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Yamaha F6Z Service Manual

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SERVICE MANUAL
LIT-18616-02-19
F6Z
F8Z
68T-28197-ZA-11

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Summary of Contents for Yamaha F6Z

  • Page 1 SERVICE MANUAL LIT-18616-02-19 68T-28197-ZA-11...
  • Page 2 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...

  • Page 3: Table Of Contents

    HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organised in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handly reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
  • Page 4 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the outboard motor.

  • Page 5: How To Use This Manual

    HOW TO USE THIS MANUAL 1 The main points regarding removing/installing and disassembly/assembly procedure are shown in the exploded views. 2 The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. 3 Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page.

  • Page 6: Specifications

    (A)] Symbols F to I in an exploded diagram indicate the grade of lubricant and the location of the lubricant point. F Apply Yamaha 4-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply Yamaha grease D...
  • Page 7 CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECK AND ADJUSTMENT FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEM TROUBLE ANALYSIS...
  • Page 8 CHAPTER 1 GENERAL INFORMATION IDENTIFICATION....................1-1 SERIAL 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 AND ASSEMBLY .............1-4 SPECIAL TOOLS ....................1-5 MEASURING ....................1-5 REMOVING AND INSTALLING ..............1-7...

  • Page 9: Identification

    IDENTIFICATION IDENTIFICATION SERIAL NUMBER The outboard motor’s serial number is stamped on a label which is attached to the port clamp bracket. NOTE: As an antitheft measure, a special label on which the outboard motor’s serial number is stamped is bonded to the port clamp bracket.

  • Page 10: Safety While Working

    Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing. OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.

  • Page 11: Good Working Practices

    SAFETY WHILE WORKING Under normal conditions or use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all- important, and by adopting good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1.

  • Page 12: Disassembly And Assembly

    SAFETY WHILE WORKING 3. Non-reusable items Always use new gaskets, packings, O- rings, split-pins, circlips, etc., on reassembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly. 3. After assembly, check that moving parts operate normally.

  • Page 13: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment. NOTE: For U.S.A. and Canada, use part numbers that start with “J-”, “YB-” “YM-”, “YU-”...
  • Page 14 SPECIAL TOOLS 9 Bearing house puller P/N. YB-06234 0 Universal puller P/N. YB-06117 N.A. A Dial gauge stand P/N. YU-03097 90890-01252 B Magnet base P/N. YU-34481 90890-06705 C Backlash indicator P/N. YU-06265 90890-06706 D Magnetic base attaching plate P/N. YB-07003 90890-07003...

  • Page 15: Removing And Installing

    SPECIAL TOOLS REMOVING AND INSTALLING 1 Flywheel holder P/N. YB-06139 ....... 90890-06522 ......2 Universal puller P/N. YB-06117 ....... 90890-06521 ......3 Valve spring compressor P/N. YM-01253 90890-04019 4 Valve spring compressor attachment P/N. YM-04108 90890-04108 5 Valve guide remover P/N.
  • Page 16 SPECIAL TOOLS D Bearing puller assembly P/N. N.A. 90890-06535 E Bushing installer center bolt P/N. YB-06029 ....... 90890-06601 ......F Driver rod (small) P/N. YB-06229 ....... 90890-06652 ......G Driver rod (large) P/N. YB-06071 ....... 90890-06606 ......H Driver rod (short) P/N.
  • Page 17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS (F6AMH/F6MH) ..........2-1 GENERAL SPECIFICATIONS (F8CMH/F8MH) ..........2-3 MAINTENANCE SPECIFICATIONS..............2-5 POWER UNIT....................2-5 LOWER UNIT....................2-8 ELECTRICAL ....................2-9 OUTBOARD DIMENSIONS..............2-11 BRACKET DIMENSIONS................2-13 TIGHTENING TORQUES ................2-14 SPECIFIED TORQUES ................2-14 GENERAL TORQUES ................2-16...

  • Page 18: General Specifications (F6Amh/F6Mh)

    GENERAL SPECIFICATIONS (F6AMH/F6MH) GENERAL SPECIFICATIONS (F6AMH/F6MH) Model Item World wide Unit F6AMH USA, Canada F6MH DIMENSION Overall length mm (in) 1,031 (40.6) Overall width mm (in) 419 (16.5) Overall height mm (in) 998 (39.3) mm (in) 1,125 (44.3) WEIGHT (with aluminum propeller) kg(lb) 38.0 (83.8) kg(lb)
  • Page 19 GENERAL SPECIFICATIONS (F6AMH/F6MH) Model Item World wide Unit F6AMH USA, Canada F6MH FUEL AND OIL Fuel type Unleaded regular gasoline Fuel rating PON(* 1 ) Engine oil type RON(* 2 ) Engine oil grade 4-stroke engine oil API SE, SF, SG or SH SAE 10W-30, 10W-40 Total quantity (US oz,...

  • Page 20: General Specifications (F8Cmh/F8Mh)

    GENERAL SPECIFICATIONS (F8CMH/F8MH) GENERAL SPECIFICATIONS (F8CMH/F8MH) Model Item World wide Unit F8CMH USA, Canada F8MH DIMENSION Overall length mm (in) 1,031 (40.6) Overall width mm (in) 419 (16.5) Overall height mm (in) 998 (39.3) mm (in) 1,125 (44.3) WEIGHT (with aluminum propeller) kg (lb) 38.0 (83.8) kg (lb)
  • Page 21 GENERAL SPECIFICATIONS (F8CMH/F8MH) Model Item World wide Unit F8CMH USA, Canada F8MH FUEL AND OIL Fuel type Unleaded regular gasoline Fuel rating PON(* 1 ) Engine oil type RON(* 2 ) Engine oil grade 4-stroke engine oil API SE, SF, SG or SH SAE 10W-30, 10W-40 Total quantity (US oz,...

  • Page 22: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS POWER UNIT Model Item World wide Unit F6AMH F8CMH USA, Canada F6MH F8MH CYLINDER HEAD Warpage mm (in) 0.1 (0.004) limit CYLINDER BODY Bore (D1, D2) mm (in) 56.000 - 56.015 (2.2047 - 2.2053) Taper limit mm (in) 0.08 (0.0031) Out-of-round limit...
  • Page 23 MAINTENANCE SPECIFICATIONS Model Item World wide Unit F6AMH F8CMH USA, Canada F6MH F8MH Face width “B” mm (in) 1.84 - 2.26 (0.072 - 0.089) mm (in) 1.84 - 2.26 (0.072 - 0.089) Seat width”C” mm (in) 0.6 - 0.8 (0.023 - 0.031) mm (in) 0.6 - 0.8 (0.023 - 0.031) Mergin thickness “D”...
  • Page 24 MAINTENANCE SPECIFICATIONS Model Item World wide Unit F6AMH F8CMH USA, Canada F6MH F8MH 2nd ring Dimension (B) mm (in) 1.5 (0.06) Dimension (T) mm (in) 2.5 (0.10) End gap (installed) mm (in) 0.30 - 0.45 (0.012 - 0.018) Side clearance mm (in) 0.03 - 0.07(0.012 - 0.0028) Oil ring...

  • Page 25: Lower Unit

    MAINTENANCE SPECIFICATIONS Model Item World wide Unit F6AMH F8CMH USA, Canada F6MH F8MH OIL PUMP Discharge (@ 3,000 r/min) L/h (US gal/h, Abobe 3.5 (0.925, 0.77) Imp gal/h) Outer rotor-housing mm (in) 0.10 - 0.15 (0.004 - 0.006) clearance Outer rotor-inner rotor mm (in) 0.04 - 0.14 (0.002 - 0.006) clearance...

  • Page 26: Electrical

    MAINTENANCE SPECIFICATIONS ELECTRICAL Model Item World wide Unit F6AMH F8CMH USA, Canada F6MH F8MH IGNITION SYSTEM Ignition timing Degree (BTDC) 5 - 30 Charge coil output peak voltage (Br – L) @ cranking (opened) @ cranking (closed) @ 1,500 r/min @ 3,500 r/min Pulser coil output peak voltage (W/R –...
  • Page 27 MAINTENANCE SPECIFICATIONS Model Item World wide Unit F6AMH F8CMH USA, Canada F6MH F8MH STARTER MOTOR Type Bendix Rating Second Output Brush length mm (in) 12.5 (0.49) Brush length limit mm (in) 9.0 (0.35) Commutator diameter mm (in) 30.0 (1.18) Commutator diameter limit mm (in) 29.0 (1.14) CHARGING SYSTEM...

  • Page 28: Outboard Dimensions

    MAINTENANCE SPECIFICATIONS OUTBOARD DIMENSIONS 2-11...
  • Page 29 MAINTENANCE SPECIFICATIONS Symbol Model World wide Unit F6AMH F8CMH USA, Canada F6MH F8MH mm (in) 430 (16.9) mm (in) 121.5 (4.8) mm (in) 601 (23.7) mm (in) 355 (14.0) mm (in) 72 (2.8) mm (in) 98.5 (3.9) mm (in) 705.5 (27.8) mm (in) 822 (32.4) mm (in)

  • Page 30: Bracket Dimensions

    MAINTENANCE SPECIFICATIONS BRACKET DIMENSIONS Symbol Model World wide Unit F6AMH F8CMH USA, Canada F6MH F8MH mm (in) 70.5 (2.8) mm (in) 198 (7.8) mm (in) 95.3 (3.8) mm (in) 112 (4.4) mm (in) 105.3 (4.1) mm (in) 207 (8.1) mm (in) —...

  • Page 31: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torques Part Thread Parts to be tightened Q’ty Remarks name size TOP COWLING Top cowling hook mounting Bolt FUEL SYSTEM Fuel joint mounting Bolt Fuel pump housing Screw 0.15 1.11 Fuel pump check valve Screw 0.05 0.37...
  • Page 32 TIGHTENING TORQUES Part Thread Tightening torques Parts to be tightened Q’ty Remarks name size Water inlet cover mounting Screw Ground terminal mounting Screw BRACKET Shift handle mounting Bolt 0.35 Cowling clamp mounting Bolt Bottom cowling mounting Bolt Handle bracket mounting 26.5 Handle throttle grip Screw...

  • Page 33: General Torques

    TIGHTENING TORQUES GENERAL TORQUES General torque specifications This chart specifies tightening torques for Nut (A) Bolt (B) standard fasteners with a standard ISO thread pitch. Tightening torque 8 mm specifications for special components or 10 mm assemblies are provided in applicable 12 mm sections of this manual.
  • Page 34 CHAPTER 3 PERIODIC CHECK AND ADJUSTMENT MAINTENANCE INTERVAL CHART ............... 3-1 TOP COWLING ....................3-2 CHECKING THE WATER DRAIN HOLE ........... 3-2 CHECKING THE TOP COWLING FIT ............3-2 FUEL SYSTEM ....................3-3 CHECKING THE FUEL LINE ..............3-3 CONTROL SYSTEM ..................3-4 ADJUSTING THE SHIFT CONTROL CABLE ..........3-4 ADJUSTING THE THROTTLE CONTROL CABLES ........

  • Page 35: Maintenance Interval Chart

    Propeller Check/replace GENERAL: Anode Check/replace 3-17 Battery Check/replace (every 1 month) 3-17 Spark plug Cleaning/ 3-18 adjust/ replace Wiring and connector Check/ – reconnect Bolts and nuts Tighten – Lubrication points Grease 3-20 *1..If Yamaha portable fuel tank is used.

  • Page 36: Top Cowling

    TOP COWLING TOP COWLING CHECKING THE WATER DRAIN HOLE Check: Water drain hole 1 Obstruction Clean. CHECKING THE TOP COWLING FIT 1. Check: Top cowling fit Loose/unlatched Adjust the top cowling hook. 2. Adjust: Top cowling hook position Adjusting steps: (1)Loosen the bolt 1 approximately 1/4 of a turn.

  • Page 37: Fuel System

    FUEL SYSTEM FUEL SYSTEM CHECKING THE FUEL LINE Check: Fuel line Cracks/damage/leak Replace the defective part(s). Refer to “REMOVING/INSTALLING THE FUEL JOINT, FUEL FILTER AND FUEL PUMP” on page 4-1. CAUTION: When replacing the fuel filter, the arrow mark must face toward the fuel pump.

  • Page 38: Control System

    CONTROL SYSTEM CONTROL SYSTEM ADJUSTING THE SHIFT CONTROL CABLE 1. Check: Shift control cable Damage Replace. Incorrect shift handle position/poor shifting Adjust. 2. Adjust: Shift control cable Adjusting steps: (1)Move the shift handle so the shift rod lever 1 is in the neutral position. (2)Remove the locknut 2.

  • Page 39: Adjusting The Throttle Control Cables

    CONTROL SYSTEM ADJUSTING THE THROTTLE CONTROL CABLES NOTE: Before adjusting the throttle control cables, make sure that the shift control cable is properly adjusted (for long handle model only). 1. Check: Throttle control cables Damage Replace. Excessive slack or the stoppers do not contact each other Adjust.

  • Page 40: Adjusting The Throttle Axle Link

    CONTROL SYSTEM ADJUSTING THE THROTTLE AXLE LINK NOTE: Before adjusting the throttle axle link, make sure that the throttle control cables is properly adjusted. 1. Check: Throttle axle link Bend/damage Replace. Incorrect position Adjust. 2. Adjust: Throttle axle link Adjusting steps: (1)Loosen lock screw 1.

  • Page 41: Adjusting The Engine Idling Speed

    CONTROL SYSTEM ADJUSTING THE ENGINE IDLING SPEED NOTE: Before adjusting the engine idling speed, make sure the throttle axle link is properly adjusted. Before adjusting the engine idling speed, warm-up the engine. Correct adjustment cannot be obtained when the engine is cold.

  • Page 42: Adjusting The Start-In-Gear Protection Device

    CONTROL SYSTEM ADJUSTING THE START-IN-GEAR PROTECTION DEVICE 1. Check: Start-in-gear protection device operation Incorrect Adjust. 2. Adjust: Start-in-gear protection cable. Adjusting steps: (1)Set the shift lever in the neutral position. (2)Loosen the locknut 1. (3)Adjust the adjusting nut 2 so that the point on the wire connector 3 aligns with the mark...

  • Page 43: Power Unit

    POWER UNIT POWER UNIT CHECKING THE ENGINE OIL LEVEL Check: Engine oil level (At engine stopped) Above Check if there is any fuel or water mixed with the engine oil. If no abnormality is found, drain the oil until the level is between Below Add engine oil so that the level is between...

  • Page 44: Adjusting The Valve Clearance

    POWER UNIT ADJUSTING THE VALVE CLEARANCE NOTE: Valve clearance adjustment shoule be carried out when the engine is “cold”. 1. Remove: Recoil starter 1 Dust cover 2 Fuel pump 3 Cylinder head cover 4 2. Check: Intake valve clearance Exhaust valve clearance Out of specification Adjust.
  • Page 45 POWER UNIT 3. Adjust: Intake valve clearance Exhaust valve clearance Adjusting steps: (1)Loosen the locknut 8. (2)Turn the adjusting screw 9 in or out until the specified valve clearance is obtained. (3)Tighten the locknut 8. Locknut: m (0.8 kgf m, 5.9 ft (4)Perform the above steps for all valves which clearance are out of specification.

  • Page 46: Measuring The Compression Pressure

    POWER UNIT MEASURING THE COMPRESSION PRESSURE NOTE: Before measuring the compression pressure, warm-up the engine. Correct measurement cannot be obtained when the engine is cold. Measure: Compression pressure Below minimum compression pressure Check the valve clearance, valve face, valve seat, piston rings, cylinder sleeve, piston, cylinder head gasket and cylinder head.

  • Page 47: Checking The Ignition Timing

    POWER UNIT CHECKING THE IGNITION TIMING NOTE: Ignition timing is automatically controlled by the CDI unit. Therefore, only checking the procedure is shown in this section. Before ignition timing, warm-up the engine. Correct checking cannot be obtained when the engine is cold. Check: Ignition timing Incorrect firing range...

  • Page 48: Checking The Timing Belt

    COOLING SYSTEM CHECKING THE TIMING BELT 1. Remove: Recoil starter 1 Dust cover 2 2. Check: Timing belt Wear/damage Replace. NOTE: Install the timing belt with the part name facing up. 3. Install: Dust cover 2 Recoil starter 1 COOLING SYSTEM CHECKING THE COOLING WATER DISCHARGE Check:...

  • Page 49: Lower Unit

    LOWER UNIT LOWER UNIT CHECKING THE GEAR OIL LEVEL Check: Gear oil level Level is low Add gear oil to the proper level. CHANGING AND CHECKING THE GEAR OIL LEVEL 1. Check: Gear oil Milky oil Replace the oil seal. Slug oil Check the gears, bearings, and clutch dog.

  • Page 50: Checking The Lower Unit (For Air Leaks)

    LOWER UNIT CHECKING THE LOWER UNIT (FOR AIR LEAKS) Check: Lower unit holding pressure Pressure drops Check the seals and components. Lower unit holding pressure: 100 kPa (1.0 kgf/cm , 14.2 psi) for 10 seconds Checking steps: CAUTION: Do not overpressurize the lower unit. Excessive pressure may damage the oil seals.

  • Page 51: General

    GENERAL GENERAL CHECKING THE ANODE Check: Anode (engine side) Anode (lower unit) Scales Clean. Oil/grease Clean. Excessive wear/damage Replace. CAUTION: Do not oil, grease, or paint the anode, or it will no operate properly. Anode mounting plug (engine): 18 N m (1.8 kgf m, 13.3 ft Anode mounting screw (engine):...

  • Page 52: Checking The Spark Plugs

    GENERAL DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN. NOTE: Batteries vary among manufacturers. Therefore, the following procedures may not always apply. Consult your battery manufacturer’s instructions. First, disconnect the negative lead, then the positive lead.
  • Page 53 GENERAL 4. Measure: Spark plug gap Out of specification Replace. Spark plug gap: 0.9 - 1.0 mm (0.035 - 0.039 in) 5. Tighten: Spark plug Spark plug: 25 N m (2.5 kgf m, 18.4 ft NOTE: Before installing the spark plug, clean the gasket surface and spark plug surface.

  • Page 54: Lubrication Points

    GENERAL LUBRICATION POINTS Apply: Water resistant grease NOTE: Use a grease gun. 3-20...
  • Page 55 GENERAL 3-21...
  • Page 56 CHAPTER 4 FUEL SYSTEM FUEL JOINT, FUEL FILTER AND FUEL PUMP ..........4-1 REMOVING/INSTALLING THE FUEL JOINT, FUEL FILTER AND FUEL PUMP ....................4-1 CHECKING THE FUEL JOINT ..............4-2 CHECKING THE FUEL FILTER ..............4-2 INSTALLING THE FUEL FILTER ...............4-2 FUEL PUMP ......................4-3 DISASSEMBLING/ASSEMBLING THE FUEL PUMP .......4-3 CHECKING THE FUEL PUMP ..............4-4 ASSEMBLING THE FUEL PUMP ..............4-4...
  • Page 57 FUEL JOINT, FUEL FILTER AND FUEL PUMP FUEL JOINT, FUEL FILTER AND FUEL PUMP REMOVING/INSTALLING THE FUEL JOINT, FUEL FILTER AND FUEL PUMP Step Job/Part Q'ty Remarks Clip Fuel hose Bolt (with washer) Fuel joint Clip Fuel hose (with tube) Fuel filter Clip Fuel hose (with tube)

  • Page 58: Fuel Joint, Fuel Filter And Fuel Pump

    FUEL JOINT, FUEL FILTER AND FUEL PUMP CHECKING THE FUEL JOINT 1. Check: Fuel joint Cracks/leak/clog/damage Replace. 2. Check: Fuel joint operation Impossible to maintain the specified pressure for 10 sec. Replace. NOTE: Do not overpressurize the fuel joint. Excessive pressure may cause air to leak out.

  • Page 59: Fuel Pump

    FUEL PUMP FUEL PUMP DISASSEMBLING/ASSEMBLING THE FUEL PUMP Step Job/Part Q'ty Remarks Screw Body #3 Diaphragm Screw Check valve Body #2 Plunger Plunger spring Diaphragm Diaphragm spring Body #1 For installation, reverse the removal procedure.

  • Page 60: Checking The Fuel Pump

    FUEL PUMP CHECKING THE FUEL PUMP Check: Diaphragms Damage Replace. ASSEMBLING THE FUEL PUMP Install: Body #1 Body #2 Body #3 NOTE: Install so that notched portion of body #1, joint portion of body #2, and casting mold letter of body #3 are in the relative positions shown in the diagram on the left.

  • Page 61: Intake System

    INTAKE SYSTEM INTAKE SYSTEM REMOVING/INSTALLING THE INTAKE SYSTEM Step Job/Part Q'ty Remarks Breather hose Bolt (with washer) Clamp Water pilot hose Clamp Water Hose Throttle axle link Choke rod Link joint Choke knob Bolt (with washer) Coller Silensor assembly Continued on next page.
  • Page 62 INTAKE SYSTEM Step Job/Part Q'ty Remarks O-ring 31.5 x 2.4 mm Not reusable Carburetor Gasket Not reusable Insulator Clamp Fuel hose Bolt Bolt Clamp Intake manifold Gasket Not reusable For installation, reverse the removal procedure.

  • Page 63: Installing The Intake Manifold

    INTAKE SYSTEM INSTALLING THE INTAKE MANIFOLD Install: Intake manifold NOTE: Tighten the intake manifold mounting bolt in sequence and two steps of torque. Intake manifold mounting bolt: 1st: 6.0 N m (0.6 kfg m, 4.4 ft 2nd: 12.0 N m (1.2 kfg 8.8 ft...

  • Page 64: Carburetor

    CARBURETOR CARBURETOR DISASSEMBLING/ASSEMBLING THE CARBURETOR Step Job/Part Q'ty Remarks Drain plug Gasket Not reusable Throttle stop screw Spring Screw Screw (with washer) Cover plate Cover gasket Not reusable Screw (with washer) Float chamber O-ring 48 x 1.8 mm Not reusable Float pin Float Continued on next page.
  • Page 65 CARBURETOR Step Job/Part Q'ty Remarks Needle valve Main jet Pilot Plug Main nozzle Body assembly For installation, reverse the removal procedure.

  • Page 66: Disassembling The Carburetor

    CARBURETOR DISASSEMBLING THE CARBURETOR Remove: Float pin 1 Float 2 Needle valve NOTE: Tap float pin 1 in the direction of arrow of carburetor body 3 and in the reverse direction with a pin to remove. CHECKING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated...

  • Page 67: Assembling The Carburetor

    CARBURETOR ASSEMBLING THE CARBURETOR NOTE: Before assembling the carburetor, make sure to turn out the pilot screw the same number of times, as noted before disassembly, from the seated position to the set position. 1. Install: Needle valve 3 Float 1 Float pin 2 NOTE: When setting the float 1 into the...
  • Page 68 CHAPTER 5 POWER UNIT MANUAL STARTER ..................5-1 REMOVING/INSTALLING THE MANUAL STARTER .......5-1 INSTALLING THE DUST COVER GROMMET ..........5-2 ADJUSTING THE START-IN-GEAR PROTECTION DEVICE ....5-2 DISASSEMBLING/ASSEMBLING THE MANUAL STARTER ....5-3 DISASSEMBLING THE MANUAL STARTER ...........5-5 CHECKING THE MANUAL STARTER ............5-6 ASSEMBLING THE MANUAL STARTER ..........5-6 FLYWHEEL ROTOR ..................5-9 REMOVING/INSTALLING THE FLYWHEEL ROTOR ........5-9 REMOVING THE FLYWHEEL ROTOR ............5-10...
  • Page 69 ANODE AND EXHAUST COVER ..............5-29 REMOVING/INSTALLING THE ANODE AND EXHAUST COVER ..5-29 CHECKING THE ANODE .................5-30 INSTALLING THE EXHAUST COVER ............5-30 CYLINDER HEAD AND OIL PUMP ..............5-31 REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP ..5-31 CHECKING THE SPARK PLUG ...............5-33 INSTALLING THE OIL PUMP ..............5-33 INSTALLING THE CYLINDER HEAD ............5-33 INSTALLING THE CYLINDER HEAD COVER .........5-34...

  • Page 70: Manual Starter

    MANUAL STARTER MANUAL STARTER REMOVING/INSTALLING THE MANUAL STARTER Step Job/Part Q'ty Remarks Start-in-gear protection cable Bolt (with washer) Manual starter assembly Dust cover Grommet For installation, reverse the removal procedure.

  • Page 71: Installing The Dust Cover Grommet

    MANUAL STARTER INSTALLING THE DUST COVER GROMMET Install: Dust cover grommet NOTE: Set the grommet so that the large flange diameter is at the bottom and install to the dust cover. ADJUSTING THE START-IN-GEAR PROTECTION DEVICE Adjust: Start-in-gear protection device Refer to “ADJUSTING THE START- IN-GEAR PROTECTION DEVICE”...

  • Page 72: Disassembling/Assembling The Manual Starter

    MANUAL STARTER DISASSEMBLING/ASSEMBLING THE MANUAL STARTER Step Job/Part Q'ty Remarks Wire assembly Return spring Screw Drive plate Drive spring Sheave drum assembly Circlip Drive pawl Return spring Spring Sheave dram Starter spring Cover Continued on next page.
  • Page 73 MANUAL STARTER Step Job/Part Q'ty Remarks Starter handle Dumper Starter wire 1,500mm Return spring Stopper Coller Starter case For installation, reverse the removal procedure.

  • Page 74: Disassembling The Manual Starter

    MANUAL STARTER DISASSEMBLING THE MANUAL STARTER 1. Rotate: Sheave drum 1 NOTE: Before removing the drive plate and drive spring, turn the sheave drum to make the starter spring inside the sleeve drum free. Rotating steps: (1)Turn the sheave drum 1 so that the cutaway on the outer surface of the sheave drum faces toward the starter...

  • Page 75: Checking The Manual Starter

    MANUAL STARTER CHECKING THE MANUAL STARTER 1. Check: Start-in-gear protection lever Cracks/wear/damage Replace. 2. Check: Drive pawl Cracks/wear/damage Replace. Drive spring Damage Replace. 3. Check: Sheave drum Cracks/wear/damage Replace. 4. Check: Return springs Damage Replace. 5. Check: Starter wire Frayed/wear/damage Replace.
  • Page 76 MANUAL STARTER 2. Install: Starter wire 2 Installing steps: (1)Insert the starter wire 2 through the wire holes and then tie a knot on the end of the wire. (2)Place the starter wire at the cutaway of the sheave drum. 3.
  • Page 77 MANUAL STARTER 5. Set: Starter spring Setting steps: (1)Place the starter wire 2 at the cutaway of the sheave drum 3. (2)Wind the sheave drum 3 5 turns counterclockwise with the starter wire (3)Remove starter wire 2 from cutaway , then wind on sheave drum 3. 6.

  • Page 78: Flywheel Rotor

    FLYWHEEL ROTOR FLYWHEEL ROTOR REMOVING/INSTALLING THE FLYWHEEL ROTOR Step Job/Part Q'ty Remarks Washer Flywheel rotor Woodruff key For installation, reverse the removal procedure.

  • Page 79: Removing The Flywheel Rotor

    FLYWHEEL ROTOR REMOVING THE FLYWHEEL ROTOR 1. Remove: Flywheel rotor nut Flywheel holder: YB-06139/90890-06522 For USA and Canada Except for USA and Canada NOTE: The major load should be applied in the direction of the arrows. If the load is not applied as shown, the flywheel holder may easily slip off of the flywheel rotor.

  • Page 80: Installing The Flywheel Rotor

    FLYWHEEL ROTOR INSTALLING THE FLYWHEEL ROTOR Install: Flywheel rotor nut Flywheel holder: YB-06139/90890-06522 For USA and Canada Except for USA and Canada NOTE: The major load should be applied in the direction of the arrows. If the load is not applied as shown, the flywheel holder may easily slip off of the flywheel rotor.

  • Page 81: Power Unit

    POWER UNIT POWER UNIT DISCONNECTING/CONNECTING THE ELECTRICAL LEADS Step Job/Part Q'ty Remarks Bolt (with washer) Engine stop switch connector and White, Black terminal Emergency signal light connector Yellow/red, Pink For installation, reverse the removal procedure. 5-12...

  • Page 82: Disconnecting/Connecting The Cables And Hose

    POWER UNIT DISCONNECTING/CONNECTING THE CABLES AND HOSE Step Job/Part Q'ty Remarks Engine oil drain Refer to “REPLACING THE ENGINE OIL” on page 3-9. Throttle cable Shift cable Oil level gauge Water hose For installation, reverse the removal procedure. 5-13...

  • Page 83: Adjusting The Throttle Control Cable(S)

    POWER UNIT ADJUSTING THE THROTTLE CONTROL CABLE(S) Adjust: Throttle control cable(s) Refer to “ADJUSTING THE THROTTLE CONTROL CABLES” on page 3-5. 5-14...

  • Page 84: Removing/Installing The Power Unit

    POWER UNIT REMOVING/INSTALLING THE POWER UNIT Step Job/Part Q'ty Remarks Screw (with washer) Apron Plug Apron Rubber seal Bolt (with washer) Power unit Relief valve assembly O-ring 12.0 x 1.8 mm Not reusable Gasket Not reusable Dowel pin For installation, reverse the removal procedure.

  • Page 85: Installing The Power Unit

    POWER UNIT INSTALLING THE POWER UNIT Install: Power unit NOTE: Tighten the power unit mounting bolt by the order shown in the diagram on the left. Tighten up the exhaust guide mounting bolt at the same time. 5-16...

  • Page 86: Removing/Installing The Throttle Link And Right Side Electrical Components

    POWER UNIT REMOVING/INSTALLING THE THROTTLE LINK AND RIGHT SIDE ELECTRICAL COMPONENTS Step Job/Part Q'ty Remarks Bolt (with washer) Bolt (with washer) Washer Collar Throttle control lever Link joint Throttle control cam Bracket Screw Oil pressure switch lead Pink Oil pressure switch Bolt Attachment Continued on next page.
  • Page 87 POWER UNIT Step Job/Part Q'ty Remarks Pulser coil For installation, reverse the removal procedure. 5-18...

  • Page 88: Removing/Installing The Left Side Electrical Components 1 (One Lighting Coil Model)

    POWER UNIT REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 1 (ONE LIGHTING COIL MODEL) Step Job/Part Q'ty Remarks Screw (with washer) Rectifier 4 leads (Black, Red, Green x 2) Bolt (with washer) Ignition coil 2 leads (Orange, Black) Bolt (with washer) Bracket For installation, reverse the removal procedure.

  • Page 89: Removing/Installing The Left Side Electrical Components 2 (One Lighting Coil Model)

    POWER UNIT REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 2 (ONE LIGHTING COIL MODEL) Step Job/Part Q'ty Remarks Clamp Not reusable Bolt (with washer) Not reusable Charge coil 2 leads (Blue, Brown) Bolt (with washer) Clamp Bolt (with washer) Not reusable Lighting coil 2 leads (Green x 2) Screw...

  • Page 90: Removing/Installing The Left Side Electrical Components 1(Two Lighting Coils Model)

    POWER UNIT REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 1 (TWO LIGHTING COILS MODEL) Step Job/Part Q'ty Remarks Clamp Not reusable Bolt (with washer) Ignition coil 2 leads (Orange, Black) Bolt (with washer) Clamp Clamp Not reusable Bolt (with washer) Rectifier/regulator 4 leads (Black, Red, Green x 2) Bolt (with washer) Bolt (with washer)

  • Page 91: Removing/Installing The Left Side Electrical Components 2(Two Lighting Coils Model)

    POWER UNIT REMOVING/INSTALLING THE LEFT SIDE ELECTRICAL COMPONENTS 2 (TWO LIGHTING COILS MODEL) Step Job/Part Q'ty Remarks Clamp Not reusable Bolt (with washer) Not reusable Charge coil 2 leads (Blue, Brown) Bolt (with washer) Not reusable Lighting coil 2 leads (Green x 2) Screw Coupler clamp Bolt (with washer)

  • Page 92: Thermostat, Timing Belt And Gears

    THERMOSTAT, TIMING BELT AND GEARS THERMOSTAT, TIMING BELT AND GEARS REMOVING/INSTALLING THE THERMOSTAT, TIMING BELT AND GEARS Step Job/Part Q'ty Remarks Clamp Not reusable Water hose Bolt (with washer) Thermostat cover Gasket Not reusable Thermostat Timing belt Lock washer Plate washer Drive gear Woodruff key Bolt...
  • Page 93 THERMOSTAT, TIMING BELT AND GEARS Step Job/Part Q'ty Remarks Plate washer Driven gear Woodruff key Plate washer For installation, reverse the removal procedure. 5-24...

  • Page 94: Removing The Timing Belt

    THERMOSTAT, TIMING BELT AND GEARS REMOVING THE TIMING BELT Remove: Timing belt 1 NOTE: Turn the drive gear 2 and align the “∆1” mark on the driven gear 3 and “∆” mark on the thermostat housing cover 4 (portion REMOVING THE DRIVE GEAR Remove: Drive gear nut Crankshaft holder:...

  • Page 95: Checking The Thermostat

    THERMOSTAT, TIMING BELT AND GEARS CHECKING THE THERMOSTAT Measure: Valve operating temperature Valve lift Out of specification Replace. Water temperature Valve lift Below 0 mm 60 °C(140 °F) (0 in) Above Min.3 mm 70 °C(158 °F) (0.12 in) Measuring steps: (1)Suspend the thermostat in a container filled with water.

  • Page 96: Installing The Drive Gear

    THERMOSTAT, TIMING BELT AND GEARS INSTALLING THE DRIVE GEAR 1. Install: Woodruff key 1 Drive gear 2 Washer 3 Lock washer 4 NOTE: Install the washer as shown in the diagram on the left so that the curvature extends in the upward direction. (It is in the reverse direction from the curvature of the flange of the drive gear.) Pass the tab of the lock washer through...

  • Page 97: Installing The Timing Belt

    THERMOSTAT, TIMING BELT AND GEARS INSTALLING THE TIMING BELT Install: Timing belt 5 Installing steps: (1)Turn the drive gear 1 and align the washer groove on the drive gear and “∆” mark on the cylinder body 2 (portin (2)Turn the driven gear 3 and align the “∆1”...
  • Page 98 ANODE AND EXHAUST COVER ANODE AND EXHAUST COVER REMOVING/INSTALLING THE ANODE AND EXHAUST COVER Step Job/Part Q'ty Remarks Plug O-ring Not reusable Screw Anode Bolt (with washer) Exhaust cover Gasket Not reusable For installation, reverse the removal procedure. 5-29...

  • Page 99: Anode And Exhaust Cover

    ANODE AND EXHAUST COVER CHECKING THE ANODE Check: Anode Refer to “CHECKING THE ANODE” on page 3-17. INSTALLING THE EXHAUST COVER Install: Exhaust cover NOTE: Tighten the exhaust cover bolt in sequence and two steps of torque. Exhaust cover mounting bolt: 1st: 6.0 N m (0.6 kfg m, 4.4 ft...

  • Page 100: Cylinder Head And Oil Pump

    CYLINDER HEAD AND OIL PUMP CYLINDER HEAD AND OIL PUMP REMOVING/INSTALLING THE CYLINDER HEAD AND OIL PUMP Step Job/Part Q'ty Remarks Spark plug Oil filler cap O-ring 25.0 x 3.0 mm Bolt (with washer) Cylinder head cover Cover seal Screw (with washer) Breather cover Cover gasket Not reusable...
  • Page 101 CYLINDER HEAD AND OIL PUMP Step Job/Part Q'ty Remarks Cylinder head gasket Not reusable Dowel pin Bolt (with washer) Oil pump assembly Oil pump gasket Not reusable For installation, reverse the removal procedure. 5-32...

  • Page 102: Checking The Spark Plug

    PLUGS” on page 3-18. INSTALLING THE OIL PUMP Install: Oil pump NOTE: Before installing to the cylinder head, add a drop of approx. 1 cc of Yamaha 4-stroke outboard motor oil from suction port discharge port INSTALLING THE CYLINDER HEAD Install: Cylinder head...

  • Page 103: Installing The Cylinder Head Cover

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

  • Page 104: Disassembling/Assembling The Oil Pump

    OIL PUMP OIL PUMP DISASSEMBLING/ASSEMBLING THE OIL PUMP Step Job/Part Q'ty Remarks Screw Pump cover Cover gasket Not reusable Inner rotor Shaft Outer rotor Oil pump housing For installation, reverse the removal procedure. 5-35...

  • Page 105: Checking The Oil Pump

    OIL PUMP CHECKING THE OIL PUMP Measure: Oil pump clearances , and Out of specification Replace. Oil pump clearances: : 0.10 - 0.15 mm (0.004 - 0.006 in) : 0.04 - 0.14 mm (0.002 - 0.006 in) : 0.03 - 0.09 mm (0.001 - 0.004 in) ASSEMBLING THE OIL PUMP Install:...

  • Page 106: Camshaft And Valves

    CAMSHAFT AND VALVES CAMSHAFT AND VALVES REMOVING/INSTALLING THE CAMSHAFT AND VALVES Step Job/Part Q'ty Remarks Locknut Rocker arm adjusting screw Rocker shaft Spring Collar Collar Rocker arm Cam shaft Oil seal Not reusable Valve spring lock Valve spring retainer Valve spring Valve spring seat Continued on next page.
  • Page 107 CAMSHAFT AND VALVES Step Job/Part Q'ty Remarks Intake valve Exhaust valve Valve stem oil seal Not reusable Cylinder head For installation, reverse the removal procedure. 5-38...

  • Page 108: Removing The Valve

    CAMSHAFT AND VALVES REMOVING THE VALVE Remove: Valve spring lock 1 Valve spring retainer 2 Valve spring 3 Valve spring seat 4 Intake valve or exhaust valve 5 Valve spring compressor: YM-01253/90890-04019 Attachment: YM-04018/90890-04018 NOTE: Set the attachment on to the center of the spring retainer.

  • Page 109: Checking The Valve Spring

    CAMSHAFT AND VALVES 4. Measure: Valve stem outside diameter Out of specification Replace. Valve stem outside diameter Intake valve: 5.475 - 5.490 mm (0.2156 - 0.2161 in) Exhaust valve: 5.460 - 5.475 mm (0.2150 - 0.2156 in) 5. Measure: Valve stem runout Out of specification Replace.

  • Page 110: Checking The Rocker Arm Rocker Arm Shaft

    CAMSHAFT AND VALVES CHECKING THE ROCKER ARM ROCKER ARM SHAFT 1. Measure: Rocker arm inside diameter Out of specification Replace. Rocker arm inside diameter 13.000 - 13.018 mm (0.5118 - 0.5125 in) 2. Measure: Rocker arm shaft outside diameter Out of specification Replace.

  • Page 111: Checking The Cylinder Head

    CAMSHAFT AND VALVES CHECKING THE CYLINDER HEAD Measure: Cylinder head warpage Out of specification Resurface or replace. Warpage limit: 0.1 mm (0.004 in) Resurfacing steps: (1)Place a 400 - 600 grit wet sandpaper on the surface plate. (2)Resurface the cylinder head using a figure-eight sanding pattern.

  • Page 112: Refacing The Valve Seat

    CAMSHAFT AND VALVES (4)Bore the valve guide using the valve guide reamer. Valve guide reamer: NA/90890-06804 NOTE: When installing and removing the valve guide reamer, apply machining oil and turn the reamer clockwise REFACING THE VALVE SEAT NOTE: After refacing the valve seat or replacing the valve and valve guide, lap the valve seat and valve face.
  • Page 113 CAMSHAFT AND VALVES Refacing steps: Valve seat is centered on valve face but it is too wide. Valve cutter seat Desired result 90° cutter To reduce the valve lightly seat width 30° cutter Valve seat is in the middle of the valve face but it is too narrow.

  • Page 114: Installing The Valve

    CAMSHAFT AND VALVES INSTALLING THE VALVE Install: Intake valve or exhaust valve 5 Valve spring seat 4 Valve spring 3 Valve spring retainer 2 Valve spring lock 1 Valve spring compressor: YM-01253/90890-04019 Attachment: YM-04108/90890-04108 NOTE: Set the attachment on to the center of the spring retainer.

  • Page 115: Crankshaft, Piston And Cylinder Body

    CRANKSHAFT, PISTON AND CYLINDER BODY CRANKSHAFT, PISTON AND CYLINDER BODY REMOVING/INSTALLING THE CRANKSHAFT, PISTON AND CYLINDER BODY Step Job/Part Q'ty Remarks Bolt (with washer) Crankcase Dowel pin Connecting rod bolt Connecting rod cap Crankshaft Oil seal Not reusable Oil seal Not reusable Piston and connecting rod Plain bearing...

  • Page 116: Disassembling/Assembling The Piston And Connecting Rod

    CRANKSHAFT, PISTON AND CYLINDER BODY DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING ROD Step Job/Part Q'ty Remarks Circlip Piston pin Connecting rod Top ring 2nd ring Oil ring Piston For installation, reverse the removal procedure. 5-47...

  • Page 117: Checking The Cylinder Body

    CRANKSHAFT, PISTON AND CYLINDER BODY CHECKING THE CYLINDER BODY Measure: Cylinder bore (with a cylinder bore gauge) Out of specification Rebore the cylinder or replace the cylinder body. Standard Wear limit H1: 20 mm (0.8 in) Measuring H2: 40 mm (1.6 in) point “H”...

  • Page 118: Calculating The Piston-To-Cylinder Clearance

    CRANKSHAFT, PISTON AND CYLINDER BODY NOTE: When measuring the piston diameter, position the micrometer in relation to the piston pin hole as shown. 2. Measure: Piston pin boss inside diameter (with a micrometer) Out of specification Replace the piston. Piston pin boss inside diameter: 14.004 - 14.015 mm (0.5513 - 0.5518 in) CALCULATING THE PISTON-TO-...

  • Page 119: Checking The Piston Ring

    CRANKSHAFT, PISTON AND CYLINDER BODY CHECKING THE PISTON RING 1. Measure: End gap Out of specification Replace the piston ring. Top ring end gap: 0.15 - 0.30 mm(0.006 - 0.012 in) 2nd ring end gap: 0.30 - 0.45 mm(0.012 - 0.018 in) Oil ring end gap: 0.20 - 0.70 mm(0.008 - 0.028 in) NOTE:...

  • Page 120: Checking The Crankshaft-Plain Bearing Oil Clearance

    CRANKSHAFT, PISTON AND CYLINDER BODY CHECKING THE CRANKSHAFT-PLAIN BEARING OIL CLEARANCE NOTE: Make sure that the crankshaft is qualified before initiating the following procedure. 1. Measure: Crankshaft-plain bearing oil clearance Out of specification Replace the upper and lower plain bearing as a set.
  • Page 121 CRANKSHAFT, PISTON AND CYLINDER BODY (6)Install the crankcase 3 onto cylinder body 2. (7)Tighten the crankcase mounting bolt NOTE: Apply engine oil onto the thread and seat of the crankcase mounting bolt. Tighten the crankcase mounting bolt in sequence and two steps of torque. Crank case mounting bolt: 1st: 15 N m (1.5 kgf...

  • Page 122: Checking The Crankshaft-Connecting Rod Oil Clearance

    Install the connecting rods and caps in their original positions. Incorrect oil clearance measurements can lead to engine damage. NOTE: Make sure that the “YAMAHA” mark on the connecting rod faces toward the flywheel side. Align the “∆“ marks on the connecting rod and cap when assembling.
  • Page 123 CRANKSHAFT, PISTON AND CYLINDER BODY (4)Install the connecting rod cap onto the crankshaft. (5)Tighten the connecting rod mounting bolt. NOTE: Apply engine oil onto the thread and seat of the connecting rod mounting bolt. Tighten the connecting rod mounting bolt in two steps of torque.

  • Page 124: Installing The Piston Ring

    Oil ring lower side rail end gap INSTALLING THE CONNECTING ROD Install: Piston 1 Connecting rod 2 Piston pin 3 Circlip 4 NOTE: Install the connecting rod with “YAMAHA” mark facing towards the “UP” mark on the piston crown. 5-55...

  • Page 125: Installing The Piston And Connecting Rod

    CRANKSHAFT, PISTON AND CYLINDER BODY INSTALLING THE PISTON AND CONNECTING ROD 1. Install: Piston and connecting rod Piston slider: YU-33294/90890-05158 NOTE: Install the piston with “UP” mark on the piston crown facing toward the flywheel side. 2. Install: Connecting rod cap NOTE: Align the “∆“...
  • Page 126 CHAPTER 6 LOWER UNIT LOWER UNIT ....................6-1 REMOVING/INSTALLING THE LOWER UNIT ..........6-1 REMOVING THE PROPELLER ..............6-3 CHECKING THE PROPELLER ..............6-3 CHECKING THE ANODE ................6-3 INSTALLING THE LOWER UNIT ..............6-3 INSTALLING THE PROPELLER ..............6-4 WATER PUMP ....................6-5 REMOVING/INSTALLING THE WATER PUMP ........6-5 CHECKING THE WATER PUMP HOUSING, CARTRIDGE INSERT AND IMPELLER ................6-6 PROPELLER SHAFT HOUSING AND PROPELLER SHAFT ......6-7...
  • Page 127 CHECKING THE COLLER ................6-19 CHECKING THE SHIFT CAM ..............6-19 CHECKING THE LOWER CASE ..............6-19 ASSEMBLING THE BEARING HOUSING ..........6-20 INSTALLING THE SOLID BUSHING ............6-21 BACKLASH .....................6-22 MEASURING THE FORWARD GEAR BACKLASH ........6-22 MEASURING THE REVERSE GEAR BACKLASH ........6-23...
  • Page 128 LOWER UNIT LOWER UNIT REMOVING/INSTALLING THE LOWER UNIT Step Job/Part Q'ty Remarks Slit pin Plate washer Propeller Spacer Bolt Anode Screw Water inlet cover Nut (short) Nut (long) Bolt (with washer) Continued on next page.
  • Page 129 LOWER UNIT Step Job/Part Q'ty Remarks Lower unit Seal rubber Dowel pin For installation, reverse the removal procedure.

  • Page 130: Removing The Propeller

    LOWER UNIT REMOVING THE PROPELLER Remove: Propeller WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the lanyard engine stop swith. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.

  • Page 131: Installing The Propeller

    LOWER UNIT INSTALLING THE PROPELLER Install: Propeller WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the lanyard engine stop swith. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.

  • Page 132: Removing/Installing The Water Pump

    WATER PUMP WATER PUMP REMOVING/INSTALLING THE WATER PUMP Step Job/Part Q'ty Remarks Water seal rubber Bolt Plate Water pump housing Cartridge insert O-ring 54.5 x 3.0 mm Not reusable Impeller Woodruff key Bolt Cartridge outer plate Dowel pin For installation, reverse the removal procedure.

  • Page 133: Checking The Water Pump Housing, Cartridge Insert And Impeller

    WATER PUMP CHECKING THE WATER PUMP HOUSING, CARTRIDGE INSERT AND IMPELLER 1. Check: Water pump housing Cartridge insert Cracks/damage Replace. 2. Check: Impeller Cracks/damage/wear Replace. CHECKING THE WOODRUFF KEY Check: Woodruff key Damage/wear Replace. INSTALLING THE CARTRIDGE INSERT AND WATER PUMP HOUSING 1.

  • Page 134: Propeller Shaft Housing And Propeller Shaft

    PROPELLER SHAFT HOUSING AND PROPELLER PROPELLER SHAFT HOUSING AND PROPELLER SHAFT REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY AND PROPELLER SHAFT ASSEMBLY Step Job/Part Q'ty Remarks Gear oil drain Refer to “CHANGING AND CHECKING THE GEAR OIL LEVEL” on page 3-15. Bolt (with washer) Propeller shaft housing assembly Plate washer...

  • Page 135: Installing The Propeller Shaft Housing Assembly

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

  • Page 136: Disassembling/Assembling The Propeller Shaft Assembly

    PROPELLER SHAFT HOUSING AND PROPELLER DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY Step Job/Part Q'ty Remarks Shift plunger Cross pin ring Cross pin Clutch dog Compression spring Propeller shaft For installation, reverse the removal procedure.

  • Page 137: Checking The Dog Clutch

    PROPELLER SHAFT HOUSING AND PROPELLER CHECKING THE DOG CLUTCH Check: Clutch dog Wear/damage Replace. CHECKING THE PROPELLER SHAFT Check: Propeller shaft Wear/damage Replace. ASSEMBLING THE PROPELLER SHAFT ASSEMBLY 1. Install: Clutch dog NOTE: Install the clutch dog with “F” mark towards the forward gear side.

  • Page 138: Disassembling/Assembling The Propeller Shaft Housing Assembly

    PROPELLER SHAFT HOUSING AND PROPELLER DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY Step Job/Part Q'ty Remarks Reverse gear Gear adjusting shim O-ring 51.0 x 3.1 mm Not reusable O-ring 55.4 x 1.9 mm Not reusable Ball bearing Oil seal Not reusable Solid bushing Propeller shaft housing For installation, reverse the removal...

  • Page 139: Disassembling The Propeller Shaft Housing Assembly

    PROPELLER SHAFT HOUSING AND PROPELLER DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY 1. Remove: Ball bearing Slide hammer handle 1: YB-06096 Stopper guide plate 2: 90890-06501 Bearing puller 3: 90890-06535 Stopper guide stand 4: 90890-06538 For USA and Canada Except for USA and Canada 2.

  • Page 140: Checking The Propeller Shaft Housing

    PROPELLER SHAFT HOUSING AND PROPELLER CHECKING THE PROPELLER SHAFT HOUSING 1. Clean: Propeller shaft housing (with a soft brush and solvent) 2. Check: Propeller shaft housing Cracks/damage Replace. ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY 1. Install: Solid bushing Driver rod: YB-06229/90890-06652 Attachment: YB-06230/90890-06617...
  • Page 141 PROPELLER SHAFT HOUSING AND PROPELLER 3. Install: Ball bearing Driver rod: YB-06071/90890-06605 Attachment: YB-06167/90890-06634 For USA and Canada Except for USA and Canada NOTE: Install the ball bearing with its manufacturer’s mark facing towards the reverse gear. 6-14...

  • Page 142: Drive Shaft And Forward Gear

    DRIVE SHAFT AND FORWARD GEAR DRIVE SHAFT AND FORWARD GEAR REMOVING/INSTALLING THE DRIVE SHAFT AND FORWARD GEAR Step Job/Part Q'ty Remarks Circlip Pinion Pinion adjusting shim Drive shaft Forward gear Ball bearing Gear adjusting shim For installation, reverse the removal procedure.

  • Page 143: Removing The Ball Bearing

    DRIVE SHAFT AND FORWARD GEAR REMOVING THE BALL BEARING Remove: Ball bearing Adjusting shim(s) Slide hammer handle 1: YB-06096 Bearing puller 2: 90890-06535 Stopper guide plate 3: 90890-06501 For USA and Canada Except for USA and Canada CHECKING THE PINION Check: Teeth Wear/damage...

  • Page 144: Installing The Ball Bearing

    DRIVE SHAFT AND FORWARD GEAR INSTALLING THE BALL BEARING Install: Gear adjusting shim(s) Ball bearing Driver rod: YB-06071/90890-06604 Attachment: YB-06167/90890-06634 For USA and Canada Except for USA and Canada NOTE: Install the ball bearing with its manufacturer’s mark facing towards the forward gear.

  • Page 145: Bearing Housing, Shift Cam And Lower Case

    BEARING HOUSING, SHIFT CAM AND LOWER CASE BEARING HOUSING, SHIFT CAM AND LOWER CASE REMOVING/INSTALLING THE BEARING HOUSING, SHIFT CAM AND LOWER CASE Step Job/Part Q'ty Remarks Bearing housing assembly Gasket Not reusable Coller Shift cam Solid bushing Lower case O-ring Not reusable Oil seal...

  • Page 146: Removing The Solid Bushing

    BEARING HOUSING, SHIFT CAM AND LOWER CASE REMOVING THE SOLID BUSHING Remove: Solid bushing Driver rod: YB-06229/90890-06652 Attachment: YB-06028/90890-06650 For USA and Canada Except for USA and Canada DISASSEMBLING THE BEARING HOUSING Remove: Solid bushing Driver rod: YB-06229/90890-06652 Bushing attachment: YB-06028/90890-06650 For USA and Canada Except for USA and Canada...

  • Page 147: Assembling The Bearing Housing

    BEARING HOUSING, SHIFT CAM AND LOWER CASE 2. Check: Water passage Mineral deposits/corrosion Clean. 3. Check: Lower case Cracks/damage Replace. ASSEMBLING THE BEARING HOUSING 1. Install: Solid bushing Driver rod: YB-06229/90890-06652 Attachment: YB-06028/90890-06650 2. Install: Oil seal Oil seal mounting depth 6.0 - 6.5 mm (0.236 - 0.256 in) Driver rod: YB-06071/90890-06652...

  • Page 148: Installing The Solid Bushing

    BEARING HOUSING, SHIFT CAM AND LOWER CASE INSTALLING THE SOLID BUSHING Install: Solid bushing Bushing installer center bolt 1: YB-06029/90890-06601 Attachment 2: YB-37350/90890-06616 NOTE: Pull up the solid bushing until the flange is in tight contact with the lower case. 6-21...

  • Page 149: Backlash

    BACKLASH BACKLASH NOTE: Both forward gear backlash and reverse gear backlash be measured. If both forward gear backlash and reverse gear backlash are smaller than specified, the pinion may be too low. If either of these conditions exist, then check the pinion shim selection. MEASURING THE FORWARD GEAR BACKLASH Measure:...

  • Page 150: Measuring The Reverse Gear Backlash

    BACKLASH (6)Determine the shims to be added or removed according to the specified. Forward gear Shim thickness backlash Less than To be decreased by 0.88 mm (0.0346 in) (1.07 - Measurement) 2.52 More than To be decreased by 1.26 mm (0.0496 in) (Measurement - 1.07) 2.52 Available shim thickness: 0.10, 0.12, 0.15, 0.18,...
  • Page 151 BACKLASH Backlash indicator: YB-06265/90890-06706 Magnet base: YU-34481/90890-06705 Magnetic base attaching plate: YB-07003/90890-07003 Dial gauge stand: YU-03097/90890-01252 (5)While pulling the drive shaft downward, slowly turn the drive shaft clockwise and counterclockwise then measure the backlash when the drive shaft stops at each direction. (6)Determine the shims to be added or removed according to the specified.

  • Page 152: Bracket Unit

    CHAPTER 7 BRACKET UNIT STEERING HANDLE ..................7-1 REMOVING/INSTALLING THE STEERING HANDLE ......7-1 INSTALLING THE STEERING HANDLE ...........7-3 ADJUSTING THE THROTTLE CONTROL CABLES .........7-3 ADJUSTING THE SHIFT CABLE ...............7-3 DISASSEMBLING/ASSEMBLING THE STEERING HANDLE ....7-4 ASSEMBLING THE STEERING HANDLE ..........7-6 SHIFT LEVER ....................7-7 REMOVING/INSTALLING THE SHIFT LEVER ...........7-7 BOTTOM COWLING ..................7-9 REMOVING/INSTALLING THE BOTTOM COWLING .......7-9...

  • Page 153: Removing/Installing The Steering Handle

    STEERING HANDLE STEERING HANDLE REMOVING/INSTALLING THE STEERING HANDLE Step Job/Part Q'ty Remarks Throttle cable Stop switch lead Shift cable Grommet Nylone nut Cover Bushing Steering handle assembly Plate washer Plate washer Wave washer Continued on next page.
  • Page 154 STEERING HANDLE Step Job/Part Q'ty Remarks Bushing Grommet Bracket Stud bolt For installation, reverse the removal procedure.

  • Page 155: Installing The Steering Handle

    STEERING HANDLE INSTALLING THE STEERING HANDLE Install: Steering handle NOTE: Pass the stop switch lead wire together with the throttle wire through the corrugated tube, pass under the throttle wire, and then insert in the grommet of the bottom cowling. ADJUSTING THE THROTTLE CONTROL CABLES Adjust:...

  • Page 156: Disassembling/Assembling The Steering Handle

    STEERING HANDLE DISASSEMBLING/ASSEMBLING THE STEERING HANDLE Step Job/Part Q'ty Remarks Rubber bushing Bolt (with washer) Shift handle Screw (with washer) Shift lever Bushing Wave washer Plate washer Cable clamp Circlip Handle cam plate Shift cable Bolt Continued on next page.
  • Page 157 STEERING HANDLE Step Job/Part Q'ty Remarks Spring Bracket Bolt Cable clamp Steering handle For installation, reverse the removal procedure.

  • Page 158: Assembling The Steering Handle

    STEERING HANDLE ASSEMBLING THE STEERING HANDLE 1. Install: Stop switch 1 NOTE: Install stop switch 1, then pull switch lead 2 out from the hole in steering handle 3. Fit switch lead 2 between steering handle 3 and stop switch 1 so that there is no interference with the throttle shaft.

  • Page 159: Removing/Installing The Shift Lever

    SHIFT LEVER SHIFT LEVER REMOVING/INSTALLING THE SHIFT LEVER Step Job/Part Q'ty Remarks Bolt Manual starter cable bracket Clip Shift rod Grommet Grommet Bolt Stopper Spring Split pin Cable end Plate washer Continued on next page.
  • Page 160 SHIFT LEVER Step Job/Part Q'ty Remarks Bolt Shift rod lever Clamp Bracket For installation, reverse the removal procedure.

  • Page 161: Removing/Installing The Bottom Cowling

    BOTTOM COWLING BOTTOM COWLING REMOVING/INSTALLING THE BOTTOM COWLING Step Job/Part Q'ty Remarks Bolt Fitting plate Grommet Grommet Hose joint Hose joint O-ring Not reusable Pipe Screw Adapter Bolt (with washer) Plate Grommet Continued on next page.
  • Page 162 BOTTOM COWLING Step Job/Part Q'ty Remarks Emergency signal light Bolt (with washer) Cowling clamp Bolt (with washer) Bottom cowling Rubber seal Coller Grommet Hose nipple Rubber seal Grommet For installation, reverse the removal procedure. 7-10...

  • Page 163: Removing/Installing The Upper Case

    UPPER CASE UPPER CASE REMOVING/INSTALLING THE UPPER CASE Step Job/Part Q'ty Remarks Water tube Water seal rubber Bolt (with washer) Bolt (with washer) Lower mount rubber housing Lower front mount rubber Lower side mount rubber Screw Plate Upper case For installation, reverse the removal procedure.

  • Page 164: Installing The Lower Mount

    UPPER CASE INSTALLING THE LOWER MOUNT 1. Install: Lower front mount rubber NOTE: Set the “UP” mark upward. 2. Install: Lower mount rubber housing NOTE: Install the mounting bolt while confirming the identifying “V” mark on its head. Pass the stop switch lead wire together with the throttle wire through the corrugated tube, pass under the throttle wire, and then insert in the grommet of...

  • Page 165: Disassembling/Assembling The Upper Case

    UPPER CASE DISASSEMBLING/ASSEMBLING THE UPPER CASE Step Job/Part Q'ty Remarks Bolt (with washer) Upper side mount rubber Bolt (with washer) Exhaust guide Clip Oil strainer Oil seal Not reusable Gasket Not reusable Hose Screw Plate Damper Continued on next page. 7-13...
  • Page 166 UPPER CASE Step Job/Part Q'ty Remarks Oil drain plug Gasket Bolt (with washer) Not reusable Oil pan Bolt (with washer) Muffler Bolt (with washer) Plate Grommet Upper case For installation, reverse the removal procedure. 7-14...

  • Page 167: Installing The Oil Seal

    UPPER CASE INSTALLING THE OIL SEAL Install: Oil seal Driver rod: YB-06071/90890-06604 Attachment: YB-06112/90890-06614 INSTALLING THE MUFFLER Install: Muffler NOTE: ® Apply Three Bond 1207B to marked portion of muffler installation and check that there is no clearance after the muffler is installed.

  • Page 168: Swivel And Steering Bracket

    SWIVEL AND STEERING BRACKET SWIVEL AND STEERING BRACKET REMOVING/INSTALLING THE SWIVEL AND STEERING BRACKET Step Job/Part Q'ty Remarks Bolt Bolt (with washer) Steering friction Bolt Seal rubber Steering bracket Pivot shaft bushing Friction piece Bushing O-ring 30 x 3.8 mm Not reusable Bushing Clamp bracket...

  • Page 169: Steering Friction

    STEERING FRICTION STEERING FRICTION DISASSEMBLING/ASSEMBLING THE STEERING FRICTION Step Job/Part Q'ty Remarks Lock nut Plate washer Bolt (with washer) Friction piece Collar Friction plate Coller Plate washer Lock nob Lock shaft Friction plate For installation, reverse the removal procedure. 7-17...

  • Page 170: Assembling The Steering Friction

    STEERING FRICTION ASSEMBLING THE STEERING FRICTION Install: Lock nob NOTE: Set the “TOP” mark upward. 7-18...

  • Page 171: Removing/Installing The Clamp Bracket

    CLAMP BRACKET CLAMP BRACKET REMOVING/INSTALLING THE CLAMP BRACKET Step Job/Part Q'ty Remarks Tilt rod Plain washer Bolt Bolt Clamp bracket cap Clamp bracket plate Through tube Coller Swivel bracket Bushing Clamp bracket Clamp bracket Continued on next page. 7-19...
  • Page 172 CLAMP BRACKET Step Job/Part Q'ty Remarks Bolt Stopper Wave washer For installation, reverse the removal procedure. 7-20...

  • Page 173: Installing The Clamp Bracket Plate

    CLAMP BRACKET INSTALLING THE CLAMP BRACKET PLATE Install: Clamp bracket plate 1 NOTE: Turn clamp bracket plate 1 down until it contacts stopper boss 2 of the clamp bracket. 7-21...
  • Page 174 SWIVEL BRACKET SWIVEL BRACKET DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET Step Job/Part Q'ty Remarks Tension spring Circlip Tilt lock shaft Tilt lock rod Tilt lock plate Tension spring Circlip Reverse lock shaft Tilt lock plate Tilt lever Tilt lock rod Circlip Stopper shaft Continued on next page.
  • Page 175 SWIVEL BRACKET Step Job/Part Q'ty Remarks Circlip Tilt lever Circlip Tilt lever shaft Receiver Grease nipple Wire lead Swivel bracket For installation, reverse the removal procedure. 7-23...

  • Page 176: Electrical System

    CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ................8-1 (ONE LIGHTING COIL MODEL) ..............8-1 Top view and left side view ..............8-1 Details of the wiring harness connection ..........8-2 (TWO LIGHTING COILS MODEL) .............8-3 Top view, front view and left side view ..........8-3 Details of the wiring harness connection ..........8-4 ELECTRICAL COMPONENTS ANALYSIS ............8-5 DIGITAL CIRCUIT TESTER ................8-5...

  • Page 177: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (ONE LIGHTING COIL MODEL) Top view and left side view Pulser coil Short handle model Emergency signal light Long handle model Lighting coil Oil pressure switch Spark plug Charge coil CDI unit Rectifier Ignition coil...

  • Page 178: Details Of The Wiring Harness Connection

    ELECTRICAL COMPONENTS Details of the wiring harness connection To lighting coil : Green : White To charge coil : Red : Yellow To pulser coil : Blue To emergency signal light : Brown To stop switch W/R : White/Red To oil pressure switch : Black : Orange : Pink...

  • Page 179: (Two Lighting Coils Model)

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS (TWO LIGHTING COILS MODEL) Top view, front view and left side view Pulser coil Short handle model Emergency signal light Long handle model Lighting coil Oil pressure switch Spark plug Charge coil CDI unit Rectifier/regulator Ignition coil...

  • Page 180: Details Of The Wiring Harness Connection

    ELECTRICAL COMPONENTS Details of the wiring harness connection To lighting coil : Red : White To charge coil : Green : Yellow To pulser coil G/W : Green/White : Orange To emergency signal light : Blue To stop switch : Brown To oil pressure switch W/R : White/Red : Black...

  • Page 181: Electrical Components Analysis

    ELECTRICAL COMPONENTS ANALYSIS ELECTRICAL COMPONENTS ANALYSIS DIGITAL CIRCUIT TESTER Digital circuit tester: YU-34899-A/90890-06752 NOTE: “ ” indicates a continuity of electricity which means a closed circuit at the respective switch position. MEASURING THE PEAK VOLTAGE WARNING When checking the peak voltage do not touch any of the connections of the digital tester lead wires.

  • Page 182: Measuring A Low Resistance

    ELECTRICAL COMPONENTS ANALYSIS NOTE: When measuring the peak voltage, set the selector to the DC voltage mode. Make sure the peak voltage adapter lead are properly installed in the digital tester. Make sure the positive pin (the “+” mark facing up as shown) on the peak voltage adapter is installed into the positive terminal of the digital tester.

  • Page 183: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM CDI unit : Black Pulser coil W/R : White/Red Charge coil : Brown Ignition coil : Blue Spark plug : Orange...

  • Page 184: Checking The Spark Plugs

    IGNITION SYSTEM CHECKING THE SPARK PLUGS Check: Spark plugs Refer to “CHECKING THE SPARK PLUGS” on page 3-18. CHECKING THE IGNITION SPARK GAP WARNING Do not touch any of the connections of the spark gap tester lead wire. Do not let sparks leak out of the removed spark plug cap.
  • Page 185 IGNITION SYSTEM (2)To install the spark plug cap or high tension code, turn it clockwise until it is tightened. 2. Measure: Spark plug cap resistance Out of specification Replace. Spark plug cap resistance: 4.3 kΩ * *: Measured value. 3. Measure: Ignition coil resistance Primary Out of specification...

  • Page 186: Checking The Charge Coil

    IGNITION SYSTEM CHECKING THE CHARGE COIL Measure: Charge coil output peak voltage Below specification Replace the charge coil. Charge coil output peak voltage Brown (Br) - Blue (L) Cranking r/min. 1,500 3,500 Opened Closed D.C.V Peak voltage adaptor: YU-39991/90890-03172 Charge coil resistance Brown (Br) - Blue (L) Ω...

  • Page 187: Checking The Cdi Unit

    IGNITION SYSTEM CHECKING THE CDI UNIT Measure: CDI unit output peak voltage Below specification Replace the CDI unit. CDI unit output peak voltage Orange (O) - Black (B) Cranking r/min. 1,500 3,500 Opened Closed D.C.V 53.2 Peak voltage adaptor: YU-39991/90890-03172 NOTE: Before measuring CDI unit output peak voltage, make sure that no abnormality is...

  • Page 188: Ignition Control System

    IGNITION CONTROL SYSTEM IGNITION CONTROL SYSTEM Emergency signal light : Yellow/Red CDI unit : Pink Pulser coil : Black Charge coil W/R : White/Red Oil pressure switch : Brown : Blue 8-12...

  • Page 189: Checking The Engine Stop Switch

    IGNITION CONTROL SYSTEM CHECKING THE ENGINE STOP SWITCH Check: Engine stop switch continuity Out of specification Replace. Leads color White (W) Black (B) Remove the Lock plate A Install the Lock plate B Push the button C CHECKING THE PULSER COIL Check: Pulser coil output peak voltage Refer to “CHECKING THE PULSER...

  • Page 190: Checking The Oil Pressure Switch

    IGNITION CONTROL SYSTEM CHECKING THE OIL PRESSURE SWITCH Check: Oil pressure switch continuity Out of specification Replace. Oil pressure switch continuity pressure: 14.7 kPa (0.15 kgf/cm No continuity 2.13 psi) and above 14.7 kPa (0.15 kgf/cm Continuity 2.13 psi) and below Measuring steps: (1)Remove the silensor assembly and carburetor.

  • Page 191: Charging System

    CHARGING SYSTEM CHARGING SYSTEM (ONE LIGHTING COIL MODEL) Battery : Red Fuse (10A) : Green Rectifier : Black Lighting coil 8-15...

  • Page 192: (Two Lighting Coils Model)

    CHARGING SYSTEM CHARGING SYSTEM (TWO LIGHTING COILS MODEL) Battery : Red Fuse (10A) : Green Rectifier/regulator G/W : Green/White Lighting coil : Black 8-16...

  • Page 193: Checking The Battery

    CHARGING SYSTEM CHECKING THE BATTERY Check: Battery electrolyte level and specific gravity Refer to “CHECKING THE BATTERY” on page 3-17. CHECKING THE LIGHTING COIL Measure: Lighting coil output peak voltage Below specification Replace the lighting coil. Lighting coil output peak voltage (One lighting coil model): Green (G) - Green (G) Cranking...

  • Page 194: Checking The Rectifier And Rectifier/Regulator

    CHARGING SYSTEM CHECKING THE RECTIFIER AND RECTIFIER/REGULATOR Measure: Rectifier output peak voltage Rectifier/regulator output peak voltage Below specification Replace the rectifier or rectifier/regulator. Rectifier output peak voltage A Red (R) - Black (B) Cranking 1,500 3,500 r/min Opened Closed Opened Opened D.C.V —...

  • Page 195: Trouble Analysis

    CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................9-1 TROUBLE ANALYSIS CHART ..............9-1 TROUBLE SHOOTING FOR PEAK VOLTAGE ..........9-3...
  • Page 196 TROUBLE ANALYSIS TROUBLE ANALYSIS NOTE: Following items should be obtained before “trouble analysis”. 1. The battery is charged and its specified gravity is within specification. 2. There is no incorrect wiring connection. 3. Wiring connections are properly secured and are not any rusty. 4.
  • Page 197 TROUBLE ANALYSIS Trouble mode Check element Reference Relative part chapter LOWER UNIT Neutral position Clutch Gears Water inlet Water pump Propeller shaft and propeller Shifter/Pin Shift cam Shift rod or Shift cable Lower case Shim adjustment BRACKET UNIT Bracket Mount rubber Steering friction ELECTRICAL   ...
  • Page 198 TROUBLE SHOOTING FOR PEAK VOLTAGE TROUBLE SHOOTING FOR PEAK VOLTAGE Items Symptoms Poor starting No firing. The starter motor cranks the engine, but no firing takes place in the cylinder. Firing takes place in the cylinder, but the engine stops soon. Start-up time is too long.
  • Page 199 YAMAHA MOTOR CO., LTD. Printed in USA Apr. 2000 - (F6AMH, F8CMH) Printed on recycled paper...
  • Page 200 WIRING DIAGRAM F6MH, F8MH (FOR ONE LIGHTING COIL MODEL) Lighting coil Pulser coil Oil pressure Charge coil switch Bracket CDI unit Ignition coil Rectifier Spark plugs 0.5W Emergency AVX1.25B Y/R P signal light Stop switch 0.5W Black Brown 0.5B 0.5B Green Blue Optional parts...
  • Page 201 WIRING DIAGRAM F6MH, F8MH (FOR TWO LIGHTING COILS MODEL) Lighting coil Pulser coil Oil pressure Charge coil switch Bracket Optional parts CDI unit Ignition coil G/W G Rectifier/ Spark regulator plugs 0.5W Emergency AVX1.25B Y/R P signal light Stop switch 0.5W Black Brown...
  • Page 202 T8PH T8PR SUPPLEMENTARY SERVICE MANUAL LIT-18616-02-31 69G-28197-1A-1X...
  • Page 203 This Supplementary Service Manual has been prepared to introduce new service and data for the T8PH, T8PR. For complete service information procedures, it is necessary to use this Supplementary Service Manual together with the following manual. F6Z, F8Z SERVICE MANUAL: 68T-28197-ZA-11 LIT-18616-02-19 T8PH, T8PR SUPPLEMENTARY SERVICE MANUAL ©2000 by Yamaha Motor Corporation, USA...

  • Page 204: Manual Format

    HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organised in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handly reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
  • Page 205 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the outboard motor.
  • Page 206 HOW TO USE THIS MANUAL The main points regarding removing/installing and disassembly/assembly procedure are shown in the exploded views. The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page.
  • Page 207 (A)] Symbols in an exploded diagram indicate the grade of lubricant and the location of the lubricant point. Apply Yamaha 4-stroke motor oil Apply water resistant grease (Yamaha grease A, Yamaha marine grease) Apply Yamaha grease D Apply molybdenum disulfide grease...
  • Page 208 GENERAL INFORMATION IDENTIFICATION ....................1 SERIAL NUMBER ..................1 STARTING SERIAL NUMBERS ..............1 SPECIAL TOOLS ....................2 REMOVAL AND INSTALLATION ..............2 SPECIFICATIONS GENERAL SPECIFICATIONS (T8PH/T8MH/FT8DMH) ........3 GENERAL SPECIFICATIONS (FT8DEP/T8PR, FT8DE/T8ER) ......5 MAINTENANCE SPECIFICATIONS ..............7 POWER UNIT ....................7 LOWER UNIT ....................
  • Page 209 PROPELLER SHAFT ASS’Y ................31 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASS'Y ..31 CHECKING THE DOG CLUTCH ..............32 CHECKING THE PROPELLER SHAFT ............32 PROPELLER SHAFT HOUSING ASS’Y ............33 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASS'Y ..................33 DISASSEMBLING THE PROPELLER SHAFT HOUSING ASS'Y ....34 CHECKING THE GEARS ................
  • Page 210 CHECKING THE PT MOTOR ASSEMBLY ..........59 INSTALLING THE OIL SEAL ..............59 DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2 ....60 DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER ..62 DISASSEMBLING THE POWER TILT (PT) CYLINDER ......64 ASSEMBLING THE POWER TILT (PT) CYLINDER ........65 REMOVING/INSTALLING THE POWER TILT (PT) UNIT ......

  • Page 211: Identification

    IDENTIFICATION IDENTIFICATION SERIAL NUMBER The outboard motor’s serial number is stamped on a label which is attached to the port clamp bracket. NOTE: As an antitheft measure, a special label on which the outboard motor’s serial number is stamped is bonded to the port clamp bracket.

  • Page 212: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment. NOTE: For U.S.A. and Canada, use part numbers that start with “J-”, “YB-” “YM-”, “YU-”...
  • Page 213 GENERAL SPECIFICATIONS (T8PH/T8MH/ FT8DMH) GENERAL SPECIFICATIONS (T8PH/T8MH/FT8DMH) Model Item Unit T8PH T8MH FT8DMH DIMENSION Overall length mm (in) 1,038 (40.9) 1,038 (40.9) Overall width mm (in) 371 (14.6) 371 (14.6) 358 (14.1) Overall height mm (in) 1,187 (46.7) 1,187 (46.7) mm (in) 1,255 (49.4) —...

  • Page 214: General Specifications (T8Ph/T8Mh/Ft8Dmh)

    GENERAL SPECIFICATIONS (T8PH/T8MH/ FT8DMH) Model Item Unit T8PH T8MH FT8DMH FUEL AND OIL Fuel type Unleaded regular gasoline Fuel rating PON (*1) Engine oil type RON (*2) Engine oil grade 4-stroke engine oil SE, SF, SG or SH 10W-30, 10W-40 Total quantity (US oz, 800 (27.0, 28.2)

  • Page 215: General Specifications (Ft8Dep/T8Pr, Ft8De/T8Er)

    GENERAL SPECIFICATIONS (FT8DEP/T8PR, FT8DE/T8ER) GENERAL SPECIFICATIONS (FT8DEP/T8PR, FT8DE/T8ER) Model Item Unit World wide FT8DEP FT8DE USA, Canada T8PR T8ER DIMENSION Overall length mm (in) 552 (21.7) Overall width mm (in) 312 (12.3) Overall height mm (in) 1,187 (46.7) mm (in) 1,255 (49.4) Boat transom height mm (in)
  • Page 216 GENERAL SPECIFICATIONS (FT8DEP/T8PR, FT8DE/T8ER) Model Item World wide Unit FT8DEP FT8DE USA, Canada T8PR T8ER FUEL AND OIL Fuel type Unleaded regular gasoline Fuel rating PON (*1) Engine oil type RON (*2) Engine oil grade 4-stroke engine oil SE, SF, SG or SH 10W-30, 10W-40 Total quantity (US oz,...

  • Page 217: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS POWER UNIT Model Item World wide Unit FT8DMH FT8DE FT8DEP USA, Canada T8MH T8ER T8PR T8PH CYLINDER HEAD Warpage mm (in) 0.1 (0.004) limit CYLINDER BODY Bore (D1, D2) mm (in) 56.000 - 56.015 (2.2047 - 2.2053) Taper limit mm (in) 0.08 (0.0031)
  • Page 218 MAINTENANCE SPECIFICATIONS Model Item World wide Unit FT8DMH FT8DE FT8DEP USA, Canada T8MH T8ER T8PR T8PH Face width “B” mm (in) 1.84 - 2.26 (0.072 - 0.089) mm (in) 1.84 - 2.26 (0.072 - 0.089) Seat width”C” mm (in) 0.6 - 0.8 (0.023 - 0.031) mm (in) 0.6 - 0.8 (0.023 - 0.031) Mergin thickness “D”...
  • Page 219 MAINTENANCE SPECIFICATIONS Model Item World wide Unit FT8DMH FT8DE FT8DEP USA, Canada T8MH T8ER T8PR T8PH 2nd ring Dimension (B) mm (in) 1.5 (0.06) Dimension (T) mm (in) 2.5 (0.10) End gap (installed) mm (in) 0.30 - 0.45 (0.012 - 0.018) Side clearance mm (in) 0.03 - 0.07 (0.012 - 0.0028)

  • Page 220: Lower Unit

    MAINTENANCE SPECIFICATIONS Model Item World wide Unit FT8DMH FT8DE FT8DEP USA, Canada T8MH T8ER T8PR T8PH OIL PUMP Discharge (@ 3,000 r/min) L/h (US gal/h, 3.5 (0.925, 0.77) Imp gal/h) Outer rotor-housing clearance mm (in) 0.10 - 0.15 (0.004 - 0.006) Outer rotor-inner rotor clearance mm (in) 0.04 - 0.14 (0.002 - 0.006)

  • Page 221: Electrical

    MAINTENANCE SPECIFICATIONS ELECTRICAL Model Item World wide Unit FT8DMH FT8DE FT8DEP USA, Canada T8MH T8ER T8PR T8PH IGNITION SYSTEM Ignition timing Degree (BTDC) 5 - 30 Charge coil output peak voltage (Br – L) @ cranking (opened) @ cranking (closed) @ 1,500 r/min @ 3,500 r/min Pulser coil output peak voltage...
  • Page 222 MAINTENANCE SPECIFICATIONS Model Item World wide Unit FT8DMH FT8DE FT8DEP USA, Canada T8MH T8ER T8PR T8PH STARTER MOTOR Type Bendix Rating Second Output Brush length mm (in) 12.5 (0.49) Brush length limit mm (in) 9.0 (0.35) Commutator diameter mm (in) 30.0 (1.18) Commutator diameter limit mm (in)

  • Page 223: Outboard Dimensions (T8Ph/T8Mh/Ft8Dmh)

    MAINTENANCE SPECIFICATIONS OUTBOARD DIMENSIONS (T8PH/T8MH/FT8DMH)
  • Page 224 MAINTENANCE SPECIFICATIONS Model Symbol Unit T8PH T8MH FT8DMH mm (in) 430 (16.9) mm (in) 122 (4.8) mm (in) 608 (23.9) mm (in) 367 (14.4) mm (in) 99 (3.9) mm (in) 879 (34.6) mm (in) 941 (37.0) — 941 (37.0) mm (in) 271 (10.7) mm (in) 190 (7.5)

  • Page 225: Outboard Dimensions (Ft8Dep/T8Pr, Ft8De/T8Er)

    MAINTENANCE SPECIFICATIONS OUTBOARD DIMENSIONS (FT8DEP/T8PR, FT8DE/T8ER)
  • Page 226 MAINTENANCE SPECIFICATIONS Symbol Model World wide Unit FT8DEP FT8DE USA, Canada T8PR T8ER mm (in) 430 (16.9) mm (in) 122 (4.8) mm (in) — mm (in) 367 (14.4) mm (in) 99 (3.9) mm (in) 879 (34.6) mm (in) 941 (37.0) mm (in) 271 (10.7) mm (in)

  • Page 227: Bracket Dimension (Ft8Dmh/T8Mh, Ft8De/T8Er)

    MAINTENANCE SPECIFICATIONS BRACKET DIMENSION (FT8DMH/T8MH, FT8DE/T8ER) Symbol Model World wide Unit FT8DMH FT8DE USA, Canada T8MH T8ER mm (in) 70.5 (2.8) mm (in) 180.5 (7.2) mm (in) 95.3 (3.8) mm (in) 94.5 (3.7) mm (in) 105.3 (4.1) mm (in) 189.5 (7.5) mm (in) —...

  • Page 228: Bracket Dimension (Ft8Dep/T8Pr/T8Ph)

    MAINTENANCE SPECIFICATIONS BRACKET DIMENSION (FT8DEP/T8PR/T8PH) Model Symbol Unit T8PH T8PR FT8DEP mm (in) 95.3 (3.8) mm (in) 275.5 (10.8) mm (in) 95.3 (3.8) mm (in) 94.5 (3.7) mm (in) 111 (4.4) mm (in) 325.5 (12.8) mm (in) 155.5 (6.1) mm (in) —...
  • Page 229 TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Part Thread Tigtening torque Part to tightened Remarks Q’ty name size FUEL SYSTEM Screw 0.15 1.11 Fuel pump housing Fuel pump check valve Screw 0.05 0.37 Throttle axle link lock Screw 0.15 POWER UNIT Breather cover mounting Screw Fuel enrichment solenoid mounting...
  • Page 230 TIGHTENING TORQUES Part Thread Tigtening torque Part to tightened Q’ty Remarks name size kgf m ft lb BRACKET Shift handle mounting Bolt 0.35 Handle bracket mounting 26.5 Handle throttle grip Screw 0.35 Handle throttle shaft plate mounting Screw 0.35 Handle mounting (outside) 16.2 Handle mounting (inside) Handle rubber bushing mounting...
  • Page 231 TIGHTENING TORQUES General torque GENERAL TORQUES specifications Nut (A) Bolt (B) This chart specifies tightening torques for kgf m ft lb standard fasteners with a standard ISO 8 mm thread pitch. Tightening torque specifications 10 mm for special components or assemblies are 12 mm provided in applicable sections of this manual to avoid warpage, tighten...

  • Page 232: Maintenance Interval Chart

    Check/replace POWER TILT SYSTEM: Power tilt fluid Check/change GENERAL: Anode Check/replace Battery Check/replace (every 1 month) Spark plug Cleaning/ adjust/ replace Wiring and connector Check/ reconnect Bolts and nuts Tighten Lubrication points Grease *1..If Yamaha portable fuel tank is used.

  • Page 233: Power Unit

    POWER UNIT POWER UNIT ADJUSTING THE VALVE CLEARANCE NOTE: Valve clearance adjustment shoule be carried out when the engine is “cold”. 1. Remove: Recoil starter 1 Dust cover 2 Fuel pump 3 Cylinder head cover 4 2. Check: Intake valve clearance Exhaust valve clearance Out of specification Adjust.

  • Page 234: Power Tilt System

    POWER TILT SYSTEM/ GENERAL POWER TILT SYSTEM / GENERAL CHECKING THE POWER TILT (PT) FLUID LEVEL WARNING After tilting up the outboard, be sure to support it with the tilt lock knob. Otherwise, the outboard could suddenly lower if the power tilt unit should lose fluid pressure.

  • Page 235: Lower Unit

    LOWER UNIT LOWER UNIT REMOVING/INSTALLING THE LOWER UNIT Step Job/Part Q'ty Remarks Pin, split Washer Spacer Propeller Washer Spacer Locknut Adjusting nut Bolt Stud bolt/nut (for X-transom models) Extension (for X-transom models) Dowel pin (for X-transom models) Continued on next page.
  • Page 236 LOWER UNIT Step Job/Part Q'ty Remarks Lower unit Dowel pin Rubber seal Screw Water inlet grill Bolt Toothed washer Anode For installation, reverse the removal procedure.

  • Page 237: Water Pump

    WATER PUMP WATER PUMP REMOVING/INSTALLING THE WATER PUMP Step Job/Part Q'ty Remarks Lower unit Bolt Plate Impeller housing O-ring Impeller Impeller housing cup Woodruff key Bolt Dowel pin Metal gasket Rubber seal For installation, reverse the removal procedure.

  • Page 238: Checking The Impeller Housing

    WATER PUMP CHECKING THE IMPELLER HOUSING Check: Impeller housing Cracks/damage Replace. Æ CHECKING THE IMPELLER AND IMPELLER HOUSING CUP Check: Impeller Impeller housing cup Cracks/damage Replace. Æ INSTALLING THE IMPELLER HOUSING CUP Install: Impeller housing cup NOTE: To install the impeller housing cup, turn the drive shaft clockwise.

  • Page 239: Propeller Shaft Housing And Propeller Shaft

    PROPELLER SHAFT HOUSING AND PROPELLER SHAFT PROPELLER SHAFT HOUSING AND PROPELLER SHAFT REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASS’Y AND PROPELLER SHAFT ASS’Y Step Job/Part Q'ty Remarks Gear oil Propeller Bolt Propeller shaft housing ass’y Thrust washer Propeller shaft ass’y For installation, reverse the removal procedure.

  • Page 240: Removing The Propeller Shaft Housing Ass'y

    PROPELLER SHAFT HOUSING AND PROPELLER SHAFT REMOVING THE PROPELLER SHAFT HOUSING ASS’Y Remove: Propeller shaft housing ass’y Bearing housing puller claw: YB-06234 /90890-06503 Universal puller YB-06117 Stopper guide plate 90890-06501 Center bolt 90890-06504 For USA and CANADA Except for USA and CANADA...

  • Page 241: Propeller Shaft Ass'y

    PROPELLER SHAFT ASS’Y PROPELLER SHAFT ASS’Y DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASS'Y Step Job/Part Q'ty Remarks Spring Cross pin Dog clutch Shift plunger Spring Propeller shaft For assembly, reverse the disassembly procedure.

  • Page 242: Checking The Dog Clutch

    PROPELLER SHAFT ASS’Y CHECKING THE DOG CLUTCH Check: Dog clutch Wear/damage Replace. Æ CHECKING THE PROPELLER SHAFT Check: Propeller shaft Wear/damage Replace. Æ...

  • Page 243: Propeller Shaft Housing Ass'y

    PROPELLER SHAFT HOUSING ASS’Y PROPELLER SHAFT HOUSING ASS’Y DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASS'Y Step Job/Part Q'ty Remarks Propeller shaft housing ass’y Reverse gear Reverse gear shim O-ring Not reusable O-ring Not reusable Ball bearing Oil seal Not reusable Needle bearing Propeller shaft housing For assembly, reverse the disassembly procedure.

  • Page 244: Disassembling The Propeller Shaft Housing Ass'y

    PROPELLER SHAFT HOUSING ASS’Y DISASSEMBLING THE PROPELLER SHAFT HOUSING ASS'Y 1. Remove: Reverse gear Reverse shim(s) Ball bearing Bearing separator YB-06216/90890-06534 Slide hammer set YB-06096 Stopper guide plate 90890-06501 Bearing puller 90890-06535 Stopper guide stand 90890-06538 For USA and CANADA Except for USA and CANADA 2.

  • Page 245: Checking The Bearing

    PROPELLER SHAFT HOUSING ASS’Y CHECKING THE BEARING Check: Bearing Pitting/rumbling Replace. Æ NOTE: Rotate the bearing and check if it turns smoothly. CHECKING THE PROPELLER SHAFT HOUSING 1. Clean: Propeller shaft housing (with a soft brush and solvent) 2. Check: Propeller shaft housing Cracks/damage Replace.
  • Page 246 PROPELLER SHAFT HOUSING ASS’Y 2. Install: Oil seals Oil seal depth 4.5 - 5.0 mm (0.18 - 0.20 in) Oil seal installer (Needle bearing attachment) N.A./90980-06614 Driver rod YB-06071/90890-06604 NOTE: First, fully install the lower oil seal and then the upper. 3.

  • Page 247: Drive Shaft, Forward Gear, Shift Rod And Oil Seal Housing

    DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND OIL SEAL HOUSING DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND OIL SEAL HOUSING REMOVING/INSTALLING THE DRIVE SHAFT, FORWARD GEAR AND SHAFT ROD Step Job/Part Q'ty Remarks Propeller shaft ass’y Water pump Pinion nut Pinion Washer Thrust bearing...
  • Page 248 DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND OIL SEAL HOUSING Step Job/Part Q'ty Remarks Shift rod Sleeve Needle bearing Forward gear bearing outer race Oil seal Not reusable Bushing Not reusable Oil seal housing ass’y For installation, reverse the removal procedure.

  • Page 249: Removing The Pinion And Forward Gear

    DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND OIL SEAL HOUSING REMOVING THE PINION AND FORWARD GEAR 1. Remove : Pinion nut. Driver shaft holder YB-06565/90890-06565 Pinion nut holder YB-06078/N.A. 2. Remove : Pinion 1 Forward gear 2 (along with the tapered roller bearing and forward gear shim) DISASSEMBLING THE OIL SEAL HOUSING ASS'Y...

  • Page 250: Disassembling The Lower Case

    DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND OIL SEAL HOUSING DISASSEMBLING THE LOWER CASE 1. Remove: Needle bearing Driver rod YB-06229/90890-06602 Needle bearing attachment YB-06230/90890-06617 2. Remove: Forward gear bearing outer race Forward gear shim(s) Slide hammer set YB-06096 Stopper guide plate 90890-06501 Bearing outer race puller 90890-06535...

  • Page 251: Checking The Pinion And Forward Gear

    DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND OIL SEAL HOUSING CHECKING THE PINION AND FORWARD GEAR Check: Teeth Dog clutch Wear/damage Replace. Æ CHECKING THE DRIVE SHAFT Check: Bearing Wear/damage Replace. Æ CHECKING THE SHIFT CAM Check: Shift cam Wear/damage Replace.

  • Page 252: Assembling The Oil Seal Housing Ass'y

    DRIVE SHAFT, FORWARD GEAR, SHIFT ROD AND OIL SEAL HOUSING 2. Install: Needle bearing Needle bearing depth 0.7 - 1.2 mm (0.03 - 0.05 in) Needle bearing depth 189.3 - 189.8 mm (7.45 - 7.47 in) Driver rod YB-06229/90890-06602 Drive shaft needle bearing depth stop YB-06231 Needle bearing attachment...

  • Page 253: Shimming (For Usa And Canada)

    SHIMMING (FOR USA AND CANADA) SHIMMING (FOR USA AND CANADA) NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reassembling with the original inner parts and a new case (the difference between the original inner parts and the new case).

  • Page 254: Shimming (Except For Usa And Canada)

    SHIMMING (EXCEPT FOR USA AND CANADA) SHIMMING (EXCEPT FOR USA AND CANADA) NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reassembling with the original inner parts and a new case.

  • Page 255: Selecting The Forward Gear Shims

    SHIMMING (EXCEPT FOR USA AND CANADA) SELECTING THE FORWARD GEAR SHIMS NOTE: Find the forward gear shim thickness (T1) by selecting shims until the specified mea- surement (Mv1) is obtained with the spe- cial tool. 1. Measure: Measurement (Mv1) Shimming plate: 90890-06701 Digital caliper: 90890-06704...

  • Page 256: Selecting The Reverse Gear Shims

    SHIMMING (EXCEPT FOR USA AND CANADA) SELECTING THE REVERSE GEAR SHIMS NOTE: Find the reverse gear shim thickness (T2) by selecting shims until the specified mea- surement (Mv2) is obtained with the spe- cial tool. 1. Measure: Measurement (Mv2) Shimming plate: 90890-06701 Digital caliper: 90890-06704...

  • Page 257: Backlash Measurement

    BACKLASH MEASUREMENT BACKLASH MEASUREMENT NOTE: Do not install the water pump compo- • nents when measuring the backlash. Measure both the forward and reverse • gear backlashes. If both the forward and reverse gear • back-lashes are larger than specification, the pinion gear may be too high.

  • Page 258: Measuring The Reverse Gear Backlash

    BACKLASH MEASUREMENT (3) Attach the backlash indicator 1 onto the drive shaft (12.8 mm (0.5 in) in diameter) as shown. Backlash indicator: YB-06265/90890-06706 (4) Attach the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indicator.
  • Page 259 BACKLASH MEASUREMENT Measuring steps: (1) Load the reverse gear by installing the propeller 1 collar 2 and then tighten the propeller nut. (2) Set the lower unit upside down. Propeller nut: m (0.5 kgf m , 3.6 ft l b) (3) Attach the backlash indicator 3 onto the drive shaft (12.8 mm (0.5 in) in diameter) as shown.

  • Page 260: Upper Case

    UPPER CASE UPPER CASE DISASSEMBLING/ASSEMBLING THE UPPER CASE Step Job/Part Q'ty Remarks Bolt (with washer) Upper side mount rubber Bolt (with washer) Exhaust guide Clip Oil strainer Oil seal Not reusable Gasket Not reusable Hose Screw Plate Damper Continued on next page.
  • Page 261 UPPER CASE Step Job/Part Q'ty Remarks Oil drain plug Gasket Bolt (with washer) Not reusable Oil pan Bolt (with washer) Muffer Bolt (with washer) Plate Grommet Upper case For assembly, reverse the disassembly procedure.

  • Page 262: Steering Friction

    STEERING FRICTION STEERING FRICTION DISASSEMBLING/ASSEMBLING THE STEERING FRICTION Step Job/Part Q'ty Remarks Lock nut Plate washer Bolt (with washer) Friction piece Collar Friction Plats Collar Plate washer Lock nob Lock shaft Friction plate For assembly, reverse the disassembly procedure.

  • Page 263: Power Tilt (Pt) Unit

    POWER TILT (PT) UNIT POWER TILT (PT) UNIT DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 1 Step Job/Part Q'ty Remarks Reservoir cap O-ring 6.8 x 1.9 mm Not reusable Bolt PT motor O-ring 21.7 x 3.5 mm Not reusable O-ring Not reusable Manual release rod O-ring 5.8 x 1.9 mm...
  • Page 264 POWER TILT (PT) UNIT Step Job/Part Q'ty Remarks Absorver valve pin Ball Spring Outside diameter 7.6 x Length 14.5 mm Spring Outside diameter 8.8 x Length 18.1 mm Valve pin Valve seal For assembly, reverse the disassembly procedure.

  • Page 265: Installing The Relief Valve

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

  • Page 266: Disassembling/Assembling The Pt Motor

    POWER TILT (PT) UNIT DISASSEMBLING/ASSEMBLING THE PT MOTOR Step Job/Part Q'ty Remarks Screw (with washer) Yoke assembly 43.9 x 1.5 mm Not reusable O-ring Not reusable Screw (with washer) Armatuer Screw (with washer) Brush Brush spring Oil seal Not reusable End frame For assembly, reverse the disassembly procedure.

  • Page 267: Removing The Armature

    POWER TILT (PT) UNIT REMOVING THE ARMATURE 1. Remove: Screw 1 Brush 2 Armature 3 NOTE: Push brush 2 to the inside, then remove armature 3. CHECKING THE PT MOTOR 1. Check: Commutator Dirt Clean with 600 grit Æ sandpaper. 2.
  • Page 268 POWER TILT (PT) UNIT 4. Measure: Armature coil continuity Out of specification Replace. Æ Armature coil continuity Commutator segments Continuity Segment - laminations continuity Segment - shaft continuity 5. Measure: Brush length Out of specification Replace. Æ Brush length limit: 3 mm (0.12 in) 6.

  • Page 269: Checking The Pt Motor Assembly

    POWER TILT (PT) UNIT CHECKING THE PT MOTOR ASSEMBLY 1. Check: PT motor operation Incorrect operation Repair. Æ PT motor operation Motor turns Blue (+), Green (-) clockwise Motor turns Green (+), Blue (-) counterclockwise INSTALLING THE OIL SEAL 1. Install: Oil seal Oil seal attachment: YB-06112/90890-06614...
  • Page 270 POWER TILT (PT) UNIT DISASSEMBLING/ASSEMBLING THE VALVES AND PUMP 2 Step Job/Part Q'ty Remarks Bolt Gear pump housing Gear Dowel pin Top chamber shuttle piston O-ring 8.5 x 1.5 mm Not reusable Spring Outside diameter 2.5 x Length 10.0 mm Bottom chamber shuttle piston Circlip Valve seal...
  • Page 271 POWER TILT (PT) UNIT Step Job/Part Q'ty Remarks Spring Outside diameter 4.1 x Length 12.0 mm Filter O-ring 8.5 mm x 1.5 mm Not reusable Ball Spring Outside diameter 3.2 x Length 8.0 mm Plate For assembly, reverse the disassembly procedure.

  • Page 272: Disassembling/Assembling The Power Tilt (Pt) Cylinder

    POWER TILT (PT) UNIT DISASSEMBLING/ASSEMBLING THE POWER TILT (PT) CYLINDER Step Job/Part Q'ty Remarks Tilt ram assembly Free piston O-ring 20.8 x 2.4 mm Not reusable Backing ring Tilt cylinder O-ring 26.0 x 1.8 mm Not reusable Cylinder O-ring 29.7 x 1.9 mm Not reusable O-ring 20.8 x 2.4 mm...
  • Page 273 POWER TILT (PT) UNIT Step Job/Part Q'ty Remarks Spring Outside diameter 6.8 x Length 13.5 mm Dowel pin End screw O-ring 12.3 x 2.4 mm Not reusable Backup ring Dust seal Not reusable Tilt ram For assembly, reverse the disassembly procedure.

  • Page 274: Disassembling The Power Tilt (Pt) Cylinder

    POWER TILT (PT) UNIT DISASSEMBLING THE POWER TILT (PT) CYLINDER WARNING To prevent the hydraulic fluid from spurting out due to internal pressure, the outboard should be kept fully tilted up (the tilt rod at full length). After removing the tilt motor or oil reservoir, do not push the tilt rod down.

  • Page 275: Assembling The Power Tilt (Pt) Cylinder

    POWER TILT (PT) UNIT ASSEMBLING THE POWER TILT (PT) CYLINDER 1. Tighten: Tilt ram Power tilt wrench: YB-06560 / 90890-06560 Tilt piston: 45 N m (4.5 kgf m , 32 ft l b) NOTE: Hold the protruded portion of the tilt piston with the aluminium plate 1 and tighten the tilt ram.
  • Page 276 POWER TILT (PT) UNIT 4. Bleed: Bleeding step: (1) Open the manual valve 1. (2) Manually push in the tilt ram to its fully contracted state. (3) Remove the reservoir cap 2 and supply the fluid to the prescribed level. Reservoir cap: m (0.5 kgf m , 3.6 ft...
  • Page 277 POWER TILT (PT) UNIT (5) Connect the PT motor lead to the battery and place the tilt ram in it fully extended state. NOTE: When the tilt ram is unstable or does not • move, supply the fluid to the prescribed level.
  • Page 278 POWER TILT (PT) UNIT (7) Open the manual valve, leave it to stand for about 1 second and close it. NOTE: Check the fluid level and replenish if short. (8) Leave it to stand for about 3 minutes and then repeat steps (6) and (7).

  • Page 279: Removing/Installing The Power Tilt (Pt) Unit

    POWER TILT (PT) UNIT REMOVING/INSTALLING THE POWER TILT (PT) UNIT Step Job/Part Q'ty Remarks PT motor lead Clamp Bolt (with washer) Circlip Bushing Bushing Bolt Washer Bushing Bushing Collar Continued on next page.
  • Page 280 POWER TILT (PT) UNIT Step Job/Part Q'ty Remarks Power tilt (PT) unit For installation, reverse the removal procedure.

  • Page 281: Starter Motor

    STARTER MOTOR STARTER MOTOR DISASSEMBLING/ASSEMBLING THE STARTER MOTOR Step Job/Part Q'ty Remarks Clip Pinion stopper Spring Pinion Through bolt Front cover Washer Washer Washer Starter body Armature assembly Washer Continued on next page.
  • Page 282 STARTER MOTOR Step Job/Part Q'ty Remarks Spring washer Spring washer Plate washer Bushing O-ring Screw Brush holder Spring Brush Bushing Rear cover O-ring For installation, reverse the removal procedure.

  • Page 283: Removing The Pinion

    STARTER MOTOR REMOVING THE PINION Remove: Clip 1 NOTE: Using a pry-bar, pry off the clip. CHECKING THE PINION 1. Check: Pinion teeth Wear/damage Replace. Æ 2. Check: Clutch movement Damage Replace. Æ NOTE: Rotate the pinion clockwise, and check that it freely.

  • Page 284: Checking The Brush Holder

    STARTER MOTOR 3. Check: Commutator under cut Clog/dirty Clean. Æ NOTE: Remove all particle metal by compressed air. 4. Check: Armature coil continuity Out of specification Replace. Æ Armature coil continuity: Commutator segments Continuity Segment - Laminations No continuity Segment - Shaft No continuity CHECKING THE BRUSH HOLDER 1.

  • Page 285: Power Tilt (Pt) System

    POWER TILT (PT) SYSTEM POWER TILT (PT) SYSTEM POWER TILT (PT) SYSTEM (T8PR/FT8DEP) Battery : Black Fuse (10A) : Green PT switch : Blue PT relay : Light green Terminal : Red PT motor : Sky blue...

  • Page 286: Power Tilt (Pt) System (T8Ph)

    POWER TILT (PT) SYSTEM POWER TILT (PT) SYSTEM (T8PH) Battery : Black PT relay : Green Terminal : Blue PT motor : Light green PT switch : Red Fuse (10A) : Sky blue...

  • Page 287: Checking The Pt Switch

    POWER TILT (PT) SYSTEM CHECKING THE PT SWITCH Check: PT switch continuity Out of specification Replace. Æ Leads color Light Sky blue Red (R) green Switch (Sb) (Lg) position Free Down CHECKING THE PT RELAY 1. Check: PT relay continuity Out of specification Replace.
  • Page 288 POWER TILT (PT) SYSTEM (3) Check that there is continuity between the PT relay terminals. (4) Connect the tester between PT relay Green (G) lead and Red (R) lead. (5) Connect a 12-V battery as shown. Light green (Lg) lead Positive terminal Æ...
  • Page 289 YAMAHA MOTOR CORPORATION, USA Printed in USA Oct. 2000 -1.66 x 1 SY (T8PH, T8PR) Printed on recycled paper...
  • Page 290 WIRING DIAGRAM T8PH Oil pressure switch Lighting coil CDI unit Pulser coil Bracket Charge coil Rectifier/ regulator Starting motor Emergency signal light Y/R P Ignition coil Stop switch Spark plugs Nutral switch Starter relay Starter switch AV 8.0B Terminal ass'y AV 8.0B AVX3.0 AVX3.0...
  • Page 291 WIRING DIAGRAM T8PR Fuel enrich Oil pressure solenoid switch Lighting coil CDI unit Pulser coil Bracket Charge coil Rectifier/ regulator Starting motor Emergency Y/R P signal light Ignition coil 1.25R AV0.75f G AV0.75f W AV0.75f L AV0.75f G AV1.25B AV1.25R Spark AV0.75Sb plugs...

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