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Yamaha EK25BMH Service Manual

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EK25BMH
S S S S E E E E R R R R V V V V I I I I C C C C E E E E M M M M A A A A N N N N U U U U A A A A L L L L
290404
69T-28197-ZA-11

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Summary of Contents for Yamaha EK25BMH

  • Page 1 EK25BMH S S S S E E E E R R R R V V V V I I I I C C C C E E E E M M M M A A A A N N N N U U U U A A A A L L L L...
  • Page 2 NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equip- ment. It has been written to suit the needs of persons who have a basic understanding of the...

  • Page 3: How To Use This Manual

    MODEL INDICATION Multiple models are referred to in this manual and their model indications are noted as fol- lows. Model name EK25BMH Indication EK25BMH ILLUSTRATIONS The illustrations within this service manual represent all of the designated models.
  • Page 4 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person inspecting or repairing the outboard motor.
  • Page 5 HOW TO USE THIS MANUAL The main points regarding removing/installing and disassembling/assembling proce- dures are shown in the exploded views. The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page.

  • Page 6: General Information

    Symbol in an exploded diagram indicate the grade of lubricant and the loca- tion of the lubrication point. 16 Apply Yamaha 2-stroke motor oil 17 Apply water resistant grease (Yamaha grease A, Yamaha marine grease) 18 Apply water resistant grease...
  • Page 7 CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECK AND ADJUSTMENT FUEL SYSTEM FUEL RECOIL STARTER POWR LOWER UNIT LOWR 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

    Model name Approval model code Transom height Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as fol- lows: Model name Approval Starting serial model code number Worldwide S:100101 EK25BMH L:400101 Y:750101...

  • Page 11: Safety While Working

    The procedures given in this manual are those recommended by Yamaha to be fol- l o w e d b y Ya m a h a d e a l e r s a n d t h e i r mechanics.

  • Page 12: Good Working Practices

    SAFETY WHILE WORKING INFO Under normal conditions or use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important 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, circlips, etc., on reas- sembly. DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly. 3.

  • Page 14: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS Using the correct special tools recom- mended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment. MEASURING Dial gauge set P/N. 90890-01252 Crank stand alignment P/N.

  • Page 15: 17 Shimming Plate

    SPECIAL TOOLS INFO Cylinder gauge P/N. 90890-06759 Outside micrometer P/N. 90890-03006 P/N. 90890-03008 Inside micrometer P/N. 90890-03010 Thickness gauge P/N. 90890-03079 Shimming plate P/N. 90890-06701 Pinion height gauge P/N. 90890-06702 Magnet base P/N. 90890-06705 Backlash indicator P/N. 90890-06706 Magnet base plate P/N.

  • Page 16: Removing And Installing

    SPECIAL TOOLS INFO REMOVING AND INSTALLING Flywheel puller P/N. 90890-06521 Flywheel holder P/N. 90890-06522 Small end bearing installer P/N. 90890-06527 Bearing separator P/N. 90890-06534 Stopper guide plate P/N. 90890-06501 Bearing housing puller claw P/N. 90890-06564 Center bolt P/N. 90890-06504 Drive shaft holder 3 P/N.
  • Page 17 SPECIAL TOOLS INFO Crank jig ass’y P/N. 90890-02421 Frange P/N. 90890-02351 Body P/N. 90890-02352 Bolt P/N. 90890-02353 Washer P/N. 90890-02354 Bushing-5 (D25) P/N. 90890-02359 Bushing-12 (D35) P/N. 90890-02366 Height ring-13 (H57) P/N. 90890-02379 Pressure Plate P/N. 90890-02384 Press body P/N. 90890-02385 Plate A P/N.

  • Page 18: Features And Benefits

    FEATURES AND BENEFITS INFO FEATURES AND BENEFITS POWER UNIT The EK25B is designed to provide superior fuel economy, serviceability, and durability. They are based on the previous EK25A with newly designed linkage to control both throttle opening and ignition timing mechanically and simultaneously. Special attention was paid on the crankshaft bearings.

  • Page 19: Ignition System

    FEATURES AND BENEFITS INFO IGNITION SYSTEM Ignition system on the EK25B consists of flywheel magnet, charge coil, pulser coil, CDI unit, and ignition coil. Similar to the previous EK25A, the engine has the mechanical ignition timing advance system that works by way of the linkage. Superior fuel economy is attained by the modified ignition timing control arrangement.

  • Page 20: Cooling System

    FEATURES AND BENEFITS INFO COOLING SYSTEM New structure applied to the cooling system provides additional cooling capacity in the upper casing. With additional cooling water passage (indicated by ), water walls contained in the new upper casing contribute to the reduction of outer surface temperature. Fig.
  • Page 21 FEATURES AND BENEFITS INFO COOLING SYSTEM Fig. 5 1-12...

  • Page 22: Tiller Handle

    FEATURES AND BENEFITS INFO TILLER HANDLE For the throttle grip on the steering handle of the EK25B, 100 degrees of opening angle covers all ranges from full-closed to wide-open positions. Also, new steering handle parts were developed to assume the long use. Inner diameter of the steering handle engagement area, and both inner and outer diameters of steering bracket are increased.

  • Page 23: Bracket And Bottom Cowling

    FEATURES AND BENEFITS INFO BRACKET AND BOTTOM COWLING The Bracket 1 is modified on the EK25B, and newly designed rubber seal is added to provide better sealing ability for the bottom cowling. Fig. 8 1-14...
  • Page 25 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................. 2-1 MAINTENANCE SPECIFICATIONS ............... 2-3 POWER UNIT ................... 2-3 LOWER UNIT ................... 2-5 ELECTRICAL .................... 2-6 DIMENSIONS ..................2-8 DIMENSIONS ..................2-9 TIGHTENING TORQUES ................2-11 SPECIFIED TORQUES ................2-11 GENERAL TORQUES ................2-12...
  • Page 26 SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit Worldwide EK25BMH DIMENSIONS Overall length mm (in) 843 (33.2) Overall width mm (in) 399 (15.7) Overall height mm (in) 1,146 (45.1) mm (in) 1,273 (50.1) mm (in) 1,320 (52.0) Boat transom height mm (in) 381 (15.0)

  • Page 27: General Specifications

    SPEC GENERAL SPECIFICATIONS Model Item Unit Worldwide EK25BMH Lubrication system Mixed (Gasoline and oil, Kerosene and oil) Cooling system Water Ignition control system Alternator output V - W 12 - 80 POWER UNIT Starting system Manual Control system Mechanical Advanced system...

  • Page 28: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS POWER UNIT Model Item Unit Worldwide EK25BMH CYLINDER HEAD Warpage limit mm (in) 0.1 (0.004) (lines indicate straightedge position) CYLINDERS Bore size mm (in) 72.00 - 72.02 (2.8346 - 2.8354) Wear limit mm (in) 72.10 (2.8386)
  • Page 29 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit Worldwide EK25BMH PISTON RING (2nd) Type Plain mm (in) 2.0 (0.079) mm (in) 3.0 (0.118) End gap mm (in) 0.20 - 0.35 (0.0079 - 0.0137) (installed) <Limit> mm (in) 0.35 (0.014) Side clearance mm (in) 0.03 - 0.07 (0.0012 - 0.0028)

  • Page 30: Lower Unit

    SPEC MAINTENANCE SPECIFICATIONS Model Item Unit Worldwide EK25BMH REED VALVES Thickness 0.2 (0.008) Valve stopper height (Standard) mm (in) 3.46 - 3.50 (0.136 - 0.138) (for Sri Lanka) mm (in) 4.20 - 4.60 (0.165 - 0.181) Valve bending limit mm (in) 0.2 (0.008)

  • Page 31: Electrical

    SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Model Item Unit Worldwide EK25BMH IGNITION SYSTEM Ignition timing (Full retard) Degree ATDC 2 ± 2 (Full advanced) Degree BTDC 22 ± 2 Spark plug gap mm (in) 0.9 - 1.0 (0.035 - 0.039) Ignition spark gap...
  • Page 32 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit Worldwide EK25BMH CHARGING SYSTEM Lighting coil resistance Ω 0.31 - 0.37 (G - G) Lighting coil output peak voltage (G - G) @ cranking 1 @ cranking 2 — @ 1,500 r/min — @ 3,500 r/min —...

  • Page 33: Dimensions

    SPEC MAINTENANCE SPECIFICATIONS DIMENSIONS...
  • Page 34 SPEC MAINTENANCE SPECIFICATIONS DIMENSIONS Model Symbol Unit Worldwide EK25BMH mm (in) 429 (16.89) mm (in) 180 (7 .09) mm (in) 420 (16.54) mm (in) 385 (15.16) mm (in) 61 (2.40) mm (in) 83 (3.27) mm (in) 83 (3.27) mm (in) 736 (28.98)
  • Page 35 SPEC MAINTENANCE SPECIFICATIONS Model Symbol Unit Worldwide EK25BMH mm (in) 89 (3.50) mm (in) 140 (5.51) mm (in) 112.5 (4.43) mm (in) 96.5 (3.80) mm (in) 122.5 (4.82) mm (in) 176 (6.93) mm (in) 85 (3.35) mm (in) 51 (2.01) φ...

  • Page 36: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torques Part Thread Part to be tightened Q’ty Remarks name size • • • POWER UNIT Recoil starter mounting Bolt Recoil starter center boit Bolt Recoil starter center Nut — 7 .4 Flywheel magnet Power unit Bolt...

  • Page 37: General Torques

    SPEC TIGHTENING TORQUES GENERAL TORQUES General torque This chart specifies tightening torques for specifications Nut (A) Bolt (B) standard fasteners with a standard ISO • • • thread pitch. Tightening torque specifica- tions for special components or assemblies 8 mm are provided in applicable sections of this 10 mm manual.
  • Page 39 CHAPTER 3 PERIODIC CHECK AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............. 3-1 TOP COWLING ....................3-2 CHECKING THE TOP COWLING FIT ............3-2 FUEL SYSTEM ....................3-2 CHECKING THE FUEL LINE ..............3-2 CHECKING THE FUEL FILTER ..............3-3 CHECKING THE FUEL PUMP ..............3-3 CHECKING THE FUEL JOINT ..............

  • Page 40: Maintenance Interval Chart

    Frequency of maintenance operations may be adjusted according to the operating condi- tions, but the following table gives general guidelines. The mark (@) indicates the check-ups which maybe carried out by owner. The mark (:) indicates work to be carried out by Yamaha dealer. Initial Every...

  • Page 41: Top Cowling

    TOP COWLING/FUEL SYSTEM TOP COWLING CHECKING THE TOP COWLING FIT Check: • Top cowling Cracks/damage → Replace. • Hook Bent → Correct. • Rivet Damage → Repair. • Rubber of trim Peel/tear → Repair. NOTE: Hooks and latches are unadjustable. FUEL SYSTEM CHECKING THE FUEL LINE Check:...

  • Page 42: Checking The Fuel Filter

    FUEL SYSTEM CHECKING THE FUEL FILTER Check: • Fuel filter element Foreign matter → Clean. • Fuel filter cup Cracks/damage/leak → Replace. • O-ring Cracks/damage → Replace. CHECKING THE FUEL PUMP Check: • Fuel pump Cracks/damage/leak → Repair/replace. Refer "DISASSEMBLING FUEL PUMP"...

  • Page 43: Control System

    CONTROL SYSTEM CONTROL SYSTEM ADJUSTING THE IGNITION TIMING CAUTION: Ignition timing adjustment on the running engine must be performed in the test tank with a test propeller installed on the engine. Test propeller 90890-01629 WARNING While checking the engine, do not touch the rotating part (flywheel), CDI unit, igni- tion coil, and any other hazardous areas.
  • Page 44 CONTROL SYSTEM (5) Set the shift lever in forward position. (6) Fully open the throttle by moving the throttle to the “FAST” position. Full throttle operating range 5,350 ± 100 r/min (7) Check the ignition timing by pointing the timing light at the timing indicator on the starter case.
  • Page 45 CONTROL SYSTEM 2. Adjustment with full-open throttle: • Magnet base stopper CAUTION: • Make sure that engine is not running. • Remove the plug caps. Adjustment steps (1) Set the shift lever in forward posi- tion. (2) Move the throttle to full-open posi- tion.
  • Page 46 CONTROL SYSTEM (6) If they are not in contact, loosen the set bolt , adjust until they are correctly in contact with each other, and secure the bolt again. 3. Adjusting the carburetor control link: • Accelerator cam • Carburetor control link Adjustment steps (1) Set the shift lever in forward posi-...
  • Page 47 CONTROL SYSTEM (5) "Loosen the bolt, and align the full- open marking "C" with the center of carburetor throttle roller, and tighten the set-bolt." NOTE: Remove the manual starter before adjust- ing. (6) "Loosen the rod tightening screw While pushing the rod with your finger, tighten the screw so that the throttle is full-open (the full-open stopper pushed against the stopper...
  • Page 48 CONTROL SYSTEM (3) Make sure that the magnet base stop- is in contact with the stopper on the engine body (full-close end stop- per) (4) Make sure that the lever is in contact with the carburetor throttle stop screw. (5) Correct adjustment has been estab- lished if the cam roller is not in contact with the accelerator cam.
  • Page 49 CONTROL SYSTEM 5. Adjusting the throttle cable • Throttle cable Adjusting steps NOTE: After adjustment, open and close the throt- tle for several times for reassurance. (1) Set the shift lever in forward posi- tion. (2) Move the throttle to full-open posi- tion.
  • Page 50 CONTROL SYSTEM (6) After confirming the positive contact of stoppers at full-open throttle position, turn the adjusting nut on the throt- tle-closing cable so that the cable has a little slack, and then secure it by the lock (7) Once the adjustment under full-open throttle is completed, move the throttle to full-close position.
  • Page 51 CONTROL SYSTEM (11) Move the throttle to full-close posi- tion. (12) At this point, make sure that the throttle lever is in contact with the throttle stop screw on the carburetor. NOTE: • After adjustment, open and close the throttle for several times for reassur- ance.
  • Page 52 CONTROL SYSTEM (3) Check that the magnet base stopper is in contact with the stopper on the engine body (full-open end stopper) (4) Check that the throttle control lever is in contact with the stopper on the bottom cowling. (5) If they are not in contact, adjust the length of the joint link so that the throttle control lever seats on the stop- per on the bottom cowling.
  • Page 53 CONTROL SYSTEM 7 . Adjusting the engine idle speed: • Engine idle speed Adjustment steps (1) Adjust the pilot screw. Pilot screw turn-out Gasoline carburetor: : : : 1 - 1/2 ± 1/2 Kerosene carburetor: 1/2 + 2 1/2 - 1/2 (2) Adjust the idling stop screw Engine idle speed 1,300 ±...

  • Page 54: Adjusting The Engine Idle Speed

    CONTROL SYSTEM ADJUSTING THE ENGINE IDLE SPEED NOTE: • The engine should be warmed up for the adjustment. Correct adjustment cannot be obtained when the engine is cold. • Make sure that the pilot screw adjust- ment is normal before implementing idling stop screw adjustment.
  • Page 55 CONTROL SYSTEM (3) Make sure that the idle speed is stable when the throttle is opened and closed for several times. NOTE: If the idle speed is not stable, disassemble and readjust the carburetor. 3. Adjust: • Engine idle speed Adjustment steps (1) Turn the idling stop screw of carbu-...

  • Page 56: Adjusting The Start-In-Gear Protection Device

    CONTROL SYSTEM ADJUSTING THE START-IN-GEAR PROTECTION DEVICE CAUTION: • Make sure that the engine is not run- ning. • Remove the plug caps. 1. Check: • Start-in-gear protection device Checking steps (1) Set the shift lever in forward or reverse position. (2) Check that the starter rope cannot be pulled out.

  • Page 57: Power Unit

    POWER UNIT POWER UNIT MEASURING THE COMPRESSION PRESSURE NOTE: The engine should be warmed up before measuring the compression pressure. Cor- rect measurement cannot be obtained when the engine is cold. 1. Measure: • Compression pressure Below minimum compression pres- sure →...

  • Page 58: Cooling System

    COOLING SYSTEM/LOWER UNIT COOLING SYSTEM CHECKING THE COOLING WATER DISCHARGE Check: • Pilot water Does not flow → Clean and check the cooling water passage. Checking steps (1) Place the lower unit in water. (2) Start the engine. (3) Check that water flows from the pilot water outlet.

  • Page 59: Checking The Lower Unit (For Air Leaks)

    LOWER UNIT 2. Fill: • Gear oil (with the specified amount of the recommended gear oil.) Recommended gear oil Hypoid gear oil, SAE #90 (API GL-4) Oil capacity 320 cm (10.8 US oz, 11.3 lmp oz) Filling steps (1) Place the outboard in an upright posi- tion.

  • Page 60: General

    GENERAL GENERAL CHECKING THE ANODE Check: • Anodes Scales → Clean. Oil/grease → Clean. Excessive wear → Replace. CAUTION: Do not oil, grease, or paint the anode, or it will not operate properly. 3-21...

  • Page 61: Checking The Spark Plugs

    GENERAL CHECKING THE SPARK PLUGS 1. Check: • Electrodes Cracks/excessive wear → Replace. • Insulator color Distinctly different color → Check the engine condition. Color guide: Medium to light tan color Normal Whitish color • Lean fuel mixture • Plugged jet (s) •...

  • Page 62: Checking The Propeller

    GENERAL 5. Tighten: • Spark plug Spark plug 25 N m (2.5kgf m, 18 ft • • • NOTE: • Before installing the spark plug, clean the gasket surface and spark plug sur- face. Also, it it suggested to apply a thin film of anti-seize compound to the spark plug threads to prevent thread seizure.

  • Page 63: Lubrication Points

    GENERAL LUBRICATION POINTS 1. Apply: • Yamaha grease A NOTE: Using a grease gun, fill in the grease until it comes out of the bushing. NOTE: Use a grease gun. NOTE: Using a grease gun, fill in the grease until it comes out of the bushing.
  • Page 64 NOTE: Grease the area where shift rod, shift con- nector, and the nut are fastened. NOTE: Grease the sliding face of the choke knob. NOTE: Grease the inner cable and the lock nut. 2. Apply: • Yamaha grease D 3-25...
  • Page 65 FUEL CHAPTER 4 FUEL SYSTEM FUEL JOINT, FUEL FILTER, AND FUEL PUMP ..........4-1 REMOVING THE FUEL JOINT , FUEL FILTER AND FUEL PUMP ... 4-1 CHECKING THE FUEL JOINT ..............4-3 CHECKING THE FUEL FILTER ..............4-3 ASSEMBLING THE FUEL FILTER ............4-3 FUEL PUMP ....................4-4 DISASSEMBLING THE FUEL PUMP ............

  • Page 66: Fuel Joint, Fuel Filter, And Fuel Pump

    FUEL FUEL JOINT, FUEL FILTER, AND FUEL PUMP FUEL JOINT, FUEL FILTER, AND FUEL PUMP REMOVING THE FUEL JOINT, FUEL FILTER AND FUEL PUMP Step Job/Parts Q’ty Remarks Clip Fuel hose (fuel pump to carburetor) Gasoline Clip Fuel hose (fuel pump to carburetor) Kerosene Clip Fuel hose (fuel filter to fuel pump)
  • Page 67 FUEL FUEL JOINT, FUEL FILTER, AND FUEL PUMP Step Job/Parts Q’ty Remarks Fuel pump Gasket Not reusable Fuel filter Gasoline Fuel filter Kerosene Bolt Bolt Filter bracket Bolt Fuel joint Seal...

  • Page 68: Checking The Fuel Joint

    FUEL FUEL JOINT, FUEL FILTER, AND FUEL PUMP CHECKING THE FUEL JOINT 1. Check: • Fuel joint Cracks/damage/leak → Replace. • Seal Cracks/damage → Replace. 2. Measure: • Fuel joint operation Impossible to maintain the specified pressure for 10 sec. → Replace. Measuring steps (1) Attach vacuum/pressure...

  • Page 69: Fuel Pump

    FUEL FUEL PUMP FUEL PUMP DISASSEMBLING THE FUEL PUMP Step Job/Part Q’ty Remarks Screw (with washer) Body Diaphragm Gasket Not reusable Body Diaphragm gasket Not reusable Diaphragm Body Screw Seat valve Screw Washer Continued on next page.
  • Page 70 FUEL FUEL PUMP Step Job/Part Q’ty Remarks Body Diaphragm Diaphragm gasket...

  • Page 71: Checking The Fuel Pump

    FUEL FUEL PUMP CHECKING THE FUEL PUMP 1. Check: • Body • Body • Body • Body Cracks/damage/leak → Replace. Foreign matters → Clean. • Seat valve Cracks/ damage → Replace. • Diaphragm Damage → Replace. 2. Check: • Fuel pump Reverse air flow →...

  • Page 72: Assembling The Fuel Pump

    FUEL FUEL PUMP ASSEMBLING THE FUEL PUMP NOTE: Clean all parts before assembly. Assembly steps (1) Assemble Body and seat valve. (2) Insert the diaphragm between the dia- phragm gaskets, and set them on Body (3) Set Body on the diaphragm gasket. (4) Fit diaphragm and gasket on Body (5) Assemble Body as has been fitted in...
  • Page 73 FUEL FUEL PUMP (6) Assemble body , diaphragm, and diaphragm gasket in this order. (7) Assemble body and body , and fasten them with the screw.

  • Page 74: Carburetor

    FUEL CARBURETOR CARBURETOR REMOVING THE CARBURETOR Step Job/Part Q’ty Remarks Bolt Intake silencer O-ring Not reusable Carburetor Gasket Not reusable...

  • Page 75: Disassembling The Carburetor

    FUEL CARBURETOR DISASSEMBLING THE CARBURETOR Step Job/Part Q’ty Remarks Drain screw Drain gasket Not reusable Drain screw Drain gasket Not reusable Drain screw Packing Not reusable Steel ball seat Steel ball Check valve spring Check valve seat packing Lever joint Hose Continued on next page.
  • Page 76 FUEL CARBURETOR Step Job/Part Q’ty Remarks Bolt Bolt Float chamber Float chamber packing Chamber packing Starter jet Check valve O-ring Not reusable Pump spring Pump plunger Float Pilot jet Continued on next page. 4-11...
  • Page 77 FUEL CARBURETOR Step Job/Part Q’ty Remarks Float arm Needle valve Chamber cover Set screw Washer Pump lever Coller Float Needle valve Valve seat Packing Not reusable Main jet Continued on next page. 4-12...
  • Page 78 FUEL CARBURETOR Step Job/Part Q’ty Remarks Main nozzle Steel ball seat Steel ball Check valve spring Check valve seat packing Screw Lever joint Spring washer Coller Accel arm Cotter pin Not reusable Continued on next page. 4-13...
  • Page 79 FUEL CARBURETOR Step Job/Part Q’ty Remarks Washer Accel roller Accel link shaft Coller Pilot screw Kerosene Spring Pilot screw Gasoline Spring Idling stop screw Spring Bolt Plate Damper Continued on next page. 4-14...
  • Page 80 FUEL CARBURETOR Step Job/Part Q’ty Remarks Hose Hose Cover plate Cover plate packing Plunger spring Guide screw Starter lever Starter plunger Pilot jet Drain screw O-ring Not reusable Carburetor body 4-15...

  • Page 81: Checking The Carburetor

    FUEL CARBURETOR CHECKING THE CARBURETOR CAUTION: Do not use steel-wire to clean the jets. This may enlarge the jet diameters and seriously affect performance. Check: • Carburetor body Cracks/damage → Replace. Contamination → Clean. • Needle valve Grooved wear → Replace. •...

  • Page 82: Assembling The Carburetor

    FUEL CARBURETOR ASSEMBLING THE CARBURETOR 1. Install: • Main nozzle • Main jet • Valve seat • Needle valve • Float • Float pin NOTE: When installing the float into the carbure- tor, place the needle valve into the needle valve seat.
  • Page 83 FUEL CARBURETOR 2. Measure: • Float height Out of specification → Replace Float height 18.0 mm (0.709 in) NOTE: • The float should be resting on the nee- dle valve, but not compressing the nee- dle valve. • Take measurement at the top of the float flange opposite to its pivoted side.
  • Page 84 FUEL CARBURETOR 6. Install: • Cover plate • Damper 7 . Install: • Float arm • • Needle valve 8. Measure: • Float arm height Out of specification → Adjust Float arm height 3.0 mm (0.118 in) NOTE: Adjust the heights of both float arms so that they are on the same level.

  • Page 85: Installing The Carburetor

    FUEL CARBURETOR 9. Install: • Pump plunger • Float • Chamber packing NOTE: Make sure the plunger seal is not turned up. INSTALLING THE CARBURETOR 1. Install: • Gasket • Carburetor • • O-ring • Intake silencer • Bolt NOTE: Insert the projection of choke lever into the choke knob hole...
  • Page 86 FUEL CARBURETOR 3. Measure: • Engine idle speed Out of specification → adjust. Engine idle speed 1,300 ± 50 r/min Measuring steps (1) Start the engine and allow it to warm up for a few minutes. (2) Install the Digital tachometer onto the spark plug lead of cylinder #1.
  • Page 88 POWR CHAPTER 5 RECOIL STARTER RECOIL STARTER ..................5-1 REMOVIING THE RECOIL STARTER ............5-1 DISASSEMBLING THE RECOIL STARTER ..........5-2 CHECKING THE RECOIL STARTER ............5-4 ASSEMBLING THE RECOIL STARTER ........... 5-6 INSTALLING THE RECOIL STARTER ............5-9 FLYWHEEL MAGNET ................... 5-10 REMOVIING THE FLYWHEEL MAGNET ..........
  • Page 89 POWR CALCULATING THE PISTON-TO-CYLINDER CLEARANCE ....5-31 CHECKING THE PISTON PINS AND SMALL-END BEARINGS ... 5-32 CHECKING THE PISOTN RINGS ............5-33 CHECKING THE CRANKSHAFT ............5-34 INSTALLING THE PISTON AND PISTON RINGS .........5-37 INSTALLING THE CRANKSHAFT AND PISTON ........5-37 CHECKING THE ANODE ...............

  • Page 90: Recoil Starter

    POWR RECOIL STARTER RECOIL STARTER REMOVIING THE RECOIL STARTER Step Job/Parts Q’ty Remarks Starter stop wire Bolt (with washer) Recoil starter Collar...

  • Page 91: Disassembling The Recoil Starter

    POWR RECOIL STARTER DISASSEMBLING THE RECOIL STARTER Step Job/Parts Q’ty Remarks Starter stop wire Starter stop plunger Spring Cover Starter handle-grip Damper Bolt (with washer) Rope guide Center bolt Thrust washer Friction plate Collar 1 Continued on next page.
  • Page 92 POWR RECOIL STARTER Step Job/Parts Q’ty Remarks Friction spring Drive pawl Return spring Bushing Sheave drum Starter rope Spiral spring Thrust washer Starter case...

  • Page 93: Checking The Recoil Starter

    POWR RECOIL STARTER CHECKING THE RECOIL STARTER 1. Remove: • Cover • Starter handle-grip NOTE: Undo the knot in the starter rope, and wind the rope around the sheave drum. CAUTION: Be careful not to touch the sheave drum which is rotating at high speeds. 2.
  • Page 94 POWR RECOIL STARTER WARNING When removing or installing the spiral spring, use care not to injure your hand. It is advisable to wear gloves. 4. Check: • Bushing Cracks/damage/wear → Replace. 5. Check: • Spiral spring Bent/broken/damage → Replace. 6. Check: •...

  • Page 95: Assembling The Recoil Starter

    POWR RECOIL STARTER 8. Check: • Drive pawl Cracks/damage/wear → Replace. • Return spring • Friction spring Bent/broken/damage → Replace. ASSEMBLING THE RECOIL STARTER CAUTION: New spiral springs come held in a steel hoop. To install, hook the outer end onto the spring pin first, place into the starter case, and then remove the steel hoop.
  • Page 96 POWR RECOIL STARTER 2. Install: • Starter rope • Sheave drum NOTE: • Insert the rope through the rope hole and knot the end as shown. • Wind the rope 1-1/2 turns counterclock- wise onto the sheave drum. • Place the rope at the cutaway WARNING •...
  • Page 97 POWR RECOIL STARTER 6. Install: • Friction plate • Collar 1 • Friction spring 7 . Install: • Friction plate (with friction spring etc.) • Center bolt • Center bolt 15 N m (1.5 kgf m, 11 ft • • •...

  • Page 98: Installing The Recoil Starter

    POWR RECOIL STARTER NOTE: • Set the sheave drum so that the cut in the sheave drum is diametrically oppo- site the starter handle-grip. • Pass the rope through the starter han- dle-grip, and make a knot in the end of the rope as shown.

  • Page 99: Flywheel Magnet

    POWR FLYWHEEL MAGNET FLYWHEEL MAGNET REMOVIING THE FLYWHEEL MAGNET Step Job/Part Q’ty Remarks Bolt Starter pulley Washer Flywheel magnet Woodruf key 5-10...

  • Page 100: Installing The Flywheel Magnet

    POWR FLYWHEEL MAGNET Remove: • Flywheel magnet Removing steps (1) Remove the starter pulley (2) Remove the flywheel magnet nut. Flywheel holder 90890-06522 NOTE: The major load should be applied in the direction of the arrows. If the load is not applied as shown, the flywheel holder may easily slip off of the flywheel magnet.

  • Page 101: Power Unit

    POWR POWER UNIT POWER UNIT DISCONNECTING THE LEADS AND STAYS Step Job/Part Q’ty Remarks Bolt Washer Bolt Electrical unit Bolt Earth lead Bolt Bolt Stay Bolt Stay Bolt Stay Continued on next page. 5-12...
  • Page 102 POWR POWER UNIT Step Job/Part Q’ty Remarks Bolt CDI unit Bolt Ignition coil Bracket Pipe Damper Grommet 5-13...

  • Page 103: Removing The Power Unit

    POWR POWER UNIT REMOVING THE POWER UNIT Step Job/Part Q’ty Remarks Cotter pin Not reusable Washer Wavewasher Throttle cable 1 Throttle cable 2 Bolt (with washer) Power unit Dowel pin Gasket Not reusable 5-14...

  • Page 104: Magnet Base And Control Lever

    POWR MAGNET BASE AND CONTROL LEVER MAGNET BASE AND CONTROL LEVER REMOVING THE MAGNET BASE AND MAGNET CONTROL LEVER Step Job/Part Q’ty Remarks Clamp Joint link Bolt Magnet base Screw Change coil Screw Lighting coil Screw Pulser coil Screw Magnet base retainer 2 Magnet base retainer 1 Continued on next page.
  • Page 105 POWR MAGNET BASE AND CONTROL LEVER Step Job/Part Q’ty Remarks Magnet base friction plate Joint link Bolt (with washer) Collar Magneto control lever Bolt (with washer) Throttle cable stay Bolt (with washer) Collar 5-16...

  • Page 106: Intake Manifold And Reed Valves

    POWR INTAKE MANIFOLD AND REED VALVES INTAKE MANIFOLD AND REED VALVES REMOVING THE INTAKE MANIFOLD AND REED VALVES Step Job/Part Q’ty Remarks Bolt (with washer) Bolt (with washer) Clamp (Fuel hose) Bolt (with washer) Intake manifold Intake manifold gasket Not reusable Reed valve Gasket Not reusable...

  • Page 107: Checking The Reed Valves

    POWR INTAKE MANIFOLD AND REED VALVES CHECKING THE REED VALVES 1. Check: • Reed valve Cracks/damage → Replace. 2. Measure: • Valve bending Out of specification → Replace. Valve bending limit 0.2 mm (0.008 in) 3. Measure: • Valve stopper height Out of specification →...

  • Page 108: Cylinder Head

    POWR CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Step Job/Part Q’ty Remarks Spark plug Hose Bolt (with washer) Thermostat cover Gasket Not reusable Plain washer Thermostat Bolt (with washer) Bolt (with washer) Cylinder head cover Head cover gasket Not reusable Cylinder head Cylinder head gasket Not reusable...

  • Page 109: Checking The Cylinder Head

    POWR CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Check: • Combustion chamber Carbon deposits → Clean. • Water jacket Mineral deposits/rust → Clean. CAUTION: Do not scratch the contacting surface of the cylinder head and cylinder head cover. 2. Measure: •...

  • Page 110: Checking The Thermostat

    POWR CYLINDER HEAD CHECKING THE THERMOSTAT 1. Check: • Thermostat Damage/stick → Replace. 2. Measure: • Valve opening temperature • Valve lift Out of specification → Replace. W W W W a a a a t t t t e e e e r r r r t t t t e e e e m m m m p p p p e e e e r r r r a a a a t t t t u u u u r r r r e e e e V V V V a a a a l l l l ve ve li li li lif f f f t t t t B B B B e e e e l l l l o o o o w w w w 48...

  • Page 111: Installing The Cylinder Head And Cylinder Head Cover

    POWR CYLINDER HEAD INSTALLING THE CYLINDER HEAD AND CYLINDER HEAD COVER Install: • Cylinder head and cylinder head cover NOTE: • Temporarily assemble; cylinder head cover , cylinder head cover gasket cylinder head , and cylinder head gasket in that order, and then install the assembled parts onto the crank- case.

  • Page 112: Exhaust Cover

    POWR EXHAUST COVER EXHAUST COVER REMOVING THE EXHAUST COVER Step Job/Part Q’ty Remarks Bolt (with washer) Bolt (with washer) Exhaust outer cover Gasket Not reusable Exhaust inner cover Gasket Not reusable 5-23...

  • Page 113: Checking The Exhaust Cover

    POWR EXHAUST COVER CHECKING THE EXHAUST COVER Check: • Exhaust inner cover Cracks/damage → Replace. Carbon deposits → Clean. (use a round scraper) • Exhaust outer cover Cracks/damage → Replace. CAUTION: Do not scratch the fitting surfaces of the cylinder and exhaust cover. INSTALLING THE EXHAUST COVER Install: •...

  • Page 114: Crankcase

    POWR CRANKCASE CRANKCASE REMOVING THE CRANKCASE Step Job/Part Q’ty Remarks Bolt (with washer) Bolt (with washer) Crankcase Bolt (with washer) Oil seal housing O-ring Not reusable Oil seal Not reusable Oil seal Not reusable 5-25...

  • Page 115: Assembling The Oil Seal Housing

    Needle bearing attachment ..90890-06608 Ball bearing attachment....90890-06633 Driver rod L3........90890-06652 NOTE: Apply Yamaha grease A (water resistant grease) on the oil seals. IINSTALLING THE CRANKCASE 1. Apply: • Gasket Maker® Applying steps (1) Clean the matching surfaces of the crankcase and cylinder body.
  • Page 116 POWR CRANKCASE 3. Install: • Crankcase NOTE: ® • Apply LOCTITE No.572 on the bolts. • Tighten the crankcase mounting bolts in sequence and in two steps of torque. Crankcase mounting bolts 1st: 15 N m (1.5 kgf m, 11 ft •...

  • Page 117: Crankshaft And Cylinder Body

    POWR CRANKSHAFT AND CYLINDER BODY CRANKSHAFT AND CYLINDER BODY REMOVING THE CRANKSHAFT AND CYLINDER BODY Step Job/Part Q’ty Remarks Crankshaft Cylinder body Piston pin clip Piston pin Piston pin washer Small end bearing 34 pins/1set Piston ring Piston 5-28...

  • Page 118: Checking The Cylinder Body

    POWR CRANKSHAFT AND CYLINDER BODY CHECKING THE CYLINDER BODY 1. Check: • Cylinder inner surface Score mark → Repair/replace. (use #600 – 800 grit wet sandpaper) • Water jacket Mineral deposits/rust/corrosion → Clean/replace. CAUTION: Do not scratch the contacting surfaces of the crankcase and cylinder head.

  • Page 119: Checking The Piston

    POWR CRANKSHAFT AND CYLINDER BODY S S S S t t t t a a a a n n n n d d d d a a a a r r r r d d d d W W W W ea ear r r r li li li lim m m m i i i i t t t t C C C C y y y y li li li lin n n n d d d d e e e e r r r r b b b b o o o o r r r r e e e e 7 7 7 7 2 2 2 2 .

  • Page 120: Calculating The Piston-To-Cylinder Clearance

    POWR CRANKSHAFT AND CYLINDER BODY 3. Measure: • Piston diameter (use an outside micrometer) Out of specification → Replace. Outside micrometer 90890-03008 Measuring Piston diameter point “H” 10.0 mm 71.94 – 71.96 mm S S S S t t t t a a a a nd nda a a a r r r r d d d d (0.3937 in) (2.8323 –...

  • Page 121: Checking The Piston Pins And Small-End Bearings

    POWR CRANKSHAFT AND CYLINDER BODY CHECKING THE PISTON PINS AND SMALL-END BEARINGS 1. Check: • Piston pin • Small-end bearing Heat discoloration → Replace. Damage/scratches → Replace. 2. Measure: • Piston pin outside diameter (use an outside micrometer) Out of specification → Replace. Outside micrometer 90890-03006 Piston pin outside diameter...

  • Page 122: Checking The Pisotn Rings

    POWR CRANKSHAFT AND CYLINDER BODY 4. Check: • Free play (when piston pin is in place of the piston). There should be no noticeable play. Free play exists → Replace the pin and/or piston. CHECKING THE PISOTN RINGS NOTE: • Before checking the piston rings, be sure to check the cylinder body.

  • Page 123: Checking The Crankshaft

    POWR CRANKSHAFT AND CYLINDER BODY NOTE: Push the piston ring into the cylinder with the piston crown. 3. Measure: • Piston ring side clearance (use a thickness gauge) Out of specification → Replace. Piston ring side clearance Top: 0.03 - 0.05 mm (0.0012 - 0.0020 in) 2nd: 0.03 - 0.07 mm (0.0012 - 0.0028 in)
  • Page 124 POWR CRANKSHAFT AND CYLINDER BODY 2. Measure: • Runout (Use a crank stand alignment and dial gauge.) Out of specification → Repair/replace. Crank stand alignment 90890-03107 Dial gauge set 90890-01252 Runout limit 0.03 mm (0.0012 in) 3. Measure: • Connecting rod side clearance (Use a thickness gauge.) Out of specification →...
  • Page 125 POWR CRANKSHAFT AND CYLINDER BODY 5. Check: • Crankshaft bearings Abnormal noise/damage / roughness → Replace. CAUTION: Do not use compressed air to spin the bear- ings dry. This causes damage to the bearing surfaces. NOTE: Do not reuse the bearing, always replace it with a new one.

  • Page 126: Installing The Piston And Piston Rings

    • Align each piston ring end gap with its respective locating pin. • After installing the piston rings, check that they move smoothly. NOTE: Apply Yamaha 2-stroke motor oil on the pis- ton ring and piston ring groove. INSTALLING THE CRANKSHAFT AND PISTON 1. Install: •...

  • Page 127: Checking The Anode

    • Crankshaft and piston • Dowel pin NOTE: • Apply Yamaha 2-stroke motor oil to each cylinder wall and piston and their ring grooves. • Coat all the crankshaft bearings with the engine oil. • The crankshaft bearing locating pin should fit into the slit in the cylinder.

  • Page 128: Crank Shaft

    POWR CRANK SHAFT CRANK SHAFT DISASSEMBLING THE CRANKSHAFT Step Job/Part Q’ty Remarks O-ring Not reusable Oil seal Not reusable Bearing Collar Crank 1 Crank pin Washer Connecting rod Bearing Crank 2 Bearing Labyrinth seal Clip Continued on next page. 5-39...
  • Page 129 POWR CRANK SHAFT Step Job/Part Q’ty Remarks Crank 3 Crank 4 Bearing Washer 5-40...

  • Page 130: Removing The Crankshaft Bearing

    POWR CRANK SHAFT REMOVING THE CRANKSHAFT BEARING Upper bearing 1. Remove: • Upper bearing Remove the upper bearing with hands. 2. Remove: • Collar Pressure pin B ....... 90890-02390 Bearing separator ......90890-06534 NOTE: • By forcing the pressure pin B with a hydraulic press, remove the bearing.
  • Page 131 POWR CRANK SHAFT Crank 1 and crank 4 removal Remove: • Crank 1 • Crank 4 Plate A..........90890-02386 Pressure pin B ....... 90890-02390 Removing steps (1) By forcing the pressure pin B with a hydraulic press, remove the crank pin. (2) When forcing out the crank pin, use care so that the crankshaft does not fall off.
  • Page 132 POWR CRANK SHAFT CAUTION: • Apply pressure to the pressure pin B slowly. • Hold the pressure pin B in line with the press screw spindle. 2. Remove: • Labyrinth seal • Clip 3. Remove: • Bearing Removing steps (1) Remove roller bearing (outer race) (2) Remove roller bearing (inner race) using hydraulic press.

  • Page 133: Assembling The Crankshaft

    Spacer B ........90890-02396 Support.......... 90890-02394 2. Install: • Crank pin (new) NOTE: • Insert the crank pin into the pin hole by tapping it with a copper hammer • Apply Yamaha 2-stroke motor oil on the crank pin. 5-44...
  • Page 134 POWR CRANK SHAFT 3. Press-fit: • Crank pin NOTE: • Don’t apply force in excess of 5 tons. • The crank pin should be press-fitted into both crank 2 and crank 4. CAUTION: Take care so that the crank pin is set squarely to the crank web Assembling cranks 1 and 2,3 and 4...
  • Page 135 • Washer CAUTION: • The model No. facing upward (crank 1 or crank 3 side). • Apply Yamaha 2-stroke motor oil on the connecting rod and washer. 4. Install (special service tools): • Pressure plate • Bushing-14 (for crank 1)or Bushing- 12 (for crank 3) 5.
  • Page 136 Press body ........90890-02385 CAUTION: • Be sure to press-fit the crank 1 or crank 3 squarely onto the crank pin. • Apply Yamaha 2-stroke motor oil on the crank pin. 8. Measure: • Crank width Use the digital caliper.
  • Page 137 Roller bearing (inner race) NOTE: • Position the roller bearing with the stamped mark facing upward and press-fit it until it contacts the crank 2. • Apply Yamaha 2-stroke motor oil on the roller bearing. Plate A..........90890-02386 Bearing pressure B......90890-02392...
  • Page 138 Plate B..........90890-02387 CAUTION: • Align the match marks on crank 3 and 2. • Apply Yamaha 2-stroke motor oil on the crank 3 and 2. 3. Press-fit: • Crank 2 and crank 3 (apply a force of 7 ton) Height ring-13 (H57) .....

  • Page 139: Installing Crankshaft Bearing

    90890-02392 CAUTION: • Install the bearing with its stamped mark facing upward. • Apply Yamaha 2-stroke motor oil on the bearing. • Be sure to press-fit the ball bearing squarely onto crank 4. Upper bearing (for crank 1) 1. Install: •...

  • Page 140: Checking The Crankshaft

    POWR CRANK SHAFT Run-out check 1. Measure: • Runout Use the crank stand alignment and digital gauge Out of specification → Adjust. Crank stand alignment 90890-03107 Digital gauge set 90890-01252 Runout limit 0.03 mm (0.0012 in) NOTE: If the dial gauge reading is 0.03 mm (0.0012 in) or more, adjust the crankshaft so that the reading is less than 0.03 mm (0.0012 in).
  • Page 142 LOWR CHAPTER 6 LOWER UNIT LOWER UNIT ....................6-1 REMOVING THE LOWER UNIT ............... 6-1 REMOVING THE PROPELLER ..............6-3 CHECKING THE PROPELLER ..............6-3 INSTALLING THE PROPELLER ............... 6-3 INSTALLING THE TRIM TAB ..............6-3 WATER PUMP ....................6-4 REMOVING THE WATER PUMP .............
  • Page 143 LOWR CHECKING THE DRIVE SHAFT SLEEVE ..........6-19 CHECKING THE NEEDLE BEARING ............. 6-20 ASSEMBLING THE LOWER CASE ............6-20 SHIMMING ....................6-21 SELECTING THE PINION SHIMS ............6-22 SELECTING THE FORWARD GEAR SHIMS ......... 6-24 SELECTING THE REVERSE GEAR SHIMS ........... 6-26 BACKLASH ....................

  • Page 144: Lower Unit

    LOWR LOWER UNIT LOWER UNIT REMOVING THE LOWER UNIT Step Job/Part Q’ty Remarks Cotter pin Not reusable Castle nut Washer Spacer Propeller Spacer Shift connector Bolt (with washer) Trim tab Bolt Anode Screw Continued on next page.
  • Page 145 LOWR LOWER UNIT Step Job/Part Q’ty Remarks Water inlet cover 1 Water inlet cover 2 Gear oil level check screw Gasket Gear oil drain screw Gasket Bolt Transom S, L Transom Y Lower unit Extension Transom Y Transom Y...

  • Page 146: Removing The Propeller

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

  • Page 147: Water Pump

    LOWR WATER PUMP WATER PUMP REMOVING THE WATER PUMP Step Job/Part Q’ty Remarks Bolt Plate Transom S, L Water tube O-ring Not reusable O-ring Not reusable Water seal rubber Water pump housing Insert cartridge O-ring Not reusable Impeller Impeller plate Dowel pin Woodruff key...

  • Page 148: Checking The Water Pump Housing

    • When installing the water pump hous- ing, turn the drive shaft clockwise. • Apply Yamaha grease A (water resis- tant grease) on the impeller , the insert cartridge...

  • Page 149: Shift Rod

    LOWR SHIFT ROD SHIFT ROD REMOVING THE SHIFT ROD Step Job/Part Q’ty Remarks Impeller plate Refer to "WATER PUMP" on page 6-4. Bolt Bracket Plate O-ring Not reusable Oil seal housing Lower casing packing Not reusable Dowel pin Shift rod Rubber seal Oil seal...

  • Page 150: Propeller Shaft Housing

    LOWR PROPELLER SHAFT HOUSING PROPELLER SHAFT HOUSING REMOVING THE PROPELLER SHAFT HOUSING Step Job/Part Q’ty Remarks Gear oil Refer to "CHANGING AND CHECKING THE GEAR OIL" on page 3-19. Shift rod assembly Refer to "SHIFT ROD" on page 6-6. Bolt Propeller shaft housing Washer Propeller shaft...

  • Page 151: Disassembling The Propeller Shaft Housing

    LOWR PROPELLER SHAFT HOUSING DISASSEMBLING THE PROPELLER SHAFT HOUSING Step Job/Part Q’ty Remarks O-ring Not reusable O-ring Not reusable Reverse gear Reverse gear shim Ball bearing Oil seal Needle bearing Propeller shaft housing Washer * As required...

  • Page 152: Disassembling The Propeller Shaft

    LOWR PROPELLER SHAFT HOUSING DISASSEMBLING THE PROPELLER SHAFT Step Job/Part Q’ty Remarks Shift plunger Cross pin ring Cross pin Spring Dog clutch Propeller shaft...

  • Page 153: Removing The Propeller Shaft Housing

    LOWR PROPELLER SHAFT HOUSING REMOVING THE PROPELLER SHAFT HOUSING Remove: • Propeller shaft housing Bearing housing puller claw ..90890-06546 Stopper guide plate ...... 90890-06501 Center bolt........90890-06504 DISASSEMBLING THE PROPELLER SHAFT HOUSING 1. Remove: • Reverse gear Bearing separator ......90890-06534 Stopper guide plate ......

  • Page 154: Checking The Reverse Gear

    LOWR PROPELLER SHAFT HOUSING 2. Remove: • Ball bearing Stopper guide plate ...... 90890-06501 Stopper guide stand..... 90890-06538 Bearing puller ass’y ...... 90890-06535 NOTE: Do not reuse the bearing. Always replace it with a new one. 3. Remove: • Oil seal •...

  • Page 155: Assembling The Propeller Shaft Housing

    Needle bearing attachment ..90890-06615 Bearing depth plate ...... 90890-06603 NOTE: Install the needle bearing with its manufac- turer’s marks facing up. Apply Yamaha motor oil. 2. Install: • Oil seals Oil seal position ......6.0 - 6.5 mm (0.26 in) Driver rod L3........

  • Page 156: Checking The Dog Clutch

    LOWR PROPELLER SHAFT HOUSING 3. Install: • Reverse gear • Reverse gear shim(s) • Ball bearing • Propeller shaft housing NOTE: • Before press-fitting the ball bearing, install the reverse gear shim(s). • Install the ball bearing with its manu- facturer’s marks facing the reverse gear.

  • Page 157: Drive Shaft

    LOWR DRIVE SHAFT DRIVE SHAFT REMOVING THE DRIVE SHAFT Step Job/Part Q’ty Remarks Propeller shaft housing Refer to "PROPELLER SHAFT HOUS- ING" on page 6-7. Pinion gear nut Pinion gear Drive shaft Forward gear Drive shaft bearing 6-14...

  • Page 158: Removing The Drive Shaft Bearing

    LOWR DRIVE SHAFT REMOVING THE DRIVE SHAFT Remove: • Pinion gear nut • Drive shaft Drive shaft holder 3 ...... 90890-06517 Removing Steps (1) Apply 12mm wrench on the pinion gear nut. (2) Support the lower case with rags to hold the wrench in position.

  • Page 159: Checking The Pinion And Forward Gear

    LOWR DRIVE SHAFT CHECKING THE PINION AND FORWARD GEAR Check: • Teeth • Dogs Damage/wear → Replace. CHECKING THE DRIVE SHAFT Check: • Drive shaft Damage/wear → Replace. Maximum runout 0.5 mm (0.020 in) CHECKING THE BEARINGS Check: • Bearings Pitting/rumbling →...
  • Page 160 LOWR DRIVE SHAFT INSTALLING THE DRIVE SHAFT 1. Install: • Forward gear (with the tapered roller bearing) • Drive shaft (with the tapered roller bearing) • Pinion gear Drive shaft holder 3 ...... 90890-06517 2. Tighten: • Pinion gear nut Pinion gear nut 50 Nm (5.0 kgf m, 37 ft...

  • Page 161: Lower Case

    LOWR LOWER CASE LOWER CASE DISASSEMBLING THE LOWER CASE Step Job/Part Q’ty Remarks Drive shaft bearing outer race Pinion gear shim Drive shaft sleeve Needle bearing Tapered roller bearing outer race Forward gear shim * As required 6-18...

  • Page 162: Checking The Drive Shaft Sleeve

    LOWR LOWER CASE 1. Remove: • Drive shaft bearing outer race • Pinion gear shim(s) Stopper guide plate ...... 90890-06501 Bearing puller ass’y ...... 90890-06535 Stopper guide stand..... 90890-06538 2. Remove: • Drive shaft needle bearing and sleeve Driver rod L3........90890-06652 Needle bearing attachment ..

  • Page 163: Checking The Needle Bearing

    LOWR LOWER CASE CHECKING THE NEEDLE BEARING Check: • Needle bearing Pitting/rumbling → Replace. ASSEMBLING THE LOWER CASE 1. Install: • Forward gear shim(s) • Tapered roller bearing outer race Bearing outer race attachment 90890-06622 Driver rod LL 90890-06605 2. Install: •...

  • Page 164: Shimming

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

  • Page 165: Selecting The Pinion Shims

    LOWR SHIMMING SELECTING THE PINION SHIMS NOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calcula- tion formula. Select: • Shim thickness (T3) Selecting steps (1) Install the pinion height gauge, drive shaft and bearing (with bearing race). Pinion height gauge .....
  • Page 166 LOWR SHIMMING (4) Calculate the pinion gear shim thick- ness (T3). Pinion gear shim thickness (T3) = M - 27 mm - P/100 mm NOTE: • "P" is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01 mm units.

  • Page 167: Selecting The Forward Gear Shims

    LOWR SHIMMING SELECTING THE FORWARD GEAR SHIMS NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calcula- tion formula. Select: • Shim thickness (T1) Selecting steps (1) Measure (M). Shimming plate ......90890-06701 Digital caliper ........ 90890-06704 NOTE: •...
  • Page 168 LOWR SHIMMING Example: If M is "16.25 mm" and "F" is "+4", then: T1 = 17 .5 mm + (+4)/100 - 16.25 mm = 17 .5 mm + 0.04 - 16.25 mm = 1.29 mm (0.051 in) If M is "16.26 mm" and "F" is "-3", then: T1 = 17 .5 mm + (-3)/100 - 16.26 mm = 17 .5 mm - 0.03 - 16.26 mm = 1.21 mm (0.048 in)

  • Page 169: Selecting The Reverse Gear Shims

    LOWR SHIMMING SELECTING THE REVERSE GEAR SHIMS NOTE: Select the shim thickness (T2) the specified measurement(s) and the calculation for- mula. Select: • Shim thickness (T2) Selecting steps (1) Measure (M2). Shimming plate ......90890-06701 Digital caliper ........ 90890-06704 NOTE: •...
  • Page 170 LOWR SHIMMING Example: If M2 is "78.79 mm" and "R" is "+5", then: T2 = 80 mm + (+5)/100 - 78.79 mm = 80 mm + 0.05 mm - 78.79 mm = 1.26 mm (0.050 in) If M2 is "78.75 mm" and "R" is "-3", then: T2 = 80 mm + (-3)/100 - 78.75 mm = 80 mm - 0.03 mm - 78.75 mm = 1.22 mm (0.048 in)

  • Page 171: Backlash

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

  • Page 172: Measuring The Reverse Gear Backlash

    LOWR BACKLASH (3) Install the backlash indicator onto the drive shaft (16mm (0.63 in) diameter). Backlash indicator ......90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indi- cator.
  • Page 173 LOWR BACKLASH Measuring steps (1) Set the shift rod into the neutral posi- tion. (2) Load the reverse gear by installing the propeller without the collar , and then tighten the propeller nut. Propeller nut m (0.5 kgf m, 3.7 ft •...

  • Page 175: Bracket Unit

    BRKT CHAPTER 7 BRACKET UNIT STEERING HANDLE ..................7-1 DISASSEMBLING THE STEERING HANDLE ......... 7-1 CHECKING THE STEERING HANDLE ............ 7-3 ASSEMBLING THE STEERING HANDLE ..........7-3 BOTTOM COWLING ..................7-5 REMOVING THE BOTTOM COWLING ........... 7-5 CHECKING THE BOTTOM COWLING ............ 7-7 INSTALLING THE BOTTOM COWLING ..........

  • Page 176: Steering Handle

    BRKT STEERING HANDLE STEERING HANDLE DISASSEMBLING THE STEERING HANDLE Step Job/Part Q’ty Remarks Throttle cable Throttle cable Grommet Bolt (with washer) Bolt (with washer) Steering handle cover Collar Collar Plain washer Wave washer Screw Handle Washer Continued on next page.
  • Page 177 BRKT STEERING HANDLE Step Job/Part Q’ty Remarks Compression spring Bushing Bolt Self-locking nut Steering friction Throttle lever Steering handle 1...

  • Page 178: Checking The Steering Handle

    Throttle cable (tight cable side) NOTE: • Connect the inner cable end in the groove, and fit the outer cable end into the hole. • Apply Yamaha grease A (water resis- tant grease) to the throttle lever and throttle cable.
  • Page 179 • Steering handle • Collar • Steering handle cover • Bolt NOTE: Apply Yamaha grease A (water resistant grease) to the throttle cables, washers and the steering handle crown. 5. Install: • Throttle cables (through bottom cowling) • Grommet NOTE: Pass the throttle cables through the steer- ing handle on the steering bracket.

  • Page 180: Bottom Cowling

    BRKT BOTTOM COWLING BOTTOM COWLING REMOVING THE BOTTOM COWLING Step Job/Part Q’ty Remarks Collar Grommet Washer Bottom cowling Grommet Engine stop switch Choke knob Grommet Grommet Grommet Spring pin Throttle lever Continued on next page.
  • Page 181 BRKT BOTTOM COWLING Step Job/Part Q’ty Remarks Bushing Throttle control shaft Friction spacer Bolt (with washer) Clamp lever 2 Bushing Wave washer Clamp lever 1...

  • Page 182: Checking The Bottom Cowling

    • Bottom cowling Crack/damage → Replace. 2. Check: • Clamp lever Wear/damage → Replace. NOTE: Apply Yamaha grease A (water resistant grease) or replace parts as required. INSTALLING THE BOTTOM COWLING 1. Install: • Bushing • Throttle control shaft •...

  • Page 183: Shift Actuator

    BRKT SHIFT ACTUATOR SHIFT ACTUATOR DISASSEMBLING THE SHIFT ACTUATOR Step Job/Part Q’ty Remarks Rubber seal Rubber seal 2 Bolt (with washer) Washer Bracket Gasket Washer Bolt Bolt (with washer) Bracket Dowel pin Continued on next page.
  • Page 184 BRKT SHIFT ACTUATOR Step Job/Part Q’ty Remarks Bushing 2 Compression spring Compression spring Shift cam plunger Cotter pin Not reusable Washer Cotter pin Not reusable Washer Joint Bolt Shift lever Grommet Cam plate Continued on next page.
  • Page 185 BRKT SHIFT ACTUATOR Step Job/Part Q’ty Remarks Bushing Grease nipple Cotter pin Not reusable Washer Plate washer Shift rod 1 Spring pin Not reusable Shift rod lever Plate washer Collar Shift rod Torsion spring 7-10...

  • Page 186: Removing The Bracket

    Joint • Shift rod lever • Shift rod • Shift rod 1 Wear/damage → Replace. NOTE: Apply Yamaha grease A (water resistant grease) or replace parts as required. 2. Check: • Bracket • Bracket (remote control attach- ment) Crack/damage → Replace.

  • Page 187: Assembling The Shift Actuator

    • Grease nipple NOTE: • Always use the new spring pin and the cotter pin. • Apply Yamaha grease A (water resis- tant grease) to the collar inner surface, grease nipple and shift rod 1. 2. Hook: • Torsion spring...
  • Page 188 BRKT SHIFT ACTUATOR 4. Install: • Shift cam plunger • Compression spring • Bushing NOTE: Apply Yamaha grease A (water resistant grease) to the shift cam plunger. 5. Install: • Shift lever • Bolt • Bolt 11 N m (1.1 kgf m, 8.1 ft...

  • Page 189: Upper Case

    BRKT UPPER CASE UPPER CASE REMOVING THE UPPER CASE Step Job/Part Q’ty Remarks Bolt (with washer) Bolt (with washer) Bolt (with washer) Lower mount rubber housing Mount rubber (side lower) Lower mount cover Mount rubber (front lower) Washer Upper case Continued on next page.
  • Page 190 BRKT UPPER CASE Step Job/Part Q’ty Remarks Bolt Washer Mount rubber (side upper) Gasket Bolt (with washer) Mount rubber (front upper) 7-15...

  • Page 191: Checking The Upper Case

    BRKT UPPER CASE CHECKING THE UPPER CASE Check: • Upper case Crack/damage → Replace. • Mount rubber Wear/crack/damage → Replace. INSTALLING THE UPPER CASE Install: • Mount rubber (front upper) • Mount rubber (side upper) – with gaskets • • Upper case (to swivel bracket) •...

  • Page 192: Disassembling The Upper Case

    BRKT UPPER CASE DISASSEMBLING THE UPPER CASE Step Job/Part Q’ty Remarks Bolt Exhaust guide Bolt Exhaust manifold Exhaust seal 2 Not reusable Exhaust seal 1 Not reusable Cotter pin Not reusable Gasket Gasket Not reusable Water tube Water seal rubber 7-17...

  • Page 193: Checking The Exhaust Manifold

    BRKT UPPER CASE CHECKING THE EXHAUST MANIFOLD Check: • Exhaust manifold • Exhaust guide Carbon deposits → Clean. Crack/corrosion → Replace. ASSEMBLING THE UPPER CASE 1. Install: • Exhaust manifold • Exhaust guide • Exhaust seals • Gasket NOTE: Always use new gaskets and exhaust seals. If old ones are used, gas leakage may result due to invisible scratches or stretches.

  • Page 194: Steering Arm

    BRKT STEERING ARM STEERING ARM REMOVING THE STEERING ARM Step Job/Part Q’ty Remarks Bolt Seal rubber Bolt Bracket Dowel pin Steering pivot shaft Washer Bushing Friction piece Bushing O-ring Not reusable Bushing 7-19...

  • Page 195: Checking The Steering Arm

    • Bolt (steering friction) NOTE: • Always use the new O-ring. • Apply Yamaha grease A (water resis- tant grease) to the busing, O-ring and the grease nipples. • After installing the steering bracket, make sure the movement of steering pivot shaft by moving it.

  • Page 196: Clamp Brackets

    BRKT CLAMP BRACKETS CLAMP BRACKETS REMOVING THE CLAMP BRACKETS Step Job/Part Q’ty Remarks Tension spring Tilt rod Conical spring Washer Bolt Collar Clamp bracket cap Clamp bracket plate Clamp bracket 1 Clamp bracket 2 Clamp bracket bolt Continued on next page. 7-21...
  • Page 197 BRKT CLAMP BRACKETS Step Job/Part Q’ty Remarks Washer Bushing Tilt lever cover Tilt lever Torsion spring Circlip Spring return lever Tilt lock rod Tilt lock rod Cotter pin Tilt lock plate (outer) Continued on next page. 7-22...
  • Page 198 BRKT CLAMP BRACKETS Step Job/Part Q’ty Remarks Tension spring Bolt Shallow water lever Cover Tilt lock plate (inner) Grease nipple Swivel bracket Spring pin Stopper knob Stopper shaft 7-23...

  • Page 199: Checking The Clamp Brackets

    BRKT CLAMP BRACKETS CHECKING THE CLAMP BRACKETS 1. Check: • Clamp bracket (port side) • Clamp bracket (starboard side) • Swivel bracket Crack/damage → Replace. 2. Check: • Tilt lock plate (outer) • Tilt lock plate (inner) • Shallow water lever •...

  • Page 200: Installing The Clamp Brackets

    BRKT CLAMP BRACKETS INSTALLING THE CLAMP BRACKETS 1. Install: • Swivel bracket (with bushings) • Shallow water lever • Tension springs • Tilt lock lever (inner) – front side • Tilt lock lever (outer) – rear side • • Cotter pin NOTE: •...
  • Page 201 Stopper knob • Spring pin NOTE: • Always use the new pin and a spring pin. • Apply Yamaha grease A (water resis- tant grease) to the transom clamp screw, stopper shaft and the grease nipple. 4. Install: • Clamp bracket bolt •...

  • Page 203: Electrical System

    – ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENT ................8-1 ELECTRICAL COMPONENTS ANALYSIS .............8-2 DIGITAL CIRCUIT TESTER ..............8-2 MEASURING THE PEAK VOLTAGE ............8-2 PEAK VOLTAGE ADAPTER ..............8-2 MEASURING A LOW RESISTANCE .............. 8-3 IGNITION SYSTEM ..................8-4 WIRING DIAGRAM ..................8-4 CHECKING THE SPARK PLUGS .............

  • Page 204: Electrical Component

    – ELEC ELECTRICAL COMPONENT ELECTRICAL COMPONENT : Black Ignition coil : Brown Charge coil : Green Pulser coil : Blue CDI unit : White Engine stop switch B/O : Black/Orange Lighting coil B/W : Black/White W/B : White/Black W/R : White/Red...

  • Page 205: Electrical Components Analysis

    – ELEC ELECTRICAL COMPONENTS ANALYSIS ELECTRICAL COMPONENTS ANALYSIS DIGITAL CIRCUIT TESTER Digital circuit tester 90890-03174 NOTE: “ ” indicates a continuity of electric- ity which means a closed circuit at the respective switch position. MEASURING THE PEAK VOLTAGE WARNING When checking the peak voltage, do not touch any of the connections of the digital tester lead wires.

  • Page 206: Measuring A Low Resistance

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

  • Page 207: Ignition System

    – ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM : Black Spark plug : Brown Ignition coil : Blue Charge coil B/O : Black/Orange Pulser coil B/W : Black/White CDI unit W/B : White/Black W/R : White/Red...

  • Page 208: Checking The Spark Plugs

    – ELEC IGNITION SYSTEM CHECKING THE SPARK PLUGS Refer "CHECKING SPARK PLUGS" on page 3-22. Standard spark plug NGK B7HS-10 CHECKING THE IGNITION SPARK GAP WARNING • Do not touch any of the connections of the spark gap tester lead wires. •...

  • Page 209: Checking The Spark Plug Caps

    – ELEC IGNITION SYSTEM (4) Crank the engine and observe the spark through the discharge window of the ignition tester. NOTE: • If there is no spark or the spark is weak, check spark plug cap, ignition coil, pulser coil, charge coil and CDI unit. •...

  • Page 210: Checking The Ignition Coils

    – ELEC IGNITION SYSTEM (2) Press in the plug cap spring until it touches the high tension cable at then bend as shown. CHECKING THE IGNITION COILS 1. Check: • Ignition coil Crack/damage → Replace. 2. Measure: • Ignition coil resistance Out of specification →...

  • Page 211: Checking The Charge Coil

    – ELEC IGNITION SYSTEM CHECKING THE CHARGE COIL 1. Measure: • Charge coil resistance Out of specification → Check the peak voltage. Charge coil resistance Br - L 342 - 418 Ω Ω Ω Ω Measuring steps (1) Disconnect the Brown (Br) and Blue (L) leads from the wire harness.

  • Page 212: Checking The Pulser Coil

    – ELEC IGNITION SYSTEM CHECKING THE PULSER COIL 1. Measure: • Pulser coil resistance Out of specification → Check the peak voltage. Pulser coil resistance W/R - B (#1), W/B - B (#2) 311 - 381 Ω Ω Ω Ω Measuring steps (1) Disconnect the White/Red (W/R), White/ Black (W/B) and Black (B) leads from the...

  • Page 213: Cdi Unit

    – ELEC IGNITION SYSTEM CDI UNIT : Black CDI unit : Brown : Blue : White B/O : Black/Orange B/W : Black/White W/B : White/Black W/R : White/Red 8-10...

  • Page 214: Checking The Cdi Unit

    – ELEC IGNITION SYSTEM CHECKING THE CDI UNIT 1. Measure: • CDI unit resistance Out of specification → Check the peak voltage. Pocket tester 90890-03112 NOTE: • Digital circuit tester cannot be used for this check. Use analogue tester. • CDI resistance values will vary from meter to meter, especially with elec- tronic digital meters.
  • Page 215 – ELEC IGNITION SYSTEM 2. Measure: • CDI unit output peak voltage Below specification → Replace. CDI unit output peak voltage B/O - B, B/W - B C C C C r r r r a a a a n n n n k k k k i i i i n n n n g g g g 1 1 1 1 , , , , 5 5 5 5 0 0 0 0 0 0 0 0 3 3 3 3 , , , , 5 5 5 5 0 0 0 0 0 0 0 0 r r r r / / / / m m m m i i i i n n n n...

  • Page 216: Ignition Control System

    – ELEC IGNITION CONTROL SYSTEM IGNITION CONTROL SYSTEM WIRING DIAGRAM : Black CDI unit : White Engine stop switch 8-13...

  • Page 217: Checking The Engine Stop Switch

    – ELEC IGNITION CONTROL SYSTEM CHECKING THE ENGINE STOP SWITCH Check: • Continuity Out of specification → Replace. Lead color White Black Remove the lock-plate Install the lock-plate Push the button 8-14...

  • Page 218: Charging System

    – ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM : Green Lighting coil 8-15...

  • Page 219: Checking The Lighting Coil

    – ELEC CHARGING SYSTEM CHECKING THE LIGHTING COIL 1. Measure: • Lighting coil resistance Out of specification → Checking the peak voltage. Lighting coil resistance: G – G 0.31 - 0.37 Ω Ω Ω Ω Measuring steps (1) Connect the tester to the lighting coil as shown.

  • Page 221: Trouble Analysis

    TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................9-1 TROUBLE ANALYSIS CHART ..............9-1 TROUBLE SHOOTING FOR PEAK VOLTAGE ..........9-4...
  • Page 222 TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: The following items should be checked before the "TROUBLE ANALYSIS CHART" is con- sulted. 1. The battery is charged and its specific gravity is within specification. 2. There are no incorrect wiring connections. 3.
  • Page 223 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part Chapter : : : Seal Cylinder body Pistons Piston rings Crankcase Crankshaft Bearing Thermostat Water passage LOWER UNIT Neutral position Dog clutch Gears Water inlets Water pump Propeller shaft Propeller Shift rod joint/Pin Shift rod...
  • Page 224 TRBL TROUBLE ANALYSIS ANLS Trouble mode Check elements Reference Relative part Chapter • Ignition coils • Charge coil : : : • Pulser coil : : : • CDI unit Ignition control system • Engine stop switch Charging system • Lighting coil...
  • Page 225 TRBL TROUBLE SHOOTING FOR PEAK VOLTAGE ANLS TROUBLE SHOOTING FOR PEAK VOLTAGE Items Symptoms Poor starting • No firing. The starter motor cranks the engine, but no firing takes place in the cylinder. • Firing takes place in the cylinder, but the engine stops soon. •...
  • Page 228 YAMAHA MOTOR CO., LTD. Printed in Japan Oct. 2000-0.3 × 1 (EK25BMH) Printed on recycled paper...
  • Page 229 WIRING DIAGRAM EK25BMH Black Brown Green Blue White Black/orange Black/white Green/white White/black White/red Charge coil Pulser coil Ignition coil Ignition coil CDI unit Engine stop switch...

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