Yamaha 55DEHD Service Manual
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Yamaha 55DEHD Service Manual

Yamaha 55DEHD Service Manual

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55D
75A
85A
SERVICE MANUAL
688-28197-5J-11

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Summary of Contents for Yamaha 55DEHD

  • Page 1 SERVICE MANUAL 688-28197-5J-11...

  • Page 2: Important Information

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

  • Page 3: Table Of Contents

    Contents General information INFO Specification SPEC Periodic check and adjustment Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Electrical system ELEC Troubleshooting TRBL SHTG Index...

  • Page 5: General Information

    INFO General information How to use this manual................1-1 Manual format................... 1-1 Symbol...................... 1-2 Abbreviation ....................1-3 Safety while working ................... 1-4 Fire prevention ..................1-4 Ventilation ....................1-4 Self-protection ..................1-4 Part, lubricant, and sealant ..............1-4 Good working practice ................1-5 Disassembly and assembly ..............

  • Page 6: How To Use This Manual

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 9 Parts are shown and detailed in an exploded diagram and are listed in the components list (see in the figure below for an example page).

  • Page 7: Specification

    7 Apply Yamaha 2-stroke motor oil q Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) w Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)

  • Page 8: Abbreviation

    INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description Aft end American Petroleum Institute ATDC After Top Dead Center Automatic Transmission Fluid Bow end BTDC Before Top Dead Center Cold Cranking Ampere Capacitor Discharged Ignition system Downside or downward European Norm (European standard) Forward...

  • Page 9: Safety While Working

    Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the out- board motor. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous.

  • Page 10: Good Working Practice

    INFO General information Disassembly and assembly 6. Keep a supply of clean, lint-free cloths for 1. Use compressed air to remove dust and wiping up spills, etc. dirt during disassembly. Good working practice 2. Apply engine oil to the contact surfaces Special service tool of moving parts before assembly.

  • Page 11: Identification

    Safety while working / Identification Identification Approved Starting Model name Model model code serial No. This manual covers the following models. 55DEHD 1001700– 75AEHD Applicable model 75AED 1020817– 55DEHD, 75AEHD, 75AED, 75AET, 75AET 85AEHD, 85AED, 85AET 85AEHD 85AED 1013061– Serial number...

  • Page 12: Special Service Tool

    INFO General information Special service tool Digital tachometer Test propeller 90890-06760 90890-01620 Timing light Compression gauge 90890-03141 90890-03160 Dial gauge set Flywheel holder 90890-01252 90890-06522 Leakage tester Flywheel puller 90890-06840 90890-06521 Vacuum/pressure pump gauge set Gear puller 90890-06756 90890-06540 6885J11...
  • Page 13 Special service tool Needle bearing attachment Bearing Separator 90890-06607, 90890-06608, 90890-06611, 90890-06534 90890-06612, 90890-06615, 90890-06632, 90890-06636, 90890-06655 Cylinder gauge Driver rod LS 90890-06759 90890-06606 Support Bearing inner race attachment 90890-02394 90890-06639, 90890-06640, 90890-06643 Bearing pressure C Small end bearing installer 90890-02393 90890-06527 Driver rod SS...
  • Page 14 INFO General information Ring nut wrench 3 Stopper guide stand 90890-06511 90890-06538 Bearing puller assembly Ring nut wrench extension 90890-06535 90890-06513 Stopper guide plate Driver rod L3 90890-06501 90890-06652 Bearing depth plate Bearing housing puller claw L 90890-06603 90890-06502 Drive shaft holder 5 Center bolt 90890-06519 90890-06504...
  • Page 15 Special service tool Driver rod LL Pinion nut holder 90890-06605 90890-06715 Socket adapter 2 Shift rod push arm 90890-06507 90890-06052 Pinion height gauge plate B Bearing outer race puller assembly 90890-06712 90890-06523 Pinion height gauge Driver rod SL 90890-06602 90890-06710 Bearing outer race attachment Digital caliper 90890-06621, 90890-06625, 90890-06626,...
  • Page 16 INFO General information PTT oil pressure gauge assembly Shimming plate 90890-06580 90890-06701 Backlash indicator Cylinder-end screw wrench 90890-06706 90890-06568 Magnet base plate PTT piston vice attachment 90890-07003 90890-06572 Magnet base B Tilt rod wrench 90890-06844 90890-06569 Test harness Trim and tilt wrench 90890-06878 90890-06587 1-11...
  • Page 17 Special service tool Throttle sensor adjusting lead 90890-06857 Test harness 90890-06871 Digital circuit tester 90890-03174 Peak voltage adapter B 90890-03172 Ignition tester 90890-06754 6885J11 1-12...

  • Page 18: Propeller Selection

    INFO General information Propeller selection Propeller size (in) Material The performance of a boat and outboard 12 5/8 × 21 - K motor will be critically affected by the size and 13 × 19 - K type of propeller you choose. Propellers 13 1/4 ×...

  • Page 19: Checking The Gear Oil

    Propeller selection / Predelivery check Checking the gear oil 1. Check the gear oil level. 69D10080 NOTE: 69D10055 The optimum mounting height is affected by the combination of the boat and the outboard Recommended gear oil: motor. To determine the optimum mounting Hypoid gear oil height, test run the outboard motor at differ- API: GL-4...

  • Page 20: Checking The Steering System

    INFO General information Checking the steering system 4. Check that the control lever 1 comes in 1. Check that the steering operates smooth- contact with the adjusting screw 4. 68810090 68810060 NOTE: To adjust the throttle cable, refer to page 3-7. 5.

  • Page 21: Checking The Gear Shift And Throttle Operation

    Predelivery check Checking the gear shift and throttle Checking the engine start switch operation and engine stop lanyard switch 1. Check that the gear shift operates 1. Check that the engine starts when the smoothly when the shift lever or remote engine start switch is turned to START.

  • Page 22: Checking The Cooling Water Pilot Hole

    INFO General information Test run 4. Check that the engine turns off when the 1. Start the engine, and then check that the engine stop lanyard is pulled from the gear shift operates smoothly. engine stop lanyard switch. å 2. Check that the engine idle speed after the engine has been warmed up.

  • Page 23: After Test Run

    Predelivery check 5. After the first 10 hours. Use standard pre- mix ratio of fuel and oil. Refer to page 1-13. 6F610180 å Hours After test run 1. Check for water in the gear oil. 2. Check for fuel leakage in the cowling. 3.
  • Page 24 INFO General information — MEMO — 1-19 6885J11...
  • Page 25 SPEC Specification General specification ..................2-1 Maintenance specification ................2-5 Power unit (55D, 75A models) ..............2-5 Lower unit (55D, 75A models) ..............2-7 Electrical (55D, 75A models) ..............2-7 Power unit (85A models) .................2-10 Lower unit (85A models)................2-12 Electrical (85A models)................2-12 Dimension ....................2-15 Tightening torque..................2-19 Specified torque..................2-19 General torque..................2-21 6885J11...

  • Page 26: Specification

    SPEC Specification General specification Model Item Unit 55DEHD 75AEHD 75AED 75AET Dimension Overall length mm (in) 1,337 (52.6) 726 (28.6) Overall width mm (in) 398 (15.7) 374 (14.7) Overall height mm (in) 1,422 (56.0) mm (in) — 1,548 (60.9) —...
  • Page 27 General specification Model Item Unit 55DEHD 75AEHD 75AED 75AET Cooling system Water Exhaust system Propeller boss Lubrication system Pre-mixed fuel and oil Fuel and oil Fuel type Regular unleaded gasoline Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3...
  • Page 28 SPEC Specification Model Item Unit 85AEHD 85AED 85AET Dimension Overall length mm (in) 1,337 (52.6) 726 (28.6) Overall width mm (in) 398 (15.7) 374 (14.7) Overall height mm (in) 1,422 (56.0) mm (in) 1,473 (58.0) — mm (in) — 1,548 (60.9) Boat transom height mm (in) 508 (20.0)
  • Page 29 General specification Model Item Unit 85AEHD 85AED 85AET Cooling system Water Exhaust system Propeller boss Lubrication system Pre-mixed fuel and oil Fuel and oil Fuel type Regular unleaded gasoline Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3 Gear oil type Hypoid gear oil Gear oil grade (*1)

  • Page 30: Maintenance Specification

    SPEC Specification Maintenance specification Power unit (55D, 75A models) Model Item Unit 55DEHD 75AEHD 75AED 75AET Power unit Minimum compression pressure (*1) at electric starter (kgf/cm , psi) (3.4, 49) Cylinder head Warpage limit mm (in) 0.1 (0.0039) (lines indicate straightedge...
  • Page 31 Maintenance specification Model Item Unit 55DEHD 75AEHD 75AED 75AET Piston ring Top ring Dimension B mm (in) 1.965–1.980 (0.0774–0.0780) Dimension T mm (in) 3.100–3.300 (0.1220–0.1299) End gap (reference data) mm (in) 0.40–0.60 (0.0157–0.0236) Side clearance mm (in) 0.05–0.08 (0.0020–0.0032) Oversize outside diameter mm (in) 82.25 (3.24)

  • Page 32: Lower Unit (55D, 75A Models)

    SPEC Specification Lower unit (55D, 75A models) Model Item Unit 55DEHD 75AEHD 75AED 75AET Gear backlash Pinion-to-forward gear mm (in) 0.08–0.25 (0.0032–0.0098) Pinion-to-reverse gear mm (in) 0.67–1.00 (0.0264–0.0394) Pinion gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50...
  • Page 33 Maintenance specification Model Item Unit 55DEHD 75AEHD 75AED 75AET Charge coil output peak voltage (R–Br) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) (R–L) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded)
  • Page 34 SPEC Specification Model Item Unit 55DEHD 75AEHD 75AED 75AET PTT system Ω Trim sensor resistance — 168.3–288.3 at 20°C (68°F) (P–B) Ω Trim sensor setting resistance — 9–11 at 20°C (68°F) (P–B) Fluid type — Dexron 2 Motor type —...

  • Page 35: Power Unit (85A Models)

    Maintenance specification Power unit (85A models) Model Item Unit 85AEHD 85AED 85AET Power unit Minimum compression pressure (*1) at electric starter (kgf/cm , psi) (4.1, 59) Cylinder head Warpage limit mm (in) 0.1 (0.0039) (lines indicate straightedge position) Cylinder Bore size mm (in) 82.000–82.020 (3.2283–3.2291) Piston...
  • Page 36 SPEC Specification Model Item Unit 85AEHD 85AED 85AET Piston ring Top ring Dimension B mm (in) 1.965–1.980 (0.0774–0.0780) Dimension T mm (in) 3.100–3.300 (0.1220–0.1299) End gap (reference data) mm (in) 0.40–0.60 (0.0157–0.0236) Side clearance mm (in) 0.05–0.08 (0.0020–0.0032) Oversize outside diameter mm (in) 82.25 (3.24) mm (in)

  • Page 37: Lower Unit (85A Models)

    Maintenance specification Lower unit (85A models) Model Item Unit 85AEHD 85AED 85AET Gear backlash Pinion-to-forward gear mm (in) 0.08–0.25 (0.0032–0.0098) Pinion-to-reverse gear mm (in) 0.67–1.00 (0.0264–0.0394) Pinion gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Electrical (85A models)
  • Page 38 SPEC Specification Model Item Unit 85AEHD 85AED 85AET Charge coil output peak voltage (R–Br) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) (R–L) at Cranking (unloaded) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Charge coil resistance at 20°C (68°F) Ω...
  • Page 39 Maintenance specification Model Item Unit 85AEHD 85AED 85AET PTT system Ω Trim sensor resistance — 168.3–288.3 at 20°C (68°F) (P–B) Ω Trim sensor setting resistance — 9–11 at 20°C (68°F) (P–B) Fluid type — Dexron 2 Motor type — 6H102 Output —...

  • Page 40: Dimension

    SPEC Specification Dimension Exterior 55DEHD, 75AEHD, 85AEHD mm (in) 790 (31.1) L: 968 (38.1) Y: 1,015 (40.0) 459 (18.1) X: 1,080 (42.5) 180 (7.1) 545 (21.5) 67 (2.6) 164 (6.5) 547 (21.5) 6882001M 2-15 6885J11...
  • Page 41 Maintenance specification Exterior 75AED, 75AET, 85AED, 85AET mm (in) L: 968 (38.1) 459 (18.1) X: 1,080 (42.5) 180 (7.1) 545 (21.5) 67 (2.6) 164 (6.5) L: 14.0 (0.6) 547 (21.5) X: 23.0 (0.9) 6882002M 6885J11 2-16...
  • Page 42 SPEC Specification Clamp bracket 55DEHD, 75AEHD, 75AED, 85AEHD, 85AED mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 68.5 (2.7) 13 (0.5) 13 (0.5) 125 (4.9) 125.4 (4.9) 6882003M 2-17 6885J11...
  • Page 43 Maintenance specification Clamp bracket 75AET, 85AET mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 68.5 (2.7) 13 (0.5) 13 (0.5) 125.4 (4.9) 125.4 (4.9) 6882003M 6885J11 2-18...

  • Page 44: Tightening Torque

    SPEC Specification Tightening torque Specified torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Power unit Power unit mount bolt 15.5 Flywheel magnet nut — 16.0 Ignition coil mount bolt Spark plug Intake manifold bolt 11.1 Cylinder head bolt 22.1 14.8 29.5...
  • Page 45 Tightening torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb PTT unit (ET) PTT motor mount bolt Reservoir mount bolt Reservoir cap — Main valve — Trim spring screw — Valve lock screw — Manual valve — Pipe joint —...

  • Page 46: General Torque

    SPEC Specification General torque General torque specifications This chart specifies tightening torques for Nut (A) Bolt (B) standard fasteners with a standard ISO N·m kgf·m ft·lb thread pitch. Tightening torque specification 8 mm for special components or assemblies are 10 mm provided in applicable sections of this manu- 12 mm 14 mm...

  • Page 47: Periodic Check And Adjustment

    Periodic check and adjustment Maintenance interval chart ................3-1 Top cowling ....................3-2 Checking the top cowling ................. 3-2 Fuel system ....................3-2 Checking the fuel joint and fuel hose (fuel tank-to-carburetor) ....3-2 Checking the fuel filter ................3-3 Power unit .....................

  • Page 48: Maintenance Interval Chart

    Check / charge 3-19 Cooling water passages Clean Cowling clamp Check Fuel filter (can be dis- Check / clean assembled) Fuel system Check Fuel tank (Yamaha por- Check / clean — table tank) Gear oil Change 3-17 Lubrication points Lubricate 3-20...

  • Page 49: Fuel System

    Maintenance interval chart / Top cowling / Fuel system Top cowling 8. Check the lock lever, bushings and wash- Checking the top cowling ers. Replace if worn or damaged. 1. Check the top cowling. Replace the top 9. Check the hooks and rivets. Replace the cowling if cracked or other damaged.

  • Page 50: Power Unit

    Periodic check and adjustment Checking the fuel filter 4. Check the spark plug gap a. Adjust or 1. Remove the nut, and then remove the replace if out of specification. fuel filter assembly. NOTE: Be sure not to spill any fuel when removing the fuel cap assembly.

  • Page 51: Checking The Cooling Water Passage

    Fuel system / Power unit Checking the cooling water passage 3. Place a thermometer in the water and 1. Check the cooling water inlet covers 1 slowly heat the water. and cooling water inlet. Clean the water inlet cover and cooling water inlet if clogged.

  • Page 52: Control System

    Periodic check and adjustment Control system 3. Loosen the throttle stop screw 6 at the carburetor assembly #2 until it does not Synchronizing the carburetor contact from the stopper 7. NOTE: Make sure to synchronizing the carburetor, always disassemble or replace. 1.

  • Page 53: Checking The Control Link Position

    Control system 9. Check that the throttle cam 4 slightly 6. Tighten the throttle lever tightening screws 8 on the carburetor assembly #1 contacts to the cam roller 5. If it is not in and #3 by pushing down throttle lever 9 contact, remove the throttle link rod 3 with your finger.

  • Page 54: Adjusting The Throttle Cable

    Periodic check and adjustment 3. Remove the control link rod 2, and then Adjusting the throttle cable measure the length a of the link. 1. Loosen the locknut 1, remove the pin 2 and then disconnect the throttle cable joint 3. 68830160 2.

  • Page 55: Checking The Engine Idle Speed

    Control system 3. Check the engine idle speed. Adjust the engine idle speed if out of specification. The throttle cable joint 3 must be screwed in a minimum of 8.0 mm (0.31 in) NOTE: Pull the throttle cable toward the engine to remove any free play in the cable before adjusting the position of the throttle cable joint.

  • Page 56: Checking The Ignition Timing

    Periodic check and adjustment Checking the ignition timing 4. Attach the special service tool 4 and 5 to the spark plug wire #1, and then start NOTE: the engine. Check the engine idle speed Install the test propeller, when checking the and ignition timing.

  • Page 57: Checking The Timing Plate

    Control system 6. Set the control lever 2 3 to full advanced 9. Turn off the engine, and then remove the position. special service tools. 10. Install the throttle link rod and connect the throttle cable. Checking the timing plate NOTE: Remove the all spark plugs and lock plate before adjusting the timing plate.

  • Page 58: Checking The Ignition Timing Stopper

    Periodic check and adjustment Checking the ignition timing stopper 3. While checking the dial gauge, slightly 1. Disconnect the throttle cable and remove turn the flywheel magnet counterclock- the throttle link rod. wise to the specified position. NOTE: To disconnect and connect the throttle cable, refer to page 3-7.
  • Page 59 Control system 4. Check that the mark b on the flywheel 6. Check the screw out length d of the magnet is aligned with the pointer 4 on adjusting screw 3. the pulser coil assembly. 68830260 68830250 5. If it is not aligned, remove the control link Specified length d rod 5, and then adjust the control link (full advanced, reference data):...

  • Page 60: Checking The Gear Shift Operation

    Periodic check and adjustment 8. Set the control lever 2 2 to the full retard 11. Install the throttle link rod and connect position, and then check that the adjust- the throttle cable. ing screw 6 comes in contact with the crankcase.

  • Page 61: Checking The Neutral Switch Operation (Ehd)

    Control system 1. Check that the neutral switch 1 is 5. Adjust the position of the shift cable joint 3 until its hole is aligned with the set pin pushed by the shift lever 2, when the gear shift is in the “N” position. 68830355 68830360 2.

  • Page 62: Bracket

    Periodic check and adjustment 3. Check the choke solenoid. 2. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1 to NOTE: check the lock mechanism of the lever. 9 To measure the choke solenoid resistance, refer to page 8-11.

  • Page 63: Checking The Tilt Operation (Ehd, Ed)

    Control system / Bracket 2. Remove the reservoir cap 2, and then Checking the tilt operation check the fluid level in the reservoir. (EHD, ED) Be sure to tilt the outboard motor fully and support it with the tilt stop lever. It can not be tilted up partially.

  • Page 64: Lower Unit

    Periodic check and adjustment NOTE: 4. Fully tilt the outboard motor up, and then If the fluid is at the correct level, the fluid support it with the tilt stop lever 2 to should overflow out of the filler hole when the check the lock mechanism of the lever.

  • Page 65: Checking The Lower Unit For Air Leakage

    Bracket / Lower unit Checking the lower unit for air leak- 3. Check the oil for metal, discoloration and its viscosity. Check the internal parts of the lower case if necessary. Do not over pressurize the lower unit, oth- 4. Fully tilt the outboard motor down. erwise the oil seals may be damaged.

  • Page 66: Checking The Propeller

    Periodic check and adjustment Checking the propeller 1. Check the propeller blades. Replace if Do not oil, grease, or paint the anodes, cracked. Check the splines. Replace if otherwise they will be ineffective. damaged or worn. NOTE: If it is necessary to disassemble the outboard General motor to check an anode, refer to Chapter 5 Checking the anode...

  • Page 67: Lubricating The Outboard Motor

    Lower unit / General Lubricating the outboard motor 2. Fully charge the battery. Check the spe- 1. Apply Yamaha grease A to the areas cific gravity of the electrolyte. Replace the shown. battery if below specification. NOTE: Apply Yamaha grease A to the grease nipple Battery electrolyte is dangerous;...
  • Page 68 Periodic check and adjustment 2. Apply temperature resistant grease to the areas shown. 68830490 68830570 3. Apply corrosion resistant grease to the area shown. 68830500 6B430300 68830510 68830520 3-21 6885J11...
  • Page 69 FUEL Fuel system Hose routing ....................4-1 Fuel line ......................4-3 Fuel pump ..................... 4-5 Checking the primer pump ................4-6 Checking the fuel joint ................4-6 Checking the fuel pump ................4-7 Disassembling the fuel pump ..............4-7 Assembling the fuel pump ............... 4-8 Carburetor .....................

  • Page 70: Fuel System

    FUEL Fuel system Hose routing 6884006E 1 Fuel hose (Fuel tank-to-primer pump) 2 Fuel hose (Primer pump-to-fuel joint) 3 Fuel hose (Fuel joint-to-fuel filter) 4 Fuel hose (Fuel filter-to-fuel pump) 5 Fuel hose (Fuel pump-to-carburetor) 6 Cooling water hose 6885J11...
  • Page 71 Hose routing 6884007E 1 Breather hose : 275 mm (10.8 in) 2 Breather hose : 185 mm (7.3 in) 3 Breather hose : 102 mm (4.0 in) 4 Breather hose : 465 mm (18.3 in) 6885J11...

  • Page 72: Fuel Line

    FUEL Fuel system Fuel line 6884030E Part name Q’ty Remarks Fuel joint M6 × 20 mm Bolt Clip Fuel hose Fuel hose Fuel filter assembly M6 × 14 mm Bolt Bracket Fuel hose M6 × 40 mm Joint Fuel hose Fuel hose Fuel hose Fuel hose...
  • Page 73 Fuel line 6884030E Part name Q’ty Remarks M6 × 40 mm Bolt Fuel filter element Float Not reusable O-ring 6885J11...

  • Page 74: Fuel Pump

    FUEL Fuel system Fuel pump 6884050E Part name Q’ty Remarks ø5 × 30 mm Screw Cover Diaphragm Not reusable Gasket ø3 × 5 mm Screw Check valve Fuel pump body Not reusable Gasket Diaphragm Base 6885J11...

  • Page 75: Checking The Primer Pump

    Fuel pump Checking the primer pump Checking the fuel joint 1. Place a drain pan under the fuel hose 1. Disconnect the fuel hose, and then connections, and then disconnect the remove the fuel joint. fuel hose from the primer pump. 2.

  • Page 76: Checking The Fuel Pump

    FUEL Fuel system Checking the fuel pump 6. Apply the specified positive pressure and 1. Place a rag under the fuel hose connec- check that there is no air leakage. tions, and then disconnect the fuel hoses Disassemble the fuel pump if air leaked. from the fuel pump.

  • Page 77: Assembling The Fuel Pump

    Fuel pump Assembling the fuel pump NOTE: Clean the parts and soak the valves and the diaphragms in gasoline before assembly. 1. Install the check valves 1 onto the fuel pump body 2. 68840020 2. Install gaskets diaphragms 5, 6, cover 7 and base 8 to the fuel pump body 9.

  • Page 78: Carburetor

    FUEL Fuel system Carburetor ED, ET 12 N·m (1.2 kgf·m, 8.9 ft·lb) 6884060E Part name Q’ty Remarks ø6 × 15 mm Screw Washer Cover Gasket Not reusable M6 × 18 mm Bolt Intake silencer Gasket Not reusable Carburetor assembly #1 Carburetor assembly #2 Carburetor assembly #3 Link rod...
  • Page 79 Carburetor ED, ET 12 N·m (1.2 kgf·m, 8.9 ft·lb) 6884060E Part name Q’ty Remarks Choke solenoid ED, ET ø6 × 15 mm : ED, ET Screw 6885J11 4-10...
  • Page 80 FUEL Fuel system 6884070E Part name Q’ty Remarks ø5 × 10 mm Screw Cover Rubber seal 2 Plate 2 Rubber seal 1 Plate 1 Throttle stop screw Spring Carburetor body Spring Pilot screw Main nozzle Main jet Float pin Needle valve Clip Pilot jet 4-11...
  • Page 81 Carburetor 6884070E Part name Q’ty Remarks Float ø4 × 8 mm Screw Gasket Not reusable ø4 × 14 mm Screw Float chamber O-ring Not reusable Drain bolt Carburetor assembly #1 Carburetor assembly #3 6885J11 4-12...

  • Page 82: Disassembling The Carburetor

    FUEL Fuel system Disassembling the carburetor 4. Check the pilot screw and needle valve. Replace the pilot screw and needle valve NOTE: if bend or worn. Disassembled jets and other components should be sorted out and kept in order, so that they can be re-assembled in their original positions.

  • Page 83: Assembling The Carburetor

    Carburetor Assembling the carburetor 4. Install the new gasket 9, float chamber 1. Install the main nozzle 1 and main jet 2. 0, and then tighten the float chamber screws q. 2. Install the pilot jet 3 and cap 4. 5.
  • Page 84 FUEL Fuel system 7. Install the spring p, pilot screw a, then 8. Install the new gaskets s, carburetor assembly d, new gasket f, carburetor turn it in until it is lightly seated, and then caps g, intake silencer h and bolts j. turn it out the specified number of turns.
  • Page 85 — MEMO — 6885J11 4-16...
  • Page 86 POWR Power unit Power unit ..................... 5-1 Checking the compression pressure ............5-1 Removing the power unit ................. 5-9 Removing the flywheel magnet ............. 5-11 Removing the electrical component ............5-11 Removing the control lever and throttle cam ......... 5-12 Intake manifold ...................
  • Page 87 Disassembling the oil seal housing ............5-31 Checking the oil seal housing ..............5-31 Assembling the oil seal housing ............5-31 Assembling the power unit ..............5-32 Installing the electrical component ............5-36 Install the control lever and throttle cam ..........5-38 Installing the power unit .................

  • Page 88: Power Unit

    POWR Power unit Power unit Minimum compression pressure Checking the compression pressure (reference data): 1. Start the engine, warm it up for 5 min- 55D, 75A: utes, and then turn it off. 340 kPa (3.4 kgf/cm , 49 psi) 85A: 2.
  • Page 89 Power unit ED, ET 21 N·m (2.1 kgf·m, 15.5 ft·lb) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 6885010E Part name Q’ty Remarks Power unit Not reusable Gasket Dowel M6 × 20 mm Bolt M6 × 30 mm Bolt M8 × 30 mm Bolt M8 ×...
  • Page 90 POWR Power unit 160 N·m (16.0 kgf·m, 118 ft·lb) 6885020E Part name Q’ty Remarks Washer Flywheel magnet M6 × 30 mm Bolt Stator assembly Pulser coil assembly ø6 × 12 mm Screw Plate Control link Retainer Woodruff key Timing plate M6 ×...
  • Page 91 Power unit 6885030E Part name Q’ty Remarks M8 × 45 mm Bolt Collar Bushing Control lever 1 Bushing Spring Lock nut Spring Control lever 2 Screw Plastic washer Washer Shift lever M8 × 30 mm Bolt Bracket Joint 6885J11...
  • Page 92 POWR Power unit 6885030E Part name Q’ty Remarks Lock nut Throttle link rod M6 × 35 mm Bolt Wave washer Collar Screw Lock nut 6885J11...
  • Page 93 Power unit 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6885060E 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks M6 × 20 mm Bolt Rectifier Regulator M6 × 30 mm Bolt Grommet Bracket Collar Ignition coil M6 ×...
  • Page 94 POWR Power unit 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6885060E 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks PTT motor lead Green : ET Spring washer PTT motor lead Blue : ET ø6 ×...
  • Page 95 Power unit 30 N·m (3.0 kgf·m, 22.1 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 6885050E Part name Q’ty Remarks M8 × 30 mm Bolt Negative battery cable Spring washer Positive battery lead Starter motor 6885J11...

  • Page 96: Removing The Power Unit

    POWR Power unit Removing the power unit 3. Remove the cover, then remove the pos- itive battery cable 9, fuse holder lead 0, NOTE: PTT motor leads q (ET), Rectifier It is recommended to loosen the flywheel Regulator leads w, thermoswitch leads magnet nut before removing the power unit to e and main harness coupler r.
  • Page 97 Power unit 8. Install the special service tool f as 5. Disconnect the fuel hose, and then remove the choke knob. shown. NOTE: To disconnect and remove the fuel hose and choke link rod. Refer to page 4-3 and 4-9. 6.

  • Page 98: Removing The Flywheel Magnet

    POWR Power unit Removing the flywheel magnet 1. Loosen the flywheel magnet nut. To prevent damage to the engine or tools, screw in the flywheel puller set bolts even- ly and completely so that the flywheel puller is parallel to the flywheel magnet. NOTE: Apply force to the crankshaft end until the fly- wheel magnet comes off the tapered portion...

  • Page 99: Removing The Control Lever And Throttle Cam

    Power unit 3. Disconnect the Ignition coil leads 6, and 6. Remove the starter motor bolts y, and then remove the ignition coils 7. then remove the starter motor u. 68850165 7. Remove the control link i, then remove the stator assembly o, pulser coil assembly p and retainer a.
  • Page 100 POWR Power unit Intake manifold 12 N·m (1.2 kgf·m, 8.9 ft·lb) 6885070E Part name Q’ty Remarks M6 × 30 mm Bolt Intake manifold Not reusable Gasket Plate ø5 × 20 mm Screw Reed valve assembly 5-13 6885J11...

  • Page 101: Intake Manifold

    Intake manifold Removing the reed valve assembly ∫ 1. Remove the intake manifold bolts 1, and then remove the intake manifold 2. 68850200 å 75A ∫ 55D, 85A Valve bend limit a: 0.2 mm (0.0079 in) 2. Measure the reed valve stopper height 68850170 b.

  • Page 102: Cylinder Head, Exhaust Cover

    POWR Power unit Cylinder head, exhaust cover 25 N·m (2.5 kgf·m, 18.4 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 6885090E Part name Q’ty Remarks M6 × 35 mm Bolt Holder Thermostat cover Spring Thermostat Not reusable Gasket Grommet...
  • Page 103 Cyilnder head, exhaust cover 25 N·m (2.5 kgf·m, 18.4 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 30 N·m (3.0 kgf·m, 22.1 ft·lb) 6885090E Part name Q’ty Remarks ø4 × 15 mm Screw Anode 6885J11 5-16...
  • Page 104 POWR Power unit 6885080E Part name Q’ty Remarks M8 × 40 mm Bolt Exhaust outer cover Not reusable Gasket Exhaust inner cover Not reusable Gasket 5-17 6885J11...

  • Page 105: Removing The Cylinder Head

    Cyilnder head, exhaust cover Removing the cylinder head 1. Remove the spark plugs. 2. Remove the thermostat cover 1, spring 2, PCV 3, thermostat 4, gasket 5 and grommet 6. 68850260 NOTE: 68850230 Insert a flat-head screw driver between the pry tabs to pry off the cylinder head cover.

  • Page 106: Checking The Cylinder Head

    POWR Power unit 7. Remove the cylinder head 0 and gasket 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in directions as shown. Replace the cylin- der head if above specification. 68850300 68850280 68850310 Cylinder head warpage limit: 0.1 mm (0.0039 in) Removing the exhaust cover...

  • Page 107: Checking The Exhaust Cover

    Cyilnder head, exhaust cover 2. Remove the exhaust outer cover 1, gas- ket 2, exhaust inner cover 3 and gasket 68850330 68850340 NOTE: Insert a flat-head screw driver between the pry tabs to pry off the exhaust covers. Checking the exhaust cover 1.

  • Page 108: Crankcase

    POWR Power unit Crankcase 20 N·m (2.0 kgf·m, 14.8 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 6885100E Part name Q’ty...
  • Page 109 Crankcase 12 N·m (1.2 kgf·m, 8.9 ft·lb) 35 N·m (3.5 kgf·m, 25.8 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 35 N·m (3.5 kgf·m, 25.8 ft·lb) 6885110E Part name Q’ty Remarks Not reusable O-ring Not reusable Oil seal Not reusable Needle bearing Crankshaft Not reusable Roller bearing...
  • Page 110 POWR Power unit 6885120E Part name Q’ty Remarks Connecting rod Piston Washer Needle bearing Not reusable Clip Piston pin Piston ring 5-23 6885J11...

  • Page 111: Removing The Crankcase

    Crankcase Removing the crankcase NOTE: Insert a flat-head screw driver between the 1. Disconnect the breather hoses. pry tabs to pry off the crankcase. 4. Remove the oil seal housing. Removing the piston, connecting rod assembly and crankshaft assembly 1. Remove the connecting rod bolts and connecting rod caps, bearings.

  • Page 112: Checking The Cylinder Block

    POWR Power unit Disassembling the piston and con- 2. Remove the crankshaft assembly. necting rod assembly 1. Remove the piston pin clips 1 with pliers, and then remove the piston pin 2, nee- dle bearings 3 and washers 4. 2. Remove the top piston ring 5 and 2nd piston ring 6.

  • Page 113: Disassembling The Crankshaft

    Crankcase Disassembling the crankshaft 1. Remove the roller bearing. Do not reuse the ball bearing, always replace it with a new one. Gear puller 4: 90890-06540 Bearing separator 5: 90890-06534 or commercially available tool. Checking the cylinder bore 6S650340 1. Measure the cylinder bore (D –D ) at 2.

  • Page 114: Checking The Piston Diameter

    POWR Power unit Checking the piston diameter Checking the piston pin boss bore 1. Measure the piston outside diameter at 1. Measure the piston pin boss bore. the specified measuring point. Replace Replace the piston if out of specification. the piston if out of specification. 6F650450 69R50310 Piston pin boss bore:...

  • Page 115: Checking The Crankshaft

    Crankcase 2. Measure the crankshaft runout. Replace the crankshaft if above specification. 68850500 68850440 Crankshaft runout limit c: Piston ring end gap a: (reference 0.02 mm (0.0008 in) data) Top and 2nd piston ring: Checking the connecting rod big 0.40–0.60 mm end side clearance (0.0157–0.0236 in) 1.

  • Page 116: Checking The Connecting Rod Small End Axial Play

    POWR Power unit Checking the connecting rod small Assembling the upper bearing 1. Apply grease to the new oil seal 1, new end axial play O-ring 2, and then install them onto the 1. Install the bearing and connecting rod. upper bearing.

  • Page 117: Assembling The Crankshaft

    68850510 68850530 NOTE: Do not reuse the ball bearing, always 9 Face the embossed “YAMAHA” mark a on replace it with a new one. the connecting rod in the same direction as the “UP” mark b on the piston. Support 2:...

  • Page 118: Disassembling The Oil Seal Housing

    POWR Power unit 2. Install the new oil seal 4 and new O-ring 5 into the oil seal housing. Do not scratch the pistons or break the piston rings. NOTE: Install the piston rings with the recess for the locating pin facing up toward the piston crown.

  • Page 119: Assembling The Power Unit

    Crankcase Assembling the power unit 3. Install the connecting rod bearings and 1. Install the pistons into the cylinders with connecting rod caps onto the connecting the “UP” mark on the piston crown facing rods, and then tighten the connecting rod towards the flywheel magnet.
  • Page 120 POWR Power unit 4. Install the oil seal housing 5 onto the 6. Install the dowels 6, crankcase 7 onto cylinder block. the cylinder block, and then temporarily tighten the crankcase bolts and nuts. 68850620 5. Apply sealant to the mating surface of the crankcase.
  • Page 121 Crankcase 11. Install the new gasket 9, exhaust inner 8. Tighten the crankcase bolts and nuts to cover 0, new gasket q, exhaust outer the specified torques in 2 stages and in cover w, and then tighten the exhaust the sequence as shown. cover bolts e to the specified torques in the sequence as shown.
  • Page 122 POWR Power unit 12. Install the new gasket r and cylinder 13. Install the thermoswitch u, new gasket head t, and then tighten the cylinder i, cylinder head cover o, and then tight- head bolts y to the specified torques in 2 en the cylinder head cover bolts p.

  • Page 123: Installing The Electrical Component

    Crankcase Installing the electrical component 14. Install the grommet a, thermostat s, 1. Install the CDI unit 1, Rectifier Regulator PCV d, spring f, new gasket g, ther- 2, starter relay 3 and PTT relay 4 (ET) mostat cover h, holder j, and then onto the CDI unit bracket.
  • Page 124 POWR Power unit 3. Install the ignition coils 0, and then con- 6. Install the Rectifier Regulator ground nect the ignition coil leads q. lead o and PTT relay ground lead p (ET). 6885012a 7. Install the starter motor a, and then tighten the starter motor mount bolts s 6885013a to the specified torque.

  • Page 125: Install The Control Lever And Throttle Cam

    Crankcase Install the control lever and throttle 3. Install the Woodruff key and flywheel magnet 3 temporally tighten, and then install the special service tool 4, lift up 1. Install the spring 1 onto the control lever 2 2, and then install the control the power unit 5.
  • Page 126 POWR Power unit 7. Install the apron 8 onto the bottom cowl- ing. To prevent damage to the engine or tools, screw in the flywheel puller set bolts even- ly and completely so that the flywheel puller is parallel to the flywheel magnet. Power unit mount bolt 6: 21 N·m (2.1 kgf·m, 15.5 ft·lb) 5.
  • Page 127 Crankcase 9. Connect the fuel hose. ∫ NOTE: To connect the fuel hose, refer to page 4-3. 10. Connect the ground leads e and pilot water hose r. 6885006a å ED, ET ∫ EHD 6885007a Starter relay terminal nut d: 11.
  • Page 128 POWR Power unit 14. Install the spark plug caps to the spark plugs. 15. Connect the positive battery lead ; and negative battery cable z to the starter motor. PORT 6885004a Positive battery terminal nut: 9 N·m (0.9 kgf·m, 6.6 ft·lb) Negative battery terminal bolt: 30 N·m (3.0 kgf·m, 22.1 ft·lb) 5-41...
  • Page 129 LOWR Lower unit Lower unit ..................... 6-1 Removing the lower unit ................6-4 Removing the water pump ..............6-5 Checking the water pump ................ 6-6 Disassembling the oil seal housing ............6-6 Assembling the oil seal housing .............. 6-6 Propeller shaft housing ................6-7 Removing the propeller shaft housing assembly ........

  • Page 130: Lower Unit

    LOWR Lower unit Lower unit 40 N·m (4.0 kgf·m, 29.5 ft·lb) ¥ 9 N·m (0.9 kgf·m, 6.6 ft·lb) ≈ 35 N·m (3.5 kgf·m, 25.8 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6886010E Part name Q’ty...
  • Page 131 Lower unit 40 N·m (4.0 kgf·m, 29.5 ft·lb) ¥ 9 N·m (0.9 kgf·m, 6.6 ft·lb) ≈ 35 N·m (3.5 kgf·m, 25.8 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6886010E Part name Q’ty...
  • Page 132 LOWR Lower unit 6886020E Part name Q’ty Remarks M8 × 70 mm Bolt M8 × 50 mm Bolt ø4 × 12 mm Screw Grommet Seal Water pump housing Insert cartridge Impeller Dowel Not reusable Gasket Outer plate cartridge Not reusable Gasket Oil seal housing Not reusable...

  • Page 133: Removing The Lower Unit

    Lower unit Removing the lower unit 1. Remove the lock plate from the engine 9 Do not hold the propeller with your stop lanyard switch. hands when loosening or tightening it. 9 Be sure to disconnect the battery cables 2. Place a drain pan under the drain hole. from the battery and the lock plate from the engine stop lanyard switch.

  • Page 134: Removing The Water Pump

    LOWR Lower unit 8. Mark the trim tab at the area shown. 11. Remove the stud bots. (X, Y-transom) 9. Remove the cover 3, then remove the trim tab bolt 4 and trim tab 5. 10. Loosen the bolts(nuts) 6, and then remove the lower unit (X, Y-transom: and extension 7) from the upper case.

  • Page 135: Checking The Water Pump

    Lower unit 4. Remove the oil seal housing 7 and gas- ket 8. 68860030 Disassembling the oil seal housing 68860020 1. Remove the O-ring and oil seals as shown. 68860040 Assembling the oil seal housing 68860416 1. Install the new oil seals and new O-ring onto the oil seal housing to the specified NOTE: depth.

  • Page 136: Propeller Shaft Housing

    LOWR Lower unit Propeller shaft housing 105 N·m (10.5 kgf·m, 77.4 ft·lb) 6886030E Part name Q’ty Remarks Shift plunger Shift slider Spring Dog clutch Cross pin Spring Propeller shaft Reverse gear shim — Reverse gear Washer Not reusable O-ring Not reusable Ball bearing Propeller shaft housing Straight key...

  • Page 137: Removing The Propeller Shaft Housing Assembly

    Propeller shaft housing Removing the propeller shaft hous- 3. Remove the propeller shaft housing 4 ing assembly and straight key 5. 1. Straighten the one tab 1 of the lock washer. 6F660060 68860076 2. Remove the ring nut from the propeller shaft housing.

  • Page 138: Disassembling The Propeller Shaft Housing

    LOWR Lower unit 2. Remove the cross pin 4, and then 3. Set the special service tools as shown. remove the dog clutch 3. 4. Remove the ball bearing 5 from the pro- peller shaft housing. 68860075 3. Remove the shift slider 5 and spring 6. 68860090 Disassembling the propeller shaft Stopper guide plate 2:...

  • Page 139: Checking The Propeller Shaft Housing

    Propeller shaft housing Checking the propeller shaft hous- Assembling the propeller shaft housing 1. Check the propeller shaft housing. 1. Install a new needle bearing into the pro- Replace the propeller shaft housing if peller shaft housing to the specified cracked or corroded.
  • Page 140 LOWR Lower unit Lower unit NOTE: 2. Install the new oil seals into the propeller Install a new ball bearing with the identifica- shaft housing to the specified depth. tion mark e facing toward the forward gear side. Needle bearing attachment: 90890-06608 8 90890-06607 9 4.

  • Page 141: Assembling The Propeller Shaft Assembly

    Propeller shaft housing Assembling the propeller shaft assembly 1. Install the spring 1, dog clutch 2, shift slider 3, cross pin 4, and then install the shift plunger 5 temporarily. 68860160 NOTE: 9 Align the hole a of the dog clutch 2, hole b of shift slider 3 with the slot c of the propeller shaft and then install the dog clutch 2.

  • Page 142: Drive Shaft And Lower Case

    LOWR Lower unit Lower unit Drive shaft and lower case 95 N·m (9.5 kgf·m, 70.1 ft·lb) 6886040E Part name Q’ty Remarks Drive shaft Not reusable Taper roller bearing Pinion shim — Sleeve Not reusable Needle bearing Not reusable Oil seal M6 ×...

  • Page 143: Removing The Drive Shaft

    Drive shaft and lower case Removing the drive shaft Removing the shift rod 1. Loosen the pinion nut 1 as shown. 1. Remove the bolts 1, plate 2, shift rod 3, and then remove the shift cam 4. 68860180 68860325 Drive shaft holder 5 2: 90890-06519 Pinion nut holder 3:...

  • Page 144: Disassembling The Forward Gear

    LOWR Lower unit Lower unit Disassembling the forward gear 3. Remove the taper roller bearing outer 1. Remove the taper roller bearing from the race and shim(s). forward gear using a press. 69R60160 68860250 Stopper guide plate 5: 90890-06501 Do not reuse the bearing, always replace it Stopper guide stand 6: with a new one.

  • Page 145: Checking The Pinion And Forward Gear

    Drive shaft and lower case Checking the pinion and forward gear Do not reuse the bearing, always replace it 1. Check the teeth of pinion. Check the with a new one. teeth and dogs of forward gear. Replace the pinion and forward gear if cracked or worn.

  • Page 146: Assembling The Lower Case

    LOWR Lower unit Assembling the lower case 2. Install the sleeve, shim(s) and new taper 1. Install a new needle bearing into the roller bearing outer race. lower case to specified depth. 68860290 6F660280 Do not reuse the bearing, always replace it Do not reuse the bearing, always replace it with a new one.

  • Page 147: Installing The Shift Rod

    Drive shaft and lower case Installing the shift rod 3. Install the shim(s) and new taper roller 1. Install the shift cam 1, shift rod 2 and bearing outer race. plate 3, then tighten the bolts 4. 68860300 68860320 NOTE: Do not reuse the bearing, always replace it Install the shift cam 1 with the “UP”...

  • Page 148: Installing The Oil Seal Housing

    LOWR Lower unit Lower unit Installing the propeller shaft hous- 2. Tighten the pinion nut 4 to the specified torque. 1. Install a new O-ring 1. 2. Install the propeller shaft assembly 2 and shim(s) 3 into the propeller shaft housing assembly 4.

  • Page 149: Installing The Water Pump

    Drive shaft and lower case 4. Install the propeller shaft housing assem- 5. Make sure check the shift operation. bly 4, straight key 6 and lock washer 7 Disassemble and assemble the lower into the lower case, then tighten the ring case if operated improperly.
  • Page 150 LOWR Lower unit Lower unit 2. Install the Woodruff key 5 onto the drive 5. Install the water seal rubber 9 and grom- met 0 onto the water pump housing 8, shaft groove. then install onto the lower case. 3. Align the groove a in the impeller 6 with the Woodruff key 5, and then install the impeller.

  • Page 151: Installing The Lower Unit

    Drive shaft and lower case Installing the lower unit 2. Set the gear shift to “N” position at the lower unit. Make sure that the shift rod is in the neutral position. 9 When installing the lower unit without removing the power unit, be sure to sus- pend the outboard motor.
  • Page 152 LOWR Lower unit Lower unit 4. Install the dowels 4 onto the lower case 5. Install the lower unit to the upper case, and extension 5 (X, Y-transom). and then tighten the lower case bolts (nut) 6 to the specified torque. å...
  • Page 153 Drive shaft and lower case 9. Place a block of wood between the anti- 11. Insert a gear oil tube into the drain hole cavitation plate and the propeller, and and slowly fill the gear oil until oil flows then tighten the nut to the specified out of the check hole and no air bubbles torque.

  • Page 154: Shimming

    LOWR Lower unit Shimming 68860480 6-25 6885J11...

  • Page 155: Selecting The Pinion Shim

    Shimming Shimming Pinion height gauge plate B 1: 90890-06712 NOTE: 9 Shimming is not required when assembling Pinion height gauge 2: 90890-06710 the original lower case and inner parts. 9 Shimming is required when assembling a new lower case and the original inner parts. 2.

  • Page 156: Selecting The Forward Gear Shim

    LOWR Lower unit 4. Calculate the pinion shim thickness (T3) Example: as shown in the examples below. If “T3” is 0.43 mm, then the pinion shim is 0.45 mm. If “T3” is 0.38 mm, then the pinion shim is 0.38 mm. Selecting the forward gear shim 1.

  • Page 157: Selecting The Reverse Gear Shim

    Shimming 2. Calculate the forward gear shim thick- Example: ness (T1) as shown in the examples If “T1” is 0.44 mm, then the forward gear below. shim is 0.42 mm. If “T1” is 0.50 mm, then the forward gear shim is 0.48 mm. Selecting the reverse gear shim 1.

  • Page 158: Backlash

    LOWR Lower unit 3. Calculate the reverse gear shim thick- Example: ness (T2) as shown in the examples If “T2” is 0.47 mm, then the reverse gear below. shim is 0.48 mm. If “T2” is 0.41 mm, then the reverse gear shim is 0.42 mm.
  • Page 159 Shimming / Backlash 3. Install the special service tools so that it 4. Install the backlash indicator onto the pushes against the propeller shaft, and drive shaft (20.0 mm [0.79 in] in diame- then turn the lower unit 90° to the upside ter), then install the dial gauge onto the position.
  • Page 160 LOWR Lower unit 6. Add or remove shim(s) if out of specifica- tion. Forward gear Shim thickness backlash Less than To be decreased by (0.17 – M) × 0.60 0.08 mm (0.0032 in) More than To be increased by (M – 0.17) × 0.60 0.25 mm (0.0098 in) M: Measurement Available shim thicknesses:...
  • Page 161 Backlash 9. While pushing the drive shaft slightly, turn the drive shaft slowly clockwise and counterclockwise, then measure the backlash when the drive shaft stops in each direction. 68860520 Reverse gear backlash: 0.67–1.00 mm (0.0264–0.0394 in) 10. Add or remove the shim(s) if out of spec- ification.

  • Page 162: Bracket Unit

    BRKT Bracket unit Tiller handle ....................7-1 Checking the throttle cable and shift cable (EHD) ........7-3 Assembling the tiller handle (EHD) ............7-3 Lubricating the throttle gear (EHD) ............7-4 Bottom cowling .................... 7-5 Upper case, steering arm ................7-8 Disassembling the upper case ..............
  • Page 163 Gear pump ....................7-46 Disassembling the gear pump, down relief valve and main valve ..7-48 Disassembling the relief valve and manual valve ........7-49 Checking the gear pump ............... 7-49 Checking the main valve ............... 7-49 Checking the manual valve ..............7-50 Checking the gear housing ..............
  • Page 164 BRKT Bracket unit Tiller handle 11 N·m (1.1 kgf·m, 8.1 ft·lb) 37 N·m (3.7 kgf·m, 27.3 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 37 N·m (3.7 kgf·m, 27.3 ft·lb) 6887010E Part name Q’ty Remarks Throttle grip Washer Spring Bushing Tiller handle Grommet Throttle cable Plastic washer...
  • Page 165 Tiller handle 11 N·m (1.1 kgf·m, 8.1 ft·lb) 37 N·m (3.7 kgf·m, 27.3 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 37 N·m (3.7 kgf·m, 27.3 ft·lb) 6887010E Part name Q’ty Remarks Plate Shift lever Bushing Spring Ball Collar Washer Bushing Bracket M12 ×...

  • Page 166: Tiller Handle 2

    BRKT Bracket unit Checking the throttle cable and shift 3. Turn the throttle shaft 1 clockwise to cable (EHD) wind the inner cable until the bolt 6 1. Check the throttle cable and shift cable comes in contact with tiller handle. for smooth operation.

  • Page 167: Lubricating The Throttle Gear (Ehd)

    Tiller handle 6. Push the throttle grip so that the throttle grip holes are aligned with the throttle shaft holes. 68870030 Lubricating the throttle gear (EHD) 1. Inject grease into the grease nipple until grease comes out from the screw hole 69D70170 6885J11...

  • Page 168: Bottom Cowling

    BRKT Bracket unit Bottom cowling 6887020E Part name Q’ty Remarks Washer Bracket Bolt Spring Ball Bushing M8 × 30 mm : EHD Bolt Neutral switch assembly Shift lever Washer Bracket Shift lever Bushing Shift rod Seal Grommet 6885J11...
  • Page 169 Bottom cowling 4 N·m (0.4 kgf·m, 3.0 ft·lb) EHD, ED 6887030E Part name Q’ty Remarks Lock lever Bushing Bushing Wave washer Clamp lever M6 × 12 mm Bolt Grommet Grommet ED, ET Grommet Retaining plate M6 × 16 mm Bolt Warning indicator Clamp Bracket...
  • Page 170 BRKT Bracket unit 4 N·m (0.4 kgf·m, 3.0 ft·lb) EHD, ED 6887030E Part name Q’ty Remarks Clip Hose Grommet EHD, ED Grommet Grommet Collar Bracket ø6 × 20 mm Screw M6 × 30 mm Bolt 6885J11...

  • Page 171: Upper Case, Steering Arm

    Bottom cowling / Upper case, steering arm Upper case, steering arm X, Y 6887090E Part name Q’ty Remarks Washer Cover ø6 × 15 mm Screw Ground lead M8 × 25 mm Bolt Mount housing Spring Lower mount Rubber washer Washer M12 ×...
  • Page 172 BRKT Bracket unit X, Y 6887090E Part name Q’ty Remarks Upper mount Washer Rubber washer Washer M10 × 175 mm Bolt Damper Rubber seal Not reusable Upper case assembly 6885J11...
  • Page 173 Upper case, steering arm 21 N·m (2.1 kgf·m, 15.5 ft·lb) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 6887100E Part name Q’ty Remarks M8 × 30 mm Bolt Exhaust guide Gasket Not reusable Collar Gasket Not reusable Exhaust manifold M8 ×...

  • Page 174: Disassembling The Upper Case

    BRKT Bracket unit Disassembling the upper case 3. Remove the bolts q, exhaust manifold 1. Remove the bolts 1, muffler assembly w, gasket e and rubber seal r. 2, dowels 3 and rubber seal 4 from the upper case 5. 68870070 Checking the upper case 1.
  • Page 175 Upper case, steering arm 2. Install the rubber damper 5 onto the muffler 6. 3. Install the cooling water pipe 7 onto the muffler 6. 4. Install the new gasket 8, muffler 6 onto the exhaust guide assembly 9, and then tighten the bolts 0 to the specified torque.
  • Page 176 BRKT Bracket unit 8. Install the upper mounts r and bracket 10. Install the lower mounts i and mount y into the upper case assembly, and housings p, and then tighten the bolts a then tighten it with the bolts u. temporarily.
  • Page 177 Upper case, steering arm ED,ET 20 N·m (2.0 kgf·m, 14.8 ft·lb) 6887110E Part name Q’ty Remarks Steering hook ED, ET ED, ET Washer ED, ET Steering arm Washer Bushing O-ring Not reusable Bushing Clamp bracket assembly O-ring Not reusable Washer Steering yoke Circlip 6885J11...

  • Page 178: Removing The Steering Arm

    BRKT Bracket unit Removing the steering arm Checking the steering arm 1. Fully tilt the swivel bracket up, and then 1. Check the steering arm and steering support it with the tilt stop lever 1. yoke. Replace the steering arm and steering yoke if corroded, deformed or cracked.
  • Page 179 Upper case, steering arm 5. Install the steering yoke 0 to the steer- 7. Inject grease into the grease nipple until ing arm 5 by aligning the center a of the grease comes out from both the upper steering yoke with the center b of the and lower bushings c.

  • Page 180: Installing The Upper Case

    BRKT Bracket unit Installing the upper case 3. Install the covers. 1. Install the upper and lower mount assem- bly into the bracket assembly 1 simulta- neously. 2. Install the upper mount nuts 2 and lower mount nuts 3, and then tighten them. 68870250 68870230 STBD...
  • Page 181 Upper case, steering arm / Clamp bracket and swivel bracket Clamp bracket and swivel bracket EHD, ED 8 N·m (0.8 kgf·m, 5.9 ft·lb) 6887070E Part name Q’ty Remarks Bushing Bracket Bushing Shock absorber M6 × 10 mm Bolt Reverse lock lever Tilt lock lever Washer Joint...
  • Page 182 BRKT Bracket unit EHD, ED 15 N·m (1.5 kgf·m, 11.1 ft·lb) 6887050E Part name Q’ty Remarks Self-locking nut Clamp bracket Ground lead ø6 × 12 mm Screw Washer Bushing Grease nipple Ground lead Swivel bracket assembly Clamp bracket Through tube Spring Tilt pin Plate...

  • Page 183: Clamp Bracket And Swivel Bracket

    Clamp bracket and swivel bracket EHD, ED 15 N·m (1.5 kgf·m, 11.1 ft·lb) 6887050E Part name Q’ty Remarks Washer M6 × 12 mm Bolt M6 × 16 mm Bolt 6885J11 7-20...
  • Page 184 BRKT Bracket unit EHD, ED 30.3 30.4 mm (1.19 1.20 in) 6887040E Part name Q’ty Remarks Tilt stop lever Tilt stop lever Bushing Swivel bracket Spring Plate M6 × 10 mm Bolt Distance collar Bushing Collar Lever 7-21 6885J11...

  • Page 185: Removing The Clamp Bracket (Ehd, Ed)

    Clamp bracket and swivel bracket Removing the clamp bracket 3. Remove the caps 5, self-locking nut 6 (EHD, ED) and then ground lead 7. 9 Be sure to tilt the outboard motor fully and support it with the tilt stop lever. It can not be tilted up partially.

  • Page 186: Checking The Shock Absorber

    BRKT Bracket unit 6. Remove the starboard clamp bracket t 3. Remove the tilt stop levers 3. in the direction of the arrow shown in the 4. Remove the distance collar 4, collar 5 illustration. and lever 6. 7. Remove the washer y. 5.

  • Page 187: Assembling The Swivel Bracket (Ehd, Ed)

    Clamp bracket and swivel bracket Assembling the swivel bracket NOTE: Install the pins 7 so that they extend equal (EHD, ED) distances a. 1. Install the bushings 1 into the swivel bracket. 5. Install the spring 8 as shown. 2. Install the lever 2, collar 3, and then install the tilt stop lever 4 as shown.
  • Page 188 BRKT Bracket unit 8. Install the bushings w, bracket e and pin 2. Install the swivel bracket 4 to the clamp bracket 2. 3. Install the washer 3, starboard clamp bracket 5 and ground lead 6. 68870335 9. Install the anode t temporarily. 10.
  • Page 189 Clamp bracket and swivel bracket 6887080E Part name Q’ty Remarks Lock tie Not reusable Tube M10 × 45 mm Bolt Trim sensor lead PTT motor lead Circlip Bushing Bushing PTT unit Ground lead M6 × 10 mm Bolt 6885J11 7-26...
  • Page 190 BRKT Bracket unit 15 N·m (1.5 kgf·m, 11.1 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6887060E Part name Q’ty Remarks Self-locking nut Clamp bracket Ground lead ø6 × 12 mm Screw Washer Bushing Grease nipple Ground lead Swivel bracket assembly Trim stopper ø6 ×...
  • Page 191 Clamp bracket and swivel bracket 15 N·m (1.5 kgf·m, 11.1 ft·lb) 18 N·m (1.8 kgf·m, 13.3 ft·lb) 6887060E Part name Q’ty Remarks Spring Tilt pin Plate Anode Ground lead Washer M6 × 12 mm Bolt M6 × 16 mm Bolt 6885J11 7-28...
  • Page 192 BRKT Bracket unit 30.3 30.4 mm (1.19 1.20 in) 6887045E Part name Q’ty Remarks Tilt stop lever Tilt stop lever Bushing Swivel bracket Spring Plate M6 × 10 mm Bolt Distance collar Bushing Collar 7-29 6885J11...

  • Page 193: Removing The Ptt Unit (Et)

    Clamp bracket and swivel bracket Removing the PTT unit (ET) 3. Remove the tilt pin and 4 anode 5. 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. 4. Remove the bracket bolts 6. 68830390 68870455 5.

  • Page 194: Removing The Clamp Bracket (Et)

    BRKT Bracket unit 7. Remove the circlip 9, and then remove 4. Remove the through tube 6, clamp the pin 0. brackets 7, washers 8, swivel bracket 9, and then remove the bushings 0. 8. Remove the PTT unit q, bushings w and 68870430 5.

  • Page 195: Assembling The Swivel Bracket (Et)

    Clamp bracket and swivel bracket Assembling the swivel bracket (ET) Installing the PTT unit (ET) 1. Fully tilt the outboard motor up, and then NOTE: support it with the tilt stop lever 1. To assemble the swivel bracket, refer to page 7-24.

  • Page 196: Adjusting The Trim Sensor Cam (Et)

    BRKT Bracket unit 5. Tighten the self-locking nut 8 to the 9. Inject grease into all grease nipples until grease comes out from the bushings a. specified torque. 68870490 68830510 Self-locking nut 8: Adjusting the trim sensor cam (ET) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 1.
  • Page 197 Clamp bracket and swivel bracket 5. Fully tilt the outboard motor up, and then support it with the tilt stop lever 4. 68870530 6. Loosen the screws 5. 7. Adjust the position of the trim sensor, and then tighten the screws 5 temporarily. 68870510 8.

  • Page 198: Ptt Unit

    BRKT Bracket unit PTT unit 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 6887120E Part name Q’ty...
  • Page 199 PTT unit 7 N·m (0.7 kgf·m, 5.2 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 6887120E Part name Q’ty Remarks Bushing...

  • Page 200: Checking The Hydraulic Pressure

    BRKT Bracket unit Checking the hydraulic pressure Battery Rams PTT motor lead 1. Check the hydraulic pressure. Check the terminal internal parts if out of specification. Green (G) Down Blue (L) 2. Fully extend the PTT rams. 3. Loosen the pipe joints 1, and then Hydraulic pressure (down): remove the pipe joint a.
  • Page 201 PTT unit 9. Connect the PTT motor leads to the bat- PTT oil pressure gauge tery terminals to fully retract the trim and assembly 2: 90890-06580 tilt rams. 12. Hold the PTT unit 4 in a vice using alu- minum plates c on both sides. 13.
  • Page 202 BRKT Bracket unit 14. Reverse the PTT motor leads between 19. Connect the PTT motor leads to the bat- the battery terminals to fully retract the tery terminals to fully extend the trim and rams. tilt rams. 68870650 68870660 Battery Battery Rams PTT motor lead...
  • Page 203 PTT unit NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is removed. 68870670 Recommended PTT fluid: ATF Dexron 2 21. Install the new O-ring and reservoir cap 5, then tighten it to the specified torque.

  • Page 204: Ptt Motor

    BRKT Bracket unit PTT motor 3.4 N·m (0.34 kgf·m, 2.5 ft·lb) 6887130E Part name Q’ty Remarks Stator ø6 × 16 mm Screw Armature ø4 × 10 mm Screw Brush 1 Plate Bushing O-ring Not reusable Brush 2 Holder Spring PTT motor base Oil seal Not reusable 7-41...

  • Page 205: Disassembling The Ptt Motor

    PTT motor Disassembling the PTT motor 3. Remove the armature 7 from the stator 1. Remove the bolts 1, then remove the PTT motor 2, O-ring 3, and joint 4 from the PTT unit. 68870700 Do not allow grease or oil to contact the commutator 8.

  • Page 206: Checking The Ptt Motor

    BRKT Bracket unit 5. Remove the O-ring 0, screws q, then 2. Measure the commutator diameter. remove the brushes w and springs e. Replace the armature if below specifica- tion limit. 6F680175 Digital caliper 1: 90890-06704 Commutator standard diameter a: 68870720 22.0 mm (0.87 in) Wear limit:...

  • Page 207: Assembling The Ptt Motor

    PTT motor Assembling the PTT motor 4. Check the armature for continuity. 1. Install new O-ring 1 springs 2 and Replace the armature if not shown in the brushes 3, and then tighten the screws chart below. 69R80320 Armature continuity: c d e f Tester probe 68870740...
  • Page 208 BRKT Bracket unit 3. Push the brushes 3 into the brush hold- er, and then install the armature 6. 68870760 4. Install the stator 7 onto the PTT motor base. 68870770 NOTE: Place a rag over the end of the armature shaft, hold it with a pair of pliers, and then carefully slide the stator over the armature.
  • Page 209 PTT motor / Gear pump Gear pump 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6887140E Part name Q’ty Remarks Spring Filter M4 × 25 mm Bolt Gear housing 1 Ball Driven gear Drive gear Gear housing 2 O-ring Not reusable Down-relief spring...
  • Page 210 BRKT Bracket unit 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6887150E Part name Q’ty Remarks ø5 × 10 mm Screw Trim spring Up-relief spring Valve support pin Relief valve seal Relief valve seat O-ring Not reusable Filter Valve lock screw O-ring Not reusable Ball Washer...

  • Page 211: Gear Pump

    Gear pump Disassembling the gear pump, down 6. Hold the gear pump assembly 4 in a vice relief valve and main valve using aluminum plates a on both sides, and then remove the pins q. 1. Drain the PTT fluid. 2.

  • Page 212: Disassembling The Relief Valve And Manual Valve

    BRKT Bracket unit Disassembling the relief valve and 4. Remove the circlip r, then remove the manual valve manual valve t, manual valve seal y, spring u, adapter i, spring o, manual 1. Drain the PTT fluid. valve seal p and O-ring a. 2.

  • Page 213: Checking The Manual Valve

    Gear pump Checking the manual valve 2. Check the valve seal and valve seat. 1. Check the manual valve 1. Clean the Clean the valve seal and valve seat if dirt manual valve if dirt or residue appears. or residue appears. Replace them if dam- aged or worn.
  • Page 214 BRKT Bracket unit 2. Install the filter 6 and new O-ring 7 into 4. Install the trim spring w, and then tighten the screws e to the specified torque. the PTT body. 68870930 68870910 Trim spring screw e: 3. Install the relief valve seal 8, valve sup- 4 N·m (0.4 kgf·m, 3.0 ft·lb) port pin 9 and up-relief spring 0 into the relief valve seat q, then install into the...

  • Page 215: Assembling The Gear Pump

    Gear pump Assembling the gear pump NOTE: Inject a small amount fluid to the gear pump 1. Install the drive gear 1 and driven gear 2 and balls 3 into the gear housing 1 assembly, and then rotate the drive gear in the direction shown.

  • Page 216: Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit Tilt cylinder and trim cylinder 65 N·m (6.5 kgf·m, 47.9 ft·lb) 90 N·m (9.0 kgf·m, 66.4 ft·lb) 160 N·m (16.0 kgf·m, 118 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 6887160E Part name Q’ty Remarks Tilt ram Dust seal Not reusable Tilt cylinder end screw Backup ring...
  • Page 217 Tilt cylinder and trim cylinder 65 N·m (6.5 kgf·m, 47.9 ft·lb) 90 N·m (9.0 kgf·m, 66.4 ft·lb) 160 N·m (16.0 kgf·m, 118 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 6887160E Part name Q’ty Remarks Tilt piston assembly Tilt ram assembly Tilt cylinder assembly Free piston O-ring...

  • Page 218: Disassembling The Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit Disassembling the tilt cylinder and 3. Hold the tilt cylinder 5 in a vice using trim cylinder aluminum plates a on both sides. 1. Loosen the pipe joint, then remove the pipes 1, 2 and 3. 4. Loosen the tilt cylinder end screw, and then remove the tilt ram assembly.
  • Page 219 Tilt cylinder and trim cylinder 6. Blow compressed air through the hole b 8. Remove the tilt piston absorber valves 8. to remove the free piston 7. 68871050 9. Remove the O-ring 9 and backup ring Never look into the tilt cylinder opening when removing the free piston.

  • Page 220: Checking The Tilt Cylinder And Trim Cylinder

    BRKT Bracket unit 12. Hold the PTT body e in a vice using alu- 3. Check the tilt piston 1 and free piston 2. minum plates a on both sides. Replace the tilt piston and free piston if worn or deteriorated. 13.

  • Page 221: Assembling The Tilt Ram

    Tilt cylinder and trim cylinder Assembling the tilt ram 3. Hold the tilt piston in a vice using the alu- minum plates a and special service tool 8 on both sides. Do not use a rag when assembling the PTT unit as dust and particles on the PTT 4.

  • Page 222: Assembling The Trim Ram

    BRKT Bracket unit Assembling the trim ram Installing the tilt cylinder 1. Install the new O-ring 1, backup ring 2 1. Install the new O-ring 1 to the free pis- onto the trim piston 3. ton 2. 2. Push the free piston 2 into the tilt cylin- der 3 until it bottoms out.

  • Page 223: Installing The Trim Ram

    Tilt cylinder and trim cylinder Installing the trim ram Do not push the trim rams down while installing them into the trim cylinders. Do not use a rag when installing the PTT Otherwise, the PTT fluid may spurt out unit as dust and particles on the PTT unit from the unit.

  • Page 224: Installing The Reservoir

    BRKT Bracket unit 4. Install the new O-ring 4 and PTT motor 2. Fill the PTT fluid into the reservoir, and 5, and then tighten the bolts to the spec- then install the new O-ring 4 and reser- voir cap 5, and then tighten it to the ified torque.

  • Page 225: Bleeding The Ptt Unit

    Tilt cylinder and trim cylinder 3. Install the tilt ram assembly into the tilt 3. Remove the reservoir cap, and then cylinder, and then tighten the tilt cylinder check the fluid level in the reservoir. end screw 1 to the specified torque. NOTE: The fluid level should be at the brim of the filler hole.

  • Page 226: Bleeding The Ptt Unit (Built-In)

    BRKT Bracket unit NOTE: 3. Let the fluid settle for 5 minutes. 9 Repeat this procedure so that the rams go up and down 4–5 times (be sure to wait for 4. Push and hold the PTT switch in the up 2–3 seconds before switching the leads).

  • Page 227: Ptt Electrical System

    Tilt cylinder and trim cylinder / PTT electrical system PTT electrical system Lead color Tester Checking the fuse Orange Pink probe 1. Check the fuse (20A) for continuity. Replace if there is no continuity. Test harness – NOTE: Test harness Fuse position, refer to page 8-3.

  • Page 228: Checking The Trim Sensor

    BRKT Bracket unit Checking the trim sensor 6. Connect the sky blue (Sb) lead to the 1. Measure the trim sensor resistance. positive battery terminal and the black (B) Replace if out of specification. lead to the negative battery terminal as shown.

  • Page 229: Elec

    ELEC Electrical system Checking the electrical component..............8-1 Measuring the peak voltage ..............8-1 Electrical component ..................8-2 Starboard view...................8-2 Ignition and ignition control system ............8-4 Checking the ignition spark gap ..............8-4 Checking the spark plug cap (with resister type) ........8-4 Checking the spark plug cap ..............8-5 Checking the ignition coil................8-5 Checking the CDI unit................8-6 Checking the pulser coil ................8-7...

  • Page 230: Electrical System

    ELEC Electrical system Checking the electrical NOTE: 9 Before measuring the peak voltage, check component all wiring for proper connection and corro- Measuring the peak voltage sion, and check that the battery is fully To check the electrical components or mea- charged.

  • Page 231: Electrical Component

    Checking the electrical component / Electrical component Electrical component Starboard view 55DEHD, 75AEHD, 85AEHD B / W 6888010E 1 Ignition coil #1 8 Engine start switch r Warning indicator : Blue 2 Ignition coil #2 9 Engine stop lanyard t Thermoswitch...
  • Page 232 ELEC Electrical system 75AED, 75AET, 85AED, 85AET B / W 6888020E 1 Ignition coil #1 9 Fuse (20A) B : Black : White 2 Ignition coil #2 0 Rectifier Regulator Br : Brown B/W : Black/white 3 Ignition coil #3 q Choke solenoid G : Green G/W : Green/white...

  • Page 233: Ignition And Ignition Control System

    Electrical component / Ignition and ignition control system Ignition and ignition control sys- Checking the spark plug cap (with resister type) 1. Check the spark plug caps. Replace the Checking the ignition spark gap spark plug caps if cracked or damaged. 1.

  • Page 234: Checking The Ignition Coil

    ELEC Electrical system Checking the spark plug cap 3. Disconnect the ignition coil connector, 1. Check the spark plug caps. Replace the and then remove the spark plug cap. spark plug caps if cracked or damaged. 4. Remove the ignition coil from the power 2.

  • Page 235: Checking The Cdi Unit

    Ignition and ignition control system Checking the CDI unit CDI unit output peak voltage: z Black/white (B/W)–Ground (B) NOTE: x Black/white (B/W)–Ground (B) Be sure to install the test propeller before c Black/white (B/W)–Ground (B) checking the peak voltage. Loaded r/min Cranking 1,500...

  • Page 236: Checking The Pulser Coil

    ELEC Electrical system Checking the pulser coil 6. Measure the pulser coil resistance. 1. Remove the cover. Replace the pulser coil assembly if out of specification. 2. Connect the test harness 1 and digital circuit tester with peak voltage adapter B to the pulser coil coupler 2.

  • Page 237: Checking The Thermoswitch

    Ignition and ignition control system Checking the thermoswitch Charge coil output peak voltage: 1. Remove the thermoswitch from cylinder Red (R)–Blue (L) head. Unloaded Loaded r/min NOTE: Cranking 1,500 3,500 To remove the thermoswitch, refer to page 5- DC V Charge coil output peak voltage: 2.

  • Page 238: Checking The Warning Indicator (Ehd)

    ELEC Electrical systems Checking the warning indicator 2. Check the engine start switch for continu- (EHD) ity at the main harness coupler. Check 1. Disconnect the warning indicator connec- the wiring harness or replace the engine tor. start switch of the remote control box or tiller handle if it is not shown in the chart 2.

  • Page 239: Checking The Engine Stop Lanyard Switch

    Ignition and ignition control system / Starting system ∫ ∫ 68880115 68880145 Lead color Lead color Switch position White (W) Black (B) White Black Pink Brown Switch (Br) Lock plate position removed a Lock plate installed b START ∫ EHD å...

  • Page 240: Checking The Starter Relay

    ELEC Electrical system Checking the starter relay 4. Check the neutral switch for continuity. 1. Remove the cover and starter relay. Replace the neutral switch if it is not shown in the chart below. 2. Connect the digital circuit tester to the starter relay terminals.
  • Page 241 Starting system / Starter motor Starter motor 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6888030E Part name Q’ty Remarks ø4 × 10 mm Screw Cover Not reusable Clip Pinion stopper Not reusable Spring Pinion Bushing Front bracket Washer — Armature Stator assembly Spring washer Washer Holder...
  • Page 242 ELEC Electrical systems 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6888030E Part name Q’ty Remarks Brush holder Rear bracket Cover ø4 × 12 mm Screw M5 × 130 mm Bolt 8-13 6885J11...

  • Page 243: Removing The Starter Motor Pinion

    Starter motor Removing the starter motor pinion 4. Mark the alignment line on the starter 1. Remove the starter motor from the power motor before disassembly. unit. NOTE: To remove the starter motor, refer to page 5- 2. Remove the cover, and then remove the spring 1 from the starter motor.

  • Page 244: Checking The Brush

    ELEC Electrical systems 2. Measure the commutator diameter a. 4. Check the armature for continuity. Replace the armature if below specifica- Replace the armature if it is not shown in tion limit. the chart below. 6F680175 Digital caliper 1: 90890-06704 69R80320 Standard diameter a: 33.0 mm (1.30 in)

  • Page 245: Installing The Starter Motor Pinion

    Starter motor / Charging system Charging system 2. Check the brush holder assembly for continuity. Replace the brush holder if it is Checking the lighting coil not shown in the chart below. 1. Remove the cover. 2. Disconnect the lighting coil connector. 3.

  • Page 246: Checking The Rectifier Regulator

    ELEC Electrical systems 6. Measure the lighting coil resistance. 3. Measure the Rectifier Regulator output Replace the stator assembly if out of peak voltage. If less than specification, specification. measure the lighting coil output peak voltage. Replace the Rectifier Regulator if the output peak voltage of the lighting coil is more than specification.

  • Page 247: Trbl Shtg

    TRBL TRBL SHTG SHTG Troubleshooting Troubleshooting the power unit ..............9-1 Troubleshooting the power unit ..............9-1 Troubleshooting the PTT unit ..............9-7 Troubleshooting the lower unit ..............9-9 6885J11...

  • Page 248: Contents

    TRBL TRBL SHTG SHTG Troubleshooting Troubleshooting the power unit Troubleshooting the power unit Symptom 1: Specific trouble conditions. Symptom 2: Trouble conditions of an area or individual part. Cause 1: The content considered as the trouble factors of symptom 2. Cause 2: The content considered as the trouble causes of cause 1 (described if necessary).
  • Page 249 Troubleshooting the power unit Symptom 1: Engine dose not crank Refer Symptom 2 Cause 1 Cause 2 Checking step page Broken woodruffkey Stuck piston and crank Disassemble and shaft — check the power unit. Piston lock due to — water in the combus- tion chamber Salt buildup on the Disassemble and check...
  • Page 250 TRBL SHTG Troubleshooting Refer Symptom 2 Cause 1 Cause 2 Checking step page CDI unit output Measure the charge peak voltage CDI unit malfunction coil output peak voltage less than speci- and resistance. fications Measure the pulser coil Pulser coil out- resistance.

  • Page 251: Fuel

    Trouble shooting the power unit Symptom 1: Unstable engine idle speed, poor acceleration Refer Symptom 2 Cause 1 Cause 2 Checking step page Throttle stop screw Check and adjust the — adjusting improperly throttle stop screw. Pilot screw adjusting Check and adjust the —...
  • Page 252 TRBL SHTG Troubleshooting Symptom 1: Limited engine speed (below 2,000 r/min) Refer Symptom 2 Cause 1 Cause 2 Checking step page Clogged cooling water Check the cooling — inlet water inlet. Check the impeller. Water pump impeller Check the Woodruff malfunction key.
  • Page 253 Trouble shooting the power unit Symptom 1: Poor performance Refer Symptom 2 Cause 1 Cause 2 Checking step page Spark plug gap Check the spark plug Spark plug malfunction improperly gap and condition. Short or open connec- Check the wiring har- tion in ignition coil cir- —...

  • Page 254: Troubleshooting The Ptt Unit

    TRBL SHTG Troubleshooting Troubleshooting the PTT unit Symptom 1: PTT unit does not operate Refer Symptom 2 Cause 1 Cause 2 Checking step page Short, open, or loose Check the wiring har- connection of the — ness for continuity. PTT relay does wiring harness not operate PTT relay malfunction...
  • Page 255 Troubleshooting the PTT unit Symptom 1: PTT unit does not hold the outboard motor up Refer Symptom 2 Cause 1 Cause 2 Checking step page Manual valve Check the manual Manual valve opened — malfunction valve for open. Insufficient PTT fluid —...

  • Page 256: Shtg

    TRBL SHTG Troubleshooting Troubleshooting the lower unit Symptom 1: Gear shift does not operate properly Refer Symptom 2 Cause 1 Cause 2 Checking step page Remote control box Check and adjust the — — malfunction remote control box. Check the shift cable 3-13 Shift cable and shift and shift cable end.
  • Page 257 Index (ED, ET) ..........3-14 Checking the compression pressure ..5-1 Abbreviation ..........1-3 Checking the connecting rod big end Adjusting the throttle cable ...... 3-7 side clearance ........5-28 Adjusting the trim sensor cam (ET) ..7-33 Checking the connecting rod small end After test run ..........
  • Page 258 Index Checking the pinion and forward gear ... 6-16 Disassembling the carburetor ....4-13 Checking the piston diameter ....5-27 Disassembling the crankshaft ....5-26 Checking the piston pin ......5-25 Disassembling the drive shaft ....6-14 Checking the piston pin boss bore ..5-27 Disassembling the forward gear ....
  • Page 259 Install the control lever and throttle Removing the clamp bracket (ET) ..7-31 cam ............5-38 Removing the control lever and throttle Installing the clamp bracket (ET) ... 7-32 cam ............5-12 Installing the drive shaft ......6-18 Removing the crankcase ....... 5-24 Installing the electrical component ..
  • Page 260 — MEMO —...
  • Page 261 — MEMO —...

  • Page 262: Lowr

    WIRING DIAGRAM 55DEHD, 75AEHD, 85AEHD Color code : Black 1 Spark plug : Brown 2 Ignition coil : Green 3 Thermoswitch : Blue 4 Starter relay 5 Rectifier Regulator : Pink : Red 6 CDI unit : White 7 Lighting coil...
  • Page 264 YAMAHA MOTOR CO., LTD. Printed in Japan Oct. 2006 – 1.1 × 1 ! Printed on recycled paper (E_2)
  • Page 265 55DEHD, 75AEHD, 85AEHD 1 2 3 4 1 3 2 3 2 4 688CWD0A...
  • Page 266 75AED, 85AED Color code 1 Spark plug : Black : Brown 2 Ignition coil : Green 3 Thermoswitch 4 Starter relay : Blue 5 Rectifier Regulator : Pink : Red 6 CDI unit 7 Lighting coil : White 8 Charge coil B/W : Black/White G/W : Green/White 9 Pulser coil...
  • Page 267 75AED, 85AED 1 2 3 4 1 3 2 3 2 4 688CWD01...
  • Page 268 75AET, 85AET Color code 1 Spark plug : Black : Brown 2 Ignition coil : Green 3 Thermoswitch 4 Starter relay : Blue 5 Rectifier Regulator : Pink : Red 6 CDI unit 7 Lighting coil : White 8 Charge coil : Light green : Sky blue 9 Pulser coil...
  • Page 269 75AET, 85AET 1 2 3 4 1 3 2 2 1 3 688CWD02...

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