Yamaha F6Z Service Manual Download Page 71

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5-2

MANUAL STARTER

INSTALLING THE DUST COVER
GROMMET

Install:

Dust cover grommet

NOTE:

Set the grommet so that the large flange
diameter is at the bottom and install to the
dust cover.

ADJUSTING THE START-IN-GEAR
PROTECTION DEVICE

Adjust:

Start-in-gear protection device
Refer to “ADJUSTING THE START-
IN-GEAR PROTECTION DEVICE” on
page 3-8.

Summary of Contents for F6Z

Page 1: ...SERVICEMANUAL LIT 18616 02 19 68T 28197 ZA 11 F6Z F8Z ...

Page 2: ...Because Yamaha has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual F6Z F...

Page 3: ...action required will follow the symbol e g Bearings Pitting scratches Replace To assist you in finding your way through this manual the section title and major heading is given at the top of every page MODEL INDICATION Multiple models are referred to in this manual and their model indications are noted as follows ILLUSTRATIONS The illustrations within this service manual represent all of the desig...

Page 4: ...R SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer ...

Page 5: ...ction charts at the same time as the exploded views These charts list the sequence that the procedures should be carried out in as well as providing exploded on part names quantities dimensions and important points relating to each relevant task Example O ring 39 5 x 2 5 mm inside diameter D x ring diameter d 5 In addition to tightening torques the dimensions of the bolts and screws are also menti...

Page 6: ...ctrical current A Symbols F to I in an exploded diagram indicate the grade of lubricant and the location of the lubricant point F Apply Yamaha 4 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease H Apply Yamaha grease D I Apply molybdenum disufied oil Symbols J to O in an exploded diagram indicate the grade of the sealing or locking agent and the location of the a...

Page 7: ...1 2 3 4 5 6 7 8 9 CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECK AND ADJUSTMENT FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEM TROUBLE ANALYSIS ...

Page 8: ... 1 STARTING SERIAL NUMBERS 1 1 SAFETY WHILE WORKING 1 2 FIRE PREVENTION 1 2 VENTILATION 1 2 SELF PROTECTION 1 2 OILS GREASES AND SEALING FLUIDS 1 2 GOOD WORKING PRACTICES 1 3 DISASSEMBLY AND ASSEMBLY 1 4 SPECIAL TOOLS 1 5 MEASURING 1 5 REMOVING AND INSTALLING 1 7 1 ...

Page 9: ... number is stamped is bonded to the port clamp bracket The label is specially treated so that peeling it off causes cracks across the serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows 1 Model name 2 Approval model code 3 Transom height 4 Serial number Model name Applicable model code Starting serial number World wide USA Canada F6AMH F6MH 68R S 000101 L 300101 ...

Page 10: ...um vapor is heavier than air and is deadly if inhaled in large quantities Engine exhaust gases are harmful to breathe When test running an engine indoors maintain good ventilation SELF PROTECTION Protect your eyes with suitable safety glasses or safety goggles when grinding or when doing any operation which may cause particles to fly off Protect hands and feet by wearing safety gloves or protectiv...

Page 11: ...d wipingrag in your pocket 4 Hands and any other parts of the body which have been in contact with lubricants or lubricant contaminated clothing should be thoroughly washed with hot water and soap as soon as practicable 5 To protect the skin the application of a suitable barrier cream to the hands before working is recommended 6 A supply of clean lint free cloths should be available for wiping pur...

Page 12: ...with compressed air when disassembling 2 Oil the contact surfaces of moving parts before assembly 3 After assembly check that moving parts operate normally 4 Install bearings with the manufacturers markings on the side exposed to view and liberally oil the bearings 5 When installing oil seals apply a light coating of water resistant grease to the outside diameter ...

Page 13: ...r YW For other countries use part numbers that start with 90890 MEASURING 1 Engine tachometer 2 Compression gauge 3 Timing light 4 Mity vac 5 Leakage tester 6Digital circuit tester 7 Peak voltage tester 8 Spark gap tester P N YU 08036 B a 90890 06760 b P N YU 33223 90890 03160 P N YM 33277 A 90890 03141 P N YB 35956 A a 90890 06756 b P N N A 90890 06762 P N YU 34899 A a 90890 06752 b P N YU 39991 ...

Page 14: ...iversal puller A Dial gauge stand B Magnet base C Backlash indicator D Magnetic base attaching plate P N YB 06234 N A P N YB 06117 N A P N YU 03097 90890 01252 P N YU 34481 90890 06705 P N YU 06265 90890 06706 P N YB 07003 90890 07003 9 0 A B C D ...

Page 15: ...eat lapper 0 Piston slider A Slide hammer handle B Stopper guide plate C Stopper guide stand P N YB 06139 a 90890 06522 b P N YB 06117 a 90890 06521 b P N YM 01253 90890 04019 P N YM 04108 90890 04108 P N N A 90890 06801 P N YM 01122 90890 06801 P N N A 90890 06804 P N YM 91043 C a 90890 06803 b P N N A 90890 04101 P N YU 33294 90890 05158 P N YB 06096 90890 06531 P N N A 90890 06501 P N N A 90890...

Page 16: ...l seal attachment L Crankshaft holder P N N A 90890 06535 P N YB 06029 a 90890 06601 b P N YB 06229 a 90890 06652 b P N YB 06071 a 90890 06606 b P N N A 90890 06604 P N YB 06197 YB 06298 YB 06230 YB 06112 YB 06611 YB 37350 a 90890 06653 90890 06649 90890 06617 90890 06614 90890 0661 b P N YB 06167 a 90890 06634 b P N YB 06028 a 90890 06650 b P N YB 06561 90890 06561 I a b b J a b K a F a b G a b H...

Page 17: ... F6AMH F6MH 2 1 GENERAL SPECIFICATIONS F8CMH F8MH 2 3 MAINTENANCE SPECIFICATIONS 2 5 POWER UNIT 2 5 LOWER UNIT 2 8 ELECTRICAL 2 9 OUTBOARD DIMENSIONS 2 11 BRACKET DIMENSIONS 2 13 TIGHTENING TORQUES 2 14 SPECIFIED TORQUES 2 14 GENERAL TORQUES 2 16 2 ...

Page 18: ...500 Maximum fuel consumption L US gal Imp gal h 5 500 r min 2 5 0 66 0 55 POWER UNIT Type 4 stroke SOHC in line Number of cylinders 2 Total displacement cm3 cu in 197 11 8 Bore x stroke mm in 56 0 x 40 0 2 2 x 1 6 Compression ratio 8 79 Compression pressure kPa kgf cm2 psi 950 9 5 135 1 Number of carburetors 1 Control system Tiller control Starting system Manual Ignition control system CDI Alterna...

Page 19: ...e Hypoid gear oil Gear oil grade GL 4 SAE 90 Gear oil capacity cm3 US oz Imp oz 150 5 1 5 3 BRACKET Tilt angle Degree 78 Shallow water drive angle Degree 24 37 Steering angle right left Degree 45 45 DRIVE UNIT Gear positions F N R Gear ratio gear pinion 2 08 27 13 Gear type Straight bevel gear Propeller direction Clockwise Back view Propeller drive system Spline Propeller ID mark N ELECTRICAL Batt...

Page 20: ...000 Maximum fuel consumption L US gal Imp gal h 5 500 r min 3 3 0 87 0 73 POWER UNIT Type 4 stroke SOHC in line Number of cylinders 2 Total displacement cm3 cu in 197 11 8 Bore x stroke mm in 56 0 x 40 0 2 2 x 1 6 Compression ratio 8 79 Compression pressure kPa kgf cm2 psi 950 9 5 135 1 Number of carburetors 1 Control system Tiller control Starting system Manual Ignition control system CDI Alterna...

Page 21: ...e Hypoid gear oil Gear oil grade GL 4 SAE 90 Gear oil capacity cm3 US oz Imp oz 150 5 1 5 3 BRACKET Tilt angle Degree 78 Shallow water drive angle Degree 24 37 Steering angle right left Degree 45 45 DRIVE UNIT Gear positions F N R Gear ratio gear pinion 2 08 27 13 Gear type Straight bevel gear Propeller direction Clockwise Back view Propeller drive system Spline Propeller ID mark N ELECTRICAL Batt...

Page 22: ... Rocker shaft mm in 12 941 12 951 0 5095 0 5099 outside diameter b CAMSHAFT Intake A mm in 23 45 23 55 0 9232 0 9271 Intake B mm in 23 45 23 55 0 9232 0 9271 Exhaust A mm in 19 95 20 05 0 7854 0 7893 Exhaust B mm in 19 95 20 05 0 7854 0 7893 Cylinder head mm in 17 975 17 991 0 7077 0 7083 Journal diameter Oil pump housing journal diameter mm in 15 975 15 991 0 6289 0 6296 Camshaft round limit mm i...

Page 23: ...EX mm in 0 025 0 052 0 0010 0 0020 Stem runout limit IN mm in 0 03 0 0012 EX mm in 0 03 0 0012 VALVE SPRING Free length mm in 27 6 1 09 Free length limit mm in 27 6 1 09 Tilt limit mm in 1 0 0 04 PISTON Piston to cylinder clearance mm in 0 035 0 065 0 0014 0 0026 Piston diameter D mm in 55 950 55 965 2 2028 2 2033 Measuring point H mm in 1 5 0 06 Pin boss inside diameter mm in 14 004 14 015 0 5513...

Page 24: ...journal diameter mm in 29 997 30 009 1 1810 1 1815 Crank pin journal diameter mm in 26 997 27 009 1 0629 1 0633 Runout limit mm in 0 03 0 0012 CRANKCASE Crankshaft journal inside diameter mm in 33 016 33 040 1 3000 1 3008 Crankshaft journal oil clearance bearing installed mm in 0 011 0 039 0 0004 0 0015 Bearing mark color mm in A Blue 33 032 33 040 1 3005 1 3008 B Black 33 024 33 032 1 30016 1 300...

Page 25: ...ARBURETOR Stamped mark 68R 00 F6AMH F6MH 68R 20 F6AMH for SAV 69F 20 F6BMH 68T 00 F8CMH F8MH 68T 20 F8CMH for SAV 68T 30 F8CW Main jet 74 74 Pilot jet 39 39 Float height a mm in 19 0 20 0 0 75 0 79 19 0 20 0 0 75 0 79 Idle speed r min 1 050 50 1 050 50 Item Unit Model World wide F6AMH F8CMH USA Canada F6MH F8MH GEAR BACKLASH Pinion Forward gear mm in 0 88 1 26 0 0346 0 0496 Pinion Reverse gear mm ...

Page 26: ...k voltage O B cranking opened V 53 2 cranking closed V 140 1 500 r min V 168 3 500 r min V 168 Ignition spark gap mm in 0 9 0 04 Charge coil resistance Br L Ω 232 348 Pulser coil resistance W R B Ω 240 360 Ignition coil resistance Primary O B Ω 0 6 Secondary Between outputs kΩ 8 75 Spark plug cap resistance kΩ 4 3 IGNITION CONTROL SYSTEM Oil pressure switch operating pressure kPa kg cm2 psi 14 7 0...

Page 27: ...min opened V 14 3 500 r min opened V 33 Rectifier output peak voltage R B cranking opened V 2 8 cranking closed V 1 500 r min opened V 13 3 3 500 r min opened V 32 2 Charging current A 5 000 r min 5 5 Lighting coil resistance G G Ω 0 24 0 36 CHARGING SYSTEM TWO LIGHTING COILS MODEL Lighting coil output peak voltage G G cranking opened V 8 4 cranking closed V 8 4 1 500 r min opened V 33 6 3 500 r m...

Page 28: ...2 11 MAINTENANCE SPECIFICATIONS OUTBOARD DIMENSIONS ...

Page 29: ...10 7 L8 mm in 189 7 4 L9 mm in L10 mm in 66 5 2 6 H1 S mm in 681 5 26 9 L mm in 808 5 31 8 H2 mm in 317 12 5 H3 mm in 123 4 8 H4 S mm in 435 5 17 1 L mm in 562 5 22 1 H5 mm in 675 5 26 6 H6 S mm in 593 5 23 4 L mm in 546 21 5 H7 mm in 202 5 8 0 H8 mm in 4 0 16 H9 mm in 528 20 8 H10 mm in 32 1 3 H11 mm in W1 mm in 171 5 6 8 W2 mm in 247 5 9 7 W3 mm in 158 5 6 2 W4 mm in 158 5 6 2 W5 mm in 285 5 11 ...

Page 30: ... USA Canada F6MH F8MH B1 mm in 70 5 2 8 B2 mm in 198 7 8 B3 mm in 95 3 3 8 B4 mm in 112 4 4 B5 mm in 105 3 4 1 B6 mm in 207 8 1 B7 mm in B8 mm in B9 mm in 18 0 7 B10 mm in B11 mm in B12 mm in C1 mm in 28 1 1 C2 mm in 65 2 6 C3 mm in D1 mm in 8 3 0 3 D2 mm in 8 3 0 3 D3 mm in D4 mm in T1 mm in ...

Page 31: ...t M8 6 21 2 1 15 5 Relief valve assembly M14 1 8 0 8 5 9 Throttle link bracket mounting Bolt M6 2 8 0 8 5 9 Anode mounting Plug M16 1 18 1 8 13 3 Screw M5 1 2 0 2 1 5 Exhaust outer cover mounting 1st Bolt M6 5 6 0 6 4 4 2nd 12 1 2 8 8 Spark plug M14 2 25 2 5 18 4 Cylinder head mounting 1st Bolt M8 6 15 1 5 11 1 2nd 30 3 0 22 1 1st Bolt M6 3 6 0 6 4 4 2nd 12 1 2 8 8 Oil pump assembly mounting Bolt ...

Page 32: ...3 0 3 2 2 Steering friction plate mounting Bolt M5 2 5 4 0 54 3 9 Steering friction piece mounting Bolt M5 1 5 4 0 54 3 9 Steering friction self locking Nut M10 1 4 0 4 2 9 Neutral switch stay mounting Bolt M6 2 10 1 0 7 4 Recoil starter cable mounting Bolt M6 1 or 2 10 1 0 7 4 Ground lead mounting Screw M5 1 2 5 0 25 1 8 ELECTRICAL Charge coil mounting Bolt M6 2 12 1 2 8 8 Pulser coil mounting Bo...

Page 33: ... of this manual To avoid warpage tighten multifastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature Nut A Bolt B General torque specifications N m kgf m ft lb 8 mm M5 5 0 5 3 6 10 mm M6 8 0 8 5 8 12 mm M8 18 1 8...

Page 34: ...ING THE START IN GEAR PROTECTION DEVICE 3 8 POWER UNIT 3 9 CHECKING THE ENGINE OIL LEVEL 3 9 REPLACING THE ENGINE OIL 3 9 ADJUSTING THE VALVE CLEARANCE 3 10 MEASURING THE COMPRESSION PRESSURE 3 12 CHECKING THE IGNITION TIMING 3 13 CHECKING THE TIMING BELT 3 14 COOLING SYSTEM 3 14 CHECKING THE COOLING WATER DISCHARGE 3 14 LOWER UNIT 3 15 CHECKING THE GEAR OIL LEVEL 3 15 CHANGING AND CHECKING THE GE...

Page 35: ... Check replace 3 9 Timing belt Check replace 3 14 Valve clearance Check adjust 3 10 Ignition timing Check 3 13 Thermostat Check replace 5 26 Water leakage Check Motor exterior Check Exhaust leakage Check Cooling water passage Check 3 14 CONTROL SYSTEM Shift cable Check adjust 3 4 Throttle cables Check adjust 3 5 Throttle axle link Check adjust 3 6 Engine idling speed Check adjust 3 7 Start in gear...

Page 36: ...op cowling hook position Adjusting steps 1 Loosen the bolt 1 approximately 1 4 of a turn 2 Move the top cowling hook 2 either up or down slightly NOTE Moving the hook toward the seal will loosen the top cowling Moving the hook away from the seal will tighten the top cowling 3 Secure the bolt 1 4 Check the top cowling fitting and repeat the adjustment necessary Top cowling hook bolt 5 N m 0 5 kgf m...

Page 37: ... FUEL LINE Check Fuel line Cracks damage leak Replace the defective part s Refer to REMOVING INSTALLING THE FUEL JOINT FUEL FILTER AND FUEL PUMP on page 4 1 CAUTION When replacing the fuel filter the arrow mark must face toward the fuel pump ...

Page 38: ...cknut 2 3 Set the shift handle to the neutral position Then hold it in this position 4 Adjust the shift control cable 3 to the proper length with the adjusting nut 4 5 Install the locknut 2 and tighten it 6 Move the shift handle to the forward neutral and reverse positions and make sure it shifts smoothly and correctly If the shifting operations unsmooth or incorrect repeat the above procedure NOT...

Page 39: ...with the adjusting nut 3 until the stopper portion a on the pulley 4 contacts the stopper portion b on the throttle wire stay 5 4 Tighten the locknut 1 5 Loosen locknut 6 6 Adjust the length of the throttle wire 7 with the adjusting nut 8 NOTE Adjust the length so that there is no clearance between the drum hole of pulley 4 and the drum at the tip of decelerator cable 7 7 Tighten the locknut 6 8 F...

Page 40: ...w 1 2 Turn the throttle grip to the fully open position 3 Hold so that the rear side face a of free axle lever 2 is in contact with the actuating portion b of pulley 3 4 Turn throttle link 4 fully clockwise until it stops then tighten lock screw 1 5 Operate the throttle grip to the fully open position and fully closed position and check that carburetor throttle link 4 opens and closes fully If it ...

Page 41: ...cification Adjust Measuring steps 1 Start the engine and allow it to warm up for several minutes 2 Attach the engine tachometer 1 to the spark plug lead 2 of the cylinder 1 3 Measure the engine idling speed 2 Adjust Engine idling speed Adjusting steps 1 Turn the throttle stop screw 3 in direction a or b until the specified engine idling speed is obtained Engine idling speed 1 050 50 r min Engine t...

Page 42: ...tion cable Adjusting steps 1 Set the shift lever in the neutral position 2 Loosen the locknut 1 3 Adjust the adjusting nut 2 so that the point a on the wire connector 3 aligns with the mark b on the starter cover 4 Tighten locknut 1 NOTE Shift the shift lever into neutral and make sure the starter can be pulled If it cannot be pulled repeat the above procedure ...

Page 43: ...NGINE OIL 1 Remove Oil filler cap 1 Drain plug 2 2 Install Drain plug 2 3 Fill Engine oil 3 into the crank case 4 Install Oil filler cap 1 5 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 9 NOTE Run the engine for several minutes turn it off and check the oil level If the engine oil is still not at proper level add drain as needed Drain plug 24 N m 2 4 kgf m 17 8 ft lb Rec...

Page 44: ...and align the 1 mark on the driven gear 5 and mark on the thermostat cover 6 2 Check the intake valve clearance a and exhaust valve clearance b on the cylinder 1 using the feeler gauge 7 3 Turn the crankshaft 360 and align the 2 mark on the driven gear 5 and mark on the thermostat cover 6 4 Check the intake valve clearance a and exhaust valve clearance b on the cylinder 2 using the feeler gauge 7 ...

Page 45: ...above steps for all valves which clearance are out of specification 4 Recheck Intake valve clearance a Exhaust valve clearance b NOTE If any valve clearance is still out of specification repeat all of the valve clearance adjustment steps until the specified clearance is obtained 5 Install Cylinder head cover 4 Fuel pump 3 Dust cover 2 Recoil starter 1 NOTE Tighten the cylinder head cover bolt in s...

Page 46: ...emove the spark plugs 1 CAUTION Before removing the spark plugs use compressed air to blow away dirt accumulated in the spark plug well to prevent it from falling into the cylinder that is being tested 3 Install the compression gauge 2 into the spark plug hole to be measured 4 Open the throttle valve wide 5 Crank the engine using the recoil starter manual starter model or starter motor electric st...

Page 47: ...Check the ignition system components Checking steps 1 Start the engine and allow it to warm up for several minutes 2 Attach the engine tachometer and the timing light 1 to the spark plug lead 2 of cylinder 1 3 Aim the timing light 1 at the flywheel cover 3 and make sure the stationary pointer 4 is with in the firing range 5 and 6 when engine is running with specified speed Ignition timing At idlin...

Page 48: ...he timing belt with the part name facing up 3 Install Dust cover 2 Recoil starter 1 COOLING SYSTEM CHECKING THE COOLING WATER DISCHARGE Check Cooling water discharge Dose not flow Clean and check the cooling water passage Checking steps 1 Place the lower unit in water 2 Start the engine 3 Check that water flows from the pilot water outlet ...

Page 49: ...ar oil level check screw 2 2 Fill Gear oil with the specified amount of the recommended gear oil Filling steps 1 Place the outboard in an upright position 2 Insert the gear oil tube into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible 3 Install the gear oil level check screw 2 and then quickly install the gear oil drain screw 1 Recom...

Page 50: ...e gear oil level check screw 2 Install the leakage tester 1 or mity vac into the check hole 3 Apply the specified pressure 4 The lower unit should hold the specified pressure for 10 seconds 5 Remove the pressure tester 1 then install the gear oil level check screw Lower unit holding pressure 100 kPa 1 0 kgf cm2 14 2 psi for 10 seconds Leakage tester NA 90890 06762 Mity vac YB 35956 A 90890 06756 G...

Page 51: ... injury Wear protective eye gear when handling or working near batteries Antidote EXTERNAL SKIN Flush with water EYES Flush with water for 15 minutes and get immediate medical attention Antidote INTERNAL Drink large quantities of water or milk followed by milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydrogen gas therefore you should...

Page 52: ...tilled water to the proper level Electrolyte specific gravity Less than specification Recharge the battery CHECKING THE SPARK PLUGS 1 Spark plug type BR6HS 10 2 Check Electrodes 1 Cracks excessive wear Replace Insulator color 2 Distinctly different color Check the engine condition 3 Clean Spark plug with a spark plug cleaner or wire brush Electrolyte specific gravity 1 280 at 20 C 68 F Color guide...

Page 53: ...ace Also it is suggested to apply a thin film of anti seize compound to the spark plug threads to prevent thread seizure If a torque wrench is not available a good estimate of the correct tightening torque is to finger tighten a the spark plug and then tighten it another 1 4 to 1 2 of a turn b Spark plug gap 0 9 1 0 mm 0 035 0 039 in Spark plug 25 N m 2 5 kgf m 18 4 ft lb ...

Page 54: ...3 20 GENERAL LUBRICATION POINTS Apply Water resistant grease NOTE Use a grease gun ...

Page 55: ...3 21 GENERAL ...

Page 56: ...TALLING THE FUEL FILTER 4 2 FUEL PUMP 4 3 DISASSEMBLING ASSEMBLING THE FUEL PUMP 4 3 CHECKING THE FUEL PUMP 4 4 ASSEMBLING THE FUEL PUMP 4 4 INTAKE SYSTEM 4 5 REMOVING INSTALLING THE INTAKE SYSTEM 4 5 INSTALLING THE INTAKE MANIFOLD 4 7 CARBURETOR 4 8 DISASSEMBLING ASSEMBLING THE CARBURETOR 4 8 DISASSEMBLING THE CARBURETOR 4 10 CHECKING THE CARBURETOR 4 10 ASSEMBLING THE CARBURETOR 4 11 4 ...

Page 57: ... FILTER AND FUEL PUMP Step Job Part Q ty Remarks 1 Clip 2 2 Fuel hose 1 3 Bolt with washer 1 4 Fuel joint 1 5 Clip 2 6 Fuel hose with tube 1 7 Fuel filter 1 8 Clip 1 9 Fuel hose with tube 1 10 Bolt with washer 2 11 Fuel pump assembly 1 12 O ring 1 2 7 x 2 3mm Not reusable For installation reverse the removal procedure ...

Page 58: ... Do not overpressurize the fuel joint Excessive pressure may cause air to leak out Checking steps 1 Attach the mity vac 2 Apply the specified pressure CHECKING THE FUEL FILTER Check Fuel filter Cracks leak clog Replace INSTALLING THE FUEL FILTER Install Fuel filter NOTE Install the fuel filter with arrow mark facing towards the fuel pump Mity vac YB 3956 A 90890 06756 Specified pressure 50 kpa 0 5...

Page 59: ... FUEL PUMP Step Job Part Q ty Remarks 1 Screw 4 2 Nut 4 3 Body 3 1 4 Diaphragm 1 5 Screw 2 6 Check valve 2 7 Body 2 1 8 Pin 1 9 Plunger 1 10 Plunger spring 1 11 Diaphragm 1 12 Diaphragm spring 1 13 Body 1 1 For installation reverse the removal procedure ...

Page 60: ...hragms Damage Replace ASSEMBLING THE FUEL PUMP Install Body 1 Body 2 Body 3 NOTE Install so that notched portion a of body 1 joint portion b of body 2 and casting mold letter c of body 3 are in the relative positions shown in the diagram on the left ...

Page 61: ...Step Job Part Q ty Remarks 1 Breather hose 1 2 Bolt with washer 1 3 Clamp 1 4 Water pilot hose 1 5 Clamp 1 6 Water Hose 1 7 Throttle axle link 1 8 Choke rod 1 9 Link joint 1 10 Choke knob 1 11 Bolt with washer 2 12 Coller 2 13 Silensor assembly 1 1 Continued on next page ...

Page 62: ... 14 O ring 1 31 5 x 2 4 mm Not reusable 15 Carburetor 1 16 Gasket 2 Not reusable 17 Insulator 1 18 Clamp 1 19 Fuel hose 1 20 Bolt 2 21 Bolt 3 22 Clamp 1 23 Intake manifold 1 24 Gasket 1 Not reusable For installation reverse the removal procedure ...

Page 63: ...LING THE INTAKE MANIFOLD Install Intake manifold NOTE Tighten the intake manifold mounting bolt in sequence and two steps of torque Intake manifold mounting bolt 1st 6 0 N m 0 6 kfg m 4 4 ft lb 2nd 12 0 N m 1 2 kfg m 8 8 ft lb ...

Page 64: ...Remarks 1 Drain plug 1 2 Gasket 1 Not reusable 3 Throttle stop screw 1 4 Spring 1 5 Screw 1 6 Screw with washer 1 7 Cover plate 1 8 Cover gasket 1 Not reusable 9 Screw with washer 1 10 Float chamber 1 11 O ring 1 48 x 1 8 mm Not reusable 12 Float pin 1 13 Float 1 Continued on next page ...

Page 65: ...4 9 CARBURETOR Step Job Part Q ty Remarks 14 Needle valve 1 15 Main jet 1 16 Pilot 1 17 Plug 1 18 Main nozzle 1 19 Body assembly 1 For installation reverse the removal procedure ...

Page 66: ... to note the number of times the pilot screw is turned out from the seated position to its set position CAUTION Do not use steel wire for cleaning the jets This may enlarge the jet diameters and seriously affect performance 1 Check Carburetor body Cracks damage Replace Contamination Clean 2 Check Needle valve Pilot screw Grooved wear Replace 3 Check Main nozzle Main jet Pilot jet Contamination Cle...

Page 67: ...body hook the needle valve 3 into the float 1 and insert the needle valve seat y Tap float pin 2 in the direction of arrow a of carburetor body 4 and with a pin to install y After installation make sure that the float 1 operates smoothly 2 Measure y Float hight b Out of specification Æ Replace NOTE y Make sure to tilt the carburetor body clockwise 45 for needle valve with spring no load when measu...

Page 68: ...IT 5 15 INSTALLING THE POWER UNIT 5 16 REMOVING INSTALLING THE THROTTLE LINK AND RIGHT SIDE ELECTRICAL COMPONENTS 5 17 REMOVING INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 1 ONE LIGHTING COIL MODEL 5 19 REMOVING INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 2 ONE LIGHTING COIL MODEL 5 20 REMOVING INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 1 TWO LIGHTING COILS MODEL 5 21 REMOVING INSTALLING...

Page 69: ...ER ARM ROCKER ARM SHAFT 5 41 CHECKING THE CAMSHAFT 5 41 CHECKING THE CYLINDER HEAD 5 42 REPLACING THE VALVE GUIDE 5 42 REFACING THE VALVE SEAT 5 43 INSTALLING THE VALVE 5 45 INSTALLING THE CAMSHAFT OIL SEAL 5 45 CRANKSHAFT PISTON AND CYLINDER BODY 5 46 REMOVING INSTALLING THE CRANKSHAFT PISTON AND CYLINDER BODY 5 46 DISASSEMBLING ASSEMBLING THE PISTON AND CONNECTING ROD 5 47 CHECKING THE CYLINDER ...

Page 70: ...ARTER REMOVING INSTALLING THE MANUAL STARTER Step Job Part Q ty Remarks 1 Start in gear protection cable 1 2 Bolt with washer 3 3 Manual starter assembly 1 4 Dust cover 1 5 Grommet 3 For installation reverse the removal procedure ...

Page 71: ...cover grommet NOTE Set the grommet so that the large flange diameter is at the bottom and install to the dust cover ADJUSTING THE START IN GEAR PROTECTION DEVICE Adjust Start in gear protection device Refer to ADJUSTING THE START IN GEAR PROTECTION DEVICE on page 3 8 ...

Page 72: ...TER Step Job Part Q ty Remarks 1 Wire assembly 1 2 Return spring 1 3 Screw 1 4 Drive plate 1 5 Drive spring 1 6 Sheave drum assembly 1 7 Circlip 1 8 Drive pawl 1 9 Return spring 1 10 Spring 1 11 Sheave dram 1 12 Starter spring 1 13 Cover Continued on next page ...

Page 73: ...ANUAL STARTER Step Job Part Q ty Remarks 14 Starter handle 1 15 Dumper 1 16 Starter wire 1 1 500mm 17 Return spring 1 18 Stopper 1 19 Coller 1 20 Starter case 1 For installation reverse the removal procedure ...

Page 74: ...ass the starter wire 2 through the cutaway a 3 Turn the sheave drum 1 clockwise until the starter spring is free 2 Remove Screw 3 Drive plate 4 Drive spring 5 Sheave drum 1 WARNING When removing the sheave drum be sure to turn the sheave drum upside down to prevent the starter spring from popping up at you Do not leave the sheave drum removed The starter spring may pop out 3 Remove Starter spring ...

Page 75: ...wire Frayed wear damage Replace NOTE When replacing the starter wire cut it to the specified length and then burn its end so it will not unravel Apply water resistant grease onto the new starter wire ASSEMBLING THE MANUAL STARTER 1 Install Starter spring 1 WARNING When installing the starter spring onto the starter case use care so that the starter spring does not pop out To help the spring stay c...

Page 76: ...he cutaway of the sheave drum 3 Install Sheave drum 3 NOTE Position the inner end of the starter spring on the retainer post of sheave drum 4 Install Drive spring 4 Drive plate 5 Screw 6 Installing steps 1 Install drive spring 4 to drive plate 5 2 Pass the tip of drive spring 4 through the coil portion of return spring 7 and install drive plate 5 to the sheave drum 3 Install screw 6 ...

Page 77: ... the sheave drum 3 2 Wind the sheave drum 3 5 turns counterclockwise with the starter wire 2 3 Remove starter wire 2 from cutaway a then wind on sheave drum 3 6 Check Manual starter operation Rough operation Repair NOTE When checking the manual starter only release the start in gear protection device ...

Page 78: ...5 9 FLYWHEEL ROTOR FLYWHEEL ROTOR REMOVING INSTALLING THE FLYWHEEL ROTOR Step Job Part Q ty Remarks 1 Nut 1 2 Washer 1 3 Flywheel rotor 1 4 Woodruff key 1 For installation reverse the removal procedure ...

Page 79: ...f the flywheel rotor 2 Remove Flywheel rotor A For USA and Canada B Except for USA and Canada CAUTION Keep the nut side flush with the crankshaft end until the flywheel rotor comes off the tapered portion of the crankshaft To prevent damage to the engine or tools screw in the universal puller bolts evenly and completely so that the universal puller plate is parallel to the flywheel rotor Flywheel ...

Page 80: ... rotor nut A For USA and Canada B Except for USA and Canada NOTE The major load should be applied in the direction of the arrows If the load is not applied as shown the flywheel holder may easily slip off of the flywheel rotor Flywheel holder YB 06139 90890 06522 A B ...

Page 81: ...NG CONNECTING THE ELECTRICAL LEADS Step Job Part Q ty Remarks 1 Bolt with washer 1 2 Engine stop switch connector and terminal 2 White Black 3 Emergency signal light connector 2 Yellow red Pink For installation reverse the removal procedure ...

Page 82: ...ING THE CABLES AND HOSE Step Job Part Q ty Remarks Engine oil drain Refer to REPLACING THE ENGINE OIL on page 3 9 1 Throttle cable 2 2 Nut 1 3 Shift cable 1 4 Oil level gauge 1 5 Water hose 1 For installation reverse the removal procedure ...

Page 83: ...5 14 POWER UNIT ADJUSTING THE THROTTLE CONTROL CABLE S Adjust Throttle control cable s Refer to ADJUSTING THE THROTTLE CONTROL CABLES on page 3 5 ...

Page 84: ... Remarks 1 Screw with washer 2 2 Nut 2 3 Apron 1 4 Plug 2 5 Apron 1 6 Rubber seal 1 7 Bolt with washer 6 8 Power unit 1 9 Relief valve assembly 1 10 O ring 1 12 0 x 1 8 mm Not reusable 11 Gasket 1 Not reusable 12 Dowel pin 2 For installation reverse the removal procedure ...

Page 85: ...6 POWER UNIT INSTALLING THE POWER UNIT Install Power unit NOTE Tighten the power unit mounting bolt by the order shown in the diagram on the left Tighten up the exhaust guide mounting bolt at the same time ...

Page 86: ...S Step Job Part Q ty Remarks 1 Bolt with washer 1 2 Bolt with washer 1 3 Washer 1 4 Collar 1 5 Throttle control lever 1 6 Link joint 1 7 Throttle control cam 1 8 Bracket 1 9 Screw 1 10 Oil pressure switch lead 1 Pink 11 Oil pressure switch 1 12 Bolt 2 13 Attachment 1 Continued on next page ...

Page 87: ...5 18 POWER UNIT Step Job Part Q ty Remarks 14 Pulser coil 1 For installation reverse the removal procedure ...

Page 88: ...MPONENTS 1 ONE LIGHTING COIL MODEL Step Job Part Q ty Remarks 1 Screw with washer 1 2 Rectifier 1 4 leads Black Red Green x 2 3 Bolt with washer 2 4 Ignition coil 1 2 leads Orange Black 5 Bolt with washer 2 6 Bracket 1 For installation reverse the removal procedure ...

Page 89: ...emarks 1 Clamp 1 Not reusable 2 Bolt with washer 2 Not reusable 3 Charge coil 1 2 leads Blue Brown 4 Bolt with washer 2 5 Clamp 1 6 Bolt with washer 2 Not reusable 7 Lighting coil 1 2 leads Green x 2 8 Screw 2 9 Coupler clamp 1 10 Bolt with washer 2 11 CDI unit 1 13 leads For installation reverse the removal procedure ...

Page 90: ... 1 Clamp 1 Not reusable 2 Bolt with washer 2 3 Ignition coil 1 2 leads Orange Black 4 Bolt with washer 1 5 Clamp 1 6 Clamp 1 Not reusable 7 Bolt with washer 1 8 Rectifier regulator 1 4 leads Black Red Green x 2 9 Bolt with washer 2 10 Bolt with washer 1 11 Starter motor bracket 1 For installation reverse the removal procedure ...

Page 91: ...p Job Part Q ty Remarks 1 Clamp 1 Not reusable 2 Bolt with washer 2 Not reusable 3 Charge coil 1 2 leads Blue Brown 4 Bolt with washer 4 Not reusable 5 Lighting coil 1 2 leads Green x 2 6 Screw 2 7 Coupler clamp 1 8 Bolt with washer 2 9 CDI unit 1 13 leads For installation reverse the removal procedure ...

Page 92: ...RMOSTAT TIMING BELT AND GEARS Step Job Part Q ty Remarks 1 Clamp 1 Not reusable 2 Water hose 1 3 Bolt with washer 2 4 Thermostat cover 1 5 Gasket 1 Not reusable 6 Thermostat 1 7 Timing belt 1 8 Nut 1 9 Lock washer 1 10 Plate washer 1 11 Drive gear 1 12 Woodruff key 1 13 Bolt 1 Continued on next page ...

Page 93: ...5 24 THERMOSTAT TIMING BELT AND GEARS Step Job Part Q ty Remarks 14 Plate washer 1 15 Driven gear 1 16 Woodruff key 1 17 Plate washer 1 For installation reverse the removal procedure ...

Page 94: ...ven gear 3 and mark on the thermostat housing cover 4 portion a REMOVING THE DRIVE GEAR Remove Drive gear nut NOTE Loosen the drive gear nut with a 30 mm deep socket REMOVING THE DRIVEN GEAR Remove Driven gear bolt A For USA and Canada B Except for USA and Canada Crankshaft holder YB 06561 90890 06561 Flywheel holder YB 06139 90890 06522 B A ...

Page 95: ...ring the water check that the thermometer opens at the specified temperature CHECKING THE TIMING BELT Check Timing belt Refer to CHECKING THE TIMING BELT on page 3 14 INSTALLING THE DRIVEN GEAR 1 Install Driven gear NOTE Install the driven gear so that counter mark is at the top 2 Install Driven gear bolt A For USA and Canada B Except for USA and Canada Water temperature Valve lift Below 60 C 140 ...

Page 96: ... that the curvature extends in the upward direction It is in the reverse direction from the curvature of the flange of the drive gear Pass the tab of the lock washer through the hole in the drive gear and washer 2 Install Drive gear nut NOTE Tighten the drive gear nut with a 30 mm deep socket 3 Bend Lock washer 5 NOTE Bend the lock washer securely Crankshaft holder YB 06561 90890 06561 ...

Page 97: ...he driven gear 3 and align the 1 mark on the driven gear and mark on the thermostat cover 4 portin b 3 Install the timing belt 5 NOTE Install the timing belt with the part name facing up 4 Turn the crankshaft clockwise 2 turns and make sure the drive gear and driven gear are correctly aligned with the timing marks ADJUSTING THE VALVE CLEARANCE Adjust Valve clearance Refer to the ADJUSTING THE VALV...

Page 98: ...ST COVER REMOVING INSTALLING THE ANODE AND EXHAUST COVER Step Job Part Q ty Remarks 1 Plug 1 2 O ring 1 Not reusable 3 Screw 1 5 Anode 1 6 Bolt with washer 5 7 Exhaust cover 1 8 Gasket 1 Not reusable For installation reverse the removal procedure ...

Page 99: ...de Refer to CHECKING THE ANODE on page 3 17 INSTALLING THE EXHAUST COVER Install Exhaust cover NOTE Tighten the exhaust cover bolt in sequence and two steps of torque Exhaust cover mounting bolt 1st 6 0 N m 0 6 kfg m 4 4 ft lb 2nd 12 0 N m 1 2 kfg m 8 8 ft lb ...

Page 100: ...rt Q ty Remarks 1 Spark plug 2 2 Oil filler cap 1 3 O ring 1 25 0 x 3 0 mm 4 Bolt with washer 4 5 Cylinder head cover 1 6 Cover seal 1 7 Screw with washer 5 8 Breather cover 1 9 Cover gasket 1 Not reusable 10 Bolt with washer 3 11 Bolt with washer 4 12 Bolt with washer 2 13 Cylinder head assembly 1 Continued on next page ...

Page 101: ... AND OIL PUMP Step Job Part Q ty Remarks 14 Cylinder head gasket 1 Not reusable 15 Dowel pin 2 16 Bolt with washer 3 17 Oil pump assembly 1 18 Oil pump gasket 1 Not reusable For installation reverse the removal procedure ...

Page 102: ...r head add a drop of approx 1 cc of Yamaha 4 stroke outboard motor oil from suction port a or discharge port b INSTALLING THE CYLINDER HEAD Install Cylinder head NOTE Tighten the cylinder head mounting bolt in sequence and two steps of torque Cylinder head mounting bolt 1st M8 15 N m 1 5 kgf m 11 1 ft lb M6 6 N m 0 6 kgf m 4 4 ft lb 2nd M8 30 N m 3 0 kgf m 22 1 ft lb M6 12 N m 1 2 kgf m 8 8 ft lb ...

Page 103: ...5 34 CYLINDER HEAD AND OIL PUMP INSTALLING THE CYLINDER HEAD COVER Install Cylinder head cover NOTE Tighten the cylinder head mounting bolt in sequence ...

Page 104: ...EMBLING ASSEMBLING THE OIL PUMP Step Job Part Q ty Remarks 1 Screw 2 2 Pump cover 1 3 Cover gasket 1 Not reusable 4 Inner rotor 1 5 Shaft 1 6 Pin 1 7 Outer rotor 1 8 Oil pump housing 1 For installation reverse the removal procedure ...

Page 105: ...MBLING THE OIL PUMP Install Outer rotor 1 Inner rotor 2 NOTE The mark a on the outer rotor 1 faces towards the pump cover side The mark b on the inner rotor 2 faces towards the oil pump housing side Oil pump clearances a 0 10 0 15 mm 0 004 0 006 in b 0 04 0 14 mm 0 002 0 006 in c 0 03 0 09 mm 0 001 0 004 in ...

Page 106: ... Step Job Part Q ty Remarks 1 Locknut 4 2 Rocker arm adjusting screw 4 3 Rocker shaft 1 4 Spring 2 5 Collar 1 6 Collar 3 7 Rocker arm 4 8 Cam shaft 1 9 Oil seal 1 Not reusable 10 Valve spring lock 4 11 Valve spring retainer 4 12 Valve spring 4 13 Valve spring seat 4 Continued on next page ...

Page 107: ...5 38 CAMSHAFT AND VALVES Step Job Part Q ty Remarks 14 Intake valve 2 15 Exhaust valve 2 16 Valve stem oil seal 4 Not reusable 17 Cylinder head 1 For installation reverse the removal procedure ...

Page 108: ... 1 Measure Valve guide inside diameter a Out of specification Replace 2 Measure Valve seat width b Out of specification Replace 3 Measure Valve margin thickness c Out of specification Replace Valve spring compressor YM 01253 90890 04019 Attachment YM 04018 90890 04018 Valve guide inside diameter a intake guide and exhaust guide 5 500 5 512 mm 0 2165 0 2170 in Valve seat width b intake valve and ex...

Page 109: ... CHECKING THE VALVE SPRING 1 Measure Valve spring free length a Out of specification Replace 2 Measure Valve spring tilt b Out of specification Replace Valve stem outside diameter d Intake valve 5 475 5 490 mm 0 2156 0 2161 in Exhaust valve 5 460 5 475 mm 0 2150 0 2156 in Valve stem runout limit intake valve and exhaust valve 0 03 mm 0 0012 in Valve spring free length limit a 27 6 mm 1 09 in Valve...

Page 110: ...ter b Out of specification Replace CHECKING THE CAMSHAFT Measure Camshaft lobe diameter a and b Out of specification Replace Rocker arm inside diameter a 13 000 13 018 mm 0 5118 0 5125 in Rocker arm shaft outside diameter b 12 941 12 951 mm 0 5095 0 5099 in Camshaft lobe diameter intake cam and exhaust cam a 23 45 23 55 mm 0 9232 0 9271 in b 19 95 20 05 mm 0 7854 0 7893 in ...

Page 111: ...an oven to 200 C 392 F to ease valve guide removal and installation and maintain the correct interference fit 1 Remove the valve guide using the valve guide remover 2 Make a counter mark at the protrusion dimension position from the cylinder head on the new valveguide Valve guide protrusion dimension a 3 Using a valve guide installer press fit the valve guide so that the counter mark on the valve ...

Page 112: ... seat or replacing the valve and valve guide lap the valve seat and valve face Reface Valve seat CAUTION When turning the valve seat cutter keep an even downward pressure 4 5 kg to prevent chatter mark Valve guide reamer NA 90890 06804 Valve seat width intake valve and exhaust valve 0 6 0 8 mm 0 02 0 03 in Valve seat cutter set YM 91043 C 90890 06803 Valve seat lapper NA 90890 04101 Cut section of...

Page 113: ...ve seat is too narrow and it is near the valve stem Valve cutter seat Desired result Use lightly 90 cutter To reduce the valve seat width 30 cutter Valve cutter seat Desired result Use 45 cutter To increase the valve seat width Valve cutter seat Desired result Use 90 cutter To center the valve seat and set it width 45 cutter Valve cutter seat Desired result Use 30 cutter To center the valve seat a...

Page 114: ...ng retainer Do not overtighten the valve spring compressor INSTALLING THE CAMSHAFT OIL SEAL Install Cam shaft oil seal 1 A For USA and Canada B Except for USA and Canada NOTE Press fit the oil seal to the stepped portion of the cylinder head and check that it is not at an angle Valve spring compressor YM 01253 90890 04019 Attachment YM 04108 90890 04108 Driver rod YM 06229 90890 06652 Attachment Y...

Page 115: ...ND CYLINDER BODY Step Job Part Q ty Remarks 1 Bolt with washer 6 2 Crankcase 1 3 Dowel pin 4 4 Connecting rod bolt 2 5 Connecting rod cap 4 6 Crankshaft 2 7 Oil seal 1 Not reusable 8 Oil seal 1 Not reusable 9 Piston and connecting rod 2 10 Plain bearing 2 11 Cylinder body 1 For installation reverse the removal procedure ...

Page 116: ...DER BODY DISASSEMBLING ASSEMBLING THE PISTON AND CONNECTING ROD Step Job Part Q ty Remarks 1 Circlip 4 2 Piston pin 2 3 Connecting rod 2 4 Top ring 2 5 2nd ring 2 6 Oil ring 2 7 Piston 2 For installation reverse the removal procedure ...

Page 117: ...ometer Out of specification Replace the piston Standard Wear limit Measuring point H H1 20 mm 0 8 in H2 40 mm 1 6 in H2 60 mm 2 4 in Cylinder bore D 56 000 56 015mm 2 2047 2 2053 in Taper limit T 0 08 mm 0 0031 in Out of round limit R 0 05 mm 0 0020 in D Maximum D1 D2 D3 D4 D5 or D6 T Maximum D1 or D2 Minimum D5 or D6 R Maximum D1 or D2 or D3 or D4 or D5 or D6 Measuring point H 1 5 mm 0 06 in Stan...

Page 118: ...ARANCE Calculate Piston to cylinder clearance a Out of specification Replace the piston and piston rings the cylinder or both CHECKING THE PISTON PIN Measure Piston pin outside diameter Out of specification Replace the piston pin Piston pin boss inside diameter 14 004 14 015 mm 0 5513 0 5518 in Piston to cylinder clearance a 0 035 0 065 mm 0 0014 0 0026 in Piston to cylinder clearance Cylinder bor...

Page 119: ...pecification Replace the piston and piston rings as a set CHECKING THE CRANKSHAFT Measure Crankshaft runout Out of specification Replace the crankshaft Top ring end gap 0 15 0 30 mm 0 006 0 012 in 2nd ring end gap 0 30 0 45 mm 0 012 0 018 in Oil ring end gap 0 20 0 70 mm 0 008 0 028 in Top ring side clearance b 0 04 0 08 mm 0 0016 0 0031 in 2nd ring side clearance c 0 03 0 07 mm 0 0012 0 0028 in C...

Page 120: ...s can lead to engine damage 1 Clean the plain bearings main journal of the crankshaft and plain bearing portion of the cylinder body and crankcase 2 Place the cylinder body 2 upside down on a bench 3 Install the half of the plain bearings 1 to the cylinder body 2 and the crankcase 3 NOTE Set the part of the plain bearing with the tab in tab groove a and insert the part with no tab in corner b 4 In...

Page 121: ...uence and two steps of torque 8 Loosen the crankcase mounting bolt 5 and remove the crankcase 2 9 Measure the width of compressed Plastigauge on each main journal 2 Select Plain bearing Select the suitable plain bearing from the table below Crank case mounting bolt 1st 15 N m 1 5 kgf m 11 1 ft lb 2nd 30 N m 3 0 kgf m 22 1 ft lb Plain bearing selection table Upper journal size mark c Lower journal ...

Page 122: ...ting rods and caps in their original positions Incorrect oil clearance measurements can lead to engine damage NOTE Make sure that the YAMAHA mark a on the connecting rod faces toward the flywheel side Align the marks b on the connecting rod and cap when assembling 1 Clean the bearing portion of the connecting rod and crank pin journal of the crankshaft 2 Install the connecting rod onto the cranksh...

Page 123: ...e oil onto the thread and seat of the connecting rod mounting bolt Tighten the connecting rod mounting bolt in two steps of torque 6 Loosen the connecting rod mounting bolt and remove the connecting rod and cap 7 Measure the width of compressed on crank pin journal Connecting rod mounting bolt 1st 6 N m 0 6 kgf m 4 4 ft lb 2nd 11 N m 1 1 kgf m 8 1 ft lb ...

Page 124: ...e N mark faces upward After installing the piston rings check that they move smoothly 2 Set Set the piston ring end gaps as shown Top ring end gap a 2nd ring end gap b Oil ring Upper side rail end gap c Oil ring expander ring end gap a Oil ring lower side rail end gap d INSTALLING THE CONNECTING ROD Install Piston 1 Connecting rod 2 Piston pin 3 Circlip 4 NOTE Install the connecting rod with YAMAH...

Page 125: ...ll Oil seal 1 and 2 CAUTION Do not install the oil seals after tightening the crankcase mounting bolts this can damage the oil seals To prevent the inclined seal installation install the oil seals crankshaft and crankcase finger tighten the mounting bolts then lightly knock the seal INSTALLING THE CRANKCASE Install Crankcase NOTE When Gasket Maker is applied prevent it from sticking to the inner s...

Page 126: ...KING THE PROPELLER SHAFT 6 10 ASSEMBLING THE PROPELLER SHAFT ASSEMBLY 6 10 DISASSEMBLING ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6 11 DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6 12 CHECKING THE REVERSE GEAR 6 12 CHECKING THE BALL BEARING 6 12 CHECKING THE PROPELLER SHAFT HOUSING 6 13 ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY 6 13 DRIVE SHAFT AND FORWARD GEAR 6 15 REMOVING IN...

Page 127: ... CHECKING THE SHIFT CAM 6 19 CHECKING THE LOWER CASE 6 19 ASSEMBLING THE BEARING HOUSING 6 20 INSTALLING THE SOLID BUSHING 6 21 BACKLASH 6 22 MEASURING THE FORWARD GEAR BACKLASH 6 22 MEASURING THE REVERSE GEAR BACKLASH 6 23 6 ...

Page 128: ...LING THE LOWER UNIT Step Job Part Q ty Remarks 1 Slit pin 1 2 Nut 1 3 Plate washer 1 4 Propeller 1 5 Spacer 1 6 Bolt 1 7 Anode 1 8 Screw 1 9 Nut 1 10 Water inlet cover 2 11 Nut short 1 12 Nut long 1 13 Bolt with washer 4 Continued on next page ...

Page 129: ...6 2 LOWER UNIT Step Job Part Q ty Remarks 14 Lower unit 1 15 Seal rubber 1 16 Dowel pin 2 For installation reverse the removal procedure ...

Page 130: ...HECKING THE PROPELLER Check Blades Splines Cracks damage wear Replace CHECKING THE ANODE Check Anode Refer to CHECKING THE ANODE on page 3 17 INSTALLING THE LOWER UNIT Connect Shift rod and shift cam Connecting steps 1 Screw in locknut 1 to the bottom end of the thread of shift cam 2 2 Push down shift cam 2 and mesh the dog clutch with the reverse gear 3 Set the shift lever to the reverse position...

Page 131: ...ING Do not hold the propeller with your hands when removing or installing it Be sure to remove the battery leads from the batteries and the lanyard engine stop swith Put a block of wood between the cavitation plate and propeller to keep the propeller from turning ...

Page 132: ...b Part Q ty Remarks 1 Water seal rubber 1 2 Bolt 4 3 Plate 2 4 Water pump housing 1 5 Cartridge insert 1 6 O ring 1 54 5 x 3 0 mm Not reusable 7 Impeller 1 8 Woodruff key 1 9 Bolt 2 10 Cartridge outer plate 1 11 Dowel pin 2 For installation reverse the removal procedure ...

Page 133: ...RUFF KEY Check Woodruff key Damage wear Replace INSTALLING THE CARTRIDGE INSERT AND WATER PUMP HOUSING 1 Install Water pump housing 1 Cartridge insert 2 NOTE When installing the cartridge insert 2 align its projection with the hole in the water pump housing 1 2 Install Water pump housing and cartridge insert 3 NOTE When installing the water pump housing and insert cartridge 3 turn the impeller clo...

Page 134: ...PELLER SHAFT HOUSING ASSEMBLY AND PROPELLER SHAFT ASSEMBLY Step Job Part Q ty Remarks Gear oil drain Refer to CHANGING AND CHECKING THE GEAR OIL LEVEL on page 3 15 1 Bolt with washer 2 2 Propeller shaft housing assembly 1 3 Plate washer 1 4 Propeller shaft assembly 1 For installation reverse the removal procedure ...

Page 135: ...PROPELLER SHAFT HOUSING AND PROPELLER INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY Install Propeller shaft housing assembly NOTE Install the propeller shaft housing assembly with the arrow mark facing up ...

Page 136: ...LER DISASSEMBLING ASSEMBLING THE PROPELLER SHAFT ASSEMBLY Step Job Part Q ty Remarks 1 Shift plunger 1 2 Cross pin ring 1 3 Cross pin 1 4 Clutch dog 1 5 Compression spring 1 6 Propeller shaft 1 For installation reverse the removal procedure ...

Page 137: ...Check Propeller shaft Wear damage Replace ASSEMBLING THE PROPELLER SHAFT ASSEMBLY 1 Install Clutch dog NOTE Install the clutch dog with F mark towards the forward gear side 2 Install Compression spring 1 Cross pin 3 NOTE Compress the compression spring 1 so that it is behind the cross pin hole in clutch dog 2 then install cross pin 3 ...

Page 138: ...ASSEMBLY Step Job Part Q ty Remarks 1 Reverse gear 1 2 Gear adjusting shim 3 O ring 1 51 0 x 3 1 mm Not reusable 4 O ring 1 55 4 x 1 9 mm Not reusable 5 Ball bearing 1 6 Oil seal 2 Not reusable 7 Solid bushing 1 8 Propeller shaft housing 1 For installation reverse the removal procedure as required ...

Page 139: ...a B Except for USA and Canada CHECKING THE REVERSE GEAR Check Teeth Wear damage Replace CHECKING THE BALL BEARING Check Ball bearing Pitting rumbling Replace NOTE Rotate the bearing and check if it turns smoothly Slide hammer handle 1 YB 06096 Stopper guide plate 2 90890 06501 Bearing puller 3 90890 06535 Stopper guide stand 4 90890 06538 Driver rod YB 06229 90890 06652 Attachment YB 06298 90890 0...

Page 140: ...LING THE PROPELLER SHAFT HOUSING ASSEMBLY 1 Install Solid bushing 2 Install Oil seal A For USA and Canada B Except for USA and Canada NOTE Check the mounting depth of each oil seal and press fit Driver rod YB 06229 90890 06652 Attachment YB 06230 90890 06617 Oil seal mounting depth a 10 0 10 5 mm 0 393 0 413 in b 3 0 3 5 mm 0 118 0 138 in Driver rod YB 06071 90890 06605 Attachment YB 06112 90890 0...

Page 141: ...ROPELLER 3 Install Ball bearing A For USA and Canada B Except for USA and Canada NOTE Install the ball bearing with its manufacturer s mark facing towards the reverse gear Driver rod YB 06071 90890 06605 Attachment YB 06167 90890 06634 ...

Page 142: ...EAR REMOVING INSTALLING THE DRIVE SHAFT AND FORWARD GEAR Step Job Part Q ty Remarks 1 Circlip 1 2 Pinion 1 3 Pinion adjusting shim 4 Drive shaft 1 5 Forward gear 1 6 Ball bearing 1 7 Gear adjusting shim For installation reverse the removal procedure as required ...

Page 143: ...k Teeth Wear damage Replace CHECKING THE DRIVE SHAFT Check Drive shaft Wear damage Replace CHECKING THE FORWARD GEAR Check Teeth Wear damage Replace CHECKING THE BALL BEARING Check Ball bearing Pitting rumbling Replace NOTE Rotate the bearing and check if it turns smoothly Slide hammer handle 1 YB 06096 Bearing puller 2 90890 06535 Stopper guide plate 3 90890 06501 A B ...

Page 144: ... BEARING Install Gear adjusting shim s Ball bearing A For USA and Canada B Except for USA and Canada NOTE Install the ball bearing with its manufacturer s mark facing towards the forward gear Driver rod YB 06071 90890 06604 Attachment YB 06167 90890 06634 ...

Page 145: ... HOUSING SHIFT CAM AND LOWER CASE Step Job Part Q ty Remarks 1 Bearing housing assembly 1 2 Gasket 1 Not reusable 3 Coller 1 4 Shift cam 1 5 Solid bushing 1 6 Lower case 1 7 O ring 1 Not reusable 8 Oil seal 2 Not reusable 9 Solid bushing 1 10 Bearing housing 1 11 Dowel pin For installation reverse the removal procedure ...

Page 146: ... Solid bushing A For USA and Canada B Except for USA and Canada CHECKING THE COLLER Check Collar Damage wear Replace CHECKING THE SHIFT CAM Check Shift cam Damage wear Replace CHECKING THE LOWER CASE 1 Clean Lower case with a soft grush and solvent Driver rod YB 06229 90890 06652 Attachment YB 06028 90890 06650 Driver rod YB 06229 90890 06652 Bushing attachment YB 06028 90890 06650 ...

Page 147: ...ge Replace ASSEMBLING THE BEARING HOUSING 1 Install Solid bushing 2 Install Oil seal NOTE Press fit both oil seals at the same time to the mounting depth Driver rod YB 06229 90890 06652 Attachment YB 06028 90890 06650 Oil seal mounting depth a 6 0 6 5 mm 0 236 0 256 in Driver rod YB 06071 90890 06652 Attachment YB 06611 90890 06614 ...

Page 148: ...LOWER CASE INSTALLING THE SOLID BUSHING Install Solid bushing NOTE Pull up the solid bushing until the flange is in tight contact with the lower case Bushing installer center bolt 1 YB 06029 90890 06601 Attachment 2 YB 37350 90890 06616 ...

Page 149: ...ing puller on the propeller shaft 3 Set the lower unit upside down 4 Attach the dial gauge on the lower case and make the dial gauge stem contact the mark on the backlash indicator 5 While pulling the drive shaft downward slowly turn the drive shaft clockwise and counterclockwise then measure the backlash when the drive shaft stops at each direction Forward gear backlash 0 88 1 26 mm 0 0346 0 0496...

Page 150: ...he reverse gear by installing the propeller without the front side spacer 1 and tighten the nut 3 Set the lower unit upside down 4 Attach the dial gauge on the lower case and make the dial gauge stem contact the mark on the backlash indicator Forward gear backlash Shim thickness Less than 0 88 mm 0 0346 in To be decreased by 1 07 Measurement 2 52 More than 1 26 mm 0 0496 in To be decreased by Meas...

Page 151: ... smallest shim available is 0 10 mm if the measurement is between 1 01 mm and 1 38 mm do not change the shim Backlash indicator YB 06265 90890 06706 Magnet base YU 34481 90890 06705 Magnetic base attaching plate YB 07003 90890 07003 Dial gauge stand YU 03097 90890 01252 Reverse gear backlash Shim thickness Less than 1 01 mm 0 0398 in To be decreased by 1 2 Measurement 2 52 More than 1 38 mm 0 0543...

Page 152: ...TOM COWLING 7 9 UPPER CASE 7 11 REMOVING INSTALLING THE UPPER CASE 7 11 INSTALLING THE LOWER MOUNT 7 12 DISASSEMBLING ASSEMBLING THE UPPER CASE 7 13 INSTALLING THE OIL SEAL 7 15 INSTALLING THE MUFFLER 7 15 SWIVEL AND STEERING BRACKET 7 16 REMOVING INSTALLING THE SWIVEL AND STEERING BRACKET 7 16 STEERING FRICTION 7 17 DISASSEMBLING ASSEMBLING THE STEERING FRICTION 7 17 ASSEMBLING THE STEERING FRICT...

Page 153: ...RING HANDLE Step Job Part Q ty Remarks 1 Throttle cable 2 2 Stop switch lead 1 3 Nut 1 4 Shift cable 1 5 Grommet 1 6 Nylone nut 1 7 Nut 1 8 Cover 1 9 Bushing 1 10 Steering handle assembly 1 11 Plate washer 2 12 Plate washer 2 13 Wave washer 1 Continued on next page ...

Page 154: ...7 2 STEERING HANDLE Step Job Part Q ty Remarks 14 Bushing 1 15 Grommet 1 16 Nut 2 17 Bracket 1 18 Stud bolt 2 For installation reverse the removal procedure ...

Page 155: ...le wire through the corrugated tube pass under the throttle wire and then insert in the grommet of the bottom cowling ADJUSTING THE THROTTLE CONTROL CABLES Adjust Throttle cables Refer to ADJUSTING THE THROTTLE CONTROL CABLES on page 3 5 ADJUSTING THE SHIFT CABLE Adjust Shift cable Refer to ADJUSTING THE SHIFT CONTROL CABLE on page 3 4 ...

Page 156: ...Step Job Part Q ty Remarks 1 Rubber bushing 1 2 Bolt with washer 1 3 Shift handle 1 4 Screw with washer 3 5 Shift lever 1 6 Bushing 2 7 Wave washer 1 8 Plate washer 1 9 Cable clamp 1 10 Circlip 1 11 Handle cam plate 1 12 Shift cable 1 13 Bolt 1 Continued on next page ...

Page 157: ...7 5 STEERING HANDLE Step Job Part Q ty Remarks 14 Spring 1 15 Bracket 1 16 Bolt 1 17 Cable clamp 1 18 Steering handle 1 For installation reverse the removal procedure ...

Page 158: ...the hole in steering handle 3 Fit switch lead 2 between steering handle 3 and stop switch 1 so that there is no interference with the throttle shaft 2 Install Throttle cables 4 Throttle shaft 5 NOTE Pass throttle cable 4 through the hole in steering handle 3 then connect to throttle shaft 5 Install throttle shaft 5 to steering handle 3 ...

Page 159: ...NG THE SHIFT LEVER Step Job Part Q ty Remarks 1 Bolt 1 2 Manual starter cable bracket 1 3 Nut 1 4 Clip 1 5 Shift rod 1 6 Grommet 1 7 Grommet 1 8 Bolt 1 9 Stopper 1 10 Spring 1 11 Split pin 1 12 Cable end 1 13 Plate washer 2 Continued on next page ...

Page 160: ...7 8 SHIFT LEVER Step Job Part Q ty Remarks 14 Bolt 2 15 Shift rod lever 1 16 Pin 1 17 Clamp 1 18 Bracket 2 For installation reverse the removal procedure ...

Page 161: ...G THE BOTTOM COWLING Step Job Part Q ty Remarks 1 Bolt 2 2 Fitting plate 1 3 Grommet 1 4 Grommet 1 5 Hose joint 1 6 Hose joint 1 7 O ring 1 Not reusable 8 Pipe 1 9 Screw 2 10 Adapter 1 11 Bolt with washer 2 12 Plate 1 13 Grommet 1 Continued on next page ...

Page 162: ... 14 Emergency signal light 1 15 Bolt with washer 1 16 Cowling clamp 1 17 Bolt with washer 4 18 Bottom cowling 1 19 Rubber seal 1 20 Coller 4 21 Grommet 4 22 Hose nipple 1 23 Rubber seal 2 24 Grommet 1 For installation reverse the removal procedure ...

Page 163: ... ty Remarks 1 Water tube 1 2 Water seal rubber 1 3 Bolt with washer 2 4 Bolt with washer 2 5 Nut 4 6 Lower mount rubber housing 2 7 Lower front mount rubber 1 8 Lower side mount rubber 2 9 Screw 1 10 Nut 2 11 Plate 1 12 Upper case 1 For installation reverse the removal procedure ...

Page 164: ...firming the identifying V mark on its head Pass the stop switch lead wire together with the throttle wire through the corrugated tube pass under the throttle wire and then insert in the grommet of the bottom cowling Tighten 2 front bolts 1 to the specified torque then tighten 2 rear bolts 2 to the specified torque Finally check that all 4 bolts are tightened to the specified torque ...

Page 165: ... Job Part Q ty Remarks 1 Bolt with washer 2 2 Upper side mount rubber 1 3 Bolt with washer 2 4 Exhaust guide 1 5 Clip 1 6 Oil strainer 1 7 Oil seal 1 Not reusable 8 Gasket 1 Not reusable 9 Pin 2 10 Hose 1 11 Screw 1 12 Plate 1 13 Damper 1 Continued on next page ...

Page 166: ...arks 14 Oil drain plug 1 15 Gasket 1 16 Bolt with washer 1 Not reusable 17 Oil pan 4 18 Pin 1 19 Bolt with washer 2 20 Muffler 2 21 Bolt with washer 1 22 Plate 1 23 Grommet 1 24 Upper case 1 1 For installation reverse the removal procedure ...

Page 167: ...to o marked portion of muffler installation and check that there is no clearance after the muffler is installed Control the applied amount so that Three Bond 1207B does not stick to the water passage Do not start the engine until 6 hours elapse after application Driver rod YB 06071 90890 06604 Attachment YB 06112 90890 06614 ...

Page 168: ...G BRACKET Step Job Part Q ty Remarks 1 Bolt 2 2 Bolt with washer 2 3 Steering friction 1 4 Bolt 1 5 Seal rubber 1 6 Steering bracket 1 7 Pivot shaft bushing 1 8 Friction piece 1 9 Bushing 1 10 O ring 1 30 x 3 8 mm Not reusable 11 Bushing 1 12 Clamp bracket 1 For installation reverse the removal procedure ...

Page 169: ...E STEERING FRICTION Step Job Part Q ty Remarks 1 Lock nut 1 2 Plate washer 1 3 Bolt with washer 1 4 Friction piece 2 5 Collar 1 6 Friction plate 1 7 Coller 1 8 Plate washer 2 9 Lock nob 1 10 Lock shaft 1 11 Friction plate 1 For installation reverse the removal procedure ...

Page 170: ...7 18 STEERING FRICTION ASSEMBLING THE STEERING FRICTION Install Lock nob NOTE Set the TOP mark upward ...

Page 171: ...MP BRACKET Step Job Part Q ty Remarks 1 Tilt rod 1 2 Nut 1 3 Plain washer 1 4 Bolt 1 5 Bolt 2 6 Clamp bracket cap 2 7 Clamp bracket plate 1 8 Through tube 1 9 Coller 1 10 Swivel bracket 1 11 Bushing 2 12 Clamp bracket 1 13 Clamp bracket 1 Continued on next page ...

Page 172: ...7 20 CLAMP BRACKET Step Job Part Q ty Remarks 14 Bolt 2 15 Stopper 2 16 Wave washer 2 For installation reverse the removal procedure ...

Page 173: ...7 21 CLAMP BRACKET INSTALLING THE CLAMP BRACKET PLATE Install Clamp bracket plate 1 NOTE Turn clamp bracket plate 1 down until it contacts stopper boss 2 of the clamp bracket ...

Page 174: ... Step Job Part Q ty Remarks 1 Tension spring 1 2 Circlip 1 3 Tilt lock shaft 1 4 Tilt lock rod 1 5 Tilt lock plate 1 6 Tension spring 2 7 Circlip 1 8 Reverse lock shaft 1 9 Tilt lock plate 1 10 Tilt lever 1 11 Tilt lock rod 1 12 Circlip 1 13 Stopper shaft 1 Continued on next page ...

Page 175: ...BRACKET Step Job Part Q ty Remarks 14 Circlip 1 15 Tilt lever 1 16 Circlip 1 17 Tilt lever shaft 1 18 Receiver 1 19 Grease nipple 1 20 Wire lead 1 21 Swivel bracket 1 For installation reverse the removal procedure ...

Page 176: ...A LOW RESISTANCE 8 6 IGNITION SYSTEM 8 7 CHECKING THE SPARK PLUGS 8 8 CHECKING THE IGNITION SPARK GAP 8 8 CHECKING THE SPARK PLUG CAPS AND IGNITION COIL 8 8 CHECKING THE CHARGE COIL 8 10 CHECKING THE PULSER COIL 8 10 CHECKING THE CDI UNIT 8 11 IGNITION CONTROL SYSTEM 8 12 CHECKING THE ENGINE STOP SWITCH 8 13 CHECKING THE PULSER COIL 8 13 CHECKING THE OIL PRESSURE SWITCH 8 14 CHECKING EMERGENCY SIG...

Page 177: ...ONENTS ONE LIGHTING COIL MODEL Top view and left side view 1 Pulser coil 2 Emergency signal light 3 Lighting coil 4 Oil pressure switch 5 Spark plug 6 Charge coil 7 CDI unit 8 Rectifier 9 Ignition coil A Short handle model B Long handle model ...

Page 178: ...ing harness connection A To lighting coil B To charge coil C To pulser coil D To emergency signal light E To stop switch F To oil pressure switch G Green R Red L Blue Br Brown W R White Red B Black O Orange P Pink Y R Yellow Red W White Y Yellow ...

Page 179: ...GHTING COILS MODEL Top view front view and left side view B A 1 Pulser coil 2 Emergency signal light 3 Lighting coil 4 Oil pressure switch 5 Spark plug 6 Charge coil 7 CDI unit 8 Rectifier regulator 9 Ignition coil A Short handle model B Long handle model ...

Page 180: ...ess connection A To lighting coil B To charge coil C To pulser coil D To emergency signal light E To stop switch F To oil pressure switch R Red G Green G W Green White L Blue Br Brown W R White Red B Black P Pink Y R Yellow Red W White Y Yellow O Orange ...

Page 181: ... When checking the condition of the ignition system it is useful to know the peak voltage Cranking speed is dependant on many factors e g fouled or weak spark plugs a weak battery If one of three is defective the peak voltage will be lower than specification If the peak voltage measurement is not within specification the engine will not operate properly PEAK VOLTAGE ADAPTOR NOTE The peak voltage a...

Page 182: ... following tests Measuring steps 1 Connect the peak voltage adapter probes to the connectors 2 Start or crank the engine and observe the measurement MEASURING A LOW RESISTANCE When measuring a resistance of 10 Ω or less with the digital tester the correct measurement cannot be obtained because of the tester s internal resistance To obtain the correct value subtract the internal resistance from the...

Page 183: ...8 7 IGNITION SYSTEM IGNITION SYSTEM 1 CDI unit 2 Pulser coil 3 Charge coil 4 Ignition coil 5 Spark plug B Black W R White Red Br Brown L Blue O Orange ...

Page 184: ...Replace the spark plug Checking steps 1 Remove the spark plugs from the engine 2 Connect a spark plug cap to the spark gap tester 3 Set the spark gap length on the adjusting knob 4 Crank the engine and observe the spark through the discharge window of the spark gap tester CHECKING THE SPARK PLUG CAPS AND IGNITION COIL 1 Check Spark plug cap 1 High tension code 2 Ignition coil 3 Loosen connection T...

Page 185: ...lug cap resistance Out of specification Replace Measured value 3 Measure Ignition coil resistance Primary A Out of specification Replace Secondary B Out of specification Replace Measured value Spark plug cap resistance 4 3 kΩ Ignition coil resistance Primary A Orange O Black B Secondary B Output port Output port 0 6 Ω 8 75 kΩ A B ...

Page 186: ...ge coil output peak voltage Brown Br Blue L r min Cranking 1 500 3 500 Opened Closed D C V 112 154 185 185 Peak voltage adaptor YU 39991 90890 03172 Charge coil resistance Brown Br Blue L Reference value 232 348 Ω Pulser coil output peak voltage White Red W R Black B r min Cranking 1 500 3 500 Opened Closed D C V 7 0 3 5 7 0 10 5 Peak voltage adaptor YU 39991 90890 03172 Pulser coil resistance Whi...

Page 187: ...eplace the CDI unit NOTE Before measuring CDI unit output peak voltage make sure that no abnormality is observed on the charge coil and the pulser coil CDI unit output peak voltage Orange O Black B r min Cranking 1 500 3 500 Opened Closed D C V 53 2 140 168 168 Peak voltage adaptor YU 39991 90890 03172 ...

Page 188: ...8 12 IGNITION CONTROL SYSTEM IGNITION CONTROL SYSTEM 1 Emergency signal light 2 CDI unit 3 Pulser coil 4 Charge coil 5 Oil pressure switch Y R Yellow Red P Pink B Black W R White Red Br Brown L Blue ...

Page 189: ...Engine stop switch continuity Out of specification Replace CHECKING THE PULSER COIL Check Pulser coil output peak voltage Refer to CHECKING THE PULSER COIL on page 8 10 Leads color White W Black B Remove the Lock plate A Install the Lock plate B Push the button C B C A ...

Page 190: ...mity vac 5 Measure the continuity when the specified pressure is reached CHECKING EMERGENCY SIGNAL LIGHT Check Emergency signal light lighting No lighting Replace NOTE LED has an direction for electrical current Therefore try reverse connection if there is no lighting Oil pressure switch continuity pressure 14 7 kPa 0 15 kgf cm2 2 13 psi and above No continuity 14 7 kPa 0 15 kgf cm2 2 13 psi and b...

Page 191: ...8 15 CHARGING SYSTEM CHARGING SYSTEM ONE LIGHTING COIL MODEL 1 Battery 2 Fuse 10A 3 Rectifier 4 Lighting coil R Red G Green B Black ...

Page 192: ...8 16 CHARGING SYSTEM CHARGING SYSTEM TWO LIGHTING COILS MODEL 1 Battery 2 Fuse 10A 3 Rectifier regulator 4 Lighting coil R Red G Green G W Green White B Black ...

Page 193: ...lighting coil model Green G Green G r min Cranking 1 500 3 500 Opened Closed Opened Opened D C V 3 5 3 5 14 33 Lighting coil resistance One lighting coil model Green G Green G Reference value 0 24 0 36 Ω Lighting coil output peak voltage Two lighting coils model Green G Green G r min Cranking 1 500 3 500 Opened Closed Opened Opened D C V 8 4 8 4 33 6 77 0 Lighting coil resistance Two lighting coil...

Page 194: ...measuring closed cranking 1500 r min and 3500 r min disconnect the positive terminal of the battery NOTE Before measuring the rectifier or the rectifier regulator peak voltage make sure that no abnormality is observed on the lighting coil Rectifier output peak voltage A Red R Black B r min Cranking 1 500 3 500 Opened Closed Opened Opened D C V 2 8 13 3 32 2 Rectifier regulator output peak voltage ...

Page 195: ...CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS 9 1 TROUBLE ANALYSIS CHART 9 1 TROUBLE SHOOTING FOR PEAK VOLTAGE 9 3 9 ...

Page 196: ...are correct 8 Engine is free from any Hull problem Trouble mode Check element ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING SHIFTING DIFFICULT IRREGULAR WARNING INDICATION POOR BATTERY CHARGING Relative part Reference chapter FUEL SYSTEM Fuel hose 4 Fuel joint 4 Fuel filter 4 Fuel pump 4 Carburetor 4 Throttle stop screw 3 Pilot sc...

Page 197: ...NDICATION POOR BATTERY CHARGING Relative part Reference chapter LOWER UNIT Neutral position 6 Clutch 6 Gears 6 Water inlet 6 Water pump 6 Propeller shaft and propeller 6 Shifter Pin 6 Shift cam 6 Shift rod or Shift cable 6 Lower case 6 Shim adjustment 6 BRACKET UNIT Bracket 7 Mount rubber 7 Steering friction 7 ELECTRICAL Ignition system 8 Ignition control system 8 Starting system 8 Charging system...

Page 198: ...run smoothly The engine speed drops during acceleration Check the ignition system 1 Check the harness couplers toignition coil CDI unit pulser coil and charge coil 2 Check the spark gap 3 Check theplug cap 4 Check the ignition coils 5 Check the CDI unit output peak voltage 6 Check the charge coil output peak voltage 7 Check the pulser coil output peak voltage Replace the CDI Unit OK NG OK OK NG OK...

Page 199: ...Printed on recycled paper Printed in USA Apr 2000 x 1 F6AMH F8CMH YAMAHA MOTOR CO LTD ...

Page 200: ...W P Y Y W R CDI unit 1 Y R P 0 5B 0 5B W R L Br B P W R L Br B P G G G G R AVX1 25B AVX1 25B AVX1 25R AVX1 25R AVX1 25B P M4 Emergency signal light 2 Battery 11 Fuse 10A 12 Stop switch 3 Oil pressure switch 10 4 M6 B 0 5W 0 5W B O B O G G L Br B W R R G Bracket A Optional parts B O B Y R P If there is no size specified for the lead wire the size is AVX0 75f C G WIRING DIAGRAM F6MH F8MH FOR ONE LIG...

Page 201: ...ency signal light 2 Battery 11 Fuse 10A 12 Stop switch 3 Oil pressure switch 10 4 G Black Brown Green Blue Orange Pink Red White Yellow B Br G L O P R W Y G W W R Y R Green white White red Yellow red 0 5W 0 5W B O B O Y R P G G L Br B W R Bracket A R G G W O B Optional parts B Optional parts B Rectifier regulator 8 If there is no size specified for the lead wire the size is AVX0 75f C WIRING DIAGR...

Page 202: ...SUPPLEMENTARY SERVICEMANUAL 69G 28197 1A 1X T8PH T8PR LIT 18616 02 31 ...

Page 203: ...lementary Service Manual together with the following manual T8PH T8PR SUPPLEMENTARY SERVICE MANUAL 2000 by Yamaha Motor Corporation USA 1st Edition October 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation USA is expressly prohibited Printed in USA LIT 18616 02 31 F6Z F8Z SERVICE MANUAL 68T 28197 ZA 11 LIT 18616 02 19 ...

Page 204: ...follow the symbol e g Bearings Pitting scratches Replace To assist you in finding your way through this manual the section title and major heading is given at the top of every page MODEL INDICATION Multiple models are referred to in this manual and their model indications are noted as follows ILLUSTRATIONS The illustrations within this service manual represent all of the designated models CROSS RE...

Page 205: ...R SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the outboard motor CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor NOTE A NOTE provides key information to make procedures easier or clearer ...

Page 206: ...exploded views to indicate important aspects of the procedure A list of meanings for these symbols is provided on the following page 4 In addition to tightening torques the dimensions of the bolts and screws are also mentioned Example Bolt and screw size bolt and screw diameter D x length L 5 In addition to the exploded views and job instruction charts this manual provides individual illustrations...

Page 207: ...rical current A Symbols F to I in an exploded diagram indicate the grade of lubricant and the location of the lubricant point F Apply Yamaha 4 stroke motor oil G Apply water resistant grease Yamaha grease A Yamaha marine grease H Apply Yamaha grease D I Apply molybdenum disulfide grease Symbols J to O in an exploded diagram indicate the grade of the sealing or locking agent and the location of the...

Page 208: ...ENING TORQUES 19 SPECIFIED TORQUES 19 GENERAL TORQUES 21 PERIODIC CHECK AND ADJUSTMENT MAINTENANCE INTERVAL CHART 22 POWER UNIT 23 ADJUSTING THE VALVE CLEARANCE 23 POWER TILT SYSTEM 24 CHECKING THE POWER TILT PT FLUID LEVEL 24 GENERAL 24 CHECKING THE ANODE 24 LOWER UNIT LOWER UNIT 25 REMOVING INSTALLING THE LOWER UNIT 25 WATER PUMP 27 REMOVING INSTALLING THE WATER PUMP 27 CHECKING THE IMPELLER HOU...

Page 209: ... PINION AND FORWARD GEAR 41 CHECKING THE DRIVE SHAFT 41 CHECKING THE SHIFT CAM 41 CHECKING THE BEARING 41 CHECKING THE SLEEVE 41 CHECKING THE LOWER CASE 41 ASSEMBLING THE LOWER CASE 41 ASSEMBLING THE OIL SEAL HOUSING ASS Y 42 ASSEMBLING THE FORWARD GEAR 42 SHIMMING FOR USA AND CANADA 43 SELECTING THE PINION SHIMS 43 SHIMMING EXCEPT FOR USA AND CANADA 44 SELECTING THE PINION SHIMS 44 SELECTING THE ...

Page 210: ...4 ASSEMBLING THE POWER TILT PT CYLINDER 65 REMOVING INSTALLING THE POWER TILT PT UNIT 69 ELECTRICAL SYSTEM STARTER MOTOR 71 DISASSEMBLING ASSEMBLING THE STARTER MOTOR 71 REMOVING THE PINION 73 CHECKING THE PINION 73 CHECKING THE ARMATURE 73 CHECKING THE BRUSH HOLDER 74 POWER TILT PT SYSTEM 75 POWER TILT PT SYSTEM T8PR FT8DEP 75 POWER TILT PT SYSTEM T8PH 76 CHECKING THE PT SWITCH 77 CHECKING THE PT...

Page 211: ...port clamp bracket The label is specially treated so that peeling it off causes cracks across the serial number 1 Model name 2 Approval model code 3 Transom height 4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows Model name Applicable model code Starting serial number World wide USA Canada FT8DMH T8MH 69G L 350101 X 650101 FT8DE T8ER 69G L 400101 X 700101 FT...

Page 212: ... NOTE O For U S A and Canada use part numbers that start with J YB YM YU or YW O For other countries use part numbers that start with 90890 REMOVAL AND INSTALLATION 1 Power tilt wrench 2 Needle bearing 3 Driver rod L3 4 Drive shaft holder 5 Pinion nut holder P N YB 06560 90890 06560 P N YB 06112 YB 06196 a 90890 06614 b P N YB 06071 a 90890 06652 b P N YB 06565 90890 06565 P N YB 06078 a 2 b a 3 b...

Page 213: ...in 5 9 8 0 5 500 Full throttle operating range r min 5 000 6 000 Maximum fuel consumption L US gal h 3 3 0 87 0 73 Imp gal h 6 000 r min POWER UNIT Type 4 stroke SOHC in line Number of cylinders 2 Total displacement cm3 cu in 197 11 8 Bore x stroke mm in 56 0 x 40 0 2 2 x 1 6 Compression ratio 8 79 Compression pressure kPa kgf cm2 psi 950 9 5 135 1 Number of carburetors 1 Control system Tiller con...

Page 214: ...3 US oz 800 27 0 28 2 Imp oz Gear oil type Hypoid gear oil Gear oil grade GL 4 SAE 90 Gear oil capacity cm3 US oz 320 10 9 11 3 Imp oz BRACKET Tilt angle Degrees 78 78 Shallow water drive angle Degrees 24 37 Steering angle right left Degrees 40 40 45 45 DRIVE UNIT Gear positions F N R Gear ratio gear pinioin 2 92 38 13 Gear type Spairal bevel gear Propeller direction Clockwise Back view Propeller ...

Page 215: ... 500 Full throttle operating range r min 5 000 6 000 Maximum fuel consumption L US gal h 3 3 0 87 0 73 Imp gal h 6 000 r min POWER UNIT Type 4 stroke SOHC in line Number of cylinders 2 Total displacement cm3 cu in 197 11 8 Bore x stroke mm in 56 0 x 40 0 2 2 x 1 6 Compression ratio 8 79 Compression pressure kPa kgf cm2 psi 950 9 5 135 1 Number of carburetors 1 Control system Remote control Startin...

Page 216: ...il type Hypoid gear oil Gear oil grade GL 4 SAE 90 Gear oil capacity cm3 US oz Imp oz 320 10 9 11 3 BRACKET Tilt angle Degree 78 78 Shallow water drive angle Degree 24 37 Steering angle right left Degree 40 40 45 45 DRIVE UNIT Gear positions F N R Gear ratio gear pinion 2 92 38 13 Gear type Spairal bevel gear Propeller direction Clockwise Back view Propeller drive system Spline Propeller ID mark R...

Page 217: ...RM SHAFT Rocker shaft mm in 12 941 12 951 0 5095 0 5099 outside diameter b CAMSHAFT Intake A mm in 23 45 23 55 0 9232 0 9271 Intake B mm in 19 95 20 05 0 7854 0 7893 Exhaust A mm in 23 45 23 55 0 9232 0 9271 Exhaust B mm in 19 95 20 05 0 7854 0 7893 Cylinder head mm in 17 975 17 991 0 7077 0 7083 Journal diameter Oil pump housing journal diameter mm in 15 975 15 991 0 6289 0 6296 Camshaft round li...

Page 218: ...015 EX mm in 0 025 0 052 0 0010 0 0020 Stem runout limit IN mm in 0 03 0 0012 EX mm in 0 03 0 0012 VALVE SPRING Free length mm in 27 6 1 09 Free length limit mm in 27 6 1 09 Tilt limit mm in 1 0 0 04 PISTON Piston to cylinder clearance mm in 0 035 0 065 0 0014 0 0026 Piston diameter D mm in 55 950 55 965 2 2028 2 2033 Measuring point H mm in 1 5 0 06 Pin boss inside diameter mm in 14 004 14 015 0 ...

Page 219: ...RANKSHAFT Crankcase journal diameter mm in 29 997 30 009 1 1810 1 1815 Crank pin journal diameter mm in 26 997 27 009 1 0629 1 0633 Runout limit mm in 0 03 0 0012 CRANKCASE Crankshaft journal inside diameter mm in 33 016 33 040 1 3000 1 3008 Crankshaft journal oil clearance bearing installed mm in 0 011 0 039 0 0004 0 0015 Bearing mark color A Blue B Black C Brown mm in 33 032 33 040 1 3005 1 3008...

Page 220: ... mm in 0 03 0 09 0 001 0 004 CARBURETOR Stamped mark 68T 00 FT8DMH 68T 30 FT8DE FT8DEP 68T 40 T8PR T8ER 68T 10 T8PH T8MH 68T 50 for SAV Main jet 74 Pilot jet 39 Float height a mm in 19 0 20 0 0 75 0 79 Idle speed r min 1 050 50 Item Unit Model World wide FT8DMH FT8DE FT8DEP USA Canada T8MH T8ER T8PR T8PH GEAR BACKLASH Pinion Forward gear mm in 0 20 1 15 0 008 0 045 Pinion Reverse gear mm in 0 66 1...

Page 221: ... 5 CDI unit output peak voltage O B cranking opened V 53 2 cranking closed V 140 1 500 r min V 168 3 500 r min V 168 Ignition spark gap mm in 0 9 0 04 Charge coil resistance Br L Ω 232 348 Pulser coil resistance W R B Ω 240 360 Ignition coil resistance Primary O B Ω 0 26 0 35 Secondary Between outputs kΩ 6 80 10 20 Spark plug cap resistance kΩ 4 3 IGNITION CONTROL SYSTEM 14 7 0 15 2 13 2 000 150 6...

Page 222: ...g closed V 1 500 r min opened V 13 3 3 500 r min opened V 32 2 Charging current A 5 000 r min 5 5 Lighting coil resistance G G Ω 0 24 0 36 CHARGING SYSTEM TWO LIGHTING COILS MODEL Lighting coil output peak voltage G G cranking opened V 8 4 cranking closed V 8 4 1 500 r min opened V 33 6 3 500 r min opened V 77 0 Rectifier regulator output peak voltage R B cranking opened V 7 7 cranking closed V 1 ...

Page 223: ...MAINTENANCE SPECIFICATIONS 13 OUTBOARD DIMENSIONS T8PH T8MH FT8DMH ...

Page 224: ...m in 67 2 6 H1 L mm in 869 34 2 X mm in 937 36 9 937 36 9 H2 mm in 318 12 5 H3 mm in 157 6 2 H4 L mm in 557 21 9 X mm in 625 24 6 625 24 6 H5 mm in 673 26 5 H6 L mm in 717 28 2 X mm in 757 29 8 757 29 8 H7 mm in 203 8 0 H8 mm in 5 0 2 H9 mm in 529 20 8 H10 mm in 32 1 3 H11 mm in W1 mm in 172 6 8 159 6 3 W2 mm in 199 7 8 W3 mm in 159 6 3 W4 mm in 159 6 3 W5 mm in 326 12 8 379 14 9 W6 mm in 586 23 1...

Page 225: ...MAINTENANCE SPECIFICATIONS 15 OUTBOARD DIMENSIONS FT8DEP T8PR FT8DE T8ER ...

Page 226: ...m in 225 8 9 L9 mm in L10 mm in 67 2 6 H1 L mm in 869 34 2 X mm in 937 36 9 H2 mm in 318 12 5 H3 mm in 157 6 2 H4 L mm in 557 21 9 X mm in 625 24 6 H5 mm in H6 L mm in 717 28 2 X mm in 757 29 8 H7 mm in 203 8 0 H8 mm in 5 0 2 H9 mm in 529 20 8 H10 mm in 32 1 3 H11 mm in W1 mm in 177 7 0 W2 mm in 135 5 3 W3 mm in 159 6 3 W4 mm in 159 6 3 W5 mm in 271 10 7 286 11 3 W6 mm in 271 10 7 286 11 3 A1 Degr...

Page 227: ...MH FT8DE USA Canada T8MH T8ER B1 mm in 70 5 2 8 B2 mm in 180 5 7 2 B3 mm in 95 3 3 8 B4 mm in 94 5 3 7 B5 mm in 105 3 4 1 B6 mm in 189 5 7 5 B7 mm in B8 mm in B9 mm in 18 0 7 B10 mm in B11 mm in B12 mm in C1 mm in 28 1 1 C2 mm in 65 2 6 C3 mm in D1 mm in 8 3 0 3 D2 mm in 8 3 0 3 D3 mm in D4 mm in T mm in ...

Page 228: ...B1 mm in 95 3 3 8 B2 mm in 275 5 10 8 B3 mm in 95 3 3 8 B4 mm in 94 5 3 7 B5 mm in 111 4 4 B6 mm in 325 5 12 8 B7 mm in 155 5 6 1 B8 mm in B9 mm in 18 0 7 B10 mm in B11 mm in 73 5 2 9 B12 mm in 69 5 2 7 C1 mm in 41 1 6 C2 mm in 65 2 6 C3 mm in D1 mm in 8 3 0 3 D2 mm in 10 0 4 D3 mm in D4 mm in T mm in ...

Page 229: ... 1 18 1 8 13 3 Screw M5 1 2 0 2 1 5 Exhaust outer cover mounting 1st Bolt M6 5 6 0 6 4 4 2nd 12 1 2 8 8 Spark plug M14 2 25 2 5 18 4 Cylinder head mounting 1st Bolt M8 6 15 1 5 11 1 2nd 30 3 0 22 1 1st Bolt M6 3 6 0 6 4 4 2nd 12 1 2 8 8 Oil pump housing Screw M6 2 5 0 5 3 7 Rocker arm locknut Nut M5 4 8 0 8 5 9 Crankcase mounting 1st Bolt M8 6 15 1 5 11 1 2nd 30 3 0 22 1 Connecting rod mounting 1s...

Page 230: ...1 4 0 4 2 9 Grease nipple Nipple 1 3 0 3 2 2 Steering friction plate mounting Bolt M5 2 5 4 0 54 3 9 Steering friction piece mounting Bolt M5 1 5 4 0 54 3 9 Neutral switch stay mounting Bolt M6 2 10 1 0 7 4 Recoil starter cable mounting Bolt M6 1 or 2 10 1 0 7 4 Ground lead mounting Screw M5 1 2 5 0 25 1 8 POWER TILT UNIT Reservoir cap Screw M10 1 5 0 5 3 6 Cylinder end screw Nut M33 1 45 4 5 32 T...

Page 231: ...ndard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual to avoid warpage tighten multifastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications require clean dry thread...

Page 232: ...il Check replace Timing belt Check replace Valve clearance Check adjust Ignition timing Check Thermostat Check replace Water leakage Check Motor exterior Check Exhaust leakage Check Cooling water passage Check CONTROL SYSTEM Shift cable Check adjust Throttle cables Check adjust Throttle axle link Check adjust Engine idling speed Check adjust Start in gear protection device Check adjust LOWER UNIT ...

Page 233: ... crankshaft and align the 1 mark on the driven gear 5 and mark on the thermostat cover 6 2 Check the intake valve clearance a and exhaust valve clearance b on the cylinder 1 using the feeler gauge 7 3 Turn the crankshaft 360 and align the 2 mark on the driven gear 5 and mark on the thermostat cover 6 4 Check the intake valve clearance a and exhaust valve clearance b on the cylinder 2 using the fee...

Page 234: ...1 Tilt up the outboard and lock it with tilt lock knob 1 2 Remove the reservoir cap 2 3 Check that the fluid level is directly below the fluid level checking hole a NOTE The fluid level should be directly below the check hole as shown 2 Add GENERAL CHECKING THE ANODE 1 Check y Anode engine y Anode clamp bracket y Anode lower unit Scales Æ Clean Oil grease Æ Clean Excessive wear half worn damage Æ ...

Page 235: ...rt Q ty Remarks 1 Pin split 1 2 Nut 1 3 Washer 1 4 Spacer 1 5 Propeller 1 6 Washer 1 7 Spacer 1 8 Locknut 1 9 Adjusting nut 1 10 Bolt 4 11 Stud bolt nut for X transom models 4 4 12 Extension for X transom models 1 13 Dowel pin for X transom models 2 Continued on next page ...

Page 236: ...UNIT Step Job Part Q ty Remarks 14 Lower unit 1 15 Dowel pin 2 16 Rubber seal 1 17 Screw 1 18 Nut 1 19 Water inlet grill 2 20 Bolt 1 21 Toothed washer 1 22 Anode 1 For installation reverse the removal procedure ...

Page 237: ...R PUMP Step Job Part Q ty Remarks Lower unit 1 Bolt 4 2 Plate 2 3 Impeller housing 1 4 O ring 1 5 Impeller 1 6 Impeller housing cup 1 7 Woodruff key 1 8 Bolt 2 9 Dowel pin 2 10 Metal gasket 1 11 Rubber seal 1 For installation reverse the removal procedure ...

Page 238: ...THE IMPELLER AND IMPELLER HOUSING CUP Check y Impeller y Impeller housing cup Cracks damage Æ Replace INSTALLING THE IMPELLER HOUSING CUP Install y Impeller housing cup NOTE To install the impeller housing cup turn the drive shaft clockwise Do not turn the drive shaft counterclockwise after installation ...

Page 239: ... PROPELLER SHAFT REMOVING INSTALLING THE PROPELLER SHAFT HOUSING ASS Y AND PROPELLER SHAFT ASS Y Step Job Part Q ty Remarks Gear oil Propeller 1 Bolt 2 2 Propeller shaft housing ass y 1 3 Thrust washer 1 4 Propeller shaft ass y 1 For installation reverse the removal procedure ...

Page 240: ...PROPELLER SHAFT HOUSING ASS Y Remove O Propeller shaft housing ass y A For USA and CANADA B Except for USA and CANADA Bearing housing puller claw YB 06234 1 90890 06503 3 Universal puller 2 YB 06117 Stopper guide plate 4 90890 06501 Center bolt 5 90890 06504 A B ...

Page 241: ...ELLER SHAFT ASS Y DISASSEMBLING ASSEMBLING THE PROPELLER SHAFT ASS Y Step Job Part Q ty Remarks 1 Spring 1 2 Cross pin 1 3 Dog clutch 1 4 Shift plunger 1 5 Spring 1 6 Propeller shaft 1 For assembly reverse the disassembly procedure ...

Page 242: ...32 PROPELLER SHAFT ASS Y CHECKING THE DOG CLUTCH Check y Dog clutch Wear damage Æ Replace CHECKING THE PROPELLER SHAFT Check y Propeller shaft Wear damage Æ Replace ...

Page 243: ...FT HOUSING ASS Y as required Step Job Part Q ty Remarks Propeller shaft housing ass y 1 Reverse gear 1 2 Reverse gear shim 3 O ring 1 Not reusable 4 O ring 1 Not reusable 5 Ball bearing 1 6 Oil seal 2 Not reusable 7 Needle bearing 1 8 Propeller shaft housing 1 For assembly reverse the disassembly procedure ...

Page 244: ...2 Remove y Oil seals y Needle bearing CHECKING THE GEARS Check y Teeth y Dog clutch Wear damage Æ Replace Bearing separator 1 YB 06216 90890 06534 Slide hammer set 2 YB 06096 Stopper guide plate 3 90890 06501 Bearing puller 4 90890 06535 Stopper guide stand 5 90890 06538 1 Slide hammer set 1 YB 06096 Driver rod 2 YB 06071 90890 06604 Needle bearing attachment 3 YB 06081 90890 06616 A B ...

Page 245: ...SING 1 Clean y Propeller shaft housing with a soft brush and solvent 2 Check y Propeller shaft housing Cracks damage Æ Replace ASSEMBLING PROPELLER SHAFT HOUSING ASS Y 1 Install y Needle bearing NOTE Install the needle bearing with its manufac turer s marks b fasing up Needle bearing depth a 0 mm 0 in Driver rod 1 YB 06071 90890 06604 Needle bearing attachment 2 YB 06081 90890 06616 ...

Page 246: ...ll the ball bearing with its manufactur er s marks a facing towards the reverse gear 4 Install O Reverse gear shim s 1 O Reverse gear 2 Oil seal depth a 4 5 5 0 mm 0 18 0 20 in Oil seal installer 1 Needle bearing attachment N A 90980 06614 Driver rod 2 YB 06071 90890 06604 Driver rod 1 YB 06071 90890 06606 Ball bearing attachment 2 YB 06015 90890 06632 ...

Page 247: ...VE SHAFT FORWARD GEAR AND SHAFT ROD as required Step Job Part Q ty Remarks Propeller shaft ass y Water pump 1 Pinion nut 1 2 Pinion 1 3 Washer 1 4 Thrust bearing 1 5 Pinion shim 6 Drive shaft 1 7 Forward gear ass y 1 along with the tapered roller bearing and forward gear shim 8 Oil seal housing ass y 1 9 Metal gasket 1 Continued on next page ...

Page 248: ...AL HOUSING Step Job Part Q ty Remarks 10 Shift rod 1 11 Sleeve 1 12 Needle bearing 1 13 Forward gear bearing outer race 1 14 Oil seal 2 Not reusable 15 Bushing 1 Not reusable 16 Oil seal housing ass y 1 For installation reverse the removal procedure ...

Page 249: ...ng with the tapered roller bearing and forward gear shim DISASSEMBLING THE OIL SEAL HOUSING ASS Y Remove O Bushing INSTALLING THE SLEEVE Install O Sleeve 1 CAUTION Install the sleeve with its hole facing forward Driver shaft holder 1 YB 06565 90890 06565 Pinion nut holder 2 YB 06078 N A Bushing attachment YB 06028 90890 06649 Driver rod YB 06229 90890 06604 ...

Page 250: ...nd CANADA B Except for USA and CANADA NOTE Make sure the bearing outer race puller sliding on the gear case attaching to the outer race and shim s bottom at horizontally Driver rod 1 YB 06229 90890 06602 Needle bearing attachment 2 YB 06230 90890 06617 Slide hammer set 1 YB 06096 Stopper guide plate 2 90890 06501 Bearing outer race puller 3 90890 06535 Stopper guide stand 4 90890 06538 A B ...

Page 251: ...CHECKING THE BEARING Check y Bearing Pitting rumbling Æ Replace CHECKING THE SLEEVE Check y Sleeve Wear damage Æ Replace CHECKING THE LOWER CASE 1 Clean y Gear case with a soft brush and solvent 2 Check y Water passage Mineral deposits corrosion Æ Clean 3 Check y Lower case Cracks damage Æ Replace ASSEMBLING THE LOWER CASE 1 Install y Tapered roller bearing outer race 1 Bearing installer Bearing o...

Page 252: ...r bearing to the forward gear Needle bearing depth a 0 7 1 2 mm 0 03 0 05 in Needle bearing depth b S 189 3 189 8 mm 7 45 7 47 in Driver rod 1 YB 06229 90890 06602 Drive shaft needle bearing depth stop 2 YB 06231 Needle bearing attachment 3 YB 06230 90890 06617 Bearing depth plate 4 90890 06603 Bushing attachment YB 06028 90890 06649 Driver rod YB 06229 90890 06604 Depth a 7 0 8 0 mm 0 28 0 31 in ...

Page 253: ...CTING THE PINION SHIMS Measure y Pinion clearance with a thickness gauge Out of specification Æ Adjust Measuring steps 1 Install the drive shaft components and tighten the pinion nut 2 Install the bearing shim selector 1 onto the gear case not onto the tapered roller bearing 3 Attach the bearing shim selector 1 4 Measure the clearance a with a thickness gauge and determine the proper shim to use S...

Page 254: ...rts and a new case Measurements and adjustments are required when replacing an inner part s SELECTING THE PINION SHIMS 1 Measure O Measurement Mv3 NOTE Measure the thickness Mv3 of the bearing and washer 2 Calculate O Pinion shim thickness T3 3 Select O Pinion shim Digital caliper 90890 06704 Pinion shim thickness T3 6 05 Mv3 mm Calculated numeral Shim more than or less 1 13 1 20 1 13 1 20 1 30 1 ...

Page 255: ...NOTE Measure the length between the shimming plate and the bearing outer race after turn ing the outer race 2 or 3 times 2 Calculate O Forward gear shim thickness T1 3 Select O Forward gear shim Shimming plate 90890 06701 Digital caliper 90890 06704 Forward gear shim thickness T1 16 50 Mv1 Calculated numeral Shim more than or less 0 0 1 0 0 1 0 2 0 1 0 2 0 3 0 2 0 3 0 4 0 3 0 4 0 5 0 4 Available s...

Page 256: ...h the spe cial tool 1 Measure O Measurement Mv2 NOTE Remove the shim s before measuring 2 Calculate O Reverse gear shim thickness T2 3 Select O Reverse gear shim Shimming plate 90890 06701 Digital caliper 90890 06704 Reverse gear shim thickness T2 81 00 Mv2 Calculated numeral Shim more than or less 0 0 1 0 0 1 0 2 0 1 0 2 0 3 0 2 0 3 0 32 0 3 Available shim thickness 0 1 0 2 and 0 3 mm ...

Page 257: ...n the pinion gear may be too low If either of these conditions exist then check the pinion gear shim s selection MEASURING THE FORWARD GEAR BACKLASH 1 Measure y Forward gear backlash Out of specification Æ Adjust Measuring steps 1 Position the bearing housing puller so that it pushes against the propeller shaft 2 Set the lower unit upside down Forward gear backlash 0 20 1 15 mm 0 008 0 045 in Bear...

Page 258: ...ve or add shim s NOTE Adjust the shim s to be added or removed according to specification M Measurement MEASURING THE REVERSE GEAR BACKLASH 1 Measure y Reverse gear backlash Out of specification Æ Adjust Backlash indicator YB 06265 90890 06706 Base plate YB 07003 90890 07003 Dial gauge set YU 03097 90890 01252 Magneto base YU 3448 90890 06705 Shim thickness Less than 0 20 mm 0 008 in To be decreas...

Page 259: ...se and counterclockwise and when the drive shaft stops in each direction measure the backlash 1 2 Adjust O Reverse gear backlash Remove or add shim s NOTE Adjust the shim s to be added or removed according to specification M Measurement Propeller nut 5 NOm 0 5 kgfOm 3 6 ftOlb Backlash indicator YB 06265 90890 06706 Base plate YB 07003 90890 07003 Dial gauge set YU 03097 90890 01252 Magneto base YU...

Page 260: ...Step Job Part Q ty Remarks 1 Bolt with washer 2 2 Upper side mount rubber 1 3 Bolt with washer 42 4 Exhaust guide 1 5 Clip 1 6 Oil strainer 1 7 Oil seal 1 Not reusable 8 Gasket 1 Not reusable 9 Pin 2 10 Hose 1 11 Screw 1 12 Plate 1 13 Damper 1 Continued on next page ...

Page 261: ...marks 14 Oil drain plug 1 15 Gasket 1 16 Bolt with washer 1 Not reusable 17 Oil pan 4 18 Pin 1 19 Bolt with washer 2 20 Muffer 2 21 Bolt with washer 1 22 Plate 1 23 Grommet 1 24 Upper case 1 For assembly reverse the disassembly procedure ...

Page 262: ... STEERING FRICTION Step Job Part Q ty Remarks 1 Lock nut 1 2 Plate washer 1 3 Bolt with washer 1 4 Friction piece 2 5 Collar 1 6 Friction Plats 1 7 Collar 1 8 Plate washer 2 9 Lock nob 1 10 Lock shaft 1 11 Friction plate 1 For assembly reverse the disassembly procedure ...

Page 263: ...8 x 1 9 mm Not reusable 3 Bolt 4 4 PT motor 1 5 O ring 1 21 7 x 3 5 mm Not reusable 6 O ring 1 Not reusable 7 Manual release rod 1 8 Pin 1 9 O ring 1 5 8 x 1 9 mm Not reusable 10 Sponge 1 Not reusable 11 Spring 2 Outside diameter 5 0 x Length 17 0 mm 12 Manual release pin 2 13 Spring 2 Outside diameter 5 7 x Length 17 2 mm Continued on next page ...

Page 264: ...b Part Q ty Remarks 14 Absorver valve pin 2 15 Ball 2 16 Spring 2 Outside diameter 7 6 x Length 14 5 mm 17 Spring 1 Outside diameter 8 8 x Length 18 1 mm 18 Valve pin 2 19 Valve seal 2 For assembly reverse the disassembly procedure ...

Page 265: ...55 POWER TILT PT UNIT INSTALLING THE RELIEF VALVE Install O Valve seal 1 O Valve pin 2 O Spring 3 NOTE Be careful to install the valve seal facing in the correct direction ...

Page 266: ...Q ty Remarks 1 Screw with washer 2 2 Yoke assembly 1 43 9 x 1 5 mm Not reusable 3 O ring 1 Not reusable 4 Screw with washer 1 5 Armatuer 1 6 Screw with washer 2 7 Brush 2 8 Brush spring 2 9 Oil seal 1 Not reusable 10 End frame 1 For assembly reverse the disassembly procedure ...

Page 267: ...ide then remove armature 3 CHECKING THE PT MOTOR 1 Check y Commutator Dirt Æ Clean with 600 grit sandpaper 2 Check y Commutator undercut Obstruction Æ Clean NOTE Remove all metal particles with compressed air 3 Measure y Commutator diameter a Out of specification Æ Replace Commutator diameter limit 15 5 mm 0 61 in ...

Page 268: ...easure y Brush length a Out of specification Æ Replace 6 Check y End frame Cracks damage Æ Replace 7 Check y Yoke bushing Cracks damage Æ Replace Armature coil continuity Commutator segments Continuity Segment laminations No continuity Segment shaft No continuity Brush length limit 3 mm 0 12 in ...

Page 269: ...k y PT motor operation Incorrect operation Æ Repair INSTALLING THE OIL SEAL 1 Install y Oil seal PT motor operation Blue Green Motor turns clockwise Green Blue Motor turns counterclockwise Oil seal attachment YB 06112 90890 06614 Driver rod YB 06071 90890 06652 ...

Page 270: ...r pump housing 1 3 Gear 2 4 Dowel pin 4 5 Top chamber shuttle piston 1 6 O ring 1 8 5 x 1 5 mm Not reusable 7 Spring 2 Outside diameter 2 5 x Length 10 0 mm 8 Bottom chamber shuttle piston 1 9 Circlip 2 10 Valve seal 2 11 Valve seat 2 12 O ring 2 11 5 x 1 5 mm Not reusable 13 Main valve 2 Continued on next page ...

Page 271: ...rt Q ty Remarks 14 Spring 2 Outside diameter 4 1 x Length 12 0 mm 15 Filter 2 16 O ring 2 8 5 mm x 1 5 mm Not reusable 17 Ball 2 18 Spring 2 Outside diameter 3 2 x Length 8 0 mm 19 Plate 2 For assembly reverse the disassembly procedure ...

Page 272: ...t ram assembly 1 2 Free piston 1 3 O ring 1 20 8 x 2 4 mm Not reusable 4 Backing ring 1 5 Tilt cylinder 1 6 O ring 1 26 0 x 1 8 mm Not reusable 7 Cylinder 1 8 O ring 1 29 7 x 1 9 mm Not reusable 9 O ring 1 20 8 x 2 4 mm Not reusable 10 Backup ring 1 11 Tilt piston 1 12 Ball 1 13 Pin 1 Continued on next page ...

Page 273: ...Q ty Remarks 14 Spring 1 Outside diameter 6 8 x Length 13 5 mm 15 Dowel pin 1 16 End screw 1 17 O ring 1 12 3 x 2 4 mm Not reusable 18 Backup ring 1 19 Dust seal 1 Not reusable 20 Tilt ram 1 For assembly reverse the disassembly procedure ...

Page 274: ...t push the tilt rod down This may cause hydraulic fluid to spurt out from the port CAUTION Do not wipe hydraulic system components with rags paper tissues or the like as fibers from such material will cause malfunctions if they enter the system 1 Loosen O End screw 2 Loosen O Tilt ram NOTE Hold the protruded portion a of the tilt piston with the aluminium plate 1 and turn to loose the tilt ram Pow...

Page 275: ...e fluid to about 70 NOTE Put the fluid with the free piston 1 installed at the bottom of the cylinder 2 Install the tilt ram assembly NOTE The tilt ram assembly is to be installed with the tilt piston 2 and end screw 3 in close contact 3 Tighten O End screw Power tilt wrench YB 06560 90890 06560 Tilt piston 45 NOm 4 5 kgfOm 32 ftOlb Recommended PT fluid ATF Dexron II Power tilt wrench YB 06560 908...

Page 276: ...eeding step 1 Open the manual valve 1 2 Manually push in the tilt ram to its fully contracted state 3 Remove the reservoir cap 2 and supply the fluid to the prescribed level 4 Close the manual valve 1 Reservoir cap 5 NOm 0 5 kgfOm 3 6 ftOlb ...

Page 277: ...ly extended state Close the reservoir cap during operation 6 Alternately connect the PT motor leads to the battery and extend and contract the cylinder about four or five times NOTE Operate the tilt ram to the full stroke and relieve it for about 2 seconds at each stroke end O Place the tilt ram finally in its fully extended state Tilt ram PT motor lead Battery terminal Up Blue Green Tilt ram PT m...

Page 278: ...Install the power tilt PT unit to the outboard motor NOTE Carrying and working should be done with the power tilt PT unit erected 10 Operate the PT switch to move down the outboard motor relieve it for about 1 second and then immediately move up the outboard motor NOTE For moving up the outboard motor stop it at about half the stroke If it does not stop air removal is not complete Take the steps 6...

Page 279: ...LLING THE POWER TILT PT UNIT Step Job Part Q ty Remarks 1 PT motor lead 1 2 Clamp 1 3 Bolt with washer 1 4 Circlip 1 5 Pin 1 6 Bushing 1 7 Bushing 2 8 Bolt 2 9 Washer 2 10 Pin 1 11 Bushing 2 12 Bushing 1 13 Collar 1 Continued on next page ...

Page 280: ...70 POWER TILT PT UNIT Step Job Part Q ty Remarks 14 Power tilt PT unit 1 For installation reverse the removal procedure ...

Page 281: ...BLING THE STARTER MOTOR Step Job Part Q ty Remarks 1 Clip 1 2 Pinion stopper 1 3 Spring 1 4 Pinion 1 5 Through bolt 2 6 Front cover 1 7 Washer 1 8 Washer 1 9 Washer 1 10 Starter body 1 11 Armature assembly 1 12 Washer 1 13 Nut 1 Continued on next page ...

Page 282: ...Remarks 14 Spring washer 1 15 Nut 1 16 Spring washer 1 17 Plate washer 1 18 Bushing 1 19 O ring 1 20 Screw 2 21 Brush holder 1 22 Spring 2 23 Brush 2 24 Bushing 1 25 Rear cover 1 26 O ring 2 For installation reverse the removal procedure ...

Page 283: ... Check y Clutch movement Damage Æ Replace NOTE Rotate the pinion clockwise and check that it freely Also try to rotate the pinion counterclockwise and confirm that it locks CHECKING THE ARMATURE 1 Check y Commutator Dirty Æ Clean with 600 abrasive paper 2 Measure y Commutator diameter Out of specification Æ Replace Commutator diameter limit 29 0 mm 1 14 in ...

Page 284: ...n Æ Replace CHECKING THE BRUSH HOLDER 1 Measure y Brush length a Out of specification Æ Replace 2 Check y Brush holder continuity Out of specification Æ Replace Armature coil continuity Commutator segments Continuity Segment Laminations No continuity Segment Shaft No continuity Brush length limit 9 0 mm 0 35 in Brush holder continuity Brush holder 1 Base 2 No continuity ...

Page 285: ...POWER TILT PT SYSTEM 75 POWER TILT PT SYSTEM POWER TILT PT SYSTEM T8PR FT8DEP 1 Battery 2 Fuse 10A 3 PT switch 4 PT relay 5 Terminal 6 PT motor B Black G Green L Blue Lg Light green R Red Sb Sky blue ...

Page 286: ...POWER TILT PT SYSTEM 76 POWER TILT PT SYSTEM T8PH 1 Battery 2 PT relay 3 Terminal 4 PT motor 5 PT switch 6 Fuse 10A B Black G Green L Blue Lg Light green R Red Sb Sky blue ...

Page 287: ...tinuity Æ Replace Checking steps 1 Connect the digital tester between PT relay Blue L lead and Red R lead 2 Connect a 12 V battery as shown Leads color Sky blue Sb Red R Light green Lg Switch position Up Free Down PT relay continuity Sky blue Sb Black B Light green Lg Black B Continuity Blue L Black B Green G Black B Continuity Blue L Red R Green G Red R No continuity Sky blue Sb lead Æ Positive t...

Page 288: ...een the PT relay terminals 4 Connect the tester between PT relay Green G lead and Red R lead 5 Connect a 12 V battery as shown 6 Check that there is continuity between the PT relay terminals Light green Lg lead Æ Positive terminal Black B lead Æ Negative terminal ...

Page 289: ...Printed on recycled paper Printed in USA Oct 2000 1 66 x 1 SY T8PH T8PR YAMAHA MOTOR CORPORATION USA ...

Page 290: ...arter relay 4 9 14 15 16 AVX1 25B M4 P Stop switch 3 2 Nutral switch Starter switch 12 13 AV 1 25R Y R P G G L Br B W R O B Bracket A AV 8 0B AV 8 0B G G W If there is no size specified for the lead wire the size is AVX0 75f B 3 0L 3 0G L G Terminal ass y 17 PT T motor 18 Lg Lg Sb Lg Sb Sb R Lg UP FREE DOWN PT T switch 20 R R Sb Lg Sb Lg L PT T relay 19 Black Brown Green Blue Orange Pink Light gre...

Page 291: ... M6 M8 M6 CDI unit 1 Battery Emergency signal light 2 Rectifier regulator 8 Fuel enrich solenoid Pulser coil Charge coil 6 Lighting coil 5 Oil pressure switch 10 Starting motor 7 Ignition coil Spark plugs 11 Fuse 10A Starter relay 3 4 9 12 13 14 AVX1 25B M4 P Y R P G G L Br B W R O B Bracket A AV 8 0B AV 8 0B G G W If there is no size specified for the lead wire the size is AVX0 75f C Sb Lg R R Sb...

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