Yamaha F4B Service Manual
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Yamaha F4B Service Manual

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SERVICE MANUAL
6BV-28197-3M-11

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Summary of Contents for Yamaha F4B

  • Page 1 SERVICE MANUAL 6BV-28197-3M-11...
  • Page 2 Preface 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 the Bronze Technical Certificate of the YTA...
  • Page 3 Contents General information INFO Specification SPEC TECH Technical features and description Rigging information GING TRBL Troubleshooting SHTG Electrical system ELEC Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Maintenance Index Appendix...

  • Page 5: Table Of Contents

    INFO General information Safety while working ............ 0-1 Rotating part ................0-1 Hot part ..................0-1 Electric shock ................0-1 Propeller ..................0-1 Handling of gasoline ..............0-1 Ventilation .................. 0-1 Self-protection ................0-2 Working with crane ..............0-2 Part, lubricant, and sealant ............0-2 Handling of sealant ..............

  • Page 6: Safety While Working

    INFO General information Safety while working Handling of gasoline • Gasoline is highly flammable. Keep gaso- To prevent an accident or injury and to pro- line and all flammable products away from vide quality service, observe the following heat, sparks, and open flames. safety procedures.

  • Page 7: Self-Protection

    Yamaha, when servicing or repairing the out- using an air compressor. board motor. • Protect your hands and feet by wearing pro- tective gloves and safety shoes when nec- essary.

  • Page 8: Tightening Torque

    INFO General information Tightening torque Follow the tightening torque specifications provided throughout the manual. When tight- ening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward. Non-reusable part Always use new gaskets, seals, O-rings, cot- ter pins, and so on, when installing or assem- bling parts.

  • Page 9: How To Use This Manual

    Safety while working / How to use this manual How to use this manual How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the following information as a guide for effective and quality service. •...

  • Page 10: Abbreviation

    INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description American Petroleum Institute BTDC Before Top Dead Center Cold Cranking Ampere Capacitor Discharge Ignition European Norm (European standard) Forward International Electrotechnical Commission Neutral Overhead Valve PORT Port side Reverse...

  • Page 11: Lubricant, Sealant, And Thread Locking Agent

    Lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbol Name Application Yamaha 4-stroke motor oil Lubricant Gear oil Lubricant Water resistant grease Lubricant (Yamaha grease A)

  • Page 12: Special Service Tool

    INFO General information Special service tool For all markets except U.S.A. and Canada Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division. Digital circuit tester Pilot screw driver 90890-03174 90890-06673 Peak voltage adapter B Compression gauge...
  • Page 13 Special service tool Flywheel puller Valve spring compressor attachment 90890-06521 90890-06320 Driver rod L3 Valve guide remover/installer 90890-06652 90890-06801 Needle bearing attachment Valve guide reamer 90890-06615 90890-06804 Needle bearing attachment Valve lapper 90890-06613 90890-04101 Valve spring compressor Valve seat cutter holder 90890-04019 90890-06316...
  • Page 14 INFO General information Valve seat cutter 30° Valve seat cutter 60° 90890-06818 90890-06813 Valve seat cutter 45° Needle bearing attachment 90890-06312 90890-06612 Valve seat cutter 60° Driver rod LL 90890-06323 90890-06605 Valve seat cutter 30° Ball bearing attachment 90890-06819 90890-06632 Valve seat cutter 45°...
  • Page 15 Special service tool Ball bearing attachment Bearing outer race attachment 90890-06655 90890-06628 Piston slider Bushing installer center bolt 90890-06529 90890-06601 Stopper guide plate Bushing attachment 90890-06501 90890-06650 Stopper guide stand Bushing attachment 90890-06538 90890-06649 Bearing puller assembly 90890-06535 0-10...
  • Page 16 INFO General information — MEMO — 0-11...
  • Page 17 SPEC Specification Model feature ..............1-1 General feature ................. 1-1 Model designation ..............1-2 Serial number ................1-2 Model data ................. 1-3 Dimension and weight ............... 1-3 Performance ................1-3 Power unit ................. 1-3 Lower unit .................. 1-4 Bracket unit ................1-4 Fuel and oil requirement ............

  • Page 18: Specification

    SPEC Specification Model feature General feature F4B, F5A, F6C Overall feature • 4-stroke, 1-cylinder, OHV, 2-valve, 139.0 cm (8.5 cu. in) engine • Low emission in compliance with EU regulations a Power unit • Compact OHV engine • Blowby gas reburning system •...

  • Page 19: Model Designation

    Model feature Model designation F 4 B M H S Model description F: 4-stroke regular rotation Model name 4: 4/5/6 Product generation B: A and up M: Manual starter Functions H: Tiller handle S: S (15 in) Transom height L: L (20 in) Serial number Approved Starting...

  • Page 20: Model Data

    SPEC Specification Model data Dimension and weight Model Item Unit F4BMH F5AMH F6CMH Overall length mm (in) 750.0 (29.5) Overall width mm (in) 403.0 (15.9) Overall height mm (in) 1040.0 (40.9) mm (in) 1168.0 (46.0) Boat transom height mm (in) 440.0 (17.3) mm (in) 568.0 (22.4)

  • Page 21: Lower Unit

    Model data Lower unit Model Item Unit F4BMH F5AMH F6CMH Gear shift positions F-N-R Gear ratio 2.08 (27/13) Reduction gear type Straight bevel gear Clutch type Dog clutch Propeller shaft type Spline Propeller direction (rear view) Clockwise Propeller mark Bracket unit Model Item Unit...

  • Page 22: Electrical Technical Data

    SPEC Specification Electrical technical data Ignition timing control system Model Item Unit F4BMH F5AMH F6CMH Spark plug Cap resistance (*1) At 20 °C (68 °F) k mm (in) 0.6–0.7 (0.024–0.028) Ignition timing At 1500 r/min Degree BTDC 7–9 CDI unit Air gap mm (in) 0.4–0.6 (0.016–0.024)

  • Page 23: Power Unit Technical Data

    Electrical technical data / Fuel system technical data / Power unit technical data Power unit technical data Model Item Unit F4BMH F5AMH F6CMH Carburetor Float height (*1) mm (in) 10.0 (0.4) Valve seat size mm (in) 0.8 (0.03) Main jet (MJ) # 60 # 70 # 75...

  • Page 24: Cylinder Head Assembly

    SPEC Specification Cylinder head assembly Model Item Unit F4BMH F5AMH F6CMH Valve Clearance Intake and exhaust mm (in) 0.08–0.12 (0.003–0.005) Margin thickness Intake mm (in) 0.800–1.200 (0.0315–0.0472) Exhaust mm (in) 1.100–1.500 (0.0433–0.0591) Runout (*1) Intake mm (in) 0.050 (0.0020) Exhaust mm (in) 0.030 (0.0012) Seat contact width...

  • Page 25: Crankcase Assembly

    Power unit technical data Crankcase assembly Model Item Unit F4BMH F5AMH F6CMH Crankcase Crankshaft journal inside mm (in) 25.020–25.041 (0.9850–0.9859) diameter Camshaft journal inside mm (in) 15.000–15.018 (0.5906–0.5913) diameter Oil pump Rotor housing inside diame- mm (in) 23.130–23.160 (0.9106–0.9118) Outer rotor diameter mm (in) 22.980–23.000 (0.9047–0.9055) Outer rotor height...

  • Page 26: Lower Unit Technical Data

    SPEC Specification Model Item Unit F4BMH F5AMH F6CMH Connecting rod Small end inside diameter mm (in) 15.015–15.029 (0.5911–0.5917) Big end inside diameter mm (in) 28.000–28.015 (1.1024–1.1030) Oil clearance mm (in) 0.016–0.046 (0.0006–0.0018) Crankshaft Runout mm (in) 0.020 (0.0008) Journal diameter (cylinder mm (in) 24.980–24.993 (0.9835–0.9840) block side)

  • Page 27: Specified Tightening Torque

    Power unit technical data / Lower unit technical data / Specified tightening torque Specified tightening torque Specified tightening torque Fuel system Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Choke cable nut — Choke holder bolt Fuel cock screw Intake manifold bolt Throttle cable locknut —...

  • Page 28: Bracket Unit

    SPEC Specification Bracket unit Tightening torques Part to be tightened Screw size N·m kgf·m ft·lb Throttle rod screw Throttle grip screw Tiller handle mounting bolt 20.7 Carrying handle bolt 14.0 Start-in-gear protection cable locknut — Primer pump holder bolt Shift lever bolt 14.0 Shift link bolt 0.35...
  • Page 29 TECH Technical features and description Engine control system ............2-1 Outline ..................2-1 CDI unit ..................2-2 Ignition timing control ..............2-2 Ignition cut-off control ..............2-3 Power unit system ............2-4 Outline ..................2-4 Automatic decompressor ............2-5 Blowby gas reburning system ........... 2-6 Lighting coil (optional for European market) ......

  • Page 30: Tech Fea

    Technical features and description Engine control system Outline The F4B, F5A, F6C adopt the CDI ignition system consisting of the CDI unit and a permanent mag- net of the flywheel magnet. The CDI unit has a compact design with an integrated ignition coil.

  • Page 31: Cdi Unit

    Engine control system CDI unit When the permanent magnet a on the flywheel magnet a passes in front of the CDI unit b, the exciter coil b in the CDI unit b induces an electric current c to produce a crank signal d that will be transmitted to the ignition control circuit e.

  • Page 32: Ignition Cut-Off Control

    TECH Technical features and description Ignition cut-off control There are two types of ignition cut-off control. One is a system to cut off the ignition during engine cranking without outputting ignition signals a from ignition control circuit b when the engine speed is 150 r/min or lower.

  • Page 33: Power Unit System

    Power unit system Outline The F4B, F5A, F6C feature an OHV engine with a newly designed cylinder head and cylinder block. The decompressor is built into the camshaft to facilitate engine cranking with a manual starter. In addition, a blowby gas reburning system is incorporated to reduce the amount of oil contained in the blowby gases.

  • Page 34: Automatic Decompressor

    TECH Technical features and description Automatic decompressor To facilitate engine cranking, the decompression actuator forcefully opens the exhaust valve on the compression stroke to release compression pressure during engine cranking and prevent pressure in the cylinder from increasing. As the cranking speed increases, the decompression actuator will move in the direction of a due to the centrifugal force and the exhaust valve will return to normal operation.

  • Page 35: Blowby Gas Reburning System

    Power unit system Blowby gas reburning system A blowby gas reburning system is adopted to be respectful with the environment. To reburn the blowby gases, this engine separates oil from the blowby gases in two labyrinths. First, oil is separated from the blowby gases in the cylinder block labyrinth, and then in the intake silencer labyrinth.

  • Page 36: Lighting Coil (Optional For European Market)

    Technical features and description Lighting coil (optional for European market) The F4B, F5A, F6C can be equipped with a flywheel magnet, lighting coil, and Rectifier Regulator, available as optional accessories, to enable battery charging. The electrical current generating capacity is 6A when the engine speed is at 6000 r/min.

  • Page 37: Fuel System

    Power unit system / Fuel system Fuel system Fuel system Outline This engine is equipped with a simply-designed and reliable butterfly-type carburetor. A built-in primer pump is also provided in order to ease engine starting when the float chamber is empty, or when operating the engine after it has been stored for a long time.

  • Page 38: Carburetor

    TECH Technical features and description Carburetor Idle and low speed operation When the engine is running at idle or at low speed, negative pressure generated in the pilot passage a will be increased. Air is drawn into the pilot passage through the pilot air jet b to be mixed with the fuel that is also sucked into the passage through the pilot jet a.
  • Page 39 Fuel system Medium speed operation When running at medium speed, the air that has entered through the main bore a flows faster, causing negative pressure to increase in the main bore a. When the negative pressure in the main bore a increases, the fuel is sucked from the main jet a to be mixed with the air that has entered from the main air jet b through the emulsion tube c, and then drawn into the main nozzle b.
  • Page 40 TECH Technical features and description High speed operation When running at high speed, the throttle valve opening is near the fully open position, and the neg- ative pressure generated in the main bore a becomes even higher. Consequently, a larger amount of air and fuel mixture is drawn from the main nozzle a to be supplied to the engine.

  • Page 41: Built-In Primer Pump

    Fuel system Built-in primer pump This engine is equipped with a built-in primer pump in order to ease engine starting when the float chamber is empty, or when operating the engine after it has been stored for a long time. The built-in primer pump sends fuel directly to the float chamber in the carburetor without operating the mechanical fuel pump.

  • Page 42: Lubrication System

    TECH Technical features and description Lubrication system Outline For the first time in a single-cylinder engine, a trochoid type oil pump has been adopted in order to improve lubrication performance. The oil hole in the crankshaft allows oil to lubricate the crankpin and connecting rod. Oil pump and engine oil flow The oil pump is driven by the camshaft.

  • Page 43: Tilt System

    Lubrication system / Tilt system Tilt system Tilt system Outline The incorporated reverse lock system prevents the outboard motor from tilting up when the shift position is in reverse and the throttle is applied. Reverse lock system In this system, the tilt up function will be automatically locked when shifted in reverse. When the shift lever a is moved to the reverse position, the rod b, which was pushing up the reverse lock c, moves down.

  • Page 44: Lubrication Diagram

    TECH Technical features and description Lubrication diagram Crankshaft Crankshaft journal bearing Camshaft Oil pump Oil strainer Cylinder head Crankshaft Crankpin Crankshaft Camshaft journal bearing Piston Cylinder block Cylinder bore Valve lifter Camshaft Oil pump Oil strainer Crank case A Engine oil flow B Splashing oil 2-15...

  • Page 45: Cooling Flow Diagram

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

  • Page 46: Intake And Exhaust Flow Diagram

    TECH Technical features and description Intake and exhaust flow diagram Carburetor Intake manifold Intake silencer A Intake air flow B Exhaust gas flow 2-17...
  • Page 47 GING Rigging information Outboard motor installation ..........3-1 Dimension ................3-2 Exterior F4BMH, F5AMH, F6CMH ..........3-2 Clamp bracket ................3-3 Uncrating procedure ............3-4 Outboard motor mounting ..........3-4 Installing the charging system (optional for European market) . 3-5 Installing the battery (optional for European market) ....

  • Page 48: Rigging Information

    • Improper mounting of the outboard motor could result in hazardous conditions, such as poor handling, loss of control, or fire hazards. Consult your dealer or have a Yamaha- trained person experienced in proper rigging mount the outboard motor.

  • Page 49: Dimension

    Outboard motor installation / Dimension Dimension Dimension Exterior F4BMH, F5AMH, F6CMH mm (in) 130 (5.2) 409 (16.2) 341 (13.5) S: 635 (25.0) 383 (15.1) L: 753 (29.0) 134 (5.3) 63 (2.5) 259 (10.2) (*1) Transom height...

  • Page 50: Clamp Bracket

    GING Rigging information Clamp bracket mm (in) 83 (3.3) 83 (3.3) 55 (2.2) 55 (2.2) 22 (0.9) 60 (2.4)

  • Page 51: Uncrating Procedure

    Dimension / Uncrating procedure / Outboard motor mounting Uncrating procedure Uncrating procedure TIP: 1. Check the crate for any shipping dam- Place the outboard motor on the boat or on a age. stand so that the clamp bracket is in the tilt- up position for easy mounting.

  • Page 52: Installing The Charging System (Optional For European Market)

    GING Rigging information 2. Adjust the position of the outboard motor so that the height of the anti-cavitation plate e is between the bottom of the boat and a maximum of 25.0 mm (1.0 in) f below it. 7. Remove the bolt e, and then install the Rectifier Regulator f using the included TIP: bolts g.

  • Page 53: Installing The Battery (Optional For European Market)

    Outboard motor mounting 11. Install the bracket l to the bottom cowling using the self-tapping bolt m, and then install the fuse box n. TIP: Check that the lighting coil leads d do not interfere with the flywheel magnet. 12. Connect Rectifier Regulator connectors of Green (G) leads and Red...

  • Page 54: Rigging Recommendations

    GING Rigging information Rigging recommendations Full throttle operating range: Battery requirement F4B: 4000–5000 r/min Make sure that the size of the battery cable F5A, F6C: 4500–5500 r/min terminals is appropriate for the size of the battery terminals. Propeller size (in)
  • Page 55 TRBL SHTG Troubleshooting Outboard motor troubleshooting ........4-1 Troubleshooting procedure ............4-1 Troubleshooting the power unit ..........4-1 Troubleshooting the lower unit ..........4-3...
  • Page 56 TRBL SHTG Troubleshooting Outboard motor troubleshooting Troubleshooting procedure 1. Before troubleshooting the outboard motor, make sure that fresh fuel of the specified type has been used. 2. Make sure that all electrical connections are secure and free from corrosion. 3. If the outboard motor is equipped with the charging system (optional for European market), check that the battery is fully charged.
  • Page 57 Outboard motor troubleshooting Symptom 2 Cause Checking step page Compression pressure Compression leakage Measure the compression pressure. is low Check the valve for bends or stuck. 7-27 Check the decompressor for proper 7-44 operation. Check the piston and piston ring for 7-41 damage.
  • Page 58 TRBL SHTG Troubleshooting Symptom 1: Improper oil lubrication. Symptom 2 Cause Checking step page Oil cannot be seen Low engine oil level Check the oil level. 10-3 through the oil lubrica- Check for engine oil leakage. 2-13 tion check window Check the valve stem seal and valve.
  • Page 59 ELEC Electrical system Electrical component and wiring harness routing ..5-1 Port ................... 5-1 Top .................... 5-2 Checking the electrical component ......... 5-3 Measuring the peak voltage ............5-3 Using the digital tester ............... 5-3 Charging unit and component ......... 5-4 Checking the lighting coil (optional for European market) ..

  • Page 60: Electrical System

    ELEC Electrical system Electrical component and wiring harness routing Port A Install the holder horizontally, and then a Engine shut-off switch lead (Black) b Spark plug cap fasten the spark plug wire using the c Spark plug holder. B Point the end of plastic tie inward (engine d Ground lead (Black) e CDI unit lead (Black) side), and then cut the end.

  • Page 61: Top

    Electrical component and wiring harness routing A Fold the holders inward so that the leads a Engine shut-off switch b CDI unit do not come out from the holders. B Check that the ground lead does not inter- c Fuse (20 A) (optional for European mar- ket) fere with the bolt or washer.

  • Page 62: Checking The Electrical Component

    Using the digital tester aged. The electrical technical data apply to the measurements taken using the Yamaha-rec- To check the electrical components or mea- ommended tester. sure the peak voltage, use the special ser-...

  • Page 63: Charging Unit And Component

    Checking the electrical component / Charging unit and component Charging unit and component Charging unit and component 2. Measure the Rectifier Regulator output peak voltage. Checking the lighting coil (optional for European market) 1. Remove the holder a, and then discon- nect the lighting coil connectors a.

  • Page 64: Ignition Unit And Component

    ELEC Electrical system 3. Crank the engine and check for a spark. WARNING! Do not touch any of the connections of the special service tool. Rectifier Regulator continuity (testing diode mode): Tester probe Display value   (reference data) Ignition tester (spark gap tester) a: 90890-06754 4.

  • Page 65: Checking The Engine Shut-Off Switch

    Charging unit and component / Ignition unit and component Ignition unit and component 3. Install the spark plug cap to the spark plug wire by turning the spark plug cap clockwise. Checking the engine shut-off switch 1. Disconnect the engine shut-off switch connector a.
  • Page 66 ELEC Electrical system — MEMO —...
  • Page 67 FUEL Fuel system Hose routing ..............6-1 Fuel hose ................... 6-1 Blowby hose, oil return hose, and cooling water hose ....6-2 Fuel tank ................6-3 Removing the fuel tank .............. 6-5 Removing the primer pump ............6-5 Checking the fuel tank ............... 6-6 Checking the fuel joint ...............

  • Page 68: Fuel System

    FUEL Fuel system Hose routing Fuel hose a Fuel hose (fuel tank to fuel cock) d Joint b Fuel hose (fuel cock to fuel strainer) e Fuel pump f Carburetor c Fuel hose (fuel strainer to joint) d Fuel hose (joint to fuel pump) g Primer pump h Fuel joint e Fuel hose (fuel pump to carburetor)

  • Page 69: Blowby Hose, Oil Return Hose, And Cooling Water Hose

    Hose routing Blowby hose, oil return hose, and cooling water hose a Blowby hose (cylinder block to intake silencer) b Oil return hose (intake silencer to crank- case) c Cooling water hose (thermostat cover to crankcase) a Intake silencer...

  • Page 70: Fuel Tank

    FUEL Fuel system Fuel tank 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks M5  10 mm Choke holder bolt Holder Grommet Fuel cap Rubber seal Fuel strainer Fuel tank M6 ...
  • Page 71 Fuel tank 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Rubber seal Choke cable nut Holder Choke cable Fuel strainer Hose Hose Holder Hose  Plastic tie Joint Primer pump Hose...

  • Page 72: Removing The Fuel Tank

    FUEL Fuel system Removing the fuel tank Cover the fuel components using a rag to prevent fuel from spilling out. 1. Drain the fuel from the fuel tank. 2. Remove manual starter. “Removing the manual starter” (7-7). 3. Disconnect the fuel hose a, and then remove the fuel tank b.

  • Page 73: Checking The Fuel Tank

    Fuel tank 2. Disconnect the fuel hoses c and d. Checking the fuel joint 1. Check the fuel joint. Replace if cracked or 3. Remove the primer pump e. damaged. 2. Connect the special service tool a to the fuel joint outlet a. 3.

  • Page 74: Checking The Primer Pump

    FUEL Fuel system 2. Install the clamps f and g temporarily Leakage tester a: 90890-06840 onto the fuel hoses a, b, c, and h, and then connect the fuel hose to the fuel Specified positive pressure: strainer i and primer pump j. 200.0 kPa (2.00 kgf/cm , 29.0 psi) 3.

  • Page 75: Installing The Fuel Tank

    Fuel tank Installing the fuel tank 1. Install the fuel joint a. 8. Pass the choke cable m through the hole in the bottom cowling, and then tighten the choke cable nut n to the specified 2. Install the clamps b and c temporarily torque.
  • Page 76 FUEL Fuel system Fuel cock screw i: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6. Connect the hoses d and f, and then fasten them using the clamps c. 7. Connect the hose e, and then fasten it using the clamp c. 8.

  • Page 77: Intake Silencer

    Fuel tank / Intake silencer Intake silencer Intake silencer 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks Hose Hose M6  35 mm Bolt Washer Collar Throttle cam Lever Holder Clamp  Gasket Throttle link rod M6  25 mm Intake manifold bolt Intake manifold ...
  • Page 78 FUEL Fuel system 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks Carburetor assembly M6  85 mm Bolt Washer Intake silencer  O-ring 6-11...

  • Page 79: Removing The Throttle Cable And Throttle Link

    Intake silencer Removing the throttle cable and throttle link 1. Loosen the screw a, and then remove the cap b and throttle link rod c. 2. Remove the throttle cables d. 3. Disconnect the fuel hose d and oil return hose e.

  • Page 80: Installing The Carburetor

    FUEL Fuel system 5. Install a new gasket k and the intake Installing the carburetor manifold i, and then tighten the intake manifold bolt l to the specified torque. Do not reuse an O-ring or gasket, always replace it with a new one. 1.

  • Page 81: Adjusting The Throttle Cable And Throttle Link

    Intake silencer 3. Install the shorter cable f to the section a of the bracket g. 4. Install the throttle cable h, and then tighten the locknuts b to the specified torque. 4. Adjust the length of cable d so that there is no clearance between the cable end d and the section e of the throttle cam b.
  • Page 82 FUEL Fuel system Throttle cable locknut a: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7. Loosen the throttle link screw e. 8. Turn the throttle grip to the fully open position. 9. While pulling the lever g, tighten the throttle link screw e to the specified torque.

  • Page 83: Carburetor

    Intake silencer / Carburetor Carburetor Carburetor B 20 1.5 N·m (0.15 kgf·m, 1.11 ft·lb) A For European market B For Oceanian market Part name Q’ty Remarks M3  15 mm Throttle stop screw Spring M4  6 mm Throttle link screw Spring ...
  • Page 84 FUEL Fuel system B 20 1.5 N·m (0.15 kgf·m, 1.11 ft·lb) A For European market B For Oceanian market Part name Q’ty Remarks Clip Needle valve Pilot screw 6-17...

  • Page 85: Disassembling The Carburetor

    Carburetor Disassembling the carburetor 1. Remove the drain screw a. 2. Remove the float chamber b and gasket 6. Remove the pilot jet k and pilot screw 3. Remove the spring d, and then remove the pin e. A For European market B For Oceanian market Pilot screw driver m: 90890-06673 Checking the carburetor...

  • Page 86: Assembling The Carburetor

    FUEL Fuel system 5. Check the needle valve. Replace if deformed or worn. Position a: 1.0 mm (0.04 in) 5. Measure the float height b. Adjust the 6. Check the float. Replace if cracked or float height by bending the tab c if out of deformed.
  • Page 87 8. Turn the pilot screw o in until it is lightly seated, and then turn it out the specified number of turns. Pilot screw setting: F4B: 1 3/8 ± 3/4 turns out F5A: 2 1/2 ± 3/4 turns out F6C: 1 3/8 ± 3/4 turns out 6-20...

  • Page 88: Fuel Pump

    FUEL Fuel system Fuel pump 2 N·m (0.2 kgf·m, 1.5 ft·lb) 0.5 N·m (0.05 kgf·m, 0.37 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Fuel pump M4  25 mm Fuel pump screw Cover  Diaphragm M3  5 mm Fuel pump valve screw Valve Fuel pump body 2...

  • Page 89: Removing The Fuel Pump

    Fuel pump Removing the fuel pump 1. Remove the fuel pump a and O-ring b. Specified positive pressure: 50.0 kPa (0.50 kgf/cm , 7.3 psi) Checking the fuel pump Disassembling the fuel pump 1. Connect the special service tool a to the 1.

  • Page 90: Checking The Diaphragm And Valve

    FUEL Fuel system 4. Remove the diaphragm g, spring h, Fuel pump valve screw b: plunger e, and spring i. 0.5 N·m (0.05 kgf·m, 0.37 ft·lb) 2. Install the springs c and d, plunger e, and diaphragm f. 5. Remove the valves j. 3.

  • Page 91: Installing The Fuel Pump

    Fuel pump 6. Install the fuel pump body 2 i, a new diaphragm j, and the cover k, and then tighten the fuel pump screws l to the specified torque. Fuel pump screw l: 2 N·m (0.2 kgf·m, 1.5 ft·lb) Installing the fuel pump 1.
  • Page 92 POWR Power unit Power unit (check and adjustment) ......... 7-1 Checking the compression pressure ......... 7-1 Checking the ignition timing ............7-1 Checking the CDI unit air gap ........... 7-1 Adjusting the CDI unit air gap ............ 7-2 Checking the valve clearance ........... 7-2 Adjusting the valve clearance ............
  • Page 93 Replacing the valve guide ............7-32 Checking the valve seat ............7-32 Refacing the valve seat ............7-33 Checking the spark plug ............7-35 Checking the thermostat cover anode ........7-35 Checking the thermostat ............7-35 Assembling the cylinder head ..........7-36 Installing the cylinder head ............

  • Page 94: Power Unit

    POWR Power unit Power unit (check and 9. Connect the spark plug cap. adjustment) Checking the ignition timing Checking the compression pressure 1. Install the special service tools a and b 1. Start the engine, warm it up for 5 min- to the spark plug wire a.

  • Page 95: Adjusting The Cdi Unit Air Gap

    Power unit (check and adjustment) 1. Remove manual starter. “Removing the manual starter” (7-7). 2. Turn the flywheel magnet clockwise to align the permanent magnet a with the protrusions b on the CDI unit. 3. Measure the CDI unit air gap c. CDI unit bolt a: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 4.

  • Page 96: Adjusting The Valve Clearance

    POWR Power unit Valve clearance: Intake d and exhaust e: 0.08–0.12 mm (0.003–0.005 in) 6. Install a new gasket h, the cylinder head cover f, the holders c, d, i, and ground lead b, and then tighten the bolts e in the order a, b, and so on. NOTICE: Do not reuse a gasket, always replace it with a new one.
  • Page 97 Power unit (check and adjustment) TIP: Do not turn the flywheel magnet counter- • To decrease the valve clearance, turn the rocker arm pivot in direction c. clockwise. Otherwise, the water pump impeller could be damaged. • To increase the valve clearance, turn the rocker arm pivot in direction d.

  • Page 98: Manual Starter

    POWR Power unit Manual starter 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Starter handle Rubber seal Starter rope 1800.0 mm (70.9 in) (reference data) M6  35 mm Bolt Guide M6  20 mm Bolt Starter plunger Spring Cover Sheave drum...
  • Page 99 Manual starter 7 N·m (0.7 kgf·m, 5.2 ft·lb) Part name Q’ty Remarks Plate Spiral spring...

  • Page 100: Removing The Manual Starter

    POWR Power unit 4. Remove the sheave drum d and plate Removing the manual starter 1. Disconnect the start-in-gear protection cable a. 2. Remove the manual starter b. 5. Remove the spiral spring j. WARNING! The spiral spring can pop out. Cover the spiral spring with rags when Disassembling the manual starter removing it.

  • Page 101: Checking The Spiral Spring

    Manual starter 3. Check the sheave drum. Replace if cracked or damaged. 4. Check the starter handle. Replace if cracked or damaged. 5. Check the starter rope. Replace if damaged. Starter rope length (reference data): 1800.0 mm (70.9 in) Checking the spiral spring 1.
  • Page 102 POWR Power unit 8. Install the sheave drum f with the protrusion g on the starter plunger b and the mark h of the manual starter i aligned. 9. Turn the sheave drum f to hook the end k of the spiral spring g onto the section m in the manual starter i.

  • Page 103: Installing The Manual Starter

    Manual starter 16. Align the protrusion g on the starter 3. Tighten the start-in-gear protection cable plunger b and the mark h on the locknut a to the specified torque. manual starter i. 17. Pull the starter handle o several times to check that the sheave drum turns smoothly and to check the starter rope e for slack.

  • Page 104: Power Unit Assembly

    POWR Power unit Power unit assembly 2 N·m (0.2 kgf ·m, 1.5 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks Dowel  Gasket Engine shut-off switch nut Engine shut-off switch  Plastic tie M6 ...

  • Page 105: Removing The Power Unit

    Power unit assembly 8. Disconnect the CDI unit coupler a, CDI Removing the power unit unit ground lead b, engine shut-off Cover the fuel components using a rag to switch ground lead c, and ground lead prevent fuel from spilling out. Do not turn the flywheel magnet counter- clockwise.
  • Page 106 POWR Power unit Flywheel magnet nut z: 60 N·m (6.0 kgf·m, 44.3 ft·lb) 15. Install the special service tool A, and then suspend power unit. NOTICE: To prevent damage to the engine or tool, screw in the puller set bolts evenly and completely so that the flywheel puller is parallel to the flywheel magnet.

  • Page 107: Installing The Power Unit

    Power unit assembly 1. Install the engine shut-off switch a, and then tighten the engine shut-off switch nut b to the specified torque. 2. Route the engine shut-off switch lead a and ground lead c. TIP: Lift up the power unit using the crane, Engine shut-off switch nut b: because the gasket on power unit is firmly 2 N·m (0.2 kgf·m, 1.5 ft·lb)
  • Page 108 POWR Power unit Flywheel holder i: 90890-06522 8. Install the starter pulley j and washer k, and then tighten the flywheel magnet nut h to the specified torque. NOTICE: Apply force in the direction of the arrow to prevent the flywheel holder i from slipping off easily.
  • Page 109 Power unit assembly 10. Connect the CDI unit coupler b, CDI unit ground lead c, engine shut-off switch ground lead d, and ground lead c. 11. Install the engine shut-off switch lead a and ground lead c to the holders n, o, and p.
  • Page 110 POWR Power unit Choke holder bolt G: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 19. Install the fuel tank. See step 8 in “Installing the fuel tank” (6-8). 20. Install the manual starter. See “Installing the manual starter” (7-10). 7-17...

  • Page 111: Flywheel Magnet

    Power unit assembly / Flywheel magnet Flywheel magnet Flywheel magnet 60 N·m (6.0 kgf·m, 44.3 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) Part name Q’ty Remarks Flywheel magnet nut Width across flats: 22 mm Washer Starter pulley Flywheel magnet Woodruff key Spark plug cap CDI unit M6 ...

  • Page 112: Removing The Flywheel Magnet

    POWR Power unit Removing the flywheel magnet Installing the flywheel magnet 1. Remove the holder a. 1. Install the Woodruff key a, flywheel magnet b, starter pulley c, and washer 2. Disconnect the spark plug cap b, and d, and then tighten the flywheel magnet then remove the CDI unit c.
  • Page 113 Flywheel magnet CDI unit bolt h: 10 N·m (1.0 kgf·m, 7.4 ft·lb) 4. Adjust the CDI unit air gap. See “Adjusting the CDI unit air gap” (7-2). 7-20...
  • Page 114 POWR Power unit Crankcase 5 N·m (0.5 kgf·m, 3.7 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) Part name Q’ty Remarks  Oil seal  Oil seal  O-ring Rotor assembly Plate M6  12 mm Screw ...

  • Page 115: Crankcase

    Crankcase 5 N·m (0.5 kgf·m, 3.7 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 20 N·m (2.0 kgf·m, 14.8 ft·lb) Part name Q’ty Remarks M8  15 mm Blind plug M6  35 mm Bolt M8  20 mm Drain bolt ...

  • Page 116: Removing The Oil Pump

    POWR Power unit Removing the oil pump Removing the oil seal housing 1. Remove the drain bolt a and gasket b, 1. Remove the oil seal housing a. and then drain the remaining engine oil. 2. Remove the O-ring b and oil seals c 2.

  • Page 117: Checking The Crankcase

    Crankcase 3. Loosen the crankcase bolts d in the order a, b, and so on, and then remove the crankcase e, gasket f, and dowels Crankshaft journal inside diameter a: 25.020–25.041 mm (0.9850–0.9859 in) Camshaft journal inside diameter b: 15.000–15.018 mm (0.5906–0.5913 in) 4.

  • Page 118: Checking The Oil Strainer

    POWR Power unit Outer rotor diameter a: 22.980–23.000 mm (0.9047–0.9055 in) Outer rotor height b: 9.950–9.980 mm (0.3917–0.3929 in) Inner rotor height c: 9.950–9.980 mm (0.3917–0.3929 in) Checking the oil strainer 1. Check the oil strainer. Clean if there is dirt or residue.

  • Page 119: Installing The Oil Pump

    Crankcase Installing the oil pump Driver rod L3 b: 90890-06652 Needle bearing attachment c: 90890-06615 Do not reuse a gasket, always replace it with a new one. 2. Install the oil seal d. 1. Install the rotor assembly a and plate b. TIP: Install the rotor assembly in the same direc- tion as when it was removed.

  • Page 120: Cylinder Head

    POWR Power unit Cylinder head 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) Part name Q’ty Remarks...
  • Page 121 Cylinder head 2 N·m (0.2 kgf·m, 1.5 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 10 N·m (1.0 kgf·m, 7.4 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 13 N·m (1.3 kgf·m, 9.6 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) Part name Q’ty Remarks Rocker arm pivot...

  • Page 122: Removing The Cylinder Head

    POWR Power unit 4. Loosen the cylinder head bolts l in the Removing the cylinder head order a, b, and so on, and then remove 1. Remove the spark plug a, thermostat the cylinder head m, gasket n, and push cover b, gasket c, thermostat d, and rods o.

  • Page 123: Checking The Cylinder Head

    Cylinder head Valve spring compressor b: Cylinder head warpage limit: 90890-04019 0.10 mm (0.0039 in) Valve spring compressor attachment c: Checking the rocker arm 90890-06320 1. Check the rocker arms. Replace if cracked, damaged, or worn. TIP: Make sure to keep the parts in the order of Checking the push rod removal.

  • Page 124: Checking The Valve

    POWR Power unit 3. Measure the valve stem diameter b. Replace if out of specification. Valve spring free length a: 27.6 mm (1.09 in) Valve stem diameter b: 2. Measure the valve spring tilt b. Replace Intake: if above specification. 5.475–5.490 mm (0.2156–0.2161 in) Exhaust: 5.460–5.475 mm (0.2150–0.2156 in)

  • Page 125: Replacing The Valve Guide

    Cylinder head Valve guide inside diameter a: Valve guide remover/installer b: Intake and exhaust: 90890-06801 5.500–5.512 mm (0.2165–0.2170 in) Valve guide installation height a: 2. Calculate the valve guide clearance. 8.2–9.1 mm (0.32–0.36 in) Replace the valve guide if out of specification.

  • Page 126: Refacing The Valve Seat

    POWR Power unit Refacing the valve seat After every lapping procedure, make sure to clean off any remaining lapping com- pound from the cylinder head and valves. 1. Reface the valve seat using valve seat cutters. Valve lapper a: 90890-04101 4.
  • Page 127 Cylinder head 45˚ 45˚ b Previous contact width a Slag or rough surface c Specified contact width 3. Adjust the top edge of the valve seat 6. Check the valve seat contact area of the contact width using a 30° cutter. valve.

  • Page 128: Checking The Spark Plug

    POWR Power unit • If the valve seat contact area is too narrow and situated near the bottom edge of the valve face, cut the bottom edge of the valve seat using a 60° cutter to center the area, and then set its width using a 45° cutter. 2.

  • Page 129: Assembling The Cylinder Head

    Cylinder head 2. Install the valve b, spring seat c, valve spring d, and valve spring retainer e in this order, and then install the special service tools f and g. 3. Measure the thermostat valve opening a at the specified water temperatures. Replace if out of specification.

  • Page 130: Installing The Cylinder Head

    POWR Power unit 4. Tap the valve spring retainer lightly using a plastic hammer to seat the valve cotter securely. 5. Install the push rod guide i, and then tighten the pivot bolts j to the specified torque. Cylinder head bolt d: 1st: 13 N·m (1.3 kgf·m, 9.6 ft·lb) 2nd: 28 N·m (2.8 kgf·m, 20.7 ft·lb) Pivot bolt j:...
  • Page 131 Cylinder head Thermostat cover anode screw g: 2 N·m (0.2 kgf·m, 1.5 ft·lb) Spark plug k: 13 N·m (1.3 kgf·m, 9.6 ft·lb) 5. Check that the mark a on the crankshaft l is aligned with the hole b on the camshaft m.

  • Page 132: Cylinder Block

    POWR Power unit Cylinder block 6 N·m (0.6 kgf·m, 4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.9 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb) Part name Q’ty Remarks  Oil seal Cylinder block Connecting rod assembly M7  35 mm Connecting rod bolt ...

  • Page 133: Disassembling The Cylinder Block

    Cylinder block Disassembling the cylinder block 1. Remove the dipstick a. 2. Remove the camshaft b, valve lifters c, and plate d. Driver rod L3 i: 90890-06652 Needle bearing attachment j: 90890-06612 6. Remove the clips k, and then remove 3.

  • Page 134: Checking The Cylinder Bore

    POWR Power unit Piston diameter a: 61.950–61.965 mm (2.4390–2.4396 in) Measuring point b: 1.0 mm (0.04 in) up from the bottom of the piston skirt Oversize piston diameter: Oversize 1st: 62.200–62.215 mm (2.4488–2.4494 in) Piston ring dimensions: Oversize 2nd: Top ring a: 62.450–62.465 mm B: 1.170–1.190 mm (0.0461–0.0469 in) (2.4587–2.4592 in)

  • Page 135: Checking The Piston Ring Groove

    Cylinder block Checking the piston ring groove 1. Measure the piston ring grooves. Piston pin boss inside diameter a: 15.004–15.015 mm (0.5907–0.5911 in) Piston ring groove: Top ring a: 1.210–1.230 mm (0.0476–0.0484 in) TIP: 2nd ring b: Do not measure it at the groove b. 1.210–1.230 mm (0.0476–0.0484 in) Oil ring c: Checking the piston pin diameter...

  • Page 136: Checking The Crankshaft

    POWR Power unit Crankshaft journal diameter (cylinder block side) b: 24.980–24.993 mm (0.9835–0.9840 in) Crankshaft journal diameter (crankcase side) c: 24.982–24.994 mm (0.9835–0.9840 in) Crankpin diameter d: 27.969–27.984 mm Connecting rod small end inside diameter (1.1011–1.1017 in) Crankpin width e: 15.015–15.029 mm 21.000–21.100 mm (0.5911–0.5917 in)

  • Page 137: Checking The Cylinder Block

    Cylinder block Connecting rod oil clearance: TIP: 0.016–0.046 mm (0.0006–0.0018 in) Do not place the Plastigauge (PG-1) over the oil hole in the crankpin of the crankshaft. Checking the cylinder block 1. Check the cylinder block. Replace if cor- 3. Install the connecting rod cap b by roded or cracked.

  • Page 138: Checking The Valve Lifter

    POWR Power unit Cam lobe height a: Camshaft runout: 0.030 mm (0.0012 in) Intake: Checking the valve lifter 32.037–32.137 mm 1. Check the valve lifter. Replace if dam- (1.2613–1.2652 in) aged or worn. Exhaust: 32.038–32.138 mm 2. Measure the valve lifter outside diameter (1.2613–1.2653 in) Cam lobe width b: Intake and exhaust:...
  • Page 139 Ball bearing attachment c: 90890-06632 2. Install a new oil seal d. TIP: Driver rod LS e: 90890-06606 • Face the “YAMAHA” mark b on the con- Ball bearing attachment f: necting rod a in the same direction as the 90890-06655 “UP”...
  • Page 140 POWR Power unit TIP: TIP: • Make sure that the “N” marks h of the 2nd Make sure that the crankshaft turns smoothly. ring f and the top ring g are facing upward. 9. Install the valve lifters n. • Make sure that the piston rings move 10.
  • Page 141 LOWR Lower unit Lower unit ................8-1 Removing the lower unit (S-transom model) ......8-3 Removing the lower unit (L-transom model) ......8-3 Disassembling the extension (L-transom model) ...... 8-4 Checking the propeller .............. 8-4 Checking the lower unit anode ..........8-4 Water pump and shift rod ..........
  • Page 142 LOWR Lower unit Lower unit 16 N·m (1.6 kgf·m, 11.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 11N·m (1.1 kgf·m, 8.1 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 11N·m (1.1 kgf·m, 8.1 ft·lb) A L-transom model 15N·m (1.5 kgf·m, 11.1 ft·lb) Part name Q’ty...

  • Page 143: Lower Unit

    Lower unit 16 N·m (1.6 kgf·m, 11.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 11N·m (1.1 kgf·m, 8.1 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 11N·m (1.1 kgf·m, 8.1 ft·lb) A L-transom model 15N·m (1.5 kgf·m, 11.1 ft·lb) Part name Q’ty Remarks...

  • Page 144: Lower Unit

    LOWR Lower unit 7. Remove the lower unit d. Removing the lower unit (S-transom model) 8. Remove the anode e and flushing screw • Make sure to remove the clip from the engine shut-off switch. • When removing the lower unit with the power unit installed, make sure to sus- pend the outboard motor.

  • Page 145: Disassembling The Extension (L-Transom Model)

    Lower unit Disassembling the extension (L- transom model) 1. Remove the circlip a, and then remove the bushing b. Stopper guide plate c: 90890-06501 Stopper guide stand d: 90890-06538 Bearing puller assembly e: 90890-06535 Checking the propeller 1. Check the propeller blades and splines. Replace the propeller if cracked, dam- aged, or worn.

  • Page 146: Water Pump And Shift Rod

    LOWR Lower unit Water pump and shift rod Part name Q’ty Remarks M6  45 mm Bolt Plate Rubber seal Water pump housing Insert cartridge Impeller  Gasket Outer plate cartridge Rubber seal M6  25 mm Bolt Dowel Housing Shift rod ...

  • Page 147: Removing The Water Pump And Shift Rod

    Water pump and shift rod Removing the water pump and shift TIP: If the engine overheated, check the water 1. Remove the rubber seal a, plates b, pump housing for deformation. water pump housing c, insert cartridge d, and impeller e. 2.

  • Page 148: Propeller Shaft Housing

    LOWR Lower unit Propeller shaft housing Part name Q’ty Remarks Shift plunger Spring Dog clutch Propeller shaft Washer Reverse gear  Ball bearing  O-ring  Oil seal Propeller shaft housing M6  15 mm Bolt...

  • Page 149: Removing The Propeller Shaft Housing Assembly

    Propeller shaft housing Removing the propeller shaft housing assembly 1. Remove the bolts a, and then remove the propeller shaft housing assembly b. 2. Remove the ball bearing c. TIP: Insert flat-head screwdrivers between the propeller shaft housing assembly b and the lower case to remove the propeller shaft housing assembly.

  • Page 150: Checking The Dog Clutch

    LOWR Lower unit Assembling the propeller shaft housing assembly Do not reuse a bearing, oil seal, or O-ring, always replace it with a new one. 1. Install new oil seals a. Propeller shaft runout: 0.02 mm (0.001 in) Checking the dog clutch 1.

  • Page 151: Drive Shaft And Lower Case

    Propeller shaft housing / Drive shaft and lower case Drive shaft and lower case Drive shaft and lower case Part name Q’ty Remarks Drive shaft  Clip  Oil seal  Bushing Lower case  Bushing Washer Pinion E-clip  Ball bearing Forward gear 8-10...

  • Page 152: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft 1. Remove the E-clip a, and then remove the drive shaft b and pinion c. 2. Remove the clip d. 3. Remove the forward gear e. 3. Remove the bushing f. Disassembling the lower case 4.

  • Page 153: Checking The Drive Shaft

    Drive shaft and lower case Checking the drive shaft 1. Check the drive shaft. Replace if dam- aged or worn. 2. Measure the drive shaft runout. Driver rod L3 d: 90890-06652 Bushing attachment e: 90890-06649 3. Install new oil seals f to the specified depth a.

  • Page 154: Installing The Drive Shaft

    LOWR Lower unit TIP: Face the identification mark b on the ball bearing toward the forward gear. Installing the drive shaft 1. Install the forward gear a. 2. Install a new clip b to the drive shaft c. NOTICE: Do not reuse a clip, always replace it with a new one.

  • Page 155: Installing The Water Pump And Shift Rod

    Drive shaft and lower case 4. Install the outer plate cartridge g, a new gasket h, and then install the pin i. Installing the water pump and shift 5. Align the slot b in the impeller j with the pin i, and then install the impeller. Do not reuse a gasket, always replace it with a new one.

  • Page 156: Checking The Lower Unit For Air Leakage

    LOWR Lower unit 4. Apply the specified pressure to check TIP: that the pressure is maintained in the While turning the drive shaft clockwise, push lower unit for at least 10 seconds. down on the water pump housing and install NOTICE: Do not over pressurize the water pump housing.

  • Page 157: Installing The Lower Unit (S-Transom Model)

    Drive shaft and lower case Installing the lower unit (S-transom model) • Make sure to remove the clip from the engine shut-off switch. • Do not hold the propeller with your hands when loosening or tightening the propeller nut. • When installing the lower unit with the power unit installed, make sure to sus- pend the outboard motor.

  • Page 158: Installing The Lower Unit (L-Transom Model)

    LOWR Lower unit Installing the lower unit (L-transom model) • Make sure to remove the clip from the engine shut-off switch. • Do not hold the propeller with your hands when loosening or tightening the propeller nut. • When installing the lower unit with the power unit installed, make sure to sus- pend the outboard motor.
  • Page 159 Drive shaft and lower case TIP: Make sure that the cooling water pipe f is inserted securely into the rubber seal g. See steps 6–12 in “Installing the lower unit (S-transom model)” (8-16). 8-18...
  • Page 160 LOWR Lower unit — MEMO — 8-19...
  • Page 161 BRKT Bracket unit Tiller handle ............... 9-1 Disassembling the tiller handle ..........9-3 Assembling the tiller handle ............9-3 Bottom cowling ..............9-6 Disassembling the bottom cowling ..........9-8 Assembling the bottom cowling ..........9-8 Upper case and shift lever ..........9-9 Removing the shift lever ............
  • Page 162 BRKT Bracket unit Tiller handle 4 N·m (0.4 kgf·m, 3.0 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks Holder Holder Throttle cable Holder M8  25 mm Tiller handle mounting bolt Plate Bushing...
  • Page 163 Tiller handle 4 N·m (0.4 kgf·m, 3.0 ft·lb) 28 N·m (2.8 kgf·m, 20.7 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) Part name Q’ty Remarks  Cotter pin Bushing Washer Spring Throttle grip M5  20 mm Throttle grip screw Bushing...

  • Page 164: Bracket Unit

    BRKT Bracket unit 5. Remove the cotter pin p and throttle Disassembling the tiller handle friction adjuster q. 1. Remove the holders a, b, and c. 2. Remove the plate d and tiller handle assembly e. 6. Remove the plate r, friction piece s, throttle cables t, and throttle rod u.
  • Page 165 Tiller handle 3. Install the friction piece d onto the throttle rod c, and then install the plate 4. Tighten the throttle rod screws f to the Throttle grip screw m: specified torque. 4 N·m (0.4 kgf·m, 3.0 ft·lb) 7. Install the bushing n, and then install the washers o, wave washer p, bushing q, washer r, and bushing s.
  • Page 166 BRKT Bracket unit Tiller handle mounting bolt v: 28 N·m (2.8 kgf·m, 20.7 ft·lb) 9. Install the holders w, x, and y.

  • Page 167: Bottom Cowling

    Tiller handle / Bottom cowling Bottom cowling Bottom cowling 11 N·m (1.1 kgf·m, 8.1 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) Part name Q’ty Remarks Start-in-gear protection cable M6 ...
  • Page 168 BRKT Bracket unit 11 N·m (1.1 kgf·m, 8.1 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) Part name Q’ty Remarks Collar Grommet...

  • Page 169: Disassembling The Bottom Cowling

    Bottom cowling Disassembling the bottom cowling 1. Remove start-in-gear protection cable a and holders b and c. Carrying handle bolt g: 19 N·m (1.9 kgf·m, 14.0 ft·lb) 2. Remove the carrying handle d. 3. Install the start-in-gear protection cable h and holders i and j. 3.

  • Page 170: Upper Case And Shift Lever

    BRKT Bracket unit Upper case and shift lever 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks M8  40 mm Shift lever bolt Shift lever Shift rod Pipe Rubber seal Shift link lever...
  • Page 171 Upper case and shift lever 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 19 N·m (1.9 kgf·m, 14.0 ft·lb) 3 N·m (0.3 kgf·m, 2.2 ft·lb) Part name Q’ty Remarks M6  35 mm Bolt Steering friction adjuster Spring Bushing Bushing Bushing Bushing Spring Bolt Reverse lock...

  • Page 172: Removing The Shift Lever

    BRKT Bracket unit Removing the shift lever 1. Remove the shift lever a, collar b, and bracket c. 2. Remove the ball d and spring e. 2. Move the plate a up, and then tilt the outboard motor up. 3. Remove the cap f, shift lever a, and O- rings g.

  • Page 173: Checking The Upper Case

    Upper case and shift lever 5. Remove the steering friction adjuster f, Bushing installer center bolt n: and then remove the cover g and friction 90890-06601 piece h. Bushing attachment o: 90890-06650 Pipe p (reference): b: 12.0 mm (0.5 in) c: 16.0 mm (0.7 in) d: 37.0 mm (1.5 in) Checking the upper case...
  • Page 174 BRKT Bracket unit 3. Install the bushings f and g. 7. Tilt the outboard motor up. 8. Install the springs m, n and reverse lock 4. Install the friction piece h to the upper case i. 5. Install the cover j, and then install the steering friction adjuster k.

  • Page 175: Installing The Shift Lever

    Upper case and shift lever Installing the shift lever Do not reuse a cotter pin or O-ring, always replace it with a new one. 1. Install the shift rod a, the washer b, and a new cotter pin c. Shift link bolt l: 3.5 N·m (0.35 kgf·m, 2.58 ft·lb) 2.

  • Page 176: Clamp Bracket

    BRKT Bracket unit Clamp bracket 15 N·m (1.5 kgf·m, 11.1 ft·lb) Part name Q’ty Remarks Self-locking nut Plate Washer Clamp bracket (STBD) Washer Collar Swivel bracket M8  135 mm Bolt Clamp bracket (PORT) M6  120 mm Bolt Tilt pin Spring Clamp pad Clamp screw...
  • Page 177 Clamp bracket 15 N·m (1.5 kgf·m, 11.1 ft·lb) Part name Q’ty Remarks Spring Bushing Plate M6  20 mm Bolt Cover Tilt lock lever 9-16...

  • Page 178: Disassembling The Clamp Bracket

    BRKT Bracket unit Disassembling the clamp bracket 1. Remove the tilt pin a. 2. Remove the self-locking nut b and nut 3. Remove the plate d, clamp bracket (STBD) e, washers f, swivel bracket g, collar h, and clamp bracket (PORT) 3.
  • Page 179 Clamp bracket Self-locking nut n: 15 N·m (1.5 kgf·m, 11.1 ft·lb) 9-18...
  • Page 180 BRKT Bracket unit — MEMO — 9-19...
  • Page 181 Maintenance Outline ................10-1 Maintenance interval chart ............10-1 Predelivery check ............10-3 Checking the battery (optional for European market) ....10-3 Checking the cooling water pilot hole ........10-3 Checking the engine oil level ........... 10-3 Checking the engine shut-off switch ........10-4 Checking the fuel system ............

  • Page 182: Maintenance

    • If replacement parts are necessary, use only genuine Yamaha parts of equivalent design and qual- ity. Any parts of inferior quality may cause a malfunction, and the resulting loss of control could endanger the operator and passengers.
  • Page 183 Outline Initial Every Item Actions 20 hours 100 hours 300 hours 500 hours page (3 months) (1 year) (3 years) (5 years)  Impeller/ Replace water pump housing 8-14   Pilot water Check 10-3   Propeller/propeller nut/ Check/replace cotter pin ...

  • Page 184: Predelivery Check

    Maintenance Predelivery check To make the delivery process smooth and efficient, complete the predelivery checks as explained in the following procedures. Checking the battery (optional for European market) Battery electrolyte is dangerous; it con- 2. Check specific gravity tains sulfuric acid, which is poisonous electrolyte.

  • Page 185: Checking The Engine Shut-Off Switch

    Predelivery check 2. Start the engine and warm it up for 5–10 Checking the fuel system minutes. 1. Check that the fuel hoses are securely connected. “Fuel hose” (6-1). 3. Stop the engine and leave it off for 5–10 NOTICE: This is a 4-stroke engine. minutes.

  • Page 186: Checking The Outboard Motor Mounting Height

    Maintenance 2. Check that the throttle operates smoothly when the throttle grip is turned from the fully closed position to the fully open position. Checking the outboard motor mounting height 1. Check that the anti-cavitation plate a is between the bottom of the boat b and a maximum of 25.0 mm (1.0 in) c below it.

  • Page 187: Checking The Tilt System

    Predelivery check Checking the tilt system 1. Move the shift lever to the N position. 2. Fully tilt up the outboard motor, and then check that the outboard motor tilts up smoothly and automatically locks in a, b, c, d positions when it is tilted up. 3.

  • Page 188: After Test Run

    Maintenance 3. For the remaining 8 hours c of 1. Check the anodes. See “Checking the operation: thermostat cover anode” (7-35), and Operate the engine at any engine speed. “Checking the lower unit anode” (8-4). However, do not operate the engine at Checking the battery (optional for full throttle for more than 5 minutes at a European market)

  • Page 189: Changing The Engine Oil

    Predelivery check / General periodic maintenance General periodic maintenance Changing the engine oil The engine oil should be extracted using an oil changer. Change the engine oil after the first 20 hours of operation or 3 months, and every 100 hours or at 1-year intervals thereafter. 1.

  • Page 190: Checking The Engine Oil Level

    Maintenance Checking the fuel joint and fuel Recommended engine oil: hoses (fuel joint to carburetor) 4-stroke motor oil with combinations of 1. Check the fuel joint and fuel hose con- the following SAE and API oil classifica- nections. See “Fuel hose” (6-1). tions: API: SE, SF, SG, SH, SJ, SL Checking the fuel strainer...

  • Page 191: Checking The Gear Oil Level

    General periodic maintenance 6. Install a new gasket f and the check Lubricating the outboard motor screw d. 1. Apply water resistant grease to the spec- ified areas. Recommended gear oil: Hypoid gear oil: API: GL-4 SAE: 90 Oil quantity: 0.1 L (0.11 US qt, 0.09 lmp qt) 7.

  • Page 192: Checking The Propeller

    Maintenance Adjusting the throttle link rod and throttle cable 1. Adjust the throttle link rod. See “Adjusting the throttle cable and throttle link” (6-14). Checking the top cowling 1. Check the fitting by pushing the top cowl- ing. Adjust if there is free play. 2.

  • Page 193: Checking The Water Pump

    General periodic maintenance Checking the water pump 1. Check the water pump housing and impeller. See “Checking the water pump” (8-6). 10-12...
  • Page 194 Index Index Checking the connecting rod oil clearance ..........7-43 Abbreviation ..........0-5 Checking the connecting rod small end inside Adjusting the CDI unit air gap .....7-2 diameter and big end inside diameter ..7-42 Adjusting the start-in-gear protection Checking the cooling water passage..10-7 cable ............7-10 Checking the cooling water pilot hole ..
  • Page 195 Index Checking the propeller shaft .......8-8 Drive shaft and lower case ....... 8-10 Checking the propeller shaft housing..8-9 Checking the push rod ......7-30 Checking the Rectifier Regulator (optional for Electric shock ..........0-1 European market) ........5-4 Electrical component and wiring harness Checking the reverse gear......8-9 routing............
  • Page 196 Index Installing the lower unit (S-transom model) ........8-16 Part, lubricant, and sealant......0-2 Installing the manual starter......7-10 Performance ..........1-3 Installing the oil pump .......7-26 Port ............. 5-1 Installing the oil seal housing ....7-26 Power unit........1-3, 1-6, 1-10 Installing the power unit ......7-14 Power unit (check and adjustment) ....
  • Page 197 Index Starting the engine........10-6 Symbol ............0-6 Test run.............10-6 Tightening torque ........0-3 Tiller handle ..........9-1 Tilt system..........2-14 Top..............5-2 Troubleshooting procedure ......4-1 Troubleshooting the lower unit....4-3 Troubleshooting the power unit....4-1 Uncrating procedure ........3-4 Upper case and shift lever ......9-9 Using the digital tester ........5-3 Ventilation ...........0-1 Water pump and shift rod......8-5 Working with crane ........0-2...
  • Page 198 Index — MEMO —...
  • Page 199 Appendix Wiring diagram ..............A-1 How to use the wiring diagram ..........A-1 F4B, F5A, F6C ................A-1...
  • Page 200 Legend symbols in the wiring diagrams a No wire connector b Optional parts Color Code : Black : Green : Red : White F4B, F5A, F6C a Fuse (20A) (Battery) Engine shut-off switch Clip installed Clip removed Pushed CDI unit...
  • Page 202 Jan. 2019 ABE (E_3)

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