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Yamaha 55DEHD, Service Manual

The Yamaha 55DEHD Service Manual is a comprehensive user manual that provides detailed instructions for operating and maintaining the Yamaha 55DEHD product. This manual is available for download free of charge from manualshive.com, offering users convenient access to essential information and ensuring optimal product performance.

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FUEL

4-

6885J11

4-7

Fuel system

6.

Apply the specified positive pressure and
check that there is no air leakage.
Disassemble the fuel pump if air leaked.

Disassembling the fuel pump

1.

Remove the 3 screws securing the pump
together.

NOTE:

To disassemble the fuel pump, refer to page
4-5.

2.

Check the diaphragms. Replace the
diaphragms if deteriorated or tears.

3.

Check the check valves. Replace the
check valve if bend or damaged. Also,
check the fuel pump body. Replace the
fuel pump body if damaged.

Checking the fuel pump

1.

Place a rag under the fuel hose connec-
tions, and then disconnect the fuel hoses
from the fuel pump.

2.

Connect the special service tool 

1

to the

fuel pump inlet.

3.

Cover the fuel pump outlet with a finger,
and then apply the specified positive
pressure. Check that there is no air leak-
age.

4.

Apply the specified negative pressure
and check that there is no air leakage.

5.

Connect the special service tool 

1

to the

fuel pump outlet.

Vacuum/pressure pump gauge set 

1

:

90890-06756

Specified positive pressure:

50 kPa (0.5 kgf/cm

2

, 7.3 psi)

69R40120

1

69R40140

1

69R40130

1

Specified negative pressure:

30 kPa (0.3 kgf/cm

2

, 4.4 psi)

Specified positive pressure:

50 kPa (0.5 kgf/cm

2

, 7.3 psi)

68840010

 6885J11_04  06.10.3 11:49  Page 8

Summary of Contents for 55DEHD

Page 1: ...YAMAHA MOTOR CO LTD Printed in Japan Oct 2006 1 1 1 E_2 Printed on recycled paper 75A SERVICE MANUAL 688 28197 5J 11 85A 55D 55D 75A 85A 688_cover qxd_1 07 9 26 16 21 Page 1 ...

Page 2: ...nd significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations Q The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED w Failure to follow WARNING instructions could result in severe injury or death to t...

Page 3: ...neral information Periodic check and adjustment Fuel system Power unit Bracket unit Electrical system Troubleshooting Index Contents Lower unit 9 8 7 6 2 1 GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT ELEC TRBL SHTG 3 4 5 ...

Page 4: ......

Page 5: ...ool 1 7 Propeller selection 1 13 Propeller size 1 13 Selection 1 13 Predelivery check 1 13 Checking the fuel system 1 13 Checking the gear oil 1 14 Checking the battery 1 14 Checking the outboard motor mounting height 1 14 Checking the remote control cable ED ET 1 14 Checking the steering system 1 15 Checking the PTT system ET 1 15 Checking the gear shift and throttle operation 1 16 Checking the e...

Page 6: ...er unit No Part name Q ty Remarks 1 Lower unit 1 2 Plastic tie 1 Not reusable 3 Hose 1 4 Check screw 1 5 Gasket 2 Not reusable 6 Dowel pin 2 7 Bolt 4 M10 40 mm 8 Drain screw 1 9 Grommet 1 10 Bolt 1 M10 45 mm 11 Bolt 1 M8 60 mm 12 Thrust washer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 18 Trim tab 1 LOWR Lower unit 6 19 62Y5A11 Removing the drive shaft...

Page 7: ...m or illustration indicate the grade of lubricant and the lubri cation point 7 Apply Yamaha 2 stroke motor oil 8 Apply gear oil 9 Apply water resistant grease Yamaha grease A 0 Apply molybdenum disulfide grease q Apply corrosion resistant grease Yamaha grease D w Apply low temperature resistant grease Yamaha grease C e Apply injector grease Symbols r to o in an exploded diagram or illustration ind...

Page 8: ...DN Downside or downward EN European Norm European standard F Forward IEC International Electrotechnical Commission LED Light Emitting Diode N Neutral NMMA National Marine Manufacturers Association PCV Pressure Control Valve PORT Port side PTT Power Trim and Tilt R Reverse SAE Society of Automotive Engineers STBD Starboard side TDC Top Dead Center UP Upside or upward WD Wiring Diagram 1401 ThreeBon...

Page 9: ...ct your hands and feet by wearing pro tective gloves and safety shoes when neces sary Part lubricant and sealant Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha when servicing or repairing the out board motor Under normal conditions the lubricants men tioned in this manual should not harm or be hazardous to your skin However you should follow these precautions ...

Page 10: ...starting in the center and moving outward Non reusable part Always use new gaskets seals O rings cot ter pins circlips etc when installing or assembling parts Disassembly and assembly 1 Use compressed air to remove dust and dirt during disassembly 2 Apply engine oil to the contact surfaces of moving parts before assembly 3 Install bearings with the manufacture identification mark in the direction ...

Page 11: ...on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number 68810010 Applicable model 55DEHD 75AEHD 75AED 75AET 85AEHD 85AED 85AET Model name Approved Starting model code serial No 55DEHD 63S 1001700 75AEHD 75AED 692 1020817 75AET 85AEHD 85AED 688 1013061 85AET Safety while working Identification ...

Page 12: ...meter 90890 06760 Timing light 90890 03141 Dial gauge set 90890 01252 Leakage tester 90890 06840 Vacuum pressure pump gauge set 90890 06756 Test propeller 90890 01620 Compression gauge 90890 03160 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Gear puller 90890 06540 ...

Page 13: ...ing pressure C 90890 02393 C Driver rod SS 90890 06604 Needle bearing attachment 90890 06607 90890 06608 90890 06611 90890 06612 90890 06615 90890 06632 90890 06636 90890 06655 Driver rod LS 90890 06606 Bearing inner race attachment 90890 06639 90890 06640 90890 06643 Small end bearing installer 90890 06527 Piston slider 90890 06530 ...

Page 14: ...ench extension 90890 06513 Stopper guide plate 90890 06501 Bearing housing puller claw L 90890 06502 Center bolt 90890 06504 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Driver rod L3 90890 06652 Bearing depth plate 90890 06603 Drive shaft holder 5 90890 06519 ...

Page 15: ...07 Bearing outer race puller assembly 90890 06523 Driver rod SL 90890 06602 Bearing outer race attachment 90890 06621 90890 06625 90890 06626 90890 06628 Driver rod LL 90890 06605 Shift rod push arm 90890 06052 Pinion height gauge plate B 90890 06712 Pinion height gauge 90890 06710 Digital caliper 90890 06704 ...

Page 16: ...dicator 90890 06706 Magnet base plate 90890 07003 Magnet base B 90890 06844 Test harness 90890 06878 PTT oil pressure gauge assembly 90890 06580 Cylinder end screw wrench 90890 06568 PTT piston vice attachment 90890 06572 Tilt rod wrench 90890 06569 Trim and tilt wrench 90890 06587 ...

Page 17: ...1 12 9 8 7 6 5 4 3 2 1 Special service tool Throttle sensor adjusting lead 90890 06857 Test harness 90890 06871 Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Ignition tester 90890 06754 ...

Page 18: ...tboard motor will be critically affected by the size and type of propeller you choose Propellers greatly affect boat speed acceleration engine life fuel economy and even boating and steering capabilities An incorrect choice could adversely affect performance and could also seriously damage the engine Use the following information as a guide for selecting a propeller that meets the operating condit...

Page 19: ...e gear oil 1 Check the gear oil level Checking the battery 1 Check the capacity electrolyte level and specified gravity of the battery 2 Check that the positive and negative bat tery cable are securely connected Checking the outboard motor mounting height 1 Check that the anti cavitation plate is aligned with the bottom of the boat If the mounting height is too high cavitation will occur and propu...

Page 20: ...f 8 0 mm 0 31 in c 68810060 1 4 Checking the steering system 1 Check that the steering operates smooth ly 2 Check that there is no interference with wires or hoses when the outboard motor is steered Checking the PTT system ET 1 Check that the outboard motor tilts up and down smoothly when operating the PTT unit 2 Check that there is no abnormal noise produced when the outboard motor is tilt ed up ...

Page 21: ...cking the gear shift and throttle operation 1 Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from N to F or R position 2 Check that the throttle operates smoothly when the throttle grip tiller handle model is turned from the fully closed position to the fully opened position a Check that the throttle operates smoothly when the remote control lev...

Page 22: ...s best 2 50 minutes b at 1 2 throttle approxi mately 3 000 r min or less Vary engine speed occasionally On an easy planing boat accelerate at full throttle onto plane then immediately reduce the throttle to 3 000 r min or less 3 1 hour c at 3 4 throttle approximately 4 000 r min Vary engine speed occa sionally Run at full throttle for 1 minute then allow about 10 minutes of operation at 3 4 thrott...

Page 23: ...hift to N position and then flush the cooling water passage with engine running at idle cC Be sure to supply sufficient water when flushing the cooling water passage other wise the engine may overheat w 9 Be sure to remove the propeller before using the flushing kit 9 Keep hands hair and clothes away from the propeller shaft while the engine is running 6885J11 1 18 9 8 7 6 5 4 3 2 1 6F610180 0 1 2...

Page 24: ...GEN INFO 1 19 6885J11 General information MEMO ...

Page 25: ...tenance specification 2 5 Power unit 55D 75A models 2 5 Lower unit 55D 75A models 2 7 Electrical 55D 75A models 2 7 Power unit 85A models 2 10 Lower unit 85A models 2 12 Electrical 85A models 2 12 Dimension 2 15 Tightening torque 2 19 Specified torque 2 19 General torque 2 21 ...

Page 26: ...aximum output kW hp 40 5 55 at 55 2 75 at 5 000 r min 5 000 r min Full throttle operating range r min 4 500 5 500 Maximum fuel consumption L 31 34 US gal 8 2 6 8 9 0 7 5 lmp gal hr 5 500 r min 5 500 r min Engine idle speed r min 750 850 Power unit Engine type 2 stroke L Cylinder quantity 3 Total displacement cm3 cu in 1 140 69 57 Bore x stroke mm in 82 0 72 0 3 23 2 83 Compression ratio 4 5 1 Inta...

Page 27: ...e Engine oil 2 stroke outboard motor oil Engine oil grade NMMA certified TC W3 Gear oil type Hypoid gear oil Gear oil grade 1 API GL 4 SAE 90 Gear oil quantity cm3 US oz 610 20 62 21 51 lmp oz Bracket unit Trim angle Degree 4 0 to 15 0 at 12 boat transom Tilt up angle Degree 67 0 Steering angle Degree 30 30 Drive unit Gear shift positions F N R Gear ratio 2 00 26 13 Reduction gear type Spiral beve...

Page 28: ...6 256 124 273 Performance Maximum output kW hp 62 5 85 at 5 000 r min Full throttle operating range r min 4 500 5 500 Maximum fuel consumption L 35 US gal 9 2 7 7 at 5 500 r min lmp gal hr Engine idle speed r min 750 850 Power unit Engine type 2 stroke L Cylinder quantity 3 Total displacement cm3 cu in 1 140 69 57 Bore x stroke mm in 82 0 72 0 3 23 2 83 Compression ratio 5 1 1 Intake system Reed v...

Page 29: ... 20 62 21 51 lmp oz Bracket unit Trim angle Degree 4 0 to 15 0 at 12 boat transom Tilt up angle Degree 67 0 Steering angle Degree 30 30 Drive unit Gear shift positions F N R Gear ratio 2 00 26 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction rear view Clockwise Propeller ID mark K Electrical Battery minimum capacity 2 CCA EN A 430 20HR...

Page 30: ...Cylinder head Warpage limit mm in 0 1 0 0039 lines indicate straightedge position Cylinder Bore size mm in 82 000 82 020 3 2283 3 2291 Piston Piston diameter D mm in 81 935 81 955 3 2258 3 2266 Measuring point H mm in 20 0 0 79 Piston clearance mm in 0 065 0 070 0 0026 0 0028 reference data Piston pin boss bore mm in 19 904 19 915 0 7836 0 7841 Oversize piston 1st mm in 0 25 0 010 2nd mm in 0 50 0...

Page 31: ... end inside diameter mm in 39 010 39 025 1 5358 1 5364 Connecting rod big end mm in 0 120 0 260 0 0047 0 0102 side clearance Small end axial play limit mm in 2 0 0 08 Crankshaft Crankshaft journal diameter mm in 34 968 34 984 1 3767 1 3773 Crankpin diameter mm in 29 985 30 000 1 1805 1 1811 Runout limit mm in 0 02 0 0008 Thermostat Opening temperature C F 48 52 118 4 125 6 Fully open temperature C...

Page 32: ...lser coil output peak voltage W R W Y W B W G at Cranking unloaded V 6 0 at Cranking loaded V 4 0 at 1 500 r min loaded V 8 0 at 3 500 r min loaded V 14 0 Pulser coil resistance Ω 256 384 at 20 C 68 F W R W Y W B W G Thermoswitch ON temperature C F 84 90 183 194 OFF temperature C F 60 74 140 165 Lower unit 55D 75A models Item Unit Model 55DEHD 75AEHD 75AED 75AET Gear backlash Pinion to forward gea...

Page 33: ... 1 Brushes Standard length mm in 16 0 0 63 Wear limit mm in 12 0 0 47 Commutator Standard diameter mm in 33 0 1 30 Wear limit mm in 31 0 1 22 Standard undercut mm in 0 8 0 03 Wear limit mm in 0 2 0 01 Choke solenoid resistance Ω 3 4 4 0 Charging system Fuse A 20 Lighting coil output peak voltage G G W at Cranking unloaded V 11 3 at 1 500 r min unloaded V 32 3 at 3 500 r min unloaded V 72 3 Lightin...

Page 34: ... 9 11 at 20 C 68 F P B Fluid type ATF Dexron 2 Motor type 6H102 Output kW 0 3 Brushes Standard length mm in 9 75 0 384 Wear limit mm in 5 5 0 22 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Standard undercut mm in 1 8 0 07 Wear limit mm in 1 3 0 05 Hydraulic pressure down MPa kgf cm2 2 2 3 8 22 38 Hydraulic pressure up MPa kgf cm2 9 11 90 110 ...

Page 35: ...er head Warpage limit mm in 0 1 0 0039 lines indicate straightedge position Cylinder Bore size mm in 82 000 82 020 3 2283 3 2291 Piston Piston diameter D mm in 81 935 81 955 3 2258 3 2266 Measuring point H mm in 20 0 0 79 Piston clearance mm in 0 065 0 070 0 0026 0 0028 reference data Piston pin boss bore mm in 19 904 19 915 0 7836 0 7841 Oversize piston 1st mm in 0 25 0 010 2nd mm in 0 50 0 020 O...

Page 36: ...iameter mm in 24 900 24 912 0 9803 0 9808 Big end inside diameter mm in 39 010 39 025 1 5358 1 5364 Connecting rod big end mm in 0 120 0 260 0 0047 0 0102 side clearance Small end axial play limit mm in 2 0 0 08 Crankshaft Crankshaft journal diameter mm in 34 968 34 984 1 3767 1 3773 Crankpin diameter mm in 29 985 30 000 1 1805 1 1811 Runout limit mm in 0 02 0 0008 Thermostat Opening temperature C...

Page 37: ...put peak voltage W R W Y W B W G at Cranking unloaded V 6 0 at Cranking loaded V 4 0 at 1 500 r min loaded V 8 0 at 3 500 r min loaded V 14 0 Pulser coil resistance Ω 256 384 at 20 C 68 F W R W Y W B W G Thermoswitch ON temperature C F 84 90 183 194 OFF temperature C F 60 74 140 165 Lower unit 85A models Item Unit Model 85AEHD 85AED 85AET Gear backlash Pinion to forward gear mm in 0 08 0 25 0 0032...

Page 38: ...in 16 0 0 63 Wear limit mm in 12 0 0 47 Commutator Standard diameter mm in 33 0 1 30 Wear limit mm in 31 0 1 22 Standard undercut mm in 0 8 0 03 Wear limit mm in 0 2 0 01 Choke solenoid resistance Ω 3 4 4 0 Charging system Fuse A 20 Lighting coil output peak voltage G G W at Cranking unloaded V 11 3 at 1 500 r min unloaded V 32 3 at 3 500 r min unloaded V 72 3 Lighting coil resistance Ω 0 36 0 54 ...

Page 39: ... F P B Fluid type ATF Dexron 2 Motor type 6H102 Output kW 0 3 Brushes Standard length mm in 9 75 0 384 Wear limit mm in 5 5 0 22 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Standard undercut mm in 1 8 0 07 Wear limit mm in 1 3 0 05 Hydraulic pressure down MPa kgf cm2 2 2 3 8 22 38 Hydraulic pressure up MPa kgf cm2 9 11 90 110 Maintenance specification ...

Page 40: ...5 21 5 67 2 6 790 31 1 547 21 5 164 6 5 199 7 8 47 1 9 23 0 9 743 29 3 L 901 35 5 Y 952 37 5 X 1 028 40 5 L 520 20 5 Y 571 22 5 X 647 25 5 191 7 5 L 698 27 5 Y 729 28 7 X 764 30 1 L 88 3 5 Y X 85 3 4 331 13 0 211 8 3 6882001M Dimension Exterior 55DEHD 75AEHD 85AEHD mm in Specification ...

Page 41: ... 545 21 5 67 2 6 547 21 5 164 6 5 199 7 8 47 1 9 23 0 9 743 29 3 L 901 35 5 X 1 028 40 5 L 520 20 5 X 647 25 5 191 7 5 L 698 27 5 X 764 30 1 L 14 0 0 6 X 23 0 0 9 27 5 1 06 L 88 3 5 X 85 3 4 331 13 0 211 8 3 6882002M Exterior 75AED 75AET 85AED 85AET mm in Maintenance specification ...

Page 42: ...17 6885J11 180 7 1 180 7 1 163 5 6 4 163 5 6 4 125 4 9 125 4 4 9 13 0 5 68 5 2 7 18 5 0 7 351 13 8 50 8 2 0 13 0 5 55 5 2 2 254 10 0 6882003M Clamp bracket 55DEHD 75AEHD 75AED 85AEHD 85AED mm in Specification ...

Page 43: ...18 9 8 7 6 5 4 3 2 1 180 7 1 180 7 1 163 5 6 4 163 5 6 4 125 4 4 9 125 4 4 9 13 0 5 68 5 2 7 18 5 0 7 351 13 8 50 8 2 0 13 0 5 55 5 2 2 254 10 0 6882003M Clamp bracket 75AET 85AET mm in Maintenance specification ...

Page 44: ...ting rod bolt 3rd M8 Loosen completely 4th 12 1 2 8 9 5th 35 3 5 25 8 Lower unit Check screw 9 0 9 6 6 Drain screw 9 0 9 6 6 Lower case bolt M10 40 4 0 29 5 Lower case nut X Y transom 40 4 0 29 5 Ring nut 105 10 5 77 4 Pinion nut 95 9 5 70 1 Propeller nut 35 3 5 25 8 Cooling water inlet cover screw 4 0 4 3 0 Bracket unit Throttle cable lock nut EHD 11 1 1 8 1 Tiller handle pivot bolt EHD M12 37 3 ...

Page 45: ...al valve 3 0 3 2 2 Pipe joint 15 1 5 11 1 Pipe joint 20 2 0 14 8 Stator mount screw PTT motor 3 4 0 34 2 5 Gear pump bolt M4 4 0 4 3 0 Tilt ram 65 6 5 47 9 Tilt cylinder end screw 90 9 0 66 4 Tilt piston bolt M6 13 1 3 9 6 Trim cylinder end screw 160 16 118 Electrical Negative battery terminal bolt M8 30 3 0 22 1 Positive battery terminal nut 9 0 9 6 6 Positive terminal nut 4 0 4 3 0 Starter relay...

Page 46: ...able sections of this manu al To avoid warpage tighten multi fastener assemblies in a crisscross fashion and pro gressive stages until the specified torque is reached Unless otherwise specified torque specification require clean dry threads Components should be at room temperature General torque Nut A Bolt B specifications N m kgf m ft lb 8 mm M5 5 0 5 3 6 10 mm M6 8 0 8 5 8 12 mm M8 18 1 8 13 14 ...

Page 47: ...Checking the engine idle speed 3 8 Checking the ignition timing 3 9 Checking the timing plate 3 10 Checking the ignition timing stopper 3 11 Checking the gear shift operation 3 13 Checking the neutral switch operation EHD 3 14 Checking the choke solenoid position ED ET 3 14 Bracket 3 15 Checking the PTT operation ET 3 15 Checking the PTT fluid level ET 3 15 Checking the tilt operation EHD ED 3 16 ...

Page 48: ... 4 Cowling clamp Check 1 3 2 Fuel filter can be dis Check clean 1 1 1 3 3 assembled Fuel system Check 1 1 1 3 2 Fuel tank Yamaha por Check clean 1 table tank Gear oil Change 1 1 3 17 Lubrication points Lubricate 1 3 20 Idle speed Check adjust 1 1 3 8 PCV Check 1 5 20 PTT unit Check replace 1 3 15 Propeller and cotter pin Check replace 1 1 3 19 Shift link shift cable Check adjust 1 3 13 Thermostat ...

Page 49: ...k the fitting again Repeat steps 3 5 if necessary 7 Check the rubber trim Replace the rub ber trim if worn deteriorated or dam aged 8 Check the lock lever bushings and wash ers Replace if worn or damaged 9 Check the hooks and rivets Replace the hooks and rivets if worn or damaged Fuel system cC Checking the fuel system procedures will allow some fuel to spill Catch fuel in a rag Wipe up any spille...

Page 50: ...electrodes 1 with a spark plug cleaner and wire brush 3 Check the electrodes 1 and gasket Replace the spark plug for erosion excessive carbon other deposits or dam age 1 2 68830050 4 Check the spark plug gap a Adjust or replace if out of specification 5 Tighten the spark plug temporarily and then tighten it to the specified torque with a spark plug wrench Checking the thermostat 1 Remove the therm...

Page 51: ...30070 Water Valve lift a temperature 48 52 C 0 05 mm 0 002 in 118 4 125 6 F valve begins to lift above more than 60 C 140 F 3 0 mm 0 12 in Checking the cooling water passage 1 Check the cooling water inlet covers 1 and cooling water inlet Clean the water inlet cover and cooling water inlet if clogged 2 Place the lower unit in water and then start the engine 3 Check for a water flow from the coolin...

Page 52: ... 3 7 2 Remove the throttle link rod 3 NOTE Separate the throttle cam 4 from cam roller 5 of the carburetor 3 Loosen the throttle stop screw 6 at the carburetor assembly 2 until it does not contact from the stopper 7 4 Loosen the throttle lever tightening screws 8 at the carburetor assembly 1 and 3 NOTE The throttle lever tightening screws are left hand thread 5 Make sure that the throttle valve is...

Page 53: ...to the cam roller 5 If it is not in contact remove the throttle link rod 3 and adjust its length 10 Install the intake silencer cover and con nect the throttle cable 11 Check the engine idle speed NOTE After synchronizing the carburetor make sure to check the engine idle speed refer to page 3 8 Checking the control link position 1 Disconnect the throttle cable NOTE To disconnect and connect the th...

Page 54: ...eck the timing stopper refer to page 3 11 7 Install the throttle link rod and the throttle cable Adjusting the throttle cable 1 Loosen the locknut 1 remove the pin 2 and then disconnect the throttle cable joint 3 2 Set the throttle grip or remote control lever to the fully closed position 3 Adjust the position of the throttle cable joint 3 until its hole aligned with the set pin 4 on control lever...

Page 55: ...s and then turn off the engine 2 Attach the special service tool 1 to spark plug wire 1 and then start the engine 3 Check the engine idle speed Adjust the engine idle speed if out of specification 4 Turn the throttle stop screw 2 in direction a or b until the specified engine idle speed is obtained NOTE 9 To increase the idle speed turn the throttle stop screw in direction a 9 To decrease the idle...

Page 56: ...full retard position NOTE To disconnect and connect the throttle cable refer to page 3 7 4 Attach the special service tool 4 and 5 to the spark plug wire 1 and then start the engine Check the engine idle speed and ignition timing 5 Check that the ignition timing is specified position a when the full retard CHK ADJ 3 9 6885J11 Periodic check and adjustment 68830285 2 1 3 68830180 4 5 Test propeller...

Page 57: ...l system 68830195 3 68830200 b Specified position b full advanced 55D 75A BTDC 21 23 85A BTDC 23 25 9 Turn off the engine and then remove the special service tools 10 Install the throttle link rod and connect the throttle cable Checking the timing plate NOTE Remove the all spark plugs and lock plate before adjusting the timing plate 1 Slowly turn the flywheel magnet clock wise and align it with th...

Page 58: ...ition timing is out of specifi cation NOTE To check the control link refer to page 3 6 Checking the ignition timing stopper 1 Disconnect the throttle cable and remove the throttle link rod NOTE To disconnect and connect the throttle cable refer to page 3 7 2 Slowly turn the flywheel magnet clock wise and check that the timing plate 1 is aligned with the scale a on the flywheel magnet in the specif...

Page 59: ...nk rod refer to page 3 6 68830250 b 4 68830038 5 c Length c reference data 71 mm 2 79 in 6 Check the screw out length d of the adjusting screw 3 7 Slowly turn the flywheel magnet clock wise and check that the timing plate 1 is aligned with the scale e on the flywheel magnet in the specified position 68830260 3 d Specified length d full advanced reference data 55D 75A 32 0 33 0 mm 1 26 1 30 in 85A ...

Page 60: ...hrottle link rod and connect the throttle cable Checking the gear shift operation 1 Check that the gear shift operates smoothly when shifting from N to F or R Adjust the shift cable if necessary by turning the cable joint 2 Set the gear shift to N position 3 Loosen the locknut 1 remove the pin 2 and then disconnect the shift cable joint 3 4 Make sure to align the mark a on the bracket 4 with mark ...

Page 61: ...ark a with the solenoid surface b 5 Adjust the position of the shift cable joint 3 until its hole is aligned with the set pin c w The shift cable joint 3 must be screwed in a minimum of 8 0 mm 0 31 in c NOTE Pull the shift cable toward the engine to remove any free play in the shift cable before adjusting the position of the cable joint 6 Connect the shift cable joint install the clip 7 Check the ...

Page 62: ...k the PTT fluid level if necessary NOTE Be sure to listen to the winding sound of the PTT motor for smooth operation 2 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 to check the lock mechanism of the lever Checking the PTT fluid level ET 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 w After tilting up the outboard motor be sure ...

Page 63: ...ew O ring reservoir cap 2 and then tighten it to the specified torque 2 68830400 Checking the tilt operation EHD ED w Be sure to tilt the outboard motor fully and support it with the tilt stop lever It can not be tilted up partially Otherwise the out board motor could fall back down sudden ly 1 Set the tilt lock lever 1 to tilt position 2 Check the outboard motor could tilting up Fully tilt the ou...

Page 64: ...eck and adjustment 69D30135 2 NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the check screw is removed 3 If necessary add sufficient gear oil of the recommended type until it overflows out of the check hole 4 Install the new gasket 2 check screw 1 and then tighten it to the specified torque Changing the gear oil 1 Tilt the outboard motor so that th...

Page 65: ...d 1 Remove the check screw 1 and then install the special service tool 2 2 Apply the specified pressure to check that the pressure is maintained in the lower unit for at least 10 seconds NOTE Cover the check hole with a rag when remov ing the special service tool from the lower unit 3 If the pressure is not maintained check the drive shaft propeller shaft oil seals O rings of propeller shaft housi...

Page 66: ... Do not oil grease or paint the anodes otherwise they will be ineffective NOTE If it is necessary to disassemble the outboard motor to check an anode refer to Chapter 5 or 6 and 7 2 Replace the anodes if excessively erod ed Checking the battery 1 Check the battery electrolyte level If the level is at or below the minimum level mark a add distilled water until the level is between the maximum and m...

Page 67: ... Wash with water 9 EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL 9 Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention 9 Charge batteries in a well ventilated area 9 Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes 9 DO NOT SMOKE wh...

Page 68: ...3 21 6885J11 Periodic check and adjustment 2 Apply temperature resistant grease to the areas shown 3 Apply corrosion resistant grease to the area shown 68830570 6B430300 68830490 a a 68830510 68830500 68830520 ...

Page 69: ...ecking the primer pump 4 6 Checking the fuel joint 4 6 Checking the fuel pump 4 7 Disassembling the fuel pump 4 7 Assembling the fuel pump 4 8 Carburetor 4 9 Disassembling the carburetor 4 13 Checking the carburetor 4 13 Checking the float height 4 13 Assembling the carburetor 4 14 FUEL ...

Page 70: ...ting 1 Fuel hose Fuel tank to primer pump 2 Fuel hose Primer pump to fuel joint 3 Fuel hose Fuel joint to fuel filter 4 Fuel hose Fuel filter to fuel pump 5 Fuel hose Fuel pump to carburetor 6 Cooling water hose OUT IN 4 1 2 3 5 6 6884006E ...

Page 71: ...6885J11 4 2 9 8 7 6 5 4 3 2 1 Hose routing 6884007E 2 3 1 4 1 Breather hose 275 mm 10 8 in 2 Breather hose 185 mm 7 3 in 3 Breather hose 102 mm 4 0 in 4 Breather hose 465 mm 18 3 in ...

Page 72: ... Fuel joint 1 2 Bolt 1 M6 20 mm 3 Clip 14 4 Fuel hose 1 5 Fuel hose 1 6 Fuel filter assembly 1 7 Bolt 1 M6 14 mm 8 Bracket 1 9 Nut 1 10 Fuel hose 1 11 Joint 2 M6 40 mm 12 Fuel hose 1 13 Fuel hose 1 14 Fuel hose 1 15 Fuel hose 1 16 Gasket 1 17 Fuel pump assembly 1 Not reusable ...

Page 73: ...6885J11 4 4 9 8 7 6 5 4 3 2 1 6884030E No Part name Q ty Remarks 18 Bolt 2 M6 40 mm 19 Fuel filter element 1 20 Float 1 21 O ring 1 22 Cup 1 Not reusable Fuel line ...

Page 74: ...stem 6884050E Fuel pump No Part name Q ty Remarks 1 Screw 3 ø5 30 mm 2 Cover 1 3 Diaphragm 1 4 Gasket 1 5 Nut 2 6 Screw 2 ø3 5 mm 7 Check valve 2 8 Fuel pump body 1 9 Gasket 2 10 Diaphragm 1 11 Base 1 Not reusable Not reusable ...

Page 75: ...ined 4 6 Fuel pump Checking the fuel joint 1 Disconnect the fuel hose and then remove the fuel joint 2 Check the fuel joint for cracks or damage 3 Connect the special service tool 1 at the outlet of fuel joint 4 Apply the specified pressure to check that the positive pressure is maintained for 10 seconds Replace the fuel joint if it is not maintained 5 Install the fuel joint and then connect the f...

Page 76: ...g the fuel pump 1 Place a rag under the fuel hose connec tions and then disconnect the fuel hoses from the fuel pump 2 Connect the special service tool 1 to the fuel pump inlet 3 Cover the fuel pump outlet with a finger and then apply the specified positive pressure Check that there is no air leak age 4 Apply the specified negative pressure and check that there is no air leakage 5 Connect the spec...

Page 77: ...sembly 1 Install the check valves 1 onto the fuel pump body 2 2 Install the new gaskets 3 4 diaphragms 5 6 cover 7 and base 8 to the fuel pump body 9 NOTE 9 Make sure that the gaskets 3 4 and diaphragms 5 6 are kept in place through the assembly process 9 After assembling check the fuel pump air leakage again 1 1 2 68840020 6 3 5 7 8 9 4 68840030 ...

Page 78: ... Screw 2 ø6 15 mm 2 Washer 2 3 Cover 1 4 Gasket 1 5 Bolt 6 M6 18 mm 6 Intake silencer 1 7 Cap 3 8 Gasket 1 9 Carburetor assembly 1 1 10 Carburetor assembly 2 1 11 Carburetor assembly 3 1 12 Rod 2 13 Link rod 1 14 Gasket 3 15 Choke knob 1 16 Bolt 1 M6 30 mm 17 O ring 1 ED ET Not reusable Not reusable Not reusable ...

Page 79: ...6885J11 4 10 9 8 7 6 5 4 3 2 1 ED ET 12 N m 1 2 kgf m 8 9 ft lb 6884060E No Part name Q ty Remarks 18 Choke solenoid 1 ED ET 19 Screw 2 ø6 15 mm ED ET Carburetor ...

Page 80: ...rks 1 Screw 6 ø5 10 mm 2 Cover 3 3 Rubber seal 2 6 4 Plate 2 3 5 Rubber seal 1 3 6 Plate 1 3 7 Throttle stop screw 1 8 Spring 1 9 Carburetor body 3 10 Spring 3 11 Pilot screw 3 12 Main nozzle 3 13 Main jet 3 14 Float pin 3 15 Needle valve 3 16 Clip 3 17 Pilot jet 3 ...

Page 81: ...0E No Part name Q ty Remarks 18 Cap 3 19 Float 3 20 Screw 3 ø4 8 mm 21 Gasket 3 22 Screw 12 ø4 14 mm 23 Float chamber 3 24 O ring 3 25 Drain bolt 3 26 Carburetor assembly 1 1 27 Carburetor assembly 3 1 Not reusable Not reusable Carburetor ...

Page 82: ...their original positions Checking the carburetor 1 Check the air and fuel passages and jets Clean the carburetor body with a petrole um based solvent if dirt and foreign mat ter 2 Blow compressed air into all passages and jets w Wear appropriate protective eye gear dur ing the cleaning process to prevent any eye injury by the blown off debris or liq uid 3 Check the main jet pilot jet and main nozz...

Page 83: ...nstall the plate 1 r rubber seal 1 t plate 2 y rubber seals 2 u cover i and then tighten the cover screws o Assembling the carburetor 1 Install the main nozzle 1 and main jet 2 2 Install the pilot jet 3 and cap 4 3 Install the needle valve 5 to the float 6 then install the float pin 7 into the float 6 and then tighten the float screw 8 1 2 3 4 68840050 9 0 q w e q 68840070 5 6 7 8 68840060 r y t u...

Page 84: ...NOTE 9 Temporarily install the carburetor caps g to the intake silencer h and then tighten the bolts j 9 Synchronizing the carburetor adjust the throttle cable and engine idle speed when ever the carburetor has been disassem bled 9 For the adjustment procedures mentioned above refer to chapter 3 10 Install the choke solenoid v and O ring b ED ET 68840090 p a 68840110 v b n 6F640100 Pilot screw set...

Page 85: ...6885J11 9 8 7 6 5 4 3 2 1 4 16 MEMO ...

Page 86: ...e 5 24 Removing the piston connecting rod assembly and crankshaft assembly 5 24 Checking the cylinder block 5 25 Disassembling the piston and connecting rod assembly 5 25 Checking the bearing 5 25 Checking the piston pin 5 25 Disassembling the crankshaft 5 26 Checking the cylinder bore 5 26 Checking the piston diameter 5 27 Checking the piston ring side clearance 5 27 Checking the piston pin boss ...

Page 87: ... oil seal housing 5 31 Checking the oil seal housing 5 31 Assembling the oil seal housing 5 31 Assembling the power unit 5 32 Installing the electrical component 5 36 Install the control lever and throttle cam 5 38 Installing the power unit 5 38 ...

Page 88: ...ntrol lever and then place hold the lever in the fully opened position of the throttle ED ET 9 Do not pull the choke knob when checking the compression pressure 9 Make a note of each cylinder measurement numeral 3 times to find the compression average 5 If the compression pressure is below specification and the compression pres sure for each cylinder is unbalanced add a small amount of engine oil ...

Page 89: ...ft lb 21 N m 2 1 kgf m 15 5 ft lb 6885010E No Part name Q ty Remarks 1 Power unit 1 2 Gasket 1 3 Dowel 2 4 Bolt 2 M6 20 mm 5 Bolt 2 M6 30 mm 6 Bolt 1 M8 30 mm 7 Bolt 8 M8 90 mm 8 Bolt 2 M8 35 mm 9 Apron 1 10 Apron 1 11 Bracket 1 12 Clip 1 13 Neutral switch 1 EHD Not reusable ...

Page 90: ... lb 6885020E No Part name Q ty Remarks 1 Nut 1 2 Washer 1 3 Flywheel magnet 1 4 Bolt 3 M6 30 mm 5 Stator assembly 1 6 Pulser coil assembly 1 7 Screw 3 ø6 12 mm 8 Plate 3 9 Control link 1 10 Retainer 1 11 Woodruff key 1 12 Timing plate 1 13 Bolt 1 M6 10 mm ...

Page 91: ... name Q ty Remarks 1 Bolt 1 M8 45 mm 2 Collar 1 3 Bushing 1 4 Control lever 1 1 5 Bushing 1 6 Spring 1 7 Cap 2 8 Lock nut 1 9 Spring 1 10 Control lever 2 1 11 Screw 1 12 Plastic washer 1 13 Washer 1 14 Shift lever 1 15 Bolt 2 M8 30 mm 16 Bracket 1 17 Joint 1 ...

Page 92: ...POWR 5 5 6885J11 Power unit 6885030E No Part name Q ty Remarks 18 Lock nut 1 19 Throttle link rod 1 20 Bolt 1 M6 35 mm 21 Wave washer 1 22 Collar 1 23 Cam 1 24 Screw 1 25 Lock nut 1 ...

Page 93: ...art name Q ty Remarks 1 Bolt 2 M6 20 mm 2 Rectifier Regulator 1 3 Bolt 2 M6 30 mm 4 Grommet 6 5 Bracket 1 6 Collar 3 7 Ignition coil 3 8 Bolt 3 M6 20 mm 9 Positive starter relay lead 1 10 Starter relay 1 11 Bolt 1 M6 16 mm 12 Positive battery cable 1 13 Spring washer 1 14 Nut 2 15 Bolt 1 M6 40 mm 16 PTT relay 1 ET 17 Bolt 2 M6 25 mm ET ...

Page 94: ...T 7 N m 0 7 kgf m 5 2 ft lb 6885060E No Part name Q ty Remarks 18 PTT motor lead 1 Green ET 19 Spring washer 2 ET 20 Nut 2 ET 21 PTT motor lead 1 Blue ET 22 Screw 2 ø6 40 mm 23 Pulser coil coupler 1 24 Main harness coupler 1 25 CDI unit 1 26 Charge coil coupler 1 27 Bolt 1 M6 12 mm ...

Page 95: ... 0 kgf m 22 1 ft lb 30 N m 3 0 kgf m 22 1 ft lb 9 N m 0 9 kgf m 6 6 ft lb 30 N m 3 0 kgf m 22 1 ft lb 6885050E No Part name Q ty Remarks 1 Bolt 3 M8 30 mm 2 Negative battery cable 1 3 Nut 1 4 Spring washer 1 5 Positive battery lead 1 6 Starter motor 1 ...

Page 96: ... ED ET EHD 2 Disconnect the negative battery cable 7 and positive battery lead 8 from starter motor 3 Remove the cover then remove the pos itive battery cable 9 fuse holder lead 0 PTT motor leads q ET Rectifier Regulator leads w thermoswitch leads e and main harness coupler r EHD warning indicator leads t neutral switch leads y å ED ET EHD 4 Disconnect the ground leads u and pilot water hose i 3 2...

Page 97: ...e the dowels j and gasket k 10 Remove the fuel system and carburetors NOTE To remove the fuel system and carburetors refer to page 4 3 and 4 9 5 Disconnect the fuel hose and then remove the choke knob NOTE To disconnect and remove the fuel hose and choke link rod Refer to page 4 3 and 4 9 6 Remove the pin o and bolts p bracket a EHD pin o bolts p neutral switch s bracket a å ED ET EHD 7 Remove the...

Page 98: ...ug caps 2 Disconnect the charge coil coupler 1 lighting coil leads 2 pulser coil coupler 3 PTT relay ground lead 4 ET and Rectifier Regulator ground lead 5 POWR 5 11 6885J11 Power unit 4 5 68850120 68850110 G W G 3 1 2 Removing the flywheel magnet 1 Loosen the flywheel magnet nut cC Apply force in the direction of the arrows shown While working do not allow the fly wheel holder to slip off the fly...

Page 99: ...tor r and CDI unit t from the CDI unit bracket 6 Remove the starter motor bolts y and then remove the starter motor u 7 Remove the control link i then remove the stator assembly o pulser coil assembly p and retainer a Removing the control lever and throttle cam 1 Remove the throttle link rod 1 control lever 1 2 control lever 2 3 and throttle cam 4 7 6 B W B 68850130 r t w e 68850140 68850160 i p a...

Page 100: ...6885J11 Power unit 12 N m 1 2 kgf m 8 9 ft lb 6885070E Intake manifold No Part name Q ty Remarks 1 Bolt 12 M6 30 mm 2 Intake manifold 1 3 Gasket 2 4 Plate 1 5 Screw 6 ø5 20 mm 6 Reed valve assembly 3 Not reusable ...

Page 101: ... reed valve 1 Check the reed valves for bends a Replace the reed valve assembly if above specification 3 4 5 6 68850180 1 2 68850170 å 75A 55D 85A 2 Measure the reed valve stopper height b Replace the reed valve assembly if out of specification å 75A 55D 85A Valve bend limit a 0 2 mm 0 0079 in a a 68850200 a a å 68850190 b b 68850220 b b å 68850210 Valve stopper height b 75A 2 8 3 2 mm 0 11 0 13 i...

Page 102: ... cover 5 15 No Part name Q ty Remarks 1 Bolt 4 M6 35 mm 2 Holder 1 3 Thermostat cover 1 4 Spring 1 5 PCV 1 6 Thermostat 1 7 Gasket 1 8 Grommet 1 9 Spark plug 3 10 Bolt 18 M6 25 mm 11 Ground lead 1 12 Cylinder head cover 1 13 Bolt 14 M8 60 mm 14 Gasket 1 15 Thermoswitch 1 16 Cylinder head 1 17 Gasket 1 Not reusable Not reusable Not reusable ...

Page 103: ...5J11 5 16 9 8 7 6 5 4 3 2 1 Cyilnder head exhaust cover 25 N m 2 5 kgf m 18 4 ft lb 15 N m 1 5 kgf m 11 1 ft lb 30 N m 3 0 kgf m 22 1 ft lb 6885090E No Part name Q ty Remarks 18 Screw 2 ø4 15 mm 19 Anode 2 ...

Page 104: ...POWR 5 6885J11 Power unit 6885080E No Part name Q ty Remarks 1 Bolt 18 M8 40 mm 2 Exhaust outer cover 1 3 Gasket 1 4 Exhaust inner cover 1 5 Gasket 1 Not reusable Not reusable 5 17 ...

Page 105: ...gasket 5 and grommet 6 3 Remove the cylinder head cover bolts in the sequence shown 4 Remove the cylinder head cover 7 and gasket 8 NOTE Insert a flat head screw driver between the pry tabs to pry off the cylinder head cover 5 Remove the thermoswitch 9 6 Remove the cylinder head bolts in the sequence shown 68850240 1 2 3 4 5 6 68850230 8 7 9 68850260 7 68850250 68850270 ...

Page 106: ...0 0039 in 68850320 7 Remove the cylinder head 0 and gasket q NOTE Insert a flat head screw driver between the pry tabs to pry off the cylinder head cC Do not scratch or damage the mating sur faces of the cylinder head and cylinder block Checking the cylinder head 1 Clean the carbon deposits from the com bustion chambers Check the cylinder head cover and cylinder head Replace the cylinder head cove...

Page 107: ... driver between the pry tabs to pry off the exhaust covers Checking the exhaust cover 1 Check the exhaust cover Replace the exhaust cover if cracked or corroded Checking the PCV 1 Check the PCV Replace the PCV if worn or deformed 2 Check the grommet Replace the grom met if deformed 3 Check the spring Replace the spring if damaged or deformed 68850330 1 2 3 4 68850340 ...

Page 108: ...14 8 ft lb 40 N m 4 0 kgf m 29 5 ft lb 6885100E Crankcase No Part name Q ty Remarks 1 Bolt 2 M8 20 mm 2 Engine hanger 1 3 Dowel 2 4 O ring 1 5 Oil seal 1 6 Oil seal 1 7 Oil seal housing 1 8 Rubber seal 1 9 Bolt 3 M6 20 mm 10 Grommet 1 11 Crankcase 1 12 Spring washer 2 13 Nut 2 14 Bolt 6 M10 55 mm 15 Bolt 12 M6 25 mm Not reusable Not reusable Not reusable ...

Page 109: ...6885110E No Part name Q ty Remarks 1 O ring 1 2 Oil seal 1 3 Needle bearing 1 4 Crankshaft 1 5 Roller bearing 3 set 6 Piston and connecting rod assembly 3 7 Bolt 6 M8 24 mm 8 Ball bearing 1 9 Circlip 1 10 Circlip 2 11 Main bearing 2 set 12 Cylinder block 1 Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Loosen completely ...

Page 110: ...POWR 5 23 6885J11 Power unit 6885120E No Part name Q ty Remarks 1 Connecting rod 3 2 Piston 3 3 Washer 6 4 Needle bearing 84 5 Clip 6 6 Piston pin 3 7 Piston ring 6 Not reusable ...

Page 111: ...he piston connecting rod assembly and crankshaft assembly 1 Remove the connecting rod bolts and connecting rod caps bearings NOTE 9 Mark each piston with the identification number a of the corresponding cylinder Also mark each connecting rod and con necting rod cap with an identification num ber b as shown 9 Be sure to keep the bearings in the order as they were removed 9 Do not mix the connecting...

Page 112: ...t 2 Remove the crankshaft assembly 3 Remove the piston with connecting rod Checking the cylinder block cC Do not scratch the mating surfaces of the cylinder head and cylinder block 1 Check the cylinder sleeves Replace the cylinder block if cracked or damaged 2 Remove any rust or deposits on the cool ing water passage walls and check the cooling water passage walls Clean or replace the cylinder blo...

Page 113: ...e cylinder head top surface b 35 mm 1 38 in from the cylinder head top surface c 80 mm 3 15 in from the cylinder head top surface 1 a b c d e D2 D4 D6 D1 D5 D3 68850430 Cylinder gauge 1 90890 06759 Cylinder bore diameter D1 D6 82 000 82 020 mm 3 2283 3 2291 in Gear puller 4 90890 06540 Bearing separator 5 90890 06534 or commercially available tool Disassembling the crankshaft 1 Remove the roller b...

Page 114: ... cylinder with a piston crown 3 Measure the piston ring end gap a at the specified measuring point Replace the piston ring set if out of specification POWR 5 27 6885J11 Power unit a 69R50310 Piston ring side clearance Top piston ring a 0 05 0 08 mm 0 0020 0 0032 in 2nd piston ring b 0 03 0 06 mm 0 0012 0 0024 in a b 68850450 Piston outside diameter 81 935 81 955 mm 3 2258 3 2266 in Measuring point...

Page 115: ... 34 984 mm 1 3767 1 3773 in Crankpin diameter b 29 985 30 000 mm 1 1805 1 1811 in a 68850480 b 68850490 2 Measure the crankshaft runout Replace the crankshaft if above specification Checking the connecting rod big end side clearance 1 Install the bearing and connecting rod 2 Measure the connecting rod big end side clearance a Replace the connecting rod or crankshaft or both if out of specifica tio...

Page 116: ...ng rod small end axial play 1 Install the bearing and connecting rod 2 Measure the connecting rod small end axial play Replace the bearing and con necting rod if above specification NOTE To measure the axial play set the dial gauge at the connecting rod small end and parallel to the crankshaft Disassembling the upper bearing 1 Remove the O ring and oil seal 69R50340 68850460 Connecting rod small e...

Page 117: ... the pistons 1 connecting rods 2 needle bearings 3 washers 4 pis ton pins 5 and new piston pin clips 6 NOTE 9 Face the embossed YAMAHA mark a on the connecting rod in the same direction as the UP mark b on the piston 9 Install the set with the identification mark in the direction indicated in the removal proce dure 9 Use the special service tool 7 to install the needle bearings 9 Always use new pi...

Page 118: ...s Checking the oil seal housing 1 Check the oil seal housing Replace the oil seal housing if cracked damaged or corrosion Assembling the oil seal housing 1 Install a new oil seal 1 into the oil seal housing 2 Install the new oil seal 4 and new O ring 5 into the oil seal housing 68850550 2 3 1 68850560 6 3 5 4 68850570 Needle bearing attachment 2 90890 06612 Driver rod SS 3 90890 06604 Needle beari...

Page 119: ...t for smooth operation Assembling the power unit 1 Install the pistons into the cylinders with the UP mark on the piston crown facing towards the flywheel magnet NOTE 9 Apply engine oil to the pistons and piston rings before installation 9 Be sure to install the piston and connecting rod assemblies into the corresponding cylinders according to the marks a made during disassembly 2 Set the cranksha...

Page 120: ...TE Do not get any sealant on the journals 68850620 5 68850630 6 Install the dowels 6 crankcase 7 onto the cylinder block and then temporarily tighten the crankcase bolts and nuts NOTE Apply engine oil to the crankcase bolts and stud bolts before installation 7 Install the oil seal housing bolts 8 tight en temporarily 68850650 8 6 7 6 68850640 ...

Page 121: ...pecified torques in 2 stages and in the sequence as shown 9 Slowly turn the crankshaft If it does not turn smoothly remove the connecting rod and replace any parts as necessary NOTE To remove the connecting rod refer to page 5 24 10 Connect the breather hoses 68850660 Crankcase bolt and nut M10 z n 1st 20 N m 2 0 kgf m 14 8 ft lb 2nd 40 N m 4 0 kgf m 29 5 ft lb M6 m 0 1st 4 N m 0 4 kgf m 3 0 ft lb...

Page 122: ...any oil or grease from the cylinder head mating surfaces y r t 68850690 68850760 Cylinder head bolt y 1st 15 N m 1 5 kgf m 11 1 ft lb 2nd 30 N m 3 0 kgf m 22 1 ft lb 13 Install the thermoswitch u new gasket i cylinder head cover o and then tight en the cylinder head cover bolts p NOTE Remove any oil or grease from the cylinder head and cylinder head cover mating sur faces u o p i 68850700 68850710...

Page 123: ...tighten the intake manifold bolts v to the specified torques Installing the electrical component 1 Install the CDI unit 1 Rectifier Regulator 2 starter relay 3 and PTT relay 4 ET onto the CDI unit bracket 2 Install the grommets 5 collars 6 CDI unit ground lead 7 and CDI unit bracket 8 then tighten the bolts 9 h f d s a k j g 68850720 l z x c 68850185 c v 68850740 Intake manifold bolt v 12 N m 1 2 ...

Page 124: ...e Rectifier Regulator ground lead o and PTT relay ground lead p ET 7 Install the starter motor a and then tighten the starter motor mount bolts s to the specified torque 8 Install the spark plugs tighten them tem porary tight then to the specified torque with a spark plug wrench 0 q B W B 6885013a 6885016a t e w r 6885011a G W G y i u p o 6885012a s a 68850166 Starter motor mount bolt s 30 N m 3 0...

Page 125: ...stall the fuel system refer to page 4 3 and 4 9 2 Install the dowels 1 and new gasket 2 NOTE Remove any oil or grease from the power unit mating surfaces 68850790 2 1 3 3 2 68850800 4 6 5 3 Install the Woodruff key and flywheel magnet 3 temporally tighten and then install the special service tool 4 lift up the power unit 5 NOTE Apply engine oil to the flywheel magnet nut before installation 4 Inst...

Page 126: ... nut to the specified torque cC Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily Power unit mount bolt 6 21 N m 2 1 kgf m 15 5 ft lb 7 Install the apron 8 onto the bottom cowl ing 8 Install the bracket 9 and pin 0 then tighten the bolts q EHD bracket 9 neutral switch w and pin 0 å ED ET EHD Flywheel magnet nut 160 N m 16 0 kgf m 118 ft lb Fly...

Page 127: ...able p then install the cover EHD neutral switch leads a and warning indicator leads s å ED ET EHD 12 Install the cover 13 Connect the choke solenoid leads f ED ET main harness coupler g shift cable h throttle cable j and then install the retaining plate k EHD shift rod l and throttle cable j å ED ET EHD e e r 6885007a AFT G p o i u y t L B P R G W R G d 6885005a å STBD P B R G Br Br Y R P y t u a...

Page 128: ...rk plug caps to the spark plugs 15 Connect the positive battery lead and negative battery cable z to the starter motor z 6885004a PORT Positive battery terminal nut 9 N m 0 9 kgf m 6 6 ft lb Negative battery terminal bolt 30 N m 3 0 kgf m 22 1 ft lb ...

Page 129: ...shaft and lower case 6 13 Removing the drive shaft 6 14 Removing the shift rod 6 14 Disassembling the drive shaft 6 14 Disassembling the forward gear 6 15 Disassembling the lower case 6 15 Checking the pinion and forward gear 6 16 Checking the drive shaft 6 16 Checking the lower case 6 16 Assembling the forward gear 6 16 Assembling the drive shaft 6 16 Assembling the lower case 6 17 Installing the...

Page 130: ...0 kgf m 29 5 ft lb 40 N m 4 0 kgf m 29 5 ft lb 6886010E No Part name Q ty Remarks 1 Cover 1 2 Bolt 1 M8 40 mm 3 Dowel 2 L transom Dowel 4 X Y transom 4 Seal 1 5 Guide 1 6 Guide 1 7 Bolt 4 M10 40 mm 8 Check screw 1 9 Gasket 2 10 Water inlet cover 2 11 Nut 1 12 Drain screw 1 13 Screw 1 ø5 45 mm 14 Lower unit 1 15 Trim tab 1 16 Bolt 1 M8 60 mm Not reusable ...

Page 131: ...m 4 0 kgf m 29 5 ft lb 40 N m 4 0 kgf m 29 5 ft lb 6886010E No Part name Q ty Remarks 17 Spacer 1 18 Propeller 1 19 Spacer 1 20 Spacer 1 21 Cotter pin 1 22 Nut 1 23 Extension 1 Y transom Extension 1 X transom 24 Washer 4 X Y transom 25 Spring washer 4 X Y transom 26 Nut 4 X Y transom 27 Bolt 1 M8 190 mm X transom Bolt 1 M8 112 mm Y transom Not reusable ...

Page 132: ...3 Screw 2 ø4 12 mm 4 Grommet 1 5 Seal 1 6 Water pump housing 1 7 Insert cartridge 1 8 Impeller 1 9 Dowel 2 10 Gasket 1 11 Outer plate cartridge 1 12 Gasket 1 13 Oil seal housing 1 14 Gasket 1 15 O ring 1 16 Oil seal 2 17 Woodruff key 1 Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 133: ... could suddenly fall and result in injury 9 Be sure to tilt the outboard motor fully and support it with the tilt stop lever It can not be tilted up partially Otherwise the outboard motor could fall back down suddenly EHD ED Removing the lower unit 1 Remove the lock plate from the engine stop lanyard switch 2 Place a drain pan under the drain hole 3 Remove the drain screw 1 and then remove the che...

Page 134: ...Y transom and extension 7 from the upper case å L transom X transom ç Y transom 68860455 4 3 å 6 6 6 5 6 68860465 3 7 7 6 6 6 5 6 ç 4 11 Remove the stud bots X Y transom Removing the water pump 1 Remove the water pump assembly 1 and gasket 2 2 Remove the Woodruff key 3 from the drive shaft then remove the outer plate cartridge 4 and gasket 5 3 Remove the dowels 6 68860456 68860415 1 3 6 2 4 5 ...

Page 135: ...ert cartridge if cracked or worn 3 Check the Woodruff key 1 Replace the woodruff key if worn 4 Check the groove a on the drive shaft Replace the drive shaft if worn Disassembling the oil seal housing 1 Remove the O ring and oil seals as shown Assembling the oil seal housing 1 Install the new oil seals and new O ring onto the oil seal housing to the specified depth 7 8 68860416 7 68860020 68860030 ...

Page 136: ...t plunger 1 2 Shift slider 1 3 Spring 1 4 Dog clutch 1 5 Cross pin 1 6 Spring 1 7 Propeller shaft 1 8 Reverse gear shim 9 Reverse gear 1 10 Washer 1 11 O ring 1 12 Ball bearing 1 13 Propeller shaft housing 1 14 Straight key 1 15 Needle bearing 1 16 Oil seal 2 17 Ring nut 1 Not reusable Not reusable Not reusable Not reusable ...

Page 137: ...nger 1 and spring 2 from dog clutch 3 Removing the propeller shaft hous ing assembly 1 Straighten the one tab 1 of the lock washer 2 Remove the ring nut from the propeller shaft housing NOTE Turn the ring nut toward to OFF 6F660060 1 68860050 3 2 Ring nut wrench 3 2 90890 06511 Ring nut wrench extension 3 90890 06513 Stopper guide plate 6 90890 06501 Bearing housing puller claw L 7 90890 06502 Cen...

Page 138: ...s shown 4 Remove the ball bearing 5 from the pro peller shaft housing cC Do not reuse the bearing always replace it with a new one 5 Remove the oil seals with needle bear ing Stopper guide plate 2 90890 06501 Stopper guide stand 3 90890 06538 Bearing puller assembly 4 90890 06535 2 3 4 5 68860090 68860100 6 7 Driver rod L3 6 90890 06652 Needle bearing attachment 7 90890 06612 Bearing separator 1 9...

Page 139: ...opeller shaft if worn 2 Measure the propeller shaft runout Runout limit 0 02 mm 0 0008 in 6F660130 Assembling the propeller shaft housing 1 Install a new needle bearing into the pro peller shaft housing to the specified depth NOTE 9 Install a new needle bearing with the identi fication mark a facing toward the propeller side 9 Be careful not to let the stopper c get out of position when using the ...

Page 140: ... 5 Install a new O ring 2 Install the new oil seals into the propeller shaft housing to the specified depth 3 Install the washer 5 and new ball bear ing 6 onto the reverse gear 7 using a press cC Do not reuse the bearing always replace it with a new one Needle bearing attachment 90890 06608 8 90890 06607 9 Needle bearing attachment 9 90890 06607 68860140 7 6 5 8 9 e 68860150 9 68860130 4 1 d Drive...

Page 141: ...in 4 and then install the shift plunger 5 temporarily NOTE 9 Align the hole a of the dog clutch 2 hole b of shift slider 3 with the slot c of the propeller shaft and then install the dog clutch 2 9 Install the dog clutch 2 with the F mark facing toward the forward gear 2 Install the spring 6 onto the dog clutch 2 1 2 3 a c 5 b 4 68860160 6 2 6 68860170 ...

Page 142: ... 1 Drive shaft 1 2 Taper roller bearing 1 3 Pinion shim 4 Sleeve 1 5 Needle bearing 1 6 Oil seal 1 7 Bolt 2 M6 16 mm 8 Plate 1 9 O ring 1 10 Shift rod 1 11 Circlip 1 12 Nut 1 13 Pinion 1 14 Shift cam 1 15 Forward gear shim 16 Taper roller bearing 1 17 Forward gear 1 Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 143: ...der 3 90890 06715 Socket adapter 2 4 90890 06507 Removing the shift rod 1 Remove the bolts 1 plate 2 shift rod 3 and then remove the shift cam 4 Disassembling the drive shaft 1 Install the pinion nut 1 and then tighten it temporarily 2 Remove the taper roller bearing 2 using a press cC 9 Do not press the drive shaft threads a directly 9 When removing the taper roller bearing do not damage the driv...

Page 144: ...earing attachment 0 90890 06611 Driver rod L3 q 90890 06652 Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press cC Do not reuse the bearing always replace it with a new one Disassembling the lower case 1 Remove the taper roller bearing outer race and shim s 68860250 1 2 2 b a Bearing separator 1 90890 06534 or commercially available tool Appropriate...

Page 145: ...keg cavitation plate and tor pedo Replace the lower case if cracked or damaged Assembling the forward gear 1 Install a new taper roller bearing into the forward gear using a press Runout limit 1 0 mm 0 039 in 68860115 2 1 68860270 cC Do not reuse the bearing always replace it with a new one Assembling the drive shaft 1 Install a new taper roller bearing onto the drive shaft using a press cC Do not...

Page 146: ...ver rod 2 Install the sleeve shim s and new taper roller bearing outer race cC Do not reuse the bearing always replace it with a new one NOTE 9 Be sure to select the pinion shim s if the lower case or taper roller bearing is replaced 9 To select the shim s refer to page 6 25 9 Install the sleeve with the projection d fac ing forward Driver rod SL 1 90890 06602 Needle bearing attachment 2 90890 066...

Page 147: ...g it up slightly and then align its splines with the pinion 2 3 Install the shim s and new taper roller bearing outer race cC Do not reuse the bearing always replace it with a new one NOTE 9 Be sure to select the forward gear shim s if the lower case or taper roller bearing is replaced 9 To select the shim s refer to page 6 25 9 Apply gear oil to the inside and outside of the taper roller bearing ...

Page 148: ...90 06507 Pinion nut 4 95 N m 9 5 kgf m 70 1 ft lb 68860340 2 1 Installing the propeller shaft hous ing 1 Install a new O ring 1 2 Install the propeller shaft assembly 2 and shim s 3 into the propeller shaft housing assembly 4 NOTE 9 Be sure to select the reverse gear shim s if the lowercase propeller shaft housing or ball bearing is replaced 9To select the shim s refer to page 6 26 3 Set the gear ...

Page 149: ...ssemble and assemble the lower case if operated improperly NOTE 9 Change the shift rod position to F R and N position using a special service tool 5 9 Make sure that the propeller shaft rotating direction is correct in F and in R position 9 Make sure that the position is correct in N position Installing the water pump 1 Install the dowels 1 new gasket 2 the outer plate cartridge 3 new gasket 4 688...

Page 150: ...NOTE Align the insert cartridge projection b with the hole c in the water pump housing 5 6 a 68860390 5 Install the water seal rubber 9 and grom met 0 onto the water pump housing 8 then install onto the lower case cC Do not turn the drive shaft counterclock wise otherwise the water pump impeller may be damaged NOTE When installing the water pump housing turn the drive shaft clockwise while pushing...

Page 151: ... stop lever It can not be tilted up partially Otherwise the outboard motor could fall back down suddenly EHD ED 1 Set the gear shift to N position and then check that the mark a on the bracket 1 is aligned with the mark b on the shift lever 2 68860420 68860430 1 2 a b 2 Set the gear shift to N position at the lower unit Make sure that the shift rod is in the neutral position 3 Install the guide 3 ...

Page 152: ...e upper case and then tighten the lower case bolts nut 6 to the specified torque NOTE Turn the flywheel magnet slightly clockwise to align the splines without removing the power unit 6 Install the trim tab 7 on its original posi tion and then tighten the trim tab bolt 8 7 Install the cover 9 8 Install the spacer 0 propeller q spacer w spacer e and the propeller nut r Lower case bolt nut 6 40 N m 4...

Page 153: ...the propeller with your hands when loosening or tightening it 9 Be sure to disconnect the battery cables from the battery and remove the lock plate from the engine stop lanyard switch 9 Put a block of wood between the anti cavitation plate and propeller to prevent the propeller from turning NOTE If the grooves in the propeller nut r do not align with the propeller shaft hole tighten the nut until ...

Page 154: ...LOWR 6 25 6885J11 Lower unit Shimming T3 M3 M2 68860480 T2 T1 M1 P R F ...

Page 155: ... onto the drive shaft so that the taper roller bearing outer race is at the center of the hole 9 Tighten the wing nuts another 1 4 of a turn after they contact the pinion height gauge plate 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M3 between the special service tool and the pinion as shown NOTE 9 Measure the pinion at 4 points to f...

Page 156: ...45 mm If T3 is 0 38 mm then the pinion shim is 0 38 mm Selecting the forward gear shim 1 Turn the taper roller bearing outer race 1 2 or 3 times to seat the rollers and then measure the bearing height M1 as shown NOTE 9 Select the shim thickness T1 by using the specified measurement s and the calcula tion formula 9 Measure the bearing outer race at 4 points to find the height average 9 Make a note...

Page 157: ...f T1 is 0 50 mm then the forward gear shim is 0 48 mm Selecting the reverse gear shim 1 Install the ball bearing to the propeller shaft housing 2 Measure the propeller shaft housing height M2 as shown NOTE 9 Without the O ring when measuring the reverse gear height 9 Select the shim thickness T2 by using the specified measurement s and the calcula tion formula 9 Measure the reverse gear at 4 point...

Page 158: ...26 00 mm 1 100 26 60 26 00 0 01 0 61 mm 4 Select the reverse gear shim s T2 as follows Example If T2 is 0 47 mm then the reverse gear shim is 0 48 mm If T2 is 0 41 mm then the reverse gear shim is 0 42 mm Backlash Measuring the forward and reverse gear backlash 1 Remove the water pump assembly and oil seal housing 2 Set the gear shift to N position 69D60360 a 69D60035 1 Calculation formula Reverse...

Page 159: ...e backlash indicator onto the drive shaft 20 0 mm 0 79 in in diame ter then install the dial gauge onto the lower unit as shown NOTE Install the dial gauge so that the plunger a comes in contact with the mark b on the backlash indicator 5 While pushing the drive shaft slightly turn the drive shaft slowly clockwise and counterclockwise then measure the backlash when the drive shaft stops in each di...

Page 160: ...and propeller nut e as shown LOWR 6 31 6885J11 Lower unit Forward gear Shim thickness backlash Less than To be decreased by 0 08 mm 0 0032 in 0 17 M 0 60 More than To be increased by 0 25 mm 0 0098 in M 0 17 0 60 Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 69D06380 9 0 q w e NOTE While turning the drive shaft clockwise 5 6 times tighten the propeller nut e to the spec ifie...

Page 161: ...r remove the shim s if out of spec ification M Measurement 11 Remove the special service tools and then install the water pump assembly Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Reverse gear Shim thickness backlash Less than To be increased by 0 67 mm 0 0264 in 0 84 M 0 60 More than To be decreased by 1 00 mm 0 0394 in M 0 84 0 60 Reverse gear backlash 0 67 1 00 mm 0 026...

Page 162: ... Removing the clamp bracket EHD ED 7 22 Checking the shock absorber 7 23 Disassembling the swivel bracket EHD ED 7 23 Checking the swivel bracket 7 23 Assembling the swivel bracket EHD ED 7 24 Assembling the clamp bracket EHD ED 7 24 Removing the PTT unit ET 7 30 Removing the clamp bracket ET 7 31 Disassembling the swivel bracket ET 7 31 Checking the swivel bracket ET 7 31 Assembling the swivel br...

Page 163: ...anual valve 7 50 Assembling the gear pump 7 52 Tilt cylinder and trim cylinder 7 53 Disassembling the tilt cylinder and trim cylinder 7 55 Checking the tilt cylinder and trim cylinder 7 57 Checking the valve 7 57 Assembling the tilt ram 7 58 Assembling the trim ram 7 59 Installing the tilt cylinder 7 59 Installing the trim ram 7 60 Installing the PTT motor 7 60 Installing the reservoir 7 61 Instal...

Page 164: ...1 1 kgf m 8 1 ft lb 6887010E EHD No Part name Q ty Remarks 1 Throttle grip 1 2 Washer 1 3 Spring 1 4 Bushing 1 5 Tiller handle 1 6 Grommet 1 7 Throttle cable 1 8 Plastic washer 2 9 Washer 2 10 Wave washer 1 11 Throttle shaft 1 12 Housing 1 13 Friction piece 1 14 Screw 1 ø5 12 mm 15 Screw 4 ø5 8 mm 16 Cover 1 17 Gasket 1 Not reusable ...

Page 165: ...kgf m 8 1 ft lb 6887010E EHD No Part name Q ty Remarks 18 Plate 1 19 Shift lever 1 20 Bushing 1 21 Spring 1 22 Ball 1 23 Collar 1 24 Washer 1 25 Bushing 1 26 Bracket 1 27 Bolt 1 M12 70 mm 28 Shift cable 1 29 Engine stop lanyard switch 1 30 Engine start switch 1 31 Bolt 1 M6 20 mm 32 Switch holder 2 33 Screw 1 ø6 24 mm 34 Bolt 1 M6 30 mm ...

Page 166: ...ith the mating surface of the tiller handle 2 in horizontal posi tion 2 Insert the throttle cable 4 into the gear 5 until the inner cable is winded with the gear 3 Turn the throttle shaft 1 clockwise to wind the inner cable until the bolt 6 comes in contact with tiller handle 4 Tighten the bolt 6 and lock nut 7 NOTE Check that the fully closed mark of the indi cator is aligned with the mark on the...

Page 167: ...dle 6 Push the throttle grip so that the throttle grip holes are aligned with the throttle shaft holes Lubricating the throttle gear EHD 1 Inject grease into the grease nipple until grease comes out from the screw hole a 68870030 69D70170 a A ...

Page 168: ...o Part name Q ty Remarks 1 Washer 1 2 Bracket 1 3 Bolt 1 4 Spring 1 5 Ball 1 6 Bushing 1 7 Arm 1 8 Bolt 2 M8 30 mm EHD 9 Neutral switch assembly 1 EHD 10 Shift lever 1 11 Washer 2 12 Bracket 1 13 Shift lever 1 14 Bushing 1 15 Shift rod 1 16 Seal 1 17 Grommet 1 ...

Page 169: ...ame Q ty Remarks 1 Lock lever 2 2 Bushing 2 3 Bushing 2 4 Wave washer 2 5 Clamp lever 2 6 Bolt 2 M6 12 mm 7 Grommet 1 8 Grommet 1 ED ET 9 Grommet 1 EHD 10 Retaining plate 1 11 Bolt 2 M6 16 mm 12 Warning indicator 1 EHD 13 Clamp 1 14 Bracket 1 15 Bolt 1 M6 16 mm 16 Clamp 1 ET 17 Cooling water pilot hole 1 ...

Page 170: ...Bracket unit 4 N m 0 4 kgf m 3 0 ft lb EHD EHD EHD ED 6887030E No Part name Q ty Remarks 18 Clip 2 19 Hose 1 20 Grommet 1 EHD ED 21 Grommet 1 22 Grommet 4 23 Collar 4 24 Bracket 1 25 Screw 1 ø6 20 mm 26 Bolt 4 M6 30 mm ...

Page 171: ...g arm X Y 6887090E No Part name Q ty Remarks 1 Nut 2 2 Washer 2 3 Nut 2 4 Cover 2 5 Screw 2 ø6 15 mm 6 Ground lead 1 7 Bolt 4 M8 25 mm 8 Mount housing 2 9 Spring 4 10 Lower mount 2 11 Rubber washer 2 12 Washer 2 13 Bolt 2 M12 160 mm 14 Damper 2 15 Washer 2 16 Bolt 3 M8 35 mm 17 Bracket 1 ...

Page 172: ...9 6885J11 Bracket unit X Y 6887090E No Part name Q ty Remarks 18 Upper mount 2 19 Washer 2 20 Rubber washer 2 21 Washer 2 22 Bolt 2 M10 175 mm 23 Damper 2 24 Rubber seal 1 25 Upper case assembly 1 Not reusable ...

Page 173: ...00E No Part name Q ty Remarks 1 Bolt 2 M8 30 mm 2 Exhaust guide 1 3 Gasket 1 4 Collar 1 5 Gasket 1 6 Exhaust manifold 1 7 Bolt 3 M8 30 mm 8 Cooling water pipe 1 9 Bolt 4 M8 30 mm 10 Rubber damper 1 11 Muffler 1 12 Rubber damper 1 13 Rubber seal 1 14 Rubber seal 1 15 Dowel 2 16 Upper case 1 17 Rubber seal 1 Not reusable Not reusable Not reusable ...

Page 174: ... rubber dampers Replace the rubber dampers if deteriorated or cracked 2 Check the cooling water pipe Replace the cooling water pipe if deformed or cor roded 3 Check the exhaust guide exhaust mani fold and muffler Replace them if deformed or corroded Assembling the upper case 1 Install the new rubber seal 1 new gasket 2 exhaust manifold 3 and bolts 4 and then tighten the bolts to the specified torq...

Page 175: ...e exhaust guide assembly 9 and then tighten the bolts 0 to the specified torque 5 Install a new rubber seal q and dowels w onto the muffler assembly 6 Tighten the bolts e to the specified torque 7 Install the upper mounts r and bolts t as shown below 5 6 7 8 9 0 0 68870090 7 68870100 Muffler bolt 0 21 N m 2 1 kgf m 15 5 ft lb q w e w 68870110 Upper case bolt e 21 N m 2 1 kgf m 15 5 ft lb r t 68870...

Page 176: ...nd then tighten it with the bolts u NOTE First tighten the center located bolt when tightening the bolts u 9 Install the lower mounts i and bolts o as shown below 10 Install the lower mounts i and mount housings p and then tighten the bolts a temporarily i p a i a p 68870150 i o 68870140 r y u r 68870130 ...

Page 177: ... 8 ft lb ED ET 6887110E No Part name Q ty Remarks 1 Steering hook 1 ED ET 2 Nut 2 ED ET 3 Washer 2 ED ET 4 Steering arm 1 5 Washer 1 6 Bushing 1 7 O ring 1 8 Bushing 2 9 Clamp bracket assembly 1 10 O ring 1 11 Washer 1 12 Steering yoke 1 13 Circlip 1 Not reusable Not reusable ...

Page 178: ... 90890 06540 Checking the steering arm 1 Check the steering arm and steering yoke Replace the steering arm and steering yoke if corroded deformed or cracked Installing the steering arm 1 Install the washer 1 bushing 2 new O ring 3 and bushing 4 onto the steering arm 5 2 Place the swivel bracket 6 in the upright position and then install the steering arm 5 onto the swivel bracket 6 3 Install the bu...

Page 179: ...eering arm 5 Install the steering yoke 0 to the steer ing arm 5 by aligning the center a of the steering yoke with the center b of the steering arm NOTE Hold the steering arm after tilt up the swivel bracket and then strike the steering yoke until the circlip installing groove appears 6 Install the circlip q 68870200 q 0 5 a b 68870210 c 68870220 ...

Page 180: ...and lower mount assem bly into the bracket assembly 1 simulta neously 2 Install the upper mount nuts 2 and lower mount nuts 3 and then tighten them NOTE Before tightening the upper case install the wiring of the ground lead cC Do not over tighten the ground lead 3 2 1 68870230 68870250 68870240 STBD ...

Page 181: ...vel bracket 8 N m 0 8 kgf m 5 9 ft lb 6887070E EHD ED No Part name Q ty Remarks 1 Pin 1 2 Bushing 4 3 Bracket 1 4 Bushing 2 5 Shock absorber 1 6 Bolt 1 M6 10 mm 7 Reverse lock lever 1 8 Tilt lock lever 1 9 Cap 1 10 Washer 1 11 Rod 1 12 Joint 1 13 Bushing 2 14 Bushing 1 15 Bolt 6 M10 45 mm 16 Pin 1 17 Circlip 1 ...

Page 182: ...rt name Q ty Remarks 1 Cap 2 2 Self locking nut 1 3 Clamp bracket 1 4 Ground lead 1 5 Screw 1 ø6 12 mm 6 Washer 2 7 Bushing 2 8 Cap 3 9 Grease nipple 3 10 Ground lead 1 11 Swivel bracket assembly 1 12 Clamp bracket 1 13 Through tube 1 14 Spring 1 15 Tilt pin 1 16 Plate 1 17 Anode 1 ...

Page 183: ...6885J11 7 20 9 8 7 6 5 4 3 2 1 Clamp bracket and swivel bracket 15 N m 1 5 kgf m 11 1 ft lb 6887050E EHD ED No Part name Q ty Remarks 18 Washer 2 19 Bolt 2 M6 12 mm 20 Bolt 2 M6 16 mm ...

Page 184: ... mm 1 19 1 20 in 6887040E EHD ED No Part name Q ty Remarks 1 Tilt stop lever 1 2 Tilt stop lever 1 3 Bushing 2 4 Swivel bracket 1 5 Spring 1 6 Plate 1 7 Bolt 1 M6 10 mm 8 Pin 3 9 Distance collar 1 10 Bushing 2 11 Collar 1 12 Lever 1 13 Cap 2 ...

Page 185: ...absorber 9 Do not deform or damage the shock absorber If the shock absorber is dam aged damping performance will suffer 1 Fully tilt the outboard motor up and then support it with the tilt stop lever 1 2 Remove the tilt pin 2 anode 3 and shock absorber mount bolts 4 68870260 1 3 Remove the caps 5 self locking nut 6 and then ground lead 7 4 Remove the pin 8 bracket 9 and bush ings 0 5 Remove the ro...

Page 186: ...ve the pins 2 1 68870350 2 2 68870360 3 Remove the tilt stop levers 3 4 Remove the distance collar 4 collar 5 and lever 6 5 Remove the bushings 7 Checking the swivel bracket 1 Check the swivel bracket Replace the swivel bracket if cracked or damaged 2 Check the distance collar Replace the distance collar if cracked or worn 3 Check the distance collar assembled length Adjust the distance collar ass...

Page 187: ...24 9 8 7 6 5 4 3 2 1 Clamp bracket and swivel bracket Assembling the swivel bracket EHD ED 1 Install the bushings 1 into the swivel bracket 2 Install the lever 2 collar 3 and then install the tilt stop lever 4 as shown 3 Install the distance collar 5 and tilt stop lever 6 4 Align the holes of the distance collar 5 and lever 2 with the holes of the tilt stop lever 4 and 6 then install the pin 7 7 7...

Page 188: ...r 8 into the swivel bracket 4 7 Install the pin 9 circlip 0 and rod q 68870320 6 3 7 5 4 2 68870330 0 q 8 4 9 8 Install the bushings w bracket e and pin r 9 Install the anode t temporarily 10 Tighten the shock absorber mount bolt y and anode t 11 Tighten the self locking nut to the speci fied torque 12 Install the tilt pin u 13 Inject grease into all grease nipples until grease comes out from the ...

Page 189: ... and swivel bracket 6887080E ET No Part name Q ty Remarks 1 Lock tie 3 2 Pin 1 3 Tube 1 4 Bolt 6 M10 45 mm 5 Trim sensor lead 1 6 PTT motor lead 1 7 Circlip 1 8 Bushing 2 9 Bushing 2 10 PTT unit 1 11 Ground lead 1 12 Bolt 1 M6 10 mm Not reusable ...

Page 190: ...o Part name Q ty Remarks 1 Cap 2 2 Self locking nut 1 3 Clamp bracket 1 4 Ground lead 1 5 Screw 1 ø6 12 mm 6 Washer 2 7 Bushing 2 8 Cap 3 9 Grease nipple 3 10 Ground lead 1 11 Swivel bracket assembly 1 12 Trim stopper 2 13 Nut 2 14 Screw 2 ø6 16 mm 15 Trim sensor 1 16 Clamp bracket 1 17 Through tube 1 ...

Page 191: ...p bracket and swivel bracket 15 N m 1 5 kgf m 11 1 ft lb 18 N m 1 8 kgf m 13 3 ft lb 6887060E ET No Part name Q ty Remarks 18 Spring 1 19 Tilt pin 1 20 Plate 1 21 Anode 1 22 Ground lead 1 23 Washer 2 24 Bolt 2 M6 12 mm 25 Bolt 2 M6 16 mm ...

Page 192: ...it 30 3 30 4 mm 1 19 1 20 in 6887045E ET No Part name Q ty Remarks 1 Tilt stop lever 1 2 Tilt stop lever 1 3 Bushing 2 4 Swivel bracket 1 5 Spring 1 6 Plate 1 7 Bolt 1 M6 10 mm 8 Pin 2 9 Distance collar 1 10 Bushing 2 11 Collar 1 ...

Page 193: ...he tilt stop lever Otherwise the outboard motor could suddenly lower if the PTT unit should lose fluid pressure NOTE If the PTT does not operate turn the manual valve 2 clockwise and tilt the outboard motor up manually 2 Disconnect the ground lead 3 at the bot tom of the PTT unit 1 68830390 68870445 2 3 Remove the tilt pin and 4 anode 5 4 Remove the bracket bolts 6 5 Remove the lock ties and then ...

Page 194: ...e the cap 4 and self locking nut 5 3 2 1 68870480 4 Remove the through tube 6 clamp brackets 7 washers 8 swivel bracket 9 and then remove the bushings 0 5 Remove the trim sensor cam screw q 6 Remove the trim sensor w Disassembling the swivel bracket ET NOTE To disassemble the swivel bracket refer to page 7 23 Checking the swivel bracket ET NOTE To check the swivel bracket refer to page 7 23 9 w w ...

Page 195: ...t mounting bolts 5 and then tighten them 4 Install the tilt ram upper end into the swiv el bracket with the pin 6 and circlip 7 1 68870475 Assembling the swivel bracket ET NOTE To assemble the swivel bracket refer to page 7 24 Installing the clamp bracket ET 1 Install the trim sensor 1 and then tight en the screws 2 2 Install the bushings 3 into the swivel bracket 4 then install the swivel bracket...

Page 196: ...ease comes out from the bushings a Adjusting the trim sensor cam ET 1 Fully tilt the outboard motor down 2 Connect the test harness 1 to the trim sensor coupler 2 3 Measure the trim sensor resistance 4 If the trim sensor resistance is out of specification adjust the trim sensor 68870490 8 a a 68830510 Self locking nut 8 15 N m 1 5 kgf m 11 1 ft lb 68870500 9 q w e 0 B P Gy G R Br B 68870520 Gy P B...

Page 197: ... 5 7 Adjust the position of the trim sensor and then tighten the screws 5 temporarily 8 Repeat the steps 1 7 if out of specifica tion 9 Fully tilt the outboard motor up and then tighten the screws 5 10 Fully tilt the outboard motor down NOTE Measure the trim sensor resistance after tightening the screws and fully tilt the out board motor down 4 68870530 68870510 5 ...

Page 198: ... 7 N m 0 7 kgf m 5 2 ft lb 6887120E No Part name Q ty Remarks 1 Bolt 3 M6 20 mm 2 PTT motor 1 3 Bolt 3 M6 20 mm 4 Reservoir 1 5 O ring 1 6 Reservoir cap 1 7 Joint 1 8 O ring 1 9 O ring 1 10 Main valve 2 11 O ring 2 12 O ring 2 13 O ring 1 14 Piston 1 15 Pipe 1 16 Pipe 1 17 Pipe 1 Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable PTT unit ...

Page 199: ...b 20 N m 2 0 kgf m 14 8 ft lb 3 N m 0 3 kgf m 2 2 ft lb 7 N m 0 7 kgf m 5 2 ft lb 6887120E No Part name Q ty Remarks 18 Pin 1 19 Bushing 2 20 Manual valve seal 2 21 Spring 1 22 Adapter 1 23 Spring 1 24 O ring 1 25 O ring 1 26 Manual valve 1 27 Circlip 1 28 Tilt cylinder assembly 1 29 PTT body 1 Not reusable Not reusable ...

Page 200: ...5 Connect the PTT motor leads to the bat tery terminals to retract the trim rams and then measure the hydraulic pres sure 6 Reverse the PTT motor leads between the battery terminals to fully extend the rams 7 Remove the special service tool 8 Install the pipe joint and then tighten them to the specified torque 68870590 2 1 a 68870610 L G 68870600 L G PTT oil pressure gauge assembly 2 90890 06580 R...

Page 201: ...t 9 Add the same amount as the spilled fluid 9 Tighten the pipe joint of the tilt cylinder tem porarily after remove the pipe joint b 12 Hold the PTT unit 4 in a vice using alu minum plates c on both sides 13 Connect the PTT motor leads to the bat tery terminals to extend the trim rams and then measure the hydraulic pres sure 68870620 L G Rams PTT motor lead Battery terminal Down Green G Blue L Hy...

Page 202: ...in a vice using alu minum plates c on both sides NOTE Add the same amount as the spilled fluid 19 Connect the PTT motor leads to the bat tery terminals to fully extend the trim and tilt rams 20 Remove the reservoir cap 5 and then check the fluid level in the reservoir w Make sure that the trim and tilt rams are fully extended when removing the reser voir cap otherwise fluid can spurt out from the ...

Page 203: ...er hole when the reservoir cap is removed 21 Install the new O ring and reservoir cap 5 then tighten it to the specified torque NOTE Bleeding the PTT unit 2 3 times and then check the fluid level To bleed the PTT unit refer to page 7 62 5 68870670 Reservoir cap 5 7 N m 0 7 kgf m 5 2 ft lb Recommended PTT fluid ATF Dexron 2 ...

Page 204: ... ft lb 6887130E No Part name Q ty Remarks 1 Stator 1 2 Screw 3 ø6 16 mm 3 Armature 1 4 Screw 2 ø4 10 mm 5 Brush 1 1 6 Plate 1 7 Bushing 1 8 O ring 1 9 Brush 2 1 10 Holder 2 11 Spring 2 12 PTT motor base 1 13 Oil seal 1 Not reusable Not reusable PTT motor ...

Page 205: ...it due to internal pressure 9 Do not push the trim and tilt rams down while the PTT motor is removed from the PTT unit otherwise fluid can spurt out 2 Remove the screws 5 stator 6 with armature 7 3 Remove the armature 7 from the stator 6 cC Do not allow grease or oil to contact the commutator 8 4 Disconnect the PTT motor lead 9 NOTE Hold the brush with a screwdriver as shown and then disconnect th...

Page 206: ...TT motor 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirty 0 q w e w e L G a 68870720 6G480220 2 Measure the commutator diameter Replace the armature if below specifica tion limit 3 Measure the commutator undercut b Replace the armature if below specifica tion limit a 1 6F680175 Commutator standard diameter a 22 0 mm 0 87 in Wear limit 21 0 mm 0 83 in Digital caliper...

Page 207: ...eal Replace the oil seal if damaged or worn 69R80320 c e f d Armature continuity Tester probe c d e f Segment Segment Segment Armature core Segment Armature shaft 6885J11 7 44 9 8 7 6 5 4 3 2 1 PTT motor Assembling the PTT motor 1 Install new O ring 1 springs 2 and brushes 3 and then tighten the screws 4 2 Connect the PTT motor leads 5 Brush standard length 9 75 mm 0 384 in Wear limit g 5 5 mm 0 2...

Page 208: ...the brush hold er and then install the armature 6 4 Install the stator 7 onto the PTT motor base NOTE Place a rag over the end of the armature shaft hold it with a pair of pliers and then carefully slide the stator over the armature 6 3 3 68870760 7 68870770 ...

Page 209: ...4 kgf m 3 0 ft lb No Part name Q ty Remarks 1 Spring 1 2 Filter 1 3 Bolt 4 M4 25 mm 4 Pin 2 5 Gear housing 1 1 6 Ball 2 7 Driven gear 1 8 Drive gear 1 9 Gear housing 2 1 10 O ring 2 11 Down relief spring 1 12 Valve support pin 1 13 Main valve seal 1 14 Gear pump assembly 1 Not reusable Gear pump ...

Page 210: ... Part name Q ty Remarks 1 Screw 2 ø5 10 mm 2 Trim spring 1 3 Up relief spring 1 4 Valve support pin 1 5 Relief valve seal 1 6 Relief valve seat 1 7 O ring 1 8 Filter 1 9 Valve lock screw 1 10 O ring 1 11 Ball 1 12 Washer 1 13 Main valve seal 1 Not reusable Not reusable ...

Page 211: ...and main valve seal 8 5 Remove the main valves 9 and shuttle piston 0 6 Hold the gear pump assembly 4 in a vice using aluminum plates a on both sides and then remove the pins q NOTE Use a 4 mm pin punch w to remove the pins q 7 Separate the gear housing 2 e as shown then remove the balls r drive t and driven gear y NOTE Turn the gear pump assembly upside down and then separate the gear housing 2 e...

Page 212: ...l q washer w and main valve seal e 4 Remove the circlip r then remove the manual valve t manual valve seal y spring u adapter i spring o manual valve seal p and O ring a Checking the gear pump 1 Check the drive gear 1 and driven gear 2 Replace the drive and driven gear if damaged scratched or excessive worn Checking the main valve 1 Check the main valves 1 Clean the main valves if dirt or residue ...

Page 213: ...d down relief valve 3 Replace the trim spring if damaged Clean the up and down relief valve if dirt or residue appears 2 Check the valve seal and valve seat Clean the valve seal and valve seat if dirt or residue appears Replace them if dam aged or worn 3 Check the valve lock screw 4 ball 5 washer 6 and main valve seal 7 Clean the valve lock screw if dirt or residue Replace them if damaged or worn ...

Page 214: ...dy 4 Install the trim spring w and then tighten the screws e to the specified torque 5 Install the new O ring r manual valve seal t spring y adapter u spring i manual valve seal o and manual valve p then install the circlip a NOTE The manual valve is left hand thread Manual valve p 3 N m 0 3 kgf m 2 2 ft lb Trim spring screw e 4 N m 0 4 kgf m 3 0 ft lb 7 6 7 6 68870910 9 8 0 q 68870920 w e 6887093...

Page 215: ... pump assembly to remains b b approximately 3 5 mm 0 14 in 4 Check the gear pump operation NOTE Inject a small amount fluid to the gear pump assembly and then rotate the drive gear in the direction shown 5 Install the new O rings 7 gear pump assembly 8 with the bolts 9 then tight en them to the specified torque 6 Install the new O rings piston 0 main valves q 4 1 2 3 3 5 68870950 6 b a 68870960 AT...

Page 216: ...E No Part name Q ty Remarks 1 Tilt ram 1 2 Dust seal 1 3 Tilt cylinder end screw 1 4 Backup ring 1 5 O ring 1 6 O ring 1 7 Tilt piston 1 8 Ball 5 9 Absorber valve 5 10 Pin 5 11 Spring 5 12 O ring 1 13 Backup ring 1 14 Washer 1 15 Plate 1 16 Washer 1 17 Bolt 1 M6 10 mm Not reusable Not reusable Not reusable Not reusable Tilt cylinder and trim cylinder ...

Page 217: ...b 13 N m 1 3 kgf m 9 6 ft lb 6887160E No Part name Q ty Remarks 18 Tilt piston assembly 1 19 Tilt ram assembly 1 20 Tilt cylinder assembly 1 21 Free piston 1 22 O ring 1 23 Tilt cylinder 1 24 Dust seal 2 25 Trim cylinder end screw 2 26 O ring 2 27 Trim ram assembly 2 28 Backup ring 2 29 O ring 2 Not reusable Not reusable Not reusable Not reusable ...

Page 218: ...nit BRKT 7 55 6885J11 Bracket unit 3 Hold the tilt cylinder 5 in a vice using aluminum plates a on both sides 4 Loosen the tilt cylinder end screw and then remove the tilt ram assembly w Make sure that the ram are fully extended before removing the end screw 5 Drain the PTT fluid 5 6 a 68871030 Cylinder end screw wrench 6 90890 06568 2 3 68871010 5 4 68871020 1 68871000 ...

Page 219: ... cover the opposite end of the tilt cylinder with a rag 7 Hold the tilt ram end in a vice using alu minum plates a on both sides and loosen the bolt 8 Remove the tilt piston absorber valves 8 9 Remove the O ring 9 and backup ring 0 10 Hold the tilt piston in a vice using the alu minum plates a and special service tool on both sides 11 Remove the tilt ram PTT piston vice attachment q 90890 06572 Ti...

Page 220: ...r e t a a 68871080 Trim and tilt wrench t 90890 06587 u y 68871090 3 Check the tilt piston 1 and free piston 2 Replace the tilt piston and free piston if worn or deteriorated 4 Check the trim ram assemblies 3 Replace the trim ram assembles if scratched 5 Check the tilt ram 4 and trim rams 5 Polish with 400 600 grit sandpaper if there is light rust or replace if bent or if there is excessive corros...

Page 221: ...tighten the bolt to the specified torque PTT piston vice attachment 8 90890 06572 Tilt rod wrench 9 90890 06569 Tilt ram 7 65 N m 6 5 kgf m 47 9 ft lb Tilt piston bolt u 13 N m 1 3 kgf m 9 6 ft lb 8 7 9 a 68871140 6 q t r u y e q 6 0 r e w 0 w 68871150 Assembling the tilt ram cC Do not use a rag when assembling the PTT unit as dust and particles on the PTT unit components can lead to poor perfor m...

Page 222: ...m 7 1 2 1 2 3 68871160 4 5 6 7 4 5 6 68871170 Installing the tilt cylinder 1 Install the new O ring 1 to the free pis ton 2 2 Push the free piston 2 into the tilt cylin der 3 until it bottoms out 3 Install the tilt cylinder 3 to the PTT body 4 4 Install the pipes 5 6 and 7 onto the PTT body and then tighten the pipe joints to the specified torque Pipe joints 5 20 N m 2 0 kgf m 14 8 ft lb Pipe join...

Page 223: ...screwdriver and then remove any air between the pump gear teeth Trim and tilt wrench 3 90890 06587 Trim cylinder end screw 2 160 N m 16 kgf m 118 ft lb 1 3 2 68871220 a 68871230 Installing the trim ram cC Do not use a rag when installing the PTT unit as dust and particles on the PTT unit components can lead to poor perfor mance 1 Hold the PTT body 1 in a vice using alu minum plates a on both sides...

Page 224: ... m 0 7 kgf m 5 2 ft lb Reservoir mount bolt 3 7 N m 0 7 kgf m 5 2 ft lb 2 Fill the PTT fluid into the reservoir and then install the new O ring 4 and reser voir cap 5 and then tighten it to the specified torque NOTE Add sufficient fluid of the recommended type until it overflows out of the filler hole Installing the tilt ram 1 Fill the tilt cylinder with the recommended fluid to the correct level ...

Page 225: ... extend the rams Reservoir cap 7 N m 0 7 kgf m 5 2 ft lb L G 2 68871300 L G 2 68871310 Ram PTT motor lead Battery terminal Up Blue L Green G Down Green G Blue L 3 Install the tilt ram assembly into the tilt cylinder and then tighten the tilt cylinder end screw 1 to the specified torque NOTE Place the tilt cylinder end screw at the bottom of the tilt ram and install the tilt ram assembly into the t...

Page 226: ...ect the PTT motor leads refer to page 7 62 68870446 1 3 Let the fluid settle for 5 minutes 4 Push and hold the PTT switch in the up position until the outboard motor is fully tilted up 5 Support the outboard motor with the tilt stop lever and then let the fluid settle for 5 minutes w After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor cou...

Page 227: ...arness O Sky blue Sb Test harness P Light green Lg Test harness R Black B R O P R P O 3 5 6 4 B Lg Sb 68871330 PTT electrical system Checking the fuse 1 Check the fuse 20A for continuity Replace if there is no continuity NOTE Fuse position refer to page 8 3 Checking the PTT relay 1 Remove the PTT relay from CDI unit bracket 2 Connect the special service tools and then check the PTT relay for conti...

Page 228: ...e the trim sensor resistance Replace if out of specification NOTE 9 Turn the trim sensor lever 1 from a to c and measure the resistance as it gradually changes 9 The position b is the trim sensor lever posi tion when the outboard motor is tilted down To adjust the trim sensor refer to page 7 33 9 The trim sensor resistance will be lower at the position c than at the position b 9 The range d is the...

Page 229: ...cking the thermoswitch 8 8 Checking the warning indicator EHD 8 9 Starting system 8 9 Checking the fuse 8 9 Checking the engine start switch 8 9 Checking the engine stop lanyard switch 8 10 Checking the starter relay 8 11 Checking the neutral switch continuity EHD 8 11 Measuring the choke solenoid resistance ED ET 8 11 Starter motor 8 12 Removing the starter motor pinion 8 14 Checking the starter ...

Page 230: ...ester leads cC When testing the voltage between the ter minals of an electrical component with the digital tester do not allow any of the leads to touch any metal parts If touched the electrical component can short and be damaged NOTE 9 Before measuring the peak voltage check all wiring for proper connection and corro sion and check that the battery is fully charged 9 Use the peak voltage adapter ...

Page 231: ... G W G W G B B W B Br R 2 3 6 0 B R 6888010E 1 Ignition coil 1 2 Ignition coil 2 3 Ignition coil 3 4 Stator assembly 5 Pulser coil assembly 6 CDI unit 7 Starter motor 8 Engine start switch 9 Engine stop lanyard switch 0 Starter relay q Fuse 20A w Neutral switch e Rectifier Regulator r Warning indicator t Thermoswitch y 10P coupler u Spark plug B Black Br Brown G Green L Blue P Pink R Red W White B...

Page 232: ...20E 75AED 75AET 85AED 85AET 1 Ignition coil 1 2 Ignition coil 2 3 Ignition coil 3 4 Stator assembly 5 Pulser coil assembly 6 CDI unit 7 Starter motor 8 Starter relay 9 Fuse 20A 0 Rectifier Regulator q Choke solenoid w Thermoswitch e PTT relay ET r 10P coupler t Spark plug B Black Br Brown G Green L Blue Lg Light green P Pink R Red Sb Sky blue W White B W Black white G W Green white ...

Page 233: ...touch any of the connections of the ignition tester leads 9 Keep flammable gas or liquids away since this test can produce sparks Checking the spark plug cap with resister type 1 Check the spark plug caps Replace the spark plug caps if cracked or damaged 2 Remove the spark plug cap 1 from the spark plug wire 2 by turning the cap counterclockwise 3 Measure the spark plug cap resistance Replace the ...

Page 234: ...e all spark plug caps from the all spark plugs 2 Remove the cover 3 Disconnect the ignition coil connector and then remove the spark plug cap 4 Remove the ignition coil from the power unit 5 Check the spark plug wire Replace the ignition coil if cracked or corroded 6 Measure the ignition coil resistance Replace the ignition coil if out of specifi cation å B W B 68880070 Ignition coil resistance re...

Page 235: ...e adapter B to the ignition coil lead and the ground 3 Measure the CDI unit output peak volt age If less than specification measure the charge coil output peak voltage Replace the CDI unit if the output peak voltage of the charge coil is more than specification Test propeller 90890 01620 1 2 3 B B B W B W B B B B W B W B W B W B W B W B W B W B W B W B W B W B W 68880010 68880080 CDI unit output p...

Page 236: ...r R L P R O 68880030 Checking the pulser coil 1 Remove the cover 2 Connect the test harness 1 and digital circuit tester with peak voltage adapter B to the pulser coil coupler 2 3 Measure the pulser coil output peak volt age If the measurement is less than specification measure the pulser coil resistance NOTE Remove the all spark plug caps when mea suring the pluser coil peak voltage at loaded eng...

Page 237: ... 4 Disconnect the charge coil coupler 5 Connect the special service tool 1 and digital circuit tester to the charge coil cou pler 6 Measure the charge coil resistance Replace the stator assembly if out of specification R O P Br L R 68880100 P O R 1 68880260 Charge coil resistance reference data Red R Brown Br 48 72 Ω at 20 C 68 F Red R Blue L 428 642 Ω at 20 C 68 F Thermoswitch continuity temperat...

Page 238: ...system Checking the fuse 1 Remove the fuse from fuse holder 2 Check the fuse 20A for continuity Replace the fuse if there is no continuity Checking the engine start switch 1 Disconnect the main harness coupler 69D80090 P Y R 2 Check the engine start switch for continu ity at the main harness coupler Check the wiring harness or replace the engine start switch of the remote control box or tiller han...

Page 239: ...nyard switch for continuity Replace the engine stop lan yard switch if it is not shown in the chart below 2 1 3 5 4 68880115 å ED ET EHD å 1 2 a a b 68880140 68880145 a b 1 2 a Lead color White Black Red Pink Brown W B R P Br 1 2 3 4 5 Switch position OFF ON START Lead color Switch position White W Black B 1 2 Lock plate removed a Lock plate installed b ...

Page 240: ...85J11 Electrical system 68880150 Br B 1 2 Battery lead Terminal position 1 2 Battery connected Battery disconnected 4 Check the neutral switch for continuity Replace the neutral switch if it is not shown in the chart below Measuring the choke solenoid resis tance ED ET 1 Disconnect the choke solenoid connec tor 2 Connect the digital circuit tester to the choke solenoid connector 3 Measure the resi...

Page 241: ...E No Part name Q ty Remarks 1 Screw 3 ø4 10 mm 2 Cover 1 3 Clip 1 4 Pinion stopper 1 5 Spring 1 6 Pinion 1 7 Bushing 1 8 Front bracket 1 9 Washer 10 Armature 1 11 Stator assembly 1 12 Nut 2 13 Spring washer 2 14 Washer 1 15 Holder 1 16 Washer 2 17 Spring 4 Not reusable Not reusable Starter motor ...

Page 242: ...ELEC 8 13 6885J11 Electrical systems 4 N m 0 4 kgf m 3 0 ft lb 6888030E No Part name Q ty Remarks 18 Brush holder 1 19 Rear bracket 1 20 Cover 1 21 Screw 2 ø4 12 mm 22 Bolt 2 M5 130 mm ...

Page 243: ... and turn it clockwise to check that it locks in place Checking the armature 1 Check the commutator Clean with 600 grit sandpaper and compressed air if dirt Removing the starter motor pinion 1 Remove the starter motor from the power unit NOTE To remove the starter motor refer to page 5 12 2 Remove the cover and then remove the spring 1 from the starter motor NOTE Do not reuse the spring 1 3 Slide ...

Page 244: ...inuity Replace the armature if it is not shown in the chart below Checking the brush 1 Measure the brush length a Replace the brush assembly if below specification limit Standard diameter a 33 0 mm 1 30 in Wear limit 31 0 mm 1 22 in 69R80320 c e f d Standard length a 16 0 mm 0 63 in Wear limit 12 0 mm 0 47 in Armature continuity c d e f Tester probe Segment Segment Segment Armature core Segment Ar...

Page 245: ...connect the lighting coil connector 3 Connect the digital circuit tester with peak voltage adapter B to the lighting coil 4 Measure the lighting coil output peak voltage If the measurement is less tan specification measure the lighting coil resistance NOTE Remove the all spark plug caps when mea suring the lighting coil peak voltage at engine cranking 5 Connect the digital circuit tester to the li...

Page 246: ...r Regulator output peak voltage If less than specification measure the lighting coil output peak voltage Replace the Rectifier Regulator if the output peak voltage of the lighting coil is more than specification 4 Remove the Rectifier Regulator from the power unit 5 Connect the digital circuit tester to the Rectifier Regulator 6 Check the Rectifier Regulator for continu ity Replace the Rectifier R...

Page 247: ...6885J11 9 8 7 6 5 4 3 2 1 TRBL SHTG TRBL SHTG Troubleshooting Troubleshooting the power unit 9 1 Troubleshooting the power unit 9 1 Troubleshooting the PTT unit 9 7 Troubleshooting the lower unit 9 9 ...

Page 248: ...e battery for electrolyte level gravity and voltage 3 19 Loose connection of battery terminal Check the battery terminal connection Short or open connec tion in starter motor cir cuit Check the wiring har ness for continuity WD Starter relay malfunction Check the starter relay 8 11 Blown fuse 20A Check the fuse 20A 8 9 Starter motor malfunction Disassemble and check the starter motor 8 12 Engine s...

Page 249: ...ion Check the fuel pump Fuel pump malfunction 4 6 Check the fuel joint pressure Fuel joint malfunction Symptom 1 Engine will not start engine cranks Symptom 1 Engine dose not crank Spark plug does not spark 4 13 Adjust and check the carburetor Carburetor malfunction Kinked fuel hose Check the fuel hose kinked Repair the fuel hose 8 10 Engine stop lanyard switch malfunction Check for continuity Spa...

Page 250: ...k the ignition spark Charge coil out put peak volt age less than specifications Spark plug does not spark Cylinder head gasket malfunction Disassemble and check the reed valves Check the compression pressure and disas sembling the cylinder head 5 1 5 18 5 14 Low compres sion pressure Scratched piston or wear the piston rings Check the compression pressure and disas sembling the power unit Scratche...

Page 251: ...e stop screw Check and adjust the pilot screw 3 8 Pilot screw adjusting improperly 4 14 Fuel supplied to the carburetor improperly Check the fuel filter for clog 3 3 Fuel not sup plied properly Fuel filter element malfunction Check the fuel joint pressure 4 6 Fuel joint malfunction Carburetor malfunction Check the fuel hose kinked Repair the fuel hose 3 2 Kinked fuel hose Check and adjust the pilo...

Page 252: ...ction Clogged cooling water passage Thermostat malfunction Check the impeller 6 6 Water pump impeller malfunction Check the Woodruff key 6 6 Water leakage from water pump housing Check the water pump housing 6 6 Check the insert car tridge 6 6 Check the outer plate cartridge Check the cooling water passage exhaust guide upper case and cooling water pipe Check the thermostat 7 11 3 3 Thermoswitch m...

Page 253: ... head gasket malfunction Reed valves malfunction Disassemble and check the reed valves Check the compression pressure and disas sembling the cylinder head 5 1 5 18 5 14 5 1 5 9 Low compres sion pressure Propeller selection improperly Check the propeller matching 1 13 Scratched piston or wear the piston rings Check the compression pressure and disas sembling the power unit Scratched cylinder WD See...

Page 254: ...motor lead and ground circuit WD PTT motor does not operate Oil pressure does not increase PTT motor malfunction Disassemble and check the PTT motor 7 42 Blown fuse 20A Check the fuse 20A 7 64 Discharged battery Check the battery 3 19 Loose connection of the battery terminal Check the battery ter minal Manual valve opened Check the manual valve for open Manual valve malfunction Insufficient PTT fl...

Page 255: ...m 1 PTT unit does not hold the outboard motor up Manual valve opened Check the manual valve for open Insufficient PTT fluid Add sufficient fluid 3 15 Manual valve malfunction PTT fluid leakage Check the PTT unit for leakage 7 37 Clogged fluid passage Disassemble and check the PTT unit 7 57 Main valves does not oper ate ...

Page 256: ...oss pin 6 7 Dog clutch worn Disassemble the lower case and check the dog clutch Troubleshooting the lower unit Symptom 1 Gear shift does not operate properly 3 13 3 13 6 7 6 13 Remote control box malfunction Shift rod operation malfunction Shift cable and shift cable end malfunction Check and adjust the remote control box Check the shift cable and shift cable end Adjust the shift cable Disassemble...

Page 257: ...Checking the connecting rod big end side clearance 5 28 Checking the connecting rod small end axial play 5 29 Checking the control link position 3 6 Checking the cooling water passage 3 4 Checking the cooling water pilot hole 1 17 Checking the crankshaft 5 28 Checking the cylinder block 5 25 Checking the cylinder bore 5 26 Checking the cylinder head 5 19 Checking the drive shaft 6 16 Checking the ...

Page 258: ...he tilt pin 3 17 Checking the timing plate 3 10 Checking the top cowling 3 2 Checking the trim sensor 7 65 Checking the upper case 7 11 Checking the valve 7 57 Checking the warning indicator EHD 8 9 Checking the water pump 6 6 Clamp bracket and swivel bracket 7 18 Control system 3 5 Crankcase 5 21 Cylinder head exhaust cover 5 15 D Dimension 2 15 Disassembling the carburetor 4 13 Disassembling the...

Page 259: ...selection 1 13 Propeller shaft housing 6 7 Propeller size 1 13 PTT electrical system 7 64 PTT motor 7 41 PTT unit 7 35 R Removing the clamp bracket EHD ED 7 22 Removing the clamp bracket ET 7 31 Removing the control lever and throttle cam 5 12 Removing the crankcase 5 24 Removing the cylinder head 5 18 Removing the drive shaft 6 14 Removing the electrical component 5 11 Removing the exhaust cover ...

Page 260: ... MEMO ...

Page 261: ... MEMO ...

Page 262: ...6 CDI unit 7 Lighting coil 8 Charge coil 9 Pulser coil 0 Starter motor q Battery w Fuse 20A e Warning indicator r Neutral switch å To main switch Color code B Black Br Brown G Green L Blue P Pink R Red W White B W Black White G W Green White Y R Yellow Red W R White Red W B White Black W G White Green W Y White Yellow ...

Page 263: ...nd significant changes in specifications and procedures and these are incorporated in successive editions of this manual Important information Particularly important information is distinguished in this manual by the following notations Q The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED w Failure to follow WARNING instructions could result in severe injury or death to t...

Page 264: ...YAMAHA MOTOR CO LTD Printed in Japan Oct 2006 1 1 1 E_2 Printed on recycled paper 75A SERVICE MANUAL 688 28197 5J 11 85A 55D 55D 75A 85A 688_cover qxd_1 07 9 26 16 21 Page 1 ...

Page 265: ...r W R W G W B W Y W R W G W B W Y Y R B B B B B Br R L Br R L Br R Br Br Br Br Br Br Br B W B W B W B B B B B B P B P B P B P P R G R B B R G R B L B B B R L P R G B W B W B W B W B W B W B W B W B W B W B W B W B B R R P Y R Y R P Y R P P B B B B G W G W G W G G W R G W L B P Br ...

Page 266: ... unit 7 Lighting coil 8 Charge coil 9 Pulser coil 0 Choke solenoid q Starter motor w Battery e Fuse 20A å To remote control box Color code B Black Br Brown G Green L Blue P Pink R Red W White B W Black White G W Green White Y R Yellow Red W R White Red W B White Black W G White Green W Y White Yellow ...

Page 267: ... G G Br W R W G W B W Y W R W G W B W Y Y R Y R B B B B B Br Br R L Br R L Br R Br B W B W B W B B B B B B P B P B P B P P P R G R B B R G R B L B B B B R L L L P R G B W B W B W B W B W B W B W B W B W B W B W B W B B R R P B B B B G W G W G W G G W R W G L B P Br ...

Page 268: ...9 Pulser coil 0 Choke solenoid q Starter motor w Battery e Trim sensor r PTT motor t Fuse 20A y PTT relay å To remote control box To trim meter Color code B Black Br Brown G Green L Blue P Pink R Red W White Lg Light green Sb Sky blue Gy Gray B W Black White G W Green White W R White Red W B White Black W G White Green W Y White Yellow ...

Page 269: ... R W G W B W Y B B B B B Br Br Br R L Br R L Br R Br B W B W B W B B B B B B B P P B P B P B P P R G G R R B B R G R B B L L B B B B R L L L L P P B P R G G B W B W B W B W B W B W B W B W B W B W B W B W B B R R R P B B B B B B G W G W G W G G W Sb R W Lg G L B P Br Gy Gy Sb Lg B Sb Lg B Sb Lg B Sb Lg ...

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