pry-bar, pry off the clip. 8-15STARTER MOTOR ion inspection 1. Inspect: * Pinion teeth Wear/Damage — Replace. 2. Check: * Clutch movement Damage — Replace. NOTE: Rotate the pinion clockwise, and check that it freely. Also try to rotate the pinion counterclock- wise and confirm that it locks. Armature inspection 1. Inspect: * Commutator Dirty + Clean with #600 abrasive paper. 2. Measure: ‘© Commutator diameter Out of specification — Replace. Commutator diameter: Limit 19.4 mm (0.76 in) 3. Check: © Commutator under cut ClogiDirty > Clean. NOTE: Removal all particles metal by compressed air. 8-16ELEC STARTER MOTOR 817 4. Inspect: © Armature coil continuity Out of specification > Replace. Armature coil continuity: ai Segment - Laminations ‘Segment - Shaft ntinuity Discontinu Discontinuity Brush holder inspection 1. Measure: * Brush length @ Out of specification + Replace. [A Brush length @: CAAL timit 45 rom (0.18 2. Check: * Brush holder continuity Out of specification ~> Replace. [eal Burush holder continuity. Cover inspection 1. Inspect: * Cover bushing ‘Wear/Damage -> Replace the cover.