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2-4

SPEC

GENERAL SPECIFICATIONS

*1: Pump Octane Number ; (Research Motor octane)/2

FUEL AND LUBRICATION:

Fuel type

Regular gasoline

Fuel rating

P.O.N.*

Min. 86

Engine oil type/grade

2-stroke outboard motor oil / TC-W3

Mixing ratio

50 : 1

—

50 : 1

—

Engine oil tank capacity

L (US qt,

Imp qt)

—

1.5 (1.6, 1.3)

—

1.5 (1.6, 1.3)

Gear oil type

Hypoid gear oil-SAE#90

Gear oil quantity

(US oz,

Imp oz)

430 (14.5, 15.1)

BRACKET:

Trim/tilt system

Manual tilt

Power trim/

tilt

Manual tilt

Power trim/

tilt

Tilt angle

degree

8, 12, 16, 20, 24

—

Tilt-up angle

degree

Trim angle

degree at 12˚

transom

—

–4 ~ 20

Shallow water crushing
angle

degree

—

Tilt angle +18

—

Steering angle

degree

(left + right)

40 + 40

DRIVE UNIT:

Gear shift position

F-N-R

Gear ratio

1.85 (24/13)

Gear type

Spiral bevel gear

Clutch type

Dog clutch

Propeller direction

Clockwise

Propeller drive system

Spline

Propeller series mark

ELECTRICAL:

Battery capacity

Ah (kC)

70 (252)

Cold cranking

Amps

385

380

385

Item

Unit

Model

Worldwide

40VE

40VEO

40VEHTO

40VET

40VETO

USA, CANADA

C40ER

40ER

P40TH

C40TR

40TR

Содержание 40V

Страница 1: ...LIT 18616 01 81 290320 SERVICE MANUAL 40V 50H WORLD WIDE 40W 50W USA CANADA...

Страница 2: ...ls may differ in detail from the descriptions and illustrations given in this publica tion Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modificatio...

Страница 3: ...h Section MODEL INDICATION Multiple models are shown in this manual These indications are noted as follows THE ILLUSTRATIONS Some illustrations in this manual may differ from the model you have This i...

Страница 4: ...MO 40VWH 40VE 40VEO 40VEHTO 40VET Starting system Manual Manual Manual Manual Manual Electric Electric Electric Electric Electric Control system Tiller Tiller Tiller Remote Tiller Remote Remote Tiller...

Страница 5: ...contents and notes of the job For the meanings of the symbols refer to the next page s 4 The REMOVAL AND INSTALLATION CHART 4 is attached to the exploded diagram and explains the job steps part names...

Страница 6: ...o J in an exploded diagram indicate grade of lubricant and location of lubrication point G Apply Yamaha 2 stroke outboard motor oil H Apply Yamaha gear case lubricant I Apply molybdenum disulfide oil...

Страница 7: ...TION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR LOWER UNIT 6 LOWER BRACKET UNIT 7 BRKT ELECTRICAL SYSTEM 8 ELEC TROUBLE ANALYSIS 9 GEN INFO INSP...

Страница 8: ......

Страница 9: ...ERIAL NUMBER 1 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...

Страница 10: ...4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as fol lows Model Approved model code Starting serial No Model Approved model code Starting serial No World wide USA CANAD...

Страница 11: ...avier 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...

Страница 12: ...led wiping rag in one s pocket 4 Hands and any other part of the body which have been in contact with lubri cants or lubricant contaminated cloth ing should be thoroughly washed with hot water and soa...

Страница 13: ...parts with compressed air on dis assembling them 2 Oil the contact surfaces of moving parts on assembly 3 After assembly check that moving parts operate normally 4 Install bearings with the manufactur...

Страница 14: ...tools recommended by Yamaha will aid the work and enable accu rate assembly and tune up Improvisations and use of improper tools can cause damage to the equipment NOTE For U S A and Canada use part n...

Страница 15: ...Thickness gauge YU 26900 9 N A Shimming 11 Pinion height gauge N A 90890 06702 Pinion shimming 12 Digital caliper N A 90890 06704 Pinion shimming Forward shimming 13 Gauge block YB 34432 9 N A Pinion...

Страница 16: ...1 7 GEN INFO E SPECIAL TOOLS...

Страница 17: ...l seal 10 Needle bearing remover YB 06112 90890 06614 Propeller shaft needle bearing 11 Needle bearing installer YB 06111 90890 06614 Propeller shaft needle bearing 12 Bearing outer race puller clow N...

Страница 18: ...1 9 GEN INFO E SPECIAL TOOLS...

Страница 19: ...ear outer bearing 26 Shift rod wrench YB 06052 N A Shift rod 27 Tilt cylinder wrench YB 06175 2B 90890 06544 PTT 28 Bearing depth plate N A 90890 06603 Propeller shaft needle bearing Drive shaft needl...

Страница 20: ......

Страница 21: ...EC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 7 ENGINE 2 7 LOWER 2 9 ELECTRICAL 2 10 DIMENSION 1 2 13 DIMENSION 2 2 15 TIGHTENING TORQUE 2 17 SPECIFIED TORQUE 2 1...

Страница 22: ...000 Full throttle operating range rpm 4 500 5 500 Maximum fuel con sumption L US gal Imp gal h at rpm 18 5 4 9 4 1 at 5 500 ENGINE Type 2 stroke L Number of cylinder 3 Total displacement cm3 cu in 698...

Страница 23: ...tilt system Manual tilt Tilt angle degree 8 12 16 20 24 8 12 16 20 24 Tilt up angle degree 66 69 66 Trim angle degree at 12 transom 4 20 Shallow water crushing angle degree Tilt angle 18 Tilt angle 18...

Страница 24: ...NCE Output ISO kW hp rpm 29 4 40 5 000 Full throttle operating range rpm 4 500 5 500 Maximum fuel con sumption L US gal Imp gal h at rpm 18 5 4 9 4 1 at 5 500 ENGINE Type 2 stroke L Number of cylinder...

Страница 25: ...ystem Manual tilt Power trim tilt Manual tilt Power trim tilt Tilt angle degree 8 12 16 20 24 Tilt up angle degree 66 69 Trim angle degree at 12 transom 4 20 Shallow water crushing angle degree Tilt a...

Страница 26: ...ANCE Output ISO kW hp rpm 36 8 50 5 000 Full throttle operation range rpm 4 500 5 500 Maximum fuel con sumption L US gal Imp gal h at rpm 22 5 8 4 8 at 5 500 ENGINE Type 2 stroke L Number of cylinder...

Страница 27: ...nual tilt Hydro tilt Manual tilt Hydro tilt Manual tilt Power trim tilt Tilt angle degree 8 12 16 20 24 8 12 16 20 24 Tilt up angle degree 66 69 66 69 Trim angle degree at 12 transom 4 20 4 20 Shallow...

Страница 28: ...0 002 0 003 2nd mm in 0 03 0 07 0 001 0 003 Over size piston mm in Diameter 1st 1 mm in 67 25 2 648 2nd mm in 67 50 2 657 PISTON PIN Diameter mm in 17 995 18 000 0 7085 0 7087 PISTON RING 1st Type mm...

Страница 29: ...W model M model E W model Identification mark 63B00 63D00 62W00 62X00 Float height mm in 15 0 1 0 0 59 0 04 Valve seat size mm in 1 2 0 05 Main jet M J 115 118 M 125 130 Main nozzle M N mm in 3 0 0 12...

Страница 30: ...10 1 4 14 3 10 3 4 16 3 10 3 4 17 3 10 3 8 13 3 10 5 8 12 3 11 1 8 13 3 11 1 4 14 3 11 3 8 12 3 11 5 8 11 3 11 3 4 10 3 12 1 4 9 3 10 1 4 14 3 10 1 4 15 3 10 1 4 16 3 10 5 8 13 3 11 1 4 14 3 11 1 2 13...

Страница 31: ...n 3 0 5 0 0 12 0 20 Rating Sec 30 RECTIFIER REGURATOR Output peak voltage R B cranking V 8 5 1 500 r min V 25 3 500 r min V 25 NEUTRAL SWITCH Length a on mm in 18 5 19 5 0 73 0 77 Length b off mm in 1...

Страница 32: ...age minimum B O B W B Y B cranking V 125 1 500 r min V 140 3 500 r min V 110 Lighting coil output peak voltage minimum G G W cranking V 9 0 1 500 r min V 25 3 500 r min V 25 CDI UNIT Over revolution l...

Страница 33: ...2 12 SPEC E MAINTENANCE SPECIFICATIONS...

Страница 34: ...2 13 SPEC E MAINTENANCE SPECIFICATIONS DIMENSION 1...

Страница 35: ...31 4 822 32 4 822 32 4 L 910 35 8 937 36 9 UL 1 010 39 8 1 040 40 9 1 040 40 9 L7 mm in 433 17 0 401 15 8 418 16 5 387 15 2 H4 S mm in 408 16 1 410 16 1 410 16 1 L 535 21 1 537 21 1 UL 649 25 6 651 25...

Страница 36: ...2 15 SPEC E MAINTENANCE SPECIFICATIONS DIMENSION 2 MANUAL TILT MODEL HYDRO TILT PTT MODEL...

Страница 37: ...208 8 2 254 10 0 B3 mm in 121 5 4 8 163 5 6 4 B4 mm in 32 1 3 50 8 2 0 B5 mm in 131 5 5 2 180 7 1 B6 mm in 245 9 6 355 14 0 B9 mm in 25 1 0 18 5 0 7 B11 mm in 90 5 3 6 B12 mm in 57 2 2 B13 mm in 122 4...

Страница 38: ...0 29 572 LT Propeller shaft housing Bolt M8 2 16 1 6 11 Pinion nut Nut M12 1 75 7 5 54 Water inlet Bolt M6 1 5 0 5 3 6 242 LT BRACKET Tiller handle mounting Nut M10 2 38 3 8 27 Steering friction moun...

Страница 39: ...ons for special compo nents or assemblies are given in applicable sections of this manual To avoid causing warpage tighten multifastener assemblies in crisscross fashion in progressive stages until th...

Страница 40: ......

Страница 41: ...ent 3 2 Throttle cable adjustment 3 3 Shift cable adjustment 3 4 Start in gear protection adjustment 3 5 Idle speed adjustment 3 5 OIL INJECTION SYSTEM 3 6 Oil tank water drain 3 6 Oil pump link adjus...

Страница 42: ...Exhaust leakage Inspection Cooling water passage Cleaning CONTROL SYSTEM Throttle link Inspection Adjustment 3 2 Throttle cable Inspection Adjustment 3 3 Shift cable Inspection Adjustment 3 4 Start in...

Страница 43: ...he full retarding stopper a Check the CDI unit indicator so that it aligns with the specified marking on the plate Full retarded position ATDC 7 Turn the magneto control lever so that it contacts the...

Страница 44: ...or aligns with the specified marking on the plate Full retarded position ATDC 7 Connect the magneto control rod Turn the magneto control lever so that it contacts the full advance adjusting screw 4 Ad...

Страница 45: ...n 8 mm 0 31 in NOTE Put the UP mark upward Shift cable adjustment 1 Check Shift operation Incorrect Adjust 2 Adjust Shift cable joint position 3 Check Shift operation Unsmooth operation Repair Adjustm...

Страница 46: ...case Tighten the lock nut Idle speed adjustment NOTE Before adjusting the idle speed be sure to adjust the throttle link 1 Measure Idle speed Out of specification Adjust 2 Adjust Idle speed Idle spee...

Страница 47: ...p screw in or out until specified idle speed is obtained Turning in Idle speed becomes higher Turning out Idle speed becomes lower While lightly pushing the throttle lever of the lower carburetor in t...

Страница 48: ...valve Check the clearance a between the oil pump lever and full open side stopper Adjustment steps Loosen the lock nut Remove the oil pump link joint at the pump Fully open the carburetor throttle va...

Страница 49: ...lug 1 Remove the drain plug then the oil level plug 2 and drain the oil thor oughly Place the outboard motor in an upright position Fill the gear oil through the drain hole until it overflows at the l...

Страница 50: ...ttery electrolyte is poisonous and dan gerous causing severe burns etc It con tains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quant...

Страница 51: ...Worn Damaged Replace Insulator color 2 Distinctly different color Check the engine condition 2 Clean Spark plug Clean the spark plug with a plug cleaner or wire brush 3 Inspect Spark plug type Color g...

Страница 52: ...ark plug NOTE Before installing the spark plug clean the gasket surface and the plug surface NOTE If a torque wrench is not available a good estimate of the correct torque is a further 1 4 to 1 2 turn...

Страница 53: ...ETOR 4 7 EXPLODED DIAGRAM 4 7 REMOVAL AND INSTALLATION CHART 4 8 SERVICE POINTS 4 9 Carburetor inspection 4 9 Carburetor assembly 4 10 PRIME STARTER 4 11 EXPLODED DIAGRAM 4 11 REMOVAL AND INSTALLATION...

Страница 54: ...4 1 FUEL E FUEL JOINT FUEL FILTER AND FUEL PUMP FUEL JOINT FUEL FILTER AND FUEL PUMP EXPLODED DIAGRAM...

Страница 55: ...1 5 Clip 2 6 Fuel hose joint filter 1 7 Fuel hose filter pump 1 8 Nut 1 9 Fuel filter 1 10 Clip 2 11 Fuel hose filter pump 1 12 Fuel hose pump joint pipe 1 13 Bolt with washer 2 6 40 mm 14 Fuel pump...

Страница 56: ...4 3 FUEL E FUEL JOINT FUEL FILTER AND FUEL PUMP FUEL LINE LAYOUT M model 1 Fuel pump 2 Fuel filter W E model 1 Fuel pump 2 Fuel filter 3 Electrothermal valve...

Страница 57: ...e for 10 sec Replace Measuring steps Attach the Mity vac Mity vac YB 35956 90890 06756 Apply the specified pressure Specified pressure 50 kPa 0 5 kg cm2 7 1 psi Fuel filter inspection 1 Inspect Filter...

Страница 58: ...4 5 FUEL E CARBURETOR REMOVAL CARBURETOR REMOVAL EXPLODED DIAGRAM...

Страница 59: ...Bolt 1 15 Electrothermal valve lead black 1 16 Electrothermal valve lead blue 1 17 Accelerator lever rod 1 18 Oil pump link rod 1 Oil injection model 19 Link joint 1 20 Choke link rod 1 M model 21 Li...

Страница 60: ...4 7 FUEL E CARBURETOR CARBURETOR EXPLODED DIAGRAM...

Страница 61: ...crew 1 7 Spring 1 8 Stopping screw 1 Middle carburetor only 9 Spring 1 10 Screw with washer 4 4 14 mm 11 Float chamber 1 12 Float chamber packing 1 13 Screw 1 4 mm 14 Arm pin 1 15 Float 1 16 Needle va...

Страница 62: ...usly affect performance Carburetor inspection 1 Inspect Carburetor body Crack Damage Replace Contamination Clean 2 Inspect Pilot screw Bend Wear Replace 3 Inspect Main jet Pilot jet Main nozzle Contam...

Страница 63: ...easure Float height a Out of specification Fold the tab b to adjust float arm height NOTE The float should be resting on the needle valve but not compressing the needle valve Take measurement at the e...

Страница 64: ...4 11 FUEL E PRIME STARTER PRIME STARTER EXPLODED DIAGRAM...

Страница 65: ...Carburetor ass y Refer to CHARBURETOR REMOVAL 1 Screw with washer 2 4 10 mm 2 Electrothermal valve 1 3 Clip 1 4 Fuel enrichment hose 1 5 Clip 2 6 Fuel hose cover chamber 1 7 Screw with washer 4 8 Pump...

Страница 66: ...Bend Damage Replace 2 Measure Fuel enrichment valve resistance Out of specification Replace NOTE When measuring the resistance of 10 or less using the digital tester the correct measurement cannot be...

Страница 67: ...4 14 FUEL E PRIME STARTER...

Страница 68: ...4 15 FUEL E OIL TANK OIL TANK EXPLODED DIAGRAM...

Страница 69: ...Bolt with washer 1 11 Oil tank ass y 1 OIL TANK DISASSEMBLY 1 Oil level sensor 1 2 Oil strainer 1 3 Strainer gasket 1 4 Oil tank cap 1 5 Hook 1 6 Hook band 1 7 Filler tube band 1 8 Filler tube 1 9 Sp...

Страница 70: ...4 17 FUEL E OIL TANK OIL LINE LAYOUT 1 Electrothermal valve EM E model 2 Oil level sensor 3 Oil drain hose 4 Oil tank 5 Oil pump...

Страница 71: ...rack Replace Oil strainer inspection 1 Inspect Oil strainer Crack Clog Replace Contamination Clean Check valve inspection 1 Check Check valve operation Does not function Replace NOTE Check the operati...

Страница 72: ...4 19 FUEL E OIL PUMP OIL PUMP EXPLODED DIAGRAM...

Страница 73: ...e 1 3 Clip 1 4 Oil return hose 1 5 Clip 1 6 Plate washer 1 7 Link joint 1 8 Clip 3 9 Oil delivery hose 1 1 250 mm 10 Oil delivery hose 2 1 180 mm 11 Oil delivery hose 3 1 90 mm 12 Bolt 1 13 Bolt 1 14...

Страница 74: ...ion 5 6 Spiral spring inspection 5 6 Starter rope inspection 5 6 Starter rope installation 5 7 Sheave drum installation 5 7 Spiral spring setting 5 7 Recoil starter checking 5 7 FLYWHEEL MAGNETO AND M...

Страница 75: ...linder body inspection 5 29 Piston to cylinder clearance 5 30 Oil pump driven gear inspection 5 30 Cylinder body and crankcase installation 5 30 CRANK SHAFT AND PISTON 5 31 EXPLODED DIAGRAM 5 31 REMOV...

Страница 76: ...5 1 POWR E POWER UNIT REMOVAL POWER UNIT REMOVAL EXPLODED DIAGRAM...

Страница 77: ...wire lead coupler 1 9 PTT motor lead 2 PTT model 10 PTT switch lead coupler 1 11 Choke lever rod 1 M model 12 Start in gear projection wire 1 13 Clip 1 14 Shift cable 1 15 Clip 1 16 Throttle cable 1...

Страница 78: ...5 3 POWR E RECOIL STARTER RECOIL STARTER EXPLODED DIAGRAM...

Страница 79: ...6 Drive pawl spring 1 7 Bolt with washer 1 6 30 mm 8 Stay 1 9 Rope roller 1 0 Collar 1 A Nut 1 B Bolt with washer 2 6 12 mm C Nut 1 D Bolt with washer 1 6 20 mm E Plane washer 1 F Bushing 1 G Sheave d...

Страница 80: ...g the sheave drum be sure to turn the sheave drum upside down to prevent the spiral spring from popping up at you NOTE Insert a slotted head screwdriver into the hole in the sheave drum and remove the...

Страница 81: ...ace them as a set Bushing inspection 1 Inspect Bushing Crack Damage Replace Sheave drum inspection 1 Inspect Sheave drum Crack Damage Replace Spiral spring inspection 1 Inspect Spiral spring Broken Be...

Страница 82: ...sheave drum Place the rope at the cutaway Sheave drum installation 1 Install Sheave drum 1 NOTE Position the inner end of the spiral spring on the retainer post of the sheave drum Spiral spring settin...

Страница 83: ...5 8 POWR E RECOIL STARTER...

Страница 84: ...5 9 POWR E FLYWHEEL MAGNETO AND MAGNETO BASE FLYWHEEL MAGNETO AND MAGNETO BASE EXPLODED DIAGRAM...

Страница 85: ...r to RECOIL STARTER 1 Screw 1 6 40 mm 2 Screw 2 6 35 mm 3 Washer 3 4 Flywheel cover 1 5 Collar 3 6 Bolt E model 3 8 14 mm 7 Bolt M model 3 8 20 mm 8 Starter pulley E model 1 9 Starter pulley M model 1...

Страница 86: ...asily slip off Flywheel holder YB 06139 90890 06522 2 Remove Flywheel magneto For USA and CANADA Except for USA and CANADA CAUTION Keep the nut side flush with the crank shaft end until the flywheel c...

Страница 87: ...5 12 POWR E FLYWHEEL MAGNETO AND MAGNETO BASE...

Страница 88: ...5 13 POWR E ELECTRICAL UNIT REMOVAL ELECTRICAL UNIT REMOVAL EXPLODED DIAGRAM...

Страница 89: ...oupler 7 6 Bolt with washer 2 7 Fitting plate ass y 1 8 Battery cable 1 9 Bolt with washer 2 10 PTT switch coupler 1 PTT model 11 PTT motor lead 2 Sky blue and light green leads 12 Bolt with washer 4...

Страница 90: ...5 15 POWR E ELECTRICAL UNIT ELECTRICAL UNIT EXPLODED DIAGRAM...

Страница 91: ...it Refer to ELECTRICAL UNIT REMOVAL 1 Fuse 1 2 Clamp 1 3 Bolt with washer 1 4 Clamp 1 5 Bolt with washer 1 6 Rectifier regurator 1 7 Nut 2 8 Spring washer 1 9 Bracker 1 10 Relay holder 1 11 Starter re...

Страница 92: ...5 17 POWR E REED VALVE AND CHECK VALVE REED VALVE AND CHECK VALVE EXPLODED DIAGRAM...

Страница 93: ...tch stay 1 WH EHTO model 5 Intake manifold ass y 1 6 Screw with washer 6 5 14 mm 7 Reed valve ass y 3 8 Valve plate gasket 2 9 Reed valve plate 1 10 Clip 6 Oil injection model 11 Oil delivery hose 1 1...

Страница 94: ...d valve inspection 1 Inspect Reed valve Crack Damage Replace 2 Measure Valve bending a Out of specification Replace 3 Measure Valve stopper height b Out of specification Replace Valve bending limit 0...

Страница 95: ...5 20 POWR E REED VALVE AND CHECK VALVE...

Страница 96: ...5 21 POWR E CYLINDER HEAD THERMOSTAT AND EXHAUST COVER CYLINDER HEAD THERMOSTAT AND EXHAUST COVER EXPLODED DIAGRAM...

Страница 97: ...ermostat cover 1 9 Thermostat cover gasket 1 10 Thermostat 1 EXHAUST COVER REMOVAL Oil tank ass y Refer to OIL TANK in chapter 4 11 Clip 1 12 Pilot water hose 1 13 Bolt with washer Bolt with washer 14...

Страница 98: ...Do not scratch the fitting surfaces of the cylinder and cylinder cover 2 Measure Cylinder head warpage Use a straightedge and thickness gauge Out of specification Resurface or replace Warpage limit 0...

Страница 99: ...sure Valve opening temperature Valve lift Out of specification Replace Water temperature Valve lift Below 48 52 C 118 126 F 0 mm 0 in Above 60 C 140 F Min 3 mm 0 12 in Measuring steps Suspend thermost...

Страница 100: ...5 25 POWR E CRANKCASE AND CYLINDER BODY CRANKCASE AND CYLINDER BODY EXPLODED DIAGRAM...

Страница 101: ...Clip 8 2 Drain less hose 1 200 mm 3 Drain less hose 1 310 mm 4 Drain less hose 1 360 mm 5 Drain less hose 1 240 mm 6 Bolt with washer 6 6 mm 7 Bolt with washer 8 8 mm 8 Crank case 1 9 Cylinder body 1...

Страница 102: ...5 27 POWR E CRANKCASE AND CYLINDER BODY EXPLODED DIAGRAM...

Страница 103: ...ASE AND CYLINDER BODY REMOVAL AND INSTALLATION CHART Step Procedure Part name Q ty Service points D Hose nipple 1 E Hose joint 3 F Check valve 2 G Check valve 2 H Hose joint 1 Reverse the removal step...

Страница 104: ...r NOTE Do not scratch the fitting surfaces of the cyl inder and exhaust cover 3 Measure Cylinder bore D Use cylinder gauge Out of specification Rebore or replace NOTE Measure the cylinder bore D in pa...

Страница 105: ...haft and piston NOTE Align the piston ring end gaps with the respective locating pins Fit the bearing and the labyrinth seal locating pins in the cylinder body 2 Apply Gasket maker Onto the connecting...

Страница 106: ...5 31 POWR E CRANK SHAFT AND PISTON CRANK SHAFT AND PISTON EXPLODED DIAGRAM...

Страница 107: ...13 Oil pump drive gear 1 Oil injection model 14 Spacer 1 Pre mixed model OIL SEAL HOUSING DISASSEMBLY 1 O ring 1 2 Oil seal 1 3 Oil seal 2 Reverse the removal steps for installation NOTE Remove the cr...

Страница 108: ...d needle bearings are reused they should be marked with No 1 2 and 3 so that they are not confused Piston ring removal 1 Remove Piston ring NOTE Remove the piston ring from the piston by opening the r...

Страница 109: ...e Piston pin boss inside diameter 18 008 18 015 mm 0 7090 0 7093 in Piston pin and small end bearing inspection 1 Inspect Piston pin Small end bearing Signs of heat discoloration Replace Scratch Damag...

Страница 110: ...n ring into the cylinder Push the ring with the piston crown End gap Top 0 40 0 60 mm 0 016 0 024 in 2nd 0 40 0 60 mm 0 016 0 024 in End gap limit Top 0 80 mm 0 031 in 2nd 0 80 mm 0 031 in Measuring p...

Страница 111: ...95 mm 2 122 2 124 in Crank width B 32 88 33 10 mm 1 294 1 303 in Runout limit 0 03 mm 0 001 in 3 Measure Axial play Out of specification Replace Axial play limit 2 0 mm 0 08 in 4 Inspect Crankshaft b...

Страница 112: ...y NOTE Piston rings should be replaced as a set Crankshaft and piston installation 1 Install Small end bearing needle 2 Install Piston 1 Piston pin 2 Piston pin clip 3 CAUTION Do not allow the clip op...

Страница 113: ......

Страница 114: ...e gear inspection 6 8 Bearing inspection 6 8 Propeller shaft housing inspection 6 8 Dog clutch inspection 6 8 Propeller shaft inspection 6 8 Propeller shaft housing assembly 6 9 DRIVE SHAFT FORWARD GE...

Страница 115: ...AND CANADA 6 19 Pinion gear shim 6 19 Forward gear shim 6 21 Reverse gear shim 6 22 SHIM SELECTION EXCEPT FOR USA AND CANADA 6 23 Pinion gear shim 6 23 Forward gear shim 6 25 Reverse gear shim 6 26 B...

Страница 116: ...6 1 LOWR E LOWER UNIT REMOVAL LOWER UNIT REMOVAL EXPLODED DIAGRAM...

Страница 117: ...odel 14 Spring washer 4 15 Plane washer 4 16 Lower unit 1 17 Dowel pin 2 18 Extension 1 X model 19 Dowel pin 2 20 Stud bolt 4 Reverse the removal steps for installation NOTE If the propeller nut does...

Страница 118: ...6 3 LOWR E WATER PUMP WATER PUMP EXPLODED DIAGRAM...

Страница 119: ...1 8 Cartridge plate 1 9 Plate gasket 1 10 Pin 2 11 Water seal cover 1 12 Water seal rubber 1 Reverse the removal steps for installation NOTE When installing the water pump housing align the hole in i...

Страница 120: ...6 5 LOWR E PROPELLER SHAFT AND REVERSE GEAR PROPELLER SHAFT AND REVERSE GEAR EXPLODED DIAGRAM...

Страница 121: ...him 3 Ball bearing 1 4 O ring 1 5 O ring 2 6 Oil seal 2 7 Needle bearing 1 8 Propeller shaft housing 1 PROPELLER SHAFT DISASSEMBLY 9 Cross pin ring 1 0 Cross pin 1 A Shift plunger 1 B Shift slider 1 C...

Страница 122: ...17 2 Stopper guide plate 90890 06501 4 Center bolt 90890 06504 5 Propeller shaft housing disassembly 1 Remove Reverse gear 2 Remove Ball bearing 1 For USA and CANADA Except for USA and CANADA Bearing...

Страница 123: ...Inspect Tooth Dog Wear Damage Replace Bearing inspection 1 Inspect Bearing Pitting Rumbling Replace Propeller shaft housing inspection 1 Clean Propeller shaft housing Use a soft brush and solvent 2 In...

Страница 124: ...NADA Except for USA and CANADA Depth a 3 0 3 5 mm 0 12 0 14 in Depth b 23 0 23 5 mm 0 91 0 93 in Driver rod YB 06071 1 90890 06604 3 Needle bearing attachment YB 06111 2 90890 06614 4 Bearing depth pl...

Страница 125: ...6 10 LOWR E PROPELLER SHAFT AND REVERSE GEAR...

Страница 126: ...6 11 LOWR E DRIVE SHAFT FORWARD GEAR AND SHIFT ROD DRIVE SHAFT FORWARD GEAR AND SHIFT ROD EXPLODED DIAGRAM...

Страница 127: ...using ass y 1 5 Plane washer 1 6 Forward gear ass y 1 7 Shift rod ass y 1 8 Shift cam 1 DRIVE SHAFT OIL SEAL HOUS ING DISASSEMBLY 1 Oil seal cover 1 2 O ring 1 3 Oil seal 2 4 Drive shaft oil seal hous...

Страница 128: ...6 13 LOWR E DRIVE SHAFT FORWARD GEAR AND SHIFT ROD EXPLODED DIAGRAM...

Страница 129: ...STALLATION CHART Step Procedure Part name Q ty Service points F Forward gear shim G Screw 1 H Water inlet cover 1 1 I Water inlet cover 2 1 J Nut 1 K Hose nipple 1 L Bolt with washer 1 M Anode 1 N Low...

Страница 130: ...Drive shaft holder YB 06079 90890 06517 1 Pinion nut wrench 90890 06505 2 Socket adapter 90890 06506 3 Bearing separator YB 06219 90890 06534 Lower case disassembly 1 Remove Drive shaft bearing outer...

Страница 131: ...ept for USA and CANADA Slide hammer set YB 06096 1 Bearing outer race puller 90890 06523 2 Bearing outer race puller claw 90890 06532 3 Stopper guide stand 90890 06538 4 Pinion and forward gear inspec...

Страница 132: ...Crack Damage Replace Lower case assembly 1 Install Forward gear shim 1 Forward gear bearing outer race 2 Bearing installer YB 41446 90890 06626 Driver rod YB 06071 90890 06605 2 Install Drive shaft ne...

Страница 133: ...071 90890 06606 2 Depth a 0 0 0 5 mm 0 00 0 02 in Bearing installer YB 06167 90890 06628 Driver rod YB 06071 90890 06605 Forward gear assembly 1 Install Forward gear Taper roller bearing For USA and C...

Страница 134: ...ess T3 by selecting shims until the specified measure ment M is obtained with the special tool 1 Calculate Specified measurement M NOTE P is the deviation of the lower case dimen sion from standard It...

Страница 135: ...a 0 50 mm shim 3 Install Pinion Pinion nut 4 Check Specified measurement M Out of specified measurement Adjust NOTE Check the fit between the shimming gauge and lower surface of the pinion Perform th...

Страница 136: ...dable assume an F mark of 0 and check the backlash when the unit is assembled If the F value is negative then subtract the F value from the measurement Example If F mark is 5 then M 0 06 mm 5 100 0 06...

Страница 137: ...ate Thickness gauge YU 26900 9 4 Adjust Shim s Remove or add Available shim thickness 0 05 0 08 0 12 0 30 and 0 50 mm Reverse gear shim NOTE Find reverse gear shim thickness T2 by backlash measurement...

Страница 138: ...haft so that the shaft is at the center of the hole Tighten the wing nuts 1 4 turn after con tacting the fixing plate 2 Install Pinion Pinion nut 3 Measure Measurement M NOTE Measure the fit between t...

Страница 139: ...tive then subtract the P value from the measurement Example If M is 11 70 mm and P mark is 5 then T3 11 70 mm 11 30 5 100 0 40 0 05 mm 0 45 mm If M is 11 70 mm and P mark is 5 then T3 11 70 mm 11 30 5...

Страница 140: ...the lower case dimen sion from standard It is stamped on the trim tab mounting surface of the lower case in 0 01 mm units If the F mark is missing or unreadable assume an F mark of 0 and check the ba...

Страница 141: ...measurement Measure the backlash with the original shim s If the original shim s is unavailable start with a 0 50 mm shim BACKLASH MEASUREMENT NOTE Do not install the water pump compo nents when meas...

Страница 142: ...R Center bolt 5 Nm 0 5 m kg 3 6 ft lb Set the lower unit upside down Attach the backlash indicator on the drive shaft 18 mm in diameter Backlash indicator YB 6265 90890 06706 Attach the dial gauge on...

Страница 143: ...0 12 0 30 and 0 50 mm Reverse gear 1 Measure Reverse gear backlash Out of specification Adjust Backlash 0 71 0 98 mm 0 028 0 039 in Measuring steps Load the reverse gear by installing the propeller wi...

Страница 144: ...ase YU 34481 90890 06705 While pulling the drive shaft slowly turn the drive shaft clockwise and counterclockwise then measure the backlash when the drive shaft stops at each direction Reverse gear ba...

Страница 145: ......

Страница 146: ...SSEMBLY 7 7 EXPLODED DIAGRAM 7 7 REMOVAL AND INSTALLATION CHART 7 8 SERVICE POINTS 7 8 Throttle arm inspection 7 8 Throttle shift ass y inspection 7 8 Cam plate inspection 7 8 Bushing inspection 7 8 S...

Страница 147: ...PUMP HOUSING AND MOTOR REMOVAL 7 27 EXPLODED DIAGRAM 7 27 REMOVAL AND INSTALLATION CHART 7 28 SERVICE POINTS 7 28 TILT CYLINDER 7 29 EXPLODED DIAGRAM 7 29 REMOVAL AND INSTALLATION CHART 7 30 SERVICE P...

Страница 148: ...7 1 BRKT E TILLER HANDLE REMOVAL TILLER HANDLE REMOVAL EXPLODED DIAGRAM...

Страница 149: ...er 1 EHTO TH model 12 Trim sensor lead coupler 1 13 Extension wire lead coupler 1 14 Clip 1 15 Shift cable 1 16 Clip 1 17 Throttle cable 1 18 Bolt 2 19 Fitting plate ass y 1 20 Clamp 1 M model 21 Engi...

Страница 150: ...7 3 BRKT E TILLER HANDLE TILLER HANDLE EXPLODED DIAGRAM...

Страница 151: ...rter cable 10 Shift cable 1 Longer cable 11 Bolt with washer 2 6 16 mm 12 Cable bracket 1 13 Screw with washer 2 14 Shift lever cover 1 15 Bolt with washer 4 16 Screw 1 17 Handle grip ass y 1 18 Plain...

Страница 152: ...7 5 BRKT E TILLER HANDLE EXPLODED DIAGRAM...

Страница 153: ...r installation SERVICE POINTS Control cable inspection 1 Inspect Throttle cable Shift cable Kink Fray Stick Replace Bushing inspection 1 Inspect Bushing Wear Crack Damage Replace Shift lever inspectio...

Страница 154: ...7 7 BRKT E LINK ASS Y DISASSEMBLY LINK ASS Y DISASSEMBLY EXPLODED DIAGRAM...

Страница 155: ...w 2 7 Spring guide 1 8 Roller 1 9 Actuator 1 10 Spring 1 11 Circlip 1 12 Cam plate 1 13 Bushing 1 14 Frame 1 15 Stopper 1 Neutral opening limit model Reverse the removal steps for installation SERVICE...

Страница 156: ...7 9 BRKT E SHIFT ACTUATOR AND BOTTOM COWLING SHIFT ACTUATOR AND BOTTOM COWLING EXPLODED DIAGRAM...

Страница 157: ...sor lead 1 PTT model 6 Grommet 1 7 Bolt 4 6 30 mm 8 Plane washer 4 9 Bottom cowling ass y 1 10 Seal rubber 1 11 Collar 4 12 Grommet 4 13 Grommet 1 SHIFT ACTUATOR ASS Y 1 Plug screw 1 2 Spring 1 3 Ball...

Страница 158: ...7 11 BRKT E UPPER CASE REMOVAL UPPER CASE REMOVAL EXPLODED DIAGRAM...

Страница 159: ...lt with washer 4 8 30 mm 3 Lower mount housing 2 4 Mount damper 2 5 Nut 2 6 Nut 2 7 Plane washer 2 12 8 22 5 mm 8 Lead wire 1 9 Plane washer 2 12 8 22 5 mm 10 Upper case ass y 1 11 Lower rubber mount...

Страница 160: ...7 13 BRKT E UPPER CASE AND EXHAUST MANIFOLD UPPER CASE AND EXHAUST MANIFOLD EXPLODED DIAGRAM...

Страница 161: ...y Refer to UPPER CASE REMOVAL 1 Bolt with washer 2 2 Upper case 1 3 Dowel pin 2 EXHAUST MANIFOLD REMOVAL 4 Muffler seal 1 5 Seal rubber 1 6 Bolt with washer 4 8 30 mm 7 Exhaust guide 1 8 Grommet 1 9 W...

Страница 162: ...7 15 BRKT E CLAMP BRACKET CLAMP BRACKET Manual tilt EXPLODED DIAGRAM...

Страница 163: ...1 Bolt 1 12 Collar 1 13 Cap 2 14 Self lock nut 1 15 Clamp bracket plate 1 16 Clamp bracket 2 ass y 1 17 Plane washer 1 18 Shallow water drive lever 1 Shallow water drive model 19 Spring 1 20 Tilt leve...

Страница 164: ...7 17 BRKT E CLAMP BRACKET CLAMP BRACKET Hydro tilt Power trim and tilt EXPLODED DIAGRAM...

Страница 165: ...nipple 1 9 Wire lead 1 10 Tilt rod ass y 1 11 Nut 1 12 Plane washer 1 13 Stud bolt 1 14 Clamp bracket spacer ass y 1 15 Nut 1 16 Cap 2 17 Self lock nut 1 18 Clamp bracket 2 1 19 Plane washer 1 20 Swi...

Страница 166: ...7 19 BRKT E STEERING BRACKET STEERING BRACKET EXPLODED DIAGRAM...

Страница 167: ...emoval Upper case ass y Refer to UPPER CASE REMOVAL 1 Flange bolt 1 Manual tilt model 2 Seal rubber 1 3 Circlip 1 4 Lower mount housing 1 5 Steering bracket 1 6 Plane washer 1 7 Bushing 1 8 O ring 1 9...

Страница 168: ...7 21 BRKT E SWIVEL BRACKET SWIVEL BRACKET EXPLODED DIAGRAM...

Страница 169: ...2 1 3 Rod joint 3 4 Clip 1 5 Tilt lever shaft 1 6 Tilt lever 1 2 Shallow water drive model 7 Tilt lock rod 3 1 2 8 Tilt lock rod 4 1 9 Clip 1 Shallow water drive model 10 Pin 1 11 Lever 1 1 12 Spring...

Страница 170: ...7 23 BRKT E SWIVEL BRACKET DISASSEMBLY SWIVEL BRACKET DISASSEMBLY EXPLODED DIAGRAM...

Страница 171: ...ep for removal Upper case ass y Refer to UPPER CASE REMOVAL Clamp bracket Refer to CLAMP BRACKET Steering bracket Refer to STEERING BRACKET 1 Bolt with washer 1 6 10 mm 2 Spring hook 1 3 Spring 1 4 Sp...

Страница 172: ...7 25 BRKT E TILT UNIT REMOVAL TILT UNIT REMOVAL EXPLODED DIAGRAM...

Страница 173: ...motor lead Trim sensor lead 3 Bolt with washer 1 6 10 mm 4 Wire lead 1 5 Bolt with washer 1 6 Wire lead 1 7 Tilt rod ass y 1 8 Nut 1 9 Plane washer 1 10 Stud bolt 1 11 Clamp bracket spacer ass y 1 12...

Страница 174: ...7 27 BRKT E TILT CYLINDER PUMP HOUSING AND MOTOR REMOVAL TILT CYLINDER PUMP HOUSING AND MOTOR REMOVAL EXPLODED DIAGRAM...

Страница 175: ...ing ass y 1 Reverse the removal steps for installation WARNING When removing the plug screw PTT unit should be fully tilt up positioned SERVICE POINTS WARNING The PTT unit should be fully tilt up posi...

Страница 176: ...7 29 BRKT E TILT CYLINDER TILT CYLINDER EXPLODED DIAGRAM...

Страница 177: ...4 7 47 7 mm 6 O ring 1 58 5 54 5 mm 7 Inner cylinder end screw 1 8 Tilt rod sub ass y 1 9 Trim piston 1 10 O ring 1 50 7 43 7 mm 11 Backup ring 1 12 O ring 1 35 7 28 7 mm 13 O ring 1 39 0 35 0 mm 14 C...

Страница 178: ...ormed Tilt rod inspection 1 Inspect Tilt rod Bend Excessive corrode Replace Rust lightly Polish with 400 600 abrasive paper Tilt cylinder inspection 1 Inspect Tilt cylinder Crack Excessive corrosion R...

Страница 179: ...cylinder end screw Tilt cylinder wrench YB 06175 2B 90890 06544 Tilt cylinder assembly 1 Install Ball 1 Tilt cylinder 2 NOTE Apply the grease to the balls to prevent them from falling down To find any...

Страница 180: ...7 33 BRKT E PUMP HOUSING PUMP HOUSING EXPLODED DIAGRAM...

Страница 181: ...2 10 Retaining plate 1 11 Spring 1 8 8 4 3 mm 12 Valve support pin 1 13 Valve seat 1 14 Spring 1 8 8 21 8 mm 15 Valve seat 1 16 Valve support pin 1 17 Valve seat 1 18 O ring 1 13 7 10 7 mm 19 Filter...

Страница 182: ...7 35 BRKT E PTT MOTOR PTT MOTOR EXPLODED DIAGRAM...

Страница 183: ...R PUMP HOUS ING AND MOTOR REMOVAL 1 Screw 3 2 Stator 1 3 Armature ass y 1 4 Plane washer 1 5 O ring 1 55 8 52 0 mm 6 Brush ass y 1 7 Screw with washer 2 8 Lead wire 1 9 Brush ass y 1 10 Cover plate 1...

Страница 184: ...Clean NOTE Remove all particles of metal with com pressed air 3 Measure Commutator diameter Out of specification Replace Commutator diameter Limit 21 mm 0 83 in 4 Inspect Armature coil continuity Out...

Страница 185: ...ification Replace Brush length a Limit 3 5 mm 0 14 in 8 Inspect Base Crack Damage Replace 9 Inspect Stator bushing Base bushing Wear Damage Replace the stator or the base 10 Inspect Base oil seal Wear...

Страница 186: ...ge measurement 8 8 Low resistance measurement 8 8 IGNITION SYSTEM 8 9 IGNITION SPARK GAP 8 10 CDI SYSTEM PEAK VOLTAGE 8 10 SPARK PLUG 8 12 SPARK PLUG CAP 8 12 ENGINE STOP SWITCH 8 13 MAIN SWITCH 8 14...

Страница 187: ...Armature inspection 8 25 Brush holder inspection 8 26 Cover inspection 8 27 CHARGING SYSTEM 8 28 CHARGING SYSTEM PEAK VOLTAGE 8 29 FUSE 8 29 BATTERY 8 29 ENRICHMENT CONTROL SYSTEM 8 30 LIGHTING COIL 8...

Страница 188: ...8 1 ELEC E ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS OIL INJECTION MODEL 1 Electrothermal valve 2 Oil level sensor L Blue B Black...

Страница 189: ...Lighting coil 5 Pulser coil 6 CDI unit 7 Ignition coil 8 2P consent 9 Rectifier regulator 0 Thermo switch To engine stop switch To 6 To 6 To 6 To 1 To 2 To 4 Europe model B Black Br Brown B O Black O...

Страница 190: ...ng coil 6 Pulser coil 7 CDI unit 8 Starter relay 9 Ignition coil 0 Fuse A Thermo switch B Rectifier regulator C Starter motor B Black Br Brown B O Black Orange B W Black White B Y Black Yellow L Blue...

Страница 191: ...9 Starter relay 0 P T T relay A Ignition coil B Fuse C Thermo switch D Rectifier regulator E Starter motor To P T T motor To trim meter To wire harness To 6 To 8 To 0 To remote control To 4 To 2 To b...

Страница 192: ...h lead 4 Battery cable 5 Extension wire harness 6 Neutral switch B Black Br Brown B O Black Orange B W Black White B Y Black Yellow L Blue O Orange O G Orange Green P Pink Y R Yellow Red W White To tr...

Страница 193: ...OMPONENTS E EO MODEL 1 Starter motor 2 Rectifier regulator 3 Ignition coil 4 Fuse 5 Starter relay a Bracket b Ground terminal B Black Br Brown B O Black Orange B W Black White B Y Black Yellow L Blue...

Страница 194: ...1 Starter motor 2 Rectifier regulator 3 Ignition coil 4 Starter relay 5 P T T relay 6 Fuse a Bracket b Ground terminal B Black Br Brown B O Black Orange B W Black White B Y Black Yellow L Blue O Oran...

Страница 195: ...age measurement NOTE The coil output varies greatly at cranking speed Cranking a cold engine with the plugs in and a weak battery does not enable proper readings Low resistance measurement When measur...

Страница 196: ...Charge coil 4 Pulser coil 5 Main switch 6 Engine stop switch 7 10P coupler 8 7P coupler 9 CDI unit Manual starter model Electrical starter model Br Brown L Blue W R White Red W B White Black W G Whit...

Страница 197: ...GE WARNING While taking CDI unit check be careful not to touch any connection of lead wires of the Digital tester NOTE If there is no spark or the spark is weak continue with the CDI test If a good sp...

Страница 198: ...3 pins test harness 3 pins test harness YB 06443 90890 06757 Connect the tester to the measurement terminal Set the tester dial to specification Range Crank or start the engine V 2 Measure Charge coi...

Страница 199: ...r min Measuring steps Disconnect the pulse coil couple Con nect the 3 pins test harness 3 pins test harness YB 06443 90890 06757 Connect the tester to the measurement terminal Set the tester dial to...

Страница 200: ...g close to the spread core wires and bend the spring end for clamping Install the plug cap spring into the spark plug cap Replacement steps For Canada and Europe Remove the spark plug cap by turning t...

Страница 201: ...8 14 ELEC E IGNITION SYSTEM MAIN SWITCH 1 Check Continuity Out of specification Replace Checking leads color Switch position White Black Red Yellow Brown OFF ON START...

Страница 202: ...3 Warning lamp 4 Oil level sensor 5 Oil level warning lamp 6 Oil level sensor 7 Meter Pre mixed model Oil injection and warning lamp model Oil injection and oil level warning lamp model Oil injection...

Страница 203: ...6 34 C 78 8 93 2 F Pink P Black B a 90 96 C 194 0 204 8 F b 76 90 C 168 0 194 0 F Measuring steps Suspend thermostat in a vessel Place reliable thermometer in a water Heat water slowly Observe thermom...

Страница 204: ...ng diode lighting No lighting Replace CAUTION Use only originally pen light battery 1 5 V other than batteries such as alkaline battery higher voltage one will be burnt the diode NOTE LED has an direc...

Страница 205: ...er voltage one will be burnt the diode NOTE LED has an direction for electrical current Therefore try reverse connection if there is no lighting Battery voltage 1 5 V Green LED Yellow Red lead Positiv...

Страница 206: ...TARTING SYSTEM STARTING SYSTEM 1 Fuse 2 10P coupler 3 7P coupler 4 Main switch 5 Starter motor 6 Battery 7 Neutral switch 8 Starter relay Except for remote control model Remote control model B Black B...

Страница 207: ...e WIRING CONNECTION 1 Check Wiring connection Poor connection Correct ENGINE STOP SWITCH Refer to IGNITION SYSTEM MAIN SWITCH Refer to IGNITION SYSTEM NEUTRAL SWITCH 1 Check Continuity Out of specific...

Страница 208: ...ation Does not function Replace Checking steps Connect the tester between the termi nals of the starter relay as shown Connect a 12 V battery Brown lead 1 Positive terminal Black lead 2 Negative termi...

Страница 209: ...8 22 ELEC E STARTING SYSTEM...

Страница 210: ...8 23 ELEC E STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM...

Страница 211: ...1 2 Pinion stopper 1 3 Spring 1 4 Pinion 1 5 Through bolt 2 6 Front cover 1 7 Washer 1 25 1 0 mm 8 Washer 2 25 0 15 mm 9 Washer 1 25 2 0 mm 10 Starter ass y 1 11 Armature ass y 1 12 Washer 1 16 0 25 m...

Страница 212: ...age Replace 2 Check Clutch movement Damage Replace NOTE Rotate the pinion clockwise and check that it freely Also try to rotate the pinion coun terclockwise and confirm that it locks Armature inspecti...

Страница 213: ...Out of specification Replace Commutator under cut Limit 0 2 mm 0 01 in 5 Inspect Armature coil continuity Out of specification Replace Armature coil continuity Commutator segments Continuity Segment L...

Страница 214: ...E STARTER MOTOR 2 Check Brush holder continuity Out of specification Replace Brush holder continuity Brush holder 1 Base 2 Discontinuity Cover inspection 1 Inspect Cover bushing Wear Damage Replace t...

Страница 215: ...8 28 ELEC E CHARGING SYSTEM CHARGING SYSTEM 1 Rectifier regulator 2 Lighting coil 3 Battery 4 Fuse G Green G W Green White R Red B Black...

Страница 216: ...TING SYSTEM BATTERY Refer to GENERAL in chapter 3 Rectifier regurator input electrical model 8 5 V cranking 25 V 1 500 r min 25 V 3 500 r min Measuring steps Connect the tester to the rectifier regu l...

Страница 217: ...ROL SYSTEM 1 Rectifier regulator 2 Lighting coil 3 Electrothermal valve G Green G W Green White L Blue B Black LIGHTING COIL Refer to CHARGING SYSTEM ELECTROTHERMAL VALVE Refer to PRIME STARTER in cha...

Страница 218: ...CONTROL SYSTEM POWER TRIM AND TILT CONTROL SYSTEM 1 P T T motor 2 P T T relay 3 P T T switch 4 3P coupler Black 5 10P coupler 6 Fuse 7 Battery Bottom cowl P T T switch model To remote control R Red Lg...

Страница 219: ...t of specification Replace 2 Check Relay operation Does not function Replace PTT relay continuity Sky blue Sb Black B Light green Lg Black B Continuity Terminal 1 Terminal Terminal 2 Terminal Continui...

Страница 220: ...Sky blue Sb lead Positive terminal Black B Negative terminal Check that there is continuity between the PTT relay terminals TRIM SENSOR 1 Measure Trim sensor resistance Out of specification Replace N...

Страница 221: ...E 1 2 3 4 5 6 7 8 9 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS 9 1 TROUBLE ANALYSIS CHART 9 1...

Страница 222: ...obtained 8 Engine is free from any Hull problem TROUBLE ANALYSIS CHART Trouble mode Check elements ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LO...

Страница 223: ...f valve 7 Fluid passage 7 PTT motor 7 PTT control system 8 ELECTRICAL Ignition system 8 Starting system 8 Enrichment control system 8 Ignition control system 8 Charging system 8 Trouble mode Check ele...

Страница 224: ...YAMAHA MOTOR Corporation USA Printed in U S A Printed on recycled paper...

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