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Yamaha E115A, Service Manual

The Yamaha E115A Service Manual is a comprehensive guide for maintaining and repairing the E115A outboard motor. This manual is available for free download at manualshive.com, providing users with essential information, diagrams, and instructions to ensure optimal performance and longevity of their Yamaha E115A.

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61U5H11

4-2

9

8

7

6

5

4

3

2

1

Hose routing

1

3

2

5

8

4

4

6

7

8

1

2

8

6

9

8

7

61U4001B

PORT

STBD

MH, WH

E, ET

1

Breather hose (manifold-to-cylinder body #2)

2

Breather hose (manifold-to-cylinder body #4)

3

Breather hose (breather hose-to-manual injection)

4

Breather hose (manifold-to-manual injection)

5

Breather hose (breather hose-to-manual injection hose)

6

Breather hose (manifold-to-cylinder body #1)

7

Breather hose (cylinder body #3-to-manual injection hose)

8

Breather hose (manifold-to-intake silencer)

9

Breather hose (manifold-to-cylinder body #3)

 61U5H11_04_1  06.2.13 1:23 PM  Page 3

Summary of Contents for E115A

Page 1: ...115B SERVICE MANUAL 61U 28197 5H 11 140B E115A E115A 115B 140B ...

Page 2: ...f modifications and 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 inj...

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: ...e tool 1 6 Propeller selection 1 11 Propeller size 1 11 Selection 1 11 Predelivery check 1 12 Checking the fuel system 1 12 Checking the gear oil 1 12 Checking the outboard motor mounting height 1 12 Checking the remote control cable Remote control model 1 13 Checking the steering system 1 14 Checking the gear shift and throttle operation 1 14 Checking the PTT system ET 1 15 Checking the engine st...

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: ...oded diagram or illustration indicate the grade of lubricant and the lubri cation point 7 Apply Yamaha 2 stroke outboard 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...

Page 8: ...sing an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary Parts 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 sho...

Page 9: ...ners starting in the center and moving outward Non reusable parts 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 dire...

Page 10: ...ped on a label attached to the port clamp bracket 1 Model name 2 Approved model code 3 Transom height 4 Serial number 6G410010 YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON 1 3 2 4 6B410020 Applicable model E115AMH E115AWH E115AE E115AET 115BE 115BET 140BET Model name Approved Starting model code serial No E115A 61U 1015056 115B 6E5 1015056 140B 6F3 1000671 ...

Page 11: ...l tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06840 Digital caliper 90890 06704 Vacuum pressure pump gauge set 90890 06756 Compression gauge 90890 03160 Flywheel holder 90890 06522 Flywheel puller 90890 06521 Ball bearing attachment 90890 06663 Driver rod LS 90890 06606 ...

Page 12: ...90890 06653 90890 06654 Gear puller 90890 06540 Bearing separator 90890 06534 Support 90890 02394 Bearing outer race attachment 90890 06620 90890 06624 Bearing inner race attachment 90890 06640 90890 06662 Cylinder gauge 90890 06759 Ball bearing attachment 90890 06633 90890 06636 90890 06637 90890 06656 Small end bearing installer 90890 06528 ...

Page 13: ...auge set 90890 01252 Shift rod push arm 90890 06052 Ring nut wrench 3 90890 06511 Stopper guide plate 90890 06501 Bearing housing puller claw L 90890 06502 Center bolt 90890 06504 Ring nut wrench extension 90890 06513 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 ...

Page 14: ...iver rod SS 90890 06604 Bearing depth plate 90890 06603 Drive shaft holder 6 90890 06520 Pinion nut holder 90890 06715 Bearing outer race puller assembly 90890 06523 Driver rod SL 90890 06602 Pinion height gauge 90890 06710 Shimming plate 90890 06701 Driver rod LL 90890 06605 ...

Page 15: ... 90890 03174 Up relief fitting 90890 06773 Down relief fitting 90890 06774 Test harness 4 pins 90890 06878 Trim and tilt wrench 90890 06587 Ignition tester 90890 06754 Magnet base plate 90890 07003 Hydraulic pressure gauge 90890 06776 Peak voltage adaptor B 90890 03172 Test harness 4 pins 90890 06871 ...

Page 16: ...d 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 conditions of the boat and the outboard motor Propeller size The size of the propeller is indicated as shown a Propeller diameter in inches b Propeller pitch in inches c...

Page 17: ...ry 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 propulsion will be reduced Also the engine speed will increase abnormally and cause the engine to over heat If the mounting height is too low water resistance will increase and reduce e...

Page 18: ... contact the stopper 3 3 Fully open the throttle lever and then check that the control lever 1 is in its fully opened position and check the con trol lever contact the adjusting screw 4 4 Check that the remote control lever is in the neutral position and check that the center of the set pin 5 is aligned with the alignment mark a on the bottom cowling cC The shift throttle cable joint must be screw...

Page 19: ...eck that the throttle operates smoothly when the remote control lever remote control model is shifted from forward or reverse to the fully open positions a Checking the steering system 1 Check the steering friction for proper adjustment NOTE 9 To increase the friction turn the friction adjusting nut in direction a 9 To decrease the friction turn the friction adjusting nut in direction b 2 Check th...

Page 20: ...e PTT unit 2 Check that there is no abnormal noise produced when the outboard motor is tilt ed up or down 3 Check that there is no interference with wires or hoses when the tilted up out board motor is steered 4 Check that the trim meter points down when the outboard motor is tilted all the way down Checking the engine start switch engine stop lanyard switch 1 Check that the engine starts when the...

Page 21: ... ating at full throttle for more than 5 min utes at a time Let the engine cool between full throttle runs Vary engine speed occasionally 5 After the first 10 hours Use standard pre mix ratio of fuel and oil Refer to page 1 12 å Hours 6F610180 0 1 2 10 Checking the cooling water pilot hole 1 Start the engine then check that the cooling water is discharged from the cooling water pilot hole Test run ...

Page 22: ...gear oil 2 Check for fuel leakage in the cowling 3 Flush the cooling water passage with fresh water using the flushing kit 1 and with the engine running at idle cC Be sure to supply sufficient water when flushing the cooling water passage other wise the engine may overheat 6S310070 1 ...

Page 23: ...e specification 2 5 Power unit E115A models 2 5 Lower unit E115A models 2 7 Electrical E115A models 2 7 Power unit 115B 140B models 2 10 Lower unit 115B 140B models 2 12 Electrical 115B 140B models 2 12 Dimension 2 15 Tightening torque 2 19 Specified torque 2 19 General torque 2 21 ...

Page 24: ... kg lb 153 337 156 344 X kg lb 157 346 160 353 153 337 160 353 Performance Maximum output kW hp 84 6 115 at 5 000 r min Full throttle operating range r min 4 500 5 500 Maximum fuel consumption L 47 12 4 10 3 5 500 r min US gal lmp gal hr Engine idle speed r min 700 800 Power unit Engine type 2 stroke V Cylinder quantity 4 Total displacement cm3 cu in 1 730 105 56 Bore x stroke mm in 90 0 68 0 3 54...

Page 25: ...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 760 25 70 26 81 lmp oz Bracket unit Trim angle Degree 4 0 to 16 0 at 12 boat transom Tilt up angle Degree 66 0 70 0 Steering angle Degree 35 35 Drive unit Gear shift positions F N R Gear ratio 2 00 26 13 Reduction gear type Spiral...

Page 26: ... r min Full throttle operating range r min 4 500 5 500 Maximum fuel consumption L 49 12 9 10 8 5 500 r min 56 14 8 12 3 US gal 5 500 r min lmp gal hr Engine idle speed r min 700 800 Power unit Engine type 2 stroke V Cylinder quantity 4 Total displacement cm3 cu in 1 730 105 56 Bore x stroke mm in 90 0 68 0 3 54 2 68 Compression ratio 6 50 1 6 80 1 Intake system Reed valve Scavenging system Loop ch...

Page 27: ...5 70 26 81 lmp oz Bracket unit Trim angle Degree 4 0 to 16 0 at 12 boat transom Tilt up angle Degree 66 0 70 0 Steering angle Degree 35 35 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 2...

Page 28: ...l starter 400 4 0 57 Cylinder head Warpage limit mm in 0 10 0 0039 lines indicate straightedge position Cylinder Bore size mm in 90 000 90 020 3 5433 3 5441 Piston Piston diameter D mm in 89 920 89 935 3 5402 3 5407 Measuring point H mm in 10 0 0 39 Piston clearance mm in 0 080 0 085 0 0032 0 0033 Piston pin boss bore mm in 21 504 21 515 0 8466 0 8470 Oversize piston 1st mm in 0 25 0 010 2nd mm in...

Page 29: ... in 26 500 26 512 1 0433 1 0438 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 53 975 53 991 2 1250 2 1256 Crankpin diameter mm in 35 985 36 000 1 4167 1 4173 Runout limit mm in 0 02 0 0008 Thermostat Opening temperature C F 48 52 118 40 125 60 Fully open temperature C F 60 140 Valve open ...

Page 30: ...150 at 3 500 r min loaded V 150 Pulser coil output peak voltage W R W Y W B W G at Cranking unloaded V 4 8 at Cranking loaded V 3 8 at 1 500 r min loaded V 8 8 at 3 500 r min loaded V 14 2 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 0 90 0 183 194 OFF temperature C F 60 0 74 0 140 165 Lower unit E115A models Item Unit Model E115AMH E115AWH E115A...

Page 31: ... B R L Ω 48 72 R Br Ω 428 642 Starter motor Type Bendix Output kW 1 10 Brushes Standard length mm in 17 0 0 67 Wear limit mm in 10 0 0 39 Commutator Standard diameter mm in 33 0 1 30 Wear limit mm in 32 0 1 26 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 8 0 at...

Page 32: ...d type ATF Dexron 2 Motor type 64E00 Output kW 0 40 Brushes Standard length mm in 9 8 0 39 Wear limit mm in 4 8 0 19 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Standard undercut mm in 1 35 0 053 Wear limit mm in 0 85 0 033 Hydraulic pressure down MPa kgf cm2 6 9 60 90 Hydraulic pressure up MPa kgf cm2 10 12 100 120 ...

Page 33: ...r head Warpage limit mm in 0 10 0 0039 lines indicate straightedge position Cylinder Bore size mm in 90 000 90 020 3 5433 3 5441 Piston Piston diameter D mm in 89 920 89 935 3 5402 3 5407 Measuring point H mm in 10 0 0 39 Piston clearance mm in 0 080 0 085 0 0032 0 0033 Piston pin boss bore mm in 23 074 23 085 0 9084 0 9089 Oversize piston 1st mm in 0 25 0 010 2nd mm in 0 50 0 020 Oversize piston ...

Page 34: ...d inside diameter mm in 28 070 28 082 1 1051 1 1056 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 53 975 53 991 2 1250 2 1256 Crankpin diameter mm in 35 985 36 000 1 4167 1 4173 Runout limit mm in 0 02 0 0008 Thermostat Opening temperature C F 48 52 118 40 125 60 Fully open temperature C ...

Page 35: ...3 500 r min loaded V 150 Pulser coil output peak voltage W R W Y W B W G at Cranking unloaded V 4 8 at Cranking loaded V 3 8 at 1 500 r min loaded V 8 8 at 3 500 r min loaded V 14 2 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 0 90 0 183 194 OFF temperature C F 60 0 74 0 140 165 Lower unit 115B 140B models Item Unit Model 115BE 115BET 140BET Gear...

Page 36: ...tarter motor Type Bendix Output kW 1 10 Brushes Standard length mm in 17 0 0 67 Wear limit mm in 10 0 0 39 Commutator Standard diameter mm in 33 0 1 30 Wear limit mm in 32 0 1 26 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 8 0 at 1 500 r min unloaded V 31 0 at...

Page 37: ... Motor type 64E00 Output kW 0 40 Brushes Standard length mm in 9 8 0 39 Wear limit mm in 4 8 0 19 Commutator Standard diameter mm in 22 0 0 87 Wear limit mm in 21 0 0 83 Standard undercut mm in 1 35 0 053 Wear limit mm in 0 85 0 033 Hydraulic pressure down MPa kgf cm2 6 9 60 90 Hydraulic pressure up MPa kgf cm2 10 12 100 120 Maintenance specification ...

Page 38: ...005 39 6 Y 1 055 41 5 X 1 120 44 1 L 735 28 9 Y 765 30 1 X 810 31 9 570 22 4 780 30 7 631 24 8 155 6 1 539 21 2 705 27 8 210 8 3 424 16 7 300 11 8 616 24 3 325 12 8 270 10 6 64 2 5 150 5 9 45 1 8 845 33 3 695 27 4 190 7 5 6 6 3 5 12 61U2001M Dimension Exterior E115A mm in MH WH Specification ...

Page 39: ...1 X 85 3 5 L 735 28 9 X 810 31 9 7 0 6 6 53 2 1 45 1 8 150 5 9 508 20 0 L 515 20 3 X 642 25 3 190 7 5 730 28 7 L 929 36 6 X 1 056 41 6 12 539 21 2 297 11 7 422 16 6 3 5 L 1 005 39 6 X 1 120 44 1 482 19 0 6IU2002M E115A 115B 140B mm in Maintenance specification E ET ...

Page 40: ...SPEC 2 17 61U5H11 182 7 2 182 7 2 163 5 6 4 163 5 6 4 125 4 4 9 125 4 4 9 13 0 5 18 5 0 7 50 8 2 0 350 13 8 13 0 5 62 2 4 55 5 2 2 254 10 0 6IU2003M Clamp bracket mm in Specification ...

Page 41: ... 18 9 8 7 6 5 4 3 2 1 6G42003M 82 3 2 254 10 0 367 14 5 163 5 6 4 163 5 6 4 101 5 4 0 101 5 4 0 125 4 4 9 125 4 4 9 180 7 1 180 7 1 50 8 2 0 18 5 0 7 52 2 0 55 5 2 2 13 0 5 13 0 5 mm in Maintenance specification ...

Page 42: ...motor mount bolt M8 29 2 9 21 4 Starter motor positive terminal nut 9 0 9 6 6 Intake manifold bolt 1st M6 4 0 4 3 0 2nd 8 0 8 5 9 Thermostat cover bolt 1st M6 4 0 4 3 0 2nd 8 0 8 5 9 Cover bolt 1st M6 4 0 4 3 0 2nd 8 0 8 5 9 PCV cover bolt 1st M6 4 0 4 3 0 2nd 8 0 8 5 9 Exhaust cover bolt 1st M6 4 0 4 3 0 2nd 8 0 8 5 9 Cylinder head cover bolt 1st M6 4 0 4 3 0 2nd 8 0 8 5 9 Cylinder head bolt 1st ...

Page 43: ... 7 27 3 Engine stop lanyard switch nut 3 0 3 2 2 Engine start switch nut WH 4 0 4 3 0 Shift position bolt 24 2 4 17 7 Upper mount nut 51 5 1 37 6 Lower mount nut 71 7 1 52 4 Exhaust guide bolt M8 18 1 8 13 3 Exhaust manifold bolt M8 18 1 8 13 3 Muffler bolt M8 18 1 8 13 3 Upper case mount bolt M8 21 2 1 15 5 Self locking nut 15 1 5 11 1 Trim stopper nut 36 3 6 26 6 Trim sensor cam screw 2 0 2 1 5 ...

Page 44: ...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 45: ...ontrol link and throttle link position 3 5 Synchronizing the carburetor 3 5 Checking the engine idle speed 3 6 Adjusting the throttle cable 3 6 Checking the gear shift operation 3 7 Checking the ignition timing 3 8 Checking the choke solenoid E ET 3 9 Bracket 3 10 Checking the PTT operation ET 3 10 Checking the PTT fluid level ET 3 10 Checking the tilt operation MH WH E 3 11 Lower unit 3 11 Checki...

Page 46: ...1 3 4 Cowling clamp Check 1 3 2 Fuel filter can be dis Check clean 1 1 1 3 2 assembled Fuel system Check 1 1 1 3 2 Fuel tank Yamaha por Check clean 1 table tank Gear oil Change 1 1 3 12 Lubrication points Lubricate 1 3 14 Idle speed carbure Check adjust 1 1 3 6 tor model PCV Check 1 5 26 PTT unit Check replace 1 1 3 10 Propeller and cotter pin Check replace 1 1 3 13 Shift link shift cable Check ad...

Page 47: ...nce interval chart Top cowling Fuel system Fuel system Checking the fuel joint and fuel hose fuel joint to carburetor 1 Check the fuel hose connections and fuel joint for leaks Replace them if necessary Also check the fuel filter 1 fuel pump 2 and carburetors 3 for leaks or deteri oration Replace if necessary Checking the fuel filter 1 Check the fuel filter element 1 for dirt and residue and check...

Page 48: ...torque with a spark plug wrench Checking the thermostat 1 Remove the thermostat covers 1 gas kets 2 and thermostats 3 2 Suspend the thermostats 3 in a con tainer with water 3 Place a thermometer in the water and slowly heat the water 4 Check the thermostat valve opening at the specified water temperatures Replace if out of specification CHK ADJ 3 3 61U5H11 Periodic check and adjustment 6B430030 a ...

Page 49: ...t a temperature 48 52 C 0 05 mm 0 002 in 118 4 125 6 F valve begins to tilt above more than 60 C 140 F 3 0 mm 0 12 in 3 Check for water flow at the cooling water pilot hole If there is no water flow check the cooling water passage inside of the outboard motor Control system Adjusting the start in gear protec tion MH WH 1 Set the gear shift to the neutral position 2 Loosen the bolt 1 and then adjus...

Page 50: ...NOTE Make a note that how many times you turn out the throttle stop screw 3 Loosen the throttle lever tightening screws 3 and 4 clockwise NOTE The screws 3 and 4 are left hand thread 4 Make sure that the throttle valves are fully closed position 5 Tighten the throttle lever tightening screw 3 counterclockwise on the upper carbu retor 6 Turn the throttle stop screw 1 until it con tacts the stopper ...

Page 51: ... 8 Tighten the throttle lever tightening screw 4 counterclockwise on the lower carbu retor NOTE The screw 4 is left hand thread 9 Make sure the throttle valves are open and close simultaneously 10 Install the throttle cable and intake silencer NOTE After synchronizing the carburetor start the engine and check the engine idle speed to adjust the throttle stop screw Checking the engine idle speed NO...

Page 52: ...utral position 3 Loosen the locknut 1 remove the clip 2 and then remove the shift cable joint 3 CHK ADJ 3 7 61U5H11 Periodic check and adjustment 1 3 2 61U30105 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 w The throttle cable joint must be screwed in a min...

Page 53: ...m 6 Install the shift cable joint 3 install the clip 2 and then tighten the locknut 1 7 Check the gear shift for smooth operation and adjust the shift cable length if nec essary repeat the steps 3 6 8 Check that the neutral switch 5 is push ing by the shift lever 6 WH Checking the ignition timing 1 Start the engine and warm it up for 5 min utes NOTE Turn off the engine when warmed it up com pletel...

Page 54: ... bolt 1 if necessary 3 Attach the special service tool 3 to spark plug wire 1 2 and then start the engine Cheek the engine idle speed and ignition timing 4 Check that the ATDC 5 scale a on the flywheel magnet is aligned with the point er b on the timing plate when the throt tle is fully closed 61U30250 2 3 CHK ADJ 3 9 61U5H11 Periodic check and adjustment a b 1 61U30120 Timing light 3 90890 03141 ...

Page 55: ...e reser voir cap otherwise fluid can spurt out from the unit due to internal pressure NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap 2 is removed 6G430380 2 Control system Bracket Bracket Checking the PTT operation ET 1 Fully tilt the outboard motor up and down a few times and check the entire trim and tilt range for smooth operati...

Page 56: ... Recommended PTT fluid ATF Dexron 2 Reservoir cap 2 7 N m 0 7 kgf m 5 2 ft lb 3 Fully tilt the outboard motor up then sup port it with the tilt stop lever 2 to check the lock mechanism of the lever Lower unit Checking the gear oil level 1 Fully tilt the outboard motor down 2 Remove the check screw 1 and then check the gear oil level in the lower case NOTE If the fluid is at the correct level the f...

Page 57: ... its viscosity Check the internal parts of the lower case if necessary 4 Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible 69D10050 69D30140 1 2 5 Install the new gaskets check screw and quickly install the drain screw and then tighten them to the specified torque 6G430420 Recommended gear o...

Page 58: ...er unit holding pressure 70 kPa 0 7 kgf cm2 10 psi Checking the lower unit for air leak age cC Do not over pressurize the lower unit oth erwise the oil seals may be damaged 1 Remove the check screw 1 and then install the special service tool 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 re...

Page 59: ...th 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 when charging or han dling batteri...

Page 60: ...rease to the grease nipple until it flows from the bushings a 2 Apply low temperature resistant grease to the area shown 3 Apply corrosion resistant grease to the area shown 6G430540 C 6B430300 D A 61U30170 a A 61U30180 A 61U30190 6G430530 a A 6G430500 A 6G430510 A ...

Page 61: ...her hose 4 1 Fuel line 4 3 Carburetor 4 6 Disassembling the carburetor 4 12 Checking the carburetor 4 12 Assembling the carburetor 4 13 Fuel pump 4 15 Checking the fuel pump 4 16 Disassembling the fuel pump 4 16 Assembling the fuel pump 4 17 Checking the fuel joint 4 17 FUEL ...

Page 62: ...se 1 Fuel hose fuel joint to fuel filter 2 Fuel hose fuel filter to manual injection MH WH 3 Fuel hose fuel filter to fuel pump 4 Manual injection pump MH WH 5 Fuel hose manual injection to upper carburetor MH WH 6 Fuel hose fuel pump to carburetor 61U4001A 1 2 3 4 5 6 ...

Page 63: ... manifold to cylinder body 4 3 Breather hose breather hose to manual injection 4 Breather hose manifold to manual injection 5 Breather hose breather hose to manual injection hose 6 Breather hose manifold to cylinder body 1 7 Breather hose cylinder body 3 to manual injection hose 8 Breather hose manifold to intake silencer 9 Breather hose manifold to cylinder body 3 ...

Page 64: ...mbly 1 3 Lock tie 18 MH WH Lock tie 10 E ET 4 Fuel hose 1 5 Fuel hose 1 MH WH 6 Fuel hose 1 7 Joint 1 MH WH 8 Hose 1 MH WH 9 Bypass valve 1 MH WH 10 Hose 1 MH WH 11 Bolt 2 M6 20 mm MH WH 12 Manual injection pump 1 MH WH 13 Bolt 2 M8 30 mm 14 Bracket 1 MH WH 15 Hose 1 MH WH 16 Bolt 2 M6 50 mm Not reusable Not reusable Fuel line ...

Page 65: ... Remarks 17 Fuel pump assembly 1 18 Gasket 1 19 Fuel hose 1 20 Joint 1 21 Fuel hose 1 22 Fuel hose 1 23 Bolt 1 M6 10 mm MH WH 24 Start in gear protection cable 1 MH WH 25 Bolt 1 M6 12 mm MH WH 26 Bolt 1 M5 10 mm MH WH 27 Cable 1 MH WH 28 Fuel joint 1 29 Bolt 1 M8 28 mm 30 Clamp 1 Not reusable ...

Page 66: ...Fuel system 6G44040E No Part name Q ty Remarks 1 Bolt 1 M6 16 mm 2 Washer 1 3 Holder 1 4 Bolt 1 M6 14 mm 5 Bracket 1 6 Fuel filter assembly 1 7 O ring 1 8 Fuel filter element 1 9 Fuel filter cup 1 10 Nut 1 Not reusable ...

Page 67: ... 8 M6 20 mm 2 Cover 1 3 Gasket 1 4 Bolt 8 M6 20 mm 5 Intake silencer 1 6 Bolt 2 M6 20 mm 7 Breather hose 1 8 Gasket 1 9 Upper carburetor assembly 1 10 Lower carburetor assembly 1 11 Link rod 1 12 Nut 8 13 Gasket 2 14 Rod 1 15 Joint 3 16 Choke knob 1 17 O ring 1 Not reusable Not reusable Not reusable Not reusable Carburetor ...

Page 68: ...FUEL 4 7 61U5H11 Fuel system 6 N m 0 6 kgf m 4 4 ft lb 61U4060E E ET No Part name Q ty Remarks 18 Bolt 2 M6 16 mm 19 Choke solenoid 1 20 Intake silencer 1 21 Grommet 2 ...

Page 69: ... ft lb 61U4070E No Part name Q ty Remarks 1 Plug 4 2 Gasket 4 3 Screw 2 4 Plate 2 5 Gasket 2 6 Main air bleed 4 7 Pilot screw 4 8 Spring 4 9 Screw 2 10 Gasket 2 11 Air bleed plug 4 12 Pilot air jet 4 13 Carburetor body 2 14 Needle valve 4 15 Clip 4 16 Float pin 4 17 Float 4 Not reusable MH WH Carburetor ...

Page 70: ... 1 0 kgf m 7 4 ft lb 61U4070E No Part name Q ty Remarks 18 Gasket 2 19 Plug 4 20 Gasket 4 21 Main jet 4 22 Drain plug 4 23 Gasket 4 24 Float chamber 2 25 Plug 4 26 Gasket 4 27 Pilot jet 4 28 Screw 8 ø5 16 mm 29 Throttle stop screw 1 30 Spring 1 31 Lower carburetor assembly 1 Not reusable ...

Page 71: ...b 10 N m 1 0 kgf m 7 4 ft lb 61U4065E No Part name Q ty Remarks 1 Plug 4 2 Gasket 4 3 Screw 2 4 Plate 2 5 Pilot screw 4 6 Spring 4 7 Screw 2 8 Gasket 2 9 Air bleed plug 4 10 Pilot air jet 4 11 Carburetor body 2 12 Needle valve 4 13 Clip 4 14 Float pin 4 15 Float 4 16 Gasket 2 17 Plug 4 Not reusable ...

Page 72: ...2 N m 0 2 kgf m 1 5 ft lb 10 N m 1 0 kgf m 7 4 ft lb 61U4065E No Part name Q ty Remarks 18 Gasket 4 19 Main jet 4 20 Float chamber 2 21 Plug 4 22 Gasket 4 23 Pilot jet 4 24 Screw 8 ø5 16 mm 25 Throttle stop screw 1 26 Spring 1 27 Lower carburetor assembly 1 ...

Page 73: ...ompressed air downward otherwise cleaning solvent may be blown into your eyes or small parts of the carburetor may be blown off 9 Do not use steel wire for cleaning the jets otherwise the jet diameters may be enlarged which may seriously affect performance 3 Check the main jet pilot jet and main nozzle for dirt or residue Clean if neces sary 4 Check the pilot screw and needle valve for bends or we...

Page 74: ...ied number of turns Assembling the carburetor 1 Install the gaskets 1 plugs 2 pilot air jets 3 and air bleed plugs 4 main air bleed 5 onto the carburetor body å MH WH E ET 2 Install a new gasket and then install the needle valves floats and float pins onto the carburetor body Check the float for smooth operation after install them 3 Install the main jets 6 and pilot jets 7 gaskets 8 drain plugs 9 ...

Page 75: ...ssemble the carburetor be sure to set the pilot screw by the specified times 7 Install the carburetor assembly 61U5H11 4 14 9 8 7 6 5 4 3 2 1 Pilot screw turns out E115A 1 1 1 2 115B 3 8 7 8 140B 5 8 1 1 8 Carburetor ...

Page 76: ... Part name Q ty Remarks 1 Base 1 2 Gasket 1 3 Diaphragm 1 4 Body assembly 1 5 Nut 4 6 Screw 4 ø5 28 mm 7 Washer 4 8 Check valve 4 9 Body 1 10 Gasket 1 11 Diaphragm 1 12 Collar 2 13 O ring 2 14 Cover 1 15 Plate 1 16 Spring 1 17 Screw 3 ø5 35 mm Not reusable Not reusable Not reusable ...

Page 77: ...cessary Disassembling the fuel pump 1 Disconnect the inlet and outlet hose from the fuel pump 2 Remove the 2 bolts 1 securing the pumps to the crankcase 3 Remove the 3 screws securing the pump together Refer to exploded diagram P4 15 NOTE Take care not to let the spring fly out or lose the plate 4 Check the diaphragm for tears or deteri oration Replace the diaphragm if neces sary 5 Check the valve...

Page 78: ...e fuel pump NOTE Clean the parts and soak the valves and the diaphragms in gasoline before assembly to obtain prompt operation of the fuel pump when starting the engine 1 Install the check valves 1 onto the fuel pump body 2 Install the spring 2 and plate 3 3 Install the new gaskets 4 diaphragms 5 collars 6 O rings 7 base 8 cover 9 on to the fuel pump body and then tighten the screws 0 to specified...

Page 79: ...61U5H11 4 18 9 8 7 6 5 4 3 2 1 MEMO ...

Page 80: ... reed valve 5 24 Exhaust cover 5 25 Removing the exhaust cover 5 26 Checking the exhaust cover 5 26 Checking the PCV 5 26 Installing the PCV 5 26 Cylinder head 5 27 Removing the cylinder head 5 29 Checking the cylinder head 5 29 Crankcase 5 31 Removing the crankcase 5 34 Disassembling the bearing housing 5 34 Disassembling the oil seal housing 5 35 Removing the piston connecting rod assembly and c...

Page 81: ...nnecting rod small end axial play 5 39 Checking the connecting rod big end side clearance 5 39 Checking the crankshaft 5 39 Assembling the crankshaft 5 40 Assembling the bearing housing 5 41 Assembling the oil seal housing 5 41 Assembling the piston and connecting rod assembly 5 42 Assembling the power unit 5 42 Installing the power unit 5 49 Adjusting the timing plate 5 52 Adjusting the ignition ...

Page 82: ... the compres sion gauge stabilizes NOTE 9 Do not pull the choke knob when checking the compression pressure 9 Disconnect the choke solenoid blue lead from the wireharness 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 to the cylin ders and then check the compression pressure again NOTE 9 If the com...

Page 83: ... ty Remarks 1 Bolt 3 M8 35 mm MH WH 2 Grommet 6 MH WH 3 Manual starter assembly 1 MH WH 4 Collar 3 MH WH 5 Bolt 2 M6 20 mm MH WH 6 Power unit 1 7 Dowel 2 8 Gasket 1 9 Bolt 2 M6 20 mm 10 Ground lead 1 11 Bolt 2 M6 16 mm 12 Retaining plate 1 13 Grommet 1 14 Washer 2 15 Nut 2 16 Bolt 4 M8 30 mm 17 Bolt 4 M6 20 mm Not reusable ...

Page 84: ... Apron 1 20 Apron 1 21 Bolt 2 M6 25 mm E ET 22 Grommet 2 E ET 23 Collar 2 E ET 24 Grommet 2 E ET 25 Flywheel cover 1 E ET 26 Negative battery cable 1 WH E ET 27 Positive battery cable 1 WH E ET 28 Positive lead 1 WH E ET 29 PTT motor lead up 1 ET 30 PTT motor lead down 1 ET 31 Neutral switch 1 WH 32 Bolt 2 M6 16 mm WH Bolt 1 MH E ET 33 Clamp 1 ...

Page 85: ...rt name Q ty Remarks 1 Nut 1 2 Washer 1 3 Starter pulley 1 MH WH 4 Bolt 3 M8 25 mm MH WH 5 Flywheel magnet 1 6 Bolt 3 M6 60 mm 7 Stator assembly 1 8 Pulser coil assembly 1 9 Screw 4 ø5 18 mm 10 Plate 4 11 Retainer 1 12 Woodruff key 1 13 Screw 1 ø6 10 mm 14 Timing plate 1 15 Bolt 2 M6 45 mm 16 Collar 2 17 Case 1 ...

Page 86: ...marks 18 Washer 2 19 Rectifier Regulator 1 20 Bolt 1 M6 12 mm 21 Main harness 1 22 Control link 1 23 Screw 2 If equipped ø5 20 mm 24 Hour meter 1 If equipped 25 Case 1 If equipped 26 Bolt 2 If equipped M6 30 mm 27 Collar 2 If equipped 28 Grommet 2 If equipped 29 Bolt 2 If equipped M6 20 mm 30 Washer 2 If equipped ...

Page 87: ... Part name Q ty Remarks 1 Joint 2 2 Lock nut 2 3 Control link rod 1 4 Throttle link rod 1 5 Bolt 1 M6 25 mm 6 Collar 1 7 Wave washer 1 8 Cam 1 9 Cap 2 10 Lock nut 2 11 Screw 1 12 Spring 1 13 Screw 1 14 Bolt 1 M8 45 mm 15 Washer 1 16 Collar 1 17 Bushing 1 ...

Page 88: ...WR 5 7 61U5H11 Power unit 61U5030E No Part name Q ty Remarks 18 Bushing 1 19 Spring 1 20 Control lever 1 1 21 Plastic washer 1 22 Washer 1 23 Bracket 1 24 Bolt 2 M8 30 mm 25 Bushing 1 26 Control lever 2 1 ...

Page 89: ...ver 1 3 Screw 2 ø6 40 mm 4 CDI unit 1 5 Charge coil coupler 1 6 Bolt 1 M6 12 mm 7 Spark plug cap 4 8 Bolt 4 M6 20 mm 9 Ignition coil 4 10 Bolt 2 M6 12 mm 11 Bolt 3 M6 28 mm 12 Grommet 3 13 Case 1 14 Collar 3 15 Pulser coil coupler 1 16 Main harness coupler 1 17 Start in gear protection cable 1 MH WH ...

Page 90: ...lb 61U5050E ET WH E No Part name Q ty Remarks 1 Bolt 2 M8 45 mm 2 Starter motor 1 3 Washer 1 4 Bolt 1 M8 35 mm 5 Positive battery lead 1 6 Washer 2 7 Nut 1 8 Bolt 1 M8 16 mm 9 Negative battery cable 1 10 Wireharness 1 11 Fuse holder 1 12 Fuse 1 20A 13 Spring washer 2 14 Nut 2 15 Starter relay 1 16 Holder 1 17 Positive battery cable 1 ...

Page 91: ...m 3 0 kgf m 22 1 ft lb 61U5050E ET WH E No Part name Q ty Remarks 18 Bolt 1 M6 12 mm 19 Clamp 1 20 Holder 1 21 PTT relay up 1 ET 22 Holder 1 ET 23 PTT relay down 1 ET 24 PTT relay lead 1 ET 25 Connector 1 ET 26 Spring washer 4 ET 27 Nut 4 ET 28 Lock tie 1 ET 29 Tube 1 ET 30 Starter motor bracket 1 31 Bolt 2 M8 25 mm 32 Cap 2 ET ...

Page 92: ...Remarks 1 Manual starter case 1 2 Plastic washer 2 3 Spiral spring 1 4 Collar 1 5 Sheave drum 1 6 Washer 1 7 Clip 1 8 Collar 1 9 Drive pawl 1 10 Spring 1 11 Spring 1 12 Drive plate 1 13 Washer 1 14 Bolt 1 M6 16 mm 15 Bolt 1 M6 12 mm 16 Washer 1 17 Bolt 1 M6 25 mm ...

Page 93: ...ty Remarks 18 Rope guide 1 19 Roller 1 20 Bushing 1 21 Bolt 4 M6 30 mm 22 Grommet 4 23 Collar 4 24 Bolt 2 M6 20 mm 25 Bracket 1 26 Nut 4 27 Damper 1 28 Starter handle 1 29 Cap 1 30 Bracket 1 31 Bolt 1 M6 12 mm 32 Cotter pin 1 33 Washer 1 34 Start in gear protection cable 1 ...

Page 94: ...POWR 5 13 61U5H11 Power unit 61U5040E MH WH No Part name Q ty Remarks 35 Spring 1 36 Guide 1 37 Bolt 1 38 Stopper 1 39 Spring 1 40 Starter rope 1 ...

Page 95: ...ave drum 4 clockwise until the spiral spring is free NOTE 9 Turn the sheave drum to hook the starter rope with the notch on the sheave drum easily 9 Pass the starter rope 5 through the notch a 3 Remove the bolt drive plate 6 spring 7 drive pawl 8 spring 9 clip 0 wash er q and collar w 4 Insert a flat head screwdriver into the hole b in the sheave drum and push down on the spiral spring so that it ...

Page 96: ...ion NOTE After winding the starter rope around the sheave drum install the starter rope in the notch b 61U50510 3 1 2 a 69D50090 b 6 Remove the plastic washers r spiral spring t from the manual starter case 7 Remove the starter rope y and collar u Checking the spiral spring MH WH 1 Check the spiral spring Replace if cracked bent or damaged Checking the drive pawl MH WH 1 Check the drive pawl Repla...

Page 97: ...wer unit 4 Install the plastic washer 4 and spiral spring 5 into the manual starter case 6 NOTE Install the outer end c of the spiral spring onto the pin d of the starter case 5 Install the collar 7 plastic washer 4 and the sheave drum 2 into the manual starter case 6 NOTE Install the sheave drum in the direction of arrow shown and then set the spiral spring by turning the sheave drum 61U50060 d c...

Page 98: ...ck the starter rope for slack Repeat steps 3 8 if necessary NOTE Align the mark f on the stopper with guide and then turn the sheave drum 10 Pull the manual starter handle complete ly then measure the starter rope length If the starter rope length is out of specifi cation refer to the step 7 and adjust the starter rope by rewind times Removing the power unit NOTE It is recommended to loosen the fl...

Page 99: ...shift cable 7 throttle cable 8 6 Remove the clip 9 and bushing 0 and then push the shift lever q down 7 Disconnect the choke link rod 8 Remove the bracket bolt w manual injection pump cable end e and start in gear protection cable end r 9 Disconnect the cooling water pilot hose t and PCV hose y 10 Remove the apron u 61U50560 6 61U50470 5 8 7 61U50570 0 9 q 6G450910 61U50460 w e t y 61U50330 u 61U5...

Page 100: ...kshaft end until the fly wheel magnet comes off the tapered portion of the crankshaft 3 Remove the Woodruff key Flywheel puller 90890 06521 11 Remove the power unit by removing the bolts i bolts o and nuts p 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 flywheel holder to slip off the flywheel 6F6502...

Page 101: ...upler 2 Remove the hour meter 2 3 Remove the stator assembly 3 retainer screw 4 retainer 5 pulser coil assem bly 6 and Rectifier Regulator 7 4 Remove the starter relay 8 and the PTT relay assembly 9 5 Remove the starter motor 0 3 6 61U50620 4 5 61U50640 0 2 61U50615 61U50600 61U50600 61U50610 1 61U50650 9 8 7 61U50630 ...

Page 102: ...POWR 5 21 61U5H11 Power unit 6 Disconnect the ignition coil leads and then remove the CDI unit q and case w 61U50600 w q ...

Page 103: ...3 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 61U5070E No Part name Q ty Remarks 1 Gasket 1 2 Reed valve 4 3 Gasket 4 4 Clamp 1 5 Bolt 9 M6 25 mm Bolt 12 E ET 6 Screw 8 ø5 15 mm 7 Hose 3 Hose 1 E ET 8 Hose 2 MH WH Hose 1 E ET 9 Hose 2 10 Hose 2 11 Clip 11 MH WH 12 Joint 2 MH WH 13 Hose 4 14 Bolt 4 M6 20 mm Not reusable Not reusable Intake manifold ...

Page 104: ...ft lb 8 N m 0 8 kgf m 5 9 ft lb E ET 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 61U5070E No Part name Q ty Remarks 15 Cap 2 16 Bracket 1 17 Bracket 1 18 Intake manifold 1 19 Bracket 1 MH WH 20 Bolt 3 M6 45 mm MH WH 21 Hose 1 E ET 22 Bolt 1 M6 12 mm ...

Page 105: ...isconnect 3 Remove the intake manifold bolts in the sequence shown Checking the reed valve 1 Check the reed valves for bends a Replace the reed valves if above specifi cation 2 Measure the reed valve stopper height b Replace the reed valve stopper if out of specification 61U50140 Valve bending limit a 0 2 mm 0 0079 in Valve stopper height b 6 2 6 8 mm 0 24 0 26 in 6G450180 a a 6G450200 b b 61U5037...

Page 106: ...ft lb 8 N m 0 8 kgf m 5 9 ft lb 61U5080E No Part name Q ty Remarks 1 Bolt 7 M6 20 mm 2 Cover 1 3 Gasket 1 4 Gasket 2 5 Exhaust inner cover 1 6 Exhaust outer cover 1 7 Bolt 23 M6 35 mm 8 Gasket 1 9 PCV cover 1 10 Bolt 2 M6 20 mm 11 Grommet 1 12 PCV 1 13 Spring 1 14 Clamp 1 15 Bolt 1 M6 12 mm 16 Clamp 1 Not reusable Not reusable Not reusable Exhaust cover ...

Page 107: ...t 1 and the PCV 2 with the its rounded side facing towards the exhaust cover and then tighten the bolts 3 to the specified torque Removing the exhaust cover 1 Remove the exhaust cover bolts in the sequence shown NOTE Insert a flat head screw driver between the pry tabs to pry off the exhaust cover Checking the exhaust cover 1 Check the exhaust cover for distortion or corrosion Replace the exhaust ...

Page 108: ... 5 9 ft lb 25 N m 2 5 kgf m 18 4 ft lb E ET MH WH 61U5090E No Part name Q ty Remarks 1 Anode 4 2 Screw 4 3 Gasket 2 4 Cylinder head 2 5 Thermoswitch 2 6 Gasket 2 7 Cylinder head cover 2 8 Gasket 2 9 Thermostat 2 10 Thermostat cover 2 11 Bolt 8 M6 40 mm 12 Spark plug 4 13 Bolt 24 M6 30 mm 14 Clamp 2 15 Bolt 20 M8 60 mm 16 Bolt 2 M6 12 mm 17 Ground lead 2 Not reusable Not reusable Not reusable ...

Page 109: ...gf m 11 1 ft lb 30 N m 3 0 kgf m 22 1 ft lb 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 9 ft lb 25 N m 2 5 kgf m 18 4 ft lb E ET MH WH 61U5090E No Part name Q ty Remarks 18 Bolt 2 M8 20 mm 19 Engine hanger 1 ...

Page 110: ...pry off the cylinder heads Checking the cylinder head 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration Removing the cylinder head 1 Remove the spark plugs 2 Remove the thermostat cover bolts in the sequence as shown and then remove the thermostat 3 Remove the cylinder head cover bolts in the sequence shown 4 Remove the thermoswitch 61U50180 PORT STBD 61U50210 ...

Page 111: ...ylinder head 2 Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in 4 directions as shown Replace the cylinder head if above specification 61U50240 2 1 61U50250 Cylinder head warpage limit 0 10 mm 0 0039 in ...

Page 112: ...8 9 ft lb No Part name Q ty Remarks 1 Bolt 4 M6 25 mm 2 Oil seal 1 3 Bearing housing 1 4 O ring 2 5 Needle bearing 1 6 Crankcase 1 7 Dowel 2 8 Bolt 6 M10 60 mm 9 Bolt 8 M8 30 mm 10 Bolt 4 M6 20 mm 11 Oil seal housing 1 12 Oil seal 1 13 Oil seal 1 14 Gasket 1 15 Cover 1 16 Bolt 2 M6 16 mm 17 O ring 1 Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 113: ... m 3 6 kgf m 26 6 ft lb 23 N m 2 3 kgf m 17 0 ft lb 61U5110E No Part name Q ty Remarks 1 Bolt 8 M8 22 mm 2 Piston and connecting rod assembly 4 3 Roller bearing 4 set 4 Crankshaft 1 5 Circlip 1 6 Main bearing 1 set 7 Cylinder block 1 8 Plug 2 9 Gasket 2 10 Circlip 1 11 Ball bearing 1 12 Seal ring 6 Not reusable Loosen completely ...

Page 114: ...3 61U5H11 Power unit 61U5120E No Part name Q ty Remarks 1 Connecting rod 4 2 Piston starboard side 2 3 Washer 8 4 Needle bearing 120 5 Clip 8 6 Piston pin 4 7 Piston ring set 4 8 Piston port side 2 Not reusable ...

Page 115: ...g 1 Remove the oil seal 1 and O rings 2 2 Remove the needle bearing 3 using a press Removing the crankcase 1 Remove the bearing housing bolts 2 Remove the oil seal housing bolts 3 Remove the crankcase bolts in the sequence shown 6G450270 61U50260 61U50280 6G450280 6G450330 1 2 4 5 3 6G450330 Ball bearing attachment 4 90890 06663 Driver rod LS 5 90890 06606 ...

Page 116: ...d 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 rods and caps Keep them organized in their each groups 2 Remove the crankshaft assembly Disassembling the piston and con necting rod assembly 1 Remove the piston pin clips 1 with pli ers and then remove the piston pin 2 needle bearings 3 and washers 4 2 Remov...

Page 117: ...bearing always replace it with a new one 61U50290 1 b a Gear puller 3 90890 06540 Bearing separator 4 90890 06534 6G450390 2 6G450400 4 3 Checking the piston diameter 1 Measure the piston outside diameter at the specified measuring point Replace the piston and piston rings as a set if out of specification Piston diameter a 89 920 89 935 mm 3 5402 3 5407 in Measuring point b 10 0 mm 0 39 in Oversiz...

Page 118: ...re the cylinder for matching the replacement oversize pistons when using the specified oversize pistons Checking the piston ring 1 Check the piston ring dimensions of B and T Replace the piston and piston rings as a set if out of specification 2 Level the piston ring 1 in a cylinder with a piston crown 3 Check the piston ring end gap a at the specified measuring point b Replace the piston ring set...

Page 119: ...0 Piston pin boss bore E115A 21 504 21 515 mm 0 8466 0 8470 in 115B 140B 23 074 23 085 mm 0 9084 0 9089 in Checking the piston pin 1 Measure the piston pin outside diameter Replace the piston pin if out of specifica tion Checking the internal anode 1 Check the anodes on the cylinder block Clean the anode s surface and replace if it has been eroded into half size or small er cC Do not oil or grease...

Page 120: ...1 Measure the connecting rod big end side clearance a Replace the connecting rod or crankshaft or both if out of specifica tion Checking the crankshaft 1 Measure the crankshaft journal diameter a and crankpin diameter b Replace the crankshaft if out of specification 6G450550 61U50680 a 61U50690 b Connecting rod small end axial play limit 2 0 mm 0 08 in 6G450560 a a Connecting rod big end side clea...

Page 121: ... reuse the ball bearing always replace it with a new one Crankshaft runout limit c 0 02 mm 0 0008 in c c 61U50430 E 6G450590 3 1 2 2 Install the seal rings 4 NOTE First pass the seal ring 4 over the crankpin a and then widen the seal ring end gap b to install the ring into the crankshaft groove 3 Install the main bearings onto the crank shaft 61U50710 E 61U50700 4 a b E Support 2 90890 02394 Beari...

Page 122: ...l it into the bearing housing Needle bearing attachment 1 90890 06654 Driver rod L3 2 90890 06652 Needle bearing attachment 90890 06654 6G450620 1 2 6G450630 Assembling the oil seal housing 1 Apply grease to the new oil seals new O ring and then install them into the oil seal housing Ball bearing attachment 1 90890 06637 Driver rod LS 2 90890 06606 Bearing outer race attachment 3 90890 06624 1 2 6...

Page 123: ...ips 9 Be sure to align the piston pin clip end with the piston pin slot c 2 Install the 2nd piston ring 8 and top ring 9 onto the pistons 6G450670 9 8 b 1 2 3 4 5 c 6 6 6 4 a 61U50720 3 7 cC Do not scratch the pistons or break the piston rings NOTE Install the piston rings with the recess for the locating pin facing up toward the piston crown Assembling the power unit 1 Set the crankshaft in the c...

Page 124: ...rk on the port side 6G450690 b 61U50730 61U50740 3 3 Install the connecting rod bearings and connecting rod caps onto the connecting rods and then tighten the connecting rod bolts 4 to the specified torques in 5 stages NOTE 9 Align the identification numbers c on the connecting rod caps and connecting rods which you made during disassembly 9 Apply engine oil to the connecting rod bear ings connect...

Page 125: ...the projec tions facing toward the cylinder block 6 Apply sealant to the mating surface of the crankcase 61U50760 61U50770 61U50450 NOTE Do not get any sealant on the journals 7 Install the dowels crankcase onto the cylinder block and then temporarily tight en the crankcase bolts NOTE Apply engine oil to the crankcase bolts before installation 8 Install the bearing housing bolts tempo rary tight 9...

Page 126: ...t M10 1st 20 N m 2 0 kgf m 14 8 ft lb 2nd 37 N m 3 7 kgf m 27 3 ft lb m 4 Crankcase bolt M8 1st 10 N m 1 0 kgf m 7 4 ft lb 2nd 18 N m 1 8 kgf m 13 3 ft lb Bearing housing bolt 12 N m 1 2 kgf m 8 9 ft lb 12 Install the new gasket 5 exhaust inner cover 6 new gasket 7 exhaust outer cover 8 and then tighten the exhaust cover bolts to the specified torques in 2 stages and in the sequence shown NOTE App...

Page 127: ... 61U50190 PORT STBD 13 Install the new gaskets 9 and the cylin der head 0 and then tighten the cylinder head bolts to the specified torques in 2 stages and in the sequence shown 15 Install the new gaskets e and the cylin der head covers r and then tighten the cylinder head cover bolts to the specified torques in 2 stages and in the sequence shown NOTE Apply LOCTITE 572 to the cylinder head cover b...

Page 128: ...the sequence shown 61U50820 61U50830 Intake manifold bolt u 1st 4 N m 0 4 kgf m 3 0 ft lb 2nd 8 N m 0 8 kgf m 5 9 ft lb 61U50810 MH WH t y u u Spark plug 25 N m 2 5 kgf m 18 4 ft lb 16 Install the new gaskets thermostats and the thermostat covers and then tighten the thermostat cover bolts to the speci fied torques in 2 stages and in the sequence shown NOTE Apply LOCTITE 572 to the thermostat cove...

Page 129: ...stall the starter motor i pulser coil assembly o and stator assembly p onto the power unit 21 Install the case s and the CDI unit d onto the power unit 61U5H11 5 48 9 8 7 6 5 4 3 2 1 Crankcase i 61U50645 a a p o 61U50625 Starter motor mount bolt a 29 N m 2 9 kgf m 21 4 ft lb 61U50605 s d 61U50655 g f h 61U50635 61U50835 ...

Page 130: ...nit 1 Clean the power unit matching surface and install the dowels 1 and a new gasket 2 2 Install the power unit 3 and then tighten the power unit bolts 4 bolts 5 and nut 6 to the specified torque Power unit bolt 4 5 nut 6 25 N m 2 5 kgf m 18 4 ft lb 4 4 6 3 5 61U50595 1 1 2 61U50850 61U50840 l k k POWR 5 49 61U5H11 Power unit Hour meter screw j 3 N m 0 3 kgf m 2 2 ft lb j 61U50636 ...

Page 131: ... end and then install the bracket bolt q 9 0 61U50335 Apron bolt 8 8 N m 0 8 kgf m 5 9 ft lb 7 61U50585 8 8 8 8 7 61U50465 q 6 Install the bushing w and clip e 7 Connect the choke link rod 8 Connect the 10 pin main harness coupler r 9 Connect the shift cable t and throttle cable y and then adjust their lengths For adjustment procedures see P3 6 Adjusting the throttle cable and P3 7 Checking the ge...

Page 132: ...e specified torque cC Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily NOTE Apply engine oil to the flywheel magnet nut thread before installation 12 Install the starter pulley 13 Tighten the cable holder plate u and retaining plate i 14 Install the manual starter start in gear protection cable and then adjust it For adjustment procedures ref...

Page 133: ...ok at the dial gauge slightly turn the flywheel counterclockwise to the speci fied position 61U50860 1 Dial gauge set 1 90890 01252 5 Align the timing plate with the flywheel at specified position and install the timing plate 2 NOTE When finish the adjusting of timing plate fly wheel must be turn clockwise twice 6 Start the engine and then check the igni tion timing once more 7 If the ignition tim...

Page 134: ...900 4 3 61U50890 61U50910 5 c 2 Specified length c Reference data E115A 115B 24 5 mm 0 96 in 140B 22 0 mm 0 87 in Adjusting the ignition timing stop per NOTE For adjust the timing plate refer to Adjusting the timing plate 1 Slowly turn the flywheel magnet clock wise and check that the timing plate a is aligned with the scale b on the flywheel magnet in the specified position 2 Set the control leve...

Page 135: ...ting screw 2 contact with the stopper 7 Check that the mark 3 on the flywheel magnet aligned with the pointer 4 on the pulser coil assembly 8 If not align them adjust the length of the adjusting screw 2 Timing plate position ATDC 5 1 2 61U10045 3 4 61U50880 2 61U50920 d Specified length d Reference data 23 5 mm 0 92 in ...

Page 136: ...POWR 5 55 61U5H11 Power unit MEMO ...

Page 137: ...Removing the drive shaft 6 13 Disassembling the drive shaft housing 6 13 Disassembling the forward gear 6 13 Disassembling the lower case 6 14 Checking the pinion and forward gear 6 14 Checking the bearing 6 14 Checking the drive shaft 6 14 Checking the lower case 6 15 Assembling the lower case 6 15 Assembling the forward gear 6 15 Assembling the drive shaft housing 6 16 Installing the drive shaft...

Page 138: ...nit No Part name Q ty Remarks 1 Lower unit 1 2 Bolt 6 M10 45 mm 3 Bolt 1 M10 70 mm 4 Trim tab 1 5 Spacer 1 6 Propeller 1 7 Washer 1 8 Washer 1 9 Cotter pin 1 10 Nut 1 11 Dowel 2 E115A Y transom 12 Bolt 1 M10 45 mm 13 Grommet 1 14 Nut 6 E115A Y transom 15 Spring washer 6 E115A Y transom 16 Washer 6 E115A Y transom 17 Extension 1 E115A Y transom Not reusable ...

Page 139: ...rt name Q ty Remarks 1 Shift rod 1 2 Oil seal 1 3 Cover 1 4 O ring 1 5 Spring 1 6 Circlip 1 7 Bolt 3 M6 20 mm 8 Joint 1 9 Woodruff key 1 10 Bolt 4 M8 45 mm 11 Cover 1 12 Seal 1 13 Water pump housing 1 14 O ring 1 15 Insert cartridge 1 16 O ring 1 17 Collar 1 Not reusable Not reusable Not reusable Not reusable ...

Page 140: ...lb 61U6020E No Part name Q ty Remarks 18 Spacer 1 19 Washer 2 20 Wave washer 1 21 Impeller 1 22 Outer plate cartridge 1 23 Gasket 1 24 Dowel 2 25 Rubber seal 1 26 Plate 1 27 Check screw 1 28 Gasket 2 29 Drain screw 1 30 Dowel 2 31 Lock tie 1 Not reusable Not reusable Not reusable ...

Page 141: ...ood between the anti cavitation plate and propeller to pre vent the propeller from turning and then remove the propeller nut and propeller w 9 Do not hold the propeller with your hands when loosening or tightening it 9 Be sure to disconnect the battery cables from the battery and the lock plate from the engine stop lanyard switch 9 Put a block of wood between the anti cavitation plate and propelle...

Page 142: ...er unit Make sure that the shift rod is in the neutral position using a spe cial service tool 5 Remove the shift rod assembly w Checking the water pump and shift rod 1 Check the water pump housing Replace if there is deformation 2 Check the impeller and insert cartridge Replace if cracked or worn 3 Check the Woodruff key 1 and the groove a on the drive shaft Replace if worn 4 Check the shift rod R...

Page 143: ...m 3 0 ft lb 61U6030E No Part name Q ty Remarks 1 Shift rod joint 1 2 Ball 2 3 Shift slider 1 4 Ball 2 5 Ball 2 6 Spring 1 7 Dog clutch 1 8 Crosspin 1 9 Spring 1 10 Propeller shaft 1 11 Reverse gear shim 12 Washer 1 13 Reverse gear 1 14 Thrust washer 1 15 Ball bearing 1 16 O ring 1 17 Propeller shaft housing 1 Not reusable ...

Page 144: ...10 3 kgf m 76 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 61U6030E No Part name Q ty Remarks 18 Straight key 1 19 Needle bearing 1 20 Oil seal 2 21 Claw washer 1 22 Ring nut 1 23 Cooling water inlet cover 2 24 Nut 1 25 Screw 1 ø5 45 mm Not reusable ...

Page 145: ...eller shaft assembly 1 Remove the spring 1 then remove the cross pin 2 dog clutch 3 balls 4 spring 5 shift slider 6 and shift rod joint 7 NOTE Mark the front side of the dog clutch 3 Disassembling the propeller shaft housing 1 Remove the reverse gear and ball bear ing 6F600060 1 2 1 7 6 5 4 3 6G460030 2 4 3 1 6 5 4 6B460580 Stopper guide plate 4 90890 06501 Bearing housing puller claw L 5 90890 06...

Page 146: ...ace it with a new one 3 Remove the oil seals and needle bearing Checking the propeller shaft hous ing 1 Clean the propeller shaft housing using a soft brush and cleaning solvent and then check it Replace if cracked or damaged 2 Check the teeth and dogs of the reverse gear Replace if cracked or worn 3 Check the bearings Replace if pitted or if there is rumbling 2 3 4 S6P26200 61U60060 6 5 Stopper g...

Page 147: ...e shift slider 61U60190 9 5 6 61U60170 61U60180 7 8 7 8 6 4 6 The hole in the dog clutch align with the 2 holes propeller shaft and shift slider 7 Install the cross pin 0 and spring q Assembling the propeller shaft housing 1 Install the new needle bearing into the propeller shaft housing to the specified depth NOTE 9 Install the needle bearing with the manufac ture identification mark a facing tow...

Page 148: ...g a press NOTE Install the ball bearing with the manufacture identification mark e facing toward the pro peller side LOWR 6 11 61U5H11 Lower unit 4 Install the reverse gear assembly into the propeller shaft housing using a press NOTE After installing the reverse gear check that the reverse gear rotates smoothly Needle bearing attachment 9 90890 06654 Depth d 4 75 5 25 mm 0 187 0 207 in Ball bearin...

Page 149: ...name Q ty Remarks 1 Drive shaft 1 2 Sleeve 1 3 Cover 1 4 Oil seal 2 5 Bolt 4 M8 25 mm 6 Drive shaft housing 1 7 Needle bearing 1 8 O ring 1 9 Pinion shim 10 Thrust bearing 1 11 Lower case 1 12 Needle bearing 1 13 Pinion 1 14 Forward gear shim 15 Taper roller bearing 1 16 Needle bearing 1 17 Forward gear 1 Not reusable Not reusable ...

Page 150: ...rive shaft housing 1 Remove the cover oil seals and needle bearing Disassembling the forward gear 1 Remove the taper roller beaning from the forward gear using a press cC Do not reuse the bearing always replace it with a new one 6F660190 1 2 61U60090 3 4 8 9 5 7 6 6F660210 1 Drive shaft holder 6 1 90890 06520 Pinion nut holder 2 90890 06715 Needle bearing attachment 1 90890 06610 Driver rod L3 2 9...

Page 151: ... shown Checking the pinion and forward gear 1 Check the teeth of the pinion and the teeth and dogs of the forward gear Replace if cracked or worn Checking the bearing 1 Check the bearing Replace if pitted or if there is rumbling Checking the drive shaft 1 Check the drive shaft Replace if bent or worn 2 Measure the drive shaft runout S6P26090E 2 1 2 1 Ball bearing attachment 1 90890 06636 Driver ro...

Page 152: ...he lower case or taper roller bearing 9 To select the shim s see Shimming 2 Install the new needle bearing into the lower case NOTE 9 Apply gear oil to the needle bearing before installation 9 Be careful not to let the stopper a get out of position when using the driver rod Bearing outer race attachment 1 90890 06620 Driver rod LL 2 90890 06605 Needle bearing attachment 3 90890 06609 Driver rod SL...

Page 153: ...t bearing 1 and original shim s 2 onto the drive shaft 3 NOTE 9 Be sure to select the pinion shim s if replacing the thrust bearing drive shaft housing drive shaft or lower case 9 To select the shim s see Shimming 3 Install the sleeve 4 drive shaft 3 into the lower case Install the pinion 5 pinion nut 6 and then tighten the pinion nut to the specified torque NOTE Install the drive shaft by lifting...

Page 154: ...e 6G460190 4 5 6 8 7 4 Install the drive shaft housing 9 and then tighten the drive shaft housing bolt 0 NOTE Apply LOCTITE 572 to the drive shaft hous ing bolts before installation Installing the propeller shaft housing 1 Set the shift rod joint and dog clutch 1 to the neutral position as shown 2 Apply grease to a new O rings and then install it onto the propeller shaft housing 3 Install the wash...

Page 155: ...d propeller shaft rotates smoothly 2 Install a new gasket 2 the outer plate cartridge 3 and dowels 4 3 Install the Woodruff key 5 into the drive shaft 4 Align the groove in the impeller 6 with the Woodruff key 5 and then install the impeller onto the drive shaft 5 Install the washers 7 wave washer 8 spacer 9 and collar 0 onto the drive shaft NOTE 9 The collar and spacer should fit together firmly ...

Page 156: ...When installing the pump housing apply grease to the inside of the housing and then turn the drive shaft clockwise while pushing down the pump housing 9 Align the cover projection d with the hole e in the pump housing Installing the lower unit w When installing the lower unit without removing the power unit be sure to sus pend the outboard motor Otherwise the outboard motor could suddenly fall and...

Page 157: ...mporarily tighten the nut Place a block of wood between the anti cavitation plate and propeller to prevent the propeller from turning and then tight en the nut to the specified torque w 9 Do not hold 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...

Page 158: ...ws out of the check hole and no air bubbles are visible 10 Install the new gasket check screw 9 and quickly install the drain screw then tighten to specified torque 69D10050 9 Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Gear oil quantity 760 cm3 25 70 US oz 26 81 Imp oz Check screw 9 and drain screw 9 N m 0 9 kgf m 6 6 ft lb ...

Page 159: ...61U5H11 6 22 9 8 7 6 5 4 3 2 1 Shimming Shimming 6G46090E T3 M3 M4 M1 M2 T1 T2 F R P ...

Page 160: ...hten the wing nuts another 1 4 of a turn after they contact the fixing plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M4 between the special service tool and the pinion as shown NOTE 9 Measure the pinion at 4 points to find the distance average 9 Make of note the each measurement numerical 4 Turn the thrust bearing 5 2 or 3 times...

Page 161: ...01 Digital caliper 3 90890 06704 5 Calculate the pinion shim thickness T3 as shown in the examples below NOTE P is the deviation of the lower case dimen sion from standard The P mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the P mark is unreadable assume that P is zero and check the backlash when the unit is assembled Example If M3 is 46 65 mm and M4 is ...

Page 162: ...ase dimen sion from standard The F mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is unreadable assume that F is zero and check the backlash when the unit is assembled Example If M1 is 23 80 mm and F is 5 then T1 24 6 5 100 23 80 mm 24 6 0 05 23 80 mm 0 85 mm If M1 is 23 80 mm and F is 0 then T1 24 6 0 100 23 80 mm 24 6 0 23 80 mm 0 80 mm 3 Sele...

Page 163: ...sume that R is zero and check the backlash when the unit is assembled Example If M2 is 28 25 mm and R is 1 then T2 28 25 27 4 1 100 mm 28 25 27 4 0 01 mm 1 36 mm 4 Select the reverse gear shim s T2 as follows Example If T2 is 1 30 mm then the reverse gear shim is 1 30 mm If T2 is 1 36 mm then the reverse gear shim is 1 38 mm Backlash Measuring the forward and reverse gear backlash 1 Remove the wat...

Page 164: ...ightens center bolt 3 to specified torque 4 Install the backlash indicator onto the drive shaft 22 4 mm 0 88 in in diame ter then the dial gauge onto the lower unit Bearing housing puller claw L 1 90890 06502 Stopper guide plate 2 90890 06501 Center bolt 3 90890 06504 Backlash indicator 4 90890 06706 Magnet base plate 5 90890 07003 Dial gauge set 6 90890 01252 Magnet base B 7 90890 06844 6S360190 ...

Page 165: ...rive shaft clockwise and counterclockwise and measure the backlash when the drive shaft stops in each direction 11 Add or remove shim s if out of specifica tion M Measurement 12 Remove the special service tools and then install the water pump assembly Reverse gear backlash 0 80 1 17 mm 0 0315 0 0461 in Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Reverse gear Shim thickness...

Page 166: ...lamp bracket MH WH E 7 24 Disassembling the swivel bracket MH WH E 7 25 Assembling the swivel bracket MH WH E 7 25 Assembling the clamp bracket MH WH E 7 26 Removing the PTT unit ET 7 30 Removing the clamp bracket ET 7 30 Installing the clamp bracket ET 7 31 Installing the PTT unit ET 7 32 Adjusting the trim sensor cam ET 7 33 PTT unit 7 34 Checking the hydraulic pressure 7 35 PTT motor 7 38 Disas...

Page 167: ...inder 7 50 Checking the tilt cylinder and trim cylinder 7 51 Assembling the tilt piston and trim piston 7 51 Assembling the PTT unit 7 52 Bleeding the PTT unit 7 55 Bleeding the PTT unit built in 7 56 PTT electrical system 7 57 Checking the fuse 7 57 Checking the PTT relay 7 57 Checking the trim sensor 7 57 ...

Page 168: ... m 3 7 kgf m 27 3 ft lb 61U7010E No Part name Q ty Remarks 1 Throttle cable 1 2 Bolt 2 M6 16 mm 3 Grommet 1 4 Nut 1 5 Tiller handle 1 6 Plastic washer 2 7 Metal washer 2 8 Wave washer 1 9 Bolt 1 M8 70 mm 10 Bushing 1 11 Engine stop lanyard switch 1 12 Bolt 2 M6 16 mm 13 Bracket 1 14 Cotter pin 1 15 Washer 1 16 Shift cable 1 17 Nut 1 Tiller handle ...

Page 169: ... 0 3 kgf m 2 2 ft lb 37 N m 3 7 kgf m 27 3 ft lb 61U7010E No Part name Q ty Remarks 18 Washer 1 19 Bushing 2 20 Collar 1 21 Ball 1 22 Spring 1 23 Shift lever 1 24 Bolt 1 M6 20 mm 25 Screw 1 ø6 26 mm 26 Bolt 1 M6 30 mm 27 Switch holder 2 28 Engine start switch 1 29 Nut 1 30 Screw 1 31 Throttle grip 1 32 Washer 1 33 Spring 1 34 Bushing 1 ...

Page 170: ...ft lb 37 N m 3 7 kgf m 27 3 ft lb 61U7010E No Part name Q ty Remarks 35 Screw 4 ø6 8 mm 36 Screw 1 ø5 12 mm 37 Grease nipple 1 38 Gasket 1 39 Cover 1 40 Plate 1 41 Throttle shaft 1 42 Housing 1 43 Bolt 1 M6 25 mm 44 Friction piece 1 45 Nut 2 46 Bracket 1 47 Bolt 1 M6 25 mm 48 Washer 1 49 Screw 1 50 Shift link rod 1 51 Nut 1 Not reusable ...

Page 171: ... of the throttle shaft 1 aligned with 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 engaged with the gear 3 Turn the throttle shaft 1 clockwise to wind the inner cable around the gear 5 4 Tighten the nut 6 5 Install the bushing 7 spring 8 throttle grip 9 and cover 0 into the tiller handle 2 Lubricating the t...

Page 172: ...7 7 ft lb No Part name Q ty Remarks 1 Clip 3 2 Shift rod 1 3 Bushing 1 4 Washer 1 5 Shift lever 1 6 O ring 1 7 Washer 1 8 Bushing 1 9 Bracket 1 10 Grease nipple 1 11 Circlip 1 12 Grommet 1 13 Ball 1 14 Spring 1 15 Bolt 1 Not reusable Not reusable Bottom cowling ...

Page 173: ...t name Q ty Remarks 1 Clamp 1 2 Bolt 1 M6 20 mm 3 Plate 1 4 Bolt 1 M8 20 mm 5 Bracket 1 6 Holder 2 7 Pin 2 8 Holder 2 9 Bolt 3 M6 12 mm 10 Wave washer 3 11 Clamp lever 3 12 Bolt 1 M6 12 mm 13 Collar 6 14 Pilot hole 1 15 Lock lever 3 16 Bolt 1 M8 35 mm 17 Clamp 1 ...

Page 174: ... unit 7 7 61U7040E No Part name Q ty Remarks 18 Bolt 1 M6 28 mm 19 Grommet 1 20 Bolt 3 M8 35 mm 21 Ground lead 1 22 Grommet 4 23 Collar 4 24 Washer 1 25 Grommet 2 26 Hose 1 27 Screw 3 E ET 28 Bracket 2 E ET 29 Bracket 1 E ET ...

Page 175: ... 1 kgf m 37 6 ft lb 61U7060E Upper case steering arm No Part name Q ty Remarks 1 Nut 2 2 Grommet 1 3 Upper mount 2 4 Bracket 1 5 Washer 2 6 Rubber washer 2 7 Washer 2 8 Bolt 2 9 Damper 2 10 Nut 2 11 Washer 2 12 Bolt 4 M10 45 mm 13 Mount housing 2 14 Spring 4 15 Washer 2 16 Lower mount 2 17 Rubber washer 2 ...

Page 176: ...er 2 19 Ground lead 1 20 Bolt 2 M14 180 mm 21 Upper case assembly 1 22 Ground lead 1 23 Hose 1 24 Bolt 3 M10 45 mm 25 Bolt 1 M6 10 mm 26 Cover 2 27 Screw 2 28 Rubber seal 1 29 Lock tie 1 Not reusable 71 N m 7 1 kgf m 52 4 ft lb 51 N m 5 1 kgf m 37 6 ft lb 61U7060E ...

Page 177: ...070E X No Part name Q ty Remarks 1 Bolt 2 M8 45 mm 2 Bolt 2 M8 30 mm 3 Gasket 1 4 Joint 1 5 Upper exhaust guide 1 6 Gasket 1 7 Lower exhaust guide 1 8 Bolt 4 M8 30 mm 9 Gasket 1 10 Exhaust manifold 1 11 Bolt 4 M8 45 mm 12 Gasket 1 13 Muffler 1 14 Bolt 5 M8 45 mm 15 Rubber damper 2 16 Clip 2 17 Rubber seal 1 Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 178: ...N m 1 8 kgf m 13 3 ft lb 18 N m 1 8 kgf m 13 3 ft lb 18 N m 1 8 kgf m 13 3 ft lb 61U7070E X No Part name Q ty Remarks 18 Dowel 2 19 Upper case 1 20 Rubber seal 1 21 Pipe 1 22 Rubber seal 1 23 Bushing 1 24 Circlip 1 25 Hose 1 26 Lock tie 1 27 Grommet 1 Not reusable ...

Page 179: ...r dampers 9 and gasket 0 NOTE Insert a flat head screw driver between the pry tabs to pry off the muffler 3 Remove the bolts q exhaust manifold w and gasket e 4 Remove the bolts r lower exhaust guide t and gasket y from the upper exhaust guide u NOTE Insert a flat head screw driver between the pry tabs to pry off the exhaust guide 61U70010 3 4 5 1 2 8 9 7 6 6 0 61U70020 w q q e 61U70040 t y r r u ...

Page 180: ...After installing the drive shaft bushing apply grease to the inside of the bushing 2 Install a new gasket 3 the lower exhaust guide 4 and bolts 5 and then tighten the bolts to the specified torque 3 Install a new gasket 6 the exhaust man ifold 7 and bolts 8 and then tighten the bolts to the specified torque 61U70230 2 1 Needle bearing attachment 1 90890 06653 Driver rod L3 2 90890 06652 Exhaust gu...

Page 181: ...during inserting the tip of the cooling water pipe w into the joint hole a of the upper case 8 Tighten the muffler assembly bolts y and u to the specified torque 9 Install the upper mounts i and bolts o as below shown NOTE Install the upper mounts i so that the mark p of the upper mounts toward the forward side w 9 0 q r e 61U70090 61U70360 Muffler bolt r 18 N m 1 8 kgf m 13 3 ft lb u t w a y 61U7...

Page 182: ...s d NOTE First tighten the center located when tighten the bolts d 11 Install the lower mounts f and bolts g as below shown NOTE Install the lower mounts f so that the mark h of the lower mounts toward the reverse side 12 Install the lower mounts f and mount housings j and tighten the bolts k 61U70240 j k f 61U70017 f g h S60V7230 a s d ...

Page 183: ...1U7080E 36 N m 3 6 kgf m 26 6 ft lb No Part name Q ty Remarks 1 Steering arm 1 2 Washer 1 3 Bushing 2 4 Bracket assembly 1 5 O ring 1 6 Bushing 1 7 Washer 1 8 Steering yoke 1 9 Circlip 1 10 Nut 2 11 Trim stopper 2 12 Damper 1 13 Oil seal 1 Not reusable Not reusable ...

Page 184: ...ff the bracket Removing the oil seal of swivel bracket MH WH E 1 Remove the oil seal by using the flat head driver 2 3 4 61U70120 S69J7075 1 Needle bearing attachment 3 90890 06611 Gear puller 4 90890 06540 Installing the oil seal of swivel bracket MH WH E 1 Install the bushing 1 and oil seal 2 61U70130 1 4 3 2 61U70250 Needle bearing attachment 3 90890 06654 Driver rod L3 4 90890 06652 ...

Page 185: ...ove visible 5 Install the circlip 0 6 Inject grease into the grease nipple until grease comes out from both the upper and lower bushings c 6S370020 b a 0 3 9 Upper case steering arm Installing the steering arm 1 Install the washer 1 and bushing 2 onto the steering arm 3 2 Place the swivel bracket 4 in an upright position and then install the steering arm 3 onto the bracket assembly 3 Install the b...

Page 186: ...ssembly 1 simulta neously 2 Install the upper mount nuts 2 and lower mount nuts 3 and then tighten them to the specified torques NOTE Before tighten the uppercase wiring the ground lead 3 Install the covers 6S370025 2 1 3 Upper mount nut 2 51 N m 5 1 kgf m 37 6 ft lb Lower mount nut 3 71 N m 7 1 kgf m 52 4 ft lb 6S370026 ...

Page 187: ... Clamp bracket and swivel bracket No Part name Q ty Remarks 1 Cap 2 2 Self locking nut 1 3 Bolt 6 M10 45 mm 4 Clamp bracket 1 5 Grease nipple 3 6 Ground lead 1 7 Washer 2 8 Bushing 2 9 Swivel bracket 1 10 Bushing 2 11 Shock absorber 1 12 Bushing 2 13 Bracket 1 14 Bolt 1 M6 14 mm 15 Pin 1 16 Through tube 1 17 Clamp bracket 1 ...

Page 188: ...BRKT 7 21 61U5H11 Bracket unit 61U7035E 15 N m 1 5 kgf m 11 1 ft lb No Part name Q ty Remarks 18 Anode 1 19 Bolt 4 M6 30 mm 20 Tilt pin 1 21 Pin 1 22 Circlip 1 ...

Page 189: ...et 61U7140E No Part name Q ty Remarks 1 Tilt stop lever 1 2 Bushing 6 3 Tilt lock lever 1 4 Pin 3 5 Spring 1 6 Plate 1 7 Bolt 1 M6 10 mm 8 Distance collar 1 9 Collar 1 10 Cotter pin 1 11 Lever 1 12 Rod 1 13 Pin 1 14 Cotter pin 2 15 Washer 2 16 Arm 1 17 Bracket 1 ...

Page 190: ...H11 Bracket unit 61U7140E No Part name Q ty Remarks 18 Bolt 2 M6 16 mm 19 Spring 2 20 Lever 1 21 Pin 2 22 Lever 1 23 Washer 1 24 Cotter pin 1 25 Spring 1 26 Washer 1 27 Tilt lock lever 1 28 Rod 1 29 Tilt stop lever 1 ...

Page 191: ...ge 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 clamp bracket bolt 4 3 Remove the caps 5 self locking nut 6 and then ground lead 7 61U70410 1 4 Remove the circlip 8 pin 9 and then shock absorber 0 5 Remove the starboard clamp bracket q in the...

Page 192: ...l the tilt stopper 9 with the pin 0 4 Install the plate q and spring w and then hook the spring w to the distance collar e 5 Install the tilt lock lever r with pin t Disassembling the swivel bracket MH WH E 1 Remove the 2 large springs 1 and 2 cot ter pins 2 2 Remove the cotter pin 3 and lever 4 3 Remove the pin 5 and tilt lock lever 6 4 Remove the 2 pins 7 and cotter pin 8 and then remove the bot...

Page 193: ...ough tube 1 into the clamp bracket 2 and washer 3 2 Install the swivel bracket 4 to the clamp bracket 2 3 Install the washer 5 and starboard clamp bracket 6 y i a p 4 p u o o 61U70560 4 Tighten the self locking nut 7 in tempo rary tight 5 Install the shock absorber 8 into the swivel bracket 4 6 Install the pin 9 with the circlip 0 7 Tighten the self locking nut 7 in the specified torque 8 Install ...

Page 194: ...rt name Q ty Remarks 1 Swivel bracket 1 2 Clamp bracket 1 3 Clamp bracket 1 4 Self locking nut 1 5 Grease nipple 6 6 Ground lead 3 7 Screw 1 ø6 12 mm 8 Washer 2 9 Bushing 2 10 Trim sensor 1 11 Screw 2 ø6 15 mm 12 Trim sensor cam 1 13 Screw 1 ø6 25 mm 14 Clamp 1 15 Bolt 4 M6 30 mm 16 Bracket 2 17 Anode 1 ...

Page 195: ...1 5 kgf m 11 1 ft lb 2 N m 0 2 kgf m 1 5 ft lb 61U7020E ET No Part name Q ty Remarks 18 Through tube 1 19 Bolt 1 M8 20 mm 20 Tilt stop lever 1 21 Bushing 4 22 Collar 1 23 Distance collar 1 24 Spring pin 2 25 Spring 1 26 Spring hook 1 27 Bolt 1 M6 10 mm 28 Tilt stop lever 1 ...

Page 196: ... 61U7090E No Part name Q ty Remarks 1 PTT unit 1 2 PTT motor lead 1 3 Pin 1 4 Lock tie 3 5 Circlip 1 6 Bolt 2 M8 16 mm 7 Washer 2 8 Shaft 1 9 Bushing 6 10 Bolt 1 M6 10 mm 11 Ground lead 1 12 Trim sensor lead 1 13 Cap 2 Not reusable ...

Page 197: ...NOTE If the PTT does not operate turn the manual valve 2 counterclockwise and tilt the out board motor up manually 2 Disconnect the ground lead 3 at the bot tom of the PTT unit 3 Remove the anode 4 4 Loosen the self locking nut 5 and then move the clamp brackets slightly in the direction of the arrows w Do not remove the tilt stop lever 1 from the clamp brackets 5 Remove the lock ties 6 and then p...

Page 198: ...round lead between the clamp brackets and the swivel bracket 3 Remove the trim sensor cam screw 4 4 Remove the self locking nut 5 and bolt 6 5 Remove the through tube 7 then disas semble the clamp brackets 8 and then remove the swivel bracket 9 6 Remove the trim sensor 0 7 Remove the pins q and tilt stop levers w Installing the clamp bracket ET 1 Install the tilt stop levers onto the swivel bracke...

Page 199: ... it with the tilt stop lever 2 Lift the PTT unit up install the lower mounting shaft 2 and then tighten the bolts 3 3 Install the tilt ram upper end into the swiv el bracket with the pin 4 and circlip 5 4 Tighten the self locking nut 6 to the specified torque 5 Install the anode 7 6 Pass the PTT motor lead 8 through the hole of the port clamp bracket 7 Fasten the PTT motor lead and trim sen sor le...

Page 200: ...he engine start switch to ON 4 Measure the trim sensor voltage 61U70580 O Gy P B B P 1 DCV R G Trim sensor voltage Pink P Black B 0 03 0 11 V Test harness 1 90890 06878 Digital circuit tester 90890 03174 5 If the trim sensor voltage is out of specifi cation adjust the trim sensor cam 2 until the specified trim sensor setting voltage is obtained 61U70590 2 ...

Page 201: ...gf m 3 7 ft lb 5 N m 0 5 kgf m 3 7 ft lb 7 N m 0 7 kgf m 5 2 ft lb 61U7100E No Part name Q ty Remarks 1 PTT motor 1 2 Reservoir 1 3 Reservoir cap 1 4 O ring 1 5 O ring 1 6 Bolt 3 M6 13 mm 7 Bolt 4 M6 34 mm 8 O ring 1 9 Filter 1 10 Joint 1 Not reusable Not reusable Not reusable PTT unit ...

Page 202: ...e reservoir cap and then tighten it to the specified torque 5 Remove the circlip 1 then remove the manual valve 2 6 Install the up relief fitting 3 and hydraulic pressure gauge 4 NOTE Quickly install the special service tools before any fluid flows out of the hole 7 Connect the PTT motor leads to the bat tery terminals to fully retract the trim and tilt rams 6G470240 2 1 4 3 6G470250 Recommended P...

Page 203: ...e fluid level NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 11 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole 12 Install the reservoir cap and then tighten it to the specified torque Lg Sb 6G470270 Rams PTT motor lead Battery terminal Up Sky blue Sb Light green Lg Hyd...

Page 204: ...ery terminals to fully extend the trim and tilt rams 15 Remove the special service tools and then install the manual valve and circlip NOTE Quickly install the manual valve before any fluid flows out of the hole Sb Lg 6G470260 Rams PTT motor lead Battery terminal Down Light green Lg Sky blue Sb Hydraulic pressure down 6 9 MPa 60 90 kgf cm2 Lg Sb 6G470270 Rams PTT motor lead Battery terminal Up Sky...

Page 205: ...name Q ty Remarks 1 Screw 1 ø4 15 mm 2 Stator 1 3 Armature 1 4 O ring 1 5 Screw 2 ø4 12 mm 6 Brush holder 1 7 Brush 1 1 8 Brush 2 1 9 Brush holder 1 10 Brush spring 2 11 PTT motor base 1 12 Oil seal 1 13 Bearing 1 14 Screw 2 ø4 15 mm Not reusable Not reusable PTT motor ...

Page 206: ...n spurt out 2 Remove the lead holder 6 and rubber spacers 7 from the stator and then slide them away from the stator 3 Remove the screws 8 and the stator 9 NOTE Place a clean cloth over the end of the arma ture shaft hold it with a pair of pliers and then carefully slide the stator off of the arma ture 4 Remove the armature from the PTT motor base cC Do not allow grease or oil to contact the commu...

Page 207: ...Replace the armature if below specifica tion limit 3 Measure the commutator undercut b Replace the armature if below specifica tion limit 4 Check the armature for continuity Replace if not shown as below chart 6G480220 a Commutator standard diameter a 22 0 mm 0 87 in Wear limit 21 0 mm 0 83 in 6F680180 b Commutator standard undercut b 1 35 mm 0 053 in Wear limit 0 85 mm 0 033 in 6S370140 c d e Arm...

Page 208: ...hold it with a pair of pliers and then carefully slide the stator over the arma ture BRKT 7 41 61U5H11 Bracket unit 6G470390 5 5 Measure the brush length Replace if below specification limit 6 Check the base Replace if cracked or damaged 7 Check the bearing and oil seal Replace if damaged or worn Checking the filter 1 Check gear pump filter 1 Clean if there is dirt or residue f 6S370150 Brush stan...

Page 209: ... kgf m 2 2 ft lb 61U7120E No Part name Q ty Remarks 1 Bolt 4 M5 16 mm 2 Gear pump assembly 1 3 Ball 2 4 Shuttle piston 2 5 O ring 2 6 Main valve 2 7 Ball 2 8 Bolt 1 9 Bolt 2 10 Circlip 1 11 Manual valve 1 12 O ring 1 13 O ring 1 14 Backup ring 1 15 Spring 1 16 Absorber valve pin 1 17 Ball 1 Not reusable Not reusable Not reusable Gear pump ...

Page 210: ...kgf m 5 9 ft lb 3 N m 0 3 kgf m 2 2 ft lb 61U7120E No Part name Q ty Remarks 18 Up relief valve seat 1 19 O ring 1 20 Filter 2 21 O ring 1 22 Down relief valve 1 23 Valve pin 1 24 O ring 5 25 Valve seat 1 26 Pin 1 27 Ball 1 28 Drive gear 1 29 Driven gear 1 Not reusable Not reusable Not reusable ...

Page 211: ...m the gear pump housing NOTE Use compressed air to remove the filter deep inside of the gear pump housing and be careful not to blow the filter out abruptly 3 Remove the bolts 9 gear pump cover 0 drive gear q and driven gear w NOTE Make sure that the shuttle pistons e and balls r are removed so that they tend to stick to the gear pump cover 4 Remove the up relief valve assembly t and balls 2 3 4 3...

Page 212: ...heck the main valve 1 Clean if there is dirt or residue Checking the gear pump 1 Check the drive gear and driven gear Replace the gear pump assembly if there are damage or wear Checking the gear pump housing 1 Check the inside of the gear pump hous ing Replace if scratched or worn Checking the reservoir 1 Check the reservoir and O ring Replace if deteriorated and cracked Checking the relief valve ...

Page 213: ...ven gear 9 into the gear pump housing as shown 4 Install the balls 0 shuttle pistons q and balls w into the gear pump cover NOTE Apply fluid to the balls w and shuttle pistons q to prevent them from falling out of the gear pump cover 5 Install the gear pump cover e into the gear pump housing and then tighten the bolts 6 Check that the gear pump turns smooth ly and then tighten the gear pump cover ...

Page 214: ...all the filter y down relief valve t and filter u into the gear pump housing i 9 Install a new O ring o p onto the man ual valve a 10 Install the manual valve a and circlip s into the gear pump housing i 6G470500 u t r y i 61U70390 a o p 61U70400 i s a Manual valve a 3 N m 0 3 kgf m 2 2 ft lb ...

Page 215: ... Tilt ram 1 2 Trim ram 2 3 Cylinder body 1 4 Free piston 1 5 Backup ring 1 6 O ring 1 7 Dust seal 2 8 Seal 2 9 Trim cylinder end screw 2 10 O ring 2 11 Backup ring 2 12 O ring 2 13 Dust seal 1 14 Tilt cylinder end screw 1 15 O ring 1 16 O ring 1 17 Tilt piston 1 Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Tilt cylinder and trim cylinder ...

Page 216: ...it 96 N m 9 6 kgf m 70 8 ft lb 132 N m 13 2 kgf m 97 4 ft lb 127 N m 12 7 kgf m 93 7 ft lb 61U7130E No Part name Q ty Remarks 18 O ring 1 19 O ring 1 20 Washer 1 21 Nut 1 22 Ball 4 23 Valve 4 24 Spring 4 Not reusable Not reusable ...

Page 217: ...en remove the trim piston assem blies 5 Drain the fluid 6 Install the trim piston assemblies and then temporarily tighten the trim cylinder end screws 7 Cover the tilt cylinder opening with a clean cloth 4 and then blow com pressed air through the hole a to remove the free piston 5 w Never look into the tilt cylinder opening while removing the free piston because the free piston and PTT fluid can ...

Page 218: ...or replace if necessary 5 Check the trim pistons Replace if scratched 6 Check the inner walls of the trim and tilt cylinders Replace if scratched Assembling the tilt piston and trim piston 1 Install the new dust seal 1 and new O rings 2 and 3 onto the tilt cylinder end screw 2 Install the tilt cylinder end screw onto the tilt ram 3 Install the new O rings 4 and 5 onto the tilt piston 6 4 Install t...

Page 219: ...o each trim piston Assembling the PTT unit 1 Fill the tilt cylinder with the specified amount of the recommended fluid through the hole a to bleed the fluid pas sage 2 Push the free piston 1 into the tilt cylin der until it bottoms out 3 Fill the trim cylinders with the recom mended fluid to the correct level through holes b and c and d as shown 6G470580 y u u i o y t t i o a 6G470590 Recommended ...

Page 220: ...y installation 6 Install the gear pump housing 7 with the bolts 8 7 Install the O ring into the reservoir cap 8 Install the reservoir and new O ring onto the gear pump housing 9 Fill the tilt cylinder with the recommended fluid to the correct level through the hole e as shown 10 Install the tilt piston assembly into the tilt cylinder and then tighten the tilt cylinder end screw 9 to the specified ...

Page 221: ...olts r to the specified torque NOTE Align the armature shaft with the recess in the joint 15 Remove the reservoir cap and then check the fluid level in the reservoir NOTE If the fluid is at the correct level the fluid should overflow out of the filler hole when the reservoir cap is removed 16 If necessary add sufficient fluid of the recommended type until it overflows out of the filler hole 17 Ins...

Page 222: ...t to the specified torque 6 Connect the PTT motor leads to the bat tery terminals to fully retract the trim and tilt rams 7 Reverse the PTT motor leads between the battery terminals to fully extend the trim and tilt rams NOTE 9 Repeat this procedure so that the rams go up and down 4 or 5 times be sure to wait a few seconds before switching the leads 9 If the rams do not move up and down easi ly pu...

Page 223: ...t it down Repeat this pro cedure 4 or 5 times 3 Support the outboard motor with the tilt stop lever 1 w After tilting up the outboard motor be sure to support it with the tilt stop lever Otherwise the outboard motor could sud denly lower if the PTT unit should lose fluid pressure 4 Let the fluid settle for 5 minutes 5 Remove the reservoir cap 2 and then check the fluid level in the reservoir NOTE ...

Page 224: ...t green Lg lead to the positive bat tery terminal and the black B lead to the negative battery terminal as shown 4 Check for continuity between terminals Replace the PTT relay if not shown as below chart Checking the trim sensor 1 Measure the trim sensor resistance Replace sensor if out of specification NOTE Turn the lever 1 and measure the resistance as it gradually changes Reservoir cap 7 N m 0 ...

Page 225: ...rmoswitch 8 9 Starting system 8 9 Checking the fuse WH E ET 8 9 Checking the engine start switch WH E ET 8 10 Checking the engine stop lanyard switch 8 10 Checking the starter relay WH E ET 8 11 Checking the neutral switch WH 8 11 Starter motor WH E ET 8 12 Removing the starter motor pinion 8 14 Checking the starter motor pinion 8 14 Checking the armature 8 14 Checking the brush 8 15 Checking the ...

Page 226: ...al circuit tester leads cC When measuring the voltage of an electri cal component with the digital circuit tester make sure that the tester leads do not contact each other Otherwise the electrical component could 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 with t...

Page 227: ... 2 1 Checking the electrical component Electrical component Electrical component Port view 3 5 4 2 1 2 3 2 61U80040D ET E 1 Starter motor WH E ET 2 Starter relay WH E ET 3 PTT relay ET 4 Ignition coil 5 Fuse holder 20A WH E ET ...

Page 228: ...61U80020B 2 1 ç å 3 3 2 ELEC 8 3 61U5H11 Electrical system Starboard view 1 Choke solenoid E ET 2 Rectifier Regulator 3 Hour meter if equipped å To pulser coil assembly To CDI unit ç To wire harness ...

Page 229: ... 6 5 4 3 2 1 Electrical component Aft view 8 2 4 7 1 5 6 3 9 å å 61U80030C TOP BOTTOM 1 Ignition coil 1 2 Ignition coil 2 3 Ignition coil 3 4 Ignition coil 4 5 Spark plug 6 Spark plug cap 7 Thermoswitch 8 CDI unit 9 PCV ...

Page 230: ...cal system Top view å å 1 1 7 9 8 5 2 6 2 4 3 61U80010A 1 Spark plug 2 Thermoswitch 3 Ignition coil 1 4 Ignition coil 2 5 Rectifier Regulator 6 Starter motor WH E ET 7 Stator assembly 8 Pulser coil assembly 9 Neutral switch WH ...

Page 231: ... the discharge window of the igni tion tester Check that the ignition system if the spark is weak w 9 Do not 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 1 Check the spark plug caps Replace if cracked or damaged 2 Remove the spark plug cap 1 from the spark plug wire 2 3 Check the spark ...

Page 232: ...ove the all spark plug caps to prevent the engine ignite when measure the CDI unit peak voltage at engine cranking Checking the ignition coil 1 Remove the spark plug cap from the spark plug 2 Disconnect the ignition coil connectors 3 Measure the ignition coil resistance Replace the ignition coil if out of specifi cation 6G480105 Ignition coil resistance å Primary coil Black white B W Black B 0 18 ...

Page 233: ...s than specification Manual start 4 Disconnect the pulser coil coupler 5 Connect the digital circuit tester to the pulser coil coupler pulser coil side 6 Measure the pulser coil resistance Replace the pulser coil resistance if out of specification Pulser coil resistance reference data White red W R 2 White yellow W Y 4 White black W B 1 White green W G 3 256 384 Ω at 20 C 68 F 61U80110 W B W B W R...

Page 234: ...d Loaded Cranking 1 500 3 500 DC V 130 140 160 160 100 80 Charge coil output peak voltage high speed Black red B R Blue L r min Unloaded Loaded Cranking 1 500 3 500 DC V 45 45 160 160 30 30 Thermoswitch continuity temperature Pink P Black B e 84 0 90 0 C 183 194 F f 60 0 74 0 C 140 165 F S6P28750 Checking the thermoswitch 1 Place the thermoswitches in a container of water and slowly heat the water...

Page 235: ...cou pler 2 Check the engine start switch for continu ity at the 10 pin main harness coupler engine start switch side Check the wiring harness or replace the engine start switch if there is no continuity å WH E ET 61U80130 4 1 2 5 3 å Lead color Switch White W Black B Red R Yellow Y Brown Br position 1 2 3 4 5 OFF ON START 4 1 2 5 3 69D80206 61U80140 å 1 2 a b c 1 2 Switch Lead color position White...

Page 236: ... check for continuity between the starter relay terminals Replace the starter relay if there is no continuity 4 Check that there is no continuity between the starter relay terminals after discon necting a battery terminal from the brown 2 or black lead 3 Replace the starter relay if there is continuity 3 2 6G480196 1 61U80030 Checking the neutral switch WH 1 Check the neutral switch for continuity...

Page 237: ... 30 N m 3 0 kgf m 22 1 ft lb 61U8010E No Part name Q ty Remarks 1 Bolt 2 M8 25 mm 2 Starter motor bracket 1 3 Clip 2 4 Pinion stopper 1 5 Spring 1 6 Pinion 1 7 Front bracket 1 8 Washer 9 Armature 1 10 Stator 1 11 Brush holder 1 12 Brush 1 13 Washer 1 14 Washer 1 15 Nut 1 16 Washer 2 17 Rear bracket 1 Starter motor WH E ET ...

Page 238: ...ELEC 8 13 61U5H11 Electrical system 9 N m 0 9 kgf m 6 6 ft lb 18 N m 1 8 kgf m 13 3 ft lb 30 N m 3 0 kgf m 22 1 ft lb 61U8010E No Part name Q ty Remarks 18 Screw 2 19 Bolt 2 M6 115 mm ...

Page 239: ... Turn the pinion counterclockwise to check that it operates smoothly and turn it clockwise to check that it locks in place Checking the armature 1 Check the commutator for dirt Clean with 600 grit sandpaper and compressed air if necessary 2 Measure the commutator diameter a Replace the armature if below specifica tion limit 3 Measure the commutator undercut b Replace the armature if below specific...

Page 240: ...easure the resistance of the choke solenoid Replace the choke solenoid if out of specification 4 Check the armature for continuity Replace the armature if not shown as below chart Checking the brush 1 Measure the brush length a Replace the brush assembly if below specification limit 6G480256 c d e Armature continuity Commutator segments c Continuity Segment Armature core d No continuity Segment Ar...

Page 241: ...ltage of the Rectifier Regulator Rectifier Regulator output peak voltage Red R Ground B r min Unloaded 1 500 3 500 DC V 13 13 Charging system Checking the lighting coil 1 Disconnect the lighting coil connector 2 Connect the probe to the lighting coil 3 Measure the lighting coil output peak voltage Replace the stator assembly if less than specification 4 Connect the digital circuit tester to the li...

Page 242: ...ring harness 2 Connect the positive battery lead to the yellow Y terminal a also connect the negative battery lead to the black B ter minal b and then check that the hour meter displayed the all segments which has been illuminated for 2 seconds Replace the hour meter if there is no illu minated 61U80160 a b ...

Page 243: ...61U5H11 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 6 Troubleshooting the lower unit 9 7 ...

Page 244: ...ectrolyte level gravity and voltage 3 14 Loose connection of battery terminal Check the battery terminal connection Short open or loose connection in starter motor circuit Check the wiring har ness continuity 1 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 14 Engine start switch malfu...

Page 245: ...ump Fuel pump malfunction Adjust and check the carburetor Carburetor malfunction 8 10 Engine stop lanyard switch malfunction Check for continuity 4 17 Check the fuel joint pressure Fuel joint malfunction Symptom 1 Engine will not start engine cranks Spark plug malfunction Spark plug does not spark 1 Short open or loose connection in ignition coil circuit and ground circuit Check the wiring har nes...

Page 246: ...rings Check the compression pressure and disas sembling the power unit Scratched cylinder wall Reed valves malfunction 5 1 5 35 Refer Symptom 2 Cause 1 Cause 2 Checking step to page Symptom 1 Unstable engine idle speed poor acceleration poor performance Throttle cable adjusting improperly Check and adjust the throttle cable Check and adjust the throttle link length 3 6 Throttle link length imprope...

Page 247: ...ifications 5 8 8 6 Change the ignition coil and check the ignition spark 8 8 5 8 8 6 CDI unit malfunction Measure the charge coil output peak voltage and resistance Change the CDI unit and check the ignition spark CDI unit output peak voltage less than speci fications 3 3 Check the spark plug gap and condition Spark plug gap improperly Cylinder head gasket malfunction Reed valves malfunction Disas...

Page 248: ...ling water does not dis charge from the cooling water pilot hole Water pump malfunction Clogged cooling water passage Thermostat malfunction Check the impeller 6 5 Water pump impeller malfunction Check the Woodruff key 6 5 Water leakage from water pump housing Check the water pump housing 6 5 Check the insert car tridge 6 5 Check the outer plate cartridge 6 5 Check the cooling water passage exhaus...

Page 249: ...tor lead Check the PTT motor lead 1 PTT motor does not operate Oil pressure does not increase PTT motor malfunction Disassemble and check the PTT motor 7 39 Blown fuse 20A Check the fuse 20A 7 57 Loose connection of the battery terminal Check the battery ter minal Discharge battery Check the battery 3 14 Manual valve opened Check the manual valve for open Manual valve malfunction Insufficient PTT ...

Page 250: ...check the PTT unit 7 44 Main valves does not oper ate Refer Symptom 2 Cause 1 Cause 2 Checking step to page Troubleshooting the lower unit Symptom 1 Shift mechanism of the forward gear and reverse gear does not operate properly 3 7 3 7 6 5 6 5 Remote control box malfunction Shift rod operation malfunction Shift cable and shift cable end malfunction Check the remote con trol box Check the shift cab...

Page 251: ...0 Checking the PTT operation ET 3 10 Checking the PTT relay 7 57 Checking the PTT system ET 1 15 Checking the Rectifier Regulator 8 16 Checking the anode 3 13 Checking the armature 8 14 Checking the battery WH E ET 3 14 Checking the bearing 5 35 6 14 Checking the brush 8 15 Checking the carburetor 4 12 Checking the charge coil 8 8 Checking the choke solenoid 8 15 Checking the choke solenoid E ET 3...

Page 252: ...hrottle cable and shift cable 7 4 Checking the tilt cylinder and trim cylinder 7 51 Checking the tilt operation MH WH E 3 11 Checking the top cowling 3 2 Checking the trim sensor 7 57 Checking the upper case 7 13 Checking the water pump and shift rod 6 5 Clamp bracket and swivel bracket 7 20 Control system 3 4 Crankcase 5 31 Cylinder head 5 27 D Dimension 2 15 Disassembling the PTT motor 7 39 Disa...

Page 253: ...oving the PTT unit ET 7 30 Removing the clamp bracket ET 7 30 Removing the clamp bracket MH WH E 7 24 Removing the crankcase 5 34 Removing the cylinder head 5 29 Removing the drive shaft 6 13 Removing the electrical component 5 20 Removing the exhaust cover 5 26 Removing the flywheel magnet 5 19 Removing the intake manifold 5 24 Removing the lower unit 6 4 Removing the piston connecting rod assemb...

Page 254: ...6 Lighting coil 7 Pulser coil 8 Rectifier Regulator 9 Engine stop lanyard switch 0 Over revolution Color code B Black Br Brown G Green Gy Gray L Blue P Pink R Red W White B R Black red B W Black white G W Green white W B White black W G White green W L White blue W R White red W Y White yellow ...

Page 255: ......

Page 256: ...YAMAHA MOTOR CO LTD Printed in Japan Oct 2005 1 2 1 E_1 Printed on recycled paper E115A 115B 140B ...

Page 257: ... 3 3 G W R B P P B B P B R R R Gy B B B W B W W W G G W G W G G G G B B B B L B R P B W B W B W B W B W B W B W B W B W B W B W B W W R W B W Y W G W R W B W Y W G W R W B W Y W G R B Br L B R R Br L B R R Br L B R R Br W B B B P B P B P P B P B ...

Page 258: ...ng coil q Pulser coil w Rectifier Regulator e Choke solenoid E115AE 115BE r Over revolution å To remote control box switch panel Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green P Pink R Red Sb Sky blue W White B R Black red B W Black white Gy B Gray black G W Green white W B White black W G White green W L White blue W R White red W Y White yellow ...

Page 259: ...Sb Lg R R R R Br Gy B B B B B B B B B W R Br B P Sb Lg W L B L L G G W G W G G G G B B B B B L B R P B W B W B W B W B W B W B W B W B W B W B W B W W R W B W Y W G W R W B Gy B Gy B Gy B Gy B B Gy B Gy B Gy B Gy B W Y W G W R W B W Y W G R B Br L B R R Br L B R R Br L B R R Br W B B P B P B G W B R G Sb R B P W Lg L Br G ...

Page 260: ...ing coil r Pulser coil t Rectifier Regulator y Choke solenoid u Hour meter E115A i Trim sender o Over revolution å To remote control box switch panel To trim meters Color code B Black Br Brown G Green Gy Gray L Blue Lg Light green P Pink R Red Sb Sky blue W White Y Yellow B R Black red B W Black white Gy B Gray black G W Green white W B White black W G White green W L White blue W R White red W Y ...

Page 261: ...r Sb Lg Gy B B B B B B B B B B B B B B B B W R Br B P Sb Lg W L B L L G G G W G W G G G G B B B B L L B R P B W B W B W B W B W B W B W B W B W B W B W B W W R W B W Y W G W R W B Gy Gy B Gy B Gy B Gy B B Gy B Gy B Gy B Gy B Gy B Gy B W Y W G W R W B W Y W G R B Br L B R R Br L B R R Br L B R R Br W B B B B P B P B G W G W B R G Y B Y B G Sb R W Y Lg G L B P Br ...

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