Page 1 Pike 9,9 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 BTDC Before Top Dead Center Cold Cranking Ampere Capacitor Discharge Ignition E model Electric starter model European Norm (European standard) Exhaust F position Forward position...
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 oil or fluid to the contact surfaces Use the recommended special service tools of moving parts before assembly.
Page 11: Identification
Safety while working / Identification Identification Approved Starting Model Model name model code serial No. This manual covers the following models. F9.9F 1000001– Applicable model FT9.9G 1000001– Pike 9.9 Serial number outboard motor serial number stamped on a label attached to the port clamp bracket.
Page 12: Special Service Tool
INFO General information Special service tool Digital tachometer Compression gauge 90890-06760 90890-03160 Timing light Tappet adjusting tool 90890-03141 90890-01311 Leakage tester Flywheel holder 90890-06840 90890-06522 Vacuum/pressure pump gauge set Flywheel puller 90890-06756 90890-06521 Pilot screw adjusting tool Shaft holder 90890-03154 90890-06561 6AU3K11...
Page 13 Special service tool Valve spring compressor Valve seat cutter 90890-04019 90890-06312, 90890-06315, 90890-06328, 90890-06813, 90890-06814, 90890-06815 Valve spring compressor attachment 90890-06320 Driver rod L3 90890-06652 Valve guide remover/installer 90890-06801 Needle bearing attachment 90890-06613, 90890-06614, 90890-06616, 90890-06653 Valve guide reamer 90890-06804 Piston slider 90890-06843 Valve seat cutter holder...
Page 14 INFO General information Bearing puller assembly Ball bearing attachment 90890-06535 90890-06634 Stopper guide stand Bushing attachment 90890-06538 90890-06650 Bushing attachment Driver rod LL 90890-06649 90890-06605 Needle bearing attachment Bushing installer center bolt 90890-06617 90890-06601 Driver rod LS Bearing housing puller claw S 90890-06606 90890-06564 6AU3K11...
Page 15 Special service tool Center bolt Ball bearing attachment 90890-06504 90890-06632 Backlash indicator Bearing outer race attachment 90890-06706 90890-06625 Magnet base plate Driver rod SL 90890-07003 90890-06602 Dial gauge set Bearing depth plate 90890-01252 90890-06603 Magnet base B Digital caliper 90890-06844 90890-06704 1-10 6AU3K11...
Page 16 INFO General information Shimming plate Ignition tester 90890-06701 90890-06754 Needle bearing attachment 90890-06615 Power tilt wrench 90890-06560 Digital circuit tester 90890-03174 Peak voltage adapter B 90890-03172 1-11 6AU3K11...
Page 17: Propeller Selection
Special service tool / Propeller selection Propeller selection Selection When the engine speed is at the full throttle The performance of a boat and outboard operating range (5,000–6,000 r/min), the motor will be critically affected by the size ideal propeller for the boat is one that pro- and type of propeller you choose.
Page 18: Predelivery Check
INFO General information Predelivery check To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is between the bottom of the boat and a S6AU1016 maximum of 25 mm (1 in) a below it.
Page 19: Checking The Gear Oil Level
Predelivery check 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. Checking the battery (E model) 1. Check the battery capacity, electrolyte S6AU1018 level, and specific gravity of the electro- lyte.
Page 20: Checking The Gear Shift And Throttle Operation
INFO General information 2. Turn the throttle cam 1 counterclock- WARNING wise until the fully closed stopper a on the cam contacts the fully closed stopper The shift/throttle cable joint must be b on the throttle cable bracket 2 and screwed in a minimum of 8.0 mm (0.31 in) hold it in that position.
Page 21: Checking The Steering System
Predelivery check Ê NOTE: To adjust the start-in-gear protection cable, see “Checking the start-in-gear protection (M model)” (3-11). Checking the steering system 1. Check the steering friction for proper adjustment. (H model) S6AU1024 È H model (short) É H model (long) Ê...
Page 22: Checking The Tilt System (Mt Model)
INFO General information 3. Check that there is no interference with leads, cables, or hoses when the out- board motor is steered. Checking the tilt system (MT model) 1. Set the tilt lock lever 1 to the release position a and fully tilt the outboard motor up.
Page 23 Predelivery check È Ê S6AU1035 S6AU1034 È H model (short) É É H model (long) Ê R model 3. Check that the engine turns off when the clip is pulled from the engine shut-off switch. È S6AU1035 È H model É...
Page 24: Checking The Cooling Water Pilot Hole
INFO General information Checking the cooling water pilot NOTE: hole The test run is part of the break-in operation. 1. Place the lower unit in water, and then start the engine. Break-in 2. Check for water flow at the cooling water Run the engine under load (in gear with a pilot hole.
Page 25: Precaution When Transporting Or Storing The Outboard Motor
Predelivery check CAUTION: Be sure to supply sufficient water and water pressure when flushing the cooling water passages. If sufficient water and sufficient water pressure are not supplied, the engine can overheat. NOTE: When using the flushing device (flushing hose joint adapter [for Europe]), flush the cooling water passages without starting the engine.
Page 26 INFO General information — MEMO — 1-21 6AU3K11...
Page 27 SPEC Specification General specification..................2-1 Maintenance specification ................2-4 Power unit....................2-4 Fuel system ....................2-7 Lower unit ....................2-8 Electrical ....................2-9 Dimension....................2-12 Tightening torque..................2-19 Specified torque..................2-19 General torque..................2-21 6AU3K11...
Page 28: Specification
SPEC Specification General specification Model Item Unit Dimension Overall length (For Europe) mm (in) 1,038 573 (22.6) (36.5) (40.9) (For Oceania) mm (in) 1,038 — 573 (22.6) (40.9) Overall width (For Europe) mm (in) 335 (13.2) (14.8) (14.6) (For Oceania) mm (in) —...
Page 29 General specification Model Item Unit Performance Maximum output kW (HP) 7.3 (9.9) at 5,500 r/min Full throttle operating range r/min 5,000–6,000 Maximum fuel consumption L (US gal, 3.9 (1.0, 0.9) at 6,000 r/min Imp gal)/hr 1,050 ± 50 Engine idle speed r/min Power unit Type...
Page 30 SPEC Specification Model Item Unit Bracket unit Trim angle Degree 0.0, 4.0, 8.0, 12.0 — (at 12° boat transom) Tilt-up angle Degree Steering angle Degree 43 + 43 38 + 38 PT system Fluid type — Dexron II Drive unit Gear shift positions F-N-R Gear ratio...
Page 31: Maintenance Specification
General specification / Maintenance specification Maintenance specification Power unit Model Item Unit Power unit Minimum compression 630 (63, 91.4) 700 (7.0, 101.5) (*1) pressure (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.10 (0.0039) (lines indicate straightedge position) Cylinder head journal inside mm (in) 18.000–18.018 (0.7087–0.7094) diameter (A)
Page 32 SPEC Specification Model Item Unit Rocker arm Inside diameter mm (in) 13.000–13.018 (0.5118–0.5125) Valve Valve clearance (cold) Intake mm (in) 0.15–0.20 (0.006–0.008) Exhaust mm (in) 0.20–0.25 (0.008–0.010) Head diameter (A) Intake mm (in) 23.9–24.1 (0.94–0.95) Exhaust mm (in) 21.9–22.1 (0.86–0.87) Face width (B) Intake and exhaust mm (in)
Page 33 Maintenance specification Model Item Unit Piston Piston diameter (D) mm (in) 55.950–55.965 (2.2028–2.2033) Measuring point (H) mm (in) 1.5 (0.06) (*1) Piston clearance mm (in) 0.035–0.065 (0.0014–0.0026) Piston pin boss bore mm (in) 14.004–14.015 (0.5513–0.5518) Oversize piston diameter mm (in) 56.200–56.215 (2.2126–2.2132) mm (in) 56.450–56.465 (2.2224–2.2230)
Page 34: Fuel System
SPEC Specification Model Item Unit Crankcase Crankshaft journal oil mm (in) 0.006–0.034 (0.0002–0.0013) (*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 35: Lower Unit
Maintenance specification Model Item Unit 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 50 (0.5, 7.3)
Page 36: Spec
SPEC Specification Model Item Unit Drive shaft Runout limit mm (in) (0.0394) 0.5 (0.0197) Electrical Model Item Unit Ignition and ignition control system Spark plug gap mm (in) 0.9–1.0 (0.035–0.039) (*1) Spark plug cap resistance kΩ 4.0–6.0 (*1) Ignition coil resistance Primary coil (O –...
Page 37 Maintenance specification Model Item Unit Oil pressure switch Specified oil pressure 14.7 (0.147, 2.132) (kgf/cm , psi) Fuel control system (*1) Choke solenoid resistance (L – B) Ω at 20 °C (68 °F) — Starter motor Type — Bendix Output —...
Page 38 SPEC Specification Model Item Unit Rectifier output peak voltage (R – Ground) at 1,500 r/min (unloaded) — at 3,500 r/min (unloaded) — Rectifier Regulator output peak voltage (R – Ground) at 1,500 r/min (loaded) at 3,500 r/min (loaded) PT motor Output —...
Page 39: Dimension
Maintenance specification Dimension Exterior mim (in) 43˚ 497 (19.6) S: 708 (27.9) 274 (10.8) L: 825 (32.5) 121 (4.8) 431 (17.0) 66 (2.6) (5.5) S: 18 (0.7) L: 27 (1.1) 71˚ 12˚ –4˚ 356 (14.1) S6AU2006 2-12 6AU3K11...
Page 40 Maintenance specification Exterior mim (in) 43˚ L: 891 (35.1) 274 (10.8) X: 954 (37.6) (4.8) 431 (17.0) 66 (2.6) (5.5) 27 (1.1) 71˚ 12˚ –4˚ 367 (14.5) S6AU2009 2-16 6AU3K11...
Page 41 Maintenance specification Clamp bracket mm (in) 70.5 (2.8) 70.5 (2.8) 8.3 (0.4) 95.3 (3.8) 95.3 (3.8) 110 (4.4) S6AU2012 2-18 6AU3K11...
Page 42: Tightening Torque
SPEC Specification Tightening torque Specified torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Fuel joint bolt Fuel pump screw Fuel pump valve screw 0.05 0.37 Power unit Drive plate screw (M model) Power unit mounting bolt 15.5 Apron screw 0.25...
Page 43 Tightening torque Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Anode screw Thermostat cover bolt Relief valve — Exhaust cover bolt 11.1 Crankcase bolt 22.1 Connecting rod cap bolt Lower unit Gear oil drain screw — Gear oil check screw —...
Page 44: General Torque
SPEC Specification Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Upper mount bolt Engine oil drain bolt — 17.7 Oil pan bolt 15.5 Exhaust manifold bolt Upper case bolt 13.3 Shift rod grommet plate bolt Self-locking nut —...
Page 45 Periodic check and adjustment Maintenance interval chart................3-1 Top cowling ....................3-3 Checking the top cowling................3-3 Fuel system ....................3-3 Checking the fuel joint and fuel hose (fuel joint-to-carburetor) ....3-3 Checking the fuel filter ................3-3 Draining the fuel ..................3-4 Power unit.......................
Page 46: 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 20 hours 100 hours 300 hours 500 hours page...
Page 47 Maintenance interval chart Initial Every Refer to Item Remarks 20 hours 100 hours 300 hours 500 hours page (3 months) (1 year) (3 years) (5 years) Main switch/stop switch/choke Check/replace 8-26, 8-27, switch 8-33 Wire harness connections/ Check/replace wire coupler connections Check/clean (Selva) Fuel tank —...
Page 48: Top Cowling
Periodic check and adjustment Top cowling Checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust if necessary. S6AU3001 2. Loosen the bolts 1. 3. Move the hook 2 up or down slightly to S6AU3003 adjust its position.
Page 49: Draining The Fuel
Top cowling / Fuel system / Power unit S6AU1018 S6AU3005 NOTE: CAUTION: • If the oil appears milky or dirty, check for When replacing the fuel filter 1, the arrow and repair the cause, and then change the mark a must face toward the fuel pump. oil.
Page 50: Checking The Timing Belt
Periodic check and adjustment 3. Place a drain pan under the drain hole, Checking the timing belt and then remove the engine oil drain bolt 2 and let the oil drain completely. CAUTION: Do not turn the flywheel magnet counter- clockwise, otherwise the water pump impeller may be damaged.
Page 51: Checking The Thermostat
Power unit 3. Check the spark plug. Replace if the electrodes are eroded or there is exces- sive carbon or other deposits, or if the gasket is damaged. 4. Check the spark plug gap a. Adjust the spark plug gap if out of specification. S6AU3015 CAUTION: Do not reuse the gasket 3, always...
Page 52: Chk Adj
Periodic check and adjustment 6. Measure the thermostat valve opening a 3. Check for water flow at the cooling water at the specified water temperatures. pilot hole. If there is no water flow, check Replace the thermostat if out of specifi- the cooling water passages inside the cation.
Page 53: Adjusting The Throttle Cable (R Model)
Power unit / Control system É NOTE: Be careful not to pull the outer cables too much towards the power unit as they could be pulled out of the holes in the pivot section of the tiller handle. If the outer cables are pulled out of the tiller handle, see “Installing the tiller handle”...
Page 54: Adjusting The Throttle Link
Periodic check and adjustment 5. Adjust the position of the throttle cable É joint 4 until its hole is aligned with the set pin on the throttle cam 6. S6AU3026 È Fully open position É Fully closed position S6AG1090 8. Connect the throttle link rod 1 to the free accel lever.
Page 55: Checking The Gear Shift Operation (H Model)
Control system 4. Turn the free accel lever 4 counterclock- wise until it contacts the throttle cam c. 5. Tighten the throttle link stopper screw 1. 6. Turn the throttle grip (H model) or remote control lever (R model) to the fully open and fully closed positions and check that the throttle cam operates smoothly.
Page 56: Checking The Start-In-Gear Protection (M Model)
Periodic check and adjustment 4. Adjust the position of the shift cable joint 1. Set the shift lever to the F position or R until its hole is aligned with the set pin on position, and then check that the starter the shift rod lever joint.
Page 57: Checking The Ignition Timing
Control system / Bracket unit 3. Check that the pointer a is aligned with the “5” mark on the flywheel magnet as Digital tachometer: 90890-06760 shown. 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.
Page 58: Checking The Tilt Operation (Mt Model)
Periodic check and adjustment 2. Adjust the self-locking nut 2 until the steering operation is proper. S6AG3220 Checking the PT fluid level S6AG3430 1. Fully tilt the outboard motor up, and then Checking the tilt operation (MT support it with the tilt stop lever. model) WARNING 1.
Page 59: Lower Unit
Bracket unit / Lower unit 4. Install a new O-ring and the reservoir cap 1, and then tighten the cap to the speci- Recommended gear oil: Hypoid gear oil fied torque. API: GL-4 Reservoir cap 1: SAE: 90 5 N·m (0.5 kgf·m, 3.7 ft·lb) 4.
Page 60: Checking The Lower Unit For Air Leakage
Periodic check and adjustment 3. Check the oil for metal and 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 61: General
Lower unit / General General CAUTION: Checking the anode Do not oil, grease, or paint the anodes, 1. Check the anodes. Clean the anodes if otherwise they will be ineffective. there are scales, grease, or oil. NOTE: • Replace the anodes if excessively eroded. In addition, check the ground lead.
Page 62: Lubricating The Outboard Motor
Periodic check and adjustment WARNING Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. S6AG3450 •...
Page 63 General 3. Apply corrosion resistant grease to the area shown. 3-18 6AU3K11...
Page 64 Periodic check and adjustment — MEMO — 3-19 6AU3K11...
Page 65: Fuel
FUEL Fuel system Hose routing ....................4-1 Fuel hose, blowby hose, and cooling water hose........4-1 Fuel pump, fuel filter, and fuel joint ............. 4-2 Checking the fuel pump................4-4 Checking the fuel filter ................4-4 Checking the fuel joint ................4-5 Disassembling the fuel pump ..............
Page 66: Fuel System
FUEL Fuel system Hose routing Fuel hose, blowby hose, and cooling water hose S6AU4001 1 Cooling water hose 8 Fuel hose (fuel pump-to-carburetor assembly) (thermostat cover-to-cylinder block) 2 Blowby hose (cylinder head cover-to-intake silencer) 3 Fuel hose (fuel joint-to-fuel filter assembly) 4 Flushing hose (flushing hose adapter-to-intake manifold) (for Europe)
Page 67: Fuel Pump, Fuel Filter, And Fuel Joint
Hose routing / Fuel pump, fuel filter, and fuel joint Fuel pump, fuel filter, and fuel joint · · · m (0.8 kgf m, 5.9 ft S6AU4005 Part name Q’ty Remarks Fuel pump M6 × 30 mm Bolt O-ring Not reusable Clamp Fuel hose Fuel hose...
Page 68 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 S6AU4006 Part name Q’ty Remarks ø4 × 30 mm Screw Cover Diaphragm...
Page 69: Checking The Fuel Pump
Fuel pump, fuel filter, and fuel joint 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 70: Checking The Fuel Joint
FUEL Fuel system Checking the fuel joint 1. Check the fuel joint. Replace if cracked or damaged. 2. Connect the special service tool to the fuel joint outlet. 90˚ 3. Apply the specified positive pressure. Replace the fuel joint if the specified pressure cannot be maintained for at S6AU4011 least 10 seconds.
Page 71: Assembling The Fuel Pump
Fuel pump, fuel filter, and fuel joint Assembling the fuel pump NOTE: Clean the parts and soak the valves and the diaphragms in gasoline before assembly. 1. Install the plunger 1 and diaphragm into fuel pump body 1 2, and then install the pin 3 to the plunger 1.
Page 72: Carburetor Unit
FUEL Fuel system Carburetor unit · · · m (0.6 kgf m, 4.4 ft · · · 12 N m (1.2 kgf m, 8.9 ft S6AU4017 Part name Q’ty Remarks Plastic tie O-ring R model M6 × 12 mm Bolt Holder Choke solenoid R model...
Page 73 Carburetor unit · · · m (0.6 kgf m, 4.4 ft · · · 12 N m (1.2 kgf m, 8.9 ft S6AU4017 Part name Q’ty Remarks Carburetor assembly Gasket Not reusable Spacer M6 × 35 mm Bolt M6 × 25 mm Bolt Intake manifold Gasket...
Page 74: Carburetor
FUEL Fuel system Carburetor S6AU4018 Part name Q’ty Remarks ø4 × 10 mm Screw Cover Gasket Not reusable Plug Carburetor body ø4 × 20 mm Throttle stop screw Spring Boot Plunger rod Pilot screw For Europe Pilot screw For Oceania O-ring Not reusable Main nozzle...
Page 75 Carburetor unit S6AU4018 Part name Q’ty Remarks Gasket Not reusable Needle valve Float Float chamber assembly ø3 × 6 mm Screw Plunger rod guide O-ring Not reusable Plunger Spring Circlip Ball Float chamber Drain screw Gasket Not reusable ø4 × 10 mm Screw 4-10 6AU3K11...
Page 76: Removing The Carburetor
FUEL Fuel system Removing the carburetor 1. Disconnect the fuel hose 1 and blowby hose 2. S6AU4035 NOTE: Remove the float pin 1 in the direction of the S6AU4020 arrow shown, which is opposite to the arrow mark a on the carburetor body 3. 2.
Page 77: Assembling The Carburetor
Carburetor unit 4. Check the pilot screw and needle valve. Replace if worn or deformed. S6AU4027 2. Install the needle valve, float 5, and float S6AG4200 pin 6 as shown, and then check the float 5. Check the float. Replace if cracked or for smooth operation.
Page 78: Installing The Carburetor
FUEL Fuel system 3. Install the pilot screw 8, turn it in until it is lightly seated, and then turn it out the specified number of turns. È É S6AU4030 È For Europe S6AU4031 É For Oceania NOTE: Pilot screw adjusting tool 9 (for •...
Page 79 Carburetor unit 4. Turn the pilot screw 1 in direction a NOTE: until it is lightly seated, and then turn it in • To increase the engine idle speed, turn the direction b the specified number of throttle stop screw 3 in direction c. turns.
Page 80: Powr
POWR Power unit Power unit (check and adjustment).............. 5-1 Checking the compression pressure ............5-1 Checking the valve clearance..............5-1 Replacing the timing belt ................5-3 Manual starter (M model)................5-6 Disassembling the manual starter ............. 5-8 Checking the manual starter..............5-8 Assembling the manual starter ..............5-9 Power unit.....................
Page 81 Cylinder block ....................5-39 Disassembling the cylinder block ............5-41 Checking the piston diameter ..............5-42 Checking the cylinder bore ..............5-42 Checking the piston clearance ..............5-42 Checking the piston ring ................5-43 Checking the piston ring end gap ............5-43 Checking the piston ring groove ..............5-43 Checking the piston ring side clearance..........
Page 82: Power Unit
POWR Power unit Power unit (check and 6. If the compression pressure is below specification or the compression pres- adjustment) sure for each cylinder is unbalanced, add Checking the compression pressure a small amount of engine oil to the cylin- 1.
Page 83 Power unit (check and adjustment) S6AU5004 S6AU5174 NOTE: 5. Measure the intake and exhaust valve • To decrease the valve clearance, turn the clearances for cylinder #1. Adjust if out of adjusting screw in direction e. specification. • To increase the valve clearance, turn the adjusting screw in direction f.
Page 84: Replacing The Timing Belt
POWR Power unit Replacing the timing belt NOTE: Use a 22 mm socket to loosen the flywheel CAUTION: magnet nut. Do not turn the flywheel magnet counter- clockwise, otherwise the water pump impeller may be damaged. Flywheel holder: 90890-06522 NOTE: 4.
Page 85 Power unit (check and adjustment) S6AU5015 S6AU5018 ” mark a on the driven CAUTION: 6. Align the “1 sprocket 3 with the “ ” mark b on the Unless directed to do so in the following thermostat cover. instructions, turn drive sprocket or driven sprocket when the tim- ing belt is not installed.
Page 86 POWR Power unit 9. Turn the drive sprocket clockwise 2 turns, and then check that the parts are aligned at the areas f and g as shown. S6AG5G40 WARNING Apply force in the direction of the arrows S6AU5020 shown to prevent the flywheel holder from 10.
Page 87: Manual Starter (M Model)
Power unit (check and adjustment) / Manual starter (M model) Manual starter (M model) · · · m (0.5 kgf m, 3.7 ft S6AU5024 Part name Q’ty Remarks Start-in-gear protection cable M6 × 20 mm Bolt Spring Starter plunger Spring Cover Fuse puller E model...
Page 88 POWR Power unit · · · m (0.5 kgf m, 3.7 ft S6AU5024 Part name Q’ty Remarks Spring Drive pawl spring 1 Drive plate ø5 × 20 mm Screw 6AU3K11...
Page 89: Disassembling The Manual Starter
Manual starter (M model) 5. Remove the starter rope 1 and E-clip 6, Disassembling the manual starter and then remove the drive pawl 7, drive 1. While holding the starter rope 1, turn the pawl spring 2 8, and spring 9 from the sheave drum 2 in the direction of the sheave drum 2.
Page 90: Assembling The Manual Starter
POWR Power unit 3. Check the sheave drum. Replace if cracked or damaged. 4. Check the spiral spring. Replace if cracked, bent, or damaged. S6AG5540 5. Check the starter handle. Replace if cracked or damaged. S6AU5030 6. Check the starter rope. Replace if dam- NOTE: aged.
Page 91 Manual starter (M model) 8. Turn the sheave drum 2 4 turns in the direction of the arrow shown. S6AU5032 NOTE: S6AU5035 Hook the end c of the spiral spring 8 onto the cut-out d in the manual starter cover 9. NOTE: Hold the starter plunger 4 while turning the sheave drum as shown.
Page 92: Power Unit
POWR Power unit 11. Install the manual starter onto the power unit, and then connect the start-in-gear protection cable. 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 (M model)”...
Page 93: Power Unit Assembly
Manual starter (M model) / Power unit Power unit Power unit assembly · · · 18 N m (1.8 kgf m, 13.3 ft · · · 2.5 N m (0.25 kgf m, 1.84 ft · · · m (0.4 kgf m, 3.0 ft ·...
Page 94 POWR Power unit · · · 18 N m (1.8 kgf m, 13.3 ft · · · 2.5 N m (0.25 kgf m, 1.84 ft · · · m (0.4 kgf m, 3.0 ft · · · 21 N m (2.1 kgf m, 15.5 ft S6AU5038 Part name...
Page 95: Ignition Coil, Cdi Unit, And Rectifier (M Model)
Power unit Ignition coil, CDI unit, and Rectifier (M model) · · · m (0.5 kgf m, 3.7 ft · · · 24 N m (2.4 kgf m, 17.7 ft · · · 18 N m (1.8 kgf m, 13.3 ft ·...
Page 96: Ignition Coil, Cdi Unit, And Rectifier Regulator (E Model)
POWR Power unit Ignition coil, CDI unit, and Rectifier Regulator (E model) · · · · · · m (0.5 kgf m, 3.7 ft 21 N m (2.1 kgf m, 15.5 ft · · · m (0.4 kgf m, 3.0 ft ·...
Page 97 Power unit · · · · · · m (0.5 kgf m, 3.7 ft 21 N m (2.1 kgf m, 15.5 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.8 kgf m, 5.9 ft ·...
Page 98: Throttle Cam And Oil Pressure Switch
POWR Power unit Throttle cam and oil pressure switch · · · m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.8 kgf m, 5.9 ft S6AU5045 Part name Q’ty Remarks Oil pressure switch Oil pressure switch lead...
Page 99: Removing The Power Unit
Power unit Removing the power unit NOTE: 1. Disconnect the start-in-gear protection To disconnect the leads, see “Electrical com- cable, and then remove the driven ponent and wiring harness routing” (8-1). sprocket cover and manual starter. (M model) Remove the driven sprocket cover and 5.
Page 100: Timing Belt And Sprocket
POWR Power unit Timing belt and sprocket · · · · · · 98 N m (9.8 kgf m, 72.3 ft 12 N m (1.2 kgf m, 8.9 ft · · · 12 N m (1.2 kgf m, 8.9 ft ·...
Page 101 Timing belt and sprocket · · · · · · 98 N m (9.8 kgf m, 72.3 ft 12 N m (1.2 kgf m, 8.9 ft · · · 12 N m (1.2 kgf m, 8.9 ft · · · 36 N m (3.6 kgf m, 26.6 ft...
Page 102: Removing The Timing Belt And Sprocket
POWR Power unit Removing the timing belt and sprocket 1. Remove the flywheel magnet, charge coil, and lighting coil(s). NOTE: See “Replacing the timing belt” (5-3). ” mark a on the driven 2. Align the “1 S6AU5056 sprocket 1 with the “ ” mark b on the thermostat cover.
Page 103: Checking The Timing Belt And Sprocket
Timing belt and sprocket Installing the sprocket and timing NOTE: belt Make sure that the driven sprocket does not turn when loosening the driven sprocket bolt. CAUTION: Unless directed to do so in the following instructions, do not turn the crankshaft or Flywheel holder 3: 90890-06522 camshaft when the timing belt is not installed.
Page 104 POWR Power unit 3. Install the power unit to the special ser- vice tool 6, and then tighten the drive sprocket nut 5 to the specified torque. S6AU5064 6. Hold the driven sprocket using the spe- cial service tool C, and then tighten the driven sprocket bolt B to the specified torque.
Page 105 Timing belt and sprocket 8. Align the notch e in the drive sprocket with the “ ” mark f on the cylinder block by turning the crankshaft counter- clockwise approximately 90° gradually. S6AU5070 11. Install the charge coil, lighting coil(s), and flywheel magnet.
Page 106: Cylinder Head
POWR Power unit Cylinder head · · · · · · 18 N m (1.8 kgf m, 13.3 ft m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft · · · 15 N m (1.5 kgf m, 11.1 ft ·...
Page 107 Cylinder head · · · m (0.7 kgf m, 5.2 ft ME-1 · · · m (0.8 kgf m, 5.9 ft S6AU5072 Part name Q’ty Remarks Oil seal Not reusable Cylinder head Intake valve Exhaust valve Camshaft Gasket Not reusable Oil pump assembly M6 ×...
Page 108 POWR Power unit · · · m (0.7 kgf m, 5.2 ft ME-1 · · · m (0.8 kgf m, 5.9 ft S6AU5072 Part name Q’ty Remarks Rocker arm Spring Collar Shaft 5-27 6AU3K11...
Page 109: Removing The Cylinder Head
Cylinder head Removing the cylinder head 1. Remove the cylinder head cover. 2. Remove the cylinder head bolts in the sequence shown. S6AU5075 NOTE: • Loosen the locknuts and adjusting screws to ease the tension on the rocker arm shaft before pulling it out.
Page 110: Checking The Cylinder Head
POWR Power unit 4. Remove the intake and exhaust valves. S6AU5078 S6AU5079 NOTE: Cylinder head warpage limit: Be sure to keep the valves, springs, and 0.10 mm (0.0039 in) other parts in the order as they were removed. Checking the valve spring 1.
Page 111: Checking The Valve
Cylinder head Valve stem diameter b: Intake: 5.475–5.490 mm (0.2156–0.2161 in) Exhaust: 5.460–5.475 mm (0.2150–0.2156 in) 4. Measure the valve stem runout. Replace the valve if above specification. Valve spring tilt limit b: 1.0 mm (0.039 in) Checking the valve 1.
Page 112: Replacing The Valve Guide
POWR Power unit 2. Calculate the valve-stem-to-valve-guide NOTE: clearance as follows. Replace the valve Apply engine oil to the surface of a new valve guide if out of specification. guide 3 before installation. Valve-stem-to-valve-guide clearance = valve guide inside diameter – valve Valve guide remover/installer 2: stem diameter: 90890-06801...
Page 113: Refacing The Valve Seat
Cylinder head 2. Apply a thin, even layer of Mechanic’s Valve seat contact width a: blueing dye (Dykem) onto the valve seat. Intake and exhaust: 3. Press the valve lightly against the valve 0.6–0.8 mm (0.024–0.031 in) seat with a valve lapper as shown. Refacing the valve seat 1.
Page 114 POWR Power unit 2. Cut the surface of the valve seat with a 45° cutter by turning the cutter clockwise until the valve seat face has become smooth. 60˚ S6AG5J70J b Previous contact width 5. Use a 45° cutter to adjust the contact width of the valve seat to specification.
Page 115: Checking The Rocker Arm And Rocker Arm Shaft
Cylinder head 8. If the valve seat contact area is too nar- CAUTION: row and situated near the top edge of the valve face, use a 30° cutter to cut the top Do not get the lapping compound on the edge of the valve seat, and then use a valve stem and valve guide.
Page 116: Checking The Camshaft
POWR Power unit Checking the camshaft 1. Measure the cam lobe. Replace if out of specification. S6AU5107 Camshaft journal diameter c: 17.975–17.991 mm (0.7077–0.7083 in) Cam lobe a: Cylinder head journal inside diameter d: Intake and exhaust: 18.000–18.018 mm 23.45–23.55 mm (0.7087–0.7094 in) (0.9232–0.9272 in) Cam lobe b:...
Page 117 Cylinder head 4. Install a new oil seal 9. ME-1 S6AU5115 Driver rod L3 0: 90890-06652 Needle bearing attachment A: 90890-06653 Valve spring compressor 6: 5. Install the camshaft B in the direction 90890-04019 Valve spring compressor shown. attachment 7: 90890-06320 3.
Page 118: Installing The Cylinder Head
POWR Power unit 7. Install the rocker arms C, springs D, and collars E and F into the cylinder Oil pump assembly bolt: 8 N·m (0.8 kgf·m, 5.9 ft·lb) head, and then install the rocker arm shaft G. Installing the cylinder head 1.
Page 119 Cylinder head S6AU5122 2. Check the inner surface of the oil pump housing. Replace the oil pump assembly if scratched. 3. Assemble the oil pump, and then tighten the oil pump screws 1 to the specified torque. S6AU5125 NOTE: • The punch mark a on the outer rotor 2 faces towards the oil pump cover.
Page 120: Cylinder Block
POWR Power unit Cylinder block · · · m (0.8 kgf m, 5.9 ft · · · m (0.6 kgf m, 4.4 ft · · · 12 N m (1.2 kgf m, 8.9 ft · · · 15 N m (1.5 kgf m, 11.1 ft ·...
Page 121 Cylinder block · · · m (0.8 kgf m, 5.9 ft · · · m (0.6 kgf m, 4.4 ft · · · 12 N m (1.2 kgf m, 8.9 ft · · · 15 N m (1.5 kgf m, 11.1 ft ·...
Page 122: Disassembling The Cylinder Block
POWR Power unit Disassembling the cylinder block 1. Remove the exhaust cover bolts in the sequence shown, and then remove the exhaust cover 1. S6AU5177 NOTE: Insert a flat-head screwdriver between the tabs 4 of the crankcase and the cylinder S6AU5127 block to separate them.
Page 123: Checking The Piston Diameter
Cylinder block Checking the cylinder bore 1. Measure the cylinder bore (D –D ) at measuring points a, b, and c, and in direction d (D ), which is parallel to the crankshaft, and in direction e (D ), which is at a right angle to the crankshaft.
Page 124: 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. S6AU5133 Piston ring dimensions: Top ring a: B: 1.17–1.19 mm S6AU5134 (0.0461–0.0469 in) NOTE: T: 1.95–2.15 mm The figures are for reference only.
Page 125: 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. S6AU5135 Piston ring groove: Top ring a: S6AU5137 1.23–1.25 mm (0.0484–0.0492 in) Piston pin boss bore: 2nd ring b: 14.004–14.015 mm 1.52–1.54 mm (0.5513–0.5518 in)
Page 126: 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. S6AU5141 S6AU5139 Connecting rod small end inside diameter a: 14.015–14.029 mm (0.5518–0.5523 in) S6AU5142 Connecting rod big end inside diameter b:...
Page 127: Checking The Crankshaft Journal Oil Clearance
Cylinder block 2. Put a piece of Plastigauge (PG-1) onto the crankpin, parallel to the crankshaft. S6AU5146 NOTE: S6AU5144 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.
Page 128 POWR Power unit 2. Place the cylinder block upside down on 6. Install the crankcase onto the cylinder a bench. block. 3. Install half of the main bearings 1 and NOTE: Apply engine oil to the threads of the crank- the crankshaft 2 into the cylinder block case bolts.
Page 129: Selecting The Crankshaft Main Bearing
Cylinder block Assembling the cylinder block NOTE: 1. Assemble the piston 1, connecting rod When loosening the crankcase bolts, loosen 2, piston pin 3, and piston pin clips 4. them in the opposite order used for tighten- ing. Crankshaft journal oil clearance (reference data): 0.006–0.034 mm (0.0002–0.0013 in)
Page 130 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 each piston and the piston rings before installation. NOTE: Make sure that the “N” marks d of the 2nd ring and the top ring are facing upward.
Page 131 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. S6AU5160 È NOTE: Do not get any sealant on the main bearings. 10.
Page 132: Installing The Power Unit
POWR Power unit 11. Install the relief valve E and tighten it to 2. Install the dowels 1, a new gasket 2, and the power unit 3, and then tighten the specified torque. the mounting bolts 4 to the specified torque.
Page 133 Cylinder block S6AU5172 6. Connect the engine shut-off switch leads, oil pressure warning indicator leads, and engine start button leads. (H model) Connect the 10-pin main harness to the power unit. (R model) NOTE: To connect the leads, see “Electrical compo- nent and wiring harness routing”...
Page 134: 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 135 Lower unit (high thrust model) ..............6-21 Removing the lower unit ................6-24 Removing the water pump............... 6-25 Checking the water pump................6-25 Propeller shaft housing (high thrust model) ..........6-26 Removing the propeller shaft housing assembly........6-27 Disassembling the propeller shaft assembly ...........6-27 Disassembling the propeller shaft housing assembly......6-27 Checking the propeller shaft housing ............6-28 Checking the propeller shaft..............
Page 136: Lower Unit
LOWR Lower unit Lower unit · · · 17 N m (1.7 kgf m, 12.5 ft · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.8 kgf m, 5.9 ft · · · 18 N m (1.8 kgf m, 13.3 ft ·...
Page 137 Lower unit · · · 17 N m (1.7 kgf m, 12.5 ft · · · 18 N m (1.8 kgf m, 13.3 ft · · · m (0.8 kgf m, 5.9 ft · · · 18 N m (1.8 kgf m, 13.3 ft ·...
Page 138 LOWR Lower unit · · · 18 N m (1.8 kgf m, 13.3 ft · · · 18 N m (1.8 kgf m, 13.3 ft S6AU6002 Part name Q’ty Remarks M8 × 45 mm Bolt Plate Rubber seal Water pump housing Insert cartridge Impeller O-ring...
Page 139: Removing The Lower Unit
Lower unit 4. Remove the locknut 1. Removing the lower unit 1. Drain the gear oil. S6AU6005 NOTE: Be sure to remove the locknut from the shift rod before removing the lower unit. S6AU6003 5. Remove the lower unit by removing the 2.
Page 140: 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 141: Propeller Shaft Housing
Lower unit / Propeller shaft housing Propeller shaft housing · · · m (0.8 kgf m, 5.9 ft S6AU6008 Part name Q’ty Remarks Cross pin Dog clutch Cross pin ring Shift plunger Spring Propeller shaft Washer Reverse gear Reverse gear shim —...
Page 142: 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 1 from the propeller 1. Remove the reverse gear and shim(s). shaft housing. 2. Remove the propeller shaft housing assembly 2. S6AU6012 2.
Page 143: 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 144: Assembling The Propeller Shaft Housing
LOWR Lower unit Assembling the propeller shaft Installation depth a: housing 3.0–3.5 mm (0.12–0.14 in) 1. Install a new bushing into the propeller shaft housing to the specified depth. 3. Install a new ball bearing into the propel- ler shaft housing. S6AU6021 Driver rod L3 1: 90890-06652 S6AU6025...
Page 145: Drive Shaft And Lower Case
Propeller shaft housing / Drive shaft and lower case Drive shaft and lower case S6AU6027 Part name Q’ty Remarks Shift rod L-transom model/S-transom model Gasket Not reusable Drive shaft sleeve O-ring Not reusable Oil seal Not reusable Bushing Drive shaft housing Drive shaft L-transom model/S-transom model Clip...
Page 146: Removing The Drive Shaft, Drive Shaft Housing, And Shift Rod
LOWR Lower unit Removing the drive shaft, drive shaft housing, and shift rod 1. Remove the E-clip 1, pinion 2, and thrust washer 3. S6AU6031 Driver rod L3 1: 90890-06652 Bushing attachment 2: 90890-06650 S6AU6028 Disassembling the lower case 2. Remove the drive shaft, drive shaft hous- ing assembly 4, gasket 5, and shift rod 1.
Page 147: Checking The Pinion And Forward Gear
Drive shaft and lower case Checking the shift rod 1. Check the shift rod. Replace if bent or worn. Checking the lower case 1. Check the skeg, torpedo, and anti-cavita- tion plate. Replace the lower case if cracked or damaged. S6AU6158 Assembling the lower case 1.
Page 148: Assembling The Drive Shaft Housing
LOWR Lower unit 2. Install a new bushing 5 into the lower 2. Apply grease to new oil seals, and then case. install them into the drive shaft housing to the specified depth. S6AU6041 S6AU6047 NOTE: Install the bushing until its flange is in tight NOTE: contact with the lower case.
Page 149: Installing The Propeller Shaft Housing
Drive shaft and lower case S6AU6051 S6AU6048 NOTE: S6AU6157 When installing the pinion, lift up the drive NOTE: shaft slightly and align the pinion and shaft Install the propeller shaft housing assembly splines. with the arrow mark a facing upward. Installing the propeller shaft housing Propeller shaft housing bolt 4: 1.
Page 150: Installing The Water Pump
LOWR Lower unit Installing the water pump NOTE: 1. Install the dowels 1 and outer plate car- Align the insert cartridge projection a with tridge 2. the hole b in the water pump housing. 4. Install the water pump housing assembly 7 into the lower case, and then install the rubber seal 8.
Page 151 Drive shaft and lower case 2. Set the shift rod to the R position. S6AU6059 S6AU6057 Screwed-in length a: 3. Install the lower unit to the upper case, 8.0–9.0 mm (0.31–0.35 in) and then tighten the lower case mounting bolts 1 to the specified torque. 5.
Page 152: Backlash
LOWR Lower unit 7. Install the propeller = and propeller nut A. 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 153 Drive shaft and lower case / Backlash S6AU6074 S6AU6076 Center bolt 1: 90890-06504 NOTE: Install the dial gauge so that the plunger tip Stopper guide plate 2: 90890-06501 a is aligned with the mark b on the back- Bearing housing puller claw S 3: lash indicator.
Page 154 LOWR Lower unit 8. Adjust the current shim thickness if the forward gear backlash is out of specifica- tion. Forward gear Shim thickness backlash Less than To be decreased by (1.39 – M) × 0.40 0.50 mm (0.0197 in) More than To be increased by (M –...
Page 155 Backlash NOTE: To install the water pump assembly, see “Installing the water pump” (6-15). 16. Fill the lower unit with gear oil to the cor- rect level. 6-20 6AU3K11...
Page 156: Lower Unit (High Thrust Model)
LOWR Lower unit Lower unit (high thrust model) 27 28 · · · 18 N m (1.8 kgf m, 13.3 ft 11 6 · · · 21 N m (2.1 kgf m, 15.5 ft · · · · · · 18 N m (1.8 kgf m, 13.3 ft...
Page 157 Lower unit (high thrust model) 27 28 · · · 18 N m (1.8 kgf m, 13.3 ft 11 6 · · · 21 N m (2.1 kgf m, 15.5 ft · · · · · · 18 N m (1.8 kgf m, 13.3 ft 18 N m (1.8 kgf...
Page 158 LOWR Lower unit · · · 18 N m (1.8 kgf m, 13.3 ft · · · 18 N m (1.8 kgf m, 13.3 ft S6AU6080 Part name Q’ty Remarks M8 × 45 mm Bolt Plate Rubber seal Water pump housing Insert cartridge Impeller O-ring...
Page 159: Removing The Lower Unit
Lower unit (high thrust model) 4. Remove the locknut 1. Removing the lower unit 1. Drain the gear oil. S6AU6005 NOTE: Be sure to remove the locknut from the shift rod before removing the lower unit. S6AU6081 5. Remove the lower unit by removing the 2.
Page 160: 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 161: Propeller Shaft Housing (High Thrust Model)
Lower unit (high thrust model) / Propeller shaft housing (high thrust model) Propeller shaft housing (high thrust model) · · · m (0.8 kgf m, 5.9 ft S6AU6086 Part name Q’ty Remarks Cross pin Dog clutch Cross pin ring Shift plunger Spring Propeller shaft Washer...
Page 162: 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 1 from the propeller 1. Remove the reverse gear and shim(s). shaft housing. 2. Remove the propeller shaft housing assembly 2. S6AU6090 2.
Page 163: Checking The Propeller Shaft Housing
Propeller shaft housing (high thrust model) Propeller shaft runout limit: 0.02 mm (0.0008 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.
Page 164: Assembling The Propeller Shaft Housing
LOWR Lower unit Assembling the propeller shaft housing 1. Install a new needle bearing into the pro- peller shaft housing to the specified depth a. S6AU6101 NOTE: Install an oil seal halfway into the propeller shaft housing, and then install the other oil seal.
Page 165 Propeller shaft housing (high thrust model) Driver rod LS 5: 90890-06606 Ball bearing attachment 6: 90890-06632 4. Install the reverse gear and original shim(s) into the propeller shaft housing. S6AU6104 NOTE: • Be sure to select the reverse gear shim(s) if replacing the propeller shaft housing, ball bearing, or lower case.
Page 166: Drive Shaft And Lower Case (High Thrust Model)
LOWR Lower unit Drive shaft and lower case (high thrust model) · · · 25 N m (2.5 kgf m, 18.4 ft S6AU6105 Part name Q’ty Remarks Shift rod L-transom model/X-transom model Gasket Not reusable Drive shaft sleeve Needle bearing Not reusable O-ring Not reusable...
Page 167: Removing The Drive Shaft, Drive Shaft Housing, And Shift Rod
Drive shaft and lower case (high thrust model) Removing the drive shaft, drive shaft housing, and shift rod 1. Remove the pinion nut. S6AU6109 Driver rod L3 1: 90890-06652 Bushing attachment 2: S6AU6106 90890-06649 2. Remove the pinion, pinion shim(s), and Disassembling the lower case roller bearing.
Page 168: Checking The Pinion And Forward Gear
LOWR Lower unit 2. Remove the needle bearing from the Drive shaft runout limit: lower case. 0.5 mm (0.0197 in) Checking the shift rod 1. Check the shift rod. Replace if bent or worn. Checking the lower case 1. Check the skeg, torpedo, and anti-cavita- tion plate.
Page 169: Assembling The Drive Shaft Housing
Drive shaft and lower case (high thrust model) NOTE: • Install the needle bearing with the manufac- ture identification mark b facing upward. • Install the stopper c onto the driver rod SL at the installation depth a as shown. Install the needle bearing until the stopper c con- tacts the special service tool 5.
Page 170: Installing The Shift Rod, Drive Shaft Housing, And Drive Shaft
LOWR Lower unit Installing the shift rod, drive shaft NOTE: housing, and drive shaft • When installing the pinion, lift up the drive 1. Install the forward gear assembly 1 into shaft slightly and align the pinion and shaft the lower case. splines.
Page 171: Installing The Water Pump
Drive shaft and lower case (high thrust model) S6AU6129 S6AG6390 Propeller shaft housing bolt 4: NOTE: When installing the impeller 4 onto the drive 8 N·m (0.8 kgf·m, 5.9 ft·lb) shaft, align the groove in the impeller with the Woodruff key 3. 3.
Page 172: Installing The Lower Unit
LOWR Lower unit 4. Install the water pump housing assembly 7 into the lower case, and then install the rubber seal 8. S6AU6135 3. Install the lower unit to the upper case, and then tighten the lower case mounting bolts 1 to the specified torque. S6AU6134 CAUTION: Do not turn the drive shaft counterclock-...
Page 173 Drive shaft and lower case (high thrust model) S6AU6059 S6AU6139 Screwed-in length a: 8.0–9.0 mm (0.31–0.35 in) 5. Tighten the locknut 5. NOTE: After connecting the shift rod, check that the gear shift operates properly. S6AU6062 6. Install the anode 8 and cooling water WARNING inlet covers 9, and then tighten the •...
Page 174: Shimming (High Thrust Model)
LOWR Lower unit Shimming (high thrust model) M2 T1 S6AU6141 6-39 6AU3K11...
Page 175: Shimming
Shimming (high thrust model) 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 176: Selecting The Reverse Gear Shim
LOWR Lower unit 3. Select the forward gear shim(s) (T1) as follows. 10 mm Shim thickness (0.39 in) Calculated number (mm) 0.00–0.10 — M3’ 0.11–0.20 0.10 0.21–0.30 0.20 0.31–0.40 0.30 S6AG6490J 0.41–0.50 0.40 M3 = M3’ – 10 mm NOTE: Available shim thicknesses: Measure the propeller shaft housing at 4 0.10, 0.20, 0.30, and 0.40 mm...
Page 177: Backlash (High Thrust Model)
Shimming (high thrust model) / Backlash (high thrust model) Backlash (high thrust model) Measuring the forward and reverse 10 mm gear backlash (0.39 in) NOTE: M4’ • Remove the water pump assembly before measuring the backlash. • Secure the drive shaft housing to the lower case using 6 bolts (M8 ×...
Page 178 LOWR Lower unit 5. Tighten the center bolt 1 to the specified NOTE: torque while turning the drive shaft. Install the dial gauge so that the plunger tip a is aligned with the mark b on the back- lash indicator. Backlash indicator 4: 90890-06706 Magnet base plate 5: 90890-07003 Dial gauge set 6: 90890-01252...
Page 179 Backlash (high thrust model) 11. Install the propeller, spacer 8, and nut, without installing the spacer 9. Reverse gear backlash: 0.76–2.30 mm (0.0299–0.0906 in) 14. Adjust the current shim thickness if the reverse gear backlash is out of specifica- tion. Reverse gear Shim thickness backlash...
Page 180: Brkt
BRKT Bracket unit Tiller handle (short)..................7-1 Removing the tiller handle ................. 7-3 Installing the tiller handle ................7-3 Tiller handle (long) ..................7-5 Removing the tiller handle ................. 7-8 Installing the tiller handle ................7-8 Friction plate (H model) ................7-11 Disassembling the friction plate...............7-12 Assembling the friction plate..............
Page 181 PT gear pump ....................7-41 Disassembling the gear pump ..............7-44 Checking the gear pump .................7-44 Checking the valve seal................7-44 Checking the filter..................7-44 Assembling the gear pump..............7-45 PT cylinder....................7-47 Disassembling the tilt cylinder ..............7-49 Checking the tilt cylinder and piston ............7-49 Assembling the tilt cylinder ..............
Page 182: Bracket Unit
BRKT Bracket unit Tiller handle (short) · · · 22 N m (2.2 kgf m, 16.2 ft · · · 36 N m (3.6 kgf m, 26.6 ft S6AU7111 Part name Q’ty Remarks Throttle cable Plate Bushing Plug M model Engine start button E model Tiller handle bracket...
Page 183 Tiller handle (short) · · · m (0.2 kgf m, 1.5 ft · · · m (0.3 kgf m, 2.2 ft S6AU7112 Part name Q’ty Remarks Throttle cable Tiller handle Throttle friction adjuster Cotter pin Friction piece Engine shut-off switch ø5 ×...
Page 184: Removing The Tiller Handle
BRKT Bracket unit 3. Install the engine shut-off switch 3 to the Removing the tiller handle tiller handle 4, and then tighten the nut 1. Disconnect the engine shut-off switch 5 to the specified torque. Pass the leads and engine start button leads (E engine shut-off switch lead through a model).
Page 185 Tiller handle (short) NOTE: Make sure that the ends b of the outer throt- tle cables 8 are fitted securely into the holes in the pivot section of the tiller handle as shown. 5. Install the tiller handle assembly to the tiller handle bracket, and then tighten the nut to the specified torque.
Page 186: Tiller Handle (Long)
BRKT Bracket unit Tiller handle (long) · · · 22 N m (2.2 kgf m, 16.2 ft · · · 10 N m (1.0 kgf m, 7.4 ft · · · 36 N m (3.6 kgf m, 26.6 ft S6AU7001 Part name Q’ty Remarks...
Page 187 Tiller handle (long) · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.6 kgf m, 4.4 ft · ·...
Page 188 BRKT Bracket unit · · · m (0.3 kgf m, 2.2 ft · · · m (0.4 kgf m, 3.0 ft · · · m (0.2 kgf m, 1.5 ft · · · m (0.6 kgf m, 4.4 ft · ·...
Page 189: Removing The Tiller Handle
Tiller handle (long) Removing the tiller handle NOTE: 1. Disconnect the engine shut-off switch See the exploded diagram for assembly (7- leads, engine start button leads (E model), and PT switch leads (PT model). 2. Remove the manual starter. (M model) 2.
Page 190 BRKT Bracket unit 4. Install the engine shut-off switch 5 to the tiller handle 6, and then tighten the nut 7 to the specified torque. Pass the engine shut-off switch lead through a hole in the pivot section of the tiller han- dle.
Page 191 Tiller handle (long) 11. Connect the engine shut-off switch leads, engine start button leads (E model), and PT switch leads (PT model). 7-10 6AU3K11...
Page 192: Friction Plate (H Model)
BRKT Bracket unit Friction plate (H 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 193: Disassembling The Friction Plate
Friction plate (H 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° c until it is S6AG7A90 aligned.
Page 194 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 (H model)” (3-12). Friction self-locking nut 6: 6 N·m (0.6 kgf·m, 4.4 ft·lb) S6AU7013 NOTE:...
Page 195: Bottom Cowling
Friction plate (H model) / Bottom cowling Bottom cowling · · · m (0.3 kgf m, 2.2 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft S6AU7015 Part name Q’ty Remarks Flushing hose For Europe...
Page 196 BRKT Bracket unit · · · m (0.3 kgf m, 2.2 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft S6AU7015 Part name Q’ty Remarks M6 × 20 mm Bolt Bracket Clip M6 ×...
Page 197 Bottom cowling · · · m (0.3 kgf m, 2.2 ft · · · m (0.8 kgf m, 5.9 ft · · · m (0.2 kgf m, 1.5 ft S6AU7015 Part name Q’ty Remarks Grommet Collar Rubber seal Water outlet Grommet Grommet H model...
Page 198: Upper Case And Steering Arm
BRKT Bracket unit Upper case and steering arm · · · 20 N m (2.0 kgf m, 14.8 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.7 kgf m, 5.2 ft · · · 12 N m (1.2 kgf m, 8.9 ft...
Page 199 Upper case and steering arm · · · 20 N m (2.0 kgf m, 14.8 ft · · · m (0.3 kgf m, 2.2 ft · · · m (0.7 kgf m, 5.2 ft · · · 12 N m (1.2 kgf m, 8.9 ft ·...
Page 200 BRKT Bracket unit · · · 11 N m (1.1 kgf m, 8.1 ft · · · 11 N m (1.1 kgf m, 8.1 ft 1207B · · · 21 N m (2.1 kgf m, 15.5 ft 1104J · · ·...
Page 201 Upper case and steering arm · · · 11 N m (1.1 kgf m, 8.1 ft · · · 11 N m (1.1 kgf m, 8.1 ft 1207B · · · 21 N m (2.1 kgf m, 15.5 ft 1104J ·...
Page 202: 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 203: Checking The Exhaust Manifold, Oil Pan, And Exhaust Guide
Upper case and steering arm Exhaust manifold bolt 3: 11 N·m (1.1 kgf·m, 8.1 ft·lb) 2. Install a new oil seal 4 into the exhaust guide 5. S6AU7022 Checking the exhaust manifold, oil S6AU7025 pan, and exhaust guide Driver rod L3 6: 90890-06652 1.
Page 204: Removing The Steering Arm
BRKT Bracket unit 4. Install the baffle plate A and rubber seal Upper case bolt G: B to the oil pan C, and then tighten the oil pan bolts D to the specified torque. 18 N·m (1.8 kgf·m, 13.3 ft·lb) Upper mount bolt I: 11 N·m (1.1 kgf·m, 8.1 ft·lb) 7.
Page 205: Installing The Upper Case
Upper case and steering arm NOTE: Install the ground lead terminal 7 so that it is within the range a (30°) shown. 5. Tighten the mount housing nuts 0 to the specified torques in 3 stages and in the sequence shown. NOTE: Tighten the mount housing nuts 0 evenly and in the following order: 1–2–3–4.
Page 206 BRKT Bracket unit Upper mounting nut 2: 20 N·m (2.0 kgf·m, 14.8 ft·lb) Mount housing nut 0: 1st: 7 N·m (0.7 kgf·m, 5.2 ft·lb) 2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb) 3rd: 14 N·m (1.4 kgf·m, 10.3 ft·lb) Grease nipple C: 3 N·m (0.3 kgf·m, 2.2 ft·lb) 7-25 6AU3K11...
Page 207: Clamp Bracket And Swivel Bracket (Mt Model)
Upper case and steering arm / Clamp bracket and swivel bracket (MT model) Clamp bracket and swivel bracket (MT model) · · · m (0.8 kgf m, 5.9 ft · · · 19 N m (1.9 kgf m, 14.0 ft ·...
Page 208 BRKT Bracket unit S6AU7038 Part name Q’ty Remarks Tilt lever shaft Tilt lock lever a > b Tilt lock rod 1 Tilt support bar Stopper shaft Tilt lever E-clip a > b Spring Swivel bracket L-transom model/S-transom model Tilt lock rod 2 Pin 1 Tilt lock plate 2 Pin 2...
Page 209: Removing The Clamp Bracket
Clamp bracket and swivel bracket (MT model) Removing the clamp bracket 1. Remove the tilt pin 1, clamp bracket nut 2, and clamp bracket bolt 3. 2. Remove the tilt stopper plate bolts 4 (swivel bracket side). 3. Remove the self-locking nuts 5 and plate 6.
Page 210: Assembling The Swivel Bracket
BRKT Bracket unit 3. Remove the springs 9. 4. Remove the E-clip 0 from pin 2 A, and then pull out the pin. 5. Remove the E-clip B from pin 1 C, and then pull out the pin and remove the col- lars D, tilt lock rod 2 E, tilt lock plate 1 F, and tilt lock plate 2 G.
Page 211: Installing The Clamp Bracket
Clamp bracket and swivel bracket (MT model) 3. Assemble the clamp brackets 5 and NOTE: swivel bracket 6, and then install the • See the exploded diagram for the installa- collar 7, clamp bracket bolt 8, and tion directions of the spring D and tilt lock through tube 4 from the port side.
Page 212: Clamp Bracket And Swivel Bracket (Pt Model)
BRKT Bracket unit Clamp bracket and swivel bracket (PT model) · · · 19 N m (1.9 kgf m, 14.0 ft · · · 24 N m (2.4 kgf m, 17.7 ft · · · m (0.3 kgf m, 2.2 ft ·...
Page 213 Clamp bracket and swivel bracket (PT model) · · · 19 N m (1.9 kgf m, 14.0 ft · · · 24 N m (2.4 kgf m, 17.7 ft · · · m (0.3 kgf m, 2.2 ft · · ·...
Page 214: Removing The Pt Unit
BRKT Bracket unit 6. Remove the PT unit 6, and then remove Removing the PT unit the collar E. 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever. S6AG7771 WARNING After tilting up the outboard motor, be sure to support it with the tilt stop lever.
Page 215: Installing The Clamp Bracket
Clamp bracket and swivel bracket (PT model) Installing the clamp bracket Self-locking nut 5: 1. Tighten the self-locking nut 1 completely 19 N·m (1.9 kgf·m, 14.0 ft·lb) onto the shorter threaded end of the Ground lead bolt 7: through tube 2. 8 N·m (0.8 kgf·m, 5.9 ft·lb) Anode bolt 8: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
Page 216 BRKT Bracket unit 2. Install the collar 1 onto the PT unit 2. 6. Pass the PT motor lead E through the hole a in the clamp bracket (STBD). 3. Install the PT unit 2, collars 3 and 4, shaft 5, and washers 6 onto the clamp 7.
Page 217: Pt Motor
Clamp bracket and swivel bracket (PT model) / PT motor PT motor · · · m (0.5 kgf m, 3.7 ft · · · m (0.5 kgf m, 3.7 ft Part name Q’ty Remarks ø4 × 10 mm Screw Stator O-ring Not reusable Armature...
Page 218: Disassembling The Pt Motor
BRKT Bracket unit Disassembling the PT motor 1. Remove the PT unit from the bracket. NOTE: To remove the PT unit, see “Removing the PT unit” (7-33). 2. Fully extend the tilt ram, and then open the manual valve 1 by turning it counter- clockwise.
Page 219: Checking The Pt Motor
PT motor NOTE: Motor commutator standard • Push the brushes apart, and then remove diameter: 16.5 mm (0.65 in) the armature assembly. Wear limit: 15.5 mm (0.61 in) • Do not remove the bearing from the arma- ture assembly. 3. Measure the commutator undercut a. Replace the armature if below specifica- tion.
Page 220: Checking The Brush Holder And Brush
BRKT Bracket unit Checking the brush holder and Motor brush standard length: brush 6.0 mm (0.24 in) 1. Check the brush holder assembly for Wear limit a: 3.0 mm (0.12 in) continuity. Replace the PT motor base if out of specification. Assembling the PT motor CAUTION: •...
Page 221 PT motor 3. Push the brushes into the holders, and then install the armature assembly 8 and tighten the armature plate screw 9. S6AU7074 4. Install a new O-ring = and the stator A to the PT motor base 7, and then tighten the screws B.
Page 222: Pt Gear Pump
BRKT Bracket unit PT gear pump · · · m (0.5 kgf m, 3.7 ft 6, 9 · · · m (0.5 kgf m, 3.7 ft S6AU7077 Part name Q’ty Remarks O-ring Not reusable Manual valve Spring Manual release pin Spring Length: 14.6 mm (0.57 in) Valve pin...
Page 223 PT gear pump · · · m (0.5 kgf m, 3.7 ft 6, 9 · · · m (0.5 kgf m, 3.7 ft S6AU7077 Part name Q’ty Remarks Driven gear E-clip Main valve seal O-ring Not reusable Shuttle piston 1 Down-main valve O-ring Not reusable...
Page 224 BRKT Bracket unit · · · m (0.5 kgf m, 3.7 ft 6, 9 · · · m (0.5 kgf m, 3.7 ft S6AU7077 Part name Q’ty Remarks Spring Dowel Reservoir cap O-ring Not reusable 7-43 6AU3K11...
Page 225: Disassembling The Gear Pump
PT gear pump Disassembling the gear pump Checking the gear pump 1. Remove the manual valve 1, filter 2 1. Check the drive gear and driven gear. manual release pins 3, valve seals 4, Replace if damaged or excessively worn. and balls 5.
Page 226: Assembling The Gear Pump
BRKT Bracket unit Assembling the gear pump CAUTION: • Do not use a rag when assembling the PT unit as dust and particles on the PT unit components can lead to poor per- formance. • Do not reuse the O-rings, always replace them with new ones.
Page 227 PT gear pump S6AU7114 PT motor assembly bolt L: 5 N·m (0.5 kgf·m, 3.7 ft·lb) 7-46 6AU3K11...
Page 228: Pt Cylinder
BRKT Bracket unit PT cylinder · · · 45 N m (4.5 kgf m, 33.2 ft · · · 45 N m (4.5 kgf m, 33.2 ft · · · m (0.5 kgf m, 3.7 ft S6AU7087 Part name Q’ty Remarks Tilt ram assembly Tilt ram...
Page 229 PT cylinder · · · 45 N m (4.5 kgf m, 33.2 ft · · · 45 N m (4.5 kgf m, 33.2 ft · · · m (0.5 kgf m, 3.7 ft S6AU7087 Part name Q’ty Remarks O-ring Not reusable Tilt cylinder O-ring Not reusable...
Page 230: Disassembling The Tilt Cylinder
BRKT Bracket unit 5. Hold the tilt piston 5 in a vise using alu- Disassembling the tilt cylinder 1. Hold the cylinder 1 in a vise using alumi- minum plates on both sides, and then remove the tilt piston 5 and tilt cylinder num plates a on both sides.
Page 231: Assembling The Tilt Cylinder
PT cylinder 4. Check the tilt ram 9. Polish with 400– NOTE: 600-grit sandpaper if there is light rust or Lubricate the parts with ATF Dexron II during replace if bent or excessively corroded. assembly. 1. Install a new dust seal 1, new O-rings 2 and 3, and the backup ring 4 into the tilt cylinder end screw 5.
Page 232 BRKT Bracket unit 4. Install the tilt piston A. S6AU7096 S6AU7115 7. Install a new O-ring E to the tilt cylinder F, and then install the tilt cylinder into NOTE: Tighten the tilt piston temporarily, and then the cylinder G. check that the spring 9 is visible through the oil hole in the piston when the tilt ram assem- bly is upright.
Page 233: Bleeding The Pt Unit
PT cylinder S6AU7098 11. Place the tilt cylinder end screw 5 at the bottom of the tilt ram 6. S6AU7100 12. Install the tilt ram assembly into the cylin- der. Power tilt wrench B: 90890-06560 Tilt cylinder end screw 5: 45 N·m (4.5 kgf·m, 33.2 ft·lb) Bleeding the PT unit NOTE:...
Page 234 BRKT Bracket unit 3. Remove the reservoir cap 2, and then Battery check the fluid level in the reservoir. PT motor lead terminal Green (G) Down Blue (L) 6. Reverse the PT motor leads between the battery terminals to fully extend the tilt ram.
Page 235: Pt Electrical System
PT cylinder / PT electrical system NOTE: • If the fluid is at the correct level, a small amount of fluid should overflow out of the filler hole when the cap is removed. • If the fluid is below the correct level, add the recommended PT fluid.
Page 236: Checking The Pt Switch
BRKT Bracket unit 2. Connect the positive battery lead to the light green (Lg) lead 6, and the negative PT relay continuity battery lead to the black (B) terminal 1 as shown, and then check the PT relay Red (R) 2 – Blue (L) 4 Continuity for continuity.
Page 237 Electrical system Electrical component and wiring harness routing........8-1 Top view ....................8-1 Bow view ....................8-9 Port view....................8-11 Checking the electrical component............8-19 Measuring the peak voltage ..............8-19 Starter motor (E model) ................8-20 Removing the starter motor ..............8-22 Checking the starter motor operation ............8-22 Checking the starter motor pinion............
Page 238: Elec
– ELEC Electrical system Electrical component and wiring harness routing Top view H model with 1 lighting coil É È Í Ê Ë Ë Ì S6AU8001 5 Rectifier + H model (short) 6 Charge coil , H model (long) 7 CDI unit 1 Lighting coil 8 Pulser coil 2 Oil pressure switch...
Page 239 Electrical component and wiring harness routing È Route the oil pressure switch lead in the direction shown. É Fit the oil pressure switch lead into the groove in the driven sprocket cover. Ê Bend the side of the junction box inward as shown. Ë...
Page 240 – ELEC Electrical system H model with 2 lighting coils É È Ê Ë Ë Ì S6AU8002 7 Pulser coil + H model (short) 8 Warning indicator , H model (long) 9 Engine shut-off switch lead 1 Lighting coils 2 Oil pressure switch 3 Spark plug 4 Rectifier Regulator 5 Charge coil...
Page 241 Electrical component and wiring harness routing È Route the oil pressure switch lead in the direction shown. É Fit the oil pressure switch lead into the groove in the driven sprocket cover. Ê Bend the side of the junction box outward as shown. Ë...
Page 242 – ELEC Electrical system H model with electric starter Ë Ê Ì É È Í Í Ï Î S6AU8003 7 CDI unit + MT model 8 Neutral switch , PT model 9 Fuse (10 A) 1 Lighting coils 0 PT relay (PT model) 2 Oil pressure switch A Warning indicator 3 Spark plug...
Page 243 Electrical component and wiring harness routing F PT switch lead (PT model) È Install the terminal plate, making sure that it contacts the PT relay. (PT model) É Route the lighting coil lead to the outside of the crankcase pin. Ê...
Page 244 – ELEC Electrical system R model Ë Ê Ì É È Í S6AU8004C 1 Lighting coils 0 PT relay (PT model) 2 Oil pressure switch A Pulser coil 3 Choke solenoid B Warning indicator 4 Spark plug C Battery cable 5 Rectifier Regulator D 10-pin main harness 6 Starter motor...
Page 245 Electrical component and wiring harness routing È Install the terminal plate, making sure that it contacts the PT relay. (PT model) É Route the lighting coil lead to the outside of the crankcase pin. Ê Route the oil pressure switch lead in the direction shown. Ë...
Page 246: Bow View
– ELEC Electrical system Bow view È É Ê S6AU8005 1 Pulser coil 0 PT relay lead (R) 2 Fuse (10 A) (E model) 3 Starter motor (E model) 4 Starter relay (E model) 5 Neutral switch (E model) 6 PT relay (PT model) 7 PT motor leads (Sb, Lg) 8 PT relay leads (Sb, Lg) 9 Negative battery cable...
Page 247 Electrical component and wiring harness routing È Pass the PT motor leads (Sb, Lg) and PT relay leads (Sb, Lg) through the caps, and then connect the leads to the terminals and cover the connections with the caps. Be sure to pass leads of the same color through the caps and connect them to the same terminal.
Page 248: Port View
– ELEC Electrical system Port view M model with 1 lighting coil È É Ë È È È Ê S6AU8062 1 Pulser coil 8 Charge coil connectors (charge coil to CDI 2 Rectifier unit) (L, Br) 3 Ignition coil 9 Ignition coil connectors (ignition coil to CDI 4 Spark plugs unit) (O, B) 5 Rectifier connector (R)
Page 249 Electrical component and wiring harness routing B Engine shut-off switch connector (engine shut-off switch to CDI unit) (Y) C Emergency circuit connector (CDI unit to CDI unit) (W) È 15 mm (0.59 in) É 55 mm (2.17 in) Ê 35 mm (1.38 in) Ë...
Page 250 – ELEC Electrical system M model and E model with 2 lighting coils È È Ë È É È Ê Ì È Ë È É È Ê S6AU8063 1 Fuse (10 A) (E model) 0 Rectifier Regulator connector (Rectifier 2 Pulser coil Regulator to fuse and engine start button) (R) 3 Starter motor (E model) A Rectifier Regulator connector (Rectifier...
Page 251 Electrical component and wiring harness routing D Charge coil connectors (charge coil to CDI unit) (L, Br) E Oil pressure switch connector (oil pressure switch to CDI unit) (P) F Warning indicator connectors (warning indicator to CDI unit) (Y/R, P) G Engine shut-off switch connector (engine shut-off switch to CDI unit) (Y) H Emergency circuit connector (CDI unit to CDI unit) (W) È...
Page 252 – ELEC Electrical system H model (short) È É È Ê Ë S6AU8064 + E model 1 Warning indicator 2 Engine shut-off switch 3 Engine start button (E model) 4 Engine shut-off switch lead 8-15 6AU3K11...
Page 253 Electrical component and wiring harness routing È Route the engine shut-off switch lead under the throttle cables. É Route the engine shut-off switch lead as shown, making sure that the lead does not contact the throttle shaft. Ê Fasten the engine start button lead at the white tape with a plastic tie. Install the plastic tie as shown. (E model) Ë...
Page 254 – ELEC Electrical system H model (long) È É È Ê Ë S6AU8065 + E model 1 Warning indicator 2 Engine shut-off switch 3 Engine start button 8-17 6AU3K11...
Page 255 Electrical component and wiring harness routing È Route the engine shut-off switch lead under the throttle cables. É Route the engine shut-off switch lead along the tiller handle bracket so that it does not contact the throttle shaft, and then route it and the throttle cables through the corrugated tube. Ê...
Page 256: 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 257: Starter Motor (E Model)
Checking the electrical component / Starter motor (E model) Starter motor (E model) · · · 0.4 N m (0.04 kgf m, 0.30 ft S6AU8008 Part name Q’ty Remarks Clip Not reusable Pinion stopper Spring Pinion stopper set Pinion Cover O-ring Not reusable Washer...
Page 258 – ELEC Electrical system · · · 0.4 N m (0.04 kgf m, 0.30 ft S6AU8008 Part name Q’ty Remarks Brush 1 Spacer Bracket O-ring Washer M5 × 120 mm Bolt O-ring Spacer Washer Spring washer 8-21 6AU3K11...
Page 259: Removing The Starter Motor
Starter motor (E 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 260: Checking The Starter Motor
– ELEC Electrical system 2. Turn the pinion 3 clockwise, and then remove the pinion. S6AU8011 3. Remove the cover 4, stator 5, armature S6AU8013 6, and washer. Checking the starter motor 1. Check the commutator. Clean with 600- grit sandpaper and compressed air if dirty.
Page 261: Checking The Brush Holder And Brush
Starter motor (E model) 3. Measure the commutator undercut a. Replace the armature if below specifica- tion. S6AG8470 Commutator standard undercut a: 0.5–0.8 mm (0.02–0.03 in) Brush holder assembly continuity Wear limit: 0.2 mm (0.01 in) Checking points Continuity 4. Check armature continuity.
Page 262: 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 263: Installing The Starter Motor
Starter motor (E model) / Starting system Checking the engine start button (H 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. Check the fuse 2 and wiring harness if S6AG8510 below specification.
Page 264: Checking The Engine Start Switch (R 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 265: Checking The Neutral Switch (R Model)
Starting system 2. Push the engine start button 2, 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 and wiring harness if Pushed a (N below specification.
Page 266: Checking The Starter Relay (E Model)
– ELEC Electrical system 3. Set the remote control lever to the F posi- 3. Push the engine start button, and then tion or R position, and then check the measure the input voltage between the neutral switch for continuity. Check the starter relay connector (neutral switch wiring harness or replace the neutral end) and the ground.
Page 267: Ignition And Ignition Control System
Starting system / Ignition and ignition control system 6. Connect the brown (Br) lead of the starter relay to the positive battery termi- nal and connect the black (B) lead to the negative battery terminal. Check for con- tinuity between the starter relay termi- nals.
Page 268: Checking The Ignition Coil
– ELEC Electrical system 2. Measure the spark plug cap resistance. Checking the pulser coil 1. Measure the pulser coil 1 output peak Replace if out of specification. voltage. Replace if below specification. S6AG8040 Spark plug cap resistance (reference data): 4.0–6.0 kΩ Checking the ignition coil 1.
Page 269: Checking The Charge Coil
Ignition and ignition control system Pulser coil resistance (reference Charge coil output peak voltage: data): Brown (Br) – Blue (L) White/red (W/R) – Black (B) Unloaded Loaded 240–360 Ω at 20 °C (68 °F) r/min Cranking 1,500 3,500 DC V 4.
Page 270: Checking The Engine Shut-Off Switch (H Model)
– ELEC Electrical system Checking the engine shut-off switch Engine shut-off switch continuity: (H model) White (W) – Black (B) 1. Disconnect the engine shut-off switch 1 connector and terminal. Switch position Continuity Clip installed a Engine stop button pushed b Clip removed c 3.
Page 271: Engine Electric Control System
Ignition and ignition control system / Engine electric control system Engine electric control system 2. Start the engine, and then measure the input voltage between the oil pressure Checking the CDI unit switch connector (wiring harness end) 1. Measure the CDI unit 1 output peak and the ground.
Page 272: Checking The Warning Indicator Assembly
– ELEC Electrical system 4. Check the oil pressure switch 1 for con- NOTE: tinuity when the engine is stopped and Slowly operate the special service tool. when it is running. Check the oil pressure and oil pressure switch if out of specifica- tion.
Page 273: Checking The Choke Solenoid (R Model)
Engine electric control system / Charging system (E model) 3. Measure the choke solenoid 1 resis- 6. Connect the yellow/red (Y/R) lead to the positive penlight battery terminal (1.5 V) tance. Replace if out of specification. and connect the pink (P) lead to the neg- ative terminal, and then check that the warning indicator comes on.
Page 274: Checking The Rectifier
– ELEC Electrical system 2. Measure the lighting coil 1 output peak Lighting coil (1 coil) output peak voltage. Replace if below specification. voltage: È Green (G) – Green (G) Unloaded r/min Cranking 1,500 3,500 DC V 14.6 33.1 Lighting coil (2 coils) output peak voltage: Green/White (G/W) –...
Page 275 Charging system (E model) S6AU8055 S6AU8054 NOTE: S6S18360 • Do not use peak voltage adapter B when NOTE: measuring the Rectifier output peak volt- Be sure to set the measurement range a, age. and display the mark b by pushing the •...
Page 276: Checking The Rectifier Regulator
– ELEC Electrical system Checking the Rectifier Regulator NOTE: 1. Measure the Rectifier Regulator 1 out- The voltage values given in the table are for put peak voltage. Check the Rectifier reference only. If voltage is produced, there Regulator for continuity if the output peak is continuity, and, if there is an overload, voltage is below specification.
Page 277 Charging system (E model) Rectifier Regulator continuity (testing diode) Tester lead Display value (V) Conti- (reference data) nuity G/W 3 0.364 G/W 3 0.741 G/W 3 1.117 0.444 G/W 3 0.772 G/W 3 0.432 0.434 G/W 3 OL: Indicates an overload 8-40 6AU3K11...
Page 278 – ELEC Electrical system — MEMO — 8-41 6AU3K11...
Page 279: Trbl Shtg
TRBL SHTG Troubleshooting Troubleshooting the outboard motor............9-1 Troubleshooting table format..............9-1 Troubleshooting the power unit ..............9-1 Troubleshooting the PT unit (PT model)............ 9-7 Troubleshooting the lower unit ..............9-8 6AU3K11...
Page 280: 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 281 Troubleshooting the outboard motor Refer Symptom 2 Cause 1 Cause 2 Checking step page Starter rope Manual starter mal- Disassemble and operates, but the function — check the manual engine does not starter. crank Damaged flywheel Check the flywheel 5-19 magnet Woodruff —...
Page 282 TRBL SHTG Troubleshooting Refer Symptom 2 Cause 1 Cause 2 Checking step page Starter motor oper- Stuck piston Seizure or rust Disassemble and ates, but the engine check the power Piston lock due to does not crank unit. water in the com- —...
Page 283 Troubleshooting the outboard motor Refer Symptom 2 Cause 1 Cause 2 Checking step page Fuel not supplied Pinched or kinked Check the fuel fuel hose — hoses and fuel hose joint. Clogged fuel filter Replace the fuel fil- — ter. Fuel pump malfunc- Disassemble and tion...
Page 284 TRBL SHTG Troubleshooting 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. Spark plug cap mal- Check the spark 8-30...
Page 285 Troubleshooting the outboard motor Refer Symptom 2 Cause 1 Cause 2 Checking step page Low compression Valve clearance not Adjust the valve — pressure adjusted correctly clearance. Damaged cylinder Disassemble and 5-28 head gasket check the cylinder 5-41 head and power Damaged valve unit.
Page 286: Troubleshooting The Pt Unit (Pt Model)
TRBL SHTG Troubleshooting Symptom 1: Limited engine speed (below 2,000 r/min) Refer Symptom 2 Cause 1 Cause 2 Checking step page • Buzzer comes on Insufficient engine Add sufficient oil. — (R model) • Oil pressure- Engine oil pressure Oil pump malfunc- Check the oil pump.
Page 287: Troubleshooting The Lower Unit
Troubleshooting the outboard motor Symptom 1: PT 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 7-44 open function valve. Insufficient PT fluid —...
Page 288 TRBL SHTG Troubleshooting Symptom 1: Cooling water does not discharge from the cooling water pilot hole Refer Symptom 2 Cause 1 Cause 2 Checking step page Clogged cooling Check the cooling — water inlet water inlets. Clogged cooling Check the cooling water passages water passages.
Page 289 Index Checking the choke solenoid (R model)... 8-36 Checking the compression pressure ..5-1 Abbreviation ..........1-3 Checking the connecting rod big end Adjusting the pilot screw ......4-13 side clearance ........5-45 Adjusting the throttle cable (H model)..3-7 Checking the connecting rod small end Adjusting the throttle cable (R model)..3-8 inside diameter and big end inside Adjusting the throttle link......3-9...
Page 290 Index Checking the ignition timing ......3-12 Checking the tilt operation (PT model) ..3-13 Checking the lighting coil ......8-36 Checking the tilt system (MT model) ..1-17 Checking the lower case....6-12 6-33 Checking the timing belt ......3-5 Checking the lower unit for air leakage..3-15 Checking the timing belt and sprocket..
Page 291 Index Electrical .............2-9 Lower unit ........2-8 3-14 Electrical component and wiring Lower unit (high thrust model) ....6-21 harness routing .........8-1 Lubricating the outboard motor....3-17 Engine electric control system ....8-34 Maintenance interval chart ......3-1 Fire prevention ..........1-4 Maintenance specification ......
Page 292 Index Removing the upper case ......7-21 Removing the water pump ....6-5 6-25 Replacing the timing belt......5-3 Replacing the valve guide......5-31 Safety while working ........1-4 Sealant and locking agent table....1-3 Selecting the crankshaft main bearing..5-48 Selecting the forward gear shim ....6-40 Selecting the pinion shim ......6-40 Selecting the reverse gear shim ....6-41 Selection ...........1-12...
Page 293 Index — MEMO — 6AU3K11...
Page 294: Wiring Diagram
Wiring diagram Pike 9.9 M 1 CDI unit Color code 2 Pulser coil : Black 3 Lighting coil (1 coil) : Brown 4 Lighting coil (2 coils) : Green 5 Charge coil : Blue 6 Oil pressure switch : Orange 7 Rectifier : Pink 8 Rectifier Regulator...
Page 295 Wiring diagram FT9.9GE, FT9.9GEP 1 CDI unit Color code 2 Choke solenoid : Black 3 Pulser coil : Brown 4 Lighting coil : Green 5 Charge coil : Blue 6 Oil pressure switch : Light green 7 Starter motor : Orange 8 Rectifier Regulator : Pink 9 Ignition coil...
Page 299 Pike 9.9 M È È...
Page 300 Pike 9.9 E È É...

SELVA MARINE Pike 9,9 Service Manual

1 General Information

Specification

Periodic Check and Adjustment

Spec Specification

General Specification

Specification

Maintenance Specification

Fuel System

Lower Unit

Tightening Torque

Chk Adj/Chk Adj

Chk Adj

Periodic Check and Adjustment

Maintenance Interval Chart

Top Cowling

Fuel System

Power Unit

Control System

Bracket Unit

Lower Unit

General

Fuel Fuel System

Fuel System

Hose Routing

Fuel Pump, Fuel Filter, and Fuel Joint

Carburetor Unit

Powr Power Unit

Power Unit

Power Unit (Check and Adjustment)

Manual Starter (M Model)

Power Unit

Timing Belt and Sprocket

Cylinder Head

Disassembling the Cylinder Block

Lowr Lower Unit

Lower Unit

Propeller Shaft Housing

Drive Shaft and Lower Case

Backlash

Lower Unit (High Thrust Model)

Propeller Shaft Housing (High Thrust Model)

Drive Shaft and Lower Case (High Thrust Model)

Shimming (High Thrust Model)

Backlash (High Thrust Model)

Brkt Bracket Unit

Tiller Handle (Short)

Bracket Unit

Tiller Handle (Long)

Friction Plate (H Model)

Bottom Cowling

Upper Case and Steering Arm

Clamp Bracket and Swivel Bracket (MT Model)

Clamp Bracket and Swivel Bracket (PT Model)

PT Motor

PT Gear Pump

PT Cylinder

PT Electrical System

Electrical System

Electrical Component and Wiring Harness Routing

Electrical System

Checking the Electrical Component

Starter Motor (E Model)

Starting System

Ignition and Ignition Control System

Engine Electric Control System

Charging System (E Model)

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for SELVA MARINE Pike 9,9

Summary of Contents for SELVA MARINE Pike 9,9