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NOTICE

This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.

Important information

Particularly important information is distinguished in this manual by the following notations:

Q

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!

w

Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.

c

C

A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

EK40G/EK40J

SERVICE MANUAL

©2004 by Yamaha Motor Co., Ltd.

1st Edition, August 2004

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in Japan

A4Cover6H9 04.7.6 9:31 Page 2

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Summary of Contents for EK40G

Page 1: ...EK40J SERVICE MANUAL 6H9 28197 5G 11 EK40G ...

Page 2: ... of 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 i...

Page 3: ...eral information Periodic checks and adjustments Fuel system Power unit Bracket unit Electrical systems 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: ...eller selection 1 5 Propeller size 1 5 Selection 1 6 Predelivery checks 1 6 Checking the fuel system 1 6 Checking the gear oil level 1 6 Checking the battery W 1 6 Checking the outboard motor mounting height 1 7 Checking the remote control cables remote control model 1 7 Checking the steering system 1 8 Checking the gear shift and throttle operation 1 8 Checking the engine start switch engine stop...

Page 6: ... 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 1 Remove the drive shaft assembly and pinion and then pull out the forward gear Disassembling the drive shaft 1 Inst...

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

Page 8: ...ing an air compressor Protect your hands and feet by wearing pro tective gloves and safety shoes when neces sary Parts lubricants and sealants 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 sh...

Page 9: ... 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 direction indicat ed in ...

Page 10: ...ating 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 on the outside of the propeller boss or the propeller blade a Propeller diamet...

Page 11: ...il mixing ratio is 30 1 For break in period gasoline 25 1 kerosene 30 1 mixture shall be used Checking the gear oil 1 Check the gear oil level Checking the battery W 1 Check the capacity electrolyte level and specified gravity of the battery Propeller size in Material 11 3 4 7 1 2 H 11 3 4 8 3 4 H 11 3 4 10 H Aluminum 11 1 2 11 H 11 1 2 12 H 11 1 2 13 H 11 1 2 13 1 2 H Propeller size in Material 1...

Page 12: ...ted by the combination of the boat and the outboard motor To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured with the clamp screws Checking the remote control cables remote control model 1 Set the remote control lever to the neutral position and fully close the throttle lever 2 Check that the throttle pulley 1 is i...

Page 13: ...e outboard motor is steered Checking the gear shift and throttle operation 1 Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from neutral to for ward or reverse 2 Check that the throttle operates smooth ly when the throttle grip tiller handle model is turned from the fully closed position to the fully open position a Check that the throttle opera...

Page 14: ...lled from the engine stop lanyard switch Checking the cooling water pilot hole 1 Check that cooling water is discharged from the cooling water pilot hole Test run 1 Start the engine then check that the gear shift operates smoothly 2 Check the engine idle speed after the engine has been warmed up 3 Operate at trolling speed 4 Run the outboard motor for 1 hour at 3 000 r min or at half throttle then...

Page 15: ...min Vary engine speed occa sionally Run at full throttle for 1 minute the allow about 10 minutes of operation at 3 4 throttle or less to let the engine cool 4 8 hours d at any speed but avoid oper 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 10hours Use standard pre mix ratio of fuel and oi...

Page 16: ...GEN INFO 1 11 6H95G11 MEMO ...

Page 17: ... 6 5 4 3 2 1 SPEC Specifications General specification 2 1 Maintenance specification 2 3 Power unit 2 3 Lower unit 2 5 Electrical 2 5 Dimensions 2 7 Tightening torques 2 9 Specified torques 2 9 General torques 2 10 ...

Page 18: ...al 19 5 5 2 4 3 at 5 500 r min lmp gal hr Engine idle speed r min 1 050 1 150 Power unit Engine type 2 stroke L Cylinder quantity 2 Total displacement cm3 cu in 669 40 82 Bore x stroke mm in 78 0 70 0 3 07 2 76 Compression ratio 5 00 Intake system Reed valve Scavenging system Loop charge Control system Tiller handle Remote control Starting system Manual Manual and electric Fuel system Carburetor I...

Page 19: ...it Trim angle Degree 8 12 16 20 24 at 12 boat transom Tilt up angle Degree 67 Steering angle Degree 45 45 Drive unit Gear shift positions F N R Gear ratio 1 85 24 13 2 00 26 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch Propeller shaft type Share pin Spline Propeller direction rear view Clockwise Propeller ID mark H G Electrical Battery minimum capacity 2 CCA EN 347 20HR IEC 40 1...

Page 20: ... 0020 Pistons Piston diameter D mm in 77 940 77 965 3 0685 3 0695 Measuring point H mm in 10 0 0 39 Piston to cylinder clearance mm in 0 055 0 060 0 0022 0 0024 limit 0 110 0 0043 Piston pin boss bore mm in 19 904 19 915 0 7836 0 7841 Oversize piston 1st mm in 0 25 0 010 2nd mm in 0 50 0 020 Oversize piston diameter 1st mm in 78 190 78 215 3 0783 3 0793 2nd mm in 78 440 78 465 3 0882 3 0892 Piston...

Page 21: ...07 2nd mm in 78 50 3 0906 Connecting rods Small end inside diameter mm in 24 900 24 912 0 9803 0 9808 Big end side clearance mm in 0 200 0 700 0 0079 0 0276 Small end axial play limit mm in 2 0 0 08 Crankshaft Crankshaft width A mm in 61 40 61 45 2 4173 2 4193 Crankshaft width B mm in 41 38 41 60 1 6291 1 6378 Crankpin diameter mm in 26 995 27 000 1 0627 1 0629 Runout limit mm in 0 03 0 0012 Therm...

Page 22: ...2 0 13 3 2 0 13 Pilot jet P J 90 60 90 60 Pilot air jet P A J ø1 00 ø1 20 ø1 00 ø1 20 Pilot screw P S turns out 3 4 1 1 4 3 4 1 1 4 Valve seat size mm in 2 0 0 08 1 2 0 05 2 0 0 08 1 2 0 05 Float height mm in 12 0 13 0 4 0 5 0 12 0 13 0 4 0 5 0 0 47 0 51 0 16 0 20 0 47 0 51 0 16 0 20 Lower unit Item Unit Model EK40GMH EK40JMH EK40JW Gear backlash Pinion to forward mm in Pinion to reverse mm in Pin...

Page 23: ... B Ω 16 2 19 8 Pulser coil resistance W B B Ω 16 2 19 8 Charge coil output peak voltage Positive side Br Negative side L at Cranking unloaded V 150 at Cranking loaded V 140 at 1 500 r min loaded V 190 at 3 500 r min loaded V 180 Charge coil resistance Br L Ω 243 297 Starter motor Type Brushes Bendix Length limit mm in 9 0 0 35 Armature Commutator undercut limit mm in 0 2 0 01 Charging system Fuse ...

Page 24: ...8 30 1 2 533 20 1 S 622 24 5 L 691 27 2 EK40JW S 764 30 1 EK40JW S 421 16 6 94 3 7 695 27 4 294 11 6 205 8 07 602 23 7 360 14 2 427 16 8 188 7 4 504 19 8 72 2 8 S 784 30 9 L 897 35 3 193 7 6 S 771 30 4 L 898 35 5 EK40JW 478 18 9 EK40JW S 797 33 4 S 444 17 5 L 570 22 4 Dimensions Exterior mm in MH ...

Page 25: ...7 6 5 4 3 2 1 Maintenance specification 60 2 36 33 1 30 124 5 4 9 16 5 0 65 10 5 0 41 93 5 3 68 134 5 5 3 217 5 8 56 249 9 80 57 2 24 50 1 97 32 1 26 124 5 4 9 93 5 3 68 134 5 5 3 10 5 0 41 6F62002M Clamp bracket mm in ...

Page 26: ...Crankcase bolt 1st M8 20 2 0 15 2nd 40 4 0 29 5 Spark plug M14 25 2 5 18 Lower unit Check screw 9 0 9 6 6 Drain screw 9 0 9 6 6 Lower case mounting bolt M8 21 2 1 15 5 Lower case cap bolt EK40G 1st M6 4 0 4 3 0 2nd 8 0 8 5 8 Cooling water inlet cover EK40J M5 4 0 4 3 0 Propeller nut EK40J M16 35 3 5 25 3 Propeller shaft housing ring nut EK40J 90 9 0 65 Pinion nut EK40J M12 74 7 4 54 6 Bracket unit...

Page 27: ...in applicable 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 specifications 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 ...

Page 28: ...2 11 6H95G11 SPEC MEMO ...

Page 29: ...3 4 Control system 3 5 Adjusting the start in gear protection 3 5 Adjusting the throttle link position 3 5 Adjusting the throttle cable MH 3 5 Adjusting the throttle cable W 3 6 Checking the gear shift operation MH 3 6 Checking the engine idle speed 3 7 Checking the gear shift operation W 3 7 Bracket 3 8 Checking the tilt operation 3 8 Lower unit 3 8 Checking the gear oil level 3 8 Changing the ge...

Page 30: ...CHK ADJ 6H95G11 3 1 Special service tools Periodic checks and adjustments CHK ADJ Digital tachometer 90890 06760 Leakage tester 90890 06840 ...

Page 31: ... 9 Cooling water passages Clean 1 1 3 4 Cowling clamp Check 1 3 3 Fuel filter can be dis Check clean 1 1 1 3 3 assembled Fuel system Check 1 1 1 3 3 Fuel tank Yamaha por Check clean 1 table tank Gear oil Change 1 1 3 8 Lubrication points Lubricate 1 3 10 Idling speed carbure Check adjust 1 1 3 7 tor model Propeller and cotter pin Check replace 1 1 3 9 Shift link shift cable Check adjust 1 3 7 Ther...

Page 32: ...t gasoline and replace the element if necessary NOTE Be sure not to spill any fuel when removing the fuel filter cup Power unit Checking the spark plugs 1 Disconnect the spark plug caps and then remove the spark plugs 2 Clean the electrodes 1 with a spark plug cleaner or wire brush Replace the spark plug if necessary 3 Check the electrodes for erosion and excessive carbon or other deposits and the...

Page 33: ...ten the cover bolts Checking the cooling water pas sages 1 Check the cooling water inlet cover 1 screw 2 and cooling water inlet for clog ging Clean if necessary å EK40G EK40J 2 Place the lower unit in water then start the engine 3 Check for water flow at the cooling water pilot hole If there is no water flow check the cooling water passage inside the out board motor 6B430060 1 2 3 6H930040 6B4300...

Page 34: ...sting the throttle cable MH NOTE Before adjusting the throttle cables the throt tle stop screw should be properly adjusted 1 Check the throttle cables for smooth operation looseness fraying or damage Replace if necessary 2 With the throttle grip in the fully opened position check that the stopper on the pulley contact with the stopper on the bracket Adjust if necessary 3 Loosen the locknut 1 and a...

Page 35: ...en and close the throttle grip and make sure the stopper on the pulley con tacts the stopper on the bracket at the fully opened position and stopper on the bracket contacts the stopper on the pul ley at the fully closed position If proper contacts are not made repeat the proce dure Adjusting the throttle cable W 1 Check that the throttle cable for smooth operation looseness fraying or damage Repla...

Page 36: ...r shift for smooth operation and if necessary repeat steps 2 6 Checking the engine idle speed 1 Start the engine and warm it up for 5 min utes 2 Attach the special service tool to spark plug wire 1 1 and then check the engine idle speed Adjust if out of specifi cation 3 Turn the throttle stop screw 2 in direc tion a or b until the specified engine idle speed is obtained NOTE 9 To increase the idle...

Page 37: ...hole and no air bubbles are visible 6H95G11 3 8 9 8 7 6 5 4 3 2 1 Bracket Checking the tilt operation 1 Fully tilt the outboard motor up and down a few times and check the entire tilt range for smooth operation 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 Bracket Lower unit 6F630180 6F6302...

Page 38: ...ines for cracks damage or wear Replace if necessary General Checking the anodes 1 Check the anodes and trim tab for scales grease and oil Clean if necessary CHK ADJ 3 9 6H95G11 Periodic checks and adjustments å EK40G EK40J cC Do not oil grease or paint the anodes or the trim tab otherwise they will be inef fective 2 Replace the anodes or trim tab if exces sively eroded Checking the battery W 1 Che...

Page 39: ...tteries 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 batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN NOTE 9 Batteries vary per manufacturer The proce dures mentioned in this manual may not always apply therefore consult the instruc tion manual of the battery 9 Dis...

Page 40: ...CHK ADJ 3 11 6H95G11 Periodic checks and adjustments 2 Apply low temperature resistant grease to the area shown 3 Apply corrosion resistant grease to the area shown 6F630300 6B430300 ...

Page 41: ...e 4 3 Carburetor 4 5 Disassembling the carburetor 4 9 Checking the carburetor 4 9 Assembling the carburetor 4 10 Adjusting the throttle stop screw 4 11 Fuel pump 4 12 Checking the fuel pump 4 14 Disassembling the fuel pump 4 15 Assembling the fuel pump 4 15 Checking the fuel joint 4 15 FUEL ...

Page 42: ...FUEL 4 1 6H95G11 Fuel system Special service tools Vacuum pressure pump gauge set 90890 06756 Digital caliper 90890 06704 ...

Page 43: ...ter For Gasoline 2 Fuel hose Fuel joint to fuel filter For Kerosene 3 Fuel hose Fuel filter to fuel pump For Gasoline 4 Fuel hose Fuel filter to fuel pump For Kerosene 5 Fuel hose Fuel pump to carburetor For Gasoline 6 Fuel hose Fuel pump to carburetor For Kerosene 7 Pilot water hose 1 2 3 5 4 6 5 6 7 7 6H94010E ...

Page 44: ...ks 1 Clip 12 2 Fuel hose 1 3 Fuel hose 1 4 Bolt 1 M6 25 mm 5 Fuel joint 1 6 Grommet 1 7 Fuel hose 1 8 Fuel hose 1 9 Fuel hose 1 10 Fuel hose 1 11 Bolt 2 M6 55 mm 12 Fuel pump 1 13 Gasket 1 14 Nut 2 15 Bolt 1 16 Bracket 1 17 Fuel filter assembly 2 Not reusable Not reusable ...

Page 45: ...filter element 2 19 O ring 2 20 Cup 2 21 Screw 3 ø6 30 mm 22 Intake silencer 1 23 O ring 1 24 Screw 4 ø6 12 mm 25 Link lever 1 26 Pin 1 27 Choke rod 1 28 Collar 1 29 Link rod 1 30 Nut 4 31 Washer 4 32 Gasket 1 33 Carburetor assembly 1 34 Gasket 1 Not reusable Not reusable Not reusable ...

Page 46: ... No Part name Q ty Remarks 1 Damper 1 2 Hose 2 3 Screw 4 ø4 14 mm 4 Cover 1 5 Gasket 1 6 Throttle stop screw 1 7 Spring 1 8 Pilot screw 2 9 Spring 2 10 O ring 2 11 Screw 1 ø4 5 mm 12 Gasket 1 13 Washer 1 14 Joint 1 15 Link rod 1 16 Nut 1 17 Washer 1 Not reusable Not reusable ...

Page 47: ... 18 Lever 1 19 Pump lever assembly 1 20 Cam 1 21 Screw 1 ø4 5 mm 22 Gasket 1 23 Drain screw 1 24 Gasket 1 25 Screw 4 ø5 16 mm 26 Main jet 2 27 Gasket 2 28 Main nozzle 2 29 Carburetor body 1 30 Pilot jet 4 31 Float pin 1 32 Float 1 33 Needle valve 1 34 Valve seat 1 Not reusable Not reusable Not reusable ...

Page 48: ...oat chamber 1 37 Nozzle 1 38 Gasket 1 39 O ring 1 40 O ring 1 41 Stopper 1 42 Plunger 1 43 Drain screw 1 44 Gasket 1 45 Drain screw 1 46 Gasket 1 47 Check valve 1 48 Starter jet 1 49 Gasket 1 50 Float 1 51 Float pin 1 Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 49: ...s 52 Float arm 1 53 Needle valve 1 54 Screw 1 ø4 5 mm 55 Valve seat 1 56 Gasket 1 57 Ball seat 1 58 Ball 1 59 Spring 1 60 Gasket 1 61 Carburetor body 1 62 Screw 8 ø5 16 mm 63 Screw 2 ø6 19 mm 64 Starter plunger 1 65 Spring 1 66 Float chamber 1 67 Screw 4 ø5 12 mm 68 Holder 1 Not reusable Not reusable ...

Page 50: ...ould be sorted out and kept in order so that they can be re assembled in their orig inal positions Checking the carburetor 1 Check the air and fuel passages and jets for dirt and foreign matter Clean the car buretor body with a petroleum based sol vent if necessary 2 Blow compressed air into all passages and jets cC 9 Direct the compressed air downward otherwise cleaning solvent may be blown into ...

Page 51: ...e kerosene side 4 Install the pilot jet w new gasket and cover to the carburetor body of the kerosene side as shown 5 Install the needle valve e float r float arm t and float pin y gasoline side float and then the check the float for smooth operation å Kerosene side Gasoline side NOTE Place the needle valve in the valve seat when installing the float to the carburetor 6 Install the new gasket onto...

Page 52: ...ection b 7 Install a new O ring u and new gasket i onto the carburetor body of the gaso line side and then install the carburetor body of the kerosene side 8 Install the pilot screw turn it in until it is lightly seated then out the specified number of turns NOTE 9 Adjust the throttle cable whenever the car buretor has been disassembled or the engine idle speed has been adjusted 9 For adjustment p...

Page 53: ...emarks 1 Screw 3 ø5 30 mm 2 Cover 1 3 Diaphragm 1 4 Gasket 1 5 Fuel pump body 1 6 Diaphragm 1 7 Spring 1 8 Spring plate 1 9 Gasket 1 10 Check valve 2 11 Cover 1 12 Gasket 1 13 Diaphragm 1 14 Pump body 1 15 Gasket 1 16 Diaphragm 1 17 Cover 1 Not reusable Not reusable Not reusable Not reusable ...

Page 54: ...FUEL 4 13 6H95G11 Fuel system 6H94030E No Part name Q ty Remarks 18 Check valve 2 19 Screw 4 ø5 24 mm ...

Page 55: ...5 Connect the special service tool to the fuel pump outlet c or d 6 Apply the specified positive pressure and check that there is no air leakage Disassemble the fuel pump if necessary NOTE Assemble the fuel pump valve to the fuel pump body and moisten the inside of fuel pump with gasoline to ensure a better seal 7 lastly connect the special service tool to the inlet a or b and then apply the pos i...

Page 56: ...iaphragms for tears or dam age Replace if necessary 3 Check the valves for bends or damage Replace if necessary Also check the fuel pump body for damage Replace if nec essary 4 Clean the fuel pump body Assembling the 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 va...

Page 57: ...der head 5 24 Removing the exhaust cover 5 24 Checking the exhaust cover 5 24 Crankcase 5 25 Removing the crankcase 5 27 Removing the crankshaft assembly and oil seal housing 5 27 Checking the cylinder bore 5 27 Disassembling the oil seal housing 5 28 Checking the oil seal housing 5 28 Assembling the oil seal housing 5 28 Disassembling the piston 5 28 Checking the piston diameter 5 29 Checking the...

Page 58: ...wheel holder 90890 06522 Flywheel puller 90890 06521 Crankshaft aligner 90890 03107 Driver rod LS 90890 06606 Bearing Separator 90890 06534 Crank jig set 90890 02422 Flange 90890 02351 Driver rod L3 90890 06652 Needle bearing attachment 90890 06613 90890 06628 90890 06631 90890 06654 ...

Page 59: ...ols Body 90890 02352 Bolt 90890 02353 Washer 90890 02354 Bushing 9 D30 90890 02363 B 9 Bushing 12 D35 90890 02366 B 12 Pressure plate 90890 02384 Press body 90890 02385 Pressure pin B 90890 02390 B Bearing pressure C 90890 02393 C Support 90890 02394 ...

Page 60: ...POWR 5 3 6H95G11 Power unit Height ring H 18 90890 02401 H 18 Plate C 90890 02402 Pressure pin C 90890 02403 Spacer C 90890 02404 C Small end bearing installer 90890 06527 Cylinder gauge 90890 06759 ...

Page 61: ...ttle and then crank the engine until the reading on the compres sion gauge stabilizes NOTE Do not pull the choke knob when checking the compression pressure 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 compression press...

Page 62: ...t lb W MH No Part name Q ty Remarks 1 Power unit 1 2 Manual starter assembly 1 3 Collar 3 4 Grommet 6 5 Bolt 3 M8 35 mm 6 Gasket 1 7 Bolt 2 M6 12 mm 8 Dowel pin 2 9 Bolt 2 M6 25 mm 10 Bolt 8 M8 40 mm 11 Apron 1 12 Spiral tube 1 13 Corrugated tube 1 Not reusable ...

Page 63: ...y Remarks 1 Flywheel magnet 1 2 Base assembly 1 3 Bolt 3 M6 40 mm 4 Oil seal 1 5 O ring 1 6 Woodruff key 1 7 Bolt 3 M8 14 mm 8 Starter pulley 1 9 Nut 1 10 Washer 1 11 Pulser coil 2 12 Screw 4 ø5 24 mm 13 Charge coil 1 14 Screw 4 ø6 25 mm 15 Light coil 1 16 Screw 1 ø4 6 mm Not reusable Not reusable ...

Page 64: ...f m 21 ft lb MH No Part name Q ty Remarks 1 Electric starter unit and 1 W model CDI unit assembly 2 CDI unit assembly 1 3 Bolt 3 M8 48 mm 4 Bolt 3 M6 30 mm 5 Bolt 2 M8 25 mm 6 Bolt 1 M6 16 mm 7 Ignition coil 1 8 Bolt 2 M6 25 mm 9 Clamp 1 10 Plug cap 2 ...

Page 65: ...Q ty Remarks 1 Starter motor 1 2 Starter relay 1 3 Bracket 1 4 Bolt 2 M6 12 mm 5 Spiral tube 1 6 Cap 3 7 Nut 3 8 Spring washer 3 9 Starter motor lead 1 10 Battery negative lead 1 11 Bolt 2 M8 16 mm 12 Washer 2 13 Collar 2 14 Bracket 1 15 Bracket 1 16 CDI unit 1 17 Bolt 2 M6 20 mm All components are for W model only ...

Page 66: ...wer unit 6F65040E 4 N m 0 4 kgf m 3 0 ft lb 29 N m 2 9 kgf m 21 ft lb No Part name Q ty Remarks 18 Rectifier 1 19 Screw 1 ø6 25 mm 20 Bolt 1 M6 16 mm 21 Battery positive lead 1 22 Cap 1 All components are for W model only ...

Page 67: ...0 9 8 7 6 5 4 3 2 1 Power unit 6F65060E No Part name Q ty Remarks 1 Bolt 1 M6 30 mm 2 Collar 1 3 Throttle control lever 1 4 Throttle pulley 1 5 Throttle cable 2 6 Bracket 1 7 Bolt 1 M6 15 mm 8 Link rod 1 9 Joint 2 ...

Page 68: ...11 1 ft lb No Part name Q ty Remarks 1 Manual starter case 1 2 Spiral spring 1 3 Washer 1 4 Sheave drum 1 5 Spring 1 6 Drive pawl 1 7 Spring 1 8 Washer 1 9 Drive plate 1 10 Washer 1 11 Bolt 1 M8 30 mm 12 Collar 1 13 Nut 1 14 Bolt 1 M6 20 mm 15 Collar 1 16 Roller 1 17 Bolt 2 M6 16 mm ...

Page 69: ...20E 10 N m 1 0 kgf m 7 2 ft lb 15 N m 1 5 kgf m 11 1 ft lb No Part name Q ty Remarks 18 Washer 2 19 Cover 1 20 Manual starter handle 1 21 Damper 1 22 Starter rope guide 1 23 Starter rope 1 24 Start in gear protection cable 1 25 Plunger 1 26 Spring 1 ...

Page 70: ... your hand then pull it out 3 Remove the sheave drum8 w The spiral spring can pop out Cover the spiral spring with cloths then pull out the sheave drum 4 Remove the spiral spring 9 from the manual starter case w The spiral spring can pop out To remove the spring cover it with cloths 5 Remove the starter rope 0 Checking the spiral spring 1 Check the spiral spring for cracks bends or damage Replace ...

Page 71: ...he sheave drum in the direction of the arrow shown in the illustration NOTE After winding the starter rope around the sheave drum install the starter rope in the notch b 5 Install the spiral spring 4 into the starter case NOTE Install the outer end c of the spiral spring onto the pin d of the starter case 6 Install the sheave drum into the manual starter case 5 NOTE Install the sheave drum then se...

Page 72: ...nec essary 10 Pull the manual starter handle complete ly then measure the starter rope length Adjust if the starter rope length is out of specification Removing the power unit NOTE It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency 1 Disconnect the start in gear protection cable 1 and then remove the manual starter 2 Remove the choke li...

Page 73: ...s 8 Ignition coil leads 9 and rectifier W leads 0 thermoswitch leads q fuel hose and pilot water hose å MH model 8 Remove the apron and then remove the power unit by removing the bolts Removing the flywheel magnet 1 Remove the starter pulley and then 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 fly...

Page 74: ... end until the fly wheel magnet comes off the tapered portion of the crankshaft 3 Remove the Woodruff key 6B450090 Removing the electrical components 1 Remove the bracket 1 W CDI unit starter motor starter relay and rectifier 2 Remove the base assembly 2 3 Remove the spark plug caps from the spark plugs and then remove the ignition coil 3 Removing the throttle pulley assembly 1 Removing the thrott...

Page 75: ...y 1 Remove the O ring and oil seal Assembling the base assembly 1 Apply grease to a new oil seal then install it into the base assembly 2 Install a new O ring 3 Power unit 6F650240 6F650250 1 2 3 Needle bearing attachment 1 90890 06654 Driver rod L3 2 90890 06652 ...

Page 76: ...lve assembly 1 1 3 Gasket 1 4 Intake manifold 2 1 5 Reed valve assembly 2 1 6 Gasket 1 7 Gasket 1 8 Gasket 1 9 Bolt 2 M6 65 mm 10 Screw 4 ø5 12 mm 11 Clip 10 12 Hose 5 13 Bolt 7 M6 25 mm 14 Arm 1 15 Collar 1 16 Bracket 1 17 Bracket 1 Not reusable Not reusable Not reusable Not reusable Reed valves ...

Page 77: ...6H95G11 5 20 9 8 7 6 5 4 3 2 1 Reed valves 6H95070E No Part name Q ty Remarks 18 Bolt 1 M6 30 mm 19 Bolt 1 M6 15 mm ...

Page 78: ...ve the intake manifold cover gasket and reed valve assembly 1 3 3 Remove the stay 4 intake manifold and reed valve assembly 2 5 Checking the reed valves 1 Check the reed valves for bends a Replace if above specification 6F650260 2 1 3 6F650270 2 1 4 5 a 6H950280 Valve bend limit a 0 20 mm 0 0079 in b c 6H950290 Valve stopper height b 2 2 2 6 mm 0 87 0 102 in Valve stopper height c 4 0 4 4 mm 0 157...

Page 79: ...b 8 N m 0 8 kgf m 5 8 ft lb Cylinder head No Part name Q ty Remarks 1 Gasket 1 2 Cylinder head 1 3 Thermoswitch 1 4 Bolt 1 M6 14 mm 5 Holder 1 6 Cover 1 7 Gasket 1 8 Bolt 4 M6 30 mm 9 Thermostat 1 10 Spark plug 2 11 Bolt 11 M8 0 mm 12 Bolt 5 M6 25 mm 13 Cylinder head cover 1 14 Gasket 1 15 Screw 1 16 Anode 1 17 Screw 2 Not reusable Not reusable Not reusable ...

Page 80: ...N m 3 0 kgf m 22 ft lb 12 N m 1 2 kgf m 8 7 ft lb 25 N m 2 5 kgf m 18 ft lb 8 N m 0 8 kgf m 5 8 ft lb No Part name Q ty Remarks 18 Anode 1 19 Bolt 16 M6 25 mm 20 Exhaust outer cover 1 21 Gasket 1 22 Exhaust inner cover 1 23 Gasket 1 24 Hose 1 Not reusable Not reusable ...

Page 81: ... block Checking the cylinder head 1 Eliminate carbon deposits from the com bustion chambers and check for deterio ration or corrosion 2 Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in four directions as shown Replace if above specification Removing the exhaust cover 1 Remove the exhaust cover bolts in the sequence shown Checking the exhaust cover 1 Check the exhaust...

Page 82: ...shaft assembly 1 2 Cylinder Block 1 3 Anode 1 4 Bolt 1 M6 16 mm 5 Oil seal 2 6 Oil seal 1 7 O ring 1 8 O ring 1 9 Oil seal housing 1 10 Circlip 1 11 Crankcase 1 12 Bolt 10 M10 55 mm 13 Bolt 4 M8 35 mm 14 Bracket 1 15 Bracket 1 16 Bolt 1 M8 35 mm 17 Engine hanger 1 Not reusable Not reusable Not reusable Not reusable Crankcase ...

Page 83: ...r 4 3 Roller bearing 2 4 Connecting rod 2 5 Needle bearing 56 6 Circlip 4 7 Piston 2 8 Piston pin 2 9 Piston ring set 2 10 Crank pin 2 11 Crank 4 1 12 Ball bearing 1 13 Labyrinth seal 1 14 Roller bearing assembly 1 15 Crank 2 1 16 Crank 1 1 17 Ball bearing 1 Not reusable Not reusable Not reusable ...

Page 84: ...e the cylinder bore D1 D6 at measuring points a b and c and in direction d D1 D3 D5 which is parallel to the crankshaft and direction e D2 D4 D6 which is at a right angle to the crankshaft a 10 0 mm 0 39 in from the cylinder head top surface b 5 0 mm 0 20 in above the exhaust port upper edge c 5 0 mm 0 20 in below the scavenging port lower edge 6F650350 6F650360 6F650355 6F650356 POWR 5 27 6H95G11...

Page 85: ...ecifi cation 3 Calculate the out of round limit Replace or rebore the cylinder block if above specification Disassembling the oil seal housing 1 Remove the O ring and oil seals Checking the oil seal housing 1 Check the oil seal housing for cracks damage or corrosion Replace if neces sary Assembling the oil seal housing 1 Apply grease to new oil seals then install them into the oil seal housing 6F6...

Page 86: ...tion 2 Level the piston rings 1 in a cylinder with a piston crown 3 Check the piston ring end gap c at the specified measuring point Replace if out of specification T B T 6B450460 B a b Piston outside diameter 77 940 77 965 mm 3 0685 3 0695 in Measuring point a 10 0 mm 0 39 in up from the bottom of the piston skirt Oversize piston diameter 1st 78 190 78 215 mm 3 0783 3 0793 in 2nd 78 440 78 465 mm...

Page 87: ...internal anodes 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 grease or the anodes other wise they will not be able to prevent gal vanic corrosion effectively Disassembling the crankshaft 1 Remove the upper and lower bearings Piston ring side clearance Top ring 0 02 0 06 mm 0 0008 0 0024 in 2nd piston r...

Page 88: ...Pressure pin C 4 90890 02403 2 Insert the plate C 1 between crank 1 2 and crank 2 3 Place pressure pin C 4 in the end of the crank pin 5 NOTE Remove the bearing before starting this pro cedures 3 Remove the crank pin by applying pres sure to pressure pin C 4 with a press cC 9 Apply pressure to pressure pin C slowly 9 Hold pressure pin C in line with the press screw spindle NOTE 9 When forcing out ...

Page 89: ...line 9 Do not reuse bearings always replace them with new ones 1 Insert spacer C 1 into the crankpin hole of crank 2 or crank 4 2 Apply engine oil to the crankpin and insert it into the crankpin hole by tapping it with a copper hammer and then install the crankpin using a press cC 9 Take care so that the crank pin is set squarely into the crank web 9 Do not apply force in excess of 5 tons NOTE Fol...

Page 90: ...ool 7 Mount the washers roller bearing and connecting rod on the crankpin NOTE 9 Take care so that spacer C 1 does not fall out of the crank turn the crank over so that the crankpin is on top and then insert the crank into the special service tool 9 The model number a on the connecting rod should face up 6F650540 E 1 a 6F650530 1 1 Bushing 9 D30 3 90890 02363 Body4 90890 02352 Flange5 90890 02351 ...

Page 91: ...itted to crank 2 or crank 4 and place the pressure plate in the body NOTE Apply engine oil to the crankpin 11 Insert the press body 9 and install crank 1 or crank 3 onto the crankpin using a press cC Do not apply force in excess of 5 tons 12 Measure the width b of the assembled crankshaft using calipers Measurements should be made at positions c to g 6B450710 9 6B450720 b c d e g f 6B450700 Bushin...

Page 92: ...and install the labyrinth ring on crank 3 before connecting crankshaft assemblies 3 and 4 16 Insert plate C q between crank 3 and crank 4 then place them onto the crank shaft assemblies 1 and 2 NOTE Align the alignment marks i on cranks 2 and 3 17 Place the press body 9 on plate C and install the crank 2 into crank 3 using a press cC Do not apply force in excess of 7 tons 6F650560 0 q w 3 6F650570...

Page 93: ...sure C 1 and a press NOTE 9 Install the upper bearing so that the manu facture identification mark a faces the fly wheel magnet side 9 Install the lower bearing so that the dowel b faces the flywheel magnet side 2 Slowly turn the crankshaft and connect ing rods If it does not turn smoothly dis assemble the crankshaft and adjust or replace any parts as necessary 6B450800 6B450780 1 a b 6B450790 c c...

Page 94: ...all end bearing installer 7 to install the needle bearings 9 Make sure that the up mark on the piston crown faces the flywheel magnet side Assembling the power unit 1 Install the oil seal housing to the crank shaft assembly 2 Install the crankshaft assembly into the cylinder block NOTE 9 Apply engine oil to the pistons piston rings and bearings before installation 9 Align the dowels of the bearing...

Page 95: ...o the specified torques in two stages and in the sequence shown NOTE Apply LOCTITE 572 to the exhaust cover bolts before installation 6 Install a new cylinder head gasket the cylinder head thermoswitch a new cylin der head cover gasket and cylinder head cover and then tighten the cylinder head bolts to the specified torques in two stages and in the sequence shown 7 Install the cylinder head cover ...

Page 96: ...omponents to the power unit Installing the power unit 1 Clean the power unit mating surface and install the dowels 1 and a new gasket 2 2 Install the power unit 3 and then tighten the power unit mounting bolts 4 to the specified torque 3 Install the apron 5 NOTE Apply LOCTITE 572 to the power unit mount ing bolts before installation 4 Connect the fuel hose and pilot water hose 5 Connect the engine...

Page 97: ... Install the starter pulley 9 Connect the remote control cables remote control model or the throttle cables tiller handle model and then adjust their length For adjustment proce dures see Chapter 3 10 Install the manual starter and start in gear protection cable 6 and then adjust it length For adjustment procedures see Chapter 3 11 Connect the battery leads W 12 Install all removed parts 6H950710 ...

Page 98: ...ng the propeller shaft housing 6 15 Drive shaft and lower case 6 16 Removing the drive shaft 6 17 Disassembling the lower case 6 17 Checking the pinion gear 6 17 Checking the bearings 6 17 Checking the drive shaft 6 17 Checking the lower case and lower case cap 6 18 Assembling the lower case 6 18 Installing the drive shaft 6 19 Installing the propeller shaft housing 6 19 Installing the water pump ...

Page 99: ... the oil seal housing 6 38 Disassembling the lower case 6 39 Checking the pinion and forward gear 6 39 Checking the bearings 6 39 Checking the drive shaft 6 39 Checking the lower case 6 39 Assembling the oil seal housing 6 40 Assembling the lower case 6 40 Assembling the forward gear 6 41 Assembling the drive shaft 6 41 Installing the drive shaft 6 41 Installing the oil seal housing 6 41 Installin...

Page 100: ...late 90890 06501 Bearing puller assembly 90890 06535 Drive shaft holder 3 90890 06517 Bearing outer race puller assembly 90890 06523 Bearing Separator 90890 06534 Ring nut wrench extension 90890 06513 Bearing housing puller claw M 90890 06503 Center bolt 90890 06504 Ring nut wrench 90890 06510 ...

Page 101: ...06608 90890 06613 90890 06616 90890 06653 Needle bearing attachment 90890 06614 Bearing outer race attachment 90890 06622 Ball bearing attachment 90890 06634 90890 06637 Stopper guide stand 90890 06538 Driver rod SL 90890 06602 Bearing depth plate 90890 06603 Driver rod SS 90890 06604 Driver rod LL 90890 06605 ...

Page 102: ...gauge plate B 90890 06712 Pinion nut holder New 90890 06715 Current 90890 06505 Magnet base B 90890 06844 Bearing inner race attachment 90890 06639 90890 06640 90890 06641 90890 06644 Ball bearing attachment 90890 06631 Driver rod L3 90890 06652 Shimming plate 90890 06701 Pinion height plate 90890 06703 ...

Page 103: ...6H95G11 6 4 9 8 7 6 5 4 3 2 1 Special service tools Backlash indicator 90890 06706 ...

Page 104: ...6 ft lb No Part name Q ty Remarks 1 Lower unit 1 2 Check screw 1 3 Gasket 3 4 Drain screw 1 5 Screw 1 6 Dowel 2 7 Bolt 3 M6 16 mm 8 Special washer 3 9 Anode 1 10 Anode 1 11 Propeller 1 12 Shear pin 1 13 Washer 1 14 Propeller nut 1 15 Cotter pin 1 16 Bolt 6 M8 30 mm 17 Screw 1 Not reusable Not reusable ...

Page 105: ...6H95G11 6 6 9 8 7 6 5 4 3 2 1 Lower unit EK40G 6H96050E 21 N m 2 1 kgf m 15 5 ft lb 9 N m 0 9 kgf m 6 6 ft lb No Part name Q ty Remarks 18 Cover 1 19 Screen 1 20 Cap 1 21 Screw 1 ...

Page 106: ... 3 Bolt 1 M6 10 mm 4 Boot 1 5 Water pump housing 1 6 Bolt 2 M8 55 mm 7 Woodruff key 1 8 Insert cartridge 1 9 Impeller 1 10 Seal 1 11 Gasket 1 12 Outer plate cartridge 1 13 Gasket 1 14 Oil seal housing 1 15 Gasket 1 16 Oil seal 2 17 Dowel 3 Not reusable Not reusable Not reusable Not reusable ...

Page 107: ...6H95G11 6 8 9 8 7 6 5 4 3 2 1 Lower unit EK40G 6F66060E 17 No Part name Q ty Remarks 18 Bolt 2 M8 45 mm 19 Screw 1 20 Gasket 1 Not reusable ...

Page 108: ...ning it 9 Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch 9 Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning 3 Loosen the locknut 1 and then remove the adjusting nut 2 4 Loosen the bolts and then remove the lower unit from the upper case Removing the water pump and shift rod 1 Remove the...

Page 109: ...r pump housing for defor mation Replace if necessary 2 Check the impeller and insert cartridge for cracks or wear Replace if necessary 3 Check the Woodruff key 1 and the key way a in the drive shaft for wear Replace if necessary 4 Check the shift rod for cracks or wear Replace if necessary 1 a 6F660050 ...

Page 110: ...emarks 1 Lower case cap 1 2 Bolt 9 M6 25 mm 3 Seal 1 4 Taper roller bearing assembly 1 5 Forward gear shim 6 Forward gear 1 7 Shift plunger 1 8 Dog clutch 1 9 Cross pin 1 10 Spring 1 11 Slider 1 12 Spring 1 13 Propeller shaft 1 14 Washer 1 15 Reverse gear 1 16 Reverse gear shim 17 Ball bearing 1 Not reusable Not reusable Not reusable ...

Page 111: ... 7 6 5 4 3 2 1 Propeller shaft housing 6F66070E 4 N m 0 4 kgf m 3 0 ft lb 8 N m 0 8 kgf m 5 8 ft lb No Part name Q ty Remarks 18 Oil seal 2 19 Propeller shaft housing 1 20 O ring 1 21 Dowel 1 Not reusable Not reusable ...

Page 112: ...lutch 3 spring 4 slider 5 and shift plunger 6 Disassembling the propeller shaft housing 1 Remove the reverse gear 2 Remove the ball bearing cC Do not reuse the bearing always replace it with a new one 3 Remove the oil seals 6F660600 z x c v b n m 1 2 3 6F660610 6F660630 4 5 6 1 2 3 4 5 6 6F660080 Stopper guide plate 1 90890 06501 Stopper guide stand 2 90890 06538 Bearing puller assembly 3 90890 06...

Page 113: ...ase cap for cracks or ware Replace if necessary Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary 2 Measure the propeller shaft runout 3 Check the dog clutch and shift plunger for cracks or wear Replace if necessary Assembling the forward gear 1 Install the original shim s 1 and the taper roller bearing 2 into the forward gear 3 cC Add or remove the sh...

Page 114: ... new ball bearing onto the pro peller shaft housing using a press 3 Install the original shim s 5 onto pro peller shaft housing 6 then install the reverse gear assembly into the propeller shaft housing cC Add or remove the shim s if necessary if replacing the reverse gear propeller shaft housing or lower case 6F660670 3 4 6F660660 5 6 6F660650 1 2 Driver rod L3 1 90890 06652 Needle bearing attachm...

Page 115: ...aft and lower case 6F66080E No Part name Q ty Remarks 1 Drive shaft 1 2 Circlip 1 3 Pinion gear 1 4 Roller bearing assembly 1 5 Pinion gear shim 6 Thrust bearing 1 7 Needle bearing 1 8 Sleeve 1 9 Needle bearing 1 10 Washer 1 11 Oil seal 2 12 Lower case 1 Not reusable ...

Page 116: ... seals and thrust washer 4 Remove the needle bearing Checking the pinion gear 1 Check the teeth of the pinion for cracks or wear Replace if necessary Checking the bearings 1 Check the bearings for pitting or rum bling Replace if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary 2 Measure the drive shaft runout 6F660690 1 1 2 3 6 4 5 6F660700 8 7 6F66...

Page 117: ...aring into the lower case to the specified depth NOTE 9 Install the needle bearing with the manufac ture identification mark c facing up 9 Be careful not to the let the stopper e get out of position when using the driver rod SL 9 Apply gear oil to the inside and outside of the sleeve before installation 6F660750 3 2 1 a 7 6 8 d 6F660740 c e 6F660760 5 4 b Ball bearing attachment 1 90890 06616 Driv...

Page 118: ...llers will not fall off Installing the propeller shaft housing 1 Install the washer 1 and propeller shaft assembly 2 into the propeller shaft housing assembly 3 2 Install the forward gear assembly to the propeller shaft housing assembly 3 Apply grease to new O rings 4 Fit the new seal into the lower case cap NOTE Cut the seal so that it projects out a about 0 8 mm 0 03 in from the lower case cap c...

Page 119: ... shown two stage Installing the water pump and shift rod 1 Install the shift rod assembly 1 NOTE Align the slit on the shift cam 1 with the hole in the lower case Then install the screw 2 as shown 2 Install the dowel 3 a new gasket 4 oil seal housing 5 dowels 6 a new gasket 7 and the outer plate cartridge 8 3 Install the Woodruff key into the drive shaft 6F660806 4 a 6F660805 m n b v c x z 6F66082...

Page 120: ...fied torque 5 Connect the shift rod NOTE Screw the adjusting nut 4 down until it light ly seated and then tighten the locknut LOWR 6 21 6H95G11 Lower unit Lower case mounting bolt 3 21 N m 2 1 kgf m 15 5 ft lb 4 Align the groove in the impeller 9 with the Woodruff key 0 and then install the impeller onto the drive shaft 5 Install the insert cartridge q into the pump housing w and then apply grease...

Page 121: ...ttery and the clip from the engine stop lanyard switch 9 Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning NOTE If the hole in the propeller nut 5 do not align with the cotter pin hole tighten or loosen the nut until they are aligned 7 Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of...

Page 122: ...LOWR 6 23 6H95G11 Lower unit Shimming M T 6F660860 ...

Page 123: ...ion formula 2 Measure the distance M between the special service tool and the pinion as shown 3 Calculate the pinion shim thickness T as shown in the examples below Example If T is 26 06 mm T 26 06 24 50 1 56 4 Select the pinion shim s T as follows Example If T is 1 65 mm then the pinion shim is 1 60 mm If T is 1 56 mm then the pinion shim is 1 55 mm Selecting the forward and reverse gear shims NO...

Page 124: ...unger vertical position from the center of gear teeth 7 Hold the drive shaft and slowly turn the forward gear clockwise and counter clockwise then measure the backlash when the gear stops in each direction 8 Adjust the shim s to specified thickness Add or remove 9 Hold the drive shaft and slowly turn the reverse gear clockwise and counter clockwise then measure the backlash when the gear stops in ...

Page 125: ...ller shaft assembly and tighten the lower case cap to specified torque in two stage 12 Tighten the bolts in sequence as shown two stage and then install the water pump assembly 6F660805 m n b v c x z Lower case cap bolt 1st 4 N m 0 4 kgf m 3 0 ft lb 2nd 8 N m 0 8 kgf m 5 8 ft lb 6F660895 6F660930 Available shim thicknesses 1 80 1 90 2 00 2 10 2 20 2 30 2 40 and 2 50 mm ...

Page 126: ...5 N m 3 5 kgf m 25 3 ft lb No Part name Q ty Remarks 1 Lower unit 1 2 Check screw 1 3 Gasket 3 4 Drain screw 1 5 Screw 1 6 Dowel 2 7 Bolt 1 M10 30 mm 8 Anode 1 9 Washer 1 10 Propeller 1 11 Washer 1 12 Washer 1 13 Propeller nut 1 14 Cotter pin 1 15 Gasket 1 16 Cooling water inlet cover 1 17 Screw 1 Not reusable Not reusable Not reusable ...

Page 127: ...3 2 1 Lower unit EK40J 6H96010E 4 N m 0 4 kgf m 3 0 ft lb 21 N m 2 1 kgf m 15 5 ft lb 9 N m 0 9 kgf m 6 6 ft lb 35 N m 3 5 kgf m 25 3 ft lb No Part name Q ty Remarks 18 Bolt 6 M8 30 mm 19 Water inlet cover 2 20 Screw 1 21 Nut 1 ...

Page 128: ... 1 M6 18 mm 4 Boot 1 5 Water pump housing 1 6 Bolt 2 M8 55 mm 7 Woodruff key 1 8 Insert cartridge 1 9 Impeller 1 10 Seal 1 11 Gasket 1 12 Outer plate cartridge 1 13 Gasket 1 14 Oil seal housing 1 15 Gasket 1 16 Oil seal 2 17 O ring 1 Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 129: ...6H95G11 6 30 9 8 7 6 5 4 3 2 1 Lower unit EK40J 6F66020E No Part name Q ty Remarks 18 Dowel 2 19 Bolt 2 M8 45 mm 20 Screw 1 21 Gasket 1 Not reusable ...

Page 130: ...not hold the propeller with your hands when loosening or tightening it 9 Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch 9 Put a block of wood between the anti cavitation plate and propeller to keep the propeller from turning 3 Mark the trim tab 1 at the area shown and then remove it 4 Loosen the locknut 2 and then remove the adjusting nut ...

Page 131: ...remove the screw 2 Checking the water pump and shift rod 1 Check the water pump housing for defor mation Replace if necessary 2 Check the impeller and insert cartridge for cracks or wear Replace if necessary 3 Check the Woodruff key 1 and the key way a in the drive shaft for wear Replace if necessary 4 Check the shift rod for cracks or wear Replace if necessary 1 a 6F660050 6F660350 1 2 1 ...

Page 132: ...s 1 Shift plunger 1 2 Dog clutch 1 3 Cross pin 1 4 Spring 1 5 Slider 1 6 Spring 1 7 Propeller shaft 1 8 Reverse gear 1 9 Reverse gear shim 10 Washer 1 11 O ring 1 12 Ball bearing 1 13 Propeller shaft housing 1 14 Needle bearing 1 15 Oil seal 2 16 Lock washer 1 17 Ring nut 1 Not reusable Not reusable Not reusable ...

Page 133: ...ing the propeller shaft assembly 1 Remove the spring 1 then the cross pin 2 dog clutch 3 spring 4 slider 5 and shift plunger 6 Disassembling the propeller shaft housing 1 Remove the reverse gear 6F600060 1 1 2 3 4 5 6 6F660080 6F660070 2 3 6B460580 5 4 6 Ring nut wrench 2 90890 06510 Ring nut wrench extension 3 90890 06513 Stopper guide plate 4 90890 06501 Bearing housing puller crow M 5 90890 065...

Page 134: ...for pitting or rum bling Replace if necessary Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary 2 Measure the propeller shaft runout 3 Check the dog clutch and shift plunger for cracks or wear Replace if necessary Assembling the propeller shaft assembly 1 Install the dog clutch as shown NOTE Install the dog clutch 1 with the F mark a facing toward the ...

Page 135: ... Install an oil seal halfway into the propeller shaft housing then the other oil seal 3 Install the washer 6 and new ball bear ing 7 onto the reverse gear 8 using a press 4 Install the reverse gear assembly into the propeller shaft housing using a press 6F660150 3 2 1 b a 6F660170 9 8 7 6 0 6F660180 6F660160 4 5 Driver rod SS 1 90890 06604 Needle bearing attachment 2 90890 06614 Bearing depth plat...

Page 136: ...No Part name Q ty Remarks 1 Drive shaft 1 2 Forward gear 1 3 Taper roller bearing assembly 1 4 Forward gear shim 5 Nut 1 6 Pinion gear 1 7 Washer 1 8 Lower case 1 9 Needle bearing 1 10 Sleeve 1 11 Pinion gear shim 12 Taper roller bearing assembly 1 13 Seal 1 14 Guide 1 Not reusable Not reusable ...

Page 137: ...he drive shaft bearing do not damage the drive shaft collar 4 9 Do not reuse the bearing always replace it with a new one Disassembling the forward gear 1 Remove the taper roller bearing from the forward gear using a press cC Do not reuse the bearing always replace it with a new one Disassembling the oil seal housing 1 Remove the oil seals using a flat head screwdriver 6F660190 1 2 6F660210 1 6F66...

Page 138: ... if necessary Checking the bearings 1 Check the bearings for pitting or rum bling Replace if necessary Checking the drive shaft 1 Check the drive shaft for bends or wear Replace if necessary 2 Measure the drive shaft runout Checking the lower case 1 Check the skeg and torpedo for cracks or damage Replace the lower case if nec essary 6F660230 1 a 6 5 5 6 4 2 3 6F660260 Bearing outer race puller ass...

Page 139: ...m s if necessary if replacing the pinion or lower case NOTE 9 Apply gear oil to the inside and outside of the sleeve before installation 9 Install the sleeve with the projection d fac ing forward 3 Install the original shim s and taper roller bearing outer race cC Add or remove shim s if necessary if replacing the forward gear or lower case 2 1 6F660270 G 6B460350 7 6 5 4 5 4 d 6F660290 Ball beari...

Page 140: ...a new O ring 1 new gasket 2 oil seal housing 3 and the dowels 4 Installing the propeller shaft housing 1 Install the original shim s 1 washer 2 and propeller shaft assembly 3 into the propeller shaft housing assembly 4 2 Apply grease to new O rings cC Add or remove shim s if necessary if replacing the reverse gear propeller shaft housing or lower case 6B460310 1 6F660330 3 4 1 2 6F660320 4 3 2 1 B...

Page 141: ...into the ring nut slot and the other towards the gear side Installing the water pump and shift rod 1 Install the shift rod assembly 1 NOTE Align the slit on the shift cam 1 with the hole in the lower case Then install the screw 2 as shown 2 Install a new gasket 3 the outer plate cartridge 4 6F660340 6 7 5 Ring nut 90 N m 9 0 kgf m 65 ft lb 6F660350 1 2 1 Ring nut wrench 8 90890 06510 Ring nut wren...

Page 142: ...nd then apply grease to the inside of the insert cartridge NOTE Align the insert cartridge projection a with the hole b in the pump housing 6 Install the seal 9 a new gasket 0 and pump housing assembly q into the lower case tighten the bolts w NOTE 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 ...

Page 143: ...e locknut 7 Install the propeller and propeller nut and then tighten the nut finger tight Place a block of wood between the anti cavitation plate and propeller to keep the propeller from turning and then tighten 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 leads from the battery and the clip from t...

Page 144: ...e drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible 9 Install the check screw and quickly install the drain screw 6F630210 Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Oil quantity 315 cm3 10 65 US oz 11 11 Imp oz ...

Page 145: ...6H95G11 6 46 9 8 7 6 5 4 3 2 1 Drive shaft and lower case Shimming Shimming T3 M3 M2 6F660440 T2 T1 M1 ƒ π ...

Page 146: ...uts another 1 4 of a turn after they contact the plate 2 2 Install the pinion and pinion nut and then tighten the nut to the specified torque 3 Measure the distance M3 between the special service tool and the pinion as shown 4 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 ...

Page 147: ...measurement s and the calcula tion formula 9 Measure the bearing outer race at three points to find the height average 2 Calculate the forward gear shim thick ness T1 as shown in the examples below NOTE F is the deviation of the lower case 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 i...

Page 148: ...cula tion formula 9 Measure the bearing housing at three points to find the height average 3 Calculate the reverse gear shim thick ness T2 as shown in the examples below NOTE R is the deviation of the lower case dimen sion from standard The R mark a is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the R mark is unreadable assume that R is zero and check the backlas...

Page 149: ...n the center bolt while turning the drive shaft until the drive shaft can no longer be turned 4 Install the backlash indicator onto the drive shaft 16 0 mm 0 63 in in diame ter then the dial gauge onto the lower unit NOTE Install the dial gauge so that the plunger a contacts the mark b on the backlash indica tor Calculation formula Reverse gear shim thickness T2 M2 26 90 R 100 Calculated numeral R...

Page 150: ...se and measure the back lash when the drive shaft stops in each direction 10 Add or remove the shim s if out of spec ification M Measurement 11 Remove the special service tools and then install the water pump assembly Forward gear backlash 0 19 0 47 mm 0 0075 0 0185 in Reverse gear backlash 0 76 1 04 mm 0 0299 0 0409 in Forward gear Shim thickness backlash Less than To be decreased by 0 19 mm 0 00...

Page 151: ...ase pivot shaft 7 7 Disassembling the upper case 7 11 Checking the upper case 7 11 Assembling the upper case 7 12 Removing the pivot shaft 7 13 Clamp brackets swivel bracket 7 14 Removing the clamp brackets 7 18 Disassembling the swivel bracket 7 18 Assembling the swivel bracket 7 18 Installing the clamp brackets 7 18 Installing the pivot shaft 7 19 ...

Page 152: ...BRKT 7 1 6H95G11 Bracket unit Special service tools Needle bearing attachment 90890 06613 Driver rod L3 90890 06652 ...

Page 153: ...Throttle cable 2 2 Self locking nut 1 3 Bolt 1 M12 68 mm 4 Washer 1 5 Collar 1 6 Plastic washer 2 7 Metal washer 2 8 Wave washer 1 9 Tiller handle bracket 1 10 Throttle friction adjuster 1 11 Throttle grip 1 12 Screw 1 13 Washer 2 14 Spring 1 15 Bushing 1 16 Throttle shaft 1 17 Friction piece 1 Tiller handle MH ...

Page 154: ...f m 2 2 ft lb No Part name Q ty Remarks 18 Bolt 2 M6 20 mm 19 Stay 1 20 Nut 1 21 Washer 1 22 Bushing 1 23 Pinion 1 24 Bolt 1 M5 10 mm 25 Bolt 1 M5 10 mm 26 Rubber grip 1 27 Pinion 1 28 Pin 1 29 Cotter pin 1 30 Nut 1 31 Stay 1 32 Wire clip 1 Not reusable ...

Page 155: ... to the pinion 3 NOTE Route the throttle cable as shown and clamp the cable protector 4 2 Install the throttle shaft 5 to the tiller handle bracket NOTE When install the throttle shaft align the marks on the pinion a with tiller handle bracket b and throttle shaft c with stay d 1 2 4 3 6F670010 6F670020 a b c d 5 ...

Page 156: ...2 M6 25 mm 2 Cotter pin 1 3 Shift lever 1 4 Bracket 1 5 Shift rod lever 1 1 6 Shift control lever 1 7 Shift rod lever 2 1 8 Bushing 1 9 Spring 2 10 Screw 2 11 Shift rod 1 12 Bolt 1 M6 10 mm 13 Lever 1 14 Bushing 1 15 Wave washer 1 16 Cowling lock lever 1 17 Bottom cowling 1 Not reusable Bottom cowling ...

Page 157: ... W No Part name Q ty Remarks 18 Rubber seal 1 19 Collar 4 20 Choke knob 1 21 Grommet 1 22 Retaining plate 1 23 Bolt 2 M6 20 mm 24 Engine stop lanyard switch 1 MH model 25 Grommet 4 26 Bolt 4 M6 30 mm 27 Locknut 1 28 Adjusting nut 1 29 Pin 1 30 Shaft 1 31 Boot 1 32 Nut 4 33 Hose 1 ...

Page 158: ...040E No Part name Q ty Remarks 1 Bolt 3 M6 25 mm 2 Exhaust guide 1 3 Gasket 1 4 Bolt 4 M6 20 mm 5 Exhaust manifold 1 6 Gasket 1 7 Seal 1 8 Rubber seal 2 9 Pipe 1 Not reusable Not reusable Not reusable Not reusable Upper case pivot shaft ...

Page 159: ...lb 55 N m 5 5 kgf m 40 ft lb No Part name Q ty Remarks 1 Cover 2 2 Lower mount 2 3 Bolt 2 M12 130 mm 4 Washer 4 5 Bolt 4 M6 25 mm 6 Cover 1 7 Nut 2 8 Nut 2 9 Washer 4 10 Bracket 2 11 Upper mount 2 12 Bolt 4 M8 50 mm 13 Bolt 2 M6 25 mm 14 Bracket 1 15 Damper 1 16 Nut 2 17 Bolt 4 M6 25 mm ...

Page 160: ... 2 8 kgf m 20 ft lb 55 N m 5 5 kgf m 40 ft lb No Part name Q ty Remarks 18 Protector 1 19 Upper case assembly 1 20 Circlip 1 21 Bushing 1 EK40J L transom model 22 Bolt 2 M8 130 mm 23 Washer 2 24 Washer 2 25 Seal 2 26 Lock tie 2 27 Seal 2 28 Nut 4 ...

Page 161: ...17 7 ft lb No Part name Q ty Remarks 1 Bolt 2 M8 30 mm 2 Bolt 2 M8 35 mm 3 Steering bracket 1 4 Dowel 2 5 Pivot shaft 1 6 Washer 1 7 Bushing 1 8 Straight key 1 9 Spring 1 10 Rubber seal 1 11 Bolt 1 M8 25 mm 12 Bushing 1 13 Oil seal 1 14 Washer 1 15 Mount housing 1 16 Clamp 1 17 Bolt 4 M8 45 mm Not reusable ...

Page 162: ...ctor 6 from the upper case 4 Remove the circlip 7 and the drive shaft bushing 8 from the upper case EK40J L transom model Checking the upper case 1 Check the drive shaft bushing for wear or cracks Replace if necessary 2 Check the cooling water pipe for defor mation or corrosion Replace if neces sary 3 Check the exhaust guide and exhaust manifold for damage or corrosion Replace if necessary 6F67003...

Page 163: ... the cooling water pipe 4 the exhaust manifold 5 and the bolts and then tighten the bolts 3 Install the protector and then install the muffler assembly into the uppercase 4 Install the upper mount bolts and nuts into the upper case 6F670100 4 5 3 6F670080 6F670090 6 6 Needle bearing attachment 1 90890 06613 Driver rod L3 2 90890 06652 6F670070 1 2 A Upper mount nuts 6 28 N m 2 8 kgf m 20 ft lb ...

Page 164: ...gasket and the muffler assembly into the upper case Removing the pivot shaft 1 Remove the pivot shaft from the swivel bracket by pulling the shaft off the brack et 2 Remove the oil seal 1 and then remove the bushing 2 6F670035 6F670130 2 1 6F670135 ...

Page 165: ...b 24 N m 2 4 kgf m 17 7 ft lb 10 N m 1 0 kgf m 7 2 ft lb No Part name Q ty Remarks 1 Tilt pin 1 2 Nut 2 3 Washer 2 4 Bolt 1 M8 230 mm 5 Tube 1 6 Washer 1 7 Clamp handle 2 8 Pin 2 9 Clamp screw 2 10 Bolt 2 M6 12 mm 11 Clamp pad 2 12 Clamp bracket 1 13 Clamp bracket 1 14 Washer 2 15 Nut 2 16 Through tube 1 17 Cap 2 Clamp brackets swivel bracket ...

Page 166: ...f m 33 ft lb 24 N m 2 4 kgf m 17 7 ft lb 10 N m 1 0 kgf m 7 2 ft lb No Part name Q ty Remarks 18 Washer 1 19 Wave washer 2 20 Pin 2 21 Circlip 2 22 Tilt stopper plate starboard side 1 23 Grease nipple 4 24 Bushing 2 25 Plate 1 26 Tilt stopper plate port side 1 27 Swivel bracket 1 ...

Page 167: ...o Part name Q ty Remarks 1 Tilt lock lever 1 2 Stopper plate starboard side 1 3 Spring 1 4 Bolt 1 M5 10 mm 5 Circlip 3 6 Tilt lever 1 7 Tilt lock rod 1 8 Tilt lock plate 1 9 Spring 2 10 Cotter pin 3 11 Pin 1 12 Pin 1 13 Tilt lock arm 1 14 Tilt lock plate 1 15 Collar 1 16 Spring 1 17 Stopper shaft 1 ...

Page 168: ...BRKT 7 17 6H95G11 Bracket unit 6F67060E 4 N m 0 4 kgf m 3 0 ft lb No Part name Q ty Remarks 18 Pin 1 19 Washer 1 20 Washer 1 21 Stopper plate port side 1 22 Cover 1 ...

Page 169: ...ck plates tilt lock arm and springs Assembling the swivel bracket 1 Install the tilt lock arm 1 tilt lock plates 2 pin 2 3 pin 1 4 collar 5 springs 6 to the swivel bracket 7 2 Install the plastic washer 8 tilt stopper plate 9 and then install the tilt lock lever 0 partially into the swivel bracket 3 Install the circlip q spring w and collar e then install the circlip r 4 Install the tilt spring t ...

Page 170: ...lace the swivel bracket 4 in an upright position and then install the pivot shaft 5 onto the swivel bracket 3 Install the bushing 6 a new oil seal 7 and the washer 8 onto the swivel brack et 4 Install the dowels 9 steering bracket 0 lower mount clamp q and lower mount case w onto the swivel bracket Then tighten the bolt e to specified torque 5 Apply water resistant grease to the grease nipples NOT...

Page 171: ...cking the ignition coil 8 8 Checking the spark plug caps 8 8 Checking the CDI unit 8 9 Checking the pulser coils 8 9 Checking the charge coil 8 9 Checking the thermoswitch 8 10 Checking the engine stop lanyard switch MH 8 10 Starting system 8 11 Checking the fuse W 8 11 Checking the starter relay W 8 11 Starter motor W 8 12 Removing the starter motor pinion 8 13 Checking the starter motor pinion 8...

Page 172: ...8 1 6H95G11 Electrical systems Special service tools Ignition tester 90890 06754 Digital circuit tester 90890 03174 Peak voltage adaptor B 90890 03172 Test harness 4 pins New 90890 06871 Current 90890 06771 ...

Page 173: ...voltage do not touch any of the connections of the digital circuit tester leads NOTE 9 Use the peak voltage adaptor with the digi tal circuit tester 9 When measuring the peak voltage set the selector on the digital circuit tester to the DC voltage mode 9 Connect the positive pin on the peak volt age adaptor to the positive terminal of the digital circuit tester Measuring low resistance When measur...

Page 174: ...Electrical systems Electrical components Top view 6H980010 1 2 3 4 5 6 7 MH 1 CDI unit 2 Starter motor W 3 Starter relay W 4 Spark plug 5 Thermoswitch 6 Engine stop lanyard switch WH 7 Engine stop button MH if equipped ...

Page 175: ...6H95G11 8 4 9 8 7 6 5 4 3 2 1 Electrical components Starboard view MH 6F680030 3 2 1 1 1 Spark plug 2 Ignition coil 3 CDI unit ...

Page 176: ...ELEC 8 5 6H95G11 Electrical systems Starboard view W 6F680040 5 2 1 1 3 4 6 7 1 Spark plug 2 Ignition coil 3 Starter relay 4 Starter motor 5 CDI unit 6 Rectifier 7 Fuse ...

Page 177: ... Br Br W B W B W R W R 6F68010M B B P L W Br B W W B W R A B 1 3 4 5 6 7 8 8 2 A B Wiring diagram MH 1 Thermoswitch 2 CDI unit 3 Lighting coil 4 Charge coil 5 Pulser coil 6 Engine stop lanyard switch 7 Ignition coil 8 Spark plug B Black Br Brown G Green L Blue O Orange P Pink W White B W Black White W B White Black W R White Red ...

Page 178: ...Br W B W B W R W R B B P L W Br B W B O W B W R 6H98030M A B 1 2 3 4 5 6 7 0 q w w 8 9 A B Wiring diagram W 1 Thermoswitch 2 Rectifier 3 CDI unit 4 Lighting coil 5 Charge coil 6 Pulser coil 7 Battery 8 Starter relay 9 Starter motor 0 Fuse q Ignition coil w Spark plug B Black Br Brown G Green L Blue O Orange P Pink W White Y Yellow B W Black White W B White Black W R White Red ...

Page 179: ... plug caps 9 Keep flammable gas or liquids away since this test can produce sparks Checking the ignition coil 1 Remove the spark plug cap from the spark plug 2 Disconnect the ignition coil connector 3 Measure the ignition coil resistance Replace if out of specification Checking the spark plug caps 1 Check the spark plug caps for cracks or damage Replace if necessary 2 Remove the spark plug cap 1 f...

Page 180: ...e pulser coil 3 Measure the pulser coil output peak volt age Replace the pulser coil if below specification O B O B 6F680080 L Br W B W R 6F680090 Digital circuit tester 90890 3174 Peak voltage adaptor B 90890 03172 Digital circuit tester 90890 3174 Peak voltage adaptor B 90890 03172 Test harness 4 pins New 90890 06871 Current 90890 06771 CDI unit output peak voltage Orange O ground B r min Loaded...

Page 181: ...1 Place the thermoswitch in a container of water and slowly heat the water 2 Check the switch for continuity at the specified temperatures Replace if out of specification a Temperature b Time c No continuity d Continuity Thermoswitch continuity temperature Pink P Black B e 84 90 C 183 194 F f 60 74 C 140 165 F 6B480160 Switch position Lead color White W Black B Clip removed a Clip installed b Engi...

Page 182: ... the starter relay terminals 2 Connect the positive battery terminal to the brown Br lead 3 Connect the negative battery terminal to the black B lead 4 Check for continuity between the starter relay terminals Replace if there is no continuity 5 Check that there is no continuity between the starter relay terminals after discon necting a battery terminal from the brown or black lead Replace if there...

Page 183: ...0mm 0 15mm 2 0mm 0 25mm 0 25mm No Part name Q ty Remarks 1 Clip 1 2 Pinion stopper 1 3 Spring 1 4 Pinion assembly 1 5 Bolt 2 6 Housing 1 7 Washer set 1 8 O ring 1 9 Armature assembly 1 10 Bracket 1 11 Brush holder 1 12 Brush 2 13 Yoke assembly 1 Not reusable Starter motor W ...

Page 184: ...if necessary NOTE 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 3 Measure the commutator undercut b Replace the armature if bel...

Page 185: ...ystem Checking the rectifier W 1 Measure the rectifier output peak volt age If below specification measure the lighting coil output peak voltage Replace the rectifier if the output peak voltage of the lighting coil is above specification NOTE After starting the engine disconnect the out put lead red lead 1 of the rectifier when measuring the output peak voltage a 6F680200 Brush length limit a 9 0 ...

Page 186: ...174 Peak voltage adaptor B 90890 03172 Digital circuit tester 90890 3174 Peak voltage adaptor B 90890 03172 Rectifier output peak voltage Red R Black B r min Unloaded 1 500 3 500 DC V 13 13 G G G G 6F680245 Lighting coil output peak voltage Green G Green G r min Unloaded Cranking 1 500 3 500 DC V 6 0 17 0 38 0 Lighting coil resistance reference data Green G Green G 0 32 0 39 Ω at 20 C 68 F ...

Page 187: ...1 9 8 7 6 5 4 3 2 1 TRBL SHTG TRBL SHTG Troubleshooting Power unit 9 1 Ignition system 9 1 Fuel system 9 3 Compression pressure 9 4 Lower unit 9 6 Electrical system 9 7 Starting system 9 7 Charging system 9 8 ...

Page 188: ...h and or engine stop button for continuity with clip installed Check the condition of the spark plugs Check the ignition spark using the spark gap tester Replace the engine stop lanyard switch and or engine stop button Is there correct continued on following page Yes Yes No Clean and replace as required No Check the spark plug wires or caps for deterioration and damage No Yes Are they in good cond...

Page 189: ...ection of the leads from CDI unit Yes Replace the charge coil No Replace the pulser coil No Check the pulser coil output peak voltage No Yes Yes Does the out put peak voltage exceed specifi cation values Does the out put peak voltage exceed specifi cation values Does the out put peak voltage exceed specifi cation values Check the CDI unit output peak voltage Ignition system troubles are clear No D...

Page 190: ...carburetor float chamber Yes Correct or replace the faulty parts Yes Replace the fuel pump No Are there any kinks or fuel leakage Check the fuel pump for leakage or internal damage No Is there any leakage or inter nal damage Check the operation of the carburetor Check the compression pressure Yes Does the carburetor set ting and throttle link operating correctly No Is there water or residue Disass...

Page 191: ...rk plug hole Check the piston piston rings and cylinder bore for wear or damage Correct or replace if worn or damaged Check the cylinder head gasket and cylinder head for wear or damage Replace if worn or damaged Does the pressure exceed the specification values Yes Check other component again Does the compression pressure increase Yes No NOTE While restoring a damaged part it is also necessary to...

Page 192: ...mpressed air clean the pilot screw needle valve main and pilot jets and main nozzle Replace any damaged parts Is the carburetor operat ing correctly Are they operat ing correctly Check the pilot screw Yes Is the pilot screw setting correct Disassemble the carburetor and check the internal parts Check the throttle valve for smooth operation No Are the fuel or air passages clogged Yes Correct or rep...

Page 193: ...ion Yes No No Check the shift lever shaft Connect correctly or replace the shift rod as necessary No Replace the spring and shift plunger as necessary Is it connected properly and in good condition Is it operating correctly Disassemble the lower case and check the dog clutch operation Yes Is it in good operating condition Check the dog clutch and forward and reverse gears and replace if necessary ...

Page 194: ...onnect or replace the wireharness or lead and replace or tighten the ground lead bolt Is there blown Check the engine start switch for continuity Yes Is there continuity Check the wireharness for connecting condition and battery positive lead terminal ground lead bolt for damage and loosen Yes Yes Is the battery fully charged Are they good condittion continued on following page Check the neutral s...

Page 195: ...rolyte level and gravity are specific condition 9 Be sure the wireharness couplers and connectores are good connection Charging system Check the lighting coil output peak voltage Check the rectifier output peak voltage Replace the battery and then check the all of the electrical equipment on the boat Replace the lighting coil Replace the rectifier No Does the out put peak voltage exceed specifi ca...

Page 196: ... drive shaft 6 17 6 39 Checking the electrical components 8 2 Checking the engine idle speed 3 7 Checking the engine start switch engine stop lanyard switch and engine stop button 1 9 Checking the engine stop lanyard switch MH 8 10 Checking the exhaust cover 5 24 Checking the fuel filters 3 3 Checking the fuel joint 4 15 Checking the fuel joint and fuel hoses fuel joint to carburetor 3 3 Checking ...

Page 197: ... Electrical 2 5 Electrical components 8 3 Electrical system 9 7 F Fire prevention 1 3 Fuel line 4 3 Fuel pump 4 10 Fuel system 3 3 9 3 G General 3 9 General specification 2 1 General torques 2 10 Good working practices 1 4 H Hose routing 4 2 How to use this manual 1 1 I Identification 1 5 Ignition and ignition control system 8 8 Ignition system 9 1 Installing the clamp brackets 7 18 Installing the...

Page 198: ...moving the throttle pulley assembly 5 17 Removing the water pump and shift rod 6 5 6 32 S Safety while working 1 3 Selecting the forward and reverse gear shims 6 24 Selecting the forward gear shims 6 48 Selecting the pinion shims 6 24 6 47 Selecting the reverse gear shims 6 49 Selection 1 6 Self protection 1 3 Serial number 1 5 Shimming 6 23 6 24 6 46 6 47 Special service tools 3 1 4 1 5 1 6 1 7 1...

Page 199: ......

Page 200: ...YAMAHA MOTOR CO LTD Printed in Japan Aug 2004 0 3 1 E Printed on recycled paper ...

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