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Yamaha F4B, Service Manual

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Yamaha F4B Service Manual Download Page 17

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Specification

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Model feature  ..................................................................... 1-1

General feature  ......................................................................... 1-1
Model designation  ..................................................................... 1-2
Serial number  ............................................................................ 1-2

Model data  ......................................................................... 1-3

Dimension and weight  ............................................................... 1-3
Performance .............................................................................. 1-3
Power unit  ................................................................................. 1-3
Lower unit .................................................................................. 1-4
Bracket unit  ............................................................................... 1-4
Fuel and oil requirement ............................................................ 1-4

Electrical technical data ................................................... 1-5

Ignition timing control system .................................................... 1-5
Charging system (optional for European market) ...................... 1-5

Fuel system technical data .............................................. 1-5

Fuel system  ............................................................................... 1-5

Power unit technical data ................................................. 1-6

Power unit  ................................................................................. 1-6
Manual starter  ........................................................................... 1-6
Cylinder head assembly  ............................................................ 1-7
Crankcase assembly  ................................................................. 1-8

Lower unit technical data ................................................. 1-9

Lower unit assembly .................................................................. 1-9

Specified tightening torque ............................................ 1-10

Fuel system  ............................................................................. 1-10
Power unit  ............................................................................... 1-10
Lower unit ................................................................................ 1-10
Bracket unit  ............................................................................. 1-11

General tightening torque .............................................. 1-11

Summary of Contents for F4B

Page 1: ...SERVICE MANUAL 6BV 28197 3M 11 F4B F5A F6C ...

Page 2: ...ifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual Also up to date parts information is available on YPEC web Additional information and up to date information on Yamaha products and services are available on Yamaha Service Portal Important information Particularly important information is distinguished in this manua...

Page 3: ...ion SPEC 1 Technical features and description TECH FEA 2 Rigging information RIG GING 3 Troubleshooting TRBL SHTG 4 Electrical system ELEC 5 Fuel system FUEL 6 Power unit POWR 7 Lower unit LOWR 8 Bracket unit BRKT 9 Maintenance MNT 10 Index Appendix A ...

Page 4: ......

Page 5: ...ine 0 1 Ventilation 0 1 Self protection 0 2 Working with crane 0 2 Part lubricant and sealant 0 2 Handling of sealant 0 2 Special service tool 0 2 Tightening torque 0 3 Non reusable part 0 3 Disassembly and assembly 0 3 How to use this manual 0 4 Manual format 0 4 Abbreviation 0 5 Lubricant sealant and thread locking agent 0 6 Symbol 0 6 Special service tool 0 7 ...

Page 6: ...ric shock Do not touch any electrical parts while start ing or operating the engine Otherwise shock or electrocution could result Propeller Do not hold the propeller with your hands when loosening or tightening the propeller nut Handling of gasoline Gasoline is highly flammable Keep gaso line and all flammable products away from heat sparks and open flames Gasoline is poisonous and can cause injur...

Page 7: ...hree point suspension If the outboard motor does not have three or more points to be suspended support it using additional ropes or the like so that the outboard motor can be lifted and carried in a stable manner Part lubricant and sealant Use only genuine Yamaha parts lubricants and sealants or those recommended by Yamaha when servicing or repairing the out board motor Handling of sealant Wear pr...

Page 8: ...hen installing or assem bling parts Disassembly and assembly Use compressed air to remove dust and dirt during disassembly Apply engine oil to the contact surfaces of moving parts before assembly Install bearings so that the bearing identifi cation mark is facing in the direction indi cated in the installation procedure In addition make sure to lubricate the bear ings liberally Apply a thin coat o...

Page 9: ... e p o r P 0 1 1 r e h s a W 1 1 1 r e l l e p o r P 2 1 1 r e c a p S 3 1 14 Lower case mounting bolt 2 M6 40 mm 1 r e h s a w k c o L 5 1 6 M 1 t l o B 6 1 20 mm 1 e d o n A 7 1 A 1 1 2 3 4 23 8 8 23 22 21 19 19 5 6 11 14 14 18 6 17 15 16 13 12 11 10 9 16 N m 1 6 kgf m 11 8 ft lb 15N m 1 5 kgf m 11 1 ft lb 11N m 1 1 kgf m 8 1 ft lb 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kg...

Page 10: ... API American Petroleum Institute BTDC Before Top Dead Center CCA Cold Cranking Ampere CDI Capacitor Discharge Ignition EN European Norm European standard F Forward IEC International Electrotechnical Commission N Neutral OHV Overhead Valve PORT Port side R Reverse RON Research Octane Number STBD Starboard side TDC Top Dead Center ...

Page 11: ... or thread locking agent and the application points Symbol Name Application Yamaha 4 stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Yamaha grease A Lubricant Molybdenum disulfide grease Lubricant Corrosion resistant grease Yamaha grease D Lubricant ThreeBond 1901 Lubricant Symbol Name Application ThreeBond 1324 Thread locking agent ThreeBond 1342J Thread locking agent Gasket ...

Page 12: ...ibuted by the Parts Division Digital circuit tester 90890 03174 Peak voltage adapter B 90890 03172 Ignition tester spark gap tester 90890 06754 Vacuum pressure pump gauge set 90890 06756 Leakage tester 90890 06840 Pilot screw driver 90890 06673 Compression gauge 90890 03160 Digital tachometer 90890 06760 Timing light 90890 03141 Flywheel holder 90890 06522 ...

Page 13: ...06652 Needle bearing attachment 90890 06615 Needle bearing attachment 90890 06613 Valve spring compressor 90890 04019 Valve spring compressor attachment 90890 06320 Valve guide remover installer 90890 06801 Valve guide reamer 90890 06804 Valve lapper 90890 04101 Valve seat cutter holder 90890 06316 ...

Page 14: ...cutter 45 90890 06312 Valve seat cutter 60 90890 06323 Valve seat cutter 30 90890 06819 Valve seat cutter 45 90890 06814 Valve seat cutter 60 90890 06813 Needle bearing attachment 90890 06612 Driver rod LL 90890 06605 Ball bearing attachment 90890 06632 Driver rod LS 90890 06606 ...

Page 15: ...90 06655 Piston slider 90890 06529 Stopper guide plate 90890 06501 Stopper guide stand 90890 06538 Bearing puller assembly 90890 06535 Bearing outer race attachment 90890 06628 Bushing installer center bolt 90890 06601 Bushing attachment 90890 06650 Bushing attachment 90890 06649 ...

Page 16: ...0 11 GEN INFO General information MEMO ...

Page 17: ...lectrical technical data 1 5 Ignition timing control system 1 5 Charging system optional for European market 1 5 Fuel system technical data 1 5 Fuel system 1 5 Power unit technical data 1 6 Power unit 1 6 Manual starter 1 6 Cylinder head assembly 1 7 Crankcase assembly 1 8 Lower unit technical data 1 9 Lower unit assembly 1 9 Specified tightening torque 1 10 Fuel system 1 10 Power unit 1 10 Lower ...

Page 18: ...engine Blowby gas reburning system Trochoid type oil pump lubrication Decompression starter Fuel line with a primer pump Dual fuel line Recoil manual starter b Electrical Ignition timing control by CDI unit CDI unit with the integrated ignition coil Charging system optional for European market c Bracket unit Manual tilt Reverse lock system Balanced carrying handle d Lower unit Under water exhaust ...

Page 19: ...al number e Production model year a Model description F 4 stroke regular rotation b Model name 4 4 5 6 c Product generation B A and up d Functions M Manual starter e H Tiller handle f Transom height S S 15 in L L 20 in F 4 B M H S b a c d e f M B K INDUSTRIE PRODUCT ASSEMBLED IN FRANCE PRODUIT ASSEMBLE EN FRANCE b c a d e Model name Approved model code Starting serial No F4BMH 6EC 1000001 F5AMH 6E...

Page 20: ...utput At 5000 r min kW HP 2 9 3 9 At 5500 r min kW HP 3 7 5 0 4 4 6 0 Full throttle operating range r min 4000 5000 4500 5500 Engine idle speed r min 1450 1550 Item Unit Model F4BMH F5AMH F6CMH Type 4 stroke OHV Cylinder quantity 1 Total displacement cm cu in 139 0 8 5 Bore stroke mm in 62 0 46 0 2 4 1 8 Compression ratio 8 90 1 Control system Tiller handle Starting system Manual Fuel system Carbu...

Page 21: ...pline Propeller direction rear view Clockwise Propeller mark BA Item Unit Model F4BMH F5AMH F6CMH Trim angle At 12º boat transom Degree 4 to 20 Tilt up angle Degree 64 Steering angle Degree 90 90 Trim and tilt system Manual Item Unit Model F4BMH F5AMH F6CMH Fuel type Regular unleaded gasoline Fuel minimum rating RON 91 Engine oil 4 stroke motor oil with combinations of the fol lowing SAE and API o...

Page 22: ... unit Air gap mm in 0 4 0 6 0 016 0 024 Item Unit Model F4BMH F5AMH F6CMH Lighting coil Output peak voltage At cranking unloaded V 20 0 At 1500 r min unloaded V 30 1 At 3500 r min unloaded V 64 3 Resistance 1 At 20 C 68 F 0 771 0 869 Rectifier Regulator Output peak voltage At 1500 r min loaded V 13 0 At 3500 r min loaded V 13 0 Item Unit Model F4BMH F5AMH F6CMH Fuel joint Holding pressure Positive...

Page 23: ... 70 75 Main nozzle mm in 1 6 0 06 2 0 0 08 2 4 0 09 Pilot jet PJ 35 42 Pilot air jet PAJ 105 110 Adjustable pilot screw PS turns out 1 3 8 3 4 2 1 8 3 4 2 1 4 3 4 Fuel pump Holding pressure Inlet positive pressure kPa kgf cm2 psi 50 0 0 50 7 3 Outlet positive pressure kPa kgf cm2 psi 50 0 0 50 7 3 Item Unit Model F4BMH F5AMH F6CMH Cylinder Minimum compression pres sure 1 kPa kgf cm2 psi 700 0 7 00...

Page 24: ...h mm in 27 6 1 09 Tilt limit mm in 1 0 0 04 Valve stem Diameter Intake mm in 5 475 5 490 0 2156 0 2161 Exhaust mm in 5 460 5 475 0 2150 0 2156 Runout 1 Intake mm in 0 050 0 0020 Exhaust mm in 0 030 0 0012 Valve guide Inside diameter Intake and exhaust mm in 5 500 5 512 0 2165 0 2170 Clearance Intake mm in 0 010 0 037 0 0004 0 0015 Exhaust mm in 0 025 0 052 0 0010 0 0020 Installation height mm in 8...

Page 25: ... 0476 0 0484 Ring groove 2nd mm in 1 210 1 230 0 0476 0 0484 Ring groove Oil mm in 2 010 2 030 0 0791 0 0799 Pin boss inside diameter mm in 15 004 15 015 0 5907 0 5911 Pin outside diameter mm in 14 995 15 000 0 5904 0 5906 Cylinder Bore mm in 62 000 62 015 2 4409 2 4415 Piston ring End gap measuring point 1 mm in 60 0 2 36 Top ring Type Barrel Dimension height B mm in 1 170 1 190 0 0461 0 0469 Dim...

Page 26: ... 020 0 0008 Journal diameter cylinder block side mm in 24 980 24 993 0 9835 0 9840 Journal diameter crankcase side mm in 24 982 24 994 0 9835 0 9840 Crankpin diameter mm in 27 969 27 984 1 1011 1 1017 Crankpin width mm in 21 000 21 100 0 8268 0 8307 Valve lifter Outside diameter mm in 7 965 7 980 0 3136 0 3142 Item Unit Model F4BMH F5AMH F6CMH Lower unit Holding pressure kPa kgf cm2 psi 98 0 0 98 ...

Page 27: ...0 7 5 2 Start in gear protection cable locknut 2 0 2 1 5 Flywheel magnet nut 60 6 0 44 3 Engine shut off switch nut 2 0 2 1 5 Power unit mounting bolt M6 12 1 2 8 9 Crankcase bolt 1st M6 5 0 5 3 7 2nd 11 1 1 8 1 Blind plug M8 20 2 0 14 8 Pivot bolt 10 1 0 7 4 Cylinder head bolt 1st M8 13 1 3 9 6 2nd 28 2 8 20 7 Thermostat cover anode screw M5 2 0 2 1 5 Spark plug 13 1 3 9 6 Connecting rod cap bolt...

Page 28: ...ations require clean dry threads Components should be at room temperature Part to be tightened Screw size Tightening torques N m kgf m ft lb Throttle rod screw M5 4 0 4 3 0 Throttle grip screw M5 4 0 4 3 0 Tiller handle mounting bolt M8 28 2 8 20 7 Carrying handle bolt M8 19 1 9 14 0 Start in gear protection cable locknut 4 0 4 3 0 Primer pump holder bolt M6 11 1 1 8 1 Shift lever bolt M8 19 1 9 1...

Page 29: ... Outline 2 4 Automatic decompressor 2 5 Blowby gas reburning system 2 6 Lighting coil optional for European market 2 7 Fuel system 2 8 Outline 2 8 Carburetor 2 9 Built in primer pump 2 12 Lubrication system 2 13 Outline 2 13 Oil pump and engine oil flow 2 13 Tilt system 2 14 Outline 2 14 Reverse lock system 2 14 Lubrication diagram 2 15 Cooling flow diagram 2 16 Intake and exhaust flow diagram 2 1...

Page 30: ...d a permanent mag net of the flywheel magnet The CDI unit has a compact design with an integrated ignition coil There are two types of ignition control systems One is ignition timing control at normal operation and the other one is ignition cut off control during engine cranking and when over revving a CDI unit b Flywheel magnet a Permanent magnet a a b ...

Page 31: ...charge the capacitor f When the ignition control circuit e transmits an ignition signal g the capacitor f will discharge and produce current h in the primary coil k and induce a high voltage m in the secondary coil n to ignite the spark plug c The CDI unit b ignites the spark plug c once per crankshaft rotation Ignition timing control The CDI unit ignites the spark plug at the ignition timings tha...

Page 32: ...when the engine speed is 150 r min or lower The other one is a system to stop ignition to prevent damage to the engine when over revving While this control system is activated the ignition control circuit b keeps output ting ignition signals a without charging the capacitor c A Ignition control during engine cranking B Engine speed control Ignition control during engine cranking Engine speed contr...

Page 33: ...s reburning system is incorporated to reduce the amount of oil contained in the blowby gases The flywheel magnet lighting coil and Rectifier Regulator are available as optional accessories and these will enable battery charging Optional for European market a Valve lifter b Push rod c Rocker arm d Valve e Rectifier Regulator optional f Lighting coil optional g Flywheel magnet optional h Intake sile...

Page 34: ...lve on the compression stroke to release compression pressure during engine cranking and prevent pressure in the cylinder from increasing As the cranking speed increases the decompression actuator will move in the direction of a due to the centrifugal force and the exhaust valve will return to normal operation A Compression pressure a A Decompression actuator ...

Page 35: ... from the blowby gases in two labyrinths First oil is separated from the blowby gases in the cylinder block labyrinth and then in the intake silencer labyrinth The oil separated from the blowby gases flows back to the crankcase and the blowby gases sepa rated from the oil are sucked into the combustion chamber a Cylinder block labyrinth b Intake silencer labyrinth A Blowby gas B Engine oil C Air B...

Page 36: ...quipped with a flywheel magnet lighting coil and Rectifier Regulator available as optional accessories to enable battery charging The electrical current generating capacity is 6A when the engine speed is at 6000 r min a Lighting coil b Rectifier Regulator c Fuse d Battery e Switch f Electrical component a b c d e f ...

Page 37: ...a simply designed and reliable butterfly type carburetor A built in primer pump is also provided in order to ease engine starting when the float chamber is empty or when operating the engine after it has been stored for a long time a Primer pump b Carburetor b a Power unit system Fuel system ...

Page 38: ...ith the fuel that is also sucked into the passage through the pilot jet a This air and fuel mixture is supplied to the engine through the pilot hole c The pilot screw b controls the amount of air and fuel mixture that will be supplied to the engine When running at low speed the air and fuel mixture is supplied to the engine through the pilot hole c and through the bypass holes d A Idle operation B...

Page 39: ...el is sucked from the main jet a to be mixed with the air that has entered from the main air jet b through the emulsion tube c and then drawn into the main nozzle b The fuel drawn into the main nozzle b is mixed with the air in the venturi producing air and fuel mix ture that will be supplied to the engine The air and fuel mixture is simultaneously supplied to the engine through the pilot hole d a...

Page 40: ...nerated in the main bore a becomes even higher Consequently a larger amount of air and fuel mixture is drawn from the main nozzle a to be supplied to the engine At high speed operation as the negative pressure in the main bore a becomes higher than the neg ative pressure in the pilot passage b fuel is not drawn through the pilot jet c A Air B Fuel C Air and fuel mixture A B C c a b a ...

Page 41: ...o ease engine starting when the float chamber is empty or when operating the engine after it has been stored for a long time The built in primer pump sends fuel directly to the float chamber in the carburetor without operating the mechanical fuel pump A Fuel passage mechanical fuel pump B Fuel passage built in primer pump A B ...

Page 42: ... pumped out by the oil pump flows into the camshaft and it is then sent to the upper part of the engine to lubricate the crankshaft journal bearing After that the oil flows down to the crankshaft and then it is splashed by the rotational force of the crankshaft to lubricate all parts of the engine There is an oil hole in the crankshaft The oil entered through the oil hole will flow down to the cra...

Page 43: ...e tilt up function will be automatically locked when shifted in reverse When the shift lever a is moved to the reverse position the rod b which was pushing up the reverse lock c moves down Then due to the return spring d force the reverse lock c is forced to move in the direction a to prevent the outboard motor from tilting up The reverse lock system does not operate when the outboard motor is til...

Page 44: ...m A Engine oil flow B Splashing oil B A Crankshaft Crankshaft journal bearing Camshaft Oil pump Oil strainer Cylinder head Camshaft Piston Cylinder bore Valve lifter Crankshaft Crankshaft journal bearing Cylinder block Camshaft Oil pump Oil strainer Crank case Crankpin ...

Page 45: ...ooling water flow B Pilot water B A Thermostat Upper case Cooling water hose Water pump Cooling water inlet Thermostat Cylinder head Cylinder block Upper case Water pump Cooling water inlet Cooling water hose Upper case Lower case Water Lubrication diagram Cooling flow diagram ...

Page 46: ...2 17 TECH FEA Technical features and description Intake and exhaust flow diagram A Intake air flow B Exhaust gas flow B A Intake manifold Carburetor Intake silencer ...

Page 47: ...H F5AMH F6CMH 3 2 Clamp bracket 3 3 Uncrating procedure 3 4 Outboard motor mounting 3 4 Installing the charging system optional for European market 3 5 Installing the battery optional for European market 3 6 Rigging recommendations 3 7 Battery requirement 3 7 Propeller selection 3 7 Propeller size 3 7 Selection 3 7 ...

Page 48: ... control or fire hazards Consult your dealer or have a Yamaha trained person experienced in proper rigging mount the outboard motor Too much weight on the transom could change the center of gravity buoyancy operating balance or performance of the boat which could cause loss of control or swamping Con sult the boat manufacturer for the maximum engine weight allowable on the transom which is differe...

Page 49: ... 16 8 325 12 8 222 8 8 181 7 2 153 6 1 134 5 3 383 15 1 63 2 5 259 10 2 341 13 5 409 16 2 130 5 2 L 562 22 2 S 435 17 2 L 93 3 7 S 71 2 8 L 637 25 1 S 555 21 9 L 771 30 4 S 644 25 4 503 19 9 191 7 6 395 15 6 430 17 0 39 1 6 104 4 1 0 6 0 02 S 635 25 0 L 753 29 0 1 mm in Outboard motor installation Dimension ...

Page 50: ...3 3 RIG GING Rigging information Clamp bracket 22 0 9 60 2 4 83 3 3 136 5 4 48 1 9 83 3 3 55 2 2 55 2 2 mm in ...

Page 51: ...ion for easy mounting Outboard motor mounting Proper mounting of the outboard motor will provide better performance maximum reli ability and highest customer satisfaction This chapter contains the specifications nec essary to mount the outboard motor and may vary slightly depending on applications When mounting the outboard motor make sure that there is sufficient clearance for the outboard motor ...

Page 52: ...m optional for European market 1 Drain any remaining fuel from the fuel tank 2 Remove the manual starter See Removing the manual starter 7 7 3 Remove the flywheel magnet See Removing the flywheel magnet 7 19 4 Slide the clamp a down and then disconnect the fuel hose b 5 Remove the fuel tank c 6 Install the lighting coil d 7 Remove the bolt e and then install the Rectifier Regulator f using the inc...

Page 53: ...ten the leads using the holder q TIP Check that the lighting coil leads d do not interfere with the flywheel magnet 15 Install the included flywheel magnet optional See Installing the flywheel magnet 7 19 16 Connect the hose b and then fasten it using the clamp a 17 Install the fuel tank c 18 Install the manual starter See Installing the manual starter 7 10 Installing the battery optional for Euro...

Page 54: ...nd 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 outboard motor Propeller size The size of the propeller is indicated on a propeller blade a Propeller diameter in inches b Propeller pitch in inches c Propeller type propeller mark Selection When the engine speed is at the full throttle op...

Page 55: ...TRBL SHTG 0 1 2 3 4 5 6 7 8 9 10 A Troubleshooting 4 Outboard motor troubleshooting 4 1 Troubleshooting procedure 4 1 Troubleshooting the power unit 4 1 Troubleshooting the lower unit 4 3 ...

Page 56: ...ble 7 10 Manual starter malfunction Disassemble and check the manual starter 7 7 Decompressor malfunction Check the camshaft 7 44 Stuck piston or crankshaft Disassemble and check the power unit 7 21 7 39 Stuck drive shaft Disassemble and check the lower unit 8 7 8 10 Starter handle can be pulled but the engine does not crank Manual starter malfunction Disassemble and check the manual starter 7 7 D...

Page 57: ... does not operate properly Check the choke valve operation Carburetor malfunction Adjust the pilot screw 6 19 Disassemble and clean the carburetor 6 18 Air leakage carburetor to cylin der head Check the O ring and gaskets of the car buretor and intake manifold 6 10 Symptom 2 Cause Checking step See page Improper fuel and air amount supplied Carburetor malfunction Adjust the pilot screw 6 19 Disass...

Page 58: ...ston ring 7 41 Insufficient oil lubrication Check the oil pump 7 23 Check the oil strainer 7 25 Check the oil passage 2 13 Symptom 2 Cause Checking step See page Battery performance decrease Check the battery capacity and specific gravity Short open or loose connec tion in charging circuit Check the battery cable and terminals for proper connections Lighting coil malfunction Measure the lighting c...

Page 59: ... 3 Measuring the peak voltage 5 3 Using the digital tester 5 3 Charging unit and component 5 4 Checking the lighting coil optional for European market 5 4 Checking the Rectifier Regulator optional for European market 5 4 Ignition unit and component 5 5 Checking the ignition spark 5 5 Checking the spark plug cap 5 5 Checking the engine shut off switch 5 6 ...

Page 60: ...ead Black b Spark plug cap c Spark plug d Ground lead Black e CDI unit lead Black f Rectifier Regulator optional for European market A Install the holder horizontally and then fasten the spark plug wire using the holder B Point the end of plastic tie inward engine side and then cut the end b c f A B a d e d ...

Page 61: ... Engine shut off switch b CDI unit c Fuse 20 A optional for European mar ket d Lighting coil optional for European mar ket A Fold the holders inward so that the leads do not come out from the holders B Check that the ground lead does not inter fere with the bolt or washer c b B a A d ...

Page 62: ...one of these factors is present the peak voltage cannot be measured properly TIP Before measuring the peak voltage check all wiring harness for corrosion Also make sure that the wiring harness is connected properly and that the battery is fully charged Use peak voltage adapter B with the rec ommended digital circuit tester Connect the positive pin of peak voltage adapter B to the positive terminal...

Page 63: ...he battery cables are connected in reverse the Rectifier Regulator can be damaged 1 Remove the holder a 2 Measure the Rectifier Regulator output peak voltage TIP Do not use peak voltage adapter B when measuring the Rectifier Regulator output peak voltage 3 Disconnect the Rectifier Regulator connectors a b c and Rectifier Regulator ground lead d 4 Check the Rectifier Regulator for continuity Replac...

Page 64: ... and check for a spark WARNING Do not touch any of the connections of the special service tool 4 Disconnect the special service tool a and then connect the spark plug cap Checking the spark plug cap 1 Remove the spark plug cap from the spark plug wire by turning the cap coun terclockwise 2 Measure the spark plug cap resistance Rectifier Regulator continuity testing diode mode Tester probe Display ...

Page 65: ...g cap clockwise Checking the engine shut off switch 1 Disconnect the engine shut off switch connector a 2 Check the engine shut off switch for continuity 3 Connect the engine shut off switch connector a Switch position Terminal b c Clip installed Clip removed Button pushed a c b Charging unit and component Ignition unit and component ...

Page 66: ...5 7 ELEC Electrical system MEMO ...

Page 67: ...p 6 7 Installing the fuel tank 6 8 Intake silencer 6 10 Removing the throttle cable and throttle link 6 12 Removing the carburetor 6 12 Installing the carburetor 6 13 Installing the throttle cable and throttle link 6 13 Adjusting the throttle cable and throttle link 6 14 Carburetor 6 16 Disassembling the carburetor 6 18 Checking the carburetor 6 18 Assembling the carburetor 6 19 Fuel pump 6 21 Rem...

Page 68: ...e fuel strainer to joint d Fuel hose joint to fuel pump e Fuel hose fuel pump to carburetor f Fuel hose joint to primer pump g Fuel hose primer pump to carburetor h Fuel hose fuel joint to fuel cock a Fuel tank b Fuel cock c Fuel strainer d Joint e Fuel pump f Carburetor g Primer pump h Fuel joint a b c d e f g h e f g a h b c d ...

Page 69: ... 8 9 10 A Blowby hose oil return hose and cooling water hose a Blowby hose cylinder block to intake silencer b Oil return hose intake silencer to crank case c Cooling water hose thermostat cover to crankcase a Intake silencer a b c a ...

Page 70: ...Fuel tank 1 8 Bolt 1 M6 25 mm 9 Grommet 2 10 Collar 2 11 Clamp 11 12 Hose 1 13 Fuel cock 1 14 Fuel cock screw 1 M6 12 mm 15 Hose 1 16 Holder 1 17 Fuel joint 1 11 31 11 29 30 28 27 27 26 11 27 22 21 18 8 3 17 16 11 15 11 20 11 23 11 11 11 25 24 13 12 11 9 10 9 7 10 11 14 6 4 5 1 2 19 4 N m 0 4 kgf m 3 0 ft lb 7 N m 0 7 kgf m 5 2 ft lb 4 N m 0 4 kgf m 3 0 ft lb ...

Page 71: ... 1 22 Fuel strainer 1 23 Hose 1 24 Hose 1 25 Holder 1 26 Hose 1 27 Plastic tie 3 28 Joint 1 29 Primer pump 1 30 Hose 1 31 Hose 1 11 31 11 29 30 28 27 27 26 11 27 22 21 18 8 3 17 16 11 15 11 20 11 23 11 11 11 25 24 13 12 11 9 10 9 7 10 11 14 6 4 5 1 2 19 4 N m 0 4 kgf m 3 0 ft lb 7 N m 0 7 kgf m 5 2 ft lb 4 N m 0 4 kgf m 3 0 ft lb ...

Page 72: ...3 Disconnect the fuel hose a and then remove the fuel tank b 4 Disconnect the fuel hoses c and d 5 Remove the fuel cock screw e 6 Remove the fuel cock f 7 Remove the fuel hoses a c and d 8 Remove the cap g and then remove the fuel joint h Removing the primer pump Cover the fuel components using a rag to prevent fuel from spilling out 1 Remove the holder a and then remove the choke cable b a b c d ...

Page 73: ... fuel joint if the specified pressure cannot be maintained for at least 10 seconds Checking the fuel strainer tank side 1 Check the fuel strainer Clean it using straight gasoline if there is foreign mate rial Checking the fuel strainer 1 Check the fuel strainer Replace if cracked or damaged 2 Connect the special service tool a to the fuel inlet a 3 Block the fuel outlet b using a rubber plug b and...

Page 74: ...tall the clamps f and g temporarily onto the fuel hoses a b c and h and then connect the fuel hose to the fuel strainer i and primer pump j 3 Fasten the fuel hose b c and h using the clamps f 4 Install the holder k 5 Install the primer pump j to the holders l 6 Connect the fuel hose a and then fasten it using the clamp g 7 Connect the fuel hose h and then fasten it using the clamp g Leakage tester...

Page 75: ...older n 11 Tighten the choke holder bolt o to the specified torque Installing the fuel tank 1 Install the fuel joint a 2 Install the clamps b and c temporarily onto the fuel hoses d e and f and then connect the hoses to the fuel cock g 3 Fasten the fuel hoses using the clamps b and then install the holder h 4 Install the fuel cock g 5 Tighten the fuel cock screw i to the specified torque Choke cab...

Page 76: ... using the clamps c 7 Connect the hose e and then fasten it using the clamp c 8 Insert the protrusion a of the fuel tank j into the grommet k 9 Install the manual starter See Installing the manual starter 7 10 Fuel cock screw i 7 N m 0 7 kgf m 5 2 ft lb i d f c e c j k a ...

Page 77: ...Washer 1 5 Collar 1 6 Throttle cam 1 7 Lever 1 8 Holder 1 9 Clamp 3 10 Gasket 1 11 Throttle link rod 1 12 Intake manifold bolt 2 M6 25 mm 13 Intake manifold 1 14 Gasket 2 15 Spacer 1 16 Cap 1 17 Hose 1 21 20 20 17 16 11 10 2 9 3 4 5 6 7 8 14 15 14 13 12 18 9 9 21 22 19 23 1 12 N m 1 2 kgf m 8 9 ft lb Fuel tank Intake silencer ...

Page 78: ...No Part name Q ty Remarks 18 Carburetor assembly 1 19 Cap 1 20 Bolt 2 M6 85 mm 21 Washer 2 22 Intake silencer 1 23 O ring 1 21 20 20 17 16 11 10 2 9 3 4 5 6 7 8 14 15 14 13 12 18 9 9 21 22 19 23 1 12 N m 1 2 kgf m 8 9 ft lb ...

Page 79: ...her e collar f throttle cam g lever h and holder i Removing the carburetor Cover the fuel components using a rag to prevent fuel from spilling out 1 Remove the blowby hose a 2 Remove the intake manifold b and gasket c 3 Disconnect the fuel hose d and oil return hose e 4 Remove the intake silencer f O ring g carburetor h gaskets i and spacer j 5 Remove the fuel hose k c b a d e f g h i a b c e d k ...

Page 80: ... to the intake manifold i 4 Connect the oil return hose j and fuel hose c and then fasten the fuel hose using the clamp b 5 Install a new gasket k and the intake manifold i and then tighten the intake manifold bolt l to the specified torque 6 Install the blowby hose m Installing the throttle cable and throttle link 1 Install the lever a throttle cam b collar c washer d and holder e 2 Turn the thro...

Page 81: ...ngth of cable a so that the stopper b of the throttle cam b contacts section c of the bracket c 4 Adjust the length of cable d so that there is no clearance between the cable end d and the section e of the throttle cam b 5 Check that the section b on the throttle cam contacts stopper c when the throttle grip is in the fully open position and that the section b contacts stopper f when the throttle ...

Page 82: ...ever g tighten the throttle link screw e to the specified torque 10 Check that the throttle link is in the fully open and fully closed positions when turning the throttle grip to the fully open and fully closed positions Throttle cable locknut a 4 N m 0 4 kgf m 3 0 ft lb Throttle link screw e 1 5 N m 0 15 kgf m 1 11 ft lb a a e g ...

Page 83: ...m 4 Spring 1 5 O ring 1 6 Pilot screw 1 7 Pilot jet 1 8 Gasket 1 9 Float chamber 1 10 Screw 2 M4 12 mm 11 O ring 1 12 Drain screw 1 13 Pin 1 14 Spring 1 15 Main nozzle 1 16 Main jet 1 17 Float 1 12 10 11 1 2 5 6 4 19 15 14 13 16 18 17 7 3 10 8 9 1 5 N m 0 15 kgf m 1 11 ft lb A B 20 A For European market B For Oceanian market Intake silencer Carburetor ...

Page 84: ...uel system No Part name Q ty Remarks 18 Clip 1 19 Needle valve 1 20 Pilot screw 1 12 10 11 1 2 5 6 4 19 15 14 13 16 18 17 7 3 10 8 9 1 5 N m 0 15 kgf m 1 11 ft lb A B 20 A For European market B For Oceanian market ...

Page 85: ...the throttle valve operates smoothly 2 Check the air and fuel passages Clean the carburetor body if there is dirt or foreign material 3 Blow compressed air into all passages and jets WARNING When using compressed air wear safety glasses or safety goggles Otherwise eye injury could result from flying debris or liquid 4 Check the main jet pilot air jet and main nozzle Clean if there is dirt or resid...

Page 86: ...at e 3 Install the float pin f to the specified installation position a 4 Install the spring g 5 Measure the float height b Adjust the float height by bending the tab c if out of specification TIP When measuring the float height b hold the carburetor body at angle of 45 so that there is no load on the needle valve spring 6 Install a new gasket h the float chamber i a new O ring j and the drain scr...

Page 87: ...t screw o A For European market B For Oceanian market 8 Turn the pilot screw o in until it is lightly seated and then turn it out the specified number of turns Pilot screw driver p 90890 06673 Pilot screw setting F4B 1 3 8 3 4 turns out F5A 2 1 2 3 4 turns out F6C 1 3 8 3 4 turns out i k h j l m n o A B o p ...

Page 88: ...el pump valve screw 2 M3 5 mm 6 Valve 2 7 Fuel pump body 2 1 8 Plunger 1 9 Nut 4 10 Spring 1 11 Fuel pump body 1 1 12 Spring 1 13 Pin 1 14 Diaphragm 1 15 Fuel pump bolt 2 M6 30 mm 16 O ring 1 14 12 13 7 6 5 1 6 5 4 2 2 2 9 15 15 10 8 16 9 2 9 9 3 11 2 N m 0 2 kgf m 1 5 ft lb 0 5 N m 0 05 kgf m 0 37 ft lb 7 N m 0 7 kgf m 5 2 ft lb ...

Page 89: ...b 4 Block the fuel pump inlet a using the rubber plug b and then apply the specified positive pressure Check that there is no air leakage Disassembling the fuel pump 1 Remove the cover a diaphragm b and fuel pump body 2 c 2 Align the slot a in the fuel pump body 1 d with the hole b in the plunger e by turning the plunger e 3 Remove the pin f by pushing the plunger and diaphragm Vacuum pressure pum...

Page 90: ...oline to obtain proper operation of the fuel pump 1 Install the valves a and then tighten the fuel pump valve screws b to the speci fied torque 2 Install the springs c and d plunger e and diaphragm f 3 Align the hole a in the plunger e with the hole b in the diaphragm f by pushing the plunger and diaphragm 4 Install the pin g 5 Turn the plunger so that the protrusions c in the diaphragm f fit into...

Page 91: ...d then tighten the fuel pump screws l to the specified torque Installing the fuel pump 1 Install a new O ring a and the fuel pump b and then tighten the fuel pump bolts c to the specified torque Fuel pump screw l 2 N m 0 2 kgf m 1 5 ft lb Fuel pump bolt c 7 N m 0 7 kgf m 5 2 ft lb c c d d f h i j l l k a b c c ...

Page 92: ...Power unit assembly 7 11 Removing the power unit 7 12 Installing the power unit 7 14 Flywheel magnet 7 18 Removing the flywheel magnet 7 19 Installing the flywheel magnet 7 19 Crankcase 7 21 Removing the oil pump 7 23 Removing the oil seal housing 7 23 Removing the crankcase 7 23 Checking the crankcase 7 24 Checking the rotor assembly 7 24 Checking the oil strainer 7 25 Checking the oil seal housi...

Page 93: ...er 7 40 Checking the cylinder bore 7 41 Checking the piston ring 7 41 Checking the piston ring end gap 7 41 Checking the piston ring groove 7 42 Checking the piston ring side clearance 7 42 Checking the piston pin boss inside diameter 7 42 Checking the piston pin diameter 7 42 Checking the connecting rod small end inside diameter and big end inside diameter 7 42 Checking the crankshaft 7 43 Checki...

Page 94: ...lled 7 Remove the special service tool 8 Install the spark plug See step 4 in Installing the cylinder head 7 37 9 Connect the spark plug cap Checking the ignition timing 1 Install the special service tools a and b to the spark plug wire a 2 Start the engine and warm it up until the idle speed stabilizes at 1450 1550 r min 3 Check that the pointer b on the manual starter is aligned with the specifi...

Page 95: ...I unit bolts a and then adjust the CDI unit air gap c 3 Tighten the CDI unit bolts a to the specified torque 4 Measure the CDI unit air gap Checking the valve clearance Measure the valve clearances when the engine is cold Do not turn the flywheel magnet counter clockwise Otherwise the water pump impeller could be damaged 1 Remove the clip from the engine shut off switch 2 Remove the engine shut of...

Page 96: ...ew gasket h the cylinder head cover f the holders c d i and ground lead b and then tighten the bolts e in the order a b and so on NOTICE Do not reuse a gasket always replace it with a new one 7 Install the ground leads a b and engine shut off switch lead a to the holders c and d Adjusting the valve clearance Adjust the valve clearances when the engine is cold e c a d b e e e f g b c e d Valve clea...

Page 97: ...t a and then turn the rocker arm pivot b until the specified valve clearance is obtained TIP To decrease the valve clearance turn the rocker arm pivot in direction c To increase the valve clearance turn the rocker arm pivot in direction d 3 Tighten the valve adjusting locknut a to the specified torque and then check the valve clearances Valve clearance Intake and exhaust 0 08 0 12 mm 0 003 0 005 i...

Page 98: ...rope 1 1800 0 mm 70 9 in reference data 5 Bolt 2 M6 35 mm 6 Guide 1 7 Bolt 1 M6 20 mm 8 Starter plunger 1 9 Spring 1 10 Cover 1 11 Sheave drum 1 12 Spring 2 13 Drive pawl 2 14 Clip 1 15 Drive plate 1 16 Drive plate screw 1 17 E clip 1 10 5 5 7 8 9 17 18 19 11 12 12 13 13 14 15 16 1 2 3 4 6 7 N m 0 7 kgf m 5 2 ft lb ...

Page 99: ...7 6 Manual starter 0 1 2 3 4 5 6 7 8 9 10 A No Part name Q ty Remarks 18 Plate 1 19 Spiral spring 1 10 5 5 7 8 9 17 18 19 11 12 12 13 13 14 15 16 1 2 3 4 6 7 N m 0 7 kgf m 5 2 ft lb ...

Page 100: ...l springs g and then remove the clip h from the drive plate e 4 Remove the sheave drum d and plate i 5 Remove the spiral spring j WARNING The spiral spring can pop out Cover the spiral spring with rags when removing it 6 Remove the starter rope c E clip k starter plunger a starter plunger spring l and guide m Checking the manual starter 1 Check the guide drive pawls drive plate plate and starter p...

Page 101: ...d 3 Route the starter rope e 4 Tie a knot in both ends a and b of the starter rope e TIP Make sure to leave c 12 0 mm 0 47 in or more at the end a of the starter rope 5 Wind the starter rope e twice around the sheave drum f counterclockwise and then fit the starter rope e into the slot d 6 Hook the end e of the spiral spring g onto the section f of the sheave drum f and then install the spiral spr...

Page 102: ...ing the protrusion n on the drive pawls k and the slots p in the drive plate m and then tighten the drive plate screw n to the specified torque 13 Align the protrusion g on the starter plunger b and the mark h on the manual starter i 14 While holding the starter rope e turn the sheave dram f 3 turns counterclock wise 15 Remove the starter rope e from the slot d and then let the sheave drum f turn ...

Page 103: ... start in gear protection 1 Move the shift lever to the N position 2 Loosen the start in gear protection cable locknut a and then align the protrusion b on the starter plunger a and the mark c on the manual starter b 3 Tighten the start in gear protection cable locknut a to the specified torque 4 Move the shift lever to the F or R position 5 Check that the starter handle cannot be pulled Measuring...

Page 104: ...lt 4 M6 12 mm 7 Holder 1 8 Bracket 1 9 CDI unit coupler 1 10 Ground lead 1 11 Power unit assembly 1 12 Plate 1 13 Bolt 5 M6 15 mm 14 Power unit mounting bolt 4 M6 50 mm 15 Power unit mounting bolt 5 M6 40 mm 16 Cover 1 1 2 1 4 6 6 5 8 7 14 15 16 13 13 13 14 15 15 13 12 5 5 11 6 3 6 9 10 2 N m 0 2 kgf m 1 5 ft lb 12 N m 1 2 kgf m 8 9 ft lb 12 N m 1 2 kgf m 8 9 ft lb ...

Page 105: ...e the holder a and then disconnect the choke cable b 6 Disconnect the throttle cables c 7 Slide the clamp d away from the carburetor e slide the clamp f away from the fuel pump g and then disconnect the fuel hoses h and i 8 Disconnect the CDI unit coupler a CDI unit ground lead b engine shut off switch ground lead c and ground lead j 9 Remove the plastic tie k 10 Loosen the screw l and then remove...

Page 106: ...lipping off easily 15 Install the special service tool A and then suspend the power unit NOTICE To prevent damage to the engine or tool screw in the puller set bolts evenly and completely so that the flywheel puller is parallel to the flywheel magnet 16 Loosen the power unit mounting bolts B and C in the order a b and so on and then remove the power unit assembly Flywheel holder x 90890 06522 Flyw...

Page 107: ... 1 Install the engine shut off switch a and then tighten the engine shut off switch nut b to the specified torque 2 Route the engine shut off switch lead a and ground lead c 3 Install the special service tool See steps 13 15 in Removing the power unit 7 12 4 Clean the power unit mating surface and then install the dowels d and a new gasket e NOTICE Do not reuse a gasket always replace it with a ne...

Page 108: ...en tighten the flywheel magnet nut h to the specified torque NOTICE Apply force in the direction of the arrow to prevent the flywheel holder i from slipping off easily 9 Install the plate l and cover m Power unit mounting bolt f and g 12 N m 1 2 kgf m 8 9 ft lb f f f f f g g g e d d i h g f e d c b a f f f f g g STBD PORT Flywheel holder i 90890 06522 Flywheel holder i 90890 06522 Flywheel magnet ...

Page 109: ... off switch lead a CDI unit ground lead c CDI unit lead e engine shut off switch ground lead d and ground leads c and y using the plastic ties z 15 Connect the fuel hoses A and B and then fasten them using the clamps C 16 Connect the throttle cables D and then adjust the throttle cables D See steps 2 9 in Adjusting the throttle cable and throttle link 6 14 17 Connect the choke cable E and then ins...

Page 110: ...OWR Power unit 19 Install the fuel tank See step 8 in Installing the fuel tank 6 8 20 Install the manual starter See Installing the manual starter 7 10 Choke holder bolt G 4 N m 0 4 kgf m 3 0 ft lb F E G G D ...

Page 111: ...gnet nut 1 Width across flats 22 mm 2 Washer 1 3 Starter pulley 1 4 Flywheel magnet 1 5 Woodruff key 1 6 Spark plug cap 1 7 CDI unit 1 8 CDI unit bolt 2 M6 25 mm 9 Bolt 1 M6 12 mm 10 Holder 1 60 N m 6 0 kgf m 44 3 ft lb 10 N m 1 0 kgf m 7 4 ft lb 1 2 3 4 5 7 8 6 10 9 Power unit assembly Flywheel magnet ...

Page 112: ...l magnet 1 Install the Woodruff key a flywheel magnet b starter pulley c and washer d and then tighten the flywheel magnet nut e to the specified torque NOTICE Apply force in the direction of the arrow to prevent the flywheel holder f from slipping off easily TIP Make sure to remove any grease from the tapered portion a of the crankshaft and the inner surface b of the flywheel magnet b 2 Install t...

Page 113: ...7 20 Flywheel magnet 0 1 2 3 4 5 6 7 8 9 10 A 4 Adjust the CDI unit air gap See Adjusting the CDI unit air gap 7 2 CDI unit bolt h 10 N m 1 0 kgf m 7 4 ft lb g i j h ...

Page 114: ...12 mm 7 Gasket 1 8 Oil strainer 1 9 Spring 1 10 Cover 1 11 Crankcase bolt 10 M6 50 mm 12 Dowel 2 13 Gasket 1 14 Crankcase 1 15 Holder 1 16 Hose 1 17 Gasket 1 13 12 12 14 16 15 17 18 21 20 19 19 10 7 8 6 6 5 4 22 23 3 1 11 11 11 11 11 9 19 2 11 11 11 11 a b 5 N m 0 5 kgf m 3 7 ft lb 11 N m 1 1 kgf m 8 1 ft lb 20 N m 2 0 kgf m 14 8 ft lb ...

Page 115: ...8 15 mm 19 Bolt 3 M6 35 mm 20 Drain bolt 1 M8 20 mm 21 Gasket 1 22 Bolt 1 M8 20 mm 23 Oil seal housing 1 13 12 12 14 16 15 17 18 21 20 19 19 10 7 8 6 6 5 4 22 23 3 1 11 11 11 11 11 9 19 2 11 11 11 11 a b 5 N m 0 5 kgf m 3 7 ft lb 11 N m 1 1 kgf m 8 1 ft lb 20 N m 2 0 kgf m 14 8 ft lb ...

Page 116: ...ainer f 3 Remove the plate g and then remove the rotor assembly h TIP Keep the rotor assembly h in the same direction as originally installed Removing the oil seal housing 1 Remove the oil seal housing a 2 Remove the O ring b and oil seals c and d Removing the crankcase 1 Remove the cooling water hose a 2 Remove the blind plug b and gasket c a b d c e f g h a b d c a c b ...

Page 117: ...r a 3 Measure the camshaft journal inside diameter b 4 Measure the rotor housing inside diameter c Checking the rotor assembly 1 Check the rotor assembly Replace if cracked or worn 2 Measure the rotor assembly dimensions a b and c j i h g f e d c b a d e f g d Crankshaft journal inside diameter a 25 020 25 041 mm 0 9850 0 9859 in Camshaft journal inside diameter b 15 000 15 018 mm 0 5906 0 5913 in...

Page 118: ... and then tighten the crankcase bolts d to the specified torques in 2 stages and in the order a b and so on 3 Install a new gasket e and then tighten the blind plug f to the specified torque 4 Install the cooling water hose g Outer rotor diameter a 22 980 23 000 mm 0 9047 0 9055 in Outer rotor height b 9 950 9 980 mm 0 3917 0 3929 in Inner rotor height c 9 950 9 980 mm 0 3917 0 3929 in d c b a Cra...

Page 119: ...new gasket e and the cover f 3 Install a new gasket g and the drain bolt h Installing the oil seal housing Do not reuse an oil seal or O ring always replace it with a new one 1 Install new oil seals a 2 Install the oil seal d 3 Install a new O ring f to the oil seal housing g and then install the oil seal housing g a b c d e f g h b c a Driver rod L3 b 90890 06652 Needle bearing attachment c 90890...

Page 120: ...1 11 Ground lead 1 12 Bolt 5 M6 25 mm 13 Holder 2 14 Cylinder head cover 1 15 Push rod guide 1 16 Pivot bolt 2 17 Rocker arm 2 31 1 2 2 3 4 5 6 7 28 26 26 25 25 8 8 24 24 24 24 15 16 16 17 17 18 18 19 23 23 22 22 21 21 20 29 30 27 9 14 12 13 13 12 11 12 12 13 N m 1 3 kgf m 9 6 ft lb 10 N m 1 0 kgf m 7 4 ft lb 10 N m 1 0 kgf m 7 4 ft lb 2 N m 0 2 kgf m 1 5 ft lb a b 13 N m 1 3 kgf m 9 6 ft lb 28 N ...

Page 121: ...4 M8 60 mm 25 Valve seal 2 26 Valve guide 2 27 Spark plug 1 28 Cylinder head 1 29 Intake valve 1 30 Exhaust valve 1 31 Dowel 2 31 1 2 2 3 4 5 6 7 28 26 26 25 25 8 8 24 24 24 24 15 16 16 17 17 18 18 19 23 23 22 22 21 21 20 29 30 27 9 14 12 13 13 12 11 12 12 13 N m 1 3 kgf m 9 6 ft lb 10 N m 1 0 kgf m 7 4 ft lb 10 N m 1 0 kgf m 7 4 ft lb 2 N m 0 2 kgf m 1 5 ft lb a b 13 N m 1 3 kgf m 9 6 ft lb 28 N ...

Page 122: ...ve adjusting locknuts i and then remove the rocker arm pivots j and rocker arms k 4 Loosen the cylinder head bolts l in the order a b and so on and then remove the cylinder head m gasket n and push rods o NOTICE Do not scratch or damage the mating surfaces of the cylinder head and cylinder block Disassembling the cylinder head 1 Remove the push rod guide a 2 Remove the intake and exhaust valves a ...

Page 123: ...ck the cylinder head warpage in 6 directions Replace the cylinder head assembly if above specification Checking the rocker arm 1 Check the rocker arms Replace if cracked damaged or worn Checking the push rod 1 Measure the push rod runout Checking the valve spring 1 Measure the valve spring free length a Valve spring compressor b 90890 04019 Valve spring compressor attachment c 90890 06320 c b d d ...

Page 124: ...ing the valve guide Before checking the valve guide make sure to check the valve 1 Measure the valve guide inside diameter a Replace if out of specification Valve spring free length a 27 6 mm 1 09 in Valve spring tilt limit b 1 0 mm 0 04 in Valve margin thickness a Intake 0 800 1 200 mm 0 0315 0 0472 in Exhaust 1 100 1 500 mm 0 0433 0 0591 in a b a Valve stem diameter b Intake 5 475 5 490 mm 0 215...

Page 125: ... guide reamer counter clockwise when removing it Make sure to clean the valve guide after reaming it 4 Measure the valve guide inside diameter Checking the valve seat 1 Remove carbon deposits from the valves 2 Apply a thin even layer of Mechanic s blueing dye Dykem onto the valve seat 3 Press the valve lightly against the valve seat using the special service tool a Valve guide inside diameter a In...

Page 126: ... valve seat cutters 2 Cut the surface of the valve seat using a 45 cutter by turning the cutter clockwise until the valve seat face has become smooth NOTICE Do not over cut the valve seat To prevent chatter marks make sure to turn the cutter evenly using a downward force of 40 50 N 4 0 5 0 kgf 8 8 11 0 lbf Valve lapper a 90890 04101 Valve seat contact width a Intake and exhaust 0 6 0 8 mm 0 02 0 0...

Page 127: ...the valve seat contact area of the valve See Checking the valve seat 7 32 Example If the valve seat contact area is too wide and situated in the center of the valve face cut the top edge of the valve seat using a 30 cutter and then cut the bottom edge using a 60 cutter to center the area and set its width b Previous contact width If the valve seat contact area is too narrow and situated near the t...

Page 128: ... Recheck the valve seat contact area of the valve See Checking the valve seat 7 32 Checking the spark plug 1 Clean the electrodes a using a spark plug cleaner 2 Check the spark plug Replace if the electrodes are eroded there is carbon or other deposits 3 Check the spark plug gap b Replace if out of specification Checking the thermostat cover anode 1 Check the anode Replace if eroded Clean if there...

Page 129: ...1 Install a new valve seal a 2 Install the valve b spring seat c valve spring d and valve spring retainer e in this order and then install the special service tools f and g 3 Compress the valve spring and then install the valve cotter h Water temperature Valve opening a 58 62 C 136 144 F Starts opening above 70 C 158 F 3 0 mm 0 12 in or above a a Valve spring compressor f 90890 04019 Valve spring ...

Page 130: ...the cylinder head bolts d to the specified torques in 2 stages and in the order a b and so on 2 Install the thermostat cover anode e to the thermostat cover f and then tighten the thermostat cover anode screw g to the specified torque 3 Install the thermostat h a new gasket i the thermostat cover f and then connect the ground lead j 4 Install the spark plug k and then tighten it to the specified t...

Page 131: ...s q 7 Install the crankcase See Installing the crankcase 7 25 8 Adjust the valve clearance See steps 2 and 3 in Adjusting the valve clearance 7 3 9 Install a new gasket r the cylinder head cover s and the clamps t u and then connect the ground lead j 10 Tighten the bolts v in the order a b and so on Thermostat cover anode screw g 2 N m 0 2 kgf m 1 5 ft lb Spark plug k 13 N m 1 3 kgf m 9 6 ft lb a ...

Page 132: ... 2 M7 35 mm 5 Clip 2 6 Piston pin 1 7 Piston 1 8 Piston ring set 1 9 Plate 1 10 Breather plate screw 2 M5 10 mm 11 Valve lifter 2 12 Camshaft 1 13 Crankshaft 1 14 Washer 1 15 Ball bearing 1 16 O ring 1 17 Dipstick 1 1 2 3 4 5 5 6 7 8 9 10 11 11 12 13 14 15 a b 6 N m 0 6 kgf m 4 4 ft lb 12 N m 1 2 kgf m 8 9 ft lb 16 17 8 N m 0 8 kgf m 5 9 ft lb ...

Page 133: ...emove the connecting rod and piston assembly b 4 Remove the washer e crankshaft f and oil seal g 5 Remove the ball bearing h 6 Remove the clips k and then remove the piston pin l and connecting rod c Checking the piston diameter 1 Measure the piston diameter a at the specified measuring point b a c d b a b e f g Driver rod L3 i 90890 06652 Needle bearing attachment j 90890 06612 i j h k k l c a b ...

Page 134: ...96 in Measuring point b 1 0 mm 0 04 in up from the bottom of the piston skirt Oversize piston diameter Oversize 1st 62 200 62 215 mm 2 4488 2 4494 in Oversize 2nd 62 450 62 465 mm 2 4587 2 4592 in Cylinder bore D1 D6 62 000 62 015 mm 2 4409 2 4415 in D1 D2 D3 D4 D5 D6 a b c d e Piston ring dimensions Top ring a B 1 170 1 190 mm 0 0461 0 0469 in T 2 500 2 700 mm 0 0984 0 1063 in 2nd ring b B 1 170 ...

Page 135: ...by align ing the mark b on the connecting rod c and the mark d on the connecting rod cap a and then tighten the connecting rod cap bolts a to the specified torques in 2 stages 2 Measure the connecting rod small end inside diameter e and the big end inside diameter f Piston ring groove Top ring a 1 210 1 230 mm 0 0476 0 0484 in 2nd ring b 1 210 1 230 mm 0 0476 0 0484 in Oil ring c 2 010 2 030 mm 0 ...

Page 136: ... parallel to the crankshaft Connecting rod small end inside diameter e 15 015 15 029 mm 0 5911 0 5917 in Connecting rod big end inside diameter f 28 000 28 015 mm 1 1024 1 1030 in Connecting rod cap bolt a 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 12 N m 1 2 kgf m 8 9 ft lb e a f a c b d e c b d a Crankshaft journal diameter cylinder block side b 24 980 24 993 mm 0 9835 0 9840 in Crankshaft journal diamet...

Page 137: ...he width of the compressed Plastigauge PG 1 on the crankpin Checking the cylinder block 1 Check the cylinder block Replace if cor roded or cracked 2 Measure the camshaft journal inside diameter a Checking the camshaft 1 Check the camshaft gear Replace the camshaft if damaged or worn 2 Check the decompression actuator Replace the camshaft if the decompression actuator does not operate smoothly 3 Me...

Page 138: ...in clip or bearing always replace it with a new one 1 Install a new ball bearing a Cam lobe height a Intake 32 037 32 137 mm 1 2613 1 2652 in Exhaust 32 038 32 138 mm 1 2613 1 2653 in Cam lobe width b Intake and exhaust 26 950 27 050 mm 1 0610 1 0650 in Fuel pump cam diameter c 19 600 mm 0 7717 in reference data Camshaft journal diameter d 14 965 14 990 mm 0 5892 0 5902 in a b c d d Camshaft runou...

Page 139: ...tion as the UP mark c on the piston crown Do not align the clip end with the groove d in the piston pin boss 5 Install the oil rings e 2nd ring f and top ring g 6 Offset the piston ring end gaps NOTICE Do not scratch the pistons or break the piston rings Driver rod LL b 90890 06605 Ball bearing attachment c 90890 06632 Driver rod LS e 90890 06606 Ball bearing attachment f 90890 06655 d e f h g d c...

Page 140: ...g rod cap bolts m to the specified torques in 2 stages TIP Make sure that the crankshaft turns smoothly 9 Install the valve lifters n 10 Align the mark p on the crankshaft o with the mark r on the camshaft p and then install the camshaft p 11 Install a new O ring q to the dipstick r and then screw in the dipstick r 12 Install the plate s and then tighten the breather plate screws t to the specifie...

Page 141: ...tch 8 9 Checking the propeller shaft housing 8 9 Checking the reverse gear 8 9 Assembling the propeller shaft assembly 8 9 Assembling the propeller shaft housing assembly 8 9 Drive shaft and lower case 8 10 Removing the drive shaft 8 11 Disassembling the lower case 8 11 Checking the pinion 8 11 Checking the forward gear 8 11 Checking the drive shaft 8 12 Checking the lower case 8 12 Assembling the...

Page 142: ...11 Washer 1 12 Propeller 1 13 Spacer 1 14 Lower case mounting bolt 2 M6 40 mm 15 Lock washer 1 16 Bolt 1 M6 20 mm 17 Anode 1 A 1 1 2 3 4 23 8 8 23 22 21 19 19 5 6 11 14 14 18 6 17 15 16 13 12 11 10 9 16 N m 1 6 kgf m 11 8 ft lb 15N m 1 5 kgf m 11 1 ft lb 11N m 1 1 kgf m 8 1 ft lb 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 7 6 20 11N m 1 1 kgf m 8 1 ft lb A L tran...

Page 143: ...ension 1 21 Bushing 1 22 Circlip 1 23 Dowel 2 A 1 1 2 3 4 23 8 8 23 22 21 19 19 5 6 11 14 14 18 6 17 15 16 13 12 11 10 9 16 N m 1 6 kgf m 11 8 ft lb 15N m 1 5 kgf m 11 1 ft lb 11N m 1 1 kgf m 8 1 ft lb 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 9 N m 0 9 kgf m 6 6 ft lb 7 6 20 11N m 1 1 kgf m 8 1 ft lb A L transom model ...

Page 144: ...propeller to keep the propeller from turning and then remove the propeller nut and propeller 5 Set the gear shift to the R position 6 Remove the covers a and then remove the joints b and c 7 Remove the lower unit d 8 Remove the anode e and flushing screw f Removing the lower unit L transom model Make sure to remove the clip from the engine shut off switch When removing the lower unit with the powe...

Page 145: ... the propeller blades and splines Replace the propeller if cracked dam aged or worn Checking the lower unit anode 1 Check the anode Replace if eroded Clean if there is grease oil or scales NOTICE Do not apply grease oil or paint to the anode Stopper guide plate c 90890 06501 Stopper guide stand d 90890 06538 Bearing puller assembly e 90890 06535 a c b d a b c d e b e ...

Page 146: ... 4 M6 45 mm 2 Plate 2 3 Rubber seal 1 4 Water pump housing 1 5 Insert cartridge 1 6 Impeller 1 7 Gasket 1 8 Outer plate cartridge 1 9 Rubber seal 1 10 Bolt 1 M6 25 mm 11 Dowel 2 12 Housing 1 13 Shift rod 1 14 Pin 1 15 Pin 1 16 Gasket 1 15 9 16 14 13 5 6 7 8 10 12 11 1 2 2 4 3 1 ...

Page 147: ...t rod j rubber seal k gasket l and pin m Checking the water pump 1 Check the water pump housing Replace if cracked or deformed TIP If the engine overheated check the water pump housing for deformation 2 Check the impeller insert cartridge and outer plate cartridge Replace if cracked or worn 3 Check the pin and pin hole in the drive shaft Replace if deformed or worn Checking the shift rod 1 Check t...

Page 148: ...sing No Part name Q ty Remarks 1 Shift plunger 1 2 Spring 1 3 Dog clutch 1 4 Propeller shaft 1 5 Washer 2 6 Reverse gear 1 7 Ball bearing 1 8 O ring 1 9 Oil seal 2 10 Propeller shaft housing 1 11 Bolt 2 M6 15 mm 1 2 3 4 5 6 7 8 10 11 11 9 9 ...

Page 149: ... propeller shaft assembly 1 Remove the shift plunger a 2 Push the spring b and then remove the dog clutch c 3 Remove the spring b Disassembling the propeller shaft housing assembly 1 Remove the washers a and reverse gear b 2 Remove the ball bearing c 3 Remove the oil seals g and O ring h Checking the propeller shaft 1 Check the propeller shaft Replace if damaged or worn 2 Measure the propeller sha...

Page 150: ...the spring a and then install the dog clutch c Assembling the propeller shaft housing assembly Do not reuse a bearing oil seal or O ring always replace it with a new one 1 Install new oil seals a TIP Install an oil seal halfway into the propeller shaft housing and then install the other oil seal 2 Install a new ball bearing d 3 Install a new O ring e TIP Face the identification mark a on the ball ...

Page 151: ...haft and lower case No Part name Q ty Remarks 1 Drive shaft 1 2 Clip 1 3 Oil seal 2 4 Bushing 1 5 Lower case 1 6 Bushing 1 7 Washer 1 8 Pinion 1 9 E clip 1 10 Ball bearing 1 11 Forward gear 1 1 2 3 4 5 6 7 8 9 10 11 Propeller shaft housing Drive shaft and lower case ...

Page 152: ...e the bushing g Checking the pinion 1 Check the teeth of the pinion Replace if cracked or worn Checking the forward gear 1 Check the teeth and dogs of the forward gear Replace if cracked or worn Stopper guide plate b 90890 06501 Stopper guide stand c 90890 06538 Bearing puller assembly d 90890 06535 a c b d e b a c d Stopper guide plate b 90890 06501 Stopper guide stand c 90890 06538 Bushing insta...

Page 153: ...oil seal always replace it with a new one 1 Install a new bushing a 2 Install a new bushing c 3 Install new oil seals f to the specified depth a 4 Install the ball bearing h Drive shaft runout 0 4 mm 0 02 in Bushing installer center bolt b 90890 06601 a b a b Driver rod L3 d 90890 06652 Bushing attachment e 90890 06649 Driver rod L3 d 90890 06652 Needle bearing attachment g 90890 06615 Depth a 1 0...

Page 154: ... propeller shaft housing assembly S transom model 1 Install the reverse gear a washers b drive shaft c and shift plunger d to the propeller shaft housing e 2 Install the propeller shaft housing assembly f Installing the propeller shaft housing assembly L transom model 1 Install the reverse gear a washers b drive shaft c and shift plunger d to the propeller shaft housing e 2 Install the lower case ...

Page 155: ...e housing d 4 Install the outer plate cartridge g a new gasket h and then install the pin i 5 Align the slot b in the impeller j with the pin i and then install the impeller 6 Align the protrusion c on the insert cartridge k with the groove d in the water pump housing l and then install the insert cartridge 7 Install the water pump housing assembly NOTICE Do not turn the drive shaft counterclockwi...

Page 156: ...maintained in the lower unit for at least 10 seconds NOTICE Do not over pressurize the lower unit Otherwise the oil seals could be damaged 5 If the specified pressure cannot be maintained check the drive shaft propeller shaft and rubber seal for bends or damage and check the shift rod rubber seal for damage or wear Assembling the extension L transom model 1 Install the bushing a and circlip b Drai...

Page 157: ...er to the R position 2 Set the gear shift to the R position 3 Install the dowels a 4 Install the lower unit b to the upper case and then tighten the lower case mounting bolts c to the specified torque 5 Install the anode d TIP Make sure that the cooling water pipe e is inserted securely into the rubber seal f 6 Install the joints g and h and then tighten the shift joint bolt i to the specified tor...

Page 158: ...m the engine shut off switch Do not hold the propeller with your hands when loosening or tightening the propeller nut When installing the lower unit with the power unit installed make sure to sus pend the outboard motor If the outboard motor is not suspended it can fall sud denly and result in severe injuries See steps 1 and 2 in Installing the lower unit S transom model 8 16 1 Install the dowels ...

Page 159: ... Drive shaft and lower case 0 1 2 3 4 5 6 7 8 9 10 A TIP Make sure that the cooling water pipe f is inserted securely into the rubber seal g See steps 6 12 in Installing the lower unit S transom model 8 16 ...

Page 160: ...8 19 LOWR Lower unit MEMO ...

Page 161: ... 9 6 Disassembling the bottom cowling 9 8 Assembling the bottom cowling 9 8 Upper case and shift lever 9 9 Removing the shift lever 9 11 Removing the upper case 9 11 Checking the upper case 9 12 Installing the upper case 9 12 Installing the shift lever 9 14 Clamp bracket 9 15 Disassembling the clamp bracket 9 17 Assembling the clamp bracket 9 17 ...

Page 162: ...ushing 1 8 Washer 1 9 Washer 2 10 Wave washer 1 11 Bushing 1 12 Throttle friction adjuster 1 13 Tiller handle 1 14 Throttle rod 1 15 Plate 1 16 Throttle rod screw 2 M5 12 mm 17 Friction piece 1 2 1 5 3 6 7 8 4 3 24 20 21 20 19 18 23 22 17 14 16 15 13 12 10 9 9 11 28 N m 2 8 kgf m 20 7 ft lb 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb ...

Page 163: ...n 1 19 Bushing 1 20 Washer 2 21 Spring 1 22 Throttle grip 1 23 Throttle grip screw 1 M5 20 mm 24 Bushing 1 2 1 5 3 6 7 8 4 3 24 20 21 20 19 18 23 22 17 14 16 15 13 12 10 9 9 11 28 N m 2 8 kgf m 20 7 ft lb 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb 4 N m 0 4 kgf m 3 0 ft lb ...

Page 164: ...ove the bushing k 4 Remove the throttle grip l washers m spring n and bushing o 5 Remove the cotter pin p and throttle friction adjuster q 6 Remove the plate r friction piece s throttle cables t and throttle rod u Assembling the tiller handle 1 Pass the throttle cables a through the holes in the tiller handle b 2 Install the cable into the throttle rod c b c a e d k i j g h f q p o m n l s r t u a...

Page 165: ...place it with a new one 6 Install the bushing i washers j spring k throttle grip l and then tighten the throttle grip screw m to the specified torque 7 Install the bushing n and then install the washers o wave washer p bushing q washer r and bushing s 8 Install the tiller handle assembly t and plate u and then tighten the tiller handle mounting bolt v to the specified torque Throttle rod screw f 4...

Page 166: ...9 5 BRKT Bracket unit 9 Install the holders w x and y Tiller handle mounting bolt v 28 N m 2 8 kgf m 20 7 ft lb t v u x y w ...

Page 167: ...ommet 4 7 Nut 2 8 Bolt 1 M6 20 mm 9 Pin 2 10 Cowling lock lever 1 11 Bracket 1 12 Clip 2 13 Bracket 1 14 Bottom cowling 1 15 Grommet 1 16 Carrying handle bolt 2 M8 20 mm 17 Carrying handle 1 2 2 3 4 20 19 18 6 6 6 5 5 5 8 15 9 9 13 11 10 12 14 17 7 7 16 16 1 18 18 2 N m 0 2 kgf m 1 5 ft lb 11 N m 1 1 kgf m 8 1 ft lb 4 N m 0 4 kgf m 3 0 ft lb 19 N m 1 9 kgf m 14 0 ft lb 12 Tiller handle Bottom cowl...

Page 168: ...me Q ty Remarks 18 Collar 4 19 Cap 1 20 Grommet 1 2 2 3 4 20 19 18 6 6 6 5 5 5 8 15 9 9 13 11 10 12 14 17 7 7 16 16 1 18 18 2 N m 0 2 kgf m 1 5 ft lb 11 N m 1 1 kgf m 8 1 ft lb 4 N m 0 4 kgf m 3 0 ft lb 19 N m 1 9 kgf m 14 0 ft lb 12 ...

Page 169: ... pins d and clips e 2 Install the carrying handle f and then tighten the carrying handle bolts g to the specified torque 3 Install the start in gear protection cable h and holders i and j 4 Tighten the start in gear protection cable locknut a and primer pump holder bolts k to the specified torque a c b i h g f e e d f Carrying handle bolt g 19 N m 1 9 kgf m 14 0 ft lb Start in gear protection cabl...

Page 170: ...ber seal 1 7 Shift link lever 1 8 O ring 2 9 Ball 1 10 Spring 1 11 Shift link bolt 1 M5 25 mm 12 Bracket 1 13 Washer 1 14 Cotter pin 1 15 Upper case 1 16 Damper 1 17 Cover 1 3 6 12 13 14 15 17 16 18 18 19 18 20 18 21 24 24 25 5 26 27 26 29 4 11 7 8 9 10 30 23 22 2 1 3 5 N m 0 35 kgf m 2 58 ft lb 19 N m 1 9 kgf m 14 0 ft lb 28 31 3 N m 0 3 kgf m 2 2 ft lb 32 ...

Page 171: ...Bushing 1 22 Bushing 1 23 Bushing 1 24 Bushing 2 25 Spring 1 26 Bolt 2 27 Reverse lock 1 28 Grommet 1 29 Friction piece 1 30 Bushing 1 31 Collar 1 32 Grease nipple 1 3 6 12 13 14 15 17 16 18 18 19 18 20 18 21 24 24 25 5 26 27 26 29 4 11 7 8 9 10 30 23 22 2 1 3 5 N m 0 35 kgf m 2 58 ft lb 19 N m 1 9 kgf m 14 0 ft lb 28 31 3 N m 0 3 kgf m 2 2 ft lb 32 ...

Page 172: ...d spring e 3 Remove the cap f shift lever a and O rings g 4 Remove the cotter pin h washer i and shift rod j Removing the upper case 1 Remove the water pipe a 2 Move the plate a up and then tilt the outboard motor up 3 Remove the reverse lock b and springs c and d 4 Remove the upper case e e d a c b f a g h i j a a c d b ...

Page 173: ... upper case Replace if cracked or eroded Installing the upper case 1 Install a new bushing a NOTICE Do not reuse a bushing always replace it with a new one 2 Install the bushings d and e e h g f i j l l k Bushing installer center bolt n 90890 06601 Bushing attachment o 90890 06650 Pipe p reference b 12 0 mm 0 5 in c 16 0 mm 0 7 in d 37 0 mm 1 5 in Driver rod L3 b 90890 06652 Needle bearing attachm...

Page 174: ... case i 5 Install the cover j and then install the steering friction adjuster k 6 Install the upper case l 7 Tilt the outboard motor up 8 Install the springs m n and reverse lock o 9 Install the rubber seal p to the water pipe q and then install the water pipe q d e g f i i h h j j k k l n m o q p ...

Page 175: ...d a new cotter pin c 2 Install new O rings d and the shift lever e 3 Tighten the shift lever bolt f to the specified torque and then install the cap g 4 Install the spring h ball i collar j bracket k and shift lever e 5 Tighten the shift link bolt l to the specified torque Shift lever bolt f 19 N m 1 9 kgf m 14 0 ft lb c b a c d f g e Shift link bolt l 3 5 N m 0 35 kgf m 2 58 ft lb i e l k h j ...

Page 176: ... Clamp bracket STBD 1 6 Washer 2 7 Collar 1 8 Swivel bracket 1 9 Bolt 1 M8 135 mm 10 Clamp bracket PORT 1 11 Bolt 1 M6 120 mm 12 Tilt pin 1 13 Spring 1 14 Clamp pad 2 15 Clamp screw 2 16 Pin 2 17 Clamp handle 2 8 6 5 2 3 15 16 17 23 14 7 6 9 10 11 12 13 14 15 16 17 19 18 22 21 20 19 1 4 15 N m 1 5 kgf m 11 1 ft lb ...

Page 177: ... 6 7 8 9 10 A No Part name Q ty Remarks 18 Spring 1 19 Bushing 2 20 Plate 1 21 Bolt 2 M6 20 mm 22 Cover 1 23 Tilt lock lever 1 8 6 5 2 3 15 16 17 23 14 7 6 9 10 11 12 13 14 15 16 17 19 18 22 21 20 19 1 4 15 N m 1 5 kgf m 11 1 ft lb ...

Page 178: ...e the spring a 2 Install the bushings b tilt lock lever c cover d and plate e 3 Hook the sections a of the spring a onto the tilt lock lever c and then fit the section b into the slot in the plate e 4 Install the bolts f and g into the clamp bracket PORT h 5 Install the washers i swivel bracket j collar k clamp bracket STBD l onto the bolts f and g 6 Install the plate m self locking nut n washer o...

Page 179: ...9 18 Clamp bracket 0 1 2 3 4 5 6 7 8 9 10 A Self locking nut n 15 N m 1 5 kgf m 11 1 ft lb q n p m l i i j k h f g o ...

Page 180: ...9 19 BRKT Bracket unit MEMO ...

Page 181: ...run 10 7 General periodic maintenance 10 7 Checking the anode 10 7 Checking the battery optional for European market 10 7 Checking the cooling water passage 10 7 Checking the engine idle speed 10 7 Changing the engine oil 10 8 Checking the engine oil level 10 9 Checking the engine shut off switch 10 9 Checking the fuel joint and fuel hoses fuel joint to carburetor 10 9 Checking the fuel strainer 1...

Page 182: ...d engine life and greater owner satisfaction The maintenance cycle on these charts assumes usage of 100 hours per year and regular flush ing of the cooling water passages Adjust the maintenance frequency when operating the engine under adverse conditions such as extended trolling Disassembly or repairs may be necessary depending on the outcome of maintenance checks Expendable or consumable parts a...

Page 183: ... Check replace 8 16 9 11 Spark plug Check replace 7 35 Spark plug cap Check replace 5 5 Throttle link throttle cable Check adjust replace 6 14 Thermostat Check replace 7 35 Valve clearance Check adjust 7 2 7 3 Water inlet Check 10 7 Wiring harness connections wiring coupler connections Check replace Fuel tank built in tank Check 6 6 Item Actions Every See page 1000 hours Upper case Check replace 9...

Page 184: ...arks or open flames for example welding equipment and lighted cigarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN 1 Check the battery electrolyte level If the level is at or below the minimum level mark a add distilled water until the level is between the maximum and minimum level marks 2 Check the specific gravity of the electrolyte...

Page 185: ...he fuel system 1 Check that the fuel hoses are securely connected See Fuel hose 6 1 NOTICE This is a 4 stroke engine Never use premixed fuel or 2 stroke outboard motor oil Checking the gear oil level 1 Place the outboard motor in an upright position 2 Remove the check screw a and then check the gear oil level in the lower case TIP If the oil is at the proper level a small amount of oil should flow...

Page 186: ... To determine the optimum mounting height test run the outboard motor at differ ent heights 2 Check that the clamp brackets are secured using the clamp screws Checking the steering system 1 Check the steering friction for proper adjustment TIP To increase the friction move the steering friction adjuster in direction a To decrease the friction move the steering friction adjuster in direction b 2 Ch...

Page 187: ...ns 1 Move the shift lever to the N position 2 Check that the engine starts when the starter handle a is pulled 3 Move the shift lever to the F or R position 4 Check that the starter handle cannot be pulled Test run 1 Start the engine and then check that the gear shift operates smoothly 2 Warm up the engine and then check the engine idle speed 3 Operate the engine at trolling speed 4 Operate the ou...

Page 188: ...e joint adapter flush the cooling water passages without starting the engine General periodic maintenance Checking the anode Do not apply grease oil or paint to the anodes Otherwise the anodes become ineffective 1 Check the anodes See Checking the thermostat cover anode 7 35 and Checking the lower unit anode 8 4 Checking the battery optional for European market 1 Check the battery See Checking the...

Page 189: ...be extracted using an oil changer Change the engine oil after the first 20 hours of operation or 3 months and every 100 hours or at 1 year intervals thereafter 1 Place the outboard motor in an upright position NOTICE If the outboard motor is not level the oil level indi cated on the dipstick may not be accu rate 2 Start the engine and warm it up for 5 10 minutes 3 Stop the engine and leave it off ...

Page 190: ...l hoses fuel joint to carburetor 1 Check the fuel joint and fuel hose con nections See Fuel hose 6 1 Checking the fuel strainer 1 Check the fuel strainer See Checking the fuel strainer 6 6 Changing the gear oil Do not reuse a gasket always replace it with a new one 1 Place the outboard motor in an upright position 2 Place a drain pan a under the gear oil drain hole 3 Remove the drain screw b and g...

Page 191: ...ue Checking the gear oil level 1 Check the gear oil level See Checking the gear oil level 10 4 Checking the ignition timing 1 Check the ignition timing See Checking the ignition timing 7 1 Lubricating the outboard motor 1 Apply water resistant grease to the spec ified areas Recommended gear oil Hypoid gear oil API GL 4 SAE 90 Oil quantity 0 1 L 0 11 US qt 0 09 lmp qt Check screw d 9 N m 0 9 kgf m ...

Page 192: ...throttle link rod and throttle cable 1 Adjust the throttle link rod See Adjusting the throttle cable and throttle link 6 14 Checking the top cowling 1 Check the fitting by pushing the top cowl ing Adjust if there is free play 2 Loosen the bolts a 3 Move the hook b up or down slightly to adjust its position TIP To loosen the fitting move the hook in direction a To tighten the fitting move the hook ...

Page 193: ...10 12 General periodic maintenance 0 1 2 3 4 5 6 7 8 9 10 A Checking the water pump 1 Check the water pump housing and impeller See Checking the water pump 8 6 ...

Page 194: ...eter 7 42 Checking the cooling water passage 10 7 Checking the cooling water pilot hole 10 3 Checking the crankcase 7 24 Checking the crankshaft 7 43 Checking the cylinder block 7 44 Checking the cylinder bore 7 41 Checking the cylinder head 7 30 Checking the diaphragm and valve 6 23 Checking the dog clutch 8 9 Checking the drive shaft 8 12 Checking the electrical component 5 3 Checking the engine...

Page 195: ...er head 7 29 Disassembling the extension L transom model 8 4 Disassembling the fuel pump 6 22 Disassembling the lower case 8 11 Disassembling the manual starter 7 7 Disassembling the propeller shaft assembly 8 8 Disassembling the propeller shaft housing assembly 8 8 Disassembling the tiller handle 9 3 Disassembly and assembly 0 3 Drive shaft and lower case 8 10 E Electric shock 0 1 Electrical comp...

Page 196: ...installation 3 1 Outboard motor mounting 3 4 Outboard motor troubleshooting 4 1 Outline 2 1 2 4 2 8 2 13 2 14 10 1 P Part lubricant and sealant 0 2 Performance 1 3 Port 5 1 Power unit 1 3 1 6 1 10 Power unit check and adjustment 7 1 Power unit assembly 7 11 Power unit system 2 4 Power unit technical data 1 6 Predelivery check 10 3 Propeller 0 1 Propeller selection 3 7 Propeller shaft housing 8 7 P...

Page 197: ...e 0 3 Tiller handle 9 1 Tilt system 2 14 Top 5 2 Troubleshooting procedure 4 1 Troubleshooting the lower unit 4 3 Troubleshooting the power unit 4 1 U Uncrating procedure 3 4 Upper case and shift lever 9 9 Using the digital tester 5 3 V Ventilation 0 1 W Water pump and shift rod 8 5 Working with crane 0 2 ...

Page 198: ...i 5 Index MEMO ...

Page 199: ...0 1 2 3 5 6 7 8 9 10 10 10 A Appendix A Wiring diagram A 1 How to use the wiring diagram A 1 F4B F5A F6C A 1 ...

Page 200: ...in the wiring diagrams a No wire connector b Optional parts Color Code F4B F5A F6C a Fuse 20A Battery a b B Black G Green R Red W White a W G B R W B B R R G B B W B Engine shut off switch Clip installed Clip removed Pushed Lighting coil Rectifier Regulator CDI unit ...

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Page 202: ...Jan 2019 ABE E_3 ...

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