SELVA MARINE Wahoo 15 Service Manual
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SELVA MARINE Wahoo 15 Service Manual

SELVA MARINE Wahoo 15 Service Manual

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Wahoo 15
Wahoo 20
SERVICE MANUAL

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Summary of Contents for SELVA MARINE Wahoo 15

  • Page 1 Wahoo 15 Wahoo 20 SERVICE MANUAL...

  • Page 2: Important Information

    NOTICE This manual has been prepared by Selva primarily for use by Selva dealers and their trained mechanics when performing maintenance procedures and repairs to Selva equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.

  • Page 3: Table Of Contents

    Contents General information INFO Specification SPEC Periodic check and adjustment Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical system ELEC Troubleshooting TRBL SHTG Index...
  • Page 5 INFO General information How to use this manual ................. 1-1 Manual format.................... 1-1 Symbol....................... 1-2 Abbreviation....................1-3 Sealant and locking agent table ..............1-3 Safety while working..................1-4 Fire prevention................... 1-4 Ventilation....................1-4 Self-protection ................... 1-4 Part, lubricant, and sealant................ 1-4 Good working practice................1-5 Disassembly and assembly ...............

  • Page 6: Gen Info

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. •...

  • Page 7: Specification

    How to use this manual Symbol The symbols below are designed to indicate the content of a chapter. General information Fuel system Bracket unit FUEL BRKT INFO Specification Power unit Electrical system – SPEC POWR ELEC Periodic check and adjustment Lower unit Troubleshooting TRBL...

  • Page 8: Abbreviation

    INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description American Petroleum Institute Bow end Cold Cranking Ampere Capacitor Discharge Ignition European Norm (European standard) Exhaust International Electrotechnical Commission Intake PORT Port side Society of Automotive Engineers STBD Starboard side Top Dead Center...

  • Page 9: Safety While Working

    How to use this manual / Safety while working Safety while working To prevent an accident or injury and to ensure quality service, follow the safety pro- cedures provided below. Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames.

  • Page 10: Good Working Practice

    INFO General information 6. Maintain good standards of personal and Disassembly and assembly industrial hygiene. 1. Use compressed air to remove dust and dirt during disassembly. Good working practice Special service tool 2. Apply engine oil to the contact surfaces Use the recommended special service tools of moving parts before assembly.

  • Page 11: Identification

    Safety while working / Identification Identification Model This manual covers the following models. Applicable model 1 Model name 2 Approved model code Serial number 3 Transom height 4 Serial number outboard motor serial number stamped on a label attached to the port Approved Starting clamp bracket.

  • Page 12: Special Service Tool

    INFO General information Special service tool Oil filter wrench Pilot screw adjusting tool 90890-01426 90890-03154 Digital tachometer Compression gauge 90890-06760 90890-03160 Timing light Flywheel holder 90890-03141 90890-06522 Leakage tester Flywheel puller 90890-06840 90890-06521 Vacuum/pressure pump gauge set Shaft holder 90890-06756 90890-06069 6AG3J11...
  • Page 13 Special service tool Valve spring compressor Valve seat cutter 90890-04019 90890-06312, 90890-06315, 90890-06323, 90890-06555, 90890-06818, 90890-06819 Valve spring compressor attachment 90890-06320 Needle bearing attachment 90890-06612, 90890-06613, 90890-06614, 90890-06616, 90890-06653 Valve guide remover/installer 90890-06801 Driver rod L3 90890-06652 Valve guide reamer 90890-06804 Piston slider 90890-06529...
  • Page 14 INFO General information Center bolt Driver rod LS 90890-06504 90890-06606 Bearing housing puller claw S Ball bearing attachment 90890-06564 90890-06632 Bearing puller assembly Drive shaft holder 1 90890-06535 90890-06515 Stopper guide stand Bushing attachment 90890-06538 90890-06649 Driver rod SS Bearing separator 90890-06604 90890-06534 6AG3J11...
  • Page 15 Special service tool Needle bearing attachment Bearing inner race attachment 90890-06617, 90890-06618 90890-06644 Bearing outer race attachment Shimming plate 90890-06625 90890-06701 Driver rod LL Digital caliper 90890-06605 90890-06704 Driver rod SL Backlash indicator 90890-06602 90890-06706 Bearing depth plate Magnet base plate 90890-06603 90890-07003 1-10...
  • Page 16 INFO General information Dial gauge set Ignition tester 90890-01252 90890-06754 Magnet base B 90890-06844 Power tilt wrench 90890-06560 Digital circuit tester 90890-03174 Peak voltage adapter B 90890-03172 1-11 6AG3J11...

  • Page 17: Propeller Selection

    Special service tool / Propeller selection / Predelivery check a Propeller diameter (in inches) Propeller selection b Propeller pitch (in inches) The performance of a boat and outboard c Propeller type (propeller mark) motor will be critically affected by the size and type of propeller you choose.

  • Page 18: Checking The Outboard Motor Mounting Height

    INFO General information Checking the outboard motor CAUTION: mounting height A protective covering 1 is installed on 1. Check that the anti-cavitation plate is the intake silencer when the outboard between the bottom of the boat and a motor is shipped from the factory and maximum of 25 mm (1 in) a below it.

  • Page 19: Checking The Gear Oil Level

    Predelivery check Setting the remote control cable NOTE: (remote control model) If the engine oil is below the minimum level mark a, add sufficient oil until the level is NOTE: between a and b. To adjust the throttle cable and shift cable, see “Adjusting the throttle cable (remote con- trol model)”...

  • Page 20: Checking The Gear Shift And Throttle Operation

    INFO General information 3. Check that the shift rod lever joint 5 is in È the neutral position as shown. Connect the shift cable 6 to the shift rod lever joint 5 and install the clip 7. S6AG1120 É S6AG1080 S6AG1280 È...

  • Page 21: Checking The Steering System

    Predelivery check 4. Set the shift lever to the forward or È reverse position, and then check that the starter handle cannot be pulled. If the starter rope can be pulled out normally, adjust the start-in-gear protection cable. (Manual starter model) S66T1060 É...

  • Page 22: Checking The Tilt System (Manual Tilt Model)

    INFO General information Checking the tilt system (manual tilt model) 1. Set the tilt lock lever 1 to the release position a and fully tilt the outboard motor up. Check that the outboard motor tilts up smoothly and automatically locks in 3 positions when it is tilted up.

  • Page 23: Checking The Engine Start Button Or Switch And Engine Stop Lanyard Switch

    Predelivery check Checking the engine start button or É switch and engine stop lanyard switch 1. Check that the engine starts when the engine start button is pushed. (Tiller han- dle model) Check that the engine starts when the engine start switch is turned to “START.” (Remote control model) S60V1070 È...

  • Page 24: Test Run

    INFO General information 2. 1 hour b at 3,000 r/min or 3/4 throttle 2. Check for water flow at the cooling water pilot hole. and 1 minute out of every 10 at full throt- tle. 3. 8 hours c with the engine at any speed. However, avoid operating at full throttle for more than 5 minutes at a time.
  • Page 25 Predelivery check CAUTION Transport and store the engine only as shown. Otherwise, engine damage could result from leaking oil. 6G8-13444-41 S6AG1240 1-20 6AG3J11...
  • Page 26 INFO General information — MEMO — 1-21 6AG3J11...
  • Page 27 SPEC Specification General specification..................2-1 Maintenance specification ................2-7 Power unit....................2-7 Fuel system ..................... 2-11 Lower unit ....................2-12 Electrical ....................2-12 Power unit....................2-16 Fuel system ..................... 2-19 Lower unit ....................2-20 Electrical ....................2-21 Dimension....................2-24 Tightening torque..................2-30 Specified torque..................2-30 General torque..................2-33 6AG3J11...

  • Page 28: Specification

    SPEC Specification General specification Model Item Unit 15E.B. 20EBT Dimension Overall length mm (in) 1,048 (41.3) Overall width mm (in) 420 (16.5) Overall height mm (in) 1,078 — 1,078 — (42.4) (42.4) mm (in) 1,205 (47.4) Transom height mm (in) —...
  • Page 29 General specification Model Item Unit 15E.B. 20EBT Advanced type Micro computer Ignition timing TDC ± 1.5 at 1,050 r/min Degree Maximum generator output V, A 12, 10.0 Spark plug DPR6EB-9 (NGK) Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump Fuel and oil Fuel type...
  • Page 30 SPEC Specification Model Item Unit 15E.B. 20EBT Electrical Battery minimum capacity CCA/EN — 347.0 — 347.0 20HR/IEC — 40.0 — 40.4 Electrolyte specific gravity at 20 °C (68 °F) — 1.280 — 1.280 6AG3J11...
  • Page 31 General specification Model Item Unit 20ET Dimension Overall length mm (in) 665 (26.2) Overall width mm (in) 390 (15.4) Overall height mm (in) 1,078 — 1,078 (42.4) (42.4) mm (in) 1,205 (47.4) Transom height mm (in) — (17.2) (17.2) (17.4) mm (in) (22.2) (22.4)
  • Page 32 SPEC Specification Model Item Unit 20ET Maximum generator output V, A 12, 10.0 Spark plug DPR6EB-9 (NGK) Cooling system Water Exhaust system Propeller boss Lubrication system Wet sump Fuel and oil Fuel type Regular unleaded gasoline Engine oil type 4-stroke motor oil (*1) Engine oil grade SE, SF, SG, SH, SJ, or SL...
  • Page 33 General specification Model Item Unit 20ET Electrical Battery minimum capacity CCA/EN 347.0 20HR/IEC 40.0 Electrolyte specific gravity at 20 °C (68 °F) 1.280 6AG3J11...

  • Page 34: Maintenance Specification

    SPEC Specification Maintenance specification Power unit Model Item Unit 15E.B. 20EBT Power unit Minimum compression (*1) pressure (kgf/cm , psi) (7.3, (8.6, (7.3, (8.6, 105.9) 124.7) 105.9) 124.7) (*2) Oil pressure 400 (4.0, 58.0) at engine idle speed (kgf/cm , psi) Cylinder head Warpage limit mm (in)
  • Page 35 Maintenance specification Model Item Unit 15E.B. 20EBT Camshaft journal diameter (C) mm (in) 21.967–21.980 (0.8648–0.8654) Camshaft journal diameter (D) mm (in) 33.935–33.955 (1.3360–1.3368) Camshaft runout limit mm (in) 0.03 (0.0012) Rocker arm shaft Outside diameter mm (in) 12.941–12.951 (0.5095–0.5099) Rocker arm Inside diameter mm (in) 13.000–13.018 (0.5118–0.5125)
  • Page 36 SPEC Specification Model Item Unit 15E.B. 20EBT Cylinder Bore size mm (in) 63.000–63.015 (2.4803–2.4809) Piston Piston diameter (D) mm (in) 62.950–62.965 (2.4783–2.4789) Measuring point (H) mm (in) 3.5 (0.14) (*1) Piston clearance mm (in) 0.035–0.065 (0.0014–0.0026) Piston pin boss bore mm (in) 16.004–16.015 (0.6301–0.6305) Oversize piston diameter...
  • Page 37 Maintenance specification Model Item Unit 15E.B. 20EBT Crankshaft Crankshaft journal diameter mm (in) 36.997–37.009 (1.4566–1.4570) Crankpin diameter mm (in) 33.997–34.009 (1.3385–1.3389) Crankpin width mm (in) 21.000–21.070 (0.8268–0.8295) Crankshaft runout limit mm (in) 0.05 (0.0020) Crankcase Crankshaft journal oil mm (in) 0.011–0.039 (0.0004–0.0015) (*1) clearance...

  • Page 38: Fuel System

    SPEC Specification Fuel system Model Item Unit 15E.B. 20EBT Carburetor ID mark (For Europe) 6AG10 6AG50 6AH10 6AH50 (For Oceania) 6AG20 6AG60 6AH20 6AH60 15.0 ± 1.0 (0.59 ± 0.04) Float height mm (in) Valve seat size mm (in) 1.0 (0.04) Main jet (M.J.) (For Europe) #112...

  • Page 39: Lower Unit

    Maintenance specification Lower unit Model Item Unit 15E.B. 20EBT Lower unit Holding pressure 100 (1.0, 14.5) (kgf/cm , psi) Gear backlash Pinion-to-forward gear mm (in) 0.18–0.87 (0.0071–0.0343) Pinion-to-reverse gear mm (in) 0.95–1.66 (0.0374–0.0654) Pinion shims 1.13, 1.20 Forward gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shims 0.1, 0.2, 0.3, 0.4, 0.5...
  • Page 40 SPEC Specification Model Item Unit 15E.B. 20EBT Charge coil output peak voltage (B/R – G/R) at cranking (unloaded) at cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) (*1) Charge coil resistance (B/R – G/R) Ω at 20 °C (68 °F) 25.5–34.5 CDI unit output peak voltage (O –...
  • Page 41 Maintenance specification Model Item Unit 15E.B. 20EBT Starter motor Type — Bendix — Bendix Output — 0.60 — 0.60 Cranking time limit Second — — Stator motor clearance mm (in) — 0.05– — 0.05– 0.25 0.25 (0.002– (0.002– 0.010) 0.010) Wear limit mm (in) —...
  • Page 42 SPEC Specification Model Item Unit 15E.B. 20EBT Power tilt motor Output — 0.18 Brushes Standard length mm (in) — 6.0 (0.24) Wear limit mm (in) — 3.0 (0.12) Commutator Standard diameter mm (in) — 16.5 (0.65) Wear limit mm (in) —...

  • Page 43: Power Unit

    Maintenance specification Power unit Model Item Unit 20ET Power unit Minimum compression 860 (8.6, 124.7) (*1) pressure (kgf/cm , psi) (*2) Oil pressure 400 (4.0, 58.0) at engine idle speed (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.10 (0.0039) (lines indicate straightedge position) Cylinder head journal inside...
  • Page 44 SPEC Specification Model Item Unit 20ET Rocker arm shaft Outside diameter mm (in) 12.941–12.951 (0.5095–0.5099) Rocker arm Inside diameter mm (in) 13.000–13.018 (0.5118–0.5125) Valve Valve clearance (cold) Intake mm (in) 0.15–0.25 (0.006–0.010) Exhaust mm (in) 0.25–0.35 (0.010–0.014) Head diameter (A) Intake mm (in) 27.9–28.1 (1.10–1.11)
  • Page 45 Maintenance specification Model Item Unit 20ET Piston Piston diameter (D) mm (in) 62.950–62.965 (2.4783–2.4789) Measuring point (H) mm (in) 3.5 (0.14) (*1) Piston clearance mm (in) 0.035–0.065 (0.0014–0.0026) Piston pin boss bore mm (in) 16.004–16.015 (0.6301–0.6305) Oversize piston diameter mm (in) 63.200–63.215 (2.4882–2.4888) mm (in) 63.450–63.465 (2.4980–2.4986)

  • Page 46: Fuel System

    SPEC Specification Model Item Unit 20ET Crankcase Crankshaft journal oil mm (in) 0.011–0.039 (0.0004–0.0015) (*1) clearance Upper and lower crankcase main journal bearing thickness A - (Blue) mm (in) 1.502–1.506 (0.0591–0.0593) B - (Black) mm (in) 1.498–1.502 (0.0590–0.0591) C - (Brown) mm (in) 1.494–1.498 (0.0588–0.0590) Oil pump...

  • Page 47: Lower Unit

    Maintenance specification Model Item Unit 20ET Fuel pump Fuel pump holding pressure Fuel inlet positive pressure 50 (0.5, 7.3) (kgf/cm , psi) Fuel inlet negative pressure 30 (0.3, 4.4) (kgf/cm , psi) Fuel outlet positive pressure 50 (0.5, 7.3) (kgf/cm , psi) Fuel joint holding pressure Positive pressure...

  • Page 48: Electrical

    SPEC Specification Electrical Model Item Unit 20ET Ignition and ignition control system Spark plug gap mm (in) 0.8–0.9 (0.031–0.035) Spark plug cap resistance kΩ 3.75–6.25 Ignition coil resistance Primary coil (O – B) Ω at 20 °C (68 °F) 0.26–0.35 Secondary coil (spark plug wire –...
  • Page 49 Maintenance specification Model Item Unit 20ET Fuel control system (*1) Prime Start resistance (L – L) Ω at 24 °C (75 °F) 16.4–24.8 (*1) Prime Start plunger length mm (in) 10.7 (0.42) Starting system Power bobbin output peak voltage (L – L) at cranking (unloaded) 10.3 at 1,500 r/min (unloaded)
  • Page 50 SPEC Specification Model Item Unit 20ET Charging system Fuse Lighting coil output peak voltage (G – G) at cranking (unloaded) 13.4 at 1,500 r/min (unloaded) 33.2 at 3,500 r/min (unloaded) 75.4 (*1) Lighting coil resistance (G – G) Ω at 20 °C (68 °F) 0.31–0.43 Rectifier Regulator output peak voltage...

  • Page 51: Dimension

    Maintenance specification Dimension Exterior 15M, 15EB, 20M mm (in) 45˚ 559 (22.0) S: 730 (28.7) L: 847 (33.3) 381 (15.0) 219 (8.6) 489 (19.3) 66 (2.6) 237 (9.3) 71˚ 12˚ –4˚ S: 9 (0.4) L: 18 (0.7) 387 (15.2) S6AG2010 2-24 6AG3J11...
  • Page 52 SPEC Specification Exterior F20BEHP 20EBT mm (in) 40˚ 559 (22.0) 840 (33.1) 356 (14.0) 220(8.7) 448 (17.6) 67 (2.6) (6.9) 67˚ –4˚ 18 (0.7) 386 (15.2) S6AG2020 2-25 6AG3J11...
  • Page 53 Maintenance specification Exterior F15CE, F20BE 15E, 20E mm (in) 45˚ S: 730 (28.7) L: 847 (33.3) 321 (12.6) 176 (6.9) 489 (19.3) 66 (2.6) 184 (7.2) 71˚ S: 9 (0.4) –4˚ L: 18 (0.7) 387 (15.2) S6AG2030 2-26 6AG3J11...
  • Page 54 SPEC Specification Exterior 20ET F15CEP, F20BEP mm (in) 40˚ S: 727 (28.6) L: 840 (33.1) 309 (12.2) 176 (6.9) 488 (19.2) 67 (2.6) 188 (7.4) S: 63˚ 12˚ L: 67˚ L: –4˚ L: 18 (0.7) 386 (15.2) S6AG2040 2-27 6AG3J11...
  • Page 55 Maintenance specification Clamp bracket 15M, 15EB, 15E, 20M, 20E mm (in) 70.5 (2.8) 70.5 (2.8) 8.3 (0.3) 95.3 (3.8) 95.3 (3.8) 110 (4.3) S6AG2050 2-28 6AG3J11...
  • Page 56 SPEC Specification Clamp bracket 20E.B.T., 20E.ST.T mm (in) 95.3 (3.8) 95.3 (3.8) 73.5 (2.9) 73.5 (2.9) 8.3 (0.3) 8.3 (0.3) 67 (2.6) 95.3 (3.8) 95.3 (3.8) 38 (1.5) 111 (4.4) 111 (4.4) S6AG2060 2-29 6AG3J11...

  • Page 57: Tightening Torque

    Maintenance specification / Tightening torque Tightening torque Specified torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Fuel filter cup — 0.25 1.84 Fuel filter assembly bracket bolt 13.3 Fuel joint bolt Fuel pump screw Fuel pump valve screw 0.05 0.37...
  • Page 58 SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Wiring harness bracket bolt (manual starter 13.3 model) Throttle cam bracket bolt Throttle cam bolt Throttle cable bracket bolt (tiller handle model) Flywheel magnet nut — 10.8 79.7 Drive sprocket nut —...
  • Page 59 Tightening torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Grommet screw Throttle cable holder bolt (tiller handle model) Shift lever bolt (tiller handle model) Tiller handle bracket cover bolt (tiller handle model) Throttle pulley holder bolt (tiller handle model) Tiller handle throttle pulley screw (tiller handle model) Power tilt switch screw (power tilt model)

  • Page 60: General Torque

    SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Gear housing bolt Tilt piston bolt Tilt cylinder end screw — 44.3 Tilt ram — 33.2 General torque This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
  • Page 61 Periodic check and adjustment Maintenance interval chart................3-1 Top cowling ....................3-2 Checking the top cowling................3-2 Fuel system ....................3-2 Checking the fuel joint and fuel hose (fuel joint-to-carburetor) ....3-2 Checking the fuel filter ................3-3 Draining the fuel ..................3-3 Power unit.......................

  • Page 62: Chk Adj

    Periodic check and adjustment Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours page...

  • Page 63: Top Cowling

    Maintenance interval chart / Top cowling / Fuel system Top cowling Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. S6AG3010 2. Loosen the bolts 1. 3. Move the hook 2 up or down slightly to S6AG3030 adjust its position.

  • Page 64: Power Unit

    Periodic check and adjustment Checking the fuel filter 3. Remove the oil dipstick again to check 1. Check the fuel filter element 1. Clean if the oil level and to check the oil for dis- coloration and its viscosity. there is dirt or residue and replace if damaged.

  • Page 65: Replacing The Oil Filter

    Fuel system / Power unit S6AG3080 S6AG3090 NOTE: NOTE: • Be sure to clean up any oil spills. • Wait more than 5 minutes after turning the • When using an oil changer to change the engine off to replace the oil filter. engine oil, insert the oil changer hose into •...

  • Page 66: Checking The Timing Belt

    Periodic check and adjustment 6. Install the oil filler cap and oil dipstick, and then start the engine and warm it up. 7. Turn the engine off, and then check the oil level and that there is no oil leakage. If the oil level is low, add engine oil to the correct level.

  • Page 67: Checking The Thermostat

    Power unit Checking the thermostat 1. Remove the sprocket cover and manual starter. (Manual starter model) Remove the sprocket cover and flywheel magnet cover. (Electric starter model) 2. Remove the thermoswitch and discon- nect the cooling water hose. NOTE: S69J5E40 To remove the manual starter or flywheel 6.

  • Page 68: Checking The Cooling Water Passage

    Periodic check and adjustment Checking the cooling water passage Control system 1. Check the cooling water inlet covers 1 Adjusting the throttle cable (tiller and cooling water inlets, clean if clogged. handle model) 1. Disconnect the throttle link rod 1 from the free accel lever.

  • Page 69: Adjusting The Throttle Cable (Remote Control Model)

    Power unit / Control system 6. Turn the throttle grip to the fully open and fully closed positions and check that the fully open stopper a and fully closed stopper b on the throttle cam contact throttle cam bracket as shown. Repeat steps 2–5 if necessary.

  • Page 70: Adjusting The Throttle Link

    Periodic check and adjustment 7. Set the remote control lever to the fully 2. Turn the throttle grip (tiller handle model) open and fully closed positions and or remote control lever (remote control check that the fully open stopper c and model) to the fully open position and hold fully closed stopper a on the throttle it in place.

  • Page 71: Checking The Gear Shift Operation (Remote Control Model)

    Control system Checking the gear shift operation (remote control model) 1. Check that the gear shift operates smoothly when the remote control lever is shifted from neutral position to forward or reverse. Adjust the shift cable length and shift rod adjusting nut if necessary. 2.

  • Page 72: Checking The Start-In-Gear Protection (Manual Starter Model)

    Periodic check and adjustment 6. Adjust the shift rod adjusting nut 4. S6AG3470 NOTE: To adjust the shift rod adjusting nut, see “Installing the lower unit” (6-17). 7. Check the gear shift for smooth opera- S6AG3140 tion. Checking the engine idle speed Checking the start-in-gear protection 1.

  • Page 73: Checking The Ignition Timing

    Control system Engine idle speed: 1,050 ± 50 r/min 3. Turn the throttle stop screw 2 in direc- tion a or b until the specified engine idle speed is obtained. S6AG3180 Timing light: 90890-03141 3. Check that the pointer a is aligned with the “T”...

  • Page 74: Bracket Unit

    Periodic check and adjustment Bracket unit Checking the tilt operation (power tilt model) Checking the steering operation 1. Fully tilt the outboard motor up and down (tiller handle model) a few times and check the entire tilt NOTE: range for smooth operation. Check the Lubricate the swivel bracket before checking power tilt fluid level if necessary.

  • Page 75: Lower Unit

    Bracket unit / Lower unit NOTE: • If the oil is at the correct level, a small amount of oil should overflow out of the check hole when the gear oil check screw is removed. • If the oil appears milky or dirty, check for and repair the cause, and then change the oil.

  • Page 76: Checking The Lower Unit For Air Leakage

    Periodic check and adjustment 3. Check the oil for metal, discoloration, and its viscosity. Check the internal parts of the lower case if necessary. 4. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill with gear oil until oil flows out of the check hole and no air bubbles are visible.

  • Page 77: General

    Lower unit / General General È Checking the anode 1. Check the anodes. Clean the anodes if there are scales, grease, or oil. S6AG3280 È Power tilt model S6AG3260 S6AG3320 CAUTION: Do not oil, grease, or paint the anodes, otherwise they will be ineffective. NOTE: •...

  • Page 78: Checking The Battery

    Periodic check and adjustment Checking the battery WARNING 1. Check the battery electrolyte level. If the Battery electrolyte is dangerous; it con- level is at or below the minimum level mark a, add distilled water until the level tains sulfuric acid which is poisonous and highly caustic.

  • Page 79: Lubricating The Outboard Motor

    General Lubricating the outboard motor 1. Apply water resistant grease to the areas shown. S6AG3450 S6AG3290 3. Apply corrosion resistant grease to the area shown. S6AG3440 È S6D53290 È Tiller handle model NOTE: Apply grease until it flows from the bushings 2.
  • Page 80 Periodic check and adjustment — MEMO — 3-19 6AG3J11...

  • Page 81: Fuel

    FUEL Fuel system Hose routing ....................4-1 Fuel hose, blowby hose, and cooling water hose........4-1 Fuel filter ......................4-2 Checking the fuel filter assembly............... 4-3 Checking the fuel joint ................4-3 Fuel pump ....................... 4-4 Checking the fuel pump................4-6 Disassembling the fuel pump ..............4-6 Checking the diaphragm and valve ............

  • Page 82: Fuel System

    FUEL Fuel system Hose routing Fuel hose, blowby hose, and cooling water hose È È É É S6AG4280 1 Cooling water hose (exhaust cover-to-joint) 0 Fuel hose (fuel filter assembly-to-fuel pump) 2 Cooling water hose (exhaust cover-to-joint) A Fuel hose (fuel pump-to-carburetor assembly) 3 Cooling water hose (joint-to-joint) 4 Cooling water hose (joint-to-fuel pump) 5 Cooling water hose...

  • Page 83: Fuel Filter

    Hose routing / Fuel filter Fuel filter · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.8 kgf m, 5.9 ft · · · 2.5 N m (0.25 kgf m, 1.84 ft S6AG4020 Part name Q’ty Remarks M8 ×...

  • Page 84: Checking The Fuel Filter Assembly

    FUEL Fuel system Checking the fuel filter assembly 3. Apply the specified positive pressure. Replace the fuel joint if the specified NOTE: pressure cannot be maintained for at To check the fuel filter element, see “Check- least 10 seconds. ing the fuel filter” (3-3). 1.

  • Page 85: Fuel Pump

    Fuel filter / Fuel pump Fuel pump O U T S6AG4030 Part name Q’ty Remarks Fuel pump Fuel hose Cooling water hose M6 × 30 mm Bolt Cooling water hose Fuel hose O-ring Not reusable Holder Clamp Plastic tie 6AG3J11...
  • Page 86 FUEL Fuel system · · · m (0.2 kgf m, 1.5 ft · · · 0.5 N m (0.05 kgf m, 0.37 ft · · · m (0.2 kgf m, 1.5 ft S6AG4040 Part name Q’ty Remarks ø4 × 30 mm Screw Cover Diaphragm...

  • Page 87: Checking The Fuel Pump

    Fuel pump Checking the fuel pump 1. Connect the special service tool to the fuel pump inlet. 2. Cover the fuel pump outlet with your fin- ger, and then apply the specified positive pressure. Check that there is no air leak- age.

  • Page 88: Checking The Diaphragm And Valve

    FUEL Fuel system 2. Remove the pin 1 from the plunger 2, Assembling the fuel pump and then disassemble the fuel pump body 1 3. NOTE: Clean the parts and soak the valves and the diaphragms in gasoline before assembly. 1.
  • Page 89 Fuel pump S6AG4160 NOTE: • Moisten the inside of the fuel pump with gasoline to ensure a good seal. • Make sure that the diaphragms are kept in place through the assembly process. • After disassembling and assembling the fuel pump, check it for air leaks. See “Checking the fuel pump”...

  • Page 90: Carburetor Unit

    FUEL Fuel system Carburetor unit S6AG4010 Part name Q’ty Remarks Intake silencer Blowby hose Carburetor assembly Gasket Not reusable Spacer Grommet M6 × 100 mm Bolt Bolt O-ring Not reusable Plastic tie Throttle link rod Clamp 6AG3J11...

  • Page 91: Carburetor

    Carburetor unit Carburetor · · · m (0.1 kgf m, 0.7 ft S6AG4050 Part name Q’ty Remarks ø4 × 5 mm Screw ø4 × 10 mm Screw Retainer Prime Start O-ring Not reusable ø4 × 10 mm Screw Cover Gasket Not reusable Throttle stop screw Spring...
  • Page 92 FUEL Fuel system · · · m (0.1 kgf m, 0.7 ft S6AG4050 Part name Q’ty Remarks Gasket Not reusable Plunger rod Plunger Spring Circlip Ball Drain screw ø4 × 13 mm Screw ø4 × 7 mm Screw Float Needle valve Main jet Main nozzle Pilot jet...

  • Page 93: Removing The Carburetor

    Carburetor unit Removing the carburetor Checking the carburetor 1. Disconnect the fuel hose 1, and the 1. Check the air and fuel passages and jets. blowby hose 2. Clean the carburetor body if there is dirt or foreign material. 2. Blow compressed air into all passages and jets.

  • Page 94: Checking The Prime Start

    FUEL Fuel system 6. Measure the float height a. Replace the float 1 or needle valve 2 if out of speci- Prime Start plunger length before supplying power (reference data): fication. 10.7 mm (0.42 in) at 24 °C (75 °F) 3.

  • Page 95: Installing The Carburetor

    Carburetor unit Installing the carburetor 1. Install the new gaskets 1, spacer 2, carburetor assembly 3, and intake silencer 4 with the bolts 5. NOTE: Install the fuel filter after tightening the bolts and fastening the Prime Start lead with the holder.

  • Page 96: Adjusting The Pilot Screw

    FUEL Fuel system Adjusting the pilot screw É 1. Adjust the throttle stop screw. NOTE: If the carburetor was disassembled, turn the throttle stop screw in until it contacts the car- buretor throttle lever, and then turn it in about 1 3/4 turns to tighten it temporarily.
  • Page 97 Carburetor unit NOTE: • To increase the engine idle speed, turn the throttle stop screw 3 in direction c. • To decrease the engine idle speed, turn the throttle stop screw 3 in direction d. Engine idle speed: 1,050 ± 50 r/min 6.

  • Page 98: Powr

    POWR Power unit Power unit (check and adjustment).............. 5-1 Checking the compression pressure ............5-1 Checking the oil pressure ................5-1 Checking the valve clearance..............5-2 Replacing the timing belt ................5-3 Manual starter (manual starter model)............5-7 Disassembling the manual starter ............. 5-9 Assembling the manual starter ..............5-10 Power unit.....................
  • Page 99 Cylinder block ....................5-49 Disassembling the cylinder block ............5-51 Checking the piston diameter ..............5-52 Checking the cylinder bore ..............5-52 Checking the piston clearance ..............5-52 Checking the piston ring ................5-53 Checking the piston ring end gap ............5-53 Checking the piston ring groove ..............5-53 Checking the piston ring side clearance..........

  • Page 100: Power Unit

    POWR Power unit Power unit (check and Minimum compression pressure adjustment) (reference data): Checking the compression pressure 730 kPa (7.3 kgf/cm , 105.9 psi) 1. Start the engine, warm it up, and then (Manual starter model) turn it off. 860 kPa (8.6 kgf/cm , 124.7 psi) (Electric starter model) 2.

  • Page 101: Checking The Valve Clearance

    Power unit (check and adjustment) NOTE: Because the Prime Start operates when the engine is started, the engine idle speed will be above specification. Therefore, measure the oil pressure after the engine has been warmed up. 3. Measure the oil pressure. Check the oil pump and oil strainer, and for oil leakage if out of specification.

  • Page 102: Replacing The Timing Belt

    POWR Power unit 6. Loosen the rocker arm locknut 7, and Replacing the timing belt then turn the adjusting screw 8 until the CAUTION: specified valve clearance is obtained. Do not turn the flywheel magnet counter- clockwise, otherwise the water pump impeller may be damaged.
  • Page 103 Power unit (check and adjustment) NOTE: Use a 24 mm socket to loosen the flywheel magnet nut. Flywheel holder: 90890-06522 4. Remove the flywheel magnet and Woo- S6AG5090 druff key. ” mark a on the driven 6. Align the “1 sprocket 4 with the “...
  • Page 104 POWR Power unit 7. Remove the timing belt 5 from the 9. Turn the drive sprocket clockwise 2 driven sprocket, and then remove it from turns, and then check that the alignment marks f and g are aligned. the drive sprocket. S6AG5101 S6AG5100 10.
  • Page 105 Power unit (check and adjustment) 12. Tighten the flywheel magnet nut to the specified torque. S6AG5G40 WARNING Apply force in the direction of the arrows shown to prevent the flywheel holder from slipping off easily. Flywheel holder: 90890-06522 Flywheel magnet nut 0: 108 N·m (10.8 kgf·m, 79.7 ft·lb) 13.

  • Page 106: Manual Starter (Manual Starter Model)

    POWR Power unit Manual starter (manual starter model) · · · m (0.8 kgf m, 5.9 ft · · · 1.5 N m (0.15 kgf m, 1.11 ft · · · m (0.7 kgf m, 5.2 ft S6AG5500J Part name Q’ty Remarks Cover...
  • Page 107 Manual starter (manual starter model) · · · m (0.8 kgf m, 5.9 ft · · · 1.5 N m (0.15 kgf m, 1.11 ft · · · m (0.7 kgf m, 5.2 ft S6AG5500J Part name Q’ty Remarks Starter rope 1,800 mm (70.9 in) Start-in-gear protection cable M6 ×...

  • Page 108: Disassembling The Manual Starter

    POWR Power unit 4. Remove the starter rope 5 and E-clip 6, Disassembling the manual starter and then remove the drive pawl 7 and 1. Remove the drive plate 1 and drive pawl springs 8 from the sheave drum. spring 1 2. S6AG5510 WARNING The sheave drum can pop out.

  • Page 109: Assembling The Manual Starter

    Manual starter (manual starter model) 4. Wind the starter rope 1 twice around the 9. Check the starter handle. Replace if sheave drum 2 in the direction of the cracked or damaged. arrow shown in the illustration. 10. Check the starter rope. Replace if dam- aged.
  • Page 110 POWR Power unit 6. Install the sheave drum 2 into the man- NOTE: ual starter cover 9. Hold the starter plunger C while turning the sheave drum as shown. 9. Remove the starter rope from the notch b, and then fit the starter rope into the groove in the sheave drum.
  • Page 111 Manual starter (manual starter model) NOTE: • Route the start-in-gear protection cable in its original position. • To adjust the start-in-gear protection cable, see “Checking the start-in-gear protection (manual starter model)” (3-11). 12. Pull the starter handle completely, and then measure the starter rope length g. S6AG5630 Starter rope pulling length g: 1,400–1,600 mm (55.12–62.99 in)

  • Page 112: Power Unit

    POWR Power unit Power unit Power unit assembly (tiller handle model) · · · m (0.8 kgf m, 5.9 ft 19 32 · · · 27 N m (2.7 kgf m, 19.9 ft · · · 27 N m (2.7 kgf m, 19.9 ft ·...
  • Page 113 Power unit · · · m (0.8 kgf m, 5.9 ft 19 32 · · · 27 N m (2.7 kgf m, 19.9 ft · · · 27 N m (2.7 kgf m, 19.9 ft · · · 2.5 N m (0.25 kgf m, 1.84 ft S6AG5G80...

  • Page 114: Power Unit Assembly (Remote Control Model)

    POWR Power unit Power unit assembly (remote control model) · · · 27 N m (2.7 kgf m, 19.9 ft · · · 27 N m (2.7 kgf m, 19.9 ft · · · 2.5 N m (0.25 kgf m, 1.84 ft S6AG5G90 Part name Q’ty...
  • Page 115 Power unit · · · 27 N m (2.7 kgf m, 19.9 ft · · · 27 N m (2.7 kgf m, 19.9 ft · · · 2.5 N m (0.25 kgf m, 1.84 ft S6AG5G90 Part name Q’ty Remarks ø6 ×...

  • Page 116: Ignition Coil And Rectifier Regulator

    POWR Power unit Ignition coil and Rectifier Regulator · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.7 kgf m, 5.2 ft · · · 17 N m (1.7 kgf m, 12.5 ft S6AG5740...

  • Page 117: Cdi Unit And Junction Box (Manual Tilt Model)

    Power unit CDI unit and junction box (manual tilt model) · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft ·...
  • Page 118 POWR Power unit · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft · ·...

  • Page 119: Cdi Unit And Junction Box (Power Tilt Model)

    Power unit CDI unit and junction box (power tilt model) · · · m (0.8 kgf m, 5.9 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft ·...
  • Page 120 POWR Power unit · · · m (0.8 kgf m, 5.9 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft · ·...

  • Page 121: Bracket (Manual Starter Model)

    Power unit Bracket (manual starter model) · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.8 kgf m, 5.9 ft ·...
  • Page 122 POWR Power unit · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.8 kgf m, 5.9 ft ·...

  • Page 123: Bracket (Electric Starter Model)

    Power unit Bracket (electric starter model) · · · · · · m (0.8 kgf m, 5.9 ft m (0.8 kgf m, 5.9 ft · · · m (0.4 kgf m, 3.0 ft · · · 30 N m (3.0 kgf m, 22.1 ft 18 19 ·...
  • Page 124 POWR Power unit · · · · · · m (0.8 kgf m, 5.9 ft m (0.8 kgf m, 5.9 ft · · · m (0.4 kgf m, 3.0 ft · · · 30 N m (3.0 kgf m, 22.1 ft 18 19 ·...

  • Page 125: Throttle Cam

    Power unit Throttle cam · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft S6AG5750 Part name Q’ty Remarks Bracket M6 × 14 mm Bolt Throttle cam Shaft...

  • Page 126: Removing The Power Unit

    POWR Power unit Removing the power unit È 1. Disconnect the start-in-gear protection cable, and then remove the sprocket cover and manual starter. (Manual starter model) Remove the sprocket cover and flywheel magnet cover. (Electric starter model) NOTE: Before removing the flywheel magnet cover, remove the junction box bracket bolts.
  • Page 127 Power unit 7. Remove the warning indicator assembly H and bracket I. S6AG5D09 8. Disconnect the throttle cables from the throttle cam. (Tiller handle model) Disconnect the cable joint from the throt- tle cam. (Remote control model) S6AG5D70 9. Remove the bolts J, and then remove the shift rod cam K.

  • Page 128: Timing Belt And Sprocket

    POWR Power unit Timing belt and sprocket · · · 108 N m (10.8 kgf m, 79.7 ft · · · 22 N m (2.2 kgf m, 16.2 ft · · · m (0.8 kgf m, 5.9 ft · · ·...

  • Page 129: Removing The Timing Belt And Sprocket

    Timing belt and sprocket Removing the timing belt and sprocket 1. Remove the flywheel magnet and stator coil assembly. NOTE: See “Replacing the timing belt” (5-3). ” mark a on the driven 2. Align the “1 S6AG5H90 sprocket 1 with the “ ” mark b on the cylinder head.

  • Page 130: Checking The Timing Belt And Sprocket

    POWR Power unit 5. Hold the driven sprocket using the spe- cial service tool 4, and then remove the Shaft holder 5: 90890-06069 driven sprocket bolt 3. 8. Remove retaining plate, drive sprocket, and Woodruff key. Checking the timing belt and sprocket 1.
  • Page 131 Timing belt and sprocket S6AG5A80 S6AG5B40 3. Install the power unit onto the special 5. Hold the driven sprocket using the spe- service tool 5, and then tighten the drive cial service tool A, and then tighten the sprocket nut 4 to the specified torque. driven sprocket bolt 0 to the specified torque.
  • Page 132 POWR Power unit ” mark c on the driven 6. Align the “1 sprocket 8 with the “ ” mark d on the CAUTION: cylinder head. • Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of 25 mm (1.0 in), otherwise it can be dam- aged.

  • Page 133: Cylinder Head

    Timing belt and sprocket / Cylinder head Cylinder head · · · · · · m (0.8 kgf m, 5.9 ft m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft · · · 18 N m (1.8 kgf m, 13.3 ft ·...
  • Page 134 POWR Power unit For Europe · · · 14 N m (1.4 kgf m, 10.3 ft 17 16 17 16 S6AG5660 Part name Q’ty Remarks Cylinder head Valve spring seat Shaft Intake valve Exhaust valve Valve spring Valve spring retainer Valve cotter Valve seal Not reusable...
  • Page 135 Cylinder head For Europe · · · 14 N m (1.4 kgf m, 10.3 ft 17 16 17 16 S6AG5660 Part name Q’ty Remarks Camshaft F15/F20 (For Europe) Oil seal Not reusable Valve guide Not reusable Gasket Not reusable Spring 5-36 6AG3J11...

  • Page 136: Removing The Cylinder Head

    POWR Power unit Removing the cylinder head 1. Remove the cylinder head cover. 2. Remove the cylinder head bolts in the sequence shown. S6AG5160 NOTE: • Loosen the locknut and adjust screw to slack off the tension, before remove the rocker arm shaft.

  • Page 137: Checking The Cylinder Head

    Cylinder head NOTE: Be sure to keep the valves, springs, and other parts in the order as they were removed. Valve spring compressor 9: 90890-04019 Valve spring compressor S68V5775 attachment 0: 90890-06320 Valve spring free length a: Checking the cylinder head 32.63 mm (1.2846 in) 1.

  • Page 138: Checking The Valve

    POWR Power unit Checking the valve 1. Check the valve face. Replace the valve if pitted or worn. 2. Measure the valve margin thickness a. Replace the valve if out of specification. Valve stem runout limit: 0.01 mm (0.0004 in) Checking the valve guide NOTE: Valve margin thickness a:...

  • Page 139: Replacing The Valve Guide

    Cylinder head Valve guide remover/installer 3: Valve-stem-to-valve-guide clearance = valve guide inside diameter – valve 90890-06801 stem diameter: Intake: Valve guide height a: 0.010–0.037 mm Intake and exhaust: (0.0004–0.0015 in) 10.8 ± 0.2 mm (0.4 ± 0.01 in) Exhaust: 0.025–0.052 mm 4.

  • Page 140: Refacing The Valve Seat

    POWR Power unit 3. Press the valve slowly against the valve Refacing the valve seat seat with a valve lapper as shown. 1. Reface the valve seat with the valve seat cutters. S6AG5200 4. Measure the valve seat contact width a where the blueing dye is adhered to the Valve seat cutter holder: valve face.
  • Page 141 Cylinder head 6. Check the valve seat contact area of the CAUTION: valve. Do not over cut the valve seat. Be sure to NOTE: turn the cutter evenly downward at a pres- To check the valve seat contact area, see sure of 40–50 N (4–5 kgf, 8.8–11 lbf) to “Checking the valve seat”...

  • Page 142: Checking The Rocker Arm And Rocker Arm Shaft

    POWR Power unit 9. If the valve seat contact area is too nar- Checking the rocker arm and rocker row and situated near the bottom edge of arm shaft the valve face, use a 60° cutter to cut the 1. Check the rocker arms, rocker arm shaft, bottom edge of the valve seat, and then and rocker arm contact surface a.

  • Page 143: Assembling The Cylinder Head

    Cylinder head Cam lobe a: Camshaft journal diameter c: Intake: 21.967–21.980 mm 28.546–28.646 mm (0.8648–0.8654 in) Camshaft journal diameter d: (1.1239–1.1278 in) Exhaust: 33.935–33.955 mm 28.582–28.682 mm (1.3360–1.3368 in) (1.1253–1.1292 in) Cylinder head journal inside Cam lobe b: diameter e: Intake and exhaust: 22.000–22.021 mm 23.95–24.05 mm...
  • Page 144 POWR Power unit 2. Install the valve 2, valve spring seat 3, valve spring 4, and valve spring retainer 5 in the sequence shown, and then attach the special service tools. S6AG5300 S6AG5310 5. Install a new oil seal 9. S6AG5290 NOTE: Face the wide pitch spring end a, identified...
  • Page 145 Cylinder head S6AG5340 S6AG5380 7. Align the keyway b in the camshaft with the mark c on the cylinder head as shown. S6AG5350 S6AG5390 8. Install the rocker arms C, springs D, NOTE: and collars E into the cylinder head, and •...

  • Page 146: Installing The Cylinder Head

    POWR Power unit Installing the cylinder head 1. Install a new gasket and the cylinder head, and then tighten the bolts to the specified torques sequence shown. S6AG5430 2. Check the inner surface of the oil pump case. Replace the oil pump assembly if scratched.
  • Page 147 Cylinder head Clearance a: 0.09–0.15 mm (0.0035–0.0059 in) Clearance b: Within 0.12 mm (0.0047 in) Clearance c: 0.03–0.08 mm (0.0012–0.0031 in) 4. Assemble the oil pump, and then tighten the oil pump screws 1 to the specified torque. S6AG5670 NOTE: When assembling the oil pump, face the “C”...

  • Page 148: Cylinder Block

    POWR Power unit Cylinder block · · · m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft S518 · · · 14 N m (1.4 kgf m, 10.3 ft · · · 27 N m (2.7 kgf m, 19.9 ft S518...
  • Page 149 Cylinder block · · · m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft S518 · · · 14 N m (1.4 kgf m, 10.3 ft · · · 27 N m (2.7 kgf m, 19.9 ft S518 20 19...

  • Page 150: Disassembling The Cylinder Block

    POWR Power unit Disassembling the cylinder block 5. Remove the connecting rod cap bolts and connecting rod caps, and then 1. Remove the exhaust cover bolts in the remove the connecting rod and piston sequence shown, and then remove the assemblies.

  • Page 151: Checking The Piston Diameter

    Cylinder block Checking the piston diameter Cylinder bore (D –D 1. Measure the piston diameter at the spec- 63.000–63.015 mm ified measuring point. Replace if out of (2.4803–2.4809 in) specification. Checking the piston clearance 1. Check the piston clearances if replacing the piston, the piston ring set, the cylin- der block, or all parts.

  • Page 152: Checking The Piston Ring

    POWR Power unit Checking the piston ring 1. Measure the piston ring dimensions B and T. Replace the piston ring set if out of specification. Piston ring dimensions: Top ring a: B: 1.17–1.19 mm S6AG5860 (0.0461–0.0469 in) NOTE: T: 2.30–2.50 mm The figures are for reference only.

  • Page 153: Checking The Piston Ring Side Clearance

    Cylinder block Checking the piston pin boss bore 1. Measure the piston pin boss bore. Replace the piston if out of specification. Piston ring groove: Top ring a: S6AG5890 1.21–1.23 mm NOTE: (0.0476–0.0484 in) When measuring the piston pin boss bore, do 2nd ring b: not measure it at the ring groove a.

  • Page 154: Checking The Connecting Rod Big End Side Clearance

    POWR Power unit 2. Measure the connecting rod small end inside diameter a and big end inside diameter b. Replace the connecting rod if out of specification. S6AG5910 S6AG5H70 Connecting rod small end inside diameter a: 16.015–16.029 mm (0.6305–0.6311 in) S6AG5920 Connecting rod big end inside diameter b:...

  • Page 155: Checking The Crankshaft Journal Oil Clearance

    Cylinder block 2. Put a piece of Plastigauge (PG-1) onto the crankpin, parallel to the crankshaft. NOTE: Do not turn the connecting rod until the crankpin oil clearance measurement has NOTE: Be sure not to put the Plastigauge (PG-1) been completed. over the oil hole in the crankpin of the crank- shaft.
  • Page 156 POWR Power unit 3. Install half of the main bearings 1 and 6. Install the crankcase onto the cylinder the crankshaft 2 into the cylinder block block. NOTE: Apply engine oil to the threads of the crank- case bolts. 7. Tighten the crankcase bolts to the speci- fied torques in 2 stages and in the sequence shown.

  • Page 157: Selecting The Crankshaft Main Bearing

    Cylinder block NOTE: Stamped marks Bearing color c a and b When loosening the crankcase bolts, loosen them in the opposite order used for tighten- Blue ing. Black Brown Crankshaft journal oil clearance (reference data): Assembling the cylinder block 0.011–0.039 mm 1.
  • Page 158 POWR Power unit 2. Install the oil ring 5, 2nd ring 6, and top NOTE: ring 7 onto each piston. Apply engine oil to the side of the pistons and piston rings before installation. NOTE: Make sure that the “T” marks d of the 2nd ring and the top ring are facing upward.
  • Page 159 Cylinder block 7. Install the connecting rod caps D to the connecting rods, and then tighten the connecting rod cap bolts to the specified torques in 2 stages. È S6AG5A20 NOTE: Do not get any sealant on the main bearings. 10.

  • Page 160: Installing The Power Unit

    POWR Power unit 12. Install the oil filter, and then tighten it to Exhaust cover bolt: the specified torque using a 64 mm (2.5 1st: 6 N·m (0.6 kgf·m, 4.4 ft·lb) in) oil filter wrench. 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) Installing the power unit 1.
  • Page 161 Cylinder block È NOTE: When installing the throttle cam 9 to the bracket D, be sure to hook the end a of the spring onto the projection b of the bracket as shown. Throttle cam bolt C: 8 N·m (0.8 kgf·m, 5.9 ft·lb) É...
  • Page 162 POWR Power unit 7. Install the throttle cables onto the throttle È cam 9, and then adjust the throttle cables. (Tiller handle model) Install the cable joint onto the throttle cam 9, and then adjust the throttle cable. (Remote control model) NOTE: •...
  • Page 163 Cylinder block 11. Fasten the leads with the plastic ties S NOTE: and holders T, and then install the junc- • To connect the start-in-gear protection tion box cover. cable, see “Checking the start-in-gear pro- tection (manual starter model)” (3-11). 12.
  • Page 164 POWR Power unit — MEMO — 5-65 6AG3J11...

  • Page 165: Lowr

    LOWR Lower unit Lower unit ....................... 6-1 Removing the lower unit ................6-4 Removing the water pump................. 6-5 Checking the water pump................6-5 Propeller shaft housing ................. 6-6 Removing the propeller shaft housing assembly........6-7 Disassembling the propeller shaft assembly ..........6-7 Disassembling the propeller shaft housing assembly........6-7 Checking the propeller shaft housing ............6-8 Checking the propeller shaft..............

  • Page 166: Lower Unit

    LOWR Lower unit Lower unit 1104J · · · 17 N m (1.7 kgf m, 12.5 ft · · · 18 N m (1.8 kgf m, 13.3 ft 1104J · · · 18 N m (1.8 kgf m, 13.3 ft ·...
  • Page 167 Lower unit 1104J · · · 17 N m (1.7 kgf m, 12.5 ft · · · 18 N m (1.8 kgf m, 13.3 ft 1104J · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.8 kgf m, 5.9 ft ·...
  • Page 168 LOWR Lower unit · · · 18 N m (1.8 kgf m, 13.3 ft · · · 18 N m (1.8 kgf m, 13.3 ft S6AG6020J Part name Q’ty Remarks Woodruff key Impeller Water pump housing Insert cartridge O-ring Not reusable Dowel Rubber seal M8 ×...

  • Page 169: Removing The Lower Unit

    Lower unit 4. Remove the locknut 2. Removing the lower unit 1. Drain the gear oil. S6AG6421 NOTE: Be sure to remove the locknut from the shift rod before removing the lower unit. S6AG6030 5. Remove the lower unit by removing the 2.

  • Page 170: Removing The Water Pump

    LOWR Lower unit Removing the water pump 1. Remove the water pump housing 1 and impeller 2. 2. Remove the Woodruff key 3 from the drive shaft, and then remove the outer plate cartridge 4. 3. Remove the dowels 5 from the lower case.

  • Page 171: Propeller Shaft Housing

    Lower unit / Propeller shaft housing Propeller shaft housing · · · m (0.8 kgf m, 5.9 ft S6AG6070 Part name Q’ty Remarks Shift plunger Dog clutch Cross pin Cross pin ring Spring Washer Reverse gear O-ring Not reusable Reverse gear shim —...

  • Page 172: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft Disassembling the propeller shaft housing assembly housing assembly 1. Remove the bolts from the propeller shaft 1. Remove the reverse gear and shim(s). housing. 2. Remove the propeller shaft housing 1, and then remove the propeller shaft 2. S6AG6100 2.

  • Page 173: Checking The Propeller Shaft Housing

    Propeller shaft housing Propeller shaft runout limit: 0.05 mm (0.0020 in) 3. Check the dog clutch, shift plunger, and cross pin. Replace if cracked or worn. Assembling the propeller shaft assembly 1. Insert the spring 1 into the propeller shaft. 2.

  • Page 174: Assembling The Propeller Shaft Housing

    LOWR Lower unit Assembling the propeller shaft NOTE: housing Install an oil seal halfway into the propeller 1. Install a new needle bearing into the pro- shaft housing, and then install the other oil peller shaft housing. seal. Driver rod L3 1: 90890-06652 Needle bearing attachment 3: 90890-06613 Installation depth a:...
  • Page 175 Propeller shaft housing S6AG6190 NOTE: • Be sure to select the reverse gear shim(s) if replacing the propeller shaft housing, ball bearing, or lower case. To select the shims, see “Shimming” (6-20). • After installing the reverse gear and shim(s), check that the reverse gear rotates smoothly.

  • Page 176: Drive Shaft And Lower Case

    LOWR Lower unit Drive shaft and lower case · · · 25 N m (2.5 kgf m, 18.4 ft S6AG6560 Part name Q’ty Remarks Drive shaft L-transom model/S-transom model Drive shaft housing Drive shaft sleeve Needle bearing Not reusable Pinion shim —...

  • Page 177: Removing The Drive Shaft, Drive Shaft Housing, And Shift Rod

    Drive shaft and lower case Removing the drive shaft, drive shaft Disassembling the drive shaft housing, and shift rod housing 1. Remove the pinion nut. 1. Remove the oil seals and bushing. S6AG6200 S6AG6230 Driver rod L3 1: 90890-06652 Drive shaft holder 1 1: 90890-06515 Bushing attachment 2: 90890-06649 2.

  • Page 178: Disassembling The Lower Case

    LOWR Lower unit Disassembling the lower case NOTE: 1. Remove the taper roller bearing outer Be sure to remove the forward gear before race and forward gear shim(s). removing the needle bearing. Driver rod L3: 90890-06652 Needle bearing attachment: 90890-06617 Checking the pinion and forward gear 1.

  • Page 179: Assembling The Lower Case

    Drive shaft and lower case Assembling the lower case Driver rod SL 5: 90890-06602 1. Install the original forward gear shim(s) Bearing depth plate 6: 90890-06603 1 and new taper roller bearing outer Needle bearing attachment 7: race 2. 90890-06617 Installation depth c: 172.7–173.2 mm (6.80–6.82 in) Assembling the forward gear...

  • Page 180: Assembling The Drive Shaft Housing

    LOWR Lower unit Assembling the drive shaft housing Driver rod L3 3: 90890-06652 1. Install the bushing into the drive shaft Needle bearing attachment 4: housing using a press. 90890-06613 Installation depth c: 7.0–8.0 mm (0.28–0.31 in) Installing the shift rod, drive shaft housing, and drive shaft 1.

  • Page 181: Installing The Propeller Shaft Housing

    Drive shaft and lower case 2. Install the washer 2 and propeller shaft NOTE: housing assembly 3 into the lower case, • When installing the pinion, lift up the drive and then tighten the bolts 4 to the speci- shaft slightly and align the gear and shaft fied torque.

  • Page 182: Installing The Lower Unit

    LOWR Lower unit 2. Install the Woodruff key 3 and impeller 4 to the drive shaft. S6AG6390 NOTE: S6AG6400 When installing the impeller 4 onto the drive shaft, align the groove in the impeller with the CAUTION: Woodruff key 3. Do not turn the drive shaft counterclock- wise, otherwise the water pump impeller may be damaged.
  • Page 183 Drive shaft and lower case NOTE: The adjusting nut 4 must be screwed in a minimum of 8.0 mm (0.31 in) a. 5. Tighten the locknut 3. NOTE: After connecting the shift rod, check that the S6AG6370 gear shift operates properly. 3.
  • Page 184 LOWR Lower unit 7. Install the propeller 9 and propeller nut 0. Place a block of wood between the Recommended gear oil: Hypoid gear oil anti-cavitation plate and propeller to keep API: GL-4 the propeller from turning, and then SAE: 90 tighten the nut to the specified torque.

  • Page 185: Shimming

    Drive shaft and lower case / Shimming Shimming S6AG6450 6-20 6AG3J11...

  • Page 186: Selecting The Pinion Shim

    LOWR Lower unit Shimming Shim thickness Calculated number (mm) NOTE: • Shimming is not required when assembling 1.14–1.20 1.13 the original lower case and inner parts. 1.21–1.30 1.20 • Shimming is required when assembling the original inner parts and a new lower case. Available shim thicknesses: •...

  • Page 187: Selecting The Reverse Gear Shim

    Shimming Calculated number Rounded number at 1/100th place 10 mm (0.39 in) 1, 2 3, 4, 5 M3’ 6, 7, 8 9, 10 S6AG6490J Available shim thicknesses: M3 = M3’–10 mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, and 0.50 mm NOTE: Measure the propeller shaft housing at 4 Example:...

  • Page 188: Backlash

    LOWR Lower unit 3. Turn the ball bearing 2 or 3 times, and Shim thickness then measure the height from the ball Calculated number (mm) bearing (M4) as shown. 0.31–0.40 0.30 0.41–0.50 0.40 0.51–0.60 0.50 0.61–0.70 0.60 Available shim thicknesses: 0.1, 0.2, 0.3, 0.4, and 0.5 mm Backlash Measuring the forward and reverse...
  • Page 189 Shimming / Backlash NOTE: Install the dial gauge so that the plunger tip a is aligned with the mark b on the back- lash indicator. Backlash indicator: 90890-06706 Magnet base plate: 90890-07003 Dial gauge set: 90890-01252 Magnet base B: 90890-06844 8.
  • Page 190 LOWR Lower unit 11. Install the propeller, washer, and nut, without installing the spacer 4. Reverse gear backlash: 0.95–1.66 mm (0.0374–0.0654 in) 15. Adjust the current shim thickness if the reverse gear backlash is out of specifica- tion. Reverse gear Shim thickness backlash Less than...
  • Page 191 Backlash — MEMO — 6-26 6AG3J11...

  • Page 192: Brkt

    BRKT Bracket unit Tiller handle (tiller handle model)..............7-1 Disassembling the tiller handle..............7-3 Assembling the tiller handle............... 7-3 Friction plate (tiller handle model) ............... 7-5 Disassembling the friction plate..............7-6 Assembling the friction plate..............7-6 Bottom cowling ....................7-8 Upper case and steering arm..............7-11 Removing the upper case................7-15 Disassembling the upper case ..............7-15 Checking the drive shaft bushing (L-transom model) ......7-15...
  • Page 193 Power tilt gear pump (power tilt model).............7-35 Disassembling the gear pump ..............7-38 Checking the gear pump .................7-38 Checking the valve seal................7-38 Checking the filter..................7-39 Assembling the gear pump..............7-39 Power tilt cylinder (power tilt model) ............7-41 Disassembling the tilt cylinder ..............7-43 Checking the tilt cylinder and piston ............

  • Page 194: Bracket Unit

    BRKT Bracket unit Tiller handle (tiller handle model) · · · m (0.4 kgf m, 3.0 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft ·...
  • Page 195 Tiller handle (tiller handle model) · · · m (0.4 kgf m, 3.0 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft ·...

  • Page 196: Disassembling The Tiller Handle

    BRKT Bracket unit Disassembling the tiller handle 1. Remove the steering bracket cover 1. S6AG7A80 4. Remove the tiller handle. S6AG7A60 NOTE: 2. Disconnect the engine stop lanyard See the exploded diagram for disassembly switch leads 2 and power tilt switch (7-1).
  • Page 197 Tiller handle (tiller handle model) S6AG7470 NOTE: • When routing the engine stop lanyard switch lead and power tilt switch lead S6AG7A00 (power tilt model), make sure that it is not pinched by the plate B and that there is no NOTE: Tighten the screws 9, and then tighten the slack in the lead in the area a shown.

  • Page 198: Friction Plate (Tiller Handle Model)

    BRKT Bracket unit Friction plate (tiller handle model) · · · m (0.7 kgf m, 5.2 ft · · · m (0.7 kgf m, 5.2 ft 9.0 mm 3.8 mm 8.0 mm · · · 18 N m (1.8 kgf m, 13.3 ft 5.4 mm ·...

  • Page 199: Disassembling The Friction Plate

    Friction plate (tiller handle model) Disassembling the friction plate 1. Remove the friction plate bolts 1 and 2, and then remove the friction plate assembly from the swivel bracket. S6AG7B01 NOTE: If the steering lock shaft is not aligned with position b, turn it less than 90°...
  • Page 200 BRKT Bracket unit 3. Install the friction plate assembly onto the NOTE: swivel bracket and tighten the friction To check and adjust the friction plate, see plate bolts 3 and 4 temporarily. “Checking the steering operation (tiller han- dle model)” (3-13). Friction self-locking nut 6: 6 N·m (0.6 kgf·m, 4.4 ft·lb) S6AG7B10...

  • Page 201: Bottom Cowling

    Friction plate (tiller handle model) / Bottom cowling Bottom cowling STBD · · · m (0.2 kgf m, 1.5 ft S6AG7460 Part name Q’ty Remarks Adapter Warning indicator assembly Bracket Tiller handle model M6 × 10 mm/Tiller handle model Bolt Bracket Remote control model M6 ×...
  • Page 202 BRKT Bracket unit STBD · · · m (0.2 kgf m, 1.5 ft S6AG7460 Part name Q’ty Remarks M6 × 30 mm Bolt Damper Grommet Grommet Tiller handle model Grommet Remote control model Plug Tiller handle model without electric starter Plug Tiller handle model with electric starter Plug...
  • Page 203 Bottom cowling STBD · · · m (0.2 kgf m, 1.5 ft S6AG7460 Part name Q’ty Remarks Grommet M6 × 12 mm Bolt Holder Fuel hose Handgrip Cowling lock lever M6 × 12 mm Bolt Rubber seal Water outlet Cable guide Remote control model M6 ×...

  • Page 204: Upper Case And Steering Arm

    BRKT Bracket unit Upper case and steering arm · · · m (0.8 kgf m, 5.9 ft · · · · · · m (0.4 kgf m, 3.0 ft m (0.4 kgf m, 3.0 ft · · · 15 N m (1.5 kgf m, 11.1 ft ·...
  • Page 205 Upper case and steering arm · · · m (0.8 kgf m, 5.9 ft · · · · · · m (0.4 kgf m, 3.0 ft m (0.4 kgf m, 3.0 ft · · · 15 N m (1.5 kgf m, 11.1 ft ·...
  • Page 206 BRKT Bracket unit · · · · · · 30 N m (3.0 kgf m, 22.1 ft m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft · · · 18 N m (1.8 kgf m, 13.3 ft ·...
  • Page 207 Upper case and steering arm · · · · · · 30 N m (3.0 kgf m, 22.1 ft m (0.8 kgf m, 5.9 ft · · · m (0.8 kgf m, 5.9 ft · · · 18 N m (1.8 kgf m, 13.3 ft ·...

  • Page 208: Removing The Upper Case

    BRKT Bracket unit Removing the upper case NOTE: • Drain the engine oil before removing the upper case assembly. • Be sure to remove the shift rod assembly before removing the upper case assembly from the clamp bracket. 1. Remove the ground lead terminal 1 from the swivel bracket.

  • Page 209: Checking The Exhaust Manifold, Oil Pan, And Exhaust Guide

    Upper case and steering arm Checking the exhaust manifold, oil pan, and exhaust guide 1. Check the exhaust manifold, oil pan and exhaust guide. Replace if cracked or cor- roded. È NOTE: Clean the removed parts before checking them. Checking the oil strainer 1.

  • Page 210: Assembling The Upper Case

    BRKT Bracket unit 2. Install the dowels 5 and a new gasket 6 onto the exhaust guide 7. È 3. Install the oil strainer 8 and oil strainer bolts 9, and then tighten the bolts to the specified torque. S6AG7630 È...

  • Page 211: Removing The Steering Arm

    Upper case and steering arm 4. Install the upper mount 9, and then tighten the upper mount bolts 0 to the specified torque. 5. Install the water pipe A. S6AG7711 NOTE: To disassemble the clamp brackets, see “Removing the clamp bracket” (7-22) or “Removing the clamp bracket”...

  • Page 212: Installing The Upper Case

    BRKT Bracket unit 4. Apply grease to the grease nipple 7 on 6. Install the ground lead terminal B to the the swivel bracket until it comes out from upper case as shown. the upper bushing a. S6AG7740 NOTE: To assemble the clamp brackets, see “Install- ing the clamp bracket”...

  • Page 213: Clamp Bracket And Swivel Bracket (Manual Tilt Model)

    Upper case and steering arm / Clamp bracket and swivel bracket (manual tilt model) Clamp bracket and swivel bracket (manual tilt model) · · · m (0.8 kgf m, 5.9 ft · · · 19 N m (1.9 kgf m, 14.0 ft ·...
  • Page 214 BRKT Bracket unit S6AG7400 Part name Q’ty Remarks Tilt lock lever a > b Tilt lock rod 1 Tilt lever a > b Spring E-clip Tilt lever shaft Stopper shaft Receiver assembly Swivel bracket L-transom model/S-transom model Tilt lock rod 2 Collar Tilt lock plate 1 Tilt lock plate 2...

  • Page 215: Clamp Bracket And Swivel Bracket (Manual Tilt Model)

    Clamp bracket and swivel bracket (manual tilt model) Removing the clamp bracket 1. Remove the tilt pin 1, and then remove the clamp bracket bolt 2, clamp bracket nut, and collar. 2. Remove the tilt stopper plate bolts 3 (swivel bracket side). 3.

  • Page 216: Assembling The Swivel Bracket

    BRKT Bracket unit 3. Remove the E-clip 9 from the reverse lock shaft 0, and then pull out the shaft. 4. Remove the springs G. 5. Remove the E-clip A from the tilt lock shaft B, and then pull out the shaft and remove the collars C, tilt lock rod 2 D, tilt lock plate 1 E, and tilt lock plate 2 F.

  • Page 217: Installing The Clamp Bracket

    Clamp bracket and swivel bracket (manual tilt model) 3. Assemble the clamp brackets 5 and NOTE: swivel bracket 6, and then install the • See the exploded diagram for the installa- through tube 4 from the port side. tion directions of the spring D and tilt lock rod 1 E (7-21).

  • Page 218: Clamp Bracket And Swivel Bracket (Power Tilt Model)

    BRKT Bracket unit Clamp bracket and swivel bracket (power tilt model) Ó · · · 19 N m (1.9 kgf m, 14.0 ft Ú · · · 24 N m (2.4 kgf m, 17.7 ft · · · 24 N m (2.4 kgf m, 17.7 ft ·...
  • Page 219 Clamp bracket and swivel bracket (power tilt model) Ó · · · 19 N m (1.9 kgf m, 14.0 ft Ú · · · 24 N m (2.4 kgf m, 17.7 ft · · · 24 N m (2.4 kgf m, 17.7 ft ·...

  • Page 220: Removing The Power Tilt Unit

    BRKT Bracket unit 5. Remove the E-clip 0, shaft A, and collar Removing the power tilt unit B, and then remove the upper end of the 1. Fully tilt the outboard motor up, and then tilt rod from the swivel bracket. support it with the tilt stop lever.

  • Page 221: Installing The Clamp Bracket

    Clamp bracket and swivel bracket (power tilt model) NOTE: Be sure to remove the ground lead terminal Ó 1 before removing the self-locking nuts 2. Ú Installing the clamp bracket 1. Apply grease to the threads of the self- locking nut, and then tighten the nut 1 completely onto the shorter threaded end of the through tube 2.
  • Page 222 BRKT Bracket unit 2. Install the collar 1 onto the power tilt unit 3. Install the power tilt unit 2, collars 3, shaft 4, and washers 5 onto the clamp bracket 6, and then tighten the bolts 7 to the specified torque. 4.
  • Page 223 Clamp bracket and swivel bracket (power tilt model) / Power tilt motor (power tilt model) Power tilt motor (power tilt model) · · · m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft · ·...

  • Page 224: Power Tilt Motor (Power Tilt Model)

    BRKT Bracket unit Disassembling the power tilt motor 1. Remove the power tilt unit from the bracket. NOTE: To remove the power tilt unit, see “Removing the power tilt unit” (7-27). 2. Fully extend the tilt ram, and then open the manual valve 1 by turning it counter- clockwise.

  • Page 225: Checking The Power Tilt Motor

    Power tilt motor (power tilt model) NOTE: Motor commutator standard • Push the brushes apart, and then remove diameter: the armature assembly. 16.5 mm (0.65 in) • Do not remove the bearing from the arma- Wear limit: 15.5 mm (0.61 in) ture assembly.

  • Page 226: Checking The Brush Holder And Brush

    BRKT Bracket unit 5. Check the bearing. Replace if damaged. NOTE: • If the bearing is damaged, replace the armature assembly. • Do not reuse the oil seal. Checking the brush holder and brush 1. Check the brush holder assembly for continuity.
  • Page 227 Power tilt motor (power tilt model) NOTE: Align the rounded section c of the stator 0 with the rounded section d of the power tilt motor base A. Stator screw B: 5 N·m (0.5 kgf·m, 3.7 ft·lb) S6AG7120 5. Install a new O-ring C, the pin D, the manual valve E, and a new O-ring F to Brush holder screw 6: the power tilt motor assembly G.
  • Page 228 BRKT Bracket unit Power tilt gear pump (power tilt model) · · · m (0.5 kgf m, 3.7 ft 6, 9 · · · m (0.5 kgf m, 3.7 ft S6AG7030 Part name Q’ty Remarks O-ring Not reusable Manual valve Spring Manual release pin Spring...
  • Page 229 Power tilt gear pump (power tilt model) · · · m (0.5 kgf m, 3.7 ft 6, 9 · · · m (0.5 kgf m, 3.7 ft S6AG7030 Part name Q’ty Remarks Driven gear Not reusable E-clip Main valve seal O-ring Not reusable Shuttle piston 1...
  • Page 230 BRKT Bracket unit · · · m (0.5 kgf m, 3.7 ft 6, 9 · · · m (0.5 kgf m, 3.7 ft S6AG7030 Part name Q’ty Remarks Spring Down-main valve Up-main valve Reservoir cap O-ring Not reusable 7-37 6AG3J11...

  • Page 231: Disassembling The Gear Pump

    Power tilt gear pump (power tilt model) Disassembling the gear pump 1. Remove the manual valve 1, manual release pins 2, relief valve seals 3, and balls 4. S6AG7170 Checking the gear pump 1. Check the drive gear and driven gear. Replace if damaged or excessively worn.

  • Page 232: Checking The Filter

    BRKT Bracket unit Checking the filter 1. Check the gear pump filters. Clean if there is dirt or residue. NOTE: See the exploded diagram for the filter instal- lation position (7-35). Assembling the gear pump S6AG7200 CAUTION: • Do not use a rag when assembling the power tilt unit as dust and particles on the power tilt unit components can lead to poor performance.
  • Page 233 Power tilt gear pump (power tilt model) S6AG7072 6. Install a new gasket K and the power tilt motor assembly L to the tilt cylinder, and then tighten the power tilt motor base bolts M to the specified torque. Power tilt motor base bolt M: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 7-40 6AG3J11...

  • Page 234: Power Tilt Cylinder (Power Tilt Model)

    BRKT Bracket unit Power tilt cylinder (power tilt model) · · · 45 N m (4.5 kgf m, 33.2 ft · · · 60 N m (6.0 kgf m, 44.3 ft · · · m (0.5 kgf m, 3.7 ft ·...
  • Page 235 Power tilt cylinder (power tilt model) · · · 45 N m (4.5 kgf m, 33.2 ft · · · 60 N m (6.0 kgf m, 44.3 ft · · · m (0.5 kgf m, 3.7 ft · · · m (0.7 kgf m, 5.2 ft S6AG7040...

  • Page 236: Disassembling The Tilt Cylinder

    BRKT Bracket unit 5. Remove the bolt 5, and then remove the Disassembling the tilt cylinder piston absorber valves 6 from the tilt 1. Hold the tilt cylinder 1 in a vise using aluminum plates a on both sides. piston. 2.

  • Page 237: Assembling The Tilt Cylinder

    Power tilt cylinder (power tilt model) 3. Check the tilt cylinder end screw 6, dust NOTE: seal 7, and backup ring 8. Replace if Lubricate the parts with ATF Dexron II during cracked or scratched. assembly. 4. Check the tilt ram 9. Polish with 400– 1.
  • Page 238 BRKT Bracket unit 5. Install a new O-ring 9 and the backup NOTE: ring 0 onto the tilt piston. To install the power tilt motor assembly and gear pump assembly, see “Assembling the 6. Install the balls A, absorber valve pins gear pump”...

  • Page 239: Bleeding The Power Tilt Unit

    Power tilt cylinder (power tilt model) 14. Tighten the tilt cylinder end screw to the specified torque. NOTE: S6AG7225 • If the fluid is at the correct level, a small amount of fluid should overflow out of the Power tilt wrench 8: 90890-06560 filler hole.

  • Page 240: Power Tilt Electrical System (Power Tilt Model)

    BRKT Bracket unit 5. Connect the power tilt motor leads to the NOTE: battery terminals to fully retract the tilt • Repeat steps 5–6 to fully extend and retract ram. the tilt ram 4 to 5 times. • If the tilt ram does not move up and down easily, push and pull on the ram to assist the operation.

  • Page 241: Checking The Power Tilt Relay

    Power tilt cylinder (power tilt model) / Power tilt electrical system (power tilt model) 2. Connect the positive battery lead to the light green (Lg) lead 6, and the negative battery lead to the terminal (B) 1 as shown, and then check the power tilt relay for continuity.

  • Page 242: Checking The Power Tilt Switch

    BRKT Bracket unit 3. Connect the positive battery lead to the sky blue (Sb) lead 5, and the negative Lead color battery lead to the terminal (B) 1 as shown, and then check the power tilt Switch Sky blue Light green Red (R) relay for continuity.

  • Page 243: Elec

    – ELEC Electrical system Electrical component and wiring harness routing........8-1 Top view ....................8-1 Bow view ....................8-3 Port view....................8-7 Checking the electrical component............8-11 Measuring the peak voltage ..............8-11 Starter motor (electric starter model)............8-12 Removing the starter motor ..............8-14 Checking the starter motor operation ............8-14 Checking the starter motor pinion............

  • Page 244: Electrical System

    – ELEC Electrical system Electrical component and wiring harness routing Top view É Ò Ê È Ì Í Ë Ï Î Ñ S6AG8310 5 Stator coil assembly (charge coil, lighting coil, + Remote control model , Tiller handle model and power bobbin) 6 Pulser coil 1 Prime Start 7 Neutral switch (tiller handle model with electric...
  • Page 245 Electrical component and wiring harness routing 0 Engine stop lanyard switch (tiller handle model) A Power tilt switch (power tilt model) È Fasten the engine stop lanyard switch lead (tiller handle model), power tilt motor lead (power tilt model), and power tilt switch lead (power tilt model) with a plastic tie. Install the plastic tie as shown and cut off the excess end of the tie to 3 mm (0.12 in) or less.

  • Page 246: Bow View

    – ELEC Electrical system Bow view Manual starter model with manual tilt È É Ê Ë Í Ì Ñ Ï Ï Ï Ñ Ò Ò Î Î Î S6AG8320 5 Neutral switch lead (tiller handle model with + Tiller handle model with manual starter , Tiller handle model with electric starter electric starter) (Br) 6 Engine stop lanyard switch lead (tiller handle...
  • Page 247 Electrical component and wiring harness routing B Charge coil connector (G/R) C Engine stop lanyard switch connector (tiller handle model) (W) D Engine start button connector (tiller handle model with electric starter) (Br) E Engine start button connector (tiller handle model with electric starter) (R) F Prime Start connectors (L) G Tachometer connector (G) H Connector (10-pin main harness coupler to CDI unit) (remote control model) (W)
  • Page 248 – ELEC Electrical system Electric starter model with power tilt Ë Ê É Ë È Ì È Ï Î Ñ Ò Ò Ó Ù Ô × Õ Þ Ú Þ Þ Þ Û Ý Ü S6AG8340 7 CDI unit + Tiller handle model 8 Power tilt relay , Remote control model 9 Engine start button connector (Br)
  • Page 249 Electrical component and wiring harness routing F Pulser coil connector (W/R) G Charge coil lead (B/R, G/R) H Engine stop lanyard switch lead (B) I Neutral switch lead (Br) J Power tilt switch connector (R) K Pulser coil connector (B) L Connector (10-pin main harness coupler to CDI unit) (P) M Lead (10-pin main harness coupler to CDI unit) (P) N Connector (10-pin main harness coupler to fuse) (R)

  • Page 250: Port View

    – ELEC Electrical system Port view Manual starter model Ô Õ Ë È É Ê Ì Í Î Ï Ò Ñ Ó S6AG8350 1 Pulser coil 9 Lighting coil connectors (G) 2 Stator coil assembly 0 Ignition coil connector (O) A Thermoswitch connector (Gy/B) (charge coil, lighting coil and power bobbin) 3 Oil pressure switch...
  • Page 251 Electrical component and wiring harness routing È Position the holder between the plastic ties. É Fasten the wiring harness at the white tape with a plastic tie. Ê Fasten the wiring harness, engine stop lanyard switch lead, and stator coil assembly lead with the holder. Ë...
  • Page 252 – ELEC Electrical system Electric starter model È É Ê Ë Ì Í Û Ú Ù × Õ Ò Ô Ó Ñ Ò Ï Î Ü Ê Þ À À ß Á Û Ù × ÔÝÓ 9 Ý S6AG8370 7 Oil pressure switch + Electric starter model without power tilt 8 Fuse (20 A) 1 Pulser coil...
  • Page 253 Electrical component and wiring harness routing F Positive battery lead connector (R) G Starter relay connector (Br) H Oil pressure switch connector (P) I Rectifier Regulator connector (R) J Lead (10-pin main harness coupler to starter relay) (Br) (remote control model) or neutral switch lead (Br) (tiller handle model) K Fuse lead (R) L Rectifier Regulator lead (B)

  • Page 254: Checking The Electrical Component

    – ELEC Electrical system Checking the electrical NOTE: component • Before measuring the peak voltage, check Measuring the peak voltage all wiring for proper connection and corro- To check the electrical components or mea- sion, and check that the battery is fully sure the peak voltage, use the special ser- charged.

  • Page 255: Starter Motor (Electric Starter Model)

    Checking the electrical component / Starter motor (electric starter model) Starter motor (electric starter model) · · · 0.4 N m (0.04 kgf m, 0.30 ft S6AG8380 Part name Q’ty Remarks Clip Not reusable Pinion stopper Spring Pinion stopper set Pinion Cover O-ring...
  • Page 256 – ELEC Electrical system · · · 0.4 N m (0.04 kgf m, 0.30 ft S6AG8380 Part name Q’ty Remarks ø4 × 8 mm Screw Spacer Bracket M5 × 120 mm Bolt O-ring Washer O-ring Spacer Washer Spring washer 8-13 6AG3J11...

  • Page 257: Starter Motor (Electric Starter Model)

    Starter motor (electric starter model) Removing the starter motor WARNING 1. Remove the starter motor from the power Do not place any objects near the pinion unit. or touch it. The pinion 9 moves slightly NOTE: away from the starter motor body and •...
  • Page 258 – ELEC Electrical system 2. Turn the pinion 3 clockwise, and then remove the pinion. S6AG8410 3. Remove the bolts 4, and then remove S6AG8430 the cover 5, stator 6, armature 7, and washer. Checking the starter motor 1. Check the commutator. Clean with 600- grit sandpaper and compressed air if dirty.

  • Page 259: Checking The Brush Holder And Brush

    Starter motor (electric starter model) 3. Measure the commutator undercut a. Replace the armature if below specifica- tion. S6AG8470 Commutator standard undercut a: 0.8 mm (0.03 in) Brush holder assembly continuity Wear limit: 0.2 mm (0.01 in) Checking points Continuity 4.

  • Page 260: Assembling The Starter Motor

    – ELEC Electrical system Assembling the starter motor CAUTION: Do not allow grease or oil to contact the commutator of the armature. 1. Install the brush holder assembly 1 into the bracket 2, and then tighten the screws 3. 2. Install the O-ring 4, spacer 5, washer 6, and spring washer 7, and then tighten the nut 8 to the specified torque.

  • Page 261: Installing The Starter Motor

    Starter motor (electric starter model) / Starting system Checking the engine start button (tiller handle model with electric starter) 1. Disconnect the engine start button 1 connectors. 2. Measure the input voltage between the connector (wiring harness end) of the engine start button 1 and the ground.

  • Page 262: Checking The Engine Start Switch (Remote Control Model)

    – ELEC Electrical system 3. Check the engine start button 1 for con- Engine start switch input voltage tinuity between the engine start button (reference data): connectors (engine start button end). Red (R) – Ground Replace if out of specification. 12 V (battery voltage) 3.
  • Page 263 Starting system 2. Push the engine start button, and then Neutral switch continuity: measure the input voltage between the Brown (Br) – Brown (Br) neutral switch connector (engine start button end) and the ground. Check the Switch position Continuity engine start button 2 and wiring harness Pushed a (neutral) if below specification.

  • Page 264: Checking The Starter Relay (Electric Starter Model)

    – ELEC Electrical system 3. Turn the engine start switch to “OFF.” Starter relay input voltage 4. Connect the 10-pin main harness cou- (reference data): pler. Brown (Br) – Ground 12 V (battery voltage) Checking the starter relay (electric starter model) 4.

  • Page 265: Checking The Spark Plug Cap

    Starting system / Ignition and ignition control system 2. Connect the spark plug cap to the special service tool. Ignition tester: 90890-06754 3. Crank the engine and check for a spark. If there is no spark, check the ignition system. S6AG8040 Spark plug cap resistance: 3.75–6.25 kΩ...

  • Page 266: Checking The Pulser Coil

    – ELEC Electrical system Checking the pulser coil Pulser coil resistance 1. Measure the pulser coil 1 output peak (reference data): voltage. Replace if below specification. White/red (W/R) – Black (B) 152–228 Ω at 20 °C (68 °F) 4. Connect the pulser coil connectors. Checking the charge coil 1.

  • Page 267: Checking The Engine Stop Lanyard Switch (Tiller Handle Model)

    Ignition and ignition control system Charge coil output peak voltage: Black/red (B/R) – Green/red (G/R) Unloaded Loaded r/min Cranking 1,500 3,500 DC V 2. Disconnect the charge coil connectors. 3. Measure the charge coil resistance. Replace the stator coil assembly if out of specification.

  • Page 268: Engine Electric Control System

    – ELEC Electrical system 2. Turn the engine start switch to “ON,” and then check the engine stop lanyard switch for continuity at the 10-pin main harness coupler (remote control box end). Check the wiring harness or replace the engine stop lanyard switch if out of specification.

  • Page 269: Checking The Oil Pressure Switch

    Ignition and ignition control system / Engine electric control system a Temperature b Time c No continuity Gy/B Gy/B d Continuity Thermoswitch continuity temperature: Gray/black (Gy/B) – Black (B) S6AG8090 e: 76–84 °C (169–183 °F) f: 63–77 °C (145–171 °F) Thermoswitch input voltage (reference data): 7.
  • Page 270 – ELEC Electrical system 2. Start the engine, and then measure the input voltage between the oil pressure switch connector (wiring harness end) and the ground. Check the wiring har- ness if below specification. S6AG8110 Oil pressure switch continuity: Oil pressure switch – Ground Engine condition Continuity S6AG8120...

  • Page 271: Checking The Warning Indicator Assembly

    Engine electric control system 8. Connect the yellow/black (Y/B) lead to Oil pressure switch continuity: the positive penlight battery terminal (1.5 Oil pressure switch – Ground V) and connect the pink/black (P/B) lead to the negative terminal, and then check Oil pressure Continuity that the warning indicator comes on.

  • Page 272: Checking The Power Bobbin (For Prime Start)

    – ELEC Electrical system Checking the power bobbin (for Power bobbin output peak voltage: Prime Start) Blue (L) – Blue (L) 1. Measure the power bobbin 1 output peak voltage. Replace the stator coil Unloaded r/min assembly if below specification. Cranking 1,500 3,500...

  • Page 273: Checking The Rectifier Regulator

    Engine electric control system / Charging system (electric starter model) Checking the Rectifier Regulator CAUTION: If the battery cables are connected in reverse, the Rectifier Regulator can be damaged. 1. Measure the Rectifier Regulator 1 out- put peak voltage. Check the Rectifier Regulator for continuity if the output peak voltage is below specification.
  • Page 274 – ELEC Electrical system 2. Disconnect the Rectifier Regulator con- Rectifier Regulator continuity nector and terminal. (testing diode) 3. Check the Rectifier Regulator for conti- Tester lead Display value (V) nuity. Replace if out of specification. (reference data) 0.434 0.454 0.838 0.458 0.460...

  • Page 275: Trbl Shtg

    TRBL SHTG Troubleshooting Troubleshooting the outboard motor............9-1 Troubleshooting table format..............9-1 Troubleshooting the power unit ..............9-1 Troubleshooting the power tilt unit (Power tilt model)........9-7 Troubleshooting the lower unit ..............9-9 6AG3J11...

  • Page 276: Troubleshooting The Outboard Motor

    TRBL SHTG Troubleshooting Troubleshooting the outboard motor NOTE: Before troubleshooting the outboard motor: • Make sure that fresh fuel of the specified type has been used. • Make sure that the battery is fully charged. • Be sure to check that the couplers, connectors, and battery terminals are securely connected. •...
  • Page 277 Troubleshooting the outboard motor Symptom 1: Engine does not crank (electric starter model) Refer Symptom 2 Cause 1 Cause 2 Checking step page Starter motor does Shift lever or Set the shift lever or not operate remote control lever remote control lever 3-10 —...
  • Page 278 TRBL SHTG Troubleshooting Symptom 1: Engine does not start (engine cranks) Refer Symptom 2 Cause 1 Cause 2 Checking step page Spark plug does not Spark plug malfunc- Check the spark — spark tion plug. Spark plug cap mal- Check the spark 8-22 —...
  • Page 279 Troubleshooting the outboard motor Symptom 1: Unstable engine idle speed, poor acceleration, poor performance, limited engine speed, or engine stalls Refer Symptom 2 Cause 1 Cause 2 Checking step page Intermittent spark Spark plug malfunc- Check the spark — tion plug.
  • Page 280 TRBL SHTG Troubleshooting Refer Symptom 2 Cause 1 Cause 2 Checking step page Low compression Valve clearance not Adjust the valve — pressure adjusted correctly clearance. Automatic decom- Disassemble and 5-37 pression actuator check the cylinder 5-43 malfunction head and power 5-51 unit.
  • Page 281 Troubleshooting the outboard motor Symptom 1: Limited engine speed (below 2,000 r/min) Refer Symptom 2 Cause 1 Cause 2 Checking step page • Buzzer comes on Clogged cooling Check the cooling — (remote control water inlet water inlets. model) Clogged cooling Check the cooling •...
  • Page 282 TRBL SHTG Troubleshooting Troubleshooting the power tilt unit (Power tilt model) Symptom 1: Power tilt unit does not operate Refer Symptom 2 Cause 1 Cause 2 Checking step page Power tilt relay Blown fuse — Check the fuse. 7-47 does not operate Power tilt switch Check the power tilt 7-49...
  • Page 283 Troubleshooting the outboard motor Symptom 1: Power tilt unit does not hold the outboard motor up Refer Symptom 2 Cause 1 Cause 2 Checking step page Manual valve left Manual valve mal- Check the manual 7-38 open function valve. Insufficient power Add sufficient fluid.

  • Page 284: Troubleshooting The Lower Unit

    TRBL SHTG Troubleshooting Troubleshooting the lower unit Symptom 1: Shift mechanism of the forward gear and reverse gear does not operate properly Refer Symptom 2 Cause 1 Cause 2 Checking step page Throttle open (tiller Turn the throttle handle model) cam to the fully —...
  • Page 285 Index Checking the battery......... 3-17 Checking the battery Abbreviation ..........1-3 (electric starter model)......1-14 Adjusting the pilot screw ......4-15 Checking the bearing........ 6-13 Adjusting the throttle cable Checking the brush (remote control model)......3-8 holder and brush......7-33 8-16 Adjusting the throttle cable Checking the camshaft ......
  • Page 286 Index Checking the fuse Checking the shift rod....... 6-13 Checking the spark plug ......3-5 (electric starter model) ......8-18 Checking the spark plug cap ....8-22 Checking the gear oil ........3-14 Checking the gear oil level......1-14 Checking the starter motor ....... 8-15 Checking the gear pump......7-38 Checking the starter motor operation ..
  • Page 287 Index Disassembling the gear pump ....7-38 Installing the power unit......5-61 Disassembling the lower case ....6-13 Installing the propeller shaft housing ..6-16 Disassembling the manual starter....5-9 Installing the shift rod, Disassembling the power tilt motor ...7-31 drive shaft housing, and drive shaft..6-15 Disassembling the propeller Installing the sprocket and timing belt ..
  • Page 288 Index Removing the intake silencer protective covering ..........1-13 Ventilation........... 1-4 Removing the lower unit ......6-4 Removing the power tilt unit......7-27 Removing the power unit ......5-27 Removing the propeller shaft housing assembly ........6-7 Removing the starter motor ......8-14 Removing the steering arm.......7-18 Removing the timing belt and sprocket..5-30 Removing the upper case ......7-15 Removing the water pump ......6-5...
  • Page 289 Index — MEMO — 6AG3J11...

  • Page 290: Wiring Diagram

    Wiring diagram 1 CDI unit Color code 2 Stator coil assembly (charge coil) : Black 3 Stator coil assembly (power bobbin) : Green 4 Stator coil assembly (lighting coil) : Blue 5 Pulser coil : Orange 6 Primary Start : Pink 7 Ignition coil : White 8 Spark plug...
  • Page 291 Wiring diagram 1 CDI unit Color code 2 Stator coil assembly (charge coil) : Black 3 Stator coil assembly (power bobbin) : Brown 4 Stator coil assembly (lighting coil) : Green 5 Pulser coil : Blue 6 Primary Start : Light green 7 Rectifier Regulator : Orange 8 Fuse (20A)
  • Page 292 Wiring diagram 1 CDI unit Color code 2 Stator coil assembly (charge coil) : Black 3 Stator coil assembly (power bobbin) : Brown 4 Stator coil assembly (lighting coil) : Green 5 Pulser coil : Blue 6 Primary Start : Light green 7 Rectifier Regulator : Orange 8 Fuse (20A)
  • Page 295 Wahoo 15M, Wahoo 20M È Gy/B Gy/B Gy/B...
  • Page 296 Wahoo 15E, Wahoo 20EBT É Gy/B Gy/B Gy/B È...
  • Page 297 Wahoo 15E, Wahoo 20E, Wahoo 20ET Gy/B Gy/B Gy/B É Sb Lg Sb Lg È...

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