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Hidea HDF6 Service Manual

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HIDEA
F6
SERVICE MANUAL
7- 3-
1

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Summary of Contents for Hidea HDF6

  • Page 1 HIDEA SERVICE MANUAL 7- 3-...
  • Page 2 Preface This manual has been prepared by primarily for use by dealers and their trained mechanics when performing maintenance procedures and repairs to equipment. It has been written to suit the needs of persons who have the equivalent basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
  • Page 3 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 INFO General information Safety while working Rotating part Hot part Electric shock Propeller Handling of gasoline Ventilation Self-protection Working with crane Part, lubricant, and sealant Handling of sealant Special service tool Tightening torque . Non-reusable part Disassembly and assembly How to use this manual Manual format Abbreviation Lubricant, sealant, and thread locking agent...
  • Page 6 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 Safety while working Self-protection Part, lubricant, and sealant • Protect your eyes by wearing safety Use only genuine parts, lubricants, glasses or safety goggles during all opera- and sealants, or those recommended by tions involving drilling and grinding, or when , when servicing or repairing the out- using an air compressor.
  • Page 8 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 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 INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description ____ _____ BTDC Before Top Dead Center Cold Cranking Ampere Capacitor Discharge Ignition _____ ____ Forward International Electrotechnical Commission Neutral Overhead Valve PORT Port side Reverse Research Octane Number STBD...
  • Page 11 How to use this manual / Lubricant, sealant, and thread locking agent 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.
  • Page 12 INFO General information Special service tool Digital circuit tester Pilot screw driver Peak voltage adapter B Compression gauge Ignition tester (spark gap tester) Digital tachometer Vacuum/pressure pump gauge set Timing light Leakage tester Flywheel holder...
  • Page 13 Special service tool Flywheel puller Valve spring compressor attachment Driver rod L3 Valve guide remover/installer Needle bearing attachment Valve guide reamer Needle bearing attachment Valve lapper Valve spring compressor Valve seat cutter holder...
  • Page 14 INFO General information Valve seat cutter Valve seat cutter 60° Valve seat cutter Needle bearing attachment 45° Valve seat cutter Driver rod LL 60° Valve seat cutter Ball bearing attachment 30° Valve seat cutter Driver rod LS 45°...
  • Page 15 Special service tool Ball bearing attachment Bearing outer race attachment Piston slider Bushing installer center bolt Stopper guide plate Bushing attachment Stopper guide stand Bushing attachme Bearing puller assembly...
  • Page 16 INFO General information — MEMO —...
  • Page 17 SPEC Specification Model feature General feature Model designation Serial number Model data Dimension and weight Performance Power unit Lower unit Bracket unit Fuel and oil requirement Electrical technical data Ignition timing control system Charging system Fuel system technical data Fuel system Power unit technical data Power unit Manual starter...
  • Page 18 SPEC Specification Model feature General feature F6 Overall feature • 4-stroke, 1-cylinder, OHV, 2-valve, 139.0 cm (8.5 cu. in) engine a Power unit • Compact OHV engine • Blowby gas reburning system • Trochoid type oil pump lubrication • Decompression starter •...
  • Page 19 Approved Starting Model name The outboard motor serial number is indi- mode code serial No. cated on a label affixed to the port clamp bracket. HDF6 H H I D E A INDUSTRIE PRODUCT ASSEMBLED IN b Approved model code...
  • Page 20 SPEC Specification Model data Dimension and weight Model Item Unit Overall length mm (in) 750.0 (29.5) Overall width mm (in) 403.0 (15.9) Overall height mm (in) 1040.0 (40.9) 1168.0 (46.0) mm (in) Boat transom height mm (in) 440.0 (17.3) mm (in) 568.0 (22.4) Weight (with propeller) kg (lb)
  • Page 21 Model data Lower unit Model Item Unit 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 Trim angle At 12º...
  • Page 22 SPEC Specification Electrical technical data Ignition timing control system Model Item Unit Spark plug Cap resistance (*1) At 20 °C (68 °F) 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) (*1) The figures are for reference only.
  • Page 23 Electrical technical data / Fuel system technical data / Power unit technical data Power unit technical data Model Item Unit 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 2.0 (0.08)
  • Page 24 SPEC Specification Cylinder head assembly Model Item Unit 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 Intake and exhaust mm (in)
  • Page 25 Power unit technical data Crankcase assembly Model Item Unit 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 mm (in)
  • Page 26 SPEC Specification Model Item Unit 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) Journal diameter (crankcase...
  • Page 27 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 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 Outline CDI unit Ignition timing control Ignition cut-off control Power unit system Outline Automatic decompressor Blowby gas reburning system Lighting coil Fuel system Outline Carburetor Built-in primer pump Lubrication system Outline Oil pump and engine oil flow Tilt system Outline Reverse lock system...
  • Page 30 TECH Technical features and description Engine control system Outline The F6 adopt the CDI ignition system consisting of the CDI unit and the flywheel magnet. The CDI unit has a compact design with an integrated ignition coil. There are two types of ignition control systems. One is ignition timing control at normal operation, and the other one is ignition cut-off control during engine cranking and when over-revving.
  • Page 31 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 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 Engine control system / Power unit system Power unit system Power unit system Outline F6 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 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 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 TECH Technical features and description Lighting coil The F6 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. a Lighting coil b Rectifier Regulator c Fuse...
  • Page 37 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 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 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 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 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 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...
  • Page 45 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 TECH Technical features and description Intake and exhaust flow diagram Carburetor Intake manifold Intake silencer A Intake air flow B Exhaust gas flow...
  • Page 47 GING Rigging information Outboard motor installation Dimension Exterior Clamp bracket Uncrating procedure Outboard motor mounting Installing the charging system Installing the battery Rigging recommendations Battery requirement Propeller selection Propeller size Selection...
  • Page 48 GING Rigging information Outboard motor installation • Overpowering a boat could cause severe instability. Do not mount an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer. •...
  • Page 49 Outboard motor installation / Dimension Dimension Dimension Exterior 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 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 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 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 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 GING Rigging information Rigging recommendations Full throttle operating range: Battery requirement F6C: 4500–5500 r/min Make sure that the size of the battery cable terminals is appropriate for the size of the battery terminals. Propeller size (in) Material To prevent the battery cable terminal connec- 7 1/2 8 - BA tions from corroding, solder each battery...
  • Page 55 TRBL SHTG Troubleshooting Outboard motor troubleshooting Troubleshooting procedure Troubleshooting the power unit Troubleshooting the lower unit...
  • 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,check that the battery is fully charged.
  • Page 57 Outboard motor troubleshooting Symptom 2 Cause Checking step Compression pressure Compression leakage Measure the compression pressure. is low Check the valve for bends or stuck. Check the decompressor for proper operation. Check the piston and piston ring for damage. Check the cylinder for damage. Improper valve timing Check the valve timing.
  • Page 58 TRBL SHTG Troubleshooting Symptom 1: Improper oil lubrication. Symptom 2 Cause Checking step Oil cannot be seen Low engine oil level Check the oil level. through the oil lubrica- Check for engine oil leakage. tion check window Check the valve stem seal and valve. Check the piston ring.
  • Page 59 ELEC Electrical system Electrical component and wiring harness routing Port Checking the electrical component Measuring the peak voltage Using the digital tester Charging unit and component Checking the lighting coil Checking the Rectifier Regulator Ignition unit and component Checking the ignition spark Checking the spark plug cap Checking the engine shut-off switch...
  • Page 60 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 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) d Lighting coil fere with the bolt or washer.
  • Page 62 ELEC Electrical system Checking the electrical TIP: component • Before measuring the peak voltage, check Measuring the peak voltage all wiring harness for corrosion. Also, make sure that the wiring harness is connected properly and that the battery is fully When measuring the peak voltage, do not charged.
  • Page 63 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 1. Remove the holder a, and then discon- nect the lighting coil connectors a. Rectifier Regulator peak voltage: Red (R)–Ground Loaded...
  • Page 64 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 4.
  • Page 65 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 Fuel hose Blowby hose, oil return hose, and cooling water hose Fuel tank Removing the fuel tank Removing the primer pump Checking the fuel tank Checking the fuel joint Checking the fuel strainer (tank side) Checking the fuel strainer Checking the primer pump Installing the primer pump...
  • Page 68 FUEL Fuel system Hose routing Fuel hose a Fuel hose (fuel tank to fuel cock) a Fuel tank b Fuel hose (fuel cock to fuel strainer) b Fuel cock c Fuel hose (fuel strainer to joint) c Fuel strainer d Fuel hose (joint to fuel pump) d Joint e Fuel hose (fuel pump to carburetor) e Fuel pump...
  • Page 69 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 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 Choke holder bolt Holder Grommet Fuel cap Rubber seal Fuel strainer Fuel tank Bolt Grommet Collar...
  • 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 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”. 3. Disconnect the fuel hose a, and then remove the fuel tank b.
  • Page 73 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 FUEL Fuel system 2. Install the clamps f and g temporarily Leakage tester a 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 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 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 Bolt Washer Collar Throttle cam Lever Holder Clamp Gasket Throttle link rod Intake manifold bolt Intake manifold Gasket Spacer Hose...
  • Page 78 FUEL Fuel system 12 N·m (1.2 kgf·m, 8.9 ft·lb) Part name Q’ty Remarks Carburetor assembly Bolt Washer Intake silencer O-ring...
  • Page 79 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 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 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 Intake silencer / Carburetor Carburetor Carburetor B 20 1.5 N·m (0.15 kgf·m, 1.11 ft·lb) Part name Q’ty Remarks Throttle stop screw Spring Throttle link screw Spring O-ring Pilot screw Pilot jet Gasket Float chamber Screw O-ring Drain screw Spring Main nozzle Main jet Float...
  • Page 84 FUEL Fuel system 1.5 N·m (0.15 kgf·m, 1.11 ft·lb) Part name Q’ty Remarks Clip Needle valve...
  • Page 85 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. Pilot screw driver m Checking the carburetor 1.
  • Page 86 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 Carburetor 7. Install the pilot jet l, the spring m, a new O-ring n, and the pilot screw o. Pilot screw driver p 8. Turn the pilot screw o in until it is lightly seated, and then turn it out the specified number of turns.
  • Page 88 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 Fuel pump screw Cover Diaphragm Fuel pump valve screw Valve Fuel pump body 2 Plunger Spring Fuel pump body 1...
  • Page 89 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 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 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) Checking the compression pressure Checking the ignition timing Checking the CDI unit air gap Adjusting the CDI unit air gap Checking the valve clearance Adjusting the valve clearance Manual starter Removing the manual starter Disassembling the manual starter Checking the manual starter Checking the spiral spring...
  • Page 93 Replacing the valve guide Checking the valve seat Refacing the valve seat Checking the spark plug Checking the thermostat cover anode Checking the thermostat Assembling the cylinder head Installing the cylinder head Cylinder block Disassembling the cylinder block Checking the piston diameter Checking the cylinder bore Checking the piston ring Checking the piston ring end gap...
  • Page 94 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 Power unit (check and adjustment) 1. Remove manual starter. “Removing the manual starter”. 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 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 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) Bolt Guide Bolt Starter plunger Spring Cover Sheave drum Spring Drive pawl Clip Drive plate Drive plate screw E-clip...
  • 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 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 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 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 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 Bolt Holder Bracket...
  • Page 105 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 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 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”. 20. Install the manual starter. See “Installing the manual starter”.
  • Page 111 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 Washer Starter pulley Flywheel magnet Woodruff key Spark plug cap CDI unit CDI unit bolt Bolt Holder...
  • Page 112 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”.
  • 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 Screw Gasket Oil strainer Spring Cover Crankcase bolt Dowel Gasket...
  • Page 115 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 Blind plug Bolt Drain bolt Gasket Bolt Oil seal housing...
  • Page 116 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 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 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 Crankcase Installing the oil pump Driver rod L3 b Needle bearing attachment c 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 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 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 Cylinder head Valve spring compressor b Cylinder head warpage limit: 0.10 mm (0.0039 in) Valve spring compressor attachment c Checking the rocker arm 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 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 Cylinder head Valve guide inside diameter a: Valve guide remover/installer b Intake and exhaust: 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 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 4. Measure the valve seat contact width a where the blueing dye is adhered to the 30˚...
  • 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 Check the valve seat contact area of the contact width using a 30° cutter. valve.
  • Page 128 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 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 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 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 Connecting rod bolt Clip Piston pin Piston Piston ring set Plate...
  • Page 133 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 Needle bearing attachment j 6. Remove the clips k, and then remove 3. Remove the connecting rod cap a, and the piston pin l and connecting rod c.
  • Page 134 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 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 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 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 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 Cylinder block Driver rod LL b Ball bearing attachment c 2. Install a new oil seal d. TIP: Driver rod LS e • Face the mark b on the con- Ball bearing attachment f necting rod a in the same direction as the “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 smoothly.
  • Page 141 LOWR Lower unit Lower unit Removing the lower unit (S-transom model) . Removing the lower unit (L-transom model) . Disassembling the extension (L-transom model) Checking the propeller Checking the lower unit anode Water pump and shift rod Removing the water pump and shift rod Checking the water pump Checking the shift rod Propeller shaft housing...
  • Page 142 LOWR Lower unit Lower unit 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 143 Lower unit 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 Drain screw...
  • Page 144 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 Lower unit Disassembling the extension (L- transom model) 1. Remove the circlip a, and then remove the bushing b. Stopper guide plate c Stopper guide stand d Bearing puller assembly e Checking the propeller 1. Check the propeller blades and splines. Replace the propeller if cracked, dam- aged, or worn.
  • Page 146 LOWR Lower unit Water pump and shift rod Part name Q’ty Remarks Bolt Plate Rubber seal Water pump housing Insert cartridge Impeller Gasket Outer plate cartridge Rubber seal Bolt Dowel Housing Shift rod Gasket...
  • Page 147 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 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 Bolt...
  • Page 149 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 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 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...
  • Page 152 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 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 Bushing attachment e 3. Install new oil seals f to the specified depth a.
  • Page 154 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 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 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 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 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)”.
  • Page 160 LOWR Lower unit — MEMO —...
  • Page 161 BRKT Bracket unit Tiller handle Disassembling the tiller handle Assembling the tiller handle Bottom cowling Disassembling the bottom cowling Assembling the bottom cowling Upper case and shift lever Removing the shift lever Removing the upper case . Checking the upper case Installing the upper case Installing the shift lever Clamp bracket .
  • 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 Tiller handle mounting bolt Plate Bushing Washer...
  • 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 Throttle grip screw Bushing...
  • Page 164 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 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 Primer pump holder bolt Holder Holder...
  • 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 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 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 Shift lever bolt Shift lever Shift rod Pipe Rubber seal Shift link lever O-ring Ball...
  • 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 Bolt Steering friction adjuster Spring Bushing Bushing Bushing Bushing Spring Bolt Reverse lock Grommet Friction piece Bushing...
  • Page 172 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 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 Bushing attachment o piece h. 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 1.
  • 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 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 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 Bolt Clamp bracket (PORT) Bolt Tilt pin Spring Clamp pad Clamp screw Clamp handle...
  • Page 177 Clamp bracket 15 N·m (1.5 kgf·m, 11.1 ft·lb) Part name Q’ty Remarks Spring Bushing Plate Bolt Cover Tilt lock lever...
  • Page 178 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)
  • Page 180 BRKT Bracket unit — MEMO —...
  • Page 181 Maintenance Outline Maintenance interval chart Predelivery check Checking the battery Checking the cooling water pilot hole Checking the engine oil level Checking the engine shut-off switch Checking the fuel system Checking the gear oil level Checking the gear shift and throttle operation Checking the outboard motor mounting height Checking the steering system Checking the throttle cable...
  • Page 182 Maintenance Outline • To obtain long product life, strongly recommends that the specified periodic checks and maintenance be performed according to the maintenance interval chart. • If replacement parts are necessary, use only genuine parts of equivalent design and qual- ity.
  • Page 183 Outline Initial Every Item Actions 20 hours 100 hours 300 hours 500 hours (3 months) (1 year) (3 years) (5 years) Impeller/ Replace water pump housing Pilot water Check Propeller/propeller nut/ Check/replace cotter pin Shift link Check/replace Spark plug Check/replace Spark plug cap Check/replace Throttle link/...
  • Page 184 Maintenance Predelivery check To make the delivery process smooth and efficient, complete the predelivery checks as explained in the following procedures. Checking the battery Battery electrolyte is dangerous; it con- 2. Check specific gravity tains sulfuric acid, which is poisonous electrolyte.
  • Page 185 Predelivery check Checking the fuel system 2. Start the engine and warm it up for 5–10 minutes. 1. Check that the fuel hoses are securely connected. “Fuel hose”. 3. Stop the engine and leave it off for 5–10 NOTICE: This is a 4-stroke engine. minutes.
  • Page 186 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 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 Maintenance 3. For the remaining 8 hours c of 1. Check the anodes. See “Checking the operation: thermostat cover anode”, Operate the engine at any engine speed. “Checking the lower unit anode”. However, do not operate the engine at Checking the battery full throttle for more than 5 minutes at a time.
  • Page 189 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 Maintenance Checking the fuel joint and fuel Recommended engine oil: hoses (fuel joint to carburetor) 4-stroke motor oil 1. Check the fuel joint and fuel hose con-nections. See “Fuel hose”. Replacement engine oil quantity: Checking the fuel strainer 0.6 L 1.
  • Page 191 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. Oil quantity: 0.1 L 7. Remove the gear oil tube, and then install a new gasket g and the drain screw b.
  • Page 192 Maintenance Adjusting the throttle link rod and throttle cable Adjust the throttle link rod. See “Adjusting the throttle cable and throttle link”. Checking the top cowling 1. Check the fitting by pushing the top cowl- ing. Adjust if there is free play. 2.
  • Page 193 General periodic maintenance Checking the water pump 1. Check the water pump housing and impeller. “Checking water pump”.
  • Page 194 Index Checking the connecting rod oil clearance Abbreviation Checking the connecting rod small end inside Adjusting the CDI unit air gap diameter and big end inside diameter Adjusting the start-in-gear protection Checking the cooling water passage cable Checking the cooling water pilot hole 3 Adjusting the throttle cable and Checking the crankcase throttle link...
  • Page 195 Index Checking the propeller shaft Drive shaft and lower case Checking the propeller shaft housing Checking the push rod Checking the Rectifier Regulator Electric shock Checking the reverse gear Electrical component and wiring harness Checking the rocker arm routing Checking the rotor assembly Electrical technical data Checking the shift rod Engine control system...
  • Page 196 Index Installing the lower unit (S-transom model) Part, lubricant, and sealant Installing the manual starter Performance Installing the oil pump Port Installing the oil seal housing Power unit Installing the power unit Power unit (check and adjustment) Installing the primer pump Power unit assembly Installing the propeller shaft housing assembly Power unit system...
  • Page 197 Index Starting the engine Symbol Test run Tightening torque Tiller handle Tilt system Troubleshooting procedure Troubleshooting the lower unit Troubleshooting the power unit Uncrating procedure Upper case and shift lever Using the digital tester Ventilation Water pump and shift rod Working with crane...
  • Page 198 Index — MEMO —...
  • Page 199 Appendix Wiring diagram How to use the wiring diagram...
  • Page 200 Wiring diagram How to use the wiring diagram Legend symbols in the wiring diagrams a No wire connector b Optional parts Color Code : Black : Green : Red : White a Fuse (20A) (Battery) Engine shut-off switch Clip installed Clip removed Pushed CDI unit...
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