Yamaha 40V Service Manual
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Yamaha 40V Service Manual

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WORLD WIDE
40V, 50H
USA/CANADA
40W, 50W
SERVICE
MANUAL
LIT-18616-01-81
290320

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Summary of Contents for Yamaha 40V

  • Page 1 WORLD WIDE 40V, 50H USA/CANADA 40W, 50W SERVICE MANUAL LIT-18616-01-81 290320...
  • Page 2 Yamaha equipment. It has been written to suit the needs of persons who have a basic under- standing 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: How To Use This Manual

    HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
  • Page 4 WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish important information in this manual in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.
  • Page 5 HOW TO READ DESCRIPTIONS 1. A disassembly installation job mainly consists of the exploded diagram 1 . 2. The numerical figures represented by the number 2 indicates the order of the job steps. 3. The symbols represented by the number 3 indicates the contents and notes of the job. For the meanings of the symbols, refer to the next page(s).
  • Page 6 [Resistance ( Ω ), Voltage (V), Electric current (A)] Symbol G to J in an exploded diagram indicate grade of lubricant and location of lubrication point: G Apply Yamaha 2-stroke outboard motor oil H Apply Yamaha gear-case lubricant I Apply molybdenum disulfide oil J Apply water...
  • Page 7 INDEX A30000-0 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENT INSP FUEL SYSTEM FUEL POWER UNIT POWR LOWER UNIT LOWER BRACKET UNIT BRKT – ELECTRICAL SYSTEM ELEC TROUBLE-ANALYSIS TRBL ANLS...

  • Page 9: Table Of Contents

    INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION..................... 1-1 SERIAL NUMBER ..................1-1 STARTING SERIAL NUMBERS ............... 1-1 SAFETY WHILE WORKING ................1-2 FIRE PREVENTION ................... 1-2 VENTILATION................... 1-2 SELF-PROTECTION.................. 1-2 OILS, GREASES AND SEALING FLUIDS..........1-2 GOOD WORKING PRACTICES ..............1-3 DISASSEMBLY AND ASSEMBLY ............

  • Page 10: Identification

    IDENTIFICATION INFO A60000-1* IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. NOTE: As an antitheft measure, a special label on which the outboard motor serial number is stamped is bonded to the portside of the clamp bracket.

  • Page 11: Safety While Working

    SAFETY WHILE WORKING INFO SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed Yamaha dealers their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling, and keep it away from heat, sparks, and open flames.

  • Page 12: Good Working Practices

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

  • Page 13: Disassembly And Assembly

    SAFETY WHILE WORKING INFO 3. Non-reusable items Always use new gaskets, packings, O- rings, split-pins and circlips etc. on reassembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed-air on dis- assembling them. 2. Oil the contact surfaces of moving parts on assembly.

  • Page 14: Special Tools

    SPECIAL TOOLS INFO A80000-0* SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accu- rate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment. NOTE: For U.S.A. and Canada, use part number starting with “YB-”, “YU-” or “YW-”.

  • Page 15: Measuring

    SPECIAL TOOLS INFO MEASURING Tool No. Except for Tool name Use for: USA and USA and Canada a Canada b Tachometer YU-08036-A 90890-06760 Idle speed Dynamic spark tester YM-34487 90890-06754 Ignition system C.D.I. tester YU-91022-B N.A. Ignition system Mity Vac YB-35956 90890-06756 Fuel joint...
  • Page 16 SPECIAL TOOLS INFO...

  • Page 17: Removal And Installation

    SPECIAL TOOLS INFO REMOVAL AND INSTALLATION Tool No. Except for Tool name Use for: USA and USA and Canada a Canada b Small end bearing YB-06106 90890-06526 Small end needle installer Reverse gear bearing Crank shaft Bearing separator YB-06219 90890-06534 Forward bearing gear inner...
  • Page 18 SPECIAL TOOLS INFO...
  • Page 19 SPECIAL TOOLS INFO Tool No. Except for Tool name Use for: USA and USA and Canada a Canada b Bearing outer race puller N.A. 90890-06523 Forward gear outer bearing Bearing outer race puller N.A. 90890-06532 Forward gear outer bearing clow Bearing installer YB-41446 90890-06626...
  • Page 21 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 MAINTENANCE SPECIFICATIONS..............2-7 ENGINE..................... 2-7 LOWER...................... 2-9 ELECTRICAL ................... 2-10 DIMENSION 1..................2-13 DIMENSION 2..................2-15 TIGHTENING TORQUE ................. 2-17 SPECIFIED TORQUE ................2-17 GENERAL TORQUE ................2-18...

  • Page 22: Specifications

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Item Model Unit Worldwide 40VMH 40VMHD 40VMHO 40VMO 40VWH USA, CANADA C40MH — 40MH — — DIMENSION: Over-all length 1,281 (50.4) mm (in) 670 (26.4) 1,281 (50.4) Over-all width 349 (13.7) 360 (14.2) mm (in) Over-all height mm (in) 1,223 (48.1)
  • Page 23 SPEC GENERAL SPECIFICATIONS Item Model Unit Worldwide 40VMH 40VMHD 40VMHO 40VMO 40VWH USA, CANADA C40MH — 40MH — — FUEL AND LUBRICATION: Fuel type Regular gasoline Fuel rating P.O.N.* Min. 86 Engine oil type/grade 2-stroke outboard motor oil / TC-W3 Mixing ratio 50 : 1 —...
  • Page 24 SPEC GENERAL SPECIFICATIONS Item Model Unit Worldwide 40VE 40VEO 40VEHTO 40VET 40VETO USA, CANADA C40ER 40ER P40TH C40TR 40TR DIMENSION: Over-all length mm (in) 670 (26.4) 1,281 (50.4) 646 (25.4) Over-all width mm (in) 349 (13.7) 360 (14.2) 350 (13.8) Over-all height mm (in) 1,192 (46.9)
  • Page 25 SPEC GENERAL SPECIFICATIONS Item Model Unit Worldwide 40VE 40VEO 40VEHTO 40VET 40VETO USA, CANADA C40ER 40ER P40TH C40TR 40TR FUEL AND LUBRICATION: Fuel type Regular gasoline Fuel rating P.O.N.* Min. 86 Engine oil type/grade 2-stroke outboard motor oil / TC-W3 Mixing ratio 50 : 1 —...
  • Page 26 SPEC GENERAL SPECIFICATIONS Item Model Unit Worldwide 50HMHO 50HMHD 50HMO 50HMDO 50HWHD 50HEDO 50HET 50HETO USA, CANADA — — — — — 50ER C50TR 50TR DIMENSION: Over-all length mm (in) 1,281 (50.4) 670 (26.4) 1,281 (50.4) 670 (26.4) Over-all width mm (in) 349 (13.7) 360 (14.2)
  • Page 27 SPEC GENERAL SPECIFICATIONS Item Model Unit Worldwide 50HMHO 50HMHD 50HMO 50HMDO 50HWHD 50HEDO 50HET 50HETO USA, CANADA — — — — — 50ER C50TR 50TR FUEL AND LUBRICA- TION: Fuel type Regular gasoline Fuel rating P.O.N.* Min. 86 Engine oil type/grade 2-stroke outboard motor oil / TC-W3 Mixing ratio —...

  • Page 28: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit 40 hp 50 hp CYLINDER HEAD: Warpage limit mm (in) 0.1 (0.004) CYLINDER: Bore size mm (in) 67.00 ~ 67.02 (2.638 ~ 2.639) Wear limit mm (in) 67.10 (2.642) Taper limi mm (in) 0.08 (0.003) Out of round limit...
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit 40 hp 50 hp THERMOSTAT: Opening temperature ˚C (˚F) 48 ~ 52 (118 ~ 126) Full-opening temperature ˚C (˚F) 60 (140) Valve lift mm (in) 3 (0.12) OIL INJECTION PUMP: Identification mark 63D00 Specified discharge 1.60 ±...

  • Page 30: Lower

    SPEC MAINTENANCE SPECIFICATIONS LOWER Model Item Unit 40 hp 50 hp GEAR BACKLASH: Pinion - forward mm (in) 0.18 ~ 0.45 (0.007 ~ 0.018) Pinion - reverse mm (in) 0.71 ~ 0.98 (0.028 ~ 0.039) Pinion shims mm (in) 0.05, 0.08, 0.12, 0.30, 0.50 Forward shims mm (in) 0.05, 0.08, 0.12, 0.30, 0.50...

  • Page 31: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model Item Unit 40 hp 50 hp IGNITION TIMING: A.T.D.C. 7 ± 1 Ignition timing (full retarded) degree (full advanced) degree B.T.D.C. 25 –1 (cam roller pick-up) degree A.T.D.C. 7 +0.97 Piston position (full advanced) mm (in) B.T.D.C.
  • Page 32 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit 40 hp 50 hp Ω (color) Charge coil resistance 368 ~ 552 (Br — L) Charging current (minimum)/rpm A/rpm 3/3,000 Charging current (maximum)/rpm A/rpm 5 ~ 7/5,500 Lighting voltage (minimum)/rpm V/rpm 12.0/3,000 Lighting voltage (maximum)/rpm V/rpm 13.5 ~ 16.5/5,500 Ω...
  • Page 33 SPEC MAINTENANCE SPECIFICATIONS 2-12...

  • Page 34: Dimension 1

    SPEC MAINTENANCE SPECIFICATIONS DIMENSION 1 2-13...
  • Page 35 SPEC MAINTENANCE SPECIFICATIONS Model 40VET 40VMH 40VMHD 40VETO Symbol Unit 40VMHO 40VMO 40VE 50HMDO 50HMHD 40VEHTO 50HEDO 40VWH 50HMO 40VEO 50HWHD 50HET 50HMHO 50HETO :S mm (in) 798 (31.4) — 822 (32.4) — 822 (32.4) 910 (35.8) 937 (36.9) — 1,010 (39.8) —...

  • Page 36: Dimension 2

    SPEC MAINTENANCE SPECIFICATIONS DIMENSION 2 MANUAL TILT MODEL HYDRO TILT/PTT MODEL 2-15...
  • Page 37 SPEC MAINTENANCE SPECIFICATIONS Model Symbol Unit Manual tilt Hydro and PTT mm (in) 62.5 (2.5) 126 (5.0) mm (in) 208 (8.2) 254 (10.0) mm (in) 121.5 (4.8) 163.5 (6.4) mm (in) 32 (1.3) 50.8 (2.0) mm (in) 131.5 (5.2) 180 (7.1) mm (in) 245 (9.6) 355 (14.0)

  • Page 38: Tightening Torque

    SPEC TIGHTENING TORQUE TIGHTENING TORQUE SPECIFIED TORQUE Tightening torque Remarks Part Thread Part to tightened Q‘ty name size m•kg ft•lb ENGINE: Engine unit Bolt Flywheel Intake manifold Bolt Reed valve Bolt Spark plug Bolt Cylinder head Bolt Exhaust cover Bolt Crank case Bolt LOWER:...

  • Page 39: General Torque

    SPEC TIGHTENING TORQUE GENERAL TORQUE General torque This chart specifies the torques for tighten- specifications Nut (A) Bolt (B) ing standard fastners with standard clean m•kg ft•lb dry ISO threads at room temperature. 8 mm Torque specifications for special compo- 10 mm nents or assemblies are given in applicable 12 mm...
  • Page 41 INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............. 3-1 PERIODIC SERVICE ..................3-2 FUEL SYSTEM..................3-2 Fuel line....................3-2 CONTROL SYSTEM ................. 3-2 Throttle link adjustment..............3-2 Throttle cable adjustment..............3-3 Shift cable adjustment ..............3-4 Start-in-gear protection adjustment ..........3-5 Idle speed adjustment...............

  • Page 42: Maintenance Interval Chart

    INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance intervals. Depending on operating conditions, the intervals of maintenance should be changed. Initial Every Refer Item Remarks 10 hours 50 hours 100 hours 200 hours page...

  • Page 43: Periodic Service

    INSP FUEL SYSTEM/CONTROL SYSTEM PERIODIC SERVICE FUEL SYSTEM Fuel line 1. Inspect: Fuel line Break/Leak/Damage → Replace. CONTROL SYSTEM Throttle link adjustment 1. Check: CDI unit indicator Incorrect → Adjust. Checking steps: Turn the magneto control lever 1 so that its adjusting screw contacts the full retarding stopper a .

  • Page 44: Throttle Cable Adjustment

    INSP CONTROL SYSTEM Loosen the lock nut 2. Disconnect the magneto control rod 3 at the CDI unit. Turn the magneto control lever so that its adjusting screw contacts the full retarding stopper b. Adjust the magneto control rod length so that the CDI unit indicator aligns with the specified marking on the plate.

  • Page 45: Shift Cable Adjustment

    INSP CONTROL SYSTEM Turn the magneto control lever 3 so that its adjusting screw contacts the full retarding stopper a. Adjust the position of the cable joint until its hole aligns with the set pin. Install the clip and tighten the lock nut. WARNING The cable joint should be screwed in more than 8 mm (0.31 in).

  • Page 46: Start-In-Gear Protection Adjustment

    INSP CONTROL SYSTEM Start-in-gear protection adjustment 1. Check: Start-in-gear protection operation Incorrect → Adjust. 2. Adjust: Start-in-gear protection wire Adjustment steps: Set the shift lever in neutral. Loosen the lock nut 1. Adjust the start-in-gear protection wire adjust nut 2 so that the end of the starter stop-plunger aligns with the center of the hole in the starter case.

  • Page 47: Oil Injection System

    INSP CONTROL SYSTEM/OIL INJECTION SYSTEM Turn in the pilot screw until it is lightly seated. Turn out the pilot screw to specification. Pilot screw (turns out): 40 hp: 1-1/2 ± 1/4 50 hp (M model): 1-5/8 ± 1/4 50 hp (EM, E model): 1-3/8 ± 1/4 Start the engine and allow it to warm up for a few minutes.

  • Page 48: Power Trim And Tilt System

    PTT unit should be kept fully tilted up (the tilt rod being fully lengthened). 2. Fill: Yamaha power trim and tilt fluid Plug screw: 7 Nm (0.7 m • kg, 5.1 ft • lb)

  • Page 49: Lower Unit

    INSP LOWER UNIT LOWER UNIT Gear oil 1. Check: Gear oil Milky oil → Replace the oil seal. Slag oil → Check the gear, bearing and dog. 2. Check: Gear oil level Oil level is low → Add oil to proper level.

  • Page 50: General

    INSP LOWER UNIT/GENERAL NOTE: Do not over-pressurize. Excess pressure may cause the air to leak out. GENERAL Anode 1. Inspect: Anode 1 Trim tab 2 Anode [(bracket bottom) except for manual tilt model] 3 Scale → Clean. Oil/grease → Clean. Wear/Excessively consumed →...

  • Page 51: Spark Plug

    INSP GENERAL NOTE: Batteries vary among manufacturers. Therefore the following procedures may not always apply. Consult your battery manufacturer’s instructions. Disconnect the black negative lead first to prevent the risk of shorting. 1. Inspect: Battery fluid level Battery fluid specific gravity Spark plug 1.

  • Page 52: Grease Points

    INSP GENERAL 4. Measure: Electrodes gap a Out of specification → Regap. Gap: 0.9 ~1.0 mm (0.035 ~ 0.039 in) 5. Tighten: Spark plug NOTE: Before installing the spark plug, clean the gasket surface and the plug surface. Spark plug: 25 Nm (2.5 m •...
  • Page 53 FUEL CHAPTER 4 FUEL SYSTEM FUEL JOINT, FUEL FILTER AND FUEL PUMP..........4-1 EXPLODED DIAGRAM ................4-1 REMOVAL AND INSTALLATION CHART ..........4-2 FUEL LINE LAYOUT................. 4-3 M model ..................... 4-3 EM, E model..................4-3 SERVICE POINTS ..................4-4 Fuel joint inspection................4-4 Fuel filter inspection................

  • Page 54: Fuel Joint, Fuel Filter And Fuel Pump

    FUEL FUEL JOINT, FUEL FILTER AND FUEL PUMP FUEL JOINT, FUEL FILTER AND FUEL PUMP EXPLODED DIAGRAM...

  • Page 55: Removal And Installation Chart

    FUEL FUEL JOINT, FUEL FILTER AND FUEL PUMP REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FUEL JOINT, FUEL FILTER AND Follow the left “Step” for removal. FUEL PUMP REMOVAL Oil tank ass’y Refer to “OIL TANK”. Clip Fuel hose (joint - filter) 6 ×...

  • Page 56: Fuel Line Layout

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

  • Page 57: Service Points

    FUEL FUEL JOINT, FUEL FILTER AND FUEL PUMP SERVICE POINTS Fuel joint inspection 1. Inspect: Fuel joint Crack/Leak/Damage → Replace. 2. Measure: Fuel joint operation Impossible to maintain the specified pressure for 10 sec. → Replace. Measuring steps: Attach the Mity vac. Mity vac: YB-35956/90890-06756 Apply the specified pressure.

  • Page 58: Carburetor Removal

    FUEL CARBURETOR REMOVAL CARBURETOR REMOVAL EXPLODED DIAGRAM...

  • Page 59: Removal And Installation Chart

    FUEL CARBURETOR REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR REMOVAL Follow the left “Step” for removal. Oil tank ass’y Refer to “OIL TANK”. 6 × 40 mm Screw 6 × 55 mm Screw Washer Silencer Seal Clip Fuel hose (joint pipe - cab.1)

  • Page 60: Carburetor

    FUEL CARBURETOR CARBURETOR EXPLODED DIAGRAM...

  • Page 61: Removal And Installation Chart

    FUEL CARBURETOR REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR DISASSEMBLY Follow the left “Step” for removal. Carburetor ass’y Refer to “CARBURETOR REMOVAL”. Drain screw O-ring 4 × 14 mm Screw (with washer) Carburetor cover Cover packing Pilot adjusting screw CAUTION: Do not damage the tip of the pilot screw...

  • Page 62: Service Points

    FUEL CARBURETOR SERVICE POINTS CAUTION: Do not use steelwire for cleaning the jets as this may enlarge the jet diameters and seri- ously affect performance. Carburetor inspection 1. Inspect: Carburetor body Crack/Damage → Replace. Contamination → Clean. 2. Inspect: Pilot screw Bend/Wear →...

  • Page 63: Carburetor Assembly

    FUEL CARBURETOR Carburetor assembly 1. Install: Needle valve Float 1 Float pin 2 Screw 3 NOTE: The float pin should be fit in the slit the carburetor and locked with the screw. When installing the float in the carburetor, place the needle valve in the valve seat. After installing, check the smooth move- ment of the float.

  • Page 64: Prime Starter

    FUEL PRIME STARTER PRIME STARTER EXPLODED DIAGRAM 4-11...

  • Page 65: Removal And Installation Chart

    FUEL PRIME STARTER REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points PRIME STARTER DISASSEMBLY Follow the left “Step” for removal. Carburetor ass’y Refer to “CHARBURETOR REMOVAL”. 4 × 10 mm Screw (with washer) Electrothermal valve Clip Fuel enrichment hose Clip Fuel hose (cover - chamber) Screw (with washer)

  • Page 66: Service Points

    FUEL PRIME STARTER SERVICE POINTS Fuel enrichment pump inspection 1. Inspect: Body Crack/Leak/Damage → Replace. 2. Inspect: Seat valve Crack/Distortion → Replace. 3. Inspect: Diaphragm Damage → Replace. Fuel enrichment valve inspection 1. Inspect: Needle valve 1 Piston valve 2 Wear/Bend/Damage →...
  • Page 67 FUEL PRIME STARTER 4-14...

  • Page 68: Oil Tank

    FUEL OIL TANK OIL TANK EXPLODED DIAGRAM 4-15...

  • Page 69: Removal And Installation Chart

    FUEL OIL TANK REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL TANK REMOVAL Follow the left “Step” for removal. Clip Oil drain hose NOTE: Drain oil from the oil tank. Clip Oil inlet hose Clip Oil return hose Oil level sensor lead coupler NOTE: Disconnect the coupler.

  • Page 70: Oil Line Layout

    FUEL OIL TANK OIL LINE LAYOUT 1 Electrothermal valve (EM, E model) 2 Oil level sensor 3 Oil drain hose 4 Oil tank 5 Oil pump 4-17...

  • Page 71: Service Points

    FUEL OIL TANK SERVICE POINTS Oil tank inspection 1. Inspect: Oil tank Crack → Replace. Oil strainer inspection 1. Inspect: Oil strainer Crack/Clog → Replace. Contamination → Clean. Check valve inspection 1. Check: Check valve operation Does not function → Replace. NOTE: Check the operation of the check valve to ensure the air is blown only in the arrow...

  • Page 72: Oil Pump

    FUEL OIL PUMP OIL PUMP EXPLODED DIAGRAM 4-19...

  • Page 73: Removal And Installation Chart

    FUEL OIL PUMP REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL PUMP REMOVAL Follow the left “Step” for removal. Engine oil Refer to “OIL TANK”. Clip Oil inlet hose Clip Oil return hose Clip Plate washer Link joint NOTE: Disconnect the joint at the pump side.
  • Page 74 POWR CHAPTER 5 POWER UNIT POWER UNIT REMOVAL ................5-1 EXPLODED DIAGRAM ................5-1 REMOVAL AND INSTALLATION CHART ..........5-2 RECOIL STARTER ................... 5-3 EXPLODED DIAGRAM ................5-3 REMOVAL AND INSTALLATION CHART ..........5-4 SERVICE POINTS ..................5-5 Sheave drum removal ..............5-5 Spiral spring removal ...............
  • Page 75 POWR CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER....... 5-21 EXPLODED DIAGRAM ................5-21 REMOVAL AND INSTALLATION CHART ..........5-22 SERVICE POINTS ................... 5-23 Cylinder head inspection ..............5-23 Thermostat inspection ..............5-24 CRANKCASE AND CYLINDER BODY ............5-25 EXPLODED DIAGRAM ................5-25 REMOVAL AND INSTALLATION CHART ..........

  • Page 76: Power Unit

    POWR POWER UNIT REMOVAL POWER UNIT REMOVAL EXPLODED DIAGRAM...

  • Page 77: Removal And Installation Chart

    POWR POWER UNIT REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points POWER UNIT REMOVAL Follow the left “Step” for removal. Bolt M model Engine stop switch lead (black) Engine stop switch coupler (blue) Maine switch lead coupler E model Oil level sensor lead coupler EHTO model...

  • Page 78: Recoil Starter

    POWR RECOIL STARTER RECOIL STARTER EXPLODED DIAGRAM...

  • Page 79: Removal And Installation Chart

    POWR RECOIL STARTER REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points RECOIL STARTER REMOVAL Follow the left “Step” for removal. Lock nut Start-in-gear protection wire NOTE: Disconnect the wire at the bottom cowl- ing side. 6 × 35 mm Bolt (with washer) Recoil starter ass’y Dowel pin...

  • Page 80: Service Points

    POWR RECOIL STARTER SERVICE POINTS Sheave drum removal 1. Turn: Sheave drum 1 Turn the sheave drum clockwise until the spiral spring is free. NOTE: Turn the sheave drum so that the cutaway on the outer surface of the sheave drum faces toward the starter handle.

  • Page 81: Drive Pawl And Spring Inspection

    POWR RECOIL STARTER Drive pawl and spring inspection 1. Inspect: Drive pawl Crack/Wear/Damage → Replace. Drive pawl spring Broken/Bent/Damage → Replace. Rope roller and collar inspection 1. Inspect: Rope roller Collar Crack/Wear/Damage → Replace them as a set. Bushing inspection 1.

  • Page 82: Starter Rope Installation

    POWR RECOIL STARTER Starter rope installation 1. Install: Starter rope NOTE: Insert the rope through the rope holes and knot the end. Wind the rope 1-9/10 turns around the sheave drum. Place the rope at the cutaway. Sheave drum installation 1.
  • Page 83 POWR RECOIL STARTER...

  • Page 84: Flywheel Magneto And Magneto Base

    POWR FLYWHEEL MAGNETO AND MAGNETO BASE FLYWHEEL MAGNETO AND MAGNETO BASE EXPLODED DIAGRAM...

  • Page 85: Removal And Installation Chart

    POWR FLYWHEEL MAGNETO AND MAGNETO BASE REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FLYWHEEL MAGNETO AND Follow the left “Step” for removal. MAGNETO BASE REMOVAL Recoil starter ass’y Refer to “RECOIL STARTER”. 6 × 40 mm Screw 6 ×...

  • Page 86: Service Points

    POWR FLYWHEEL MAGNETO AND MAGNETO BASE SERVICE POINTS Å Flywheel magneto removal 1. Remove: Flywheel nut Flywheel holder: YB-06139/90890-06522 Å For USA and CANADA ı Except for USA and CANADA ı CAUTION: The major load should be carried in the direction of the arrows.
  • Page 87 POWR FLYWHEEL MAGNETO AND MAGNETO BASE 5-12...

  • Page 88: Electrical Unit Removal

    POWR ELECTRICAL UNIT REMOVAL ELECTRICAL UNIT REMOVAL EXPLODED DIAGRAM Å 5-13...

  • Page 89: Removal And Installation Chart

    POWR ELECTRICAL UNIT REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL UNIT REMOVAL Follow the left “Step” for removal. Thermo switch coupler Pink and black leads Wire harness coupler Electrothermal valve lead Blue lead Lighting coil lead Green leads CDI unit lead coupler Bolt (with washer)

  • Page 90: Electrical Unit

    POWR ELECTRICAL UNIT ELECTRICAL UNIT EXPLODED DIAGRAM 5-15...

  • Page 91: Removal And Installation Chart

    POWR ELECTRICAL UNIT REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ELECTRICAL UNIT DISASSEMBLY Follow the left “Step” for removal. Electrical unit Refer to “ELECTRICAL UNIT REMOVAL”. Fuse Clamp Bolt (with washer) Clamp Bolt (with washer) Rectifier regurator Spring washer Bracker Relay holder...

  • Page 92: Reed Valve And Check Valve

    POWR REED VALVE AND CHECK VALVE REED VALVE AND CHECK VALVE EXPLODED DIAGRAM 5-17...

  • Page 93: Removal And Installation Chart

    POWR REED VALVE AND CHECK VALVE REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REED VALVE AND CHECK Follow the left “Step” for removal. VALVE REMOVAL Oil tank ass’y Refer to “OIL TANK” in chapter 4. Carburetor ass’y Refer to “CARBURETOR REMOVAL”...

  • Page 94: Service Points

    POWR REED VALVE AND CHECK VALVE SERVICE POINTS Reed valve inspection 1. Inspect: Reed valve Crack/Damage → Replace. 2. Measure: Valve bending a Out of specification → Replace. Valve bending limit: 0.2 mm (0.01 in) 3. Measure: Valve stopper height b Out of specification →...
  • Page 95 POWR REED VALVE AND CHECK VALVE 5-20...

  • Page 96: Cylinder Head, Thermostat And Exhaust Cover

    CYLINDER HEAD, THERMOSTAT AND EXHAUST POWR COVER CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER EXPLODED DIAGRAM 5-21...

  • Page 97: Removal And Installation Chart

    CYLINDER HEAD, THERMOSTAT AND EXHAUST POWR COVER REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER HEAD, THERMOSTAT Follow the left “Step” for removal. AND EXHAUST COVER REMOVAL Spark plug cap Disconnect the cap from the plug. Spark plug Bolt (with washer) 8 mm NOTE:...

  • Page 98: Service Points

    CYLINDER HEAD, THERMOSTAT AND EXHAUST POWR COVER SERVICE POINTS Cylinder head inspection 1. Inspect: Water jacket Material deposit/Corrosion → Clean. Cylinder inner surface Score marks → Clean. Use #600 ~ 800 grit wet sandpaper. CAUTION: Do not scratch the fitting surfaces of the cylinder and cylinder cover.

  • Page 99: Thermostat Inspection

    CYLINDER HEAD, THERMOSTAT AND EXHAUST POWR COVER Thermostat inspection 1. Inspect: Thermostat Stick/Damage → Replace. 2. Measure: Valve opening temperature Valve lift Out of specification → Replace. Water temperature Valve lift Below 48 ~ 52 ˚C 0 mm (118 ~ 126 ˚F) (0 in) Above 60 ˚C Min.3 mm...

  • Page 100: Crankcase And Cylinder Body

    POWR CRANKCASE AND CYLINDER BODY CRANKCASE AND CYLINDER BODY EXPLODED DIAGRAM 5-25...

  • Page 101: Removal And Installation Chart

    POWR CRANKCASE AND CYLINDER BODY REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANK CASE AND CYLINDER Follow the left “Step” for removal. BODY REMOVAL Oil tank ass’y Refer to “OIL TANK” in chapter 4. Oil pump Refer to “OIL PUMP” in chapter 4. Carburetor ass’y Refer to “CARBURETOR REMOVAL”...

  • Page 102: Exploded Diagram

    POWR CRANKCASE AND CYLINDER BODY EXPLODED DIAGRAM 5-27...

  • Page 103: Removal And Installation Chart

    POWR CRANKCASE AND CYLINDER BODY REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points Hose nipple Hose joint Check valve Check valve Hose joint Reverse the removal steps for installation. 5-28...

  • Page 104: Service Points

    POWR CRANKCASE AND CYLINDER BODY SERVICE POINTS Cylinder body inspection 1. Inspect: Water jacket Material deposit/Corrosion → Clean. Cylinder inner surface Score marks → Clean. Use #600 ~ 800 grit wet sandpaper. NOTE: Do not scratch the fitting surfaces of the crank case and cylinder head.

  • Page 105: Piston To Cylinder Clearance

    POWR CRANKCASE AND CYLINDER BODY Piston to cylinder clearance 1. Calculate: Piston clearance Out of specification → Replace piston and piston ring and/or cylinder. Piston Cylinder Piston – clearance bore diameter Piston clearance: 0.060 ~ 0.065 mm (0.0024 ~ 0.0026 in) Oil pump driven gear inspection 1.

  • Page 106: Crank Shaft And Piston

    POWR CRANK SHAFT AND PISTON CRANK SHAFT AND PISTON EXPLODED DIAGRAM 5-31...

  • Page 107: Removal And Installation Chart

    POWR CRANK SHAFT AND PISTON REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANK SHAFT AND PISTON Follow the left “Step” for removal. REMOVAL Crank case Refer to “CRANK CASE AND CYLINDER BODY”. 6 × 20 mm Bolt (with washer) Oil seal housing Plane washer Crankshaft ass’y...

  • Page 108: Service Points

    POWR CRANK SHAFT AND PISTON SERVICE POINTS Piston pin clip removal 1. Remove: Piston pin clip NOTE: Take care not to damage piston pin hole edge. Piston pin and small end bearing removal 1. Remove: Piston pin clip Small end needle bearing NOTE: When the piston pins, pistons, and small end needle bearings are reused, they...

  • Page 109: Piston Pin And Small End Bearing Inspection

    POWR CRANK SHAFT AND PISTON Measuring Piston diameter point “H” 10 mm 66.940 ~ 67.000 mm Standard (0.4 in) (2.6354 ~ 2.6378 in) Over size piston diameter: 1*: 67.25 mm (2.648 in) 2: 67.50 mm (2.657 in) *: Except for U.S.A. 2.

  • Page 110: Piston Ring Inspection

    POWR CRANK SHAFT AND PISTON Piston ring inspection 1. Inspect: Piston ring Breakage/Damage → Replace. 2. Measure: End gap Use a feeler gauge. Out of specification → Replace. End gap: Top: 0.40 ~ 0.60 mm (0.016 ~ 0.024 in) 2nd: 0.40 ~ 0.60 mm (0.016 ~ 0.024 in) End gap limit: Top: 0.80 mm (0.031 in)

  • Page 111: Crankshaft Inspection

    POWR CRANK SHAFT AND PISTON Crankshaft inspection 1. Measure: Crank width A Crank width B Out of specification → Replace. Crank width A: 53.90 ~ 53.95 mm (2.122 ~ 2.124 in) Crank width B: 32.88 ~ 33.10 mm (1.294 ~ 1.303 in) 2.

  • Page 112: Piston And Piston Ring Installation

    POWR CRANK SHAFT AND PISTON Piston and piston ring installation 1. Install: Piston ring (2nd) Piston ring (top) CAUTION: Take care not to scratch the piston or break piston rings. Align the each ring end gap with their locating pins. After fitting the rings, check that they move smoothly.
  • Page 114 LOWR CHAPTER 6 LOWER UNIT LOWER UNIT REMOVAL ................6-1 EXPLODED DIAGRAM ................6-1 REMOVAL AND INSTALLATION CHART ..........6-2 SERVICE POINTS ..................6-2 Propeller inspection ................6-2 WATER PUMP ....................6-3 EXPLODED DIAGRAM ................6-3 REMOVAL AND INSTALLATION CHART ..........6-4 SERVICE POINTS ..................
  • Page 115 LOWR SHIMMING....................6-19 SHIM SELECTION (FOR USA AND CANADA) ........6-19 Pinion gear shim ................6-19 Forward gear shim ................6-21 Reverse gear shim................6-22 SHIM SELECTION (EXCEPT FOR USA AND CANADA) ...... 6-23 Pinion gear shim ................6-23 Forward gear shim ................6-25 Reverse gear shim................

  • Page 116: Lower Unit

    LOWR LOWER UNIT REMOVAL LOWER UNIT REMOVAL EXPLODED DIAGRAM...

  • Page 117: Removal And Installation Chart

    LOWR LOWER UNIT REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points LOWER UNIT REMOVAL Follow the left “Step” for removal. Clamp Hose Cotter pin Propeller nut NOTE: If the propeller nut does not align with the propeller shaft hole when the nut is tightened to specification, turn it in fur- ther so that they align.

  • Page 118: Water Pump

    LOWR WATER PUMP WATER PUMP EXPLODED DIAGRAM...

  • Page 119: Removal And Installation Chart

    LOWR WATER PUMP REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points WATER PUMP REMOVAL Follow the left “Step” for removal. Lower unit ass’y Refer to “LOWER UNIT REMOVAL”. 8 × 30 mm Bolt Washer Water pump housing NOTE: When installing the water pump housing, align the hole in it with the projection in the insert cartridge.

  • Page 120: Propeller Shaft And Reverse Gear

    LOWR PROPELLER SHAFT AND REVERSE GEAR PROPELLER SHAFT AND REVERSE GEAR EXPLODED DIAGRAM...

  • Page 121: Removal And Installation Chart

    LOWR PROPELLER SHAFT AND REVERSE GEAR REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points PROPELLER SHAFT AND Follow the left “Step” for removal. REVERSE GEAR REMOVAL Gear oil Refer to “LOWER UNIT” in chapter 3. Propeller Refer to “LOWER UNIT REMOVAL”. Flange bolt Propeller shaft housing ass’y Plane washer...
  • Page 122 LOWR PROPELLER SHAFT AND REVERSE GEAR SERVICE POINTS Å Propeller shaft housing removal 1. Remove: Propeller shaft housing ass’y Bearing housing puller: YB-06234........ 1 90890-06503......3 Universal puller: YB-06117........ 2 Stopper guide plate: 90890-06501......4 ı Center bolt: 90890-06504......5 Å...

  • Page 123: Reverse Gear Inspection

    LOWR PROPELLER SHAFT AND REVERSE GEAR 3. Remove: Oil seal 1 Needle bearing 2 Driver rod: YB-06071/90890-06652 Needle bearing attachment: YB-06112/90890-06614 Reverse gear inspection 1. Inspect: Tooth Wear/Damage → Replace. Bearing inspection 1. Inspect: Bearing Pitting/Rumbling → Replace. Propeller shaft housing inspection 1.

  • Page 124: Propeller Shaft Housing Assembly

    LOWR PROPELLER SHAFT AND REVERSE GEAR Propeller shaft housing assembly Å 1. Install: Needle bearing Depth a: 3.0 ~ 3.5 mm (0.12 ~ 0.14 in) Depth b: 23.0 ~ 23.5 mm (0.91 ~ 0.93 in) Driver rod: YB-06071........ 1 90890-06604......3 ı...
  • Page 125 LOWR PROPELLER SHAFT AND REVERSE GEAR 6-10...

  • Page 126: Drive Shaft, Forward Gear And Shift Rod

    LOWR DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD EXPLODED DIAGRAM 6-11...

  • Page 127: Removal And Installation Chart

    LOWR DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points DRIVE SHAFT, FORWARD GEAR Follow the left “Step” for removal. AND SHIFT ROD REMOVAL Gear oil Refer to “LOWER UNIT” in chapter 3. Lower unit ass’y Refer to “LOWER UNIT REMOVAL”.

  • Page 128: Exploded Diagram

    LOWR DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD EXPLODED DIAGRAM 6-13...

  • Page 129: Removal And Installation Chart

    LOWR DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points Forward gear shim Screw Water inlet cover 1 Water inlet cover 2 Hose nipple Bolt (with washer) Anode Lower case Reverse the removal steps for installation. * As required 6-14...

  • Page 130: Service Points

    LOWR DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD SERVICE POINTS Pinion nut removal 1. Remove: Pinion nut Drive shaft holder: YB-06079/90890-06517 ..1 Pinion nut wrench: 90890-06505......2 Socket adapter: 90890-06506......3 Forward gear disassembly 1. Remove: Taper roller bearing 1 Forward gear 2 Bearing separator: YB-06219/90890-06534...

  • Page 131: Pinion And Forward Gear Inspection

    LOWR DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD 2. Remove: Drive shaft needle bearing Needle bearing attachment: YB-06063/90890-06614 ..1 Driver rod: YB-06071/90890-06652 ..2 3. Remove: Å Forward gear bearing outer race Slide hammer set: YB-06096........ 1 Bearing outer race puller: 90890-06523......

  • Page 132: Sleeve Inspection

    LOWR DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD Sleeve inspection 1. Inspect: Sleeve Wear/Damage → Replace. Lower case inspection 1. Clean: Gear case Use a soft brush and solvent. 2. Inspect: Water passage Mineral deposits/Corrosion → Clean. 3. Inspect: Lower case Crack/Damage →...

  • Page 133: Drive Shaft Oil Seal Housing Assembly

    LOWR DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD 3. Install: Pinion gear shim Drive shaft bearing outer race Bearing installer: YB-06110/90890-06627 ..1 Driver rod: YB-06071/90890-06606 ..2 Drive shaft oil seal housing assembly 1. Install: Oil seal 1 Depth a: 0.0 ~ 0.5 mm (0.00 ~ 0.02 in) Bearing installer: YB-06167/90890-06628...

  • Page 134: Shimming

    LOWR SHIMMING SHIMMING NOTE: Shim selection requirement guide: Not required when; reassembling with original case and inner parts. Numeric calculation is required when; reassembling with original inner parts and the new case. (Difference between original and new case) Measurement and adjustment is required when;...
  • Page 135 LOWR SHIM SELECTION 2. Install: Shimming gauge Drive shaft Bearing 1 Shim(s) 2 Gauge block: YB-34432-9......3 Adapter plate: YB-34432-10......4 Gauge base: YB-34432-11......5 Clamp: YB-34432-17......6 NOTE: Attach the adapter plate to the gauge base using 4 bolts of appropriate sizes. Fix the shimming gauge to the drive shaft so that the shaft is at the center of the hole.

  • Page 136: Forward Gear Shim

    LOWR SHIMMING Forward gear shim NOTE: Find forward gear shim thickness (T1) by selecting shims until the specified measure- ment (M) is obtained with the special tool. 1. Calculate: Specified measurement (M) Specified measurement (M) = 0.06 mm + F/100 NOTE: F is the deviation of the lower case dimen- sion from standard.
  • Page 137 LOWR SHIMMING 3. Check: Specified measurement (M) Out of specified measurement → Adjust. Thickness gauge: YU-26900-9 NOTE: Check the fit between the shimming gauge and lower surface of the press plate. 4. Adjust: Shim(s) Remove or add. Available shim thickness: 0.05, 0.08, 0.12, 0.30 and 0.50 mm Reverse gear shim NOTE:...
  • Page 138 LOWR SHIMMING SHIM SELECTION (EXCEPT FOR USA AND CANADA) Pinion gear shim NOTE: Find pinion gear shim thickness (T3) by selecting shims until the specified measure- ment is obtained with the special tool. 1. Install: Pinion height gauge Drive shaft Bearing Pinion height gauge: 90890-06702...
  • Page 139 LOWR SHIMMING NOTE: Find the average of the measurement (M). P is the deviation of the lower case dimen- sion from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01 mm units. If the P mark is missing or unreadable, assume a P mark of “0”, and check the backlash when the unit is assembled.
  • Page 140 LOWR SHIMMING Forward gear shim NOTE: Find forward gear shim thickness (T1) by selecting shims until the specified measure- ment (M) is obtained with the special tool. 1. Measure: Measurement (M) Shimming Plate: 90890-06701 Digital caliper: 90890-06704 NOTE: Measure the length between the shimming plate and the bearing outer race after turn- ing the outer race 2 to 3 times.
  • Page 141 LOWR SHIMMING 3. Select: Forward gear shim Calculated numeral Rounded at 1/100th place numeral more than or less 0.00 0.02 0.00 0.02 0.05 0.02 0.05 0.08 0.05 0.08 0.10 0.08 Available shim thickness: 0.05, 0.08, 0.12, 0.30 and 0.50 mm Example: If T1 is “0.45 mm”, then forward gear shim = 0.42 mm...
  • Page 142 LOWR SHIMMING Forward gear 1. Measure: Forward gear backlash Out of specification → Adjust. Backlash: 0.18 ~ 0.45 mm (0.007 ~ 0.018 in) Measuring steps: Set the bearing housing puller for pushing the propeller shaft. Bearing housing puller: YB-6234/90890-06503 Universal puller: YB-6117 Stopper guide plate: 90890-06501...

  • Page 143: Forward Gear

    LOWR SHIMMING 2. Adjust: Forward gear shim(s) NOTE: Adjust the shim(s) to be added or removed according to specification. Forward Shim thickness gear backlash To be decreased Less than 0.18 mm by (0.31 – mea- surement) × 0.56 To be increased by More than 0.45 (measurement –...
  • Page 144 LOWR SHIMMING Backlash adjusting plate: YB-07003 Dial gauge: YU-03097/90890-01252 Magnet base: YU-34481/90890-06705 While pulling the drive shaft, slowly turn the drive shaft clockwise and counterclockwise; then, measure the backlash when the drive shaft stops at each direction. 2. Adjust: Reverse gear shim(s) NOTE: Adjust the shim(s) to be added or removed according to specification.
  • Page 146 BRKT CHAPTER 7 BRACKET UNIT TILLER HANDLE REMOVAL................7-1 EXPLODED DIAGRAM ................7-1 REMOVAL AND INSTALLATION CHART ..........7-2 TILLER HANDLE ....................7-3 EXPLODED DIAGRAM ................7-3 REMOVAL AND INSTALLATION CHART ..........7-4 EXPLODED DIAGRAM ................7-5 REMOVAL AND INSTALLATION CHART ..........7-6 SERVICE POINTS ..................
  • Page 147 BRKT CLAMP BRACKET (Hydro tilt, Power trim and tilt)........7-17 EXPLODED DIAGRAM ................7-17 REMOVAL AND INSTALLATION CHART ..........7-18 STEERING BRACKET ..................7-19 EXPLODED DIAGRAM ................7-19 REMOVAL AND INSTALLATION CHART ..........7-20 SWIVEL BRACKET ..................7-21 EXPLODED DIAGRAM ................7-21 REMOVAL AND INSTALLATION CHART ..........

  • Page 148: Tiller Handle Removal

    BRKT TILLER HANDLE REMOVAL TILLER HANDLE REMOVAL EXPLODED DIAGRAM...

  • Page 149: Removal And Installation Chart

    BRKT TILLER HANDLE REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TILLER HANDLE REMOVAL Follow the left “Step” for removal. Bolt Steering friction model Clamp E model Screw Steering friction model Bolt Collar Clamp Bolt M model Engine stop switch lead (black) Engine stop switch coupler (blue) Main switch lead coupler...

  • Page 150: Tiller Handle

    BRKT TILLER HANDLE TILLER HANDLE EXPLODED DIAGRAM...

  • Page 151: Removal And Installation Chart

    BRKT TILLER HANDLE REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TILLER HANDLE DISASSEMBLY Follow the left “Step” for removal. Tiller handle ass’y Refer to “TILLER HANDLE REMOVAL”. 6 × 16 mm Screw 6 × 40 mm Screw Cover Engine stop switch ass’y Clamp...

  • Page 152: Exploded Diagram

    BRKT TILLER HANDLE EXPLODED DIAGRAM...

  • Page 153: Removal And Installation Chart

    BRKT TILLER HANDLE REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points Collar Wave washer Bracket Steering handle Bushing Reverse the removal steps for installation. SERVICE POINTS Control cable inspection 1. Inspect: Throttle cable Shift cable Kink/Fray/Stick → Replace. Bushing inspection 1.

  • Page 154: Link Ass'y Disassembly

    BRKT LINK ASS’Y DISASSEMBLY LINK ASS’Y DISASSEMBLY EXPLODED DIAGRAM...

  • Page 155: Removal And Installation Chart

    BRKT LINK ASS’Y DISASSEMBLY REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points LINK ASS’Y DISASSEMBLY Follow the left “Step” for removal. Circlip Throttle arm shaft Throttle arm 6 × 16 mm Screw (with washer) Throttle shaft ass’y Screw Spring guide Roller Actuator...

  • Page 156: Shift Actuator And Bottom Cowling

    BRKT SHIFT ACTUATOR AND BOTTOM COWLING SHIFT ACTUATOR AND BOTTOM COWLING EXPLODED DIAGRAM...

  • Page 157: Removal And Installation Chart

    BRKT SHIFT ACTUATOR AND BOTTOM COWLING REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SHIFT ACTUATOR AND BOT- Follow the left “Step” for removal. TOM COWLING REMOVAL Power unit ass’y Refer to “POWER UNIT REMOVAL” in chapter 5. Shift actuator ass’y Bolt (with washer) Fitting plate ass’y...

  • Page 158: Upper Case Removal

    BRKT UPPER CASE REMOVAL UPPER CASE REMOVAL EXPLODED DIAGRAM 7-11...

  • Page 159: Removal And Installation Chart

    BRKT UPPER CASE REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points UPPER CASE REMOVAL Follow the left “Step” for removal. Power unit Refer to “POWER UNIT REMOVAL” in chapter 5. Lower unit ass’y Refer to “LOWER UNIT REMOVAL” in chapter 6.

  • Page 160: Upper Case And Exhaust Manfold

    BRKT UPPER CASE AND EXHAUST MANIFOLD UPPER CASE AND EXHAUST MANIFOLD EXPLODED DIAGRAM 7-13...

  • Page 161: Removal And Installation Chart

    BRKT UPPER CASE AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points UPPER CASE AND EXHAUST Follow the left “Step” for removal. MANIFOLD Upper case ass’y Refer to “UPPER CASE REMOVAL”. Bolt (with washer) Upper case Dowel pin EXHAUST MANIFOLD REMOVAL Muffler seal...

  • Page 162: Clamp Bracket (Manual Tilt)

    BRKT CLAMP BRACKET CLAMP BRACKET (Manual tilt) EXPLODED DIAGRAM 7-15...
  • Page 163 BRKT CLAMP BRACKET REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CLAMP BRACKET REMOVAL Follow the left “Step” for removal. (Manual tilt) Upper case ass’y Refer to “UPPER CASE REMOVAL”. Spring Circlip Plane washer Tilt stop lever Tilt pin Grease nipple Lead wire Plane washer...

  • Page 164: Clamp Bracket (Hydro Tilt, Power Trim And Tilt)

    BRKT CLAMP BRACKET CLAMP BRACKET (Hydro tilt, Power trim and tilt) EXPLODED DIAGRAM 7-17...

  • Page 165: Removal And Installation Chart

    BRKT CLAMP BRACKET REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CLAMP BRACKET REMOVAL Follow the left “Step” for removal. (Hydro tilt, Power trim and tilt) Upper case ass’y Refer to “UPPER CASE REMOVAL”. PTT motor lead PTT model Trim sensor coupler Band PTT motor lead - Trim sensor lead...

  • Page 166: Steering Bracket

    BRKT STEERING BRACKET STEERING BRACKET EXPLODED DIAGRAM 7-19...

  • Page 167: Removal And Installation Chart

    BRKT STEERING BRACKET REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING BRACKET REMOVAL Follow the left “Step” for removal. Upper case ass’y Refer to “UPPER CASE REMOVAL”. Flange bolt Manual tilt model Seal rubber Circlip Lower mount housing Steering bracket Plane washer Bushing...

  • Page 168: Swivel Bracket

    BRKT SWIVEL BRACKET SWIVEL BRACKET EXPLODED DIAGRAM 7-21...

  • Page 169: Removal And Installation Chart

    BRKT SWIVEL BRACKET REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SWIVEL BRACKET REMOVAL Follow the left “Step” for removal. (Manual tilt) Upper case ass’y Refer to “UPPER CASE REMOVAL”. Clamp bracket Refer to “CLAMP BRACKET”. Steering bracket Refer to “STEERING BRACKET”.

  • Page 170: Swivel Bracket Disassembly

    BRKT SWIVEL BRACKET DISASSEMBLY SWIVEL BRACKET DISASSEMBLY EXPLODED DIAGRAM 7-23...

  • Page 171: Removal And Installation Chart

    BRKT SWIVEL BRACKET DISASSEMBLY REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SWIVEL BRACKET REMOVAL Follow the left “Step” for removal. (Hydro tilt, power trim and tilt) Upper case ass’y Refer to “UPPER CASE REMOVAL”. Clamp bracket Refer to “CLAMP BRACKET”. Steering bracket Refer to “STEERING BRACKET”.

  • Page 172: Tilt Unit Removal

    BRKT TILT UNIT REMOVAL TILT UNIT REMOVAL EXPLODED DIAGRAM 7-25...

  • Page 173: Removal And Installation Chart

    BRKT TILT UNIT REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TILT UNIT REMOVAL Follow the left “Step” for removal. Tilt up NOTE: Turn the tilt support lever toward clamp bracket and support the outboard. PTT motor lead PTT model Band PTT motor lead - Trim sensor lead...

  • Page 174: Tilt Cylinder, Pump Housing And Motor Removal

    TILT CYLINDER, PUMP HOUSING AND MOTOR BRKT REMOVAL TILT CYLINDER, PUMP HOUSING AND MOTOR REMOVAL EXPLODED DIAGRAM 7-27...

  • Page 175: Removal And Installation Chart

    TILT CYLINDER, PUMP HOUSING AND MOTOR BRKT REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TILT CYLINDER, PUMP HOUS- Follow the left “Step” for removal. ING AND MOTOR REMOVAL Power trim and tilt unit Refer to “TILT UNIT REMOVAL”. Plug screw Drain hydraulic oil.

  • Page 176: Tilt Cylinder

    BRKT TILT CYLINDER TILT CYLINDER EXPLODED DIAGRAM 7-29...

  • Page 177: Removal And Installation Chart

    BRKT TILT CYLINDER REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TILT CYLINDER DISASSEMBLY Follow the left “Step” for removal. Tilt cylinder ass’y Refer to “TILT CYLINDER, PUMP HOUS- ING AND MOTOR REMOVAL”. Tilt cylinder end screw Tilt cylinder Tilt rod ass’y Ball 3.18 mm...

  • Page 178: Inner Cylinder Disassembly

    BRKT TILT CYLINDER SERVICE POINTS Tilt cylinder disassembly 1. Loosen: Tilt cylinder end screw Tilt cylinder wrench: YB-06175-2B/90890-06544 Inner cylinder disassembly 1. Loosen: Inner cylinder end screw Tilt cylinder wrench: YB-06175-2B/90890-06544 CAUTION: Vise the top of the inner cylinder with the tilt rod pulled out in its full length, or the cylinder may be deformed.

  • Page 179: Inner Cylinder Assembly

    BRKT TILT CYLINDER Inner cylinder assembly 1. Fill: ATF (Dexiron type 2) to inner cylinder. NOTE: Depress the tilt rod fully and fill the inner cylinder with ATF before installing the end screw. 2. Tighten: Inner cylinder end screw Tilt cylinder wrench: YB-06175-2B/90890-06544 Tilt cylinder assembly 1.

  • Page 180: Pump Housing

    BRKT PUMP HOUSING PUMP HOUSING EXPLODED DIAGRAM 7-33...

  • Page 181: Removal And Installation Chart

    BRKT PUMP HOUSING REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points PUMP HOUSING DISASSEMBLY Follow the left “Step” for removal. Pump housing ass’y Refer to “TILT CYLINDER, PUMP HOUS- ING AND MOTOR REMOVAL”. Socket bolt Gear pump 8.5 × 5.5 mm O-ring Bolt (with washer) Bottom cover...

  • Page 182: Ptt Motor

    BRKT PTT MOTOR PTT MOTOR EXPLODED DIAGRAM 7-35...

  • Page 183: Removal And Installation Chart

    BRKT PTT MOTOR REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points POWER TRIM AND TILT MOTOR Follow the left “Step” for removal. DISASSEMBLY Power trim and tilt motor ass’y Refer to “TILT CYLINDER, PUMP HOUS- ING AND MOTOR REMOVAL”. Screw Stator Armature ass’y...

  • Page 184: Service Points

    BRKT PTT MOTOR SERVICE POINTS Motor inspection 1. Inspect: Commutator Dirty → Clean with #600 abrasive paper. 2. Inspect: Segment undercut Clog → Clean. NOTE: Remove all particles of metal with com- pressed air. 3. Measure: Commutator diameter Out of specification → Replace. Commutator diameter: Limit 21 mm (0.83 in) 4.

  • Page 185: Motor Assembly

    BRKT PTT MOTOR 5. Inspect: Circuit breaker Discontinuity → Replace. 6. Inspect: Lead wire Discontinuity → Replace. 7. Measure: Brush length a Out of specification → Replace. Brush length a: Limit 3.5 mm (0.14 in) 8. Inspect: Base Crack/Damage → Replace. 9.
  • Page 186 – ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................. 8-1 OIL INJECTION MODEL................8-1 MH, MHO, MO, MDO MODEL ..............8-2 WHD, WH, E, EDO, EO MODEL ............... 8-3 ET, ETO MODEL ..................8-4 EHTO MODEL................... 8-5 ELECTRICAL UNIT COMPONENTS ............... 8-6 E, EO MODEL ...................
  • Page 187 – ELEC STARTER MOTOR ..................8-23 EXPLODED DIAGRAM ................8-23 REMOVAL AND INSTALLATION CHART ..........8-24 SERVICE POINTS ................... 8-25 Pinion removal ................8-25 Pinion inspection................8-25 Armature inspection ............... 8-25 Brush holder inspection..............8-26 Cover inspection................8-27 CHARGING SYSTEM ..................8-28 CHARGING SYSTEM PEAK VOLTAGE..........

  • Page 188: Electrical Components

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS OIL INJECTION MODEL 1 Electrothermal valve : Blue 2 Oil level sensor : Black...

  • Page 189: Mh, Mho, Mo, Mdo Model

    – ELEC ELECTRICAL COMPONENTS MH, MHO, MO, MDO MODEL : Black : Brown Å To engine stop switch 1 Oil level sensor B/O : Black/Orange ı To 6 2 Warning lamp B/W : Black/White Ç To 6 3 Charge coil B/Y : Black/Yellow Î...

  • Page 190: Whd, Wh, E, Edo, Eo Model

    – ELEC ELECTRICAL COMPONENTS WHD, WH, E, EDO, EO MODEL : Black : Brown Å To wire harness 1 Oil level sensor 0 Fuse B/O : Black/Orange ı To 5 2 Electrothermal valve A Thermo switch B/W : Black/White Ç To 7 3 Oil level warning lamp B Rectifier regulator B/Y : Black/Yellow...

  • Page 191: Et, Eto Model

    – ELEC ELECTRICAL COMPONENTS ET, ETO MODEL : Black : Brown ‰ To 8 1 P.T.T. switch A Ignition coil B/O : Black/Orange Ï To 0 2 Oil level sensor B Fuse B/W : Black/White Ì To remote control 3 Electrothermal valve C Thermo switch B/Y : Black/Yellow Ó...

  • Page 192: Ehto Model

    – ELEC ELECTRICAL COMPONENTS EHTO MODEL : Black : Brown Å To trim sensor 1 Main switch B/O : Black/Orange ı To oil level sensor 2 Main switch lead B/W : Black/White Ç To starter motor and starter 3 Engine stop switch lead B/Y : Black/Yellow 4 Battery cable relay...

  • Page 193: Electrical Unit Components

    – ELEC ELECTRICAL UNIT COMPONENTS ELECTRICAL UNIT COMPONENTS : Black : Brown E, EO MODEL B/O : Black/Orange B/W : Black/White 1 Starter motor B/Y : Black/Yellow 2 Rectifier regulator : Blue 3 Ignition coil : Orange 4 Fuse O/G : Orange/Green 5 Starter relay : Pink Y/R : Yellow/Red...

  • Page 194: Et, Eto Model

    – ELEC ELECTRICAL UNIT COMPONENTS ET, ETO MODEL : Black : Brown 1 Starter motor B/O : Black/Orange 2 Rectifier regulator B/W : Black/White 3 Ignition coil B/Y : Black/Yellow 4 Starter relay : Blue 5 P.T.T. relay : Orange 6 Fuse O/G : Orange/Green : Pink...

  • Page 195: Electrical Analysis

    – ELEC ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS INSPECTION CAUTION: All measuring instruments should be han- dled with special care, or the correct mea- surement is impossible. On an instrument powered by dry batter- ies, the latter should be checked for voltage periodically and replaced, if necessary.

  • Page 196: Ignition System

    – ELEC IGNITION SYSTEM IGNITION SYSTEM : Brown 1 Spark plug : Blue 2 Ignition coil W/R : White/Red 3 Charge coil W/B : White/Black 4 Pulser coil W/G : White/Green 5 Main switch B/O : Black/Orange 6 Engine stop switch B/W : Black/White 7 10P coupler 8 7P coupler...

  • Page 197: Ignition Spark Gap

    – ELEC IGNITION SYSTEM IGNITION SPARK GAP WARNING While checking the spark be careful not to touch any connection of lead wires of the “Ignition spark gap tester”. When doing the spark test, take special care not to allow leakage from the plug cap which has been removed.
  • Page 198 – ELEC IGNITION SYSTEM 1. Measure: CDI unit output (test #1) Beyond specification → Replace igni- tion coil. → Below specification Measure charge coil output. Repeat checking two times. CDI output: 125 V @ cranking 140 V @ 1,500 r/min 110 V @ 3,500 r/min Measuring steps: Disconnect the ignition coil couple.

  • Page 199: Spark Plug

    – ELEC IGNITION SYSTEM 3. Measure: Pulser coil output (test #3) Beyond specification → Replace CDI unit. Below specification → Replace pulser coil. Pulser coil output: 3.0 V @ cranking 9.0 V @ 1,500 r/min 15.0 V @ 3,500 r/min Measuring steps: Disconnect the pulse coil couple.

  • Page 200: Engine Stop Switch

    – ELEC IGNITION SYSTEM Replacement steps: (Except for Canada and Europe) Remove the spark-plug cap by pulling the spark-plug cap. Remove the plug-cap spring. Strip the insulation cover 5 mm (0.2 in) a and spread the core wires outward. Fit the plug-cap spring close to the spread core wires and bend the spring end for clamping.

  • Page 201: Main Switch

    – ELEC IGNITION SYSTEM MAIN SWITCH 1. Check: Continuity Out of specification → Replace. Checking leads color Switch White Black Red Yellow Brown position START 8-14...

  • Page 202: Ignition Control System

    – ELEC IGNITION CONTROL SYSTEM IGNITION CONTROL SYSTEM Y/R : Yellow/Red 1 Thermo switch : Pink 2 CDI unit : Orange 3 Warning lamp O/G : Orange/Green 4 Oil level sensor : Black 5 Oil level warning lamp 6 Oil level sensor 7 Meter Å...

  • Page 203: Thermo Switch

    – ELEC IGNITION CONTROL SYSTEM THERMO SWITCH 1. Measure: Thermo switch continuity Out of specification → Replace. Thermo switch continuity temperature: Orange (O) — Orange/Green (O/G) a 38 ~ 52˚C (100.4 ~ 125.6˚F) b 26 ~ 34˚C (78.8 ~ 93.2˚F) Pink (P) —...

  • Page 204: Warning Lamp

    – ELEC IGNITION CONTROL SYSTEM Checking leads color Float position a OFF a ON Float length: a 56.8 ~ 59.8 mm (2.24 ~ 2.35 in) WARNING LAMP 1. Check: LED (Light emitting diode) lighting No lighting → Replace. Battery voltage: 1.5 V Yellow/Red lead →...

  • Page 205: Oil Level Warning Lamp

    – ELEC IGNITION CONTROL SYSTEM OIL LEVEL WARNING LAMP 1. Check: LED (Light emitting diode) lighting No lighting → Replace. Battery voltage: 1.5 V Green LED Yellow/Red lead → Positive terminal. Green lead → Negative terminal. Yellow LED Yellow/Red lead → Positive terminal. Black lead →...

  • Page 206: Starting System

    – ELEC STARTING SYSTEM STARTING SYSTEM : Black 1 Fuse : Brown 2 10P coupler : Red 3 7P coupler 4 Main switch 5 Starter motor 6 Battery 7 Neutral switch 8 Starter relay Å Except for remote control model ı...

  • Page 207: Battery

    – ELEC STARTING SYSTEM BATTERY Refer to “GENERAL” in chapter 3. WIRING HARNESS 1. Check: Continuity Discontinuity → Replace. WIRING CONNECTION 1. Check: Wiring connection Poor connection → Correct. ENGINE STOP SWITCH Refer to “IGNITION SYSTEM”. MAIN SWITCH Refer to “IGNITION SYSTEM”. NEUTRAL SWITCH 1.

  • Page 208: Starter Relay

    – ELEC STARTING SYSTEM STARTER RELAY 1. Inspect: Brown lead terminal Black lead terminal Loose → Tighten. 2. Check: Relay operation Does not function → Replace. Checking steps: Connect the tester between the termi- nals of the starter relay as shown. Connect a 12 V battery.
  • Page 209 – ELEC STARTING SYSTEM 8-22...

  • Page 210: Starter Motor

    – ELEC STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM 8-23...

  • Page 211: Removal And Installation Chart

    – ELEC STARTER MOTOR REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STARTER MOTOR DISASSEMBLY Follow the left “Step” for removal. Starter motor ass’y Refer to “ELECTRICAL UNIT REMOVAL” in chapter 5. Clip NOTE: Using a pry bar, pry off the clip. Pinion stopper Spring Pinion...

  • Page 212: Service Points

    – ELEC STARTER MOTOR SERVICE POINTS Pinion removal 1. Remove: Clip 1 NOTE: Using a pry-bar, pry off the clip. Pinion inspection 1. Inspect: Pinion teeth Wear/Damage → Replace. 2. Check: Clutch movement Damage → Replace. NOTE: Rotate the pinion clockwise, and check that it freely.

  • Page 213: Brush Holder Inspection

    – ELEC STARTER MOTOR 3. Check: Commutator under cut Clog/Dirty → Clean. NOTE: Removal all particles of mica and metal by compressed air. 4. Measure: Commutator under cut Out of specification → Replace. Commutator under cut: Limit 0.2 mm (0.01 in) 5.

  • Page 214: Cover Inspection

    – ELEC STARTER MOTOR 2. Check: Brush holder continuity Out of specification → Replace. Brush holder continuity: Brush holder 1 - Base 2 Discontinuity Cover inspection 1. Inspect: Cover bushing Wear/Damage → Replace the cover. 8-27...

  • Page 215: Charging System

    – ELEC CHARGING SYSTEM CHARGING SYSTEM : Green 1 Rectifier regulator G/W : Green/White 2 Lighting coil : Red 3 Battery : Black 4 Fuse 8-28...

  • Page 216: Charging System Peak Voltage

    – ELEC CHARGING SYSTEM CHARGING SYSTEM PEAK VOLTAGE 1. Measure: Rectifier regulator input Below specification → Lighting coil measurement. Rectifier regurator input: (electrical model) 8.5 V @ cranking 25 V @ 1,500 r/min 25 V @ 3,500 r/min Measuring steps: Connect the tester to the rectifier/regu- lator as shown.

  • Page 217: Enrichment Control System

    – ELEC ENRICHMENT CONTROL SYSTEM ENRICHMENT CONTROL SYSTEM : Green 1 Rectifier regulator G/W : Green/White 2 Lighting coil : Blue 3 Electrothermal valve : Black LIGHTING COIL Refer to “CHARGING SYSTEM”. ELECTROTHERMAL VALVE Refer to “PRIME STARTER” in chap- ter 4.

  • Page 218: Power Trim And Tilt Control System

    – ELEC POWER TRIM AND TILT CONTROL SYSTEM POWER TRIM AND TILT CONTROL SYSTEM : Red 1 P.T.T. motor : Light green 2 P.T.T. relay Sb : Sky blue 3 P.T.T. switch : Black 4 3P coupler (Black) 5 10P coupler 6 Fuse 7 Battery Å...

  • Page 219: Battery

    – ELEC POWER TRIM AND TILT CONTROL SYSTEM BATTERY Refer to “GENERAL” in chapter 3. FUSE Refer to “STARTING SYSTEM”. PTT SWITCH 1. Check: Continuity Out of specification → Replace. Checking leads color Switch Light position blue green Free PTT RELAY 1.

  • Page 220: Trim Sensor

    – ELEC POWER TRIM AND TILT CONTROL SYSTEM Connect the tester between the termi- nals of the PTT relay as shown. Connect a 12 V battery. Sky blue (Sb) lead → Positive terminal Black (B) → Negative terminal Check that there is continuity between the PTT relay terminals.
  • Page 221 TRBL ANLS CHAPTER 9 TROUBLE-ANALYSIS TROUBLE ANALYSIS ..................9-1 TROUBLE ANALYSIS CHART ..............9-1...

  • Page 222: Trouble Analysis

    TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: Following items should be obtained before “trouble analysis”. 1. Battery is charged and its specified gravity is in specification. 2. There is no incorrect wiring connection. 3. Wiring connections are surely engaged and without any rust. 4.
  • Page 223 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part Chapter LOWER UNIT Neutral position Clutch Gear Water inlet Water pump Propeller shaft Shifter/Pin Shift cam Shift shaft Lower case BRACKET UNIT Bracket Mount rubber Shift actuator PTT unit Fluid level Relief valve Fluid passage...
  • Page 224 YAMAHA MOTOR Corporation, USA Printed in U.S.A. Printed on recycled paper...

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