Yamaha F15B Service Manual Download Page 29 | Manualshive

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6D45F11

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Maintenance interval chart

Use the following chart as a guideline for general maintenance.
Adjust the maintenance intervals according to the operating conditions of the outboard motor.

Special service tools/Maintenance interval chart

Initial

Every

Item

Actions

10 hours

50 hours 100 hours 200 hours

(1 month) (3 months) (6 months)

(1 year)

Anode(s) (external)

Inspection / replacement

1

1

Anode(s) (internal)

Inspection / replacement

1

Cooling water passages

Cleaning

1

1

Cowling clamp

Inspection

1

Fuel filter

Inspection / cleaning

1

1

1

(can be disassembled)
Fuel system

Inspection

1

1

1

Fuel tank (Yamaha

Inspection / cleaning

1

portable tank)
Gear oil

Change

1

1

Greasing points

Greasing

1

Idling speed (carburetor

Inspection / adjustment

1

1

models)
Propeller and cotter pin Inspection / replacement

1

1

Shift link / shift cable

Inspection / adjustment

1

Thermostat Inspection

1

Throttle link / throttle
cable / throttle pick-up

Inspection / adjustment

1

timing
Water pump

Inspection

1

Engine oil

Inspection / change

1

1

Oil filter (cartridge)

Change

1

Spark plug(s)

Cleaning / adjustment /

1

1

replacement

Timing belt

Inspection / replacement

1

1

Valve clearance (OHC)

Inspection / adjustment

1

1

NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushed with clean water
after each use.

NOTE:

When using lead or high-sulfur gasoline, inspecting valve clearance may be required more fre-
quently than every 500 hours.

Every

Item

Actions

500 hours (2.5 years) 1,000 hours (5 years)

Timing belt

Replacement

1

(additional)

6D45F11-03 03.10.9 20:43 Page 3

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Summary of Contents for F15B

Page 1: ...YAMAHA MOTOR CO LTD Printed in Japan Oct 2003 0 4 1 E Printed on recycled paper F15B SERVICE MANUAL 6D4 28197 5F 11 290535 6D4Cover 03 10 9 20 48 Page 1 ...

Page 2: ...tions 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 dea...

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: ... model 1 5 Serial number 1 5 Propeller selection 1 5 Propeller size 1 5 Selection 1 5 Predelivery checks 1 6 Checking the fuel system 1 6 Checking the engine oil level 1 6 Checking the gear oil 1 6 Checking the outboard motor mounting height 1 6 Checking the steering system 1 7 Checking the remote control cables 1 7 Checking the gearshift and throttle operation 1 7 Checking the engine stop lanyard...

Page 6: ...ot 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 In...

Page 7: ... illustration indicate the grade of lubricant and the lubri cation point 7 Apply Yamaha 4 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 indicat...

Page 8: ...ng 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 sho...

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: ...ype propeller mark Selection When the engine speed is at the full throttle operating range 4 500 5 500 r min the ideal propeller for the boat is one that pro vides maximum performance in relation to boat speed and fuel consumption Propeller size in Material 9 1 4 8 J 9 1 4 9 J 9 1 4 9 3 4 J 9 1 4 10 J Aluminum 9 1 4 10 1 2 J 9 1 4 11 J 9 1 4 12 J 6B410030 a b c 1 5 GEN INFO 6D45F11 General informa...

Page 11: ...ller selection Predelivery checks Checking the gear oil 1 Check the gear oil level NOTE The gear oil level should be at the brim of the check hole Checking the outboard motor mounting height 1 Check that the anti cavitation plate is between the bottom of the boat and a maximum of 25 mm 1 in a below it If the mounting height is too high cavitation will occur and propulsion will be reduced Also the ...

Page 12: ...cables 1 Check that the remote control cable prop er position 2 Set the remote control lever to the neu tral position and fully close the throttle lever Adjust if necessary Checking the gearshift and throttle operation 1 Check that the gearshift operates smoothly when the shift lever and or remote control lever is shifted from neu tral into forward or reverse 2 Check that the throttle operates smo...

Page 13: ... from the power unit side to the remote con trol box side 6D410150 6D410160 E G 6D410170 Predelivery checks 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 Perfor...

Page 14: ...ne at 3000 r min or at approxi mately three quarter throttle 3 For the next eight hours of operation c Avoid continuous operation at full throttle for more than five minutes at a time 4 After the first 10 hours Operate the engine normally å Hours After test run 1 Check for water in the gear oil 2 Check for fuel leakage in the cowling 3 After a test run and while the engine is at idle flush the coo...

Page 15: ... 5 4 3 2 1 SPEC Specifications General specifications 2 1 Maintenance specifications 2 3 Power unit 2 3 Lower unit 2 6 Electrical 2 7 Dimensions 2 8 Tightening torques 2 10 Specified torques 2 10 General torques 2 11 ...

Page 16: ...m output kW hp 11 0 15 0 5 000 r min Full throttle operating range r min 4 500 5 500 Maximum fuel consumption L US gal lmp gal hr 5 3 1 4 1 2 5 500 r min Power unit Engine type 4 stroke OHC Twin Total displacement cm3 cu in 323 0 19 71 Bore x stroke mm in 59 0 59 0 2 32 2 32 Compression ratio 9 19 1 Control system Tiller handle Remote control Starting system Manual starter Enrichment system Choke ...

Page 17: ... qt without oil filter replacement L 1 0 1 06 0 88 US qt lmp qt Gear oil type Hypoid gear oil Gear oil grade SAE 90 Gear oil quantity L 0 25 8 45 8 82 US oz lmp oz Bracket unit Trim angle 1 Degree 8 0 12 0 16 0 20 0 Tilt up angle Degree 63 0 Steering angle Degree 45 0 40 0 Drive unit Gear shift positions F N R Gear ratio 2 08 27 13 Reduction gear type Spiral bevel gear Clutch type Dog clutch Prope...

Page 18: ...mm in 14 004 14 015 0 5513 0 5518 Oversize piston diameter 1 st mm in 59 2 2 33 2 nd mm in 59 5 2 34 Piston pins Outside diameter mm in 13 996 14 000 0 5510 0 5512 Piston rings Top ring Dimension B mm in 1 17 1 19 0 0461 0 0469 Dimension T mm in 2 00 2 20 0 0787 0 0866 End gap mm in 0 15 0 30 0 0059 0 0118 Side clearance mm in 0 04 0 08 0 0016 0 0032 Over size 1 st mm in 59 25 2 33 2 nd mm in 59 5...

Page 19: ...1 0904 Exhaust A mm in 27 616 27 716 1 0872 1 0912 Intake and B mm in 23 950 24 050 0 9429 0 9468 exhaust Camshaft journal diameter mm in 34 935 34 955 1 3754 1 3762 Camshaft journal oil clearance mm in 0 050 0 080 0 0020 0 0032 Camshaft run out limit mm in 0 03 0 0012 Rocker arm shafts Outside diameter mm in 12 941 12 951 0 5095 0 5099 Rocker arms Inside diameter mm in 13 000 13 018 0 5118 0 5125...

Page 20: ...Crankshaft journal diameter mm in 34 997 35 009 1 3778 1 3783 Crankpin diameter mm in 30 997 31 009 1 2204 1 2208 Crankpin width mm in 21 000 21 070 0 8268 0 8295 Run out limit mm in 0 05 0 0020 Big end side clearance mm in 0 050 0 220 0 0020 0 0087 Crankcase Crankshaft main journal oil mm in 0 012 0 045 0 0005 0 0018 clearance Upper and lower crankcase main journal bearing thickness A Blue mm in ...

Page 21: ...rse shims mm 0 10 0 20 0 30 0 40 0 50 Item Unit Model F15BMH F15BM Thermostat Opening temperature C F 58 0 62 0 136 40 143 60 Fully open temperature C F 70 0 158 00 Valve open lower limit mm in 3 0 0 12 Carburetor ID mark 6D400 Float height mm in 9 5 10 5 0 37 0 41 Valve seat size mm in 1 4 0 06 Main jet M J 104 Main nozzle M N mm in 2 5 0 10 Pilot jet P J 45 Pilot screw P S turns out 1 2 Idle spe...

Page 22: ...Pulser coil resistance W G B Ω 234 0 348 0 Charge coil output peak voltage Br L 1 Cranking unload V 175 Cranking load V 170 1 500 r min load V 180 3 500 r min load V 180 Charge coil resistance Br L Ω 272 0 408 0 CDI unit output peak voltage O B 1 Cranking load V 155 1 500 r min load V 170 3 500 r min load V 170 Charging system Charging current minimum 3 000 A 5 5 maximum 5 000 A 6 0 Lighting coil ...

Page 23: ...832 5 32 8 374 5 14 8 166 5 6 6 S 440 17 3 L 567 22 3 549 21 6 74 5 2 9 475 18 7 S 718 28 3 L 831 32 7 330 5 13 0 297 11 7 1 526 20 7 34 5 1 4 10 0 4 135 5 3 S 572 22 5 L 641 25 2 S 78 3 1 L 104 5 4 1 355 5 14 0 6D4001M 1 For tiller control model 1 1 574 5 22 7 1 245 5 9 6 1 1 44 1 7 Dimensions Exterior mm in ...

Page 24: ...SPEC 2 9 6D45F11 Specifications 92 5 3 6 2 0 1 103 4 1 70 5 2 8 103 5 4 1 8 3 0 3 8 3 0 3 49 1 9 69 2 7 54 5 2 1 176 6 9 30 1 2 56 2 2 6D4002M 92 5 3 6 70 5 2 8 103 4 1 Clamp bracket mm in ...

Page 25: ...2nd 21 2 1 16 Flywheel nut M16 110 11 81 Oil filter 18 1 8 13 Union bolt 40 4 0 30 Valve adjusting screw locknut 14 1 4 10 Drive sprocket bolt M6 13 1 3 9 6 Driven sprocket nut M28 54 5 4 39 Power unit mount bolt M8 21 2 1 16 Oil pump mount bolt M6 8 0 8 5 8 Relief valve 8 0 8 5 8 Oil pressure switch 18 1 8 13 Spark plug M12 18 1 8 13 Carburetor Intake manifold bolt M6 8 0 8 5 8 Intake silencer bo...

Page 26: ...rew M6 2 5 0 25 1 8 General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided 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 ot...

Page 27: ... 6 Checking the thermostat 3 7 Checking the cooling water passages 3 7 Control system 3 7 Checking the start in gear protection 3 7 Adjusting the throttle cable 3 8 Checking the gearshift operation 3 9 Checking the engine idle speed 3 10 Checking the ignition timing 3 11 Bracket 3 11 Checking the tilt operation 3 11 Lower unit 3 12 Checking the gear oil level 3 12 Replacing the gear oil 3 12 Check...

Page 28: ...CHK ADJ 6D45F11 3 1 Special service tools Periodic checks and adjustments CHK ADJ Digital tachometer 90890 06760 Timing light 90890 03141 Leakage tester 90890 06840 Oil filter wrench 90890 01426 ...

Page 29: ... oil Change 1 1 Greasing points Greasing 1 Idling speed carburetor Inspection adjustment 1 1 models Propeller and cotter pin Inspection replacement 1 1 Shift link shift cable Inspection adjustment 1 Thermostat Inspection 1 Throttle link throttle cable throttle pick up Inspection adjustment 1 timing Water pump Inspection 1 Engine oil Inspection change 1 1 Oil filter cartridge Change 1 Spark plug s ...

Page 30: ...t if necessary NOTE Be sure not to spill any fuel when removing the fuel filter cup Power unit Checking the engine oil 1 Place the outboard in an upright position 2 Remove the engine oil dipstick wipe it clean and then insert it back 3 Remove the dipstick again to check the oil level and the oil for discoloration and its viscosity NOTE 9 Replace the oil if it appears milky or black 9 If the engine...

Page 31: ...spills 4 Install the drain bolt and then tighten it to the specified torque 5 Pour the specified amount of the recom mended engine oil into the oil filler hole 6 Install the oil filler cap and dipstick and then start the engine and warm it up for 5 minutes 7 Turn the engine off and then check the oil level and correct it if necessary 6D430050 2 Drain bolt 27 N m 2 7 kgf m 20 ft lb Recommended engi...

Page 32: ...the cylinder block is aligned CHK ADJ 3 5 6D45F11 Periodic checks and adjustments 3 Install the oil filter and then tighten it to the specified torque Checking the timing belt 1 Remove the manual starter and cover 2 Turn the flywheel magnet clockwise to transfer the slack a of the timing belt from port to starboard and hold the fly wheel magnet 3 Slightly push the timing belt with your fin ger bet...

Page 33: ...e 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 gasket for damage Replace the spark plug if necessary 4 Check the spark plug gap a Adjust if out of specification 5 Install the spark plug tighten it finger tight b then to the specified torque with a sp...

Page 34: ...ace 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 passages Control system Checking the start in gear protection cC Be sure to remove the engine stop lanyard switch clip before checking the start in gear protection 1 Set the shift lever and or remote control lever in the forward or reverse posit...

Page 35: ...te Adjust if necessary 3 Loosen the locknut 1 and adjust the length of the throttle cable pull side 2 with the adjusting nut 3 until the stopper 4 on the pully contact the stopper plate a on the bracket then tighten the lock nut 4 Turn the throttle grip to the fully closed position 5 Loosen the locknut 5 and adjust the length of the throttle cable push side 6 with the adjusting nut 7 until the sto...

Page 36: ... cable joint if necessary 2 Set the gearshift to the neutral position N F R 6D410120 6D430500 For remote control model 1 Check that the throttle cable for smooth operation looseness fraying or damage Replace if necessary 2 Check that the stopper 1 on the pully is contact the stopper plate on the bracket a when the remote control lever is in neutral and the throttle lever is fully closed Adjust the...

Page 37: ...ecking 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 then check the engine idle speed Adjust if out of specification 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 speed turn the throttle stop screw in direction a 9 To decrease the i...

Page 38: ...eration Check the tilt mechanism if necessary 6D430180 a Ignition timing Full retarded B T D C 5 0 3 0 degree Full advanced B T D C 30 0 3 0 degree 6D430195 Checking the ignition timing 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 3 Attach the special service tool to spark plug wire 1 1 6D430150 1 6D4...

Page 39: ...sup port it with the tilt support lever 1 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 then check the gear oil level in the lower case NOTE The gear oil level should be at the brim of the check hole 3 If necessary add sufficient gear oil of the recommended type to the correct level 4 Install the chec...

Page 40: ...stall the drain screw then tighten them to the spec ified torque Checking the lower unit for air leakage cC Do not over pressurize the lower unit oth erwise the oil seals may be damaged 1 Remove the check screw 1 then install the special service tool 2 Apply the specified pressure to check whether the lower unit can hold it for at least 10 seconds 3 If pressure drops below specification check the ...

Page 41: ...f necessary 4 Check the rubber trim for wear deteriora tion or damage Replace if necessary 5 Check the lock mechanism for wear or damage Repair if necessary Lubricating the outboard motor 1 Apply water resistant grease to the areas shown 6D45F11 3 14 9 8 7 6 5 4 3 2 1 NOTE Apply grease to the grease nipple a until it flows from the bushings Lower unit General 6D430010 6D430340 6D430360 6D430370 6D...

Page 42: ...CHK ADJ 6D45F11 Periodic checks and adjustments 6B430300 2 Apply corrosion resistant grease to the area shown 3 15 ...

Page 43: ...uel filter 4 4 Carburetor 4 5 Disassembling the carburetor 4 8 Checking the carburetor 4 8 Assembling the carburetor 4 9 Adjusting the throttle link rod 4 10 Adjusting the pilot screw 4 10 Fuel pump 4 11 Checking the fuel pump 4 12 Disassembling the fuel pump 4 12 Checking the diaphragm and valves 4 13 Assembling the fuel pump 4 13 FUEL ...

Page 44: ...FUEL 4 1 6D45F11 Fuel system Special service tools Vacuum pressure pump gauge set 90890 06756 Digital caliper 90890 06704 Digital tachometer 90890 06760 ...

Page 45: ... 2 1 Special service tools Hose routing Hose routing 1 Fuel hose Fuel joint to fuel filter 2 Fuel hose Fuel filter to fuel pump 3 Fuel hose Fuel pump to carburetor 4 Breather hose 5 Pilot water hose 6D440010 4 1 1 2 2 3 3 4 4 5 ...

Page 46: ... 1 0 kgf m 7 2 ft lb OUT IN No Part name Q ty Remarks 1 Fuel joint 1 2 Bolt 1 M6 20 mm 3 Clamp 1 4 Clip 4 5 Hose 1 6 Hose 1 7 Hose 1 8 Fuel filter assembly 1 9 Screw 2 M4 30 mm 10 Fuel pump 1 11 O ring 1 12 Filter cap 1 13 Filter cup 1 14 Filter 1 15 O ring 1 16 Bracket 1 17 Nut 1 Not reusable Not reusable ...

Page 47: ...s Replace the fuel joint if neces sary Checking the fuel filter 1 Check the fuel filter element 1 for clog ging contamination or foreign sub stances and check the fuel filter cup 2 for cracks or leakage Clean with straight gasoline or replace if necessary NOTE Apply a thin coat of gasoline to the O ring 3 before assembling the fuel filter cup 6B440020 Vacuum pressure pump gauge set 90890 06756 Fue...

Page 48: ...o Part name Q ty Remarks 1 Bolt 3 M6 30 mm 2 Intake manifold 1 3 Gasket 1 4 Bolt 4 M6 30 mm 5 Dowel pin 2 6 Throttle link 1 7 Carburetor assembly 1 8 Intake silencer 1 9 Bolt 2 M6 100 mm 10 O ring 1 11 Collar 2 12 Breather hose 1 13 Insulator 1 14 Gasket 2 15 Plate 1 16 Hose 1 17 Choke rod 1 Not reusable Not reusable Not reusable ...

Page 49: ... lb No Part name Q ty Remarks 1 Carburetor body 1 2 Float chamber 1 3 O ring 1 4 Float 2 5 Float pin 1 6 Needle valve 1 7 Screw 2 8 Cover plate 1 9 Gasket 1 10 Main nozzle 1 11 Main jet 1 12 Pilot jet 1 13 Plug 1 14 Pilot screw 1 15 Spring 1 16 Screw 4 M4 12 mm 17 Drain bolt 1 Not reusable Not reusable ...

Page 50: ...6D45F11 No Part name Q ty Remarks 18 Gasket 1 19 Screw 1 20 Filter 1 Plastic 21 Screw 1 22 Spring 1 23 Plate 1 24 Screw 1 Not reusable Fuel system 6D44040E 2 N m 0 2 kgf m 1 5 ft lb 4 5 N m 0 45 kgf m 3 3 ft lb ...

Page 51: ...event any eye injury by the blown off debris or liq uid cC Do not use steel wire and the like for cleaning the carburetor Do not try to dis assemble the main nozzle if it does not come out easily Excessive force may seri ously impair performance NOTE Clean the needle valve main jet and pilot jet after removal 2 Check the carburetor body for cracks or damage Replace if necessary 3 Check the main je...

Page 52: ...le valve 9 Do not apply excessive force to screw in the pilot screw 1 Install the main nozzle 1 main jet 2 pilot jet 3 and plug 4 to the carburetor body as shown 2 Install the needle valve 5 float 6 float pin 7 and screw 8 as shown and then the check the float for smooth operation NOTE 9 Place the needle valve in the valve seat when installing the float to the carburetor body 9 Fit the float pin i...

Page 53: ...1 in direction a or b until the engine idle speed has been specified 3 Turn the throttle stop screw 2 in direc tion c or d until the specified engine idle speed is obtained NOTE 9 To increase the idle speed turn the throttle stop screw in direction c 9 To decrease the idle speed turn the throttle stop screw in direction d 4 After adjusting the idle speed rev the engine a few times and let it idle ...

Page 54: ...020E 1 5 N m 0 15 kgf m 1 1 ft lb No Part name Q ty Remarks 1 Fuel pump housing 1 2 Fuel pump body 1 3 Fuel pump cover 1 4 Plate valve 2 5 Diaphragm 1 6 Spring 1 7 Plunger 1 8 Spring 1 9 Screw 4 M4 9 mm 10 Diaphragm 1 11 Screw 2 12 Nut 4 13 Pin 1 ...

Page 55: ...ed negative pressure and check that there is no air leakage 5 Connect the special service tool to the fuel pump outlet 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 Disassembling the fuel pump 1 Dis...

Page 56: ...ves 1 Check the diaphragm 1 for tears and the plate valves 2 for cracks Replace if nec essary Assembling the fuel pump 1 Align the plunger and diaphragm installa tion holes a and then install the plunger into the diaphragm 2 Push down on the plunger and the diaphragm and then install the pin 1 3 Turn the fuel pump body 2 approximate ly 90 and then push down on the plunger several times to make sur...

Page 57: ...6D45F11 9 8 7 6 5 4 3 2 1 MEMO Fuel pump 4 14 ...

Page 58: ...5 26 Replacing the valve guides 5 26 Checking the valve seat 5 27 Refacing the valve seat 5 28 Checking the rocker arms and rocker arm shaft 5 29 Checking the camshaft 5 30 Checking the cylinder head 5 31 Checking the oil pump 5 31 Installing the valves 5 31 Installing the cylinder head 5 32 Cylinder block 5 34 Disassembling the cylinder block 5 37 Disassembling the piston and connecting rod assem...

Page 59: ...pin oil clearance 5 42 Checking the crankshaft main journal oil clearance 5 43 Selecting the crankshaft main journal bearing 5 44 Assembling the piston and connecting rod assemblies 5 45 Assembling the cylinder block 5 47 Installing the power unit 5 49 ...

Page 60: ...l holder 90890 06522 Flywheel puller 90890 06521 Crankshaft aligner 90890 03107 Driver rod LS 90890 06606 Ball bearing attacment 90890 06635 Valvespring compressor 90890 04019 Valvespring compressor attachment 90890 06320 Valve lapper 90890 04101 Valve guide remover installer 90890 06801 ...

Page 61: ...er 90890 06802 Valveguide reamer 90890 06804 Valve seat cutter holder 90890 06316 Valve seat cutter 90890 06312 90890 06313 90890 06314 90890 06315 Shaft holder 90890 06069 Oil filter wrench 90890 01426 Piston slider 90890 06529 Vacuum pressure pump gauge set 90890 06756 ...

Page 62: ...mong the cylinders add a small amount of engine oil to the cylinder and check the pressure again NOTE 9 If the compression pressure increases check the piston and piston rings for wear Replace if necessary 9 If the compression pressure does not increase check the valve clearance valve valve seat cylinder sleeve cylinder head gasket and cylinder head Adjust or replace if necessary 9 Since this outb...

Page 63: ...en disconnect the spark plug caps 1 spark plugs and fuel hoses 2 Remove the fuel pump 2 and cylinder head cover 3 3 Turn the flywheel clockwise and align the 1 mark a on the driven sprocket with the mark b on the cylinder head cC Do not turn the flywheel counter clock wise otherwise the valve system may be damaged 4 Check the intake and exhaust valve clearance for cylinders 1 Adjust if nec essary ...

Page 64: ... 4 and then turn the adjusting screw 5 until the specified valve clearance is obtained NOTE 9 To decrease the valve clearance turn the adjusting screw clockwise 9 To increase the valve clearance turn the adjusting screw counterclockwise 8 Tighten the locknut and then check the valve clearances Adjust if necessary 9 Install the cylinder head cover fuel pump and spark plugs 10 Connect the fuel hoses...

Page 65: ... Part name Q ty Remarks 1 Cover 1 2 Collar 1 3 Sheave drum 1 4 Drive pawl 1 5 Spiral spring 1 6 Drive plate 1 7 Drive pawl spring 1 8 Coil spring 1 9 Pawl spring 1 10 Circlip 1 11 Bolt 1 M6 16 mm 12 Starter rope 1 13 Starter plunger 1 14 Spring 1 15 Start in protection cable 1 16 Cap 1 17 Starter handle 1 ...

Page 66: ...E 8 N m 0 8 kgf m 5 8 ft lb 7 N m 0 7 kgf m 5 2 ft lb No Part name Q ty Remarks 18 Nut 1 19 Washer 2 20 Bolt 1 21 Washer 1 22 Bolt 2 M6 28 mm 23 Starter panel assembly 1 24 Nut 1 25 Oil pressure warning lamp assembly 1 26 Bolt 3 M6 20 mm ...

Page 67: ...magnet assembly 1 2 Woodruff key 1 3 Nut 1 4 Washer 1 5 Bolt 3 M6 30 mm 6 Choke rod 1 7 Fitting plate 1 8 Bolt 1 M6 20 mm 9 Ground lead 1 10 Ground lead 1 11 Throttle cable 2 For tiller control model 12 Remote control cable 2 For remote control model 13 Pilot water hose 1 14 Plate 1 15 Holder 1 For remote control model 16 Grommet 1 17 Clip 2 For remote control model ...

Page 68: ...0E 8 N m 0 8 kgf m 5 8 ft lb 21 N m 2 1 kgf m 16 ft lb No Part name Q ty Remarks 1 Bolt 6 M8 45 mm 2 Gasket 1 3 Dowel pin 2 4 Oil strainer 1 5 Dipstick 1 6 Relief valve 1 7 O ring 1 8 Cover 1 9 Hose 1 10 Band 2 Not reusable Not reusable ...

Page 69: ... m 5 8 ft lb 8 N m 0 8 kgf m 5 8 ft lb 8 N m 0 8 kgf m 5 8 ft lb 8 N m 0 8 kgf m 5 8 ft lb No Part name Q ty Remarks 1 CDI unit 1 2 Bolt 2 M6 20 mm 3 Pulser coil 1 4 Bolt 2 M6 16 mm 5 Lighting coil 2 6 Bolt 4 M6 30 mm 7 Bolt 2 M6 25 mm 8 Charge coil 1 9 Ignition coil 1 10 Bolt 2 M6 20 mm 11 Spark plug 2 12 Oil pressure switch 1 13 Boots 1 14 Plastic tube 1 15 Bolt 4 M6 20 mm 16 Bolt 1 M6 16 mm 17 ...

Page 70: ...gf m 5 8 ft lb No Part name Q ty Remarks 1 Pully 1 2 Free axle lever 1 3 Bolt 1 M6 10 mm 4 Washer 1 5 Bolt 1 M6 55 mm 6 Bracket 1 7 Collar 1 8 Collar 1 For remote control model 9 Bolt 1 M6 10 mm For remote control model 10 Washer 1 For remote control model 11 Shift rod lever 1 For remote control model ...

Page 71: ...g can pop out Cover the spiral spring with cloths then pull out the sheave drum 3 Remove the spiral spring 4 from the starter case w The spiral spring can pop out To remove the spring cover it with cloths 4 Remove the starter rope 5 5 Remove the drive pawl 6 and springs 7 from the sheave drum Checking the spiral spring 1 Check the spiral spring for cracks bends or damage Replace if necessary 2 1 6...

Page 72: ...ure the starter rope length Replace if the length is out of specification a a 2 3 1 5 4 6D450130 6B450210 6 Wind the starter rope 1 twice around the sheave drum 2 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 7 Install the spiral spring 6 into the starter case NOTE Bend the outer end c of t...

Page 73: ...to check the starter rope for slack Repeat steps 6 10 if nec essary 12 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 1 Remove the manual starter assembly 1 timing belt cover oil pressure warning lamp leads and start in gear protection cable 2 NOTE If the power unit is to be disassemb...

Page 74: ... on the flywheel magnet cC Apply force in the direction of the arrows shown While working do not allow the flywheel holder to slip off the flywheel 3 Remove the flywheel magnet cC 9 Screw in the flywheel puller set bolts evenly to the full extent 9 Make sure the puller plate is set parallel with the flywheel magnet NOTE Screw in the flywheel puller set bolt until the flywheel magnet comes off comp...

Page 75: ... Remove the oil strainer assembly 5 and relief valve 6 12 Remove the charge coil 7 lighting coil 8 and pulser coil 9 13 Remove the spark plug caps CDI unit 0 ignition coil q oil pressure switch and spark plugs 14 Check the oil strainer assembly for dam age clogs Clean or replace if neces sary 15 Check the relief valve for cracks or dam age Replace if necessary 6D450270 4 6D450290 5 6 6D450300 6D45...

Page 76: ...6 ft lb 54 N m 5 4 kgf m 39 ft lb No Part name Q ty Remarks 1 Driven sprocket 1 2 Bolt 1 M6 20 mm 3 Washer 1 4 Washer 1 5 Woodruff key 1 6 Timing belt 1 7 Breather hose 1 8 Drive sprocket 1 9 Retaining plate 1 10 Nut 1 11 Woodruff key 1 Timing belt and sprockets ...

Page 77: ...rive sprocket 9 and Woodruff key 0 Timing belt and sprockets Removing the timing belt and sprockets 1 Set the cylinder 1 piston position to TDC of the compression stroke by aligning the 1 mark a on the driven sprocket with the mark b on the cylinder head cC Do not turn the flywheel magnet counter clockwise otherwise the valve system may be damaged 2 Remove the breather hose and loosen the drive sp...

Page 78: ... Checking the timing belt and sprockets 1 Check the interior and exterior of the tim ing belt for cracks damage or wear Replace if necessary 2 Check the drive sprocket 1 and driven sprocket 2 for cracks damage or wear Replace if necessary Installing the timing belt and sprockets 1 Install the washer Woodruff key and check that the 1 mark a on the driven sprocket 1 is aligned with the mark b on the...

Page 79: ...ry tighten 6 Take up the timing belt slack by turning the drive sprocket clockwise at least two full turns 7 Turn the drive sprocket two turns and then check that the alignment marks are aligned 8 Tighten the driven sprocket bolt 6 to the specified torque 9 Tighten the drive sprocket nut 7 to the specified torque NOTE Use a deep socket 8 36 mm for this proce dure 10 Install the breather hose 6D450...

Page 80: ...ft lb No Part name Q ty Remarks 1 Cylinder head assembly 1 2 Gasket 1 3 Dowel pin 2 4 Bolt 6 M8 74 mm 5 Bolt 3 M6 25 mm 6 Cylinder head cover 1 7 Seal 1 8 Bolt 4 M6 20 mm 9 Oil filler cap 1 10 O ring 1 11 Fuel pump assembly 1 12 Screw 2 M6 30 mm 13 O ring 1 14 Oil pump assembly 1 15 Gasket 1 16 Bolt 3 M6 35 mm Not reusable Not reusable Not reusable Not reusable Not reusable Cylinder head ...

Page 81: ...Valve spring seat 4 3 Rocker shaft 2 4 Intake valve 2 5 Exhaust valve 2 6 Valve spring 4 7 Valve spring retainer 4 8 Valve cotter 8 9 Valve stem seal 4 10 Collar 1 r 22 5 mm 11 Collar 1 r 15 mm 12 Collar 1 r 8 5 mm 13 Spring 3 r 28 mm 14 Spring 1 r 55 mm 15 Rocker arm 4 16 Adjust screw 4 17 Rock nut 4 Not reusable Not reusable ...

Page 82: ...POWR 5 23 6D45F11 Power unit 14 N m 1 4 kgf m 10 ft lb 6D45080E No Part name Q ty Remarks 18 Camshaft assembly 1 19 Pin 1 20 Woodruff key 1 21 Oil seal 1 Not reusable ...

Page 83: ...uence shown 4 Remove the oil pump 1 gasket rocker arm shaft 2 spring collar and rocker arm assembly 3 NOTE 9 loosen the locknut and adjust screw to slack off the tension before remove the rocker arm shaft 9 Do not mix the removing parts Keep them original in their proper place 5 Remove the camshaft 4 by pulling it downward 1 6D450510 2 3 6D450520 6D450490 1 2 3 4 6D450500 1 2 3 4 5 6 7 8 9 6D45053...

Page 84: ...ut of specification Checking the valves 1 Check the valve face for pitting or wear Replace if necessary 2 Measure the valve margin thickness a Replace if out of specification Valve spring free length a 34 40 mm 1 3543 in 6D450550 a 6 5 6D450540 Valve spring compressor 5 90890 04019 Valve spring compressor attachment 6 90890 06320 Valve spring tilt limit b 1 5 mm 0 06 in b 6D450560 Valve margin thi...

Page 85: ...new valve guide 2 by striking the special service tool from the camshaft side until the valve guide clip 3 contacts the cylinder head NOTE Apply engine oil to the surface of the new valve guide Valve stem diameter b Intake 5 475 5 490 mm 0 2156 0 2161 in Exhaust 5 460 5 475 mm 0 2150 0 2156 in b 6D450580 Valve stem run out limit Intake 0 01 mm 0 0004 in Exhaust 0 01 mm 0 0004 in Valve guide inside...

Page 86: ...ic s blueing dye Dykem onto the valve seat 3 Lap the valve slowly on the valve seat with valve lapper commercially obtain able as shown 4 Measure the valve seat contact width a where the blueing dye is adhered to the valve face Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification Replace the valve guide if the valve seat contact is un...

Page 87: ...revent chatter marks 3 Use a 5 cutter to adjust the contact width of the top edge of the valve seat b Previous contact width 4 Use a 60 cutter to adjust the contact width of the bottom edge of the valve seat b Previous contact width 5 Use a 45 cutter to adjust the contact width of the valve seat to specification b Previous contact width c Specified contact width 5 45 60 6D450670 6D450700 5 b 60 6D...

Page 88: ...cut the bottom edge of the valve seat If neces sary use a 45 cutter to center the area and set its width b Previous contact width 9 Apply a thin even layer of lapping com pound onto the valve seat and then lap the valve using a valve lapper commer cially obtainable cC Do not get the lapping compound on the valve stem and valve guide 10 After every lapping procedure be sure to clean off any remaini...

Page 89: ...ft if necessary b c a 6D450770 6D450790 c d 6D450800 6D450780 Rocker arm inside diameter b 13 000 13 018 mm 0 5118 0 5125 in Rocker arm shaft outside diameter c 12 941 12 951 mm 0 5095 0 5099 in Cam lobe a Intake 27 596 27 696 mm 1 0865 1 0904 in Exhaust 27 616 27 716 mm 1 0872 1 0912 in Cam lobe b Intake 23 950 24 050 mm 0 9429 0 9468 in Exhaust 23 950 24 050 mm 0 9429 0 9468 in Camshaft journal ...

Page 90: ...Removing the screws 1 and disassem ble the oil pump 2 Measure the oil pump rotor clearances as shown Replace if out of specification Installing the valves 1 Install the new valve stem seal 1 to the valve guide and then apply engine oil to the valve guide 6D450810 c a b 6D450840 6D450840 a b c 1 2 6D450820 E 6D450850 1 1 6D450531 Cylinder head warpage limit 0 10 mm 0 0039 in Clearance a 0 100 0 150...

Page 91: ...rs 8 4 Lightly tap the spring retainer with a plas tic hammer to set the valve cotter secure ly Installing the cylinder head 1 Install the new oil seal 1 using a special tool 2 Install the camshaft 4 in the direction shown 2 5 4 3 7 6 6D450860 Valve spring compressor 6 90890 04019 Valve spring compressor attachment 7 90890 06320 8 6D450870 6D450880 1 3 2 6D450890 3 2 6D450900 4 Ball bearing attach...

Page 92: ...mbly springs and collars to the cylinder head 6 Assemble the oil pump as shown NOTE Be sure to assemble the oil pump so that the 8 mark 6 on the outer rotor faces toward the oil pump cover side 7 Install the oil pump 7 by aligning the oil pump drive shaft b with the camshaft pin c cC Before installing the oil pump be sure to fill it with engine oil through the oil pas sage a 6D450905 7 6D451011 b ...

Page 93: ... 5 N m 0 5 kgf m 3 7 ft lb 18 N m 1 8 kgf m 13 ft lb 40 N m 4 0kgf m 30 ft lb 6D45090E No Part name Q ty Remarks 1 Oil filter 1 2 Anode 1 3 Cover 1 4 Grommet 1 5 Bolt 1 M6 20 mm 6 Bolt 1 M5 12 mm 7 Plate 1 8 Breather cover 1 9 Seal 1 10 Bolt 3 M6 20 mm 11 Thermostat 1 12 Thermostat cover 1 13 Gasket 1 14 Clamp 1 15 Clamp 1 16 Gasket 1 17 Union bolt 1 Not reusable Not reusable Not reusable Cylinder...

Page 94: ...kgf m 5 8 ft lb 8 N m 0 8 kgf m 5 8 ft lb 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 7 ft lb 5 N m 0 5 kgf m 3 7 ft lb 18 N m 1 8 kgf m 13 ft lb 40 N m 4 0kgf m 30 ft lb 6D45090E No Part name Q ty Remarks 18 Exhaust cover 1 19 Bolt 7 M6 30 mm 20 Screw 1 21 Anode 1 22 Dowel pin 2 ...

Page 95: ... 5 kgf m 11 ft lb 30 N m 3 0 kgf m 22 ft lb No Part name Q ty Remarks 1 Cylinder body 1 2 Crankcase 1 3 Dowel pin 2 4 Bolt 6 M6 35 mm 5 Bolt 4 M8 55 mm 6 Oil seal 1 7 Oil seal 1 8 Crankshaft 1 9 Bearing 4 10 Connecting rod assembly 2 11 Bolt 4 M7 38 mm 12 Washer 4 13 Piston 2 14 Piston ring set 2 15 Piston pin clip 4 16 Piston pin 2 Not reusable Not reusable Not reusable ...

Page 96: ...osion on the cylinder head Replace if necessary 6 Check the exhaust cover for cracks dis tortion or corrosion Clean or replace if necessary 7 Remove the breather cover and gasket 8 Check the breather cover for cracks dis tortion or corrosion Replace if necessary Disassembling the cylinder block 1 Place a rag under the oil filter and then remove the filter NOTE Be sure to clean up any oil spills 2 ...

Page 97: ...s Disassembling the piston and connecting rod assemblies 1 Remove the clips 1 with pliers and then remove the piston pin 2 2 Remove the top ring 3 2nd piston ring 4 and oil ring set 5 Checking the piston diameter 1 Measure the piston outside diameter at the specified measuring point Replace if out of specification 1 9 5 8 4 3 7 6 10 2 6D451030 1 2 3 4 5 6 7 8 9 0 6D451040 6D451050 1 2 3 4 5 1 6D45...

Page 98: ...ce the piston and piston rings as a set or the cylinder block or all parts if out of specification Checking the piston rings 1 Check the piston ring dimensions of B and T Replace if out of specification Cylinder bore D1 D6 59 000 59 015 mm 2 3288 2 3234 in Piston clearance 0 035 0 065 mm 0 0014 0 0026 in Taper limit D1 D5 direction d D2 D6 direction e 0 08 mm 0 0032 in Out of round limit D2 D1 dir...

Page 99: ...ication Checking the piston ring side clearance 1 Measure the piston ring side clearance Replace the piston and piston rings as a set if out of specification 6D451210 1 d e 6D451220 6D451230 a b c Piston ring end gap d Top ring 0 15 0 30 mm 0 0059 0 0118 in Second ring 0 30 0 50 mm 0 0118 0 0197 in Oil ring 0 20 0 70 mm 0 0079 0 0276 in Measuring point e 10 mm 0 4 in Piston ring groove Top ring a ...

Page 100: ...connecting rod big end side clearance 1 Measure the connecting rod big end side clearance a Replace the connecting rod or crankshaft or both if out of specifica tion 6D451240 a 6D451270 6D451265 a 6D451250 Piston ring side clearance Top ring a 0 04 0 08 mm 0 0016 0 0032 in Second ring b 0 02 0 04 mm 0 0008 0 0016 in Oil ring c 0 0 22 mm 0 0 0087 in Piston pin boss bore 14 004 14 015 mm 0 5513 0 55...

Page 101: ...ut the Plastigauge PG 1 over the oil hole in the crank pin of the crank shaft 3 Install the connecting rod to the crank pin 1 NOTE 9 Align the finished side a on the connecting rod cap and connecting rod 9 Face the embossed Y mark on the con necting rod toward the flywheel side of the crankshaft 4 Tighten the connecting rod bolts to the specified torques in two stages b c a 6D451280 6D451290 Crank...

Page 102: ...y 3 3 2 1 a 6D451300 6D451370 Connecting rod bolt 1st 10 N m 1 0 kgf m 7 2 ft lb 2nd 22 N m 2 2 kgf m 16 ft lb Crank pin oil clearance 0 021 0 045 mm 0 0008 0 0018 in cC Install the bearings in their original posi tions NOTE Insert the projection a of the bearing into the notch in the cylinder body 4 Put a piece of Plastigauge PG 1 on each main journal parallel to the crank shaft NOTE Do not put t...

Page 103: ...ed on the cylinder block 3 Select the suitable color b for the main bearing from the table 4 When installing the main bearing insert the projection of the main bearing into the slot on the cylinder body cC Remove any small metal particles and oil from the contact surfaces of the cylinder body and the main bearing 5 Measure the main journal oil clearance with a piece of Plastigauge PG 1 Crankcase b...

Page 104: ...s 3 and new piston pin clips 4 NOTE 9 Face the embossed Y mark a on the con necting rod in the same direction as the UP mark b on the piston 9 Always use new piston pin clips 2 Install the oil ring 5 second ring 6 and top ring 7 to the piston with the N mark c on the piston rings facing upward 6D451400 a b 1 2 3 4 4 4 3 Offset the piston ring end gaps as shown cC Do not scratch the piston or break...

Page 105: ...als q q w w must be installed before installing the connecting rod Cylinder block 7 Install the connecting rod cap e to the connecting rod and then tighten the con necting rod bolts r to the specified torques in two stages NOTE 9 Apply engine oil to the connecting rod cap and connecting rod bolt before installation 9 Align the finished side e on the connecting rod cap and connecting rod 0 w q 6D45...

Page 106: ...ft lb Union bolt 40 N m 4 0 kgf m 30 ft lb Breather cover bolt 8 N m 0 8 kgf m 5 8 ft lb Assembling the cylinder block 1 Install half of the bearings 1 into the crankcase then dowel pins 2 2 Apply Gasket Maker to the mating sur face of the crankcase NOTE Do not get any Gasket Maker on the journal bearings 3 Install the crankcase bolts and then tighten them to the specified torques in two stages an...

Page 107: ...9 0 0118 in 6D450490 4 3 2 1 Cylinder head cover bolt 8 N m 0 8 kgf m 5 8 ft lb Mounting bolt 8 N m 0 8 kgf m 5 8 ft lb Mounting bolt 8 N m 0 8 kgf m 5 8 ft lb 7 Installing the dowel pins new gasket and cylinder head assembly 8 Check that the camshaft Woodruff key groove a is in the position shown in the illustration Adjust if necessary NOTE Align the valve position with the Top Dead Center of the...

Page 108: ...hten the locknut a 6D451520 5 6 7 b 6D451530 6 9 8 18 Install the fuel system Refer to Fuel sys tem in the chapter 4 19 Install the new O ring relief valve and oil strainer assembly Installing the power unit 1 Clean the power unit matching surface and install the dowel pins 1 and the new gasket 2 2 Install the power unit 3 by installing the bolts 4 then tightening them to the specified torque 3 Co...

Page 109: ...kgf m 13 ft lb NOTE Adjust the throttle cable to slack off 8 Turn the throttle grip from fully closed to fully open and back Check stopper is contact a b and for each cable slack 9 For remote control model connect the shift cable shift rod and throttle cable and then adjust their lengths For adjust ment procedures refer to Checking the throttle cable operation and Checking the gearshift operation ...

Page 110: ...lso check that the starter rope cannot be pulled with the gear shift in forward and reverse Adjust the start in gear protec tion cable if necessary 20 Install the choke rod fitting plate and plate then tighten the bolts to specified torques 21 Connect the oil pressure warning lamp leads Fitting plate bolt 10 N m 1 0 kgf m 7 2 ft lb 15 Fill the engine oil to specified quantity Refer to Replacing th...

Page 111: ...peller shaft housing 6 12 Drive shaft and lower case 6 14 Removing the drive shaft and forward gear 6 15 Disassembling the lower case 6 15 Checking the bearing housing 6 16 Checking the pinion gear and forward gear 6 16 Checking the bearings 6 17 Checking the drive shaft 6 17 Checking the shift rod 6 17 Checking the lower case 6 17 Assembling the lower case 6 17 Installing the drive shaft 6 19 Ins...

Page 112: ...per guide plate 90890 06501 Center bolt 90890 06504 Drive shaft holder 1 90890 06515 Bearing Separator 90890 06534 Bearing puller assembly 90890 06535 Stopper guide stand 90890 06538 Bearing housing puller claw S 90890 06564 Driver rod SL 90890 06602 Bearing depth plate 90890 06603 ...

Page 113: ...6605 Driver rod LS 90890 06606 Needle bearing attachment 90890 06613 90890 06616 Needle bearing attachment 90890 06617 Bearing outer race attachment 90890 06625 06627 Ball bearing attachment 90890 06632 Bearing inner race attachment 90890 06644 Bushing attachment 90890 06649 Driver rod L3 90890 06652 ...

Page 114: ...LOWR 6 3 6D45F11 Lower unit Digital caliper 90890 06704 Magnet base B 90890 06844 Backlash indicator 90890 06706 Magnet base plate 90890 07003 Shimming plate 90890 06701 ...

Page 115: ... ft lb 5 N m 0 5 kgf m 3 7 ft lb 9 N m 0 9 kgf m 6 6 ft lb No Part name Q ty Remarks 1 Rubber seal 1 2 Lower case 1 3 Bolt 4 M8 30 mm 4 Anode 1 5 Special washer 1 6 Bolt 1 M6 30 mm 7 Cotter pin 1 8 Propeller nut 1 9 Washer 1 10 Propeller 1 11 Spacer 1 12 Adjuster 1 13 Locknut 1 14 Dowel pin 2 15 Screw 1 16 Gasket 1 17 Inlet cover 1 Port side Not reusable Not reusable Not reusable ...

Page 116: ...ft lb 8 N m 0 8 kgf m 5 8 ft lb 8 N m 0 8 kgf m 5 8 ft lb 5 N m 0 5 kgf m 3 7 ft lb 9 N m 0 9 kgf m 6 6 ft lb No Part name Q ty Remarks 18 Inlet cover 1 Starboard side 19 Screw 1 20 Nut 1 21 Screw 1 22 Gasket 1 23 Trim tab 1 For S transom 24 Bolt 2 M6 16 mm For S transom Not reusable ...

Page 117: ...E 18 N m 1 8 kgf m 13 ft lb 18 N m 1 8 kgf m 13 ft lb No Part name Q ty Remarks 1 Woodruff key 1 2 Impeller 1 3 Water pump housing 1 4 Insert cartridge 1 5 O ring 1 6 Dowel pin 2 7 Rubber seal 1 8 Bolt 4 M8 45 mm 9 Plate 2 10 Bolt 2 M8 25 mm 11 Outer plate cartridge 1 Not reusable ...

Page 118: ...o not touch the propeller with your hands 9 Remove the clip for the engine stop lan yard switch to prevent the engine from starting 6 Disconnect the shift rod Loosen the adjuster while holding the locknut NOTE Set the gear shift in reverse first 7 Tilt up the outboard motor and remove the lower unit after removing the bolts 8 Remove the trim tab for S transom anode and cooling water inlet covers R...

Page 119: ...sert car tridge into the water pump housing 1 hole at the time of reassembly NOTE When installing the insert cartridge insert the projection on the insert cartridge into the water pump housing hole 3 Check the impeller for cracks or wear Replace if necessary 4 Check the Woodruff key 3 and the groove a for wear Replace if necessary 5 Check the outer plate cartridge for cracks or damage Replace if n...

Page 120: ... 1 Shift plunger 1 2 Dog clutch 1 3 Cross pin 1 4 Cross pin ring 1 5 Spring 1 6 Washer 1 7 Reverse gear 1 8 O ring 1 9 Reverse gear shim 1 10 Bearing 1 11 Needle bearing 1 12 O ring 1 13 Bolt 2 M6 20 mm 14 Propeller housing 1 15 Oil seal 2 16 Propeller shaft 1 Not reusable Not reusable Not reusable Not reusable Not reusable Lower unit ...

Page 121: ...emove the reverse gear and shim 2 Check that the bearing spins smoothly in the housing Check for roughness wear and damage 3 Remove the ball bearing 4 Remove the oil seals then remove the needle bearing NOTE When the oil seal or the needle bearing is removed always replace them with new ones 6D460070 6B460120 5 6 2 3 1 4 6B460110 6B460100 6B460620 Stopper guide plate 1 90890 06501 Stopper guide st...

Page 122: ...g the propeller shaft housing 1 Clean the propeller shaft housing and check it for cracks corrosion or damage Replace if necessary 2 Check the teeth and dogs of the reverse gear for cracks or wear Replace the gear if necessary Lower unit Checking the propeller shaft 1 Check the propeller shaft for bends or wear Replace if necessary 2 Measure the propeller shaft run out 3 Check the dog clutch for b...

Page 123: ...e propeller shaft housing to the specified depth NOTE First install the inner oil seal halfway into the propeller shaft housing and then install the outer oil seal to the specified depth 3 Install the ball bearing into the propeller shaft housing Propeller shaft housing Ball bearing attachment 5 90890 06632 Driver rod LS 6 90890 06606 Needle bearing attachment 3 90890 06613 Driver rod SS 4 90890 0...

Page 124: ...LOWR 6 13 6D45F11 Lower unit 4 Install the reverse gear and shim into the propeller shaft housing NOTE Shimming is required when the reverse gear or ball bearing is replaced 6B460180 ...

Page 125: ...o Part name Q ty Remarks 1 Drive shaft 1 2 Bearing housing 1 3 Drive shaft sleeve 1 4 Needle bearing 1 5 Pinion gear shim 1 6 Forward gear 1 7 Taper roller bearing 1 8 Forward gear shim 1 9 Pinion nut 1 10 Pinion gear 1 11 Thrust bearing 1 12 Bushing 1 13 Oil seal 2 14 Gasket 1 15 O ring 1 16 Shift rod 1 Not reusable Not reusable Not reusable Not reusable Not reusable ...

Page 126: ...ng gasket shift rod and dowel pins 4 Remove the drive shaft sleeve 5 Remove the forward gear Disassembling the lower case 1 Remove the taper roller bearing outer race NOTE Install the puller claw as shown 2 Remove the needle bearing 6B460240 1 6D460090 6D460100 Drive shaft holder 1 1 90890 06515 6B460250 1 3 2 Stopper guide plate 1 90890 06501 Center bolt 2 90890 06504 Bearing puller assembly 3 90...

Page 127: ...m with new ones Checking the pinion gear and forward gear 1 Check the pinion gear teeth for cracks or wear 2 Check the teeth and dogs of the forward gear for cracks or wear Also check the bearing for run out or roughness Disassemble if necessary 3 Remove the bearing NOTE When the taper roller bearing is removed always replace it with a new one 6D460110 2 1 Bushing attachment 1 90890 06649 Driver r...

Page 128: ...the lower case is replaced Record the measured height of the bearing LOWR 6D45F11 G 6B460350 1 2 Checking the bearings 1 Check the needle bearing and the thrust bearing for run out or roughness Replace if necessary cC Shimming is required when the thrust bearing is replaced Checking the drive shaft 1 Check the drive shaft for bends or wear Replace the shaft if necessary 2 Measure the drive shaft r...

Page 129: ...ing housing then install in the outer oil seal to the specified depth 6B460360 5 4 3 a Needle bearing attachment 3 90890 06617 Driver rod SL 4 90890 06602 Bearing depth plate 5 90890 06603 Depth a 172 7 173 2 mm 6 80 6 82 in 6D460120 7 8 Driver rod SS 7 90890 06604 Bushing attachment 8 90890 06649 6D460130 A A b 9 0 Needle bearing attachment 9 90890 06613 Driver rod L3 0 90890 06652 Installation d...

Page 130: ...sembly forward gear drive shaft shim thrust bearing and pinion gear cC 9 Shimming is required when the drive shaft housing or the drive shaft is replaced 9 Shimming is required when the thrust bearing is replaced NOTE Install the drive shaft by lifting it up slightly then aligning its splines with the pinion gear 2 Tighten the pinion nut 6D460180 Propeller housing bolt 8 N m 0 8 kgf m 5 8 ft lb Lo...

Page 131: ...d and in reverse Also make sure that the position is correct in neutral Installing the water pump 1 Install the dowels 1 the outer plate car tridge 2 2 Install the Woodruff key 3 into the drive shaft 3 Install the impeller 4 after aligning it with the Woodruff key NOTE 9 Align the groove on the impeller with the Woodruff key 9 Apply Yamaha grease A on the sliding face between the impeller and the ...

Page 132: ... lever in reverse Make sure that the shift rod is in the reverse position Install the lower unit onto the upper case and tighten the lower case bolts to the specified torque NOTE 9 Screw in the locknut completely 9 Push the shift rod down to shift into reverse 3 Connect the shift rod NOTE Screw the adjuster down until it comes in contact with the locknut 4 Install the anode trim tab for S transom ...

Page 133: ...eller from turning Then tighten the nut to the specified torque w 9 Place a block of wood between the anti cavitation plate and the propeller Do not touch the propeller with your hands 9 Remove the clip for the engine stop lan yard switch to prevent the engine from starting NOTE If the grooves in the propeller nut do not align with the cotter pin hole tighten the nut further until they are aligned...

Page 134: ...6 23 LOWR 6D45F11 Lower unit Shimming T3 M1 T2 M3 10 mm 0 39 in T1 M2 6D460240 ...

Page 135: ... measurement and the calculation formula 2 Calculate the pinion shim thickness 3 Select the pinion shim s T3 as follows Selecting the forward gear shims 1 Turn the taper roller bearing outer race 1 two or three times to seat the rollers then measure the bearing height M2 as shown NOTE 9 Select the shim thickness T1 by using the specified measurement s and the calcula tion formula 9 Measure the bea...

Page 136: ...2 0 15 0 18 0 30 0 40 and 0 50 mm Reverse gear shim thickness T2 80 57 M3 Available shims 0 10 0 20 0 30 0 40 and 0 50 Shimming plate 1 90890 06701 Digital caliper 2 90890 06704 Calculated numeral at 1 100th place Use shim more than less than 0 00 0 02 0 00 0 02 0 05 0 02 0 05 0 08 0 05 0 08 0 10 0 08 Forward gear shim thickness T1 16 60 M2 6B460560 1 2 6B460570 M3 10mm 0 039 in Calculated numeral...

Page 137: ...onto the drive shaft 13 mm 0 51 in in diameter 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 6 Slowly turn the drive shaft clockwise and counterclockwise and measure the back lash when the drive shaft stops in each direction 6B460430 6B760590 5 6 7 a b 4 6B460580 1 2 3 Bearing housing puller claw S 1 90890 0...

Page 138: ...cation the pin ion gear may be too high 9 If both the forward and reverse gear back lashes are smaller than specification the pinion gear may be too low 13 Remove the special service tools then install the water pump assembly Available shim thicknesses 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm Available shim thicknesses 0 10 0 20 0 30 0 40 and 0 50 mm 8 9 0 q 6B460600 Propeller nut 2 N m 0 2 kgf m...

Page 139: ...Bracket unit Special service tools 7 1 Tiller handle 7 2 Bottom cowling 7 4 Upper case and bracket unit 7 7 Disassembling the oil pan 7 13 Disassembling the upper case 7 13 Checking the upper case 7 14 Assembling the upper case 7 14 ...

Page 140: ...7 1 6D45F11 Special service tools Special service tools Needle bearing attachment 90890 06614 Driver rod SS 90890 06604 BRKT ...

Page 141: ... 2 5 ft lb 6D47010E No Part name Q ty Remarks 1 Screw 1 2 Washer 1 3 Throttle friction adjuster 1 4 Bushing 1 5 Washer 2 6 Wave washer 2 7 Washer 1 8 Bushing 1 9 Steering handle cover 1 10 Nut 1 11 Nut 1 12 Throttle cable 2 13 Steering handle 1 14 Throttle lever 1 15 Stay 1 16 Bolt 2 M6 Self tapping 17 Engine stop lanyard switch assembly 1 Not reusable Tiller handle ...

Page 142: ... 3 kgf m 17 ft lb 10 N m 1 0 kgf m 7 2 ft lb 2 5 N m 0 25 kgf m 1 8 ft lb 3 4 N m 0 34 kgf m 2 5 ft lb 6D47010E No Part name Q ty Remarks 18 Friction piece 1 19 Cotter pin 1 20 Throttle grip assembly 1 21 Bushing 1 22 Spring 1 Not reusable ...

Page 143: ...b 10 N m 1 0 kgf m 7 2 ft lb 10 N m 1 0 kgf m 7 2 ft lb 10 N m 1 0 kgf m 7 2 ft lb No Part name Q ty Remarks 1 Boots 1 2 Shift rod 1 3 Bolt 2 M6 25 mm 4 Collar 4 5 Grommet 4 6 Bolt 2 M6 36 mm 7 Seal 1 8 Hose 1 9 Bottom cowling 1 10 Cowling lock lever 1 11 Wave washer 1 12 Bushing 1 13 Clamp lever 1 14 Bushing 1 15 Bolt 1 M6 12 mm 16 Bolt 1 M6 20 mm 17 Stay 1 Bottom cowling ...

Page 144: ... name Q ty Remarks 18 Shift rod link 1 For tiller control model 19 Shift lever 1 For tiller control model 20 Grommet 1 21 Washer 1 22 Clip 1 23 Bolt 4 M6 25 mm 24 Bracket 2 25 Joint 1 For remote control model 26 Clip 1 27 Bolt 1 M6 20 mm 28 Stopper 1 29 Spring 1 30 Shift rod lever 1 31 Grommet 1 For remote control model 32 Grommet 1 For tiller control model 33 Grommet 1 For remote control model 34...

Page 145: ...N m 1 0 kgf m 7 2 ft lb 10 N m 1 0 kgf m 7 2 ft lb No Part name Q ty Remarks 35 Holder 1 For remote control model 36 Wave washer 1 For tiller control model 37 Bolt 1 M6 25 mm For tiller control model 38 Collar 1 For tiller control model 39 Clamp 1 40 Bracket 1 41 Bolt 1 M6 25 mm 42 Bracket 2 43 Bolt 2 M6 20 mm 44 Spring hook 1 45 Spring 1 46 Adjuster 1 47 Grommet 1 For tiller control model ...

Page 146: ...2 2 ft lb 8 N m 0 8 kgf m 5 8 ft lb No Part name Q ty Remarks 1 Oil pan 1 2 Oil seal 1 3 O ring 1 4 Upper case 1 5 Gasket 1 6 Bolt 2 M6 20 mm 7 Dowel pin 2 8 Exhaust pipe 1 9 Gasket 1 10 Bolt 2 M6 16 mm 11 Rubber seal 1 12 Drain bolt 1 13 Gasket 1 14 Drain bolt cap 1 15 Water tube 1 16 Rubber seal 1 17 Gasket 1 Not reusable Not reusable Not reusable Not reusable Not reusable Not reusable Upper cas...

Page 147: ...m 1 8 ft lb 3 N m 0 3 kgf m 2 2 ft lb 8 N m 0 8 kgf m 5 8 ft lb No Part name Q ty Remarks 18 Buffer plate 1 19 Lower mount rubber 2 Side 20 Lower mount housing 2 21 Lower mount rubber 1 Front 22 Bolt 2 M8 105 mm 23 Bolt 2 M8 85 mm 24 Grease nipple 1 25 Ground lead 1 26 Bolt 3 M6 25 mm 27 Upper mount 1 28 Nut 2 29 Plate 1 30 Washer 2 31 Collar 2 32 Washer 2 33 Rubber seal 1 34 Rubber seal 1 Not reu...

Page 148: ...No Part name Q ty Remarks 1 Steering bracket 1 2 Screw 2 3 Ground lead 1 4 Friction piece 1 5 Bolt 1 M6 20 mm 6 Rubber seal 1 7 Bushing 1 8 O ring 1 9 Bushing 1 10 Washer 1 11 Pivot shaft bushing 1 12 Bolt 1 M8 36 mm For remote control model 13 Ride guide 1 For remote control model Not reusable ...

Page 149: ...16 ft lb 8 N m 0 8 kgf m 5 8 ft lb No Part name Q ty Remarks 1 Nut 1 2 Plate 1 3 Starboard clamp bracket 1 4 Tilt lock arm 1 5 Nut 1 6 Bolt 1 M6 150 mm 7 Washer 1 8 Collar 1 9 Steering bracket 1 10 Transom cramp screw 2 11 Pin 2 12 Transom cramp handle 2 13 Washer 2 14 Bush 2 15 Clamp bracket bolt 1 16 Port side clamp bracket 1 17 Bush 1 ...

Page 150: ...t lb 8 N m 0 8 kgf m 5 8 ft lb No Part name Q ty Remarks 18 Spring 1 19 Spring 1 20 Rod 1 21 Washer 1 22 Tilt lock shaft 1 23 Circlip 1 24 Shaft 1 25 Tilt rod 1 26 Transom clamp pad 2 27 Screw 1 28 Tilt lever 1 29 Cover 1 30 Tilt lever assembly 1 31 Wave washer 2 32 Bolt 4 33 Tilt stop lever 2 34 Tilt lock plate 1 ...

Page 151: ...et unit 6D47050E 8 N m 0 8 kgf m 5 8 ft lb 2 N m 0 2 kgf m 1 5 ft lb 22 N m 2 2 kgf m 16 ft lb 8 N m 0 8 kgf m 5 8 ft lb No Part name Q ty Remarks 35 Reverse lock plate 1 36 Shaft 1 37 Screw 1 38 Spring 1 39 Circlip 1 40 Collar 1 41 Washer 1 42 Washer 2 ...

Page 152: ...t 1 rubber seal 2 and water tube 3 BRKT 7 13 6D45F11 Bracket unit 6D470060 Disassembling the oil pan 1 Remove the oil pan 1 and buffer plate 2 gasket from the upper case 2 Remove the oil seal 3 and O ring 4 3 Remove the exhaust pipe 5 gasket 6 drain bolt 7 gasket and rubber seal 8 6D470010 1 2 6D470020 3 4 5 6 7 8 6D470030 3 2 2 1 ...

Page 153: ...case 1 Install the new oil seal 1 to the oil pan using the special service tools 2 Install the new O ring 4 new gasket 5 exhaust pipe 6 rubber seal 7 to the oil pan and tighten the bolts 3 Install the drain bolt cap 8 and new gas ket 9 then tighten the drain bolt 0 to specified torque 6D470050 6D470070 6D470040 4 4 6D470090 1 2 3 Exhaust pipe 11 N m 1 1 kgf m 8 1 ft lb 6D470080 4 5 6 7 8 9 0 Drain...

Page 154: ...fied torques BRKT 7 15 6D45F11 Bracket unit 6 Install the buffer plate u to the oil pan NOTE Face the FRONT mark side to install 7 Install the dowel pins i new gasket o and oil pan on to the upper case 6D470110 o i i u Upper mount bolts 12 N m 1 2 kgf m 8 7 ft lb Upper mount nuts 21 N m 2 1 kgf m 16 ft lb Lower mount bolts 32 N m 3 2 kgf m 23 ft lb 6D470100 w e r q q r t y Oil pan 8 N m 0 8 kgf m ...

Page 155: ...ft view 8 5 Wiring harness 8 6 Ignition and ignition control system 8 7 Checking the ignition spark gap 8 7 Checking the spark plug caps 8 7 Checking the ignition coil 8 8 Checking the pulser coil 8 8 Checking the charge coil 8 9 Checking the CDI unit 8 10 Checking the oil pressure warning lamp 8 10 Checking the engine stop lanyard switch 8 11 Charging system 8 12 Checking the lighting coil 8 12 C...

Page 156: ...ELEC 8 1 6D45F11 Electrical systems Special service tools Ignition tester 90890 06754 Digital circuit tester 90890 03174 Peak voltage adaptor B 90890 03172 ...

Page 157: ...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 158: ...er coil 3 Lighting coil 4 Spark plug 5 Ignition coil 6 Oil pressure switch 7 Charge coil 8 Engine stop lanyard switch for tiller control model 9 Engine stop lanyard switch connector for remote control model 701 remote control type å Pass the lighting coil lead as shown Install the pink lead onto the oil pressure switch Cover the oil pressure switch after tightening it ...

Page 159: ... å Install the connector in the proper direction as shown Pass each spark plug wire through the grom met ç Cover the oil pressure switch lead ignition coil lead and charge coil lead with the plastic tube after connecting the same color leads Starboard view 1 2 3 A B C 6D480030 B O Br L P P B O Br L P ...

Page 160: ... B W 6D480040 1 Pulser coil 2 CDI unit leads 3 Rectifier regulator leads å To the lighting coil To the warning lamp ç Tighten with the CDI unit ground lead and the engine stop lanyard switch ground lead To the engine stop lanyard switch Tighten with the rectifier regulator ground lead ...

Page 161: ...r 6J8 2 3 q 6D480050 4 6 0 5 7 8 8 1 9 Wiring harness 1 CDI unit 2 Lighting coil 3 Charge coil 4 Oil pressure switch 5 Pulser coil 6 Ignition coil 7 Engine stop lanyard switch 8 Ground lead 9 Oil pressure warning lamp 0 Spark plug q Rectifier regulator Br Brown G Green L Blue O Orange P Pink R Orange W White G W Green White W G White Green Y R Yellow Red ...

Page 162: ... any of the connections of the spark gap tester leads 9 Do not let sparks leak out of the removed spark plug caps 9 Keep flammable gas or liquids away since this test can produce sparks Ignition tester 90890 06754 6D480070 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 from the spark plug wire 2 by turning the cap co...

Page 163: ...ondary coil Spark plug wire Spark plug wire 3 92 5 88 kΩ at 20 C 68 F Checking the pulser coil 1 Connect the digital circuit tester with peak voltage adaptor B to the connector 2 Measure the pulser coil output peak volt age If the measurement is below specifi cation check the leads and measure the pulser coil resistance Replace the pulser coil if necessary Digital circuit tester 90890 3174 Peak vo...

Page 164: ...Charge coil resistance use as reference Brown Br Blue L 272 0 408 0 Ω at 20 C 68 F L Br 6D480160 B W G 6D480140 Pulser coil resistance use as reference White green W G Black B 234 0 348 0 Ω at 20 C 68 F Checking the charge coil 1 Measure the charge coil output peak volt age If the measurement is below specifi cation check the leads and measure the charge coil resistance Replace if neces sary L L B...

Page 165: ... the CDI unit if output peak voltages of the pulser and charge coils are on or above specification and the CDI unit output peak voltage is below specification Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 CDI unit output peak voltage Orange ground lead r min Loaded Cranking 1 500 3 500 DC V 155 170 170 O B O B 6D480170 Checking the oil pressure warning lamp 1 Disconnect the...

Page 166: ... stop lanyard switch for continuity Replace if there is no continu ity 2 For remote control model Check the engine stop lanyard switch connector for continuity Replace if necessary Lead color White W Black B Clip removed a Clip installed b Engine shut off button pushed c 6B480160 6D480176 B W W B ...

Page 167: ... voltage Green G Green G r min Unloaded Cranking 1 500 3 500 DC V 14 30 70 G G 6D480200 Checking the rectifier regulator 1 Connect the digital circuit test leads to the red and black or ground leads from the rectifier regulator 2 Measure the rectifier regulator output peak voltage If the measurement is below specification check the leads Replace if necessary Digital circuit tester 90890 03174 Peak...

Page 168: ...ELEC 6D45F11 MEMO Electrical systems 8 13 ...

Page 169: ...6D45F11 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 ...

Page 170: ...h Ignition system Check the engine stop lanyard switch for continuity Check the condition of the spark plugs Check the ignition spark using the spark gap tester Measure the ignition coil resistance Replace the engine stop lanyard switch 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 Replace...

Page 171: ...nnection of the leads from CDI unit Yes Replace the charge coil No Replace the pulser coil No Does the engine start Measure 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 Measure the CDI unit output peak voltage Ignition sy...

Page 172: ...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 173: ...ease Add a small amount of engine oil into the cylinder through the spark plug hole Yes Check the piston piston rings and cylinder bore for wear or damage Correct or replace if worn or damaged Check the valves valve seat cylinder head gasket and cylinder head for wear or damage Replace if worn or damaged No NOTE Since this outboard motor is equipped with an automatic decom pression mechanism accur...

Page 174: ...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 175: ...No Check the shift lever shaft and spring 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 176: ...Checking the engine idle speed 3 10 Checking the engine oil 3 3 Checking the engine oil level 1 6 Checking the engine stop lanyard switch 1 8 Checking the engine stop lanyard switch 8 11 Checking the fuel filter 3 3 Checking the fuel filter 4 4 Checking the fuel joint 4 4 Checking the fuel line 3 3 Checking the fuel pump 4 12 Checking the fuel system 1 6 Checking the gear oil 1 6 Checking the gear...

Page 177: ...embly 6 10 Disassembling the upper case 7 13 Disassembly and assembly 1 4 Drive shaft and lower case 6 14 E Electrical 2 7 Electrical components 8 3 F Fire prevention 1 3 Fuel line 4 3 Fuel pump 4 11 Fuel system 3 3 9 3 G General 3 13 General specifications 2 1 General torques 2 11 Good working practices 1 4 H Hose routing 4 2 How to use this manual 1 1 I Identification 1 5 Ignition and ignition c...

Page 178: ... belt 3 5 Replacing the valve guides 5 26 S Safety while working 1 3 Selecting the crankshaft main journal bearing 5 44 Selecting the forward gear shims 6 24 Selecting the pinion shims 6 24 Selecting the reverse gear shims 6 25 Selection 1 5 Self protection 1 3 Serial number 1 5 Shimming 6 23 6 24 Special service tools 3 1 4 1 5 1 6 1 7 1 8 1 Specified torques 2 10 Starboard view 8 4 Symbols 1 2 T...

Page 179: ...tions 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 dea...

Page 180: ...YAMAHA MOTOR CO LTD Printed in Japan Oct 2003 0 4 1 E Printed on recycled paper F15B SERVICE MANUAL 6D4 28197 5F 11 290535 6D4Cover 03 10 9 20 48 Page 1 ...

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