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Yamaha 20C Service Manual

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20C
SERVICE MANUAL
E
MANUEL D'ENTRETIEN
F
MANUAL DE SERVICIO
ES
290524
6A9-28197-5F-B1

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  Summary of Contents for Yamaha 20C

  • Page 1 SERVICE MANUAL MANUEL D’ENTRETIEN MANUAL DE SERVICIO 290524 6A9-28197-5F-B1...
  • Page 2 A20000-0 NOTICE This manual has been prepared by the Yamaha Motor Company primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equiment. 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 equip- ment could render it unsafe or unfit for use.
  • Page 3 La Yamaha Motor Company a élaboré Este manual ha sido preparado por ce manuel à l’attention des concession- Yamaha Motor Company y va dirigido a naires Yamaha et de leurs mécaniciens los concesionarios Yamaha y a sus pour leurs travaux d’entretien et de répa- mecánicos encargados de los procedi-...
  • Page 4 A30000-0 INDEX GENERAL INFORMATION INFO SPECIFICATION SPEC GENERAL SERVICE SRVC FUEL SYSTEM FUEL POWER UNIT POWR LOWER UNIT LOWR BRACKET UNIT BRKT ELECTRICAL SYSTEM ELEC TROUBLE-SHOOTING TRBL SHTG...
  • Page 5 TABLE DES INDICE MATIERES INFORMATIONS INFORMACION GENERALES GENERAL INFO ESPECIFICA- SPECIFICATIONS CIONES SPEC SERVICE MANTENIMIENTO GENERAL GENERAL SRVC SISTEMA DE SYSTEMES ALIMENTACION D’ALIMENTATION DE COMBUSTIBLE FUEL MOTEUR MOTOR POWR BOITIER UNIDAD D’HELICE INFERIOR LOWR SUPPORT UNIDAD SOPORTE BRKT SISTEMA ELECTRICITE ELECTRICO ELEC LOCALIZACION Y...
  • Page 6 CONTENTS CHAPTER 1 GENERAL INFORMATION HOW TO USE THIS MANUAL...................1-1 MANUAL FORMAT ....................1-1 THE ILLUSTRATIONS..................1-1 REFERENCES .....................1-2 SPECIFICATIONS ....................1-2 WARNINGS, CAUTIONS AND NOTES..............1-3 SYMBOLS......................1-4 IDENTIFICATION......................1-5 SERIAL NUMBER....................1-5 ENGINE SERIAL NUMBER..................1-5 STARTING SERIAL NUMBERS ................1-5 SAFETY WHILE WORKING ..................1-6 FIRE PREVENTION .....................1-6 VENTILATION.......................1-6 SELF-PROTECTION ....................1-7 OILS, GREASES AND SEALING FLUIDS ............1-7...
  • Page 7: Table Of Contents

    CONTENU CONTENIDO CHAPITRE 1 CAPITULO 1 INFORMATIONS INFORMACION GENERALES GENERAL MODE D’UTILISATION DU COMO UTILIZAR ESTE MANUEL.........1-1 MANUAL.........1-1 PRESENTATION DU FORMATO DEL MANUAL..1-1 MANUEL ........1-1 LAS ILUSTRACIONES .....1-1 ILLUSTRATIONS.......1-1 REFERENCIAS ......1-2 REFERENCES ......1-2 ESPECIFICACIONES....1-2 SPECIFICATIONS ......1-2 ATENCIONES, PRECAUCIONES AVERTISSEMENT, ATTENTION, Y NOTAS ........1-3 N.B..........1-3 SIMBOLOS .........1-4...
  • Page 8 TIGHTENING TORQUE .....................2-8 GENERAL TORQUES....................2-8 CHAPTER 3 GENERAL SERVICE PREDELIVERY SERVICE ..................3-1 CONTENTS ......................3-1 PACKING LISTS ....................3-1 ELECTRIC WIRING....................3-2 FUEL LINE......................3-3 GEAR OIL LEVEL....................3-4 OPERATION OF CONTROLS AND MOVING PARTS.........3-4 FUEL LEAKAGE ....................3-5 WATER LEAKAGE ....................3-5 EXHAUST LEAKAGE ...................3-5 ENGINE AND LOWER UNIT NOISE..............3-5 IDLE-SPEED......................3-5 IGNITION TIMING ....................3-5 MOTOR EXTERIOR .....................3-5...
  • Page 9 COUPLES DE SERRAGE.....2-8 PARES DE APRIETE ....2-8 COUPLES GENERAUX....2-8 TORSIONES GENERALE ...2-8 CHAPITRE 3 CAPITULO 3 SERVICE GENERAL MANTENIMIENTO GENERAL SERVICE AVANT LIVRAISON ...3-1 CONTENU ........3-1 MANTENIMIENTO PREVIO A LA LISTE DE COLISAGE ....3-1 ENTREGA........3-1 CIRCUIT ELECTRIQUE....3-2 CONTENIDO ......3-1 TUYAU D’ALIMENTATION ..3-3 LISTA DE EMBALAJE ....3-1 NIVEAU DE L’HUILE DE CABLEADO ELECTRICO ..3-2...
  • Page 10 CHAPTER 4 FUEL SYSTEM FUEL SYSTEM......................4-1 EXPLODED DIAGRAM ..................4-1 CLEANING AND INSPECTION ................4-3 INSTALLATION.....................4-5 CARBURETTOR ......................4-6 EXPLODED DIAGRAM ..................4-6 REMOVAL AND DISASSEMBLY ................4-7 INSPECTION ......................4-8 ASSEMBLY......................4-9 INSTALLATION....................4-10 CHAPTER 5 POWER UNIT EXPLODED DIAGRAM ....................5-1 PREPARATION FOR THE OVERHAUL ..............5-2 REMOVAL ........................5-2 DISASSEMBLY ......................5-3 CHECKING THE CRANKSHAFT ...............5-14 INSPECTION ......................5-15...
  • Page 11 CHAPITRE 4 CAPITULO 4 SYSTEME SISTEMA DE D’ALIMENTATION ALIMENTACION DE COMBUSTIBLE SYSTEME D’ALIMENTATION ..4-1 VUE ECLATEE......4-1 SISTEMA DE ALIMENTACION NETTOYAGE ET DE COMBUSTIBLE ......4-1 VERIFICATION......4-3 DIAGRAMA DETALLADO ..4-1 INSTALLATION ......4-5 LIMPIEZA E INSPECCION ..4-3 INSTALACION ......4-5 CARBURATEUR......4-6 VUE ECLATEE......4-6 CARBURADOR ......4-6 DEPOSE ET DEMONTAGE ..4-7 DIAGRAMA DETALLADO ..4-6 VERIFICATION......4-8...
  • Page 12 FUEL SYSTEM AND ELECTRICAL SYSTEM ...........5-26 INSTALLATION ......................5-26 RECOIL STARTER....................5-27 REMOVAL AND DISASSEMBLY ................5-28 INSPECTION ......................5-29 ASSEMBLY......................5-30 INSTALLATION....................5-32 CHAPTER 6 LOWER UNIT EXPLODED DIAGRAM ....................6-1 REMOVAL ........................6-2 DISASSEMBLY ......................6-2 INSPECTION ......................6-6 GEAR CASE......................6-6 BEARING HOUSING....................6-6 RING-NUT ......................6-6 WATER PUMP HOUSING ..................6-6 IMPELLER ......................6-7 OIL-SEAL COVER ....................6-7 GEARS .........................6-7...
  • Page 13 CIRCUIT D’ALIMENTATION SISTEMA DE ALIMENTACION ET EQUIPEMENT DE COMBUSTIBLE Y SISTEMA ELECTRIQUE......5-26 ELECTRICO ......5-26 INSTALLATION ......5-26 INSTALACION......5-26 LANCEUR........5-27 MOTOR DE ARRANQUE DE DEPOSE ET DEMONTAGE ..5-28 RETROCESO .......5-27 VERIFICATION......5-29 EXTRACCION ASSEMBLAGE......5-30 DESMONTAJE ......5-28 INSTALLATION .......5-32 INSPECCION......5-29 MONTAJE .........5-30 INSTALACION ......5-32 CHAPITRE 6 CAPITULO 6 BOITIER D’HELICE...
  • Page 14 CHAPTER 7 BRACKET UNIT EXPLODED DIAGRAM ....................7-1 REMOVAL ........................7-2 DISASSEMBLY ......................7-3 INSPECTION ......................7-4 MOUNTING-BOLT ....................7-4 RUBBER MOUNTS ....................7-4 COLLAR........................7-4 TILT LOCK PLATES .....................7-4 LEVERS........................7-4 ASSEMBLY ........................7-5 INSTALLATION ......................7-5 CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ..................8-1 WIRING DIAGRAM ....................8-2 REMOVAL ........................8-3 MAGNETO BASE ....................8-3 CLEANING, INSPECTION AND REPAIR ..............8-5 SPARK-PLUG .......................8-5...
  • Page 15 CHAPITRE 7 CAPITULO 7 SUPPORT UNIDAD SOPORTE VUE ECLATEE ......7-1 DIAGRAMA DETALLADO..7-1 DEPOSE ..........7-2 EXTRACCION .......7-2 DEMONTAGE ........7-3 DESMONTAJE.......7-3 VERIFICATION......7-4 INSPECCION .........7-4 VIS DE MONTAGE ....7-4 PERNOS DE SUJECION....7-4 SUPPORTS ELASTIQUES..7-4 SOPORTES DE GOMA....7-4 MANCHETTES ......7-4 COLLARES.........7-4 ETRIERS DE VERROUILLAGE PLACAS DE TOPE DE D’INCLINAISON......7-4 INCLINACION ......7-4...
  • Page 16 CHAPTER 9 TROUBLE-SHOOTING TROUBLE-SHOOTING DIAGRAM ................9-1 HOW TO TROUBLE-SHOOT ................9-1 ENGINE IS HARD TO START OR WILL NOT START..........9-2 ROUGH IDLING ......................9-6 ENGINE STALLS .......................9-7 ENGINE WILL NOT STOP ..................9-8 GEAR SHIFTING IS IMPOSSIBLE OR HARD ............9-9...
  • Page 17 CHAPITRE 9 CAPITULO 9 DEPANNAGE LOCALIZATION Y REPARACION DE TABLEAU DE DEPANNAGE ..9-1 AVERIAS QUE FAIRE ENCAS DE PANNE?........9-1 DIAGRAMA DE LOCALIZACION LE MOTEUR A DU MAL A Y REPARACION DE AVERIAS...9-1 DEMARRER OU REFUSE DE COMO LOCALIZAR Y DEMARRER........9-2 REPARAR AVERIAS....9-1 LE RALENTI EST RESULTA DIFICIL ARRANCAR...
  • Page 18 INFO CHAPTER 1 GENERAL INFORMATION HOW TO USE THIS MANUAL...................1-1 MANUAL FORMAT ....................1-1 THE ILLUSTRATIONS..................1-1 REFERENCES .....................1-2 SPECIFICATIONS ....................1-2 WARNINGS, CAUTIONS AND NOTES..............1-3 SYMBOLS......................1-4 IDENTIFICATION......................1-5 SERIAL NUMBER....................1-5 ENGINE SERIAL NUMBER..................1-5 STARTING SERIAL NUMBERS ................1-5 SAFETY WHILE WORKING ..................1-6 FIRE PREVENTION .....................1-6 VENTILATION.......................1-6 SELF-PROTECTION ....................1-7 OILS, GREASES AND SEALING FLUIDS ............1-7...
  • Page 19: Mode D'utilisation Du

    INFO CHAPITRE 1 CAPITULO 1 INFORMATIONS INFORMACION GENERALES GENERAL MODE D’UTILISATION DU COMO UTILIZAR ESTE MANUEL.........1-1 MANUAL.........1-1 PRESENTATION DU FORMATO DEL MANUAL..1-1 MANUEL ........1-1 LAS ILUSTRACIONES .....1-1 ILLUSTRATIONS.......1-1 REFERENCIAS ......1-2 REFERENCES ......1-2 ESPECIFICACIONES....1-2 SPECIFICATIONS ......1-2 ATENCIONES, PRECAUCIONES AVERTISSEMENT, ATTENTION, Y NOTAS ........1-3 N.B..........1-3 SIMBOLOS .........1-4 SYMBOLES ........1-4...
  • Page 20: Manual Format

    INFO HOW TO USE THIS MANUAL A50000-0 HOW TO USE THIS MANUAL MANUAL FORMAT This manual provides the mechanic with descriptions of the operations of disassembly, repair, assembly, adjustment and inspection, each of which is presented in a sequential, step-by-step procedure. To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page.
  • Page 21: Illustrations

    MODE D’UTILISATION DU MANUEL INFO COMO UTILIZAR ESTE MANUAL A50000-0 A50000-0 MODE D’UTILISATION COMO UTILIZAR ESTE DU MANUEL MANUAL PRESENTATION DU MANUEL FORMATO DEL MANUAL Dans ce manuel, le mécanicien trouvera El objectivo de este manual es informar la description des opérations de démon- al mecánico acerca de las operaciones tage, réparation, montage, réglage et de desmontaje, reparación, montaje,...
  • Page 22: References

    INFO HOW TO USE THIS MANUAL REFERENCES These have been kept to a minimum; however, when you are referred to another section of the manual, you are told the page number to go to. SPECIFICATIONS These are given in bold type at each procedure. It is not necessary to leave the section dealing with the pro- cedure in order to look up the specifications.
  • Page 23 MODE D’UTILISATION DU MANUEL INFO COMO UTILIZAR ESTE MANUAL REFERENCES REFERENCIAS Les références ont été limitées. Se han reducido al mínimo. No obstan- Cependant, lors d’un renvoi à une autre te, cuando se le pida que consulte otra partie du manuel, les numéros de page sección, se indicará...
  • Page 24: Warnings, Cautions And Notes

    INFO HOW TO USE THIS MANUAL WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish important information in this manual in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instruction could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.
  • Page 25: Avertissement, Attention

    MODE D’UTILISATION DU MANUEL INFO COMO UTILIZAR ESTE MANUAL AVERTISSEMENT, ATTENTION, ATENCIONES, PRECAUCIONES Y N.B. NOTAS Nous attirons votre attention sur les Se le pedirá que preste atención a distin- mots Avertissement, Attention et N.B. tos Atenciones, Precauciones y Notas, Ils vous indiquent les renseiqnements referidos todos ellos a datos importantes particulièrement importants conteneus...
  • Page 26: Symbols

    Resistance (Ω), Voltage (V), Electric current (A) Symbols y to i in an exploded diagram indicate grade of lubricant and location of lubrication point: y Apply Yamaha two-cycle outboard motor oil u Apply Yamaha gear case lubricant i Apply Yamaha marine grease A...
  • Page 27: Symboles

    Huile moteur 2 temps u Huile de transmission y Utilice aceite para motor de 2-tiempos i Yamaha A (graisse hydrofuge) u Aplique grasa Yamaha para caja de engranajes i Aplique grasa marina Yamaha (de uso Les symbols o à p des vues éclatée general) indiquent la qualité...
  • Page 28: Identification

    INFO INDENTIFICATION A60002-0* IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. ENGINE SERIAL NUMBER The engine serial number is stamped on the port side of the cylinder body. STARTING SERIAL NUMBERS The starting serial number blocks are as follows: S: 1001031 –...
  • Page 29: Numero De Serie

    IDENTIFICATION INFO IDENTIFICACION A60002-0* A60002-0* IDENTIFICATION IDENTIFICACION NUMERO DE SERIE NUMERO DE SERIE Le numéro de série du moteur hors-bord El número de serie del motor fueraborda est estampillé sur la plaque fixée sur le aparece grabado en la paca fijada al lado côté...
  • Page 30: Safety While Working

    SAFETY WHILE WORKING A70000-3 SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics. FIRE PREVENTION Petrol (petroleum spirit, gasoline) is highly flammable. Petroleum vapour is explosive if ignited. Do not smoke while handling petrol, and keep it away from heat, sparks, and open flames.
  • Page 31: Mesures De Securite

    Les opérations décrites dans ce manuel sont recommandées par Yamaha et doi- Los procedimientos que se indican en vent êtré suivies par les concession- este manual son los que Yamaha reco- naires Yamaha et leur mécaniciens. mienda que sigan los concesionarios Yamaha y sus mecánicos.
  • Page 32: Self-Protection

    OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha. Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimised.
  • Page 33: Proteccion

    PARA JUNTAS N’utiliser que les huiles, graisses et Utilice únicamente aceites, grasas y liquides d’étanchéité Yamaha ou recom- líquidos para juntas Yamaha, o bien los mandés par Yamaha. recomendados por ésta. En conditions normales d’utilisation, il En condiciones de uso normal no corre- ne devrait pas y avoir de dangers liés à...
  • Page 34: Good Working Practices

    INFO SAFETY WHILE WORKING GOOD WORKING PRACTICES 1. The right tools Use the special tools that are advised to protect parts from damage. Use the right tool in the right manner – don’t improvise. 2. Tightening torque Follow the torque tightening instructions. When tightening bolts, nuts and screws, tight- en the larger sizes first, and tighten inner-positioned fixings before outer-positioned ones.
  • Page 35: Algunos Consejos

    MESURES DE SECURITE INFO MEDIDAS DE SEGURIDAD NOTES CONCERNANT L’OU- ALGUNOS CONSEJOS TILLAGE ET LES PIECES 1. Las herramientas idóneas 1. Outillage correct Utilice las herramientas especiales Utiliser outils spéciaux recomendadas para evitar dañar las conseillés afin d’éviter d’endoma- piezas. Utilice las herramientas ger les pièces.
  • Page 36 INFO – MEMO –...
  • Page 37 INFO – MEMO –...
  • Page 38: Special Tools

    SPECIAL TOOLS A80001-0* SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accurate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment. SPECIAL TOOLS FOR TUNE-UP Ref.
  • Page 39: Special Tools For Lower Unit Service

    90890-06704 Shimming plate 90890-06701 Pinion height gauge 90890-06710 Pinion height gauge plate B 90890-06712 SEALING AGENTS AND LUBRICANTS Ref. Tool name Part number Gasket maker 90790-74001 Marine grease 90890-69910 Gear case lubricant 90890-6930J Yamaha two cycle outboard oil 90890-6382H 1-11...
  • Page 40: Outillage Special

    OUTILLAGE SPECIAL Pour une plus grande précision dans vos travaux de montage et de mise au point, Yamaha vous recommande l’emploi d’outils spécia- lisés. Vos travaux s’en trouveront ainsi facilités. En outre, l’utilisation d’outils non adaptés risque d’endommager le matériel.
  • Page 41 Jauge de hauteur de pignon 90890-06710 Plaque de jauge de hauteur de pignon 90890-06712 LIQUIDES D’ETANCHEITE ET LUBRIFIANTS N° DESIGNATION N° DE REFERENCE Liqui d’ étanchéité 90790-74001 Graisse 90890-69910 Huile de transmission 90890-6930J Huile Yamaha pour hors-bord deux temps 90890-6382H 1-11...
  • Page 42: Herramientas Especiales

    HERRAMIENTAS ESPECIALES La utilización de las herramientas especiales correctas recomendadas por Yamaha le facilitará el trabajo y le permitiré realizar las tare- as de montaje y puesta a punto con precisión. Las improvisaciones y el empleo de herramientas incorrectas pueden causar daños a los equipos.
  • Page 43: Herramientas Especiales Para El Mantenimiento De La Unidad Inferior

    Placa de medidor de la altura del piñón 90890-06712 PASTAS PARA JUNTAS Y LUBRICANTES NOMBRE DE LA HERRAMIENTA No DE PIEZA Gasket MAKER (junta líquida) 90790-74001 Grasa marina 90890-69910 Lubricante de la caja de engranajes 90890-6930J Aceite Yamaha para motor fuera borda de dos tiempos 90890-6382H 1-11...
  • Page 44 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ...................2-1 MAINTENANCE SPECIFICATIONS ................2-3 POWER UNIT .......................2-3 LOWER UNIT .......................2-4 ELCTRICAL ......................2-5 DIMENSIONS .......................2-6 TIGHTENING TORQUE ....................2-8 GENERAL TORQUES ....................2-8...
  • Page 45: Capitulo 2

    SPEC CHAPITRE 2 CAPITULO 2 SPECIFICATIONS ESPECIFICACIONES SPECIFICATIONS ESPECIFICACIONES GENERALES........2-1 GENERALES........2-1 SPECIFICATIONS ESPECIFICACIONES DE D’ENTRETIEN.......2-3 MANTENIMIENTO ......2-3 BLOC DE PROPULSION ET MOTOR ........2-3 D’ALIMENTATION....2-3 COLA ..........2-4 EMBASE ........2-4 SISTEMA ELECTRICO .....2-5 ELECTRIQUES......2-5 DIMENSIONES ......2-6 DIMENSIONS......2-6 PARES DE APRIETE ....2-8 COUPLES DE SERRAGE.....2-8 TORSIONES GENERALE ...2-8 COUPLES GENERAUX....2-8...
  • Page 46: General Specifications

    SPEC GENERAL SPECIFICATIONS C20000-0* GENERAL SPECIFICATIONS Model Item Unit 20CMH Dimensions Overall length mm (in) 849 (33.4) Overall width mm (in) 399 (15.7 ) Overall height mm (in) 1,109 (43.7) mm (in) 1,236 (48.7) Transom height mm (in) 419 (16.5) mm (in) 546 (21.5) Boat transom height...
  • Page 47: Especificaciones Generales

    SPECIFICATIONS GENERALES SPEC ESPECIFICACIONES GENERALES SPECIFICATIONS ESPECIFICACIONES GENERALES GENERALES Elément Elemento Dimensions Dimensiones Longueur hors tout Longitud total Largeur hors tout Anchura total Hauteur hors tout Altura total Hauteur tableau AR Altura del peto de popa Hauteur tableau AR du bateau Altura del peto de popa del barco Poids à...
  • Page 48 SPEC GENERAL SPECIFICATIONS Model Item Unit 20CMH Fuel and oil Fuel type Regular gasoline Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3 Gear oil type Hypoid gear oil Gear oil grade (*4) GL-4 Gear oil quantity L (US oz, 0.18 (6.09, 6.07) lmp oz) Bracket unit...
  • Page 49 SPECIFICATIONS GENERALES SPEC ESPECIFICACIONES GENERALES Elément Elemento Carburant et huile Gasolina y aceite Type de carburant Tipo de combustible Huile moteur Aceite de motor Grade huile moteur Grado de aceite de motor Type d’huile pour engrenages Tipo de aceite para engranajes Grade d’huile pour engrenages Grado de aceite para engranajes (*4)
  • Page 50: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS C31000-0* MAINTENANCE SPECIFICATIONS POWER UNIT Model Item Unit 20CMH Power unit Compression pressure (*1) 834 (8.34, 120.9) (Reference) (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.10 (0.0039) (lines indicate straightedge position) Cylinder Bore size mm (in) 67.000–67.020 (2.6378–2.6386) Wear limit mm (in)
  • Page 51: Especificaciones De Mantenimiento

    SPECIFICATIONS D’ENTRETIEN SPEC ESPECIFICACIONES DE MANTENIMIENTO SPECIFICATIONS ESPECIFICACIONES DE D’ENTRETIEN MANTENIMIENTO BLOC DE PROPULSION ET MOTOR D’ALIMENTATION Elemento Elément Motor Bloc de propulsion Presión de compresión (*1) et d’alimentation (Referencia) Pression de compression (*1) Culata (Référence) Límite de alabeo Culasse (las líneas indican la posición del Limite de Déformation borde de una regla)
  • Page 52 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit 20CMH Crankshaft Crank width mm (in) 53.90–53.95 (2.1220–2.1240) mm (in) 34.88–35.10 (1.37–1.38) Crankpin diameter mm (in) 21.995–22.000 (0.8659–0.8700) Runout limit mm (in) 0.03 (0.0012) Big end side clearance (E) mm (in) 0.200–0.700 (0.0079–0.0276) Maximum small end axial play (F) mm (in) 2.0 (0.08) Thermostat...
  • Page 53: Cola

    SPECIFICATIONS D’ENTRETIEN SPEC ESPECIFICACIONES DE MANTENIMIENTO Elément Elemento Vilebrequin Cigüeñal Largeur du vilebrequin Anchura del cigüeñal Diamètre du maneton Diámetro de la muñequilla Limite d’excentricité Límite de descentramiento Jeu latéral du pied de bielle Holgura lateral de la cabeza de Jeu axial de la tête de bielle maxi.
  • Page 54 SPEC MAINTENANCE SPECIFICATIONS ELC32000-0* ELCTRICAL Model Item Unit 20CMH Ignition system Ignition timing Degree BTDC 20–22 Ignition spark gap mm (in) 6.0 (0.24) Spark plug gap mm (in) 0.6–0.7 (0.024–0.028) Ignition coil resistance Ω Primary coil (O–B) 0.26–0.35 Secondary coil (spark plug wire–spark plug wire) kΩ...
  • Page 55: Sistema Electrico

    SPECIFICATIONS D’ENTRETIEN SPEC ESPECIFICACIONES DE MANTENIMIENTO ELECTRIQUES SISTEMA ELECTRICO Elément Elemento Système d’allumage Sistema de encendido Avance à l’allumage Distribución del encendido Ecartement des électrodes de Huelgo de la bujía bougie Distancia entre electrodos Ecartement des électrodes de Resistencia de la bobina de encen- bougie dido Résistance de la bobine d’allumage...
  • Page 56: Dimensiones

    MAINTENANCE SPECIFICATIONS SPEC SPECIFICATIONS D’ENTRETIEN ESPECIFICACIONES DE MANTENIMIENTO DIMENSIONS DIMENSIONS DIMENSIONES mm (in) 420.0 (16.54) 429.0 (16.89) 397.0 (16.54) 150.0 (5.91) 379.0 (14.92) 6A9001M...
  • Page 57 MAINTENANCE SPECIFICATIONS SPEC SPECIFICATIONS D’ENTRETIEN ESPECIFICACIONES DE MANTENIMIENTO mm (in) 85.0 (3.35) 85.0 (3.35) 35.0 (1.38) 65.0 (2.56) (0.33) 89.0 (3.50) 89.0 (3.50) 112.5 (4.43) 112.5 (4.43) 122.5 (4.82) 122.5 (4.82) 6A9002M...
  • Page 58: Tightening Torque

    SPEC TIGHTENING TORQUE/GENERAL TORQUES TIGHTENING TORQUE Tightening torques Part to be tightened N·m kgf·m ft·lb POWER UNIT Crankcase Cylinder head Exhaust cover Spark plug Flywheel nut Power unit mounting bolt UPPER CASE AND GEAR CASE Upper mount rubber bolt Bracket mounting bolt Bracket bolt Ring nut Pinon nut...
  • Page 59 COUPLES DE SERRAGE/COUPLES GENERAUX SPEC PARES DE APRIETE/TORSIONES GENERALE COUPLES DE SERRAGE PARES DE APRIETE Pièces à serrer Couples de serrage Parte a apretar Bloc de propulsion Motor et d’alimentation Cárter Carter 2ème Culata Culasse 2ème Tapa de la culata Couvercle de culasse 2ème Bujía...
  • Page 60: General Service

    SRVC CHAPTER 3 GENERAL SERVICE PREDELIVERY SERVICE ..................3-1 CONTENTS ......................3-1 PACKING LISTS ....................3-1 ELECTRIC WIRING....................3-2 FUEL LINE......................3-3 GEAR OIL LEVEL....................3-4 OPERATION OF CONTROLS AND MOVING PARTS .........3-4 FUEL LEAKAGE ....................3-5 WATER LEAKAGE....................3-5 EXHAUST LEAKAGE ...................3-5 ENGINE AND LOWER UNIT NOISE ..............3-5 IDLE-SPEED......................3-5 IGNITION TIMING ....................3-5 MOTOR EXTERIOR .....................3-5...
  • Page 61 SRVC CHAPITRE 3 CAPITULO 3 SERVICE GENERAL MANTENIMIENTO GENERAL SERVICE AVANT LIVRAISON ...3-1 CONTENU ........3-1 MANTENIMIENTO PREVIO A LA LISTE DE COLISAGE ....3-1 ENTREGA........3-1 CIRCUIT ELECTRIQUE....3-2 CONTENIDO ......3-1 TUYAU D’ALIMENTATION ..3-3 LISTA DE EMBALAJE ....3-1 NIVEAU DE L’HUILE DE CABLEADO ELECTRICO ..3-2 TRANSMISSION......3-4 TUBO DE LLEGADA DEL FONCTIONNEMENT DES...
  • Page 62: Predelivery Service

    SRVC PREDELIVERY SERVICE PREDELIVERY SERVICE D20000-0* CONTENTS Model å Refer page Item 1. Packing list 2. Electric wiring 3. Fuel line 4. Gear oil level 5. Operation of controls and moving parts 6. Fuel leakage 7. Water leakage 8. Exhaust leakage 9.
  • Page 63 SERVICE AVANT LIVRAISON SRVC MANTENIMIENTO PREVIO A LA ENTREGA SERVICE AVANT MANTENIMIENTO LIVRAISON PREVIO A LA ENTREGA D20000-0* D20000-0* CONTENU CONTENIDO Désignation Elemento 1. Liste de colisage 1. Lista de embalaje 2. Raccordement electrique 2. Cableado eléctrico 3. Tuyau d’alimentation (essence 3.
  • Page 64: Electric Wiring

    SRVC PREDELIVERY SERVICE D22000-0 ELECTRIC WIRING Check that all leads and connectors are properly connected. 1 2P Consent : Black 2 Rectifier : Green 3 C.D.I : Orange 4 Ignition coil : Red 5 Cover lead wire : White A To Charge coil G/W : Green / White B To Lighting coil W/R : White / Red...
  • Page 65 SERVICE AVANT LIVRAISON SRVC MANTENIMIENTO PREVIO A LA ENTREGA D22000-0 D22000-0 CIRCUIT ELECTRIQUE CABLEADO ELECTRICO Contrôler le branchement correct de Compruebe que todos los cables y con- tous les câbles et connecteurs. nectores están conectados correctamen- 1 Connecteur2P 2 Rrdresseur 1 Consent 2P 3 CDI 2 Rectificador...
  • Page 66: Fuel Line

    SRVC PREDELIVERY SERVICE D22500-0 FUEL LINE Check that the fuel line is correctly installed. 1 Fuel filter 2 Fuel pump 3 Carburettor 4 Fuel joint...
  • Page 67 SERVICE AVANT LIVRAISON SRVC MANTENIMIENTO PREVIO A LA ENTREGA D22500-0 D22500-0 TUYAU D’ALIMENTATION TUBO DE LLEGADA DEL COM- Contrôler que le tuyau d’alimentation BUSTIBLE est correctement installé. Compruebe que el tubo de llegada del combustible está instalado correctamen- 1 Filtre à essence 2 Pompe à...
  • Page 68: Gear Oil Level

    SRVC PREDELIVERY SERVICE D23000-0 GEAR OIL LEVEL Remove the oil-drain and oil-level plugs, and add the gear oil through the oil-drain hole until it over- flows from the oil-level hole. Re-fit the plugs. (The oil level plug first.) D23502-0 OPERATION OF CONTROLS AND MOVING PARTS 1.
  • Page 69 SERVICE AVANT LIVRAISON SRVC MANTENIMIENTO PREVIO A LA ENTREGA D23000-0 D23000-0 NIVEAU DE L’HUILE DE TRANS- NIVEL DE ACEITE DE LA CAJA MISSION DE CAMBIOS Retirer le bouchon de vidange et la vis Extraiga los tapones de vaciado y de de niveau d’huile et injecter de l’huile nivel del aceite y añada el aceite para de transmission par l’orifice de vidange...
  • Page 70: Fuel Leakage

    SRVC PREDELIVERY SERVICE D24500-0 FUEL LEAKAGE Check for fuel leakage. D25000-0 WATER LEAKAGE Check for water leakage. D25500-0 EXHAUST LEAKAGE Check for exhaust leakage D26000-0 ENGINE AND LOWER UNIT NOISE Check the engine and lower unit for abnormal noise D26500-0 IDLE-SPEED Check that the engine speed at fully-closed throttle is correct.
  • Page 71 SERVICE AVANT LIVRAISON SRVC MANTENIMIENTO PREVIO A LA ENTREGA D24500-0 D24500-0 FUITE DE CARBURANT FUGAS DE COMBUSTIBLE Vérifier s’il n’y a pas de fuite de carbu- Compruebe la posible existencia de rant. fugas de combustible. D25000-0 D25000-0 FUITE D’EAU FUGAS DE AGUA Vérifier s’il n’y a pas de fuite d’eau.
  • Page 72: Periodic Service

    Greasing points Greasing Gear oil Change Fuel system Inspection Fuel filter (can be Inspection / cleaning disassembled) Fuel tank (Yamaha Inspection / cleaning portable tank) Idling speed (carburetor Inspection / adjustment models) Anode(s) (external) Inspection / replacement Anode(s) (internal) Inspection / replacement...
  • Page 73 Renouvellement Système d'alimentation Inspection Filtre à carburant Inspection / nettoyage (démontable) Réservoir à carburant Inspection / nettoyage (réservoir portable Yamaha) Régime de ralenti (modèles à Inspection / réglage carburateur) Anode(s) (externe(s)) Inspection / remplacement Anode(s) (interne(s)) Inspection / remplacement Passages d'eau de...
  • Page 74 Sistema de combustible Inspección Filtro de gasolina (puede Inspección / limpieza desmontarse) Depósito de combustible Inspección / limpieza (depósito portátil de Yamaha) Velocidad de ralentí (modelos Inspección / ajuste con carburador) Ánodo(s) (exterior(es)) Inspección / sustitución Ánodo(s) (interior(es)) Inspección / sustitución...
  • Page 75 SRVC – MEMO –...
  • Page 76: Carburettor

    SRVC PERIODIC SERVICE D31600-0 CARBURETTOR 1) Check the fuel passages and air passages for fouling or clogging. Clean fouled parts with suit- able cleaning solvent and blow out clogged passages with compressed air. Protect your eyes with suitable safety specta- cles or safety goggles when using compressed air.
  • Page 77 ENTRETIEN PERIODIQUE SRVC MANTENIMIENTO PERIODICO D31600-0 D31600-0 CARBURATEUR CABURADOR 1) Vérifier si les passages du carburant 1) Compruebe los conductos de aire y et les passages d’air ne sont pas de combustible y elimine la sucie- encrassés ou bouchés. Nettoyer les dad y las posibles obstrucciones.
  • Page 78: Fuel Tank And Fuel Line

    SRVC PERIODIC SERVICE D32600-0 FUEL TANK AND FUEL LINE 1) Check the fuel tank and fuel line for leaks. 2) Clean the fuel tank thoroughly. D32900-0 GEAR OIL 1) Drain the gear oil thoroughly, and pour in new oil. 2) Check for water or metallic sediment in the drained oil.
  • Page 79 ENTRETIEN PERIODIQUE SRVC MANTENIMIENTO PERIODICO D32600-0 D32600-0 RESERVOIR ET TUYAU D’ALI- DEPOSITO DE COMBUSTIBLE Y MENTATION TUBO DE LLEGADA DEL COM- 1) Vérifier si le réservoir ou le tuyau BUSTIBLE de carburant ne présentent pas de 1) Compruebe la existencia de posi- fuites.
  • Page 80: Ignition Timing Adjustment

    SRVC PERIODIC SERVICE D33308-0* IGNITION TIMING ADJUSTMENT 1. Full advanced position 1) Remove the magneto control rod. 2) Install a dial-gauge in the spark-plug hole of No.1 cylinder. NOTE: For easy timing-plate adjustment, it is advisable to remove the spark plugs from all the cylinders. 3) Slowly turn the flywheel CLOCKWISE, and stop it when the piston is at TDC.
  • Page 81 ENTRETIEN PERIODIQUE SRVC MANTENIMIENTO PERIODICO D33308-0* D33308-0* CALAGE DE L’ALLUMAGE AJUSTE DEL REGLAJE DE 1. Position d’avance maxi à l’alluma- ENCENDIDO 1. Posición completamente avanzada 1) Déposer la tringle de commande de 1) Extraiga la varilla de control de la magnéto.
  • Page 82 SRVC PERIODIC SERVICE 5) Turn the flywheel counterclockwise so that specified value on the timing mark aligns with the timing plate. Ignition timing: 20 – 22° (BTDC.) 6) Align the ignition mark on the flywheel magne- to base with the TDC mark on the flywheel magneto rotor.
  • Page 83 ENTRETIEN PERIODIQUE SRVC MANTENIMIENTO PERIODICO 5) Tourner le volant magnétique dans 5) Haga girar el rotor de la magneto de le sens inverse des aiguilles d’une volante en sentido contrario a las montre de façon que la valeur indi- agujas del reloj, de forma que el quée sur le repère d’allumage soit valor especificado de la marca de alignée avec la plaque de calage.
  • Page 84 SRVC PERIODIC SERVICE 2. Full-retarded position 1) It is unnecessary to adjust the ignition timing at the full-retarded position, since it is automati- cally adjusted when the timing at the full- advanced position has been correctly set. 3. Ignition timing adjustment using a timing light.
  • Page 85 ENTRETIEN PERIODIQUE SRVC MANTENIMIENTO PERIODICO 2. Position de retard maximum 2. Posición completamente retrasada 1. Il n’est pas nécessaire de caler l’al- 1. No es necesario ajustar el reglaje de lumage en position de retard maxi- encendido en la posición completa- mum car il se trove automatique- mente retrasada, ya que se ajusta ment calé...
  • Page 86 SRVC PERIODIC SERVICE 3) Direct the timing light to the timing plate and the timing indicator and make sure of the timing mark to which the timing plate points. 1 C.D.I. magneto rotor 2 Timing mark 3 Timing plate 4) If the timing plate failes to point to the specified ignition timing, loosen the C.D.I magneto base stopper bolt and align the ignition timing mark with the timing plate.
  • Page 87 ENTRETIEN PERIODIQUE SRVC MANTENIMIENTO PERIODICO 3) Diriger le stroboscope vers le pla- 3) Dirija la lámpara de reglaje hacia la teau d’avance l’indicateur placa de reglaje y el indicador de d’avance et noter où se trouve le reglaje, y compruebe la marca de plateau d’avance par rapport au reglaje a la que señala la placa de repère de calage.
  • Page 88: Carburettor Control Link Adjustment

    SRVC PERIODIC SERVICE D31906-0 CARBURETTOR CONTROL LINK ADJUSTMENT 1) Loosen the carburetor control ling set-crew. 2) Set the magneto control lever in the fully advanced position, and adjust the guide collar so that it is in the specified position (as shown) of the accelerator cam.
  • Page 89 ENTRETIEN PERIODIQUE SRVC MANTENIMIENTO PERIODICO D31906-0 D31906-0 REGLAGE DE LA BIELLETTE DE AJUSTE DE LA ARTICULACION COMMANDE DU CARBURATEUR DE CONTROL DEL CARBURA- 1) Desserrer la vis de réglage de la biellette de commande. 1) Afloje el tornillo de ajuste de la arti- 2) Placer le levier de commande de la culación de control del carburador.
  • Page 90: Spark Plug

    SRVC PERIODIC SERVICE D35000-0* SPARK PLUG 1. Check the electrode condition and state of wear, note that the insulator colour and the electrode gap. 2. Clean the spark plug with spark-plug cleaner if necessary. Use a wire gauge to adjust the plug gap to specification.
  • Page 91 ENTRETIEN PERIODIQUE SRVC MANTENIMIENTO PERIODICO D35000-0* D35000-0* BOUGIE BUJIA 1. Vérifier l’état. l’usure et l’écarte- 1. Compruebe el estado de desgaste ment des électrodes ainsi que la del electrodo, examine el color del couleur de l’isolant. aislante y mida la separación entre 2.
  • Page 92: Fuel System

    FUEL CHAPTER 4 FUEL SYSTEM FUEL SYSTEM......................4-1 EXPLODED DIAGRAM..................4-1 CLEANING AND INSPECTION................4-3 INSTALLATION .....................4-5 CARBURETTOR ......................4-6 EXPLODED DIAGRAM..................4-6 REMOVAL AND DISASSEMBLY ................4-7 INSPECTION ......................4-8 ASSEMBLY ......................4-9 INSTALLATION ....................4-10...
  • Page 93 FUEL CHAPITRE 4 CAPITULO 4 SYSTEME SISTEMA DE D’ALIMENTATION ALIMENTACION DE COMBUSTIBLE SYSTEME D’ALIMENTATION ..4-1 VUE ECLATEE......4-1 SISTEMA DE ALIMENTACION NETTOYAGE ET DE COMBUSTIBLE ......4-1 VERIFICATION......4-3 DIAGRAMA DETALLADO ..4-1 INSTALLATION ......4-5 LIMPIEZA E INSPECCION ..4-3 INSTALACION ......4-5 CARBURATEUR......4-6 VUE ECLATEE......4-6 CARBURADOR ......4-6 DEPOSE ET DEMONTAGE ..4-7 DIAGRAMA DETALLADO ..4-6...
  • Page 94: Exploded Diagram

    FUEL FUEL SYSTEM FUEL SYSTEM E20005-0 EXPLODED DIAGRAM 1 Carburettor 5 Priming pump 2 Fuel pump assembly 6 Fuel meter assembly 3 Fuel filter assembly 7 Fuel tank cap 4 Fuel joint 8 Fuel tank...
  • Page 95 SYSTEME D’ALIMENTATION FUEL SISTEMA DE ALIMENTACION DE COMBUSTIBLE SYSTEME SISTEMA DE D’ALIMENTATION ALIMENTACION DE COMBUSTIBLE E20005-0 VUE ECLATEE E20005-0 1 Carburateur DIAGRAMA DETALLADO 2 Pompe à essence 1 Carburador 3 Filtre à essence 2 Conjunto de la bomba de combustible 4 Raccord d’essence 3 Conjunto del filtro de combustible 5 Pompe d’amorçage...
  • Page 96 FUEL FUEL SYSTEM 1. Fire Prevention Petrol is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling petrol, and keep away from heat, sparks, and open flames. 2. Ventilation Petroleum vapor is heavier than air and if inhaled in large quantities will not support life. Engine exhaust gases are harmful to breathe.
  • Page 97 SYSTEME D’ALIMENTATION FUEL SISTEMA DE ALIMENTACION DE COMBUSTIBLE 1. Mesures de sécurité contre les 1. Prevención contra incendios incendies La gasolina es sumamente infla- L’essence est un produit haute- mable. El vapor de gasolina es ment inflammable. Les vapeurs explosivo si se incendia. No fume d’essence sont explosives lors- mientras manipula gasolina, y qu’elles...
  • Page 98: Cleaning And Inspection

    FUEL FUEL SYSTEM E21010-0 CLEANING AND INSPECTION Fuel Tank 1) Add a small quantity of a suitable cleaning sol- vent into the fuel tank and thoroughly clean the tank interior by shaking the tank. 2) Drain off the cleaning solvent completely. E21020-0 Fuel meter complete 1) Using a soft brush and solvent, clean the strain-...
  • Page 99 SYSTEME D’ALIMENTATION FUEL SISTEMA DE ALIMENTACION DE COMBUSTIBLE E21010-0 E21010-0 NETTOYAGE ET VERIFICATION LIMPIEZA E INSPECCION Reservoir à carburant Deposito de combustible 1) Verser une petite quantité de pro- 1) Añada una pequeña cantidad de un duit de rinçage approprié dans le disolvente de limpieza al depósito réservoir et nettoyer soiqneusement de combustible y limpie su interior,...
  • Page 100 FUEL FUEL SYSTEM E21030-0 Priming up 1) Visually inspect for cracks or breaks in the priming-pump and fuel-hoses, and replace them if required. 2) Check the operation of the check-valve by blowing into the pump. 1 Priming pump 2 Arrow mark 3 Check valve (inlet) 4 Check valve (outlet) E21040-0...
  • Page 101 SYSTEME D’ALIMENTATION FUEL SISTEMA DE ALIMENTACION DE COMBUSTIBLE E21030-0 E21030-0 Pompe d’amorçage Bomba cebadora 1) Examiner la pompe d’amorçage et 1) Compruebe que no existen grietas le tuyau d’alimentation pour détec- ni roturas en la bomba cebadora y ter toutes traces de fissure ou de los tubos de combustible.
  • Page 102: Installation

    FUEL FUEL SYSTEM E21050-0 Fuel joints 1) Inspect the fuel joints for leaks and cracks, and replace as required. E21060-0 Fuel pump 1) Using a screwdriver, disassemble the fuel pump. 2) Visually inspect the pump body for cracks, and replace if required. 3) Inspect the valves for cracks or distortion, and replace if required.
  • Page 103 SYSTEME D’ALIMENTATION FUEL SISTEMA DE ALIMENTACION DE COMBUSTIBLE E21050-0 E21050-0 Raccords d’essence Juntas de paso de combustible 1) Examiner les raccords d’essence et 1) Compruebe si existen fugas o grie- vérifier qu’ils ne portent pas de tas en las juntas de paso de combus- traces de fuit ni de fissure.
  • Page 104: Carburettor

    FUEL CARBURETTOR E31000-0 CARBURETTOR EXPLODED DIAGRAM 1 Pilot screw 6 Float 2 Needle valve assembly 7 Drain screw 3 Pilot jet 8 Float chamber 4 Main nozzle 9 Throttle stop screw 5 Main jet 0 Collar...
  • Page 105 CARBURATEUR FUEL CARBURADOR E31000-0 E31000-0 CARBURATEUR CARBURADOR VUE ECLATEE DIAGRAMA DETALLADO 1 Vis de réglage 1 Tornillo guía 2 Pointeau 2 Conjunto de válvula de aguja 3 Gicleur de ralenti 3 Inyector piloto 4 Tube de giclage 4 Boquilla principal 5 Gicleur principal 5 Inyector principal 6 Flotteur...
  • Page 106: Removal And Disassembly

    FUEL CARBURETTOR REMOVAL AND DISASSEMBLY At this step, ensure there is no spillage of petrol on removing the connections. 1) Remove the silencer cover, disconnect the fuel hoses and links, then remove the carburettor. 2) Referring to the diagram, use a screwdriver to disassemble the carburettor.
  • Page 107 CARBURATEUR FUEL CARBURADOR DEPOSE ET DEMONTAGE EXTRACCION Y DESMONTAJE Lors du retrait des raccords, s’assu- Llegado a este punto, asegúrese de no rer qu’il n’y a pas d’essence qui se derramar gasolina al retirar las cone- répande. xiones. 1) Enlever le couvercle du silencieux, 1) Retire la cubierta del silenciador, débrancher les tuyaux d’alimenta- desconecte los tubos de llegada de...
  • Page 108: Inspection

    FUEL CARBURETTOR E32000-0* INSPECTION Carburettor body 1) Inspect the carburettor body for cracks or clog- ging of the passages. Needle valve 1) Inspect the needle valve for free movement and wear, and replace if required. Pilot screw 1) Inspect the needle valve for wear, and replace if required.
  • Page 109 CARBURATEUR FUEL CARBURADOR E32000-0* E32000-0* VERIFICATION INSPECCION Corps du carburateur Cuerpo de carburador 1) Vérifier si le corps du carburateur 1) Inspeccione el cuerpo del carbura- n’est pas fissuré et si les passages dor para determinar la posible exis- ne sont pas obstrués. tencia de grietas o la obstrucción de sus conductos.
  • Page 110: Assembly

    FUEL CARBURETTOR E33003-0* ASSEMBLY 1) Screw in the main nozzle fully, and screw in the main jet until tight. 2) Install the needle-valve on the float, attach the float to the carburettor body with the float-pin, and tighten the screw. 3) Install a new gasket to the float-chamber, install it to the carburettor body, and secure with the screws.
  • Page 111 CARBURATEUR FUEL CARBURADOR E33003-0 E33003-0* ASSEMBLAGE MONTAJE 1) Visser à fond le gicleur principal et 1) Atornille completamente el inyec- le gicleur de starter. tor principal; atornille el surtidor 2) Monter le pointeau sur le flotteur, principal hasta que quede apretado. fixer le flotteur sur le corps du car- 2) Instale la válvula de aguja en el flo- burateur avec l’axe du flotteur et...
  • Page 112: Installation

    FUEL CARBURETTOR E34001-0 INSTALLATION 1) Install the carburettor and plate with new gas- kets. 2) Connect the fuel hose to the carburettor and fit the hose-clip over the recesses to ensure leak- proof connections. 4-10...
  • Page 113 CARBURATEUR FUEL CARBURADOR E34001-0 E34001-0 INSTALLATION INSTALACION 1) Monter le carburateur avec de nou- 1) Instale el carburador con una junta veaux joints. nueva. 2) Brancher le tuyau de carburant au 2) Conecte el tubo de llegada del com- carburateur et fixer le collier du bustible al carburador, y coloque la tuyau sur la tubulure afin d’éviter abrazadera del tubo sobre el orificio...
  • Page 114: Power Unit

    POWR CHAPTER 5 POWER UNIT EXPLODED DIAGRAM ....................5-1 PREPARATION FOR THE OVERHAUL ..............5-2 REMOVAL........................5-2 DISASSEMBLY ......................5-3 CHECKING THE CRANKSHAFT ...............5-14 INSPECTION ......................5-15 CYLINDER HEAD....................5-15 CYLINDER BLOCK ....................5-16 PISTON.......................5-17 PISTON RING.....................5-19 PISTON PIN AND SMALL END BEARING ............5-20 CRANKSHAFT....................5-20 REED VALVE ......................5-21 THERMOSTAT ....................5-22 BALL BEARING....................5-22 ASSEMBLY AND ADJUSTMENT ................5-23...
  • Page 115 POWR CHAPITRE 5 CAPITULO 5 MOTEUR MOTOR VUE ECLATEE ......5-1 DIAGRAMA DETALLADO..5-1 AVANT LA REVISION....5-2 PREPARACION PARA SU REVISION........5-2 DEPOSE ..........5-2 EXTRACCION .......5-2 DEMONTAGE ........5-3 VERIFICATION DU DESMONTAJE.......5-3 VILEBREQUIN......5-14 COMPROBACIÓN DEL CIGÜEÑAL.......5-14 VERIFICATION......5-15 CULASSE........5-15 INSPECCION .......5-15 BLOC-CYLINDRE ....5-16 CULATA........5-15 PISTON ........5-17 BLOQUE MOTOR....5-16 SEGMENTS DE PISTON..5-19 PISTON ........5-17...
  • Page 116: Exploded Diagram

    POWR EXPLODED DIAGRAM G20000-0 EXPLODED DIAGRAM 1 Cylinder head 9 Piston pin u Valve seat gasket 2 Cylinder head gasket 0 Bearing i Reed valve assembly 3 Thermostat cover q O-ring 4 Thermostat w Washer 5 Exhaust cover gasket e Oil seal 6 Exhaust inner cover r O-ring 7 Exhaust outer cover...
  • Page 117 VUE ECLATEE POWR DIAGRAMA DETALLADO G20000-0 G20000-0 VUE ECLATEE DIAGRAMA DETALLADO 1 Couvre-culasse 2 Joint de couvercle de culasse 1 Tapa de la culata 3 Couvercle de thermostat 2 Junta de la tapa 4 Thermostat 3 Tapa del termostato 5 Joint de couvercle d’échappement 4 Termostato 6 Couvercle interne d’échappement 5 Junta de la tapa del escape...
  • Page 118: Preparation For The Overhaul

    POWR PREPARATION FOR OVERHAUL/REMOVAL G30000-0 PREPARATION FOR THE OVERHAUL 1. Clean all dirt, mud, dust and foreign material from the engine before the engine is removed and disassembled. 2. To ensure that you can perform the work clean- ly and efficiently, check that you have the prop- er tools and cleaning equipment before com- mencing engine removal and disassembly.
  • Page 119 AVANT LA REVISION/DEPOSE POWR PREPARACION PARA SU REVISION/EXTRACCION G30000-0 G30000-0 AVANT LA REVISION PREPARACION PARA SU REVISION 1. Avant de déposer et de démonter le moteur, le nettoyer de toutes traces 1. Limpie la suciedad, el barro, el de saleté, boue, poussière, etc. polvo y otros materiales del motor 2.
  • Page 120: Disassembly

    POWR DISASSEMBLY G50002-0 DISASSEMBLY 1) Disassemble the power head, referring to the exploded diagram. 1. Cylinder head and thermostat cover 2. Intake manifold and read valve 3. Exhaust covers 4. Oil seal housing 5. Crank case 6. Crankshaft 7. Piston 8.
  • Page 121 DEMONTAGE POWR DESMONTAJE G50002-0 G50002-0 DEMONTAGE DESMONTAJE 1) Démonter le bloc-moteur en se 1) Desmonte el motor, consultando reportant à la vue éclatée. para ello el diagrama detallado. 1. Culasse et couvercle du ther- 1. Culata y cubierta del termosta- mostat 2.
  • Page 122 POWR DISASSEMBLY 2) Disassemble the crankshaft 1. Remove the upper bearing. 9 Upper bearing 1 Pressure pin B........a 90890-02390 Bearing separator ......2 90890-06534 NOTE: 9 By forcing the pressure pin B a with a hydraulic press, remove the bearing. 9 When forcing out the crank pin, use care so that the crankshaft does not fall off.
  • Page 123 DEMONTAGE POWR DESMONTAJE 2) Démonter de vilebrenguin 2) Desmontaji del cigüeñal 1. Deposer du roulment supérieur 1. Extraiga el cojinete superior 9 Roulement supérieur 1 9 Cojinete superior 1 Tige de pression B ...a Pasador de presión B ..a 90890-02390 90890-02390 Séparateur de Separador de cojinetes..2...
  • Page 124 POWR DISASSEMBLY 3. Crank 1 and crank 4 removal Remove: 9 Crank 1 9 Crank 4 Plate A ..........1 90890-02386 Pressure pin B........a 90890-02390 Removing steps (1) By forcing the pressure pin B a with a hydraulic press, remove the crank pin. (2) When forcing out the crank pin, use care so that the crankshaft does not fall off.
  • Page 125 DEMONTAGE POWR DESMONTAJE 3. Dépose de manivelle 1 et de 3. Extracción del cigüeñal 1 y del manivelle 4 cigüeñal 4 Déposer : Extraiga: 9 Manivelle 1 9 Cigüeñal 1 9 Manivelle 4 9 Cigüeñal 4 Plaque A ......1 Placa A......1 90890-02386 90890-02386 Tige de pression B ...a...
  • Page 126 POWR DISASSEMBLY 9 Apply pressure to the pressure pin B a slow- 9 Hold the pressure pin B a in line with the press screw spindle. 2. Remove: 9 Labyrinth seal 1 9 Clip 2 3. Remove: 9 Bearing Removing steps (1) Remove roller bearing (outer race) (2) Remove roller bearing (inner race) using hydraulic press.
  • Page 127 DEMONTAGE POWR DESMONTAJE 9 Appliquer la pression lentement 9 Aplique presión al pasador de pre- sur la tige de pression B a. sión B a lentamente. 9 Tenir la tige de pression B a ali- 9 Mantenga la presión B a en línea gnée sur l’arbre de la vis de presse.
  • Page 128 Spacer B ..........1 90890-02396 Support ..........2 90890-02394 2. Install: 9 Crank pin 4 (new) NOTE: 9 Insert the crank pin into the pin hole by tapping it with a copper hammer 5. 9 Apply Yamaha 2-stroke motor oil on the crank pin.
  • Page 129 9 Appliquer de l’huile moteur deux 9 Inserte el pasador del cigüeñal en el temps Yamaha sur le maneton. orificio del pasador golpeándolo con un martillo de cobre 5. 9 Aplique aceite de motor de 2 tiempos Yamaha en el pasador del cigüeñal.
  • Page 130 POWR DISASSEMBLY 3. Press-fit: 9 Crank pin 4 NOTE: 9 Don’t apply force in excess of 5 tons. 9 The crank pin should be press-fitted into both crank 2 and crank 4. Take care so that the crank pin 4 is set square- ly to the crank web 6.
  • Page 131 DEMONTAGE POWR DESMONTAJE 3. Ajuster à la presse : 3. Adapte a presión: 9 Maneton 4 9 Pasador del cigüeñal 4 N.B.: NOTA: 9 Ne pas appliquer de force supérieure 9 No aplique una fuerza que exceda de à 5 tonnes. 5 toneladas.
  • Page 132 9 Crank 1 1 or crank 3 (use pressure plate) NOTE: 9 Align the crank pin hole 2 with the crank pin 3 fitted to crank 2 or crank 4. 9 Apply Yamaha 2-stroke motor oil on the crank 1 or crank 3.
  • Page 133 NOTA: N.B.: Aplique aceite de motor de 2 tiempos Appliquer de l’huile moteur deux temps Yamaha en la arandela y en el cojinete Yamaha sur la rondelle et sur le roule- del pie. ment de pied de bielle. 3. Instale: 9 Biela 8 3.
  • Page 134 9 Crank 1 or crank 3 Press body..........4 90890-02385 9 Be sure to press-fit the crank 1 or crank 3 squarely onto the crank pin. 9 Apply Yamaha 2-stroke motor oil on the crank pin. 8. Measure: 9 Crank width a Use the digital caliper.
  • Page 135 9 Appliquer de l’huile moteur deux 9 Aplique aceite de motor de 2 tiem- temps Yamaha sur le maneton. pos Yamaha en el pasador del cigüeñal. 8. Mesurer : 9 Largeur de manivelle a 8.
  • Page 136 9 Roller bearing (inner race) 2 NOTE: 9 Position the roller bearing with the stamped mark a facing upward and press-fit it until it contacts the crank 2. 9 Apply Yamaha 2-stroke motor oil on the roller bearing. Plate A ..........b 90890-02386 Bearing pressure B......c...
  • Page 137 9 Appliquer de l’huile moteur deux se ponga en contacto con el cigüeñal temps Yamaha sur le roulement à rou- 9 Aplique aceite de motor de 2 tiempos leaux. Yamaha en el cojinete de rodillos.
  • Page 138 9 Crank 1 and crank 2 2 (on the crank 3 Plate B ..........1 90890-02387 9 Align the match marks a on crank 3 and 2. 9 Apply Yamaha 2-stroke motor oil on the crank 3 and 2. 3. Press-fit: 9 Crank 2 and crank 3 (apply a force of 7 ton) Height ring (H54) ........1...
  • Page 139 9 Appliquer de l’huile moteur deux 9 Aplique aceite de motor de 2 tiem- temps Yamaha sur les manivelles 3 pos Yamaha en los cigüeñales 3 y 2. et 2. 3. Adapte a presión: 9 Cigüeñal 2 y cigüeñal 3 3.
  • Page 140 90890-02392 NOTE: 9 Install the lower bearing so that the dowel pin a faces the drive shaft side. 9 Apply Yamaha 2-stroke motor oil on the bearing. 9 Be sure to press-fit the ball bearing squarely onto crank 4. 6B450781 5.
  • Page 141 9 Appliquer de l’huile moteur deux Yamaha en el cojinete. 9 Asegúrese de adaptar a presión con temps Yamaha sur le roulement. 9 Bien ajuster à la presse le roulement uniformidad el cojinete de bolas en el à billes solidement sur la manivelle 4.
  • Page 142: Checking The Crankshaft

    POWR DISASSEMBLY 6. Run-out check 1. Measure: 9 Runout Use the crank stand alignment 1 and digital gauge 2. Out of specification → Adjust. Crank stand alignment 90890-03107 Digital gauge set 90890-01252 Runout limit 0.03 mm (0.0012 in) NOTE: If the dial gauge reading is 0.03 mm (0,0012 in) or more, adjust the crankshaft so that the reading is less than 0.03 mm (0,0012 in).
  • Page 143 DEMONTAGE POWR DESMONTAJE 6. Vérification de l’ovalisation 6. Comprobación del descentra- 1. Mesurer : miento 9 Ovalisation 1. Mida: 9 Descentramiento Utiliser l’alignement de socle de manivelle 1 et un Emplee la alineación del calibre numérique 2. soporte del cigüeñal 1 y Hors spécifications →...
  • Page 144: Inspection

    POWR INSPECTION G61000-0* INSPECTION CYLINDER HEAD Cleaning 1) Using a gasket scraper, remove all traces of gasket material from the cylinder head. 2) Using a round scraper, remove carbon deposits from the combustion chamber. Do not scratch the surfaces of the cylinder head and combustion chamber.
  • Page 145 VERIFICATION POWR INSPECCION G61000-0* G50002-0 VERIFICATION INSPECCION CULASSE CULATA Nettoyager Limpieza 1) A’ l’aide d’un grattoir, nettoyer la 1) Utilice un raspador de juntas para cullase de toutes traces de joint. eliminar los residuos de la junta de 2) Pour enlever la calamine de la culata.
  • Page 146: Cylinder Block

    POWR INSPECTION G61501-0* CYLINDER BLOCK Cleaning 1) Using a gasket scraper, remove all traces of gasket material from the cylinder-block surface. 2) Using a soft brush and solvent, clean the cylin- der-block. Inspection 1) Visually inspect the cylinder sleeves for cracks and scratches.
  • Page 147 VERIFICATION POWR INSPECCION G61501-0* G61501-0* BLOC-CYLINDRE BLOQUE MOTOR Nettoyage Limpieza 1) A l’aide d’un grattoir, éliminer 1) Utilice un rascador de juntas para toutes traces de joint du bloc- eliminar los residuos de la junta de cylindre. la superficie del bloque motor. 2) A l’aide d’une brosse souple et d’un 2) Limpie el bloque motor con un solvant, nettoyer le bloc-cylindre.
  • Page 148: Piston

    POWR INSPECTION G62000-0* PISTON Cleaning 1) Using a gasket-scraper, remove the carbon from the piston top. 2) Using a broken ring, clean the ring grooves. The top ring is a keystone-type ring; therefore, do not use a broken top ring for cleaning the other ring grooves, nor use a broken ring from a lower groove for cleaning the top groove.
  • Page 149 VERIFICATION POWR INSPECCION G62000-0* G62000-0* PISTON PISTON Nettoyage Limpieza 1) A l’aide d’un grattoir, enlever 1) Utilice un raspador de juntas para toutes traces de calamine de la têté eliminar el carbón de la parte supe- de piston. rior del pistón. 2) Pour nettoyer les gorges des seg- 2) Limpie las ranuras de los segmentos ments, utiliser un morceau de seg-...
  • Page 150 POWR INSPECTION Inspection 1) Using a micrometer, measure the piston diam- eter at right angles to the piston-pin centreline, 10 mm (0.4 in) above the bottom edge. Piston diameter: 66.955 – 66.980 mm (2.6360 – 2.6370 in) 2) Using the measured cylinder bore diameter in thrust directions, subtract the piston diameter measurement from the cylinder bore diameter measurement.
  • Page 151 VERIFICATION POWR INSPECCION Vérification Inspección 1) Au moyen d’un micromètre, mesu- 1) Utilice un micrómetro para medir el rer le diamètre du piston perpendi- diámetro del pistón a ángulos rectos culairement à l’axe de piston et à 10 respecto de la línea central del eje mm au-dessus du bord inférieur de del pistón, 10 mm por encima de la jupe du piston.
  • Page 152: Piston Ring

    POWR INSPECTION G61501-0* PISTON RING Inspection 1) Using a feeler gauge, measure the clearance between the piston ring and the groove land. Side clearance: Top ring: 0.02 – 0.06 mm (0.0008 – 0.0024 in) 2nd: 0.03 – 0.07 mm (0.0012 – 0.0028 in) If the clearance is not within the specifications, replace the piston.
  • Page 153 VERIFICATION POWR INSPECCION G62501-0* G62501-0* SEGMENTS DE PISTON SEGMENTOS Vérification Inspección 1) En insérant une cale d’épaisseur 1) Utilice un calibrador de grosores entre la partie supérieure du seg- para medir la holgura entre el seg- ment et le cordon, mesurer le jeu mento y la parte plana entre las des segments.
  • Page 154: Piston Pin And Small End Bearing

    POWR INSPECTION G63000-0 PISTON PIN AND SMALL END BEARING Cleaning 1) Use a soft brush and solvent to clean the parts. Inspection 1) Visually inspect for surface defects, breakage, scratches and pitting. If it is decided to replace the small end bearings, replace them all. G63500-0* CRANKSHAFT Inspection...
  • Page 155 VERIFICATION POWR INSPECCION G63000-0 G63000-0 AXE DE PISTON ET BAGUE DE EJE DE PISTON Y COJINETE PIED DE BIELLE DEL PIE DE BIELA Nettoyage Limpieza 1) A’ l’aide d’une brosse douce et de 1) Utilice un cepillo suave y disolven- solvant, nettoyer les pièces.
  • Page 156: Reed Valve

    POWR INSPECTION G64000-0* REED VALVE Inspection 1) Visually inspect for warping of the reed valve. If warped, measure the distortion with feeler gauges. Valve bending limit 0.200 mm (0.0079 in) If the amount of warping is greater than specifi- cation, replace the reed valve. 2) Using a vernier caliper, measure the valve stop- per height.
  • Page 157 VERIFICATION POWR INSPECCION G64000-0* G64000-0* CLAPETS VALVULA DE LENGÜETAS Vérification Inspección 1) Vérifier la planéité des clapets. En 1) Inpeccione visualmente la válvula cas de déformation, mesurer son de lengüetas para determinar si está importance à l’aide d’un jeu de deformada.
  • Page 158: Thermostat

    POWR INSPECTION G64500-0* THERMOSTAT Cleaning 1) Using a soft brush and water, remove all traces of salt, dirt or corrosion. Inspection 1) Visually inspect the thermostat for damage. If the thermostat is damage, or if it is opens when cold, replace it. 2) Immerse the thermostat in water, and heat the water gradually.
  • Page 159 VERIFICATION POWR INSPECCION G64500-0* G64500-0* THERMOSTAT TERMOSTATO Nettoyage Limpieza 1) Eliminer toutes traces de sel, saleté 1) Utilice un cepillo suave y agua para et corrosion à la brosse et à l’eau. eliminar los residuos de sal, sucie- dad o corrosión. Vérification 1) Examiner le thermostat pour détec- Inspección...
  • Page 160: Assembly And Adjustment

    POWR ASSEMBLY AND ADJUSTMENT G71003-0 ASSEMBLY AND ADJUSTMENT BEARING, OILSEAL AND O-RING 1) Press in the new bearing. When reassembling the lower crank bearing the seal-cap side of the bearing should be installed towards the crank side, as shown in the illustra- tion.
  • Page 161 2 temps. de lo contrario puede dañarse. Graisser la lèvre intérieure du joint à huile (Graisse Yamaha Marine ou 3) Instale la nueva junta tórica. équivalent). 4) Engrase el cojinete con aceite para motor fuera borda de dos tiempos.
  • Page 162: Small End Bearings And Piston Assembly

    POWR ASSEMBLY AND ADJUSTMENT G73002-0* SMALL END BEARINGS AND PISTON ASSEM- 1) Count the small-end bearing needles. Number of needles per small end: 31 pcs Do not use a mixture of new and used bearing needles in the same small end. 2) Using the special service tool.
  • Page 163 ASSEMBLAGE ET REGLAGE POWR MONTAJE Y AJUSTE G73002-0* G73002-0* ROULEMENT DE PIED DE BIEL- COJINETES DEL PIE DE BIELA Y LE ET PISTON PISTON 1) Compter les aiguilles du roulement. 1) Cuente el número de agujas de los cojinetes del pie de biela. Nombre d’aiguilles du roule- Número de agujas por pie de ment:...
  • Page 164: Crank Cylinder Assembly

    POWR ASSEMBLY AND ADJUSTMENT G74000-0* CRANK CYLINDER ASSEMBLY 1) Lubricate the piston-rings and pistons with 2- stroke outboard-motor oil, and install then crank assembly into the cylinder block. 2) Lift the crank assembly a little so as to be able to install a washer on the lower crankcase, and align each locating-clip of the bearings and labyrinth-seals with each cut on the cylinder-...
  • Page 165 ASSEMBLAGE ET REGLAGE POWR MONTAJE Y AJUSTE G74000-0* G74000-0* EMBIELLAGE DU BLOC- COJINETES DEL CILINDRO DEL CYLINDRE CIGÜEÑAL 1) Lubrifier les segments et le piston 1) Lubrique los segmentos y el pistón avec de l’huile moteur hors-bord 2 con aceite para motor fuera borda temps et emmancher l’ensemble de de dos tiempos e instale el conjunto l’embiellage dans le bloc-cylindre.
  • Page 166: Intake Manifold

    POWR ASSEMBLY AND ADJUSTMENT/INSTALLATION G76002-0* INTAKE MANIFOLD 1) Install the reed-valve assembly, and the gasket reed-valve plate to the intake manifold. 2) Install the manifold assembly to the crankcase. G77000-0* FUEL SYSTEM AND ELECTRICAL SYSTEM 1) Install the fuel system referring to page 4-1. 2) Install the electrical system referring to page 3- G80002-0* INSTALLATION...
  • Page 167 ASSEMBLAGE ET REGLAGE/INSTALLATION POWR MONTAJE Y AJUSTE/INSTALACION G76002-0* G76002-0* COLLECTEUR D’ADMISSION COLECTOR DE ADMISION 1) Installer les clapets et le joint sur le 1) Instale el conjunto de la válvula de collecteur d’admission. lengüetas y la placa de la válvula de 2) Mettre le collecteur d’admission en lengüetas en el colector de admi- place sur le carter moteur.
  • Page 168: Recoil Starter

    POWR RECOIL STARTER H11000-0 RECOIL STARTER 1 Starter case 7 Rope guide 2 Starter spring 8 Drive pawl spring 3 Sheave drum 9 Drive pawl 4 Starter stop plunger 0 Bush 5 Starter handle q Starter shaft 6 Seal 5-27...
  • Page 169 LANCEUR POWR MOTOR DE ARRANQUE DE RETROCESO H11000-0 H11000-0 LANCEUR MOTOR DE ARRANQUE DE RETROCESO 1 Boîtier du lanceur 2 Ressort spirale 1 Caja del motor de arranque 3 Enrouleur 2 Resorte de heliccoi dal 4 Plongeur d’arrêt du démarreur 3 Tambor de polea 5 Poignée du démarreur 4 Embolo tope de arranque...
  • Page 170 POWR RECOIL STARTER REMOVAL AND DISASSEMBLY 1) Remove and disassemble the recoil starter referring to the exploded diagram. Note the fol- lowing points. 9 Remove the start-in-gear protection device at the recoil starter. 9 When removing the starter rope, insert a screwdriver into the starter stop-plunger hole to secure the sheave-drum from run- ning off.
  • Page 171 LANCEUR POWR MOTOR DE ARRANQUE DE RETROCESO DEPOSE ET DEMONTAGE EXTRACCION DESMONTAJE 1) En se référant à la vue éclatée ci- 1) Extraiga y desmonte el motor de dessus, déposer et démonter le lan- arranque de retroceso siguiendo el ceur. Lire anttentivement les notes diagrama anterior.
  • Page 172 POWR RECOIL STARTER H12002-0* INSPECTION Drive pawl and spring 1) Visually inspect the drive pawl for breaks, bends or wear and, if these are found, replace the things. Sheave drum 1) Visually inspect the sheave drum and sheave pin for damage, cracks or warping and, if these are found, replace the sheave drum.
  • Page 173 LANCEUR POWR MOTOR DE ARRANQUE DE RETROCESO H12002-0* H12002-0* VERIFICATION INSPECCION Ressort et cliquet d’entraînement Trinquete 1) Examiner le cliquet d’entraînement, 1) Inspeccione visualmente el trinque- vérifier qu’il est exempt de fêlure, te para determinar si está roto, torsion et ne porte pas de signes doblado o desgastado.
  • Page 174 NOTE: 1. Apply Yamaha marine grease to the inner surface of the starter case. 2. Each new starter-spring is bound by a steel hoop. To install, hook its outer end onto the retainer-post first, put it into the starter case, and then remove steel hoop.
  • Page 175 N.B.: NOTA: 1. Enduire la face intérieure du boîtier 1. Aplique grasa marina Yamaha a la du lanceur avec de la graisse marine superficie interior de la caja del Yamaha. motor de arranque.
  • Page 176 5) Position the inner end of the starter-spring on the retainer-post of the sheave-drum. 6) Install the bushing to the starter-case. NOTE: Apply Yamaha marine grease to the outer surface of the bushing. 7) Pass the starter-rope through the cutaway. 8) Wind-up the spring 2 turns counterclockwise with the starter-rope.
  • Page 177 N.B.: Enduire la face extérieure de la bague de NOTA: graisse marine Yamaha. Aplique grasa marina Yamaha a la superficie exterior del buje. 7) Faire passer le câble de démarrage par l’encoche. 7) Pase el cable de arranque por el 8) Enrouler 2 fois le ressort dans le corte.
  • Page 178 POWR RECOIL STARTER H14000-0 INSTALLATION 1) Install the starter stop-plunger to the starter case, referring to page 3-14. 2) Secure the starter assembly to the power unit. 5-32...
  • Page 179 LANCEUR POWR MOTOR DE ARRANQUE DE RETROCESO H14000-0* H14000-0* INSTALLATION INSTALACION 1) Installer le plongeur d’arrêt du lan- 1) Instale el émbolo tope de arranque ceur sur le boîtier du lanceur en se en la caja del motor de arranque. référant à...
  • Page 180 LOWR CHAPTER 6 LOWER UNIT EXPLODED DIAGRAM ....................6-1 REMOVAL........................6-2 DISASSEMBLY ......................6-2 INSPECTION ......................6-6 GEAR CASE......................6-6 BEARING HOUSING....................6-6 RING-NUT ......................6-6 WATER PUMP HOUSING ..................6-6 IMPELLER ......................6-7 OIL-SEAL COVER ....................6-7 GEARS .........................6-7 BEARINGS ......................6-7 CLUTCH DOG AND COMPONENTS ..............6-7 DRIVE AND PROPELLER SHAFTS ..............6-8 DRIVE SHAFT SLEEVE ..................6-8 SHIFT-PLUNGER, SHIFT-SHAFT, AND BOOT ............6-8 PROPELLER AND ANODE..................6-8...
  • Page 181 LOWR CHAPITRE 6 CAPITULO 6 BOITIER D’HELICE UNIDAD INFERIOR VUE ECLATEE ......6-1 DIAGRAMA DETALLADO..6-1 DEPOSE ..........6-2 EXTRACCION .......6-2 DEMONTAGE ........6-2 DESMONTAJE.......6-2 VERIFICATION......6-6 INSPECCION .........6-6 BOITIER D’HELICE ....6-6 CAJA DE ENGRANAJES ..6-6 BOITIER DE ROULEMENT..6-6 CAJA DE RODAMIENTOS ..6-6 ECROU A BAGUE......6-6 TUERCA DE ANILLO ....6-6 BOITIER DE LA POMPE A CAJA DE LA BOMBA DE...
  • Page 182: Exploded Diagram

    LOWR EXPLODED DIAGRAM G20000-0 EXPLODED DIAGRAM 1 Impeller q Shift cam a Shim 2 Outer plate w Pinion gear s O-Ring 3 Oil seal cover e Shim d Bearing 4 Oil seal r Bearing f Bearing housing 5 Drive shaft t Forward gear g Straight key 6 Woodruff key...
  • Page 183 VUE ECLATEE LOWR DIAGRAMA DETALLADO G20000-0 G20000-0 VUE ECLATEE DIAGRAMA DETALLADO 1 Turbine 2 Plaque extérieure 1 Rotor 3 Couvercle de joint à huile 2 Placa exterior del cartucho 4 Joint d’huile 3 Cubierta de la junta de aceite 5 Arbre de transmission 4 Retén de aceite 6 Clavette à...
  • Page 184: Removal

    LOWR REMOVAL/DISASSEMBLY I30003-0* REMOVAL 1) Remove the nut and washer, and remove the propeller and spacer from the propeller shaft. 2) Drain the gear oil by removing the plugs from the oil-filling hole and the oil-level hole. Be sure to remove the oil filling plug first. Referring page 3-8.
  • Page 185 DEPOSE/DEMONTAGE LOWR EXTRACCION/DESMONTAJE I30003-0* I30003-0* DEPOSE EXTRACCION 1) Déposer l’écrou avec rondelle pour 1) Retire la tuerca y la arandela y démonter l’hélice et l’entretoise de extraiga la hélice y el separador del l’arbre d’hélice. eje de la hélice. 2) Vidanger l’huile de transmission en 2) Vacié...
  • Page 186 LOWR DISASSEMBLY 6. Ring nut Straighten the washer tabs bent over the bearing housing nut. Using special service tool. 7. Lock washer 8. Bearing housing Using special service tool. 9. Straight key 10. Propeller shaft 11. Cross-pin ring, cross-pin, and clutch dog. 12.
  • Page 187 DEMONTAGE LOWR DESMONTAJE 6. Bague 6. Tuerca redonda Redresser la plaque d’arrêt qui Enderece las lengüetas de la freine l’écrou du corps de arandela dobladas sobre la tuer- palier. ca de la caja de cojinete. 7. Rondelle de blocage 7. Arandela de presión Utiliser l’outil spécial.
  • Page 188 LOWR DISASSEMBLY 13. Oil seals and needle bearing. Using special service tool. 14. Pinion-nut and pinion-gear. Using special service tool. 15. Drive shaft 16. Forward gear 17. Drive shaft bearing outer race and shim. Using special service tool. 18. Sleeve...
  • Page 189 DEMONTAGE LOWR DESMONTAJE 13. Joints d’huile et roulement à 13. Retenes de aceite y cojinete de aiguilles. agujas. Utiliser nun outil spécial. Utilice la herramienta especial. 14. Ecrou de pignon et pignon. 14. Tuerca de piñon, y piñón. Utiliser un outil spécial. Utilice la herramienta especial.
  • Page 190 LOWR DISASSEMBLY 19. Forward gear bearing outer race and shim. Using special service tool. 20. Taper roller bearing. Using special service tool. 21. Taper roller bearing Using special service tool. 22. Drive-shaft needle-bearing. Using special service tool. Note the following points: 1.
  • Page 191 DEMONTAGE LOWR DESMONTAJE 19. Bague extérieure du roulement 19. Anillo exterior y laminilla del de pignon de marche avant et cojinete del engranaje de mar- rondelle de réglage. cha de avance. Utilice la herra- Utiliser un outil spécial. mienta especial. 20.
  • Page 192: Inspection

    LOWR INSPECTION I51000-0 INSPECTION GEAR CASE 1) Using a soft brush and solvent, clean the case and water passage. 2) Visually inspect the gear case for cracks, corro- sion or distortion. If any crack or excessive cor- rosion is found, replace the gear case. I51500-0 BEARING HOUSING 1) Using a soft brush and solvent, clean the hous-...
  • Page 193 VERIFICATION LOWR INSPECCION I51000-0 I51000-0 VERIFICATION INSPECCION BOITIER D’HELICE CAJA DE ENGRANAJES 1) Au moyen d’une brosse douce et de 1) Utilice un cepillo suave y disolven- solvant, nettoyer le boîtier d’helice te para limpiar la caja y el conducto et la conduite d’eau.
  • Page 194: Impeller

    LOWR INSPECTION I53500-0 IMPELLER 1) Visually inspect the impeller for cracks, distor- tion or burning. If any damage is found, replace the impeller. I54009-0 OIL-SEAL COVER 1) Using a soft brush and solvent, clean the oil- seal cover. 2) Visually inspect the cover for cracks or corro- sion.
  • Page 195 VERIFICATION LOWR INSPECCION I53500-0 I53500-0 ROTOR ROTOR 1) Examiner le rotor, vérifier qu’il 1) Inspeccione el rotor y compruebe si n’est ni fissuré ni tordu et ne pré- presenta grietas, distorsión o que- sente pas de traces de brûlure. Le maduras.
  • Page 196: Drive And Propeller Shafts

    LOWR INSPECTION I56000-0 DRIVE AND PROPELLER SHAFTS 1) Visually inspect the shafts, looking for grooved wear on the surface in contact with the bearings and oil-seals, and looking for wear on the splines. Replace if worn or damaged. I56300-0 DRIVE SHAFT SLEEVE 1) Visually inspect the sleeve for wear and cracks.
  • Page 197 VERIFICATION LOWR INSPECCION I56000-0 I56000-0 ARBRES DE TRANSMISSION ET EJE MOTOR Y EJE DE LA HELI- D’HELICE 1) Examiner les arbres et vérifier que 1) Inspeccione los ejes, con el fin de les surfaces en contact avec les rou- descubrir un posible desgaste en lements et les cannelures ne sont forma de estrías en la superficie que pas usées.
  • Page 198: Assembly And Adjustment

    LOWR ASSEMBLY AND ADJUSTMENT I61003-0* ASSEMBLY AND ADJUSTMENT SHIM SELECTION NOTE: 1. When reassembling the lower unit with the origi- nal gear case and inner parts, shim selection is not required. 2. If the bearing(s) and/or gear(s) and/or gear case are replaced, carry out the shim selection.
  • Page 199 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE I61003-0* I61003-0* ASSEMBLAGE ET MONTAJE Y AJUSTE REGLAGE SELECCION DE LAMINILLAS DE SELECTION DES CALES AJUSTE D’EPAISSEUR NOTA: N.B: 1. Si vuelve a montar la unidad inferior 1. Lorsqu’on remonte l’ensemble infé- con la caja de engranajes y las piezas rieur sur le carter et les pièces internas originales, no es necesario internes d’origine, il n’est pas néces-...
  • Page 200 LOWR ASSEMBLY AND ADJUSTMENT Example: If M is “16.12 mm”, then T3 = 16.12 – 15.5 – 0/100 = 0.62 mm Available shim thickness: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: 9 Use a minimum number of shims to obtain the thickness equal or nearly equal to the calculation.
  • Page 201 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE Exemple: Ejemplo: Si la M est “16,12 mm”, Si la M es “16,12 mm”, T3 = 16,12 – 15,5 – 0/100 T3 = 16,12 – 15,5 – 0/100 = 0,62 mm = 0,62 mm Cales d’épaisseur dispo- Espesores de laminillas dis- nibles:...
  • Page 202 LOWR ASSEMBLY AND ADJUSTMENT Example: If M is “16.35 mm”, then T1 = 16.8 + 0/100 – 16.35 = 0.45 mm Available shim thickness: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: 9 Use a minimum number of shims to obtain the thickness equal or nearly equal to the calculation.
  • Page 203 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE Exemple: Ejemplo: Si la M est “16,35 mm”, Si la M es “16,35 mm”, T1 = 16,8 + 0/100 – 16,35 T1 = 16,8 + 0/100 – 16,35 = 0,45 mm = 0,45 mm Cales d’épaisseur dispo- Espesores de laminillas dis- nibles:...
  • Page 204: Backlash

    LOWR ASSEMBLY AND ADJUSTMENT Example: If M is “24.47 mm”, then T2 = 24.47 – 24 + 5/100 = 0.52 mm Available shim thickness: 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: 9 Use a minimum number of shims to obtain the thickness equal or nearly equal to the calculation.
  • Page 205 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE Exemple: Ejemplo: Si la M est “24,47 mm”, Si la M es “24,47 mm”, T2 = 24,47 – 25 + 5/100 T2 = 124,47 – 24 + 5/100 = 0,52 mm = 0,52 mm Cales d’épaisseur dispo- Espesores de laminillas dis- nibles:...
  • Page 206 LOWR ASSEMBLY AND ADJUSTMENT 4) Install the dial gauge on the dial gauge stand and install it on the gear case. Install the backlash indicator rod on the drive shaft and bring the dial gauge stem into contact with the mark on the indicator rod. Forward gear 1) Place the shift-rod in neutral.
  • Page 207 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE 4) Monteur le comparateur sur son 4) Coloque el calibrador de cuadrante support et placer le tout sur le boî- sobre su soporte e instálelo en la tier d’hélice. Monter la tige d’indi- caja de engranajes.
  • Page 208 LOWR ASSEMBLY AND ADJUSTMENT If the backlash measurement is out of specification, adjust the shim thickness according to the above graphs. NOTE: 1. If both forward and reverse gear backlashes are larger than specification, the pinion gear shim thickness needs to be smaller than installed. 2.
  • Page 209 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE 1. Roue de marche avant 1. Engranaje de marcha de avance Si la mesure est comprise entre 0,20 Cuando la medición esté comprendi- et 0,50 mm, il n’est pas nécessaire da entre 0,20 y 0,50 mm, no será d’ajouter ou d’enlever des rondelles.
  • Page 210: Assembly

    LOWR ASSEMBLY AND ADJUSTMENT I62005-0* ASSEMBLY 1) Using special service tool, install a new needle- bearing in position of flash with lower unit hous- ing. NOTE: Install the bearing with manufacture’s numbers fac- ing upperside. 2) Align the drive-shaft sleeve locating-rib with the recess in the gear case, and place the drive- shaft sleeve into the gear case.
  • Page 211 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE I62005-0* I62005-0* ASSEMBLAGE MONTAJE 1) Monter un roulement à aiguilles 1) Instale un nuevo cojinete de agujas neuf de façon qu’il soit au ras du en posición, al mismo nivel que la boîtier d’hélice. caja de la unidad inferior.
  • Page 212 LOWR ASSEMBLY AND ADJUSTMENT 6) Place the forward-gear complete on to the outer race. 7) Referring to the illustration, assemble the drive shaft. Using special service tool. 8) Install the drive-shaft complete in position. 9) Invent the gear-case, and place the pinion posi- tion, the insert the drive-shaft and tighten the locknut to the specified torque.
  • Page 213 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE 6) Mettre l’ensemble du pignon de 6) Coloque el engranaje de marcha de marche avant en place sur la cage avance completo sobre el anillo extérieure exterior. 7) En se reportant à la figure, assem- 7) Consulte la ilustración para montar bler l’arbre d’entraînement.
  • Page 214 LOWR ASSEMBLY AND ADJUSTMENT 12) Using the special tool, fit the needle bearing and oil seal to the bearing housing. 13) Using the special service tool, assemble the reverse-gear. 14) Using the special service tool, referring to the illustration, assemble the bearing-housing. 15) Grease the lips of the oil-seals, and insert the propeller shaft complete into the lower casing cap.
  • Page 215 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE 12) En utilisant l’outil spécial, mettre 12) Utilice la herramienta especial para en place le roulement à aiguilles et instalar el cojinete de agujas y la le join à huile dans le corps de junta de aceite en la caja de cojine- palier.
  • Page 216: Water Pump Installation

    LOWR ASSEMBLY AND ADJUSTMENT I64009-0 WATER PUMP INSTALLATION 1) Install a new oil-seal in the oil-seal cover, and fit a new O-ring in the O-ring groove as shown. 2) Grease the O-ring and the lip of the oil-seal, and then install the oil-seal cover complete to the gear-case, and fit the dowelpins.
  • Page 217 ASSEMBLAGE ET REGLAGE LOWR MONTAJE Y AJUSTE I64009-0 I64009-0 INSTALLATION DE LA POMPE A INSTALACION DE LA BOMBA DE AGUA 1) Monter un nouveau joint à huile 1) Instalar una junta de aceite nueva en dans le couvercle du carter d’huile la cubierta de la junta de aceite y et placer un nouveau joint torique encaje una junta tórica nueva en la...
  • Page 218: Lower Unit Leakage Check

    LOWR ASSEMBLY AND ADJUSTMENT/INSTALLATION I65000-0* LOWER UNIT LEAKAGE CHECK 1) Tighten the gear-oil-drain screw, and connect the tester to the oil-level hole. 2) Pump the tester, and apply a specified pres- sure. Then place the gear case in the water tank. 3) Check that the pressure is held at specified pressure for 10 seconds.
  • Page 219 ASSEMBLAGE ET REGLAGE/INSTALLATION LOWR MONTAJE Y AJUSTE/INSTALACION I65000-0* I65000-0 CONTROLE D’ETANCHEITE DU COMPROBACION DE FUGAS EN BLOC INFERIEUR LA UNIDAD INFERIOR 1) Serrer le bouchon de vidange d’hui- 1) Apriete el tornillo de vaciado del le de transmission et brancher le aceite de engranajes y conecte el contrôleur d’étanchéité...
  • Page 220 LOWR INSTALLATION 6) Install the spacers, propeller, washer and pro- peller nut over the propeller shaft. Propeller nut: 30 Nm (3.0 m·kg, 22 ft·lb) 7) Align the recess in the propeller nut with the hole in the propeller shaft and insert the cotter pin into the hole.
  • Page 221 INSTALLATION LOWR INSTALACION 6) Mettre les entretoises, l’hélice, la 6) Instale los separadores, la hélice, la rondelle et l’écrou sur l’arbre de arandela y la tuerca de la hélice en l’hélice. el eje de la hélice. Ecrou d’hélice: Tuerca de la hélice: 30 Nm (3,0 m·kg) 30 Nm (3,0 m·kg) 7) Aligner l’entaille de l’écrou avec...
  • Page 222 BRKT CHAPTER 7 BRACKET UNIT EXPLODED DIAGRAM ....................7-1 REMOVAL........................7-2 DISASSEMBLY ......................7-3 INSPECTION ......................7-4 MOUNTING-BOLT ....................7-4 RUBBER MOUNTS ....................7-4 COLLAR........................7-4 TILT LOCK PLATES....................7-4 LEVERS........................7-4 ASSEMBLY ........................7-5 INSTALLATION ......................7-5...
  • Page 223 BRKT CHAPITRE 7 CAPITULO 7 SUPPORT UNIDAD SOPORTE VUE ECLATEE ......7-1 DIAGRAMA DETALLADO..7-1 DEPOSE ..........7-2 EXTRACCION .......7-2 DEMONTAGE ........7-3 DESMONTAJE.......7-3 VERIFICATION......7-4 INSPECCION .........7-4 VIS DE MONTAGE ....7-4 PERNOS DE SUJECION....7-4 SUPPORTS ELASTIQUES..7-4 SOPORTES DE GOMA....7-4 MANCHETTES ......7-4 COLLARES.........7-4 ETRIERS DE VERROUILLAGE PLACAS DE TOPE DE D’INCLINAISON......7-4 INCLINACION ......7-4...
  • Page 224 BRKT EXPLODED DIAGRAM EXPLODED DIAGRAM 1 Bracket 0 Tilt lock rod o Bottom cowling 2 Steering shaft q Tilt lever cover p Mount damper 3 Bush w Tilt lever a Exhaust manifold 4 Swivel bracket e Spring s Upper casing 5 Bush r Tension spring d Mount damper...
  • Page 225 VUE ECLATEE BRKT DIAGRAMA DETALLADO K15000-0 K15000-0 VUE ECLATEE DIAGRAMA DETALLADO 1 Etrier 2 Pivot de direction 1 Soporte 3 Bague 2 Eje del pivote de dirección 4 Etrier de fixation 3 Manguitos 5 Bague 4 Soporte giratorio 6 Presse 5 Manguitos 7 Bague 6 Soporte de la abrazadera...
  • Page 226 BRKT REMOVAL K20006-0 REMOVAL 1) Remove the bottom cowling. 2) Remove the rubber-housing. 3) Remove the swivel-bracket from the upper cas- ing. Lay the outboard motor on the floor to carry out this removal.
  • Page 227 DEPOSE BRKT EXTRACCION K20006-0 K20006-0 DEPOSE EXTRACCION 1) Déposer le capot inférieur. 1) Retire la cubierta inferior. 2) Déposer l’enveloppe en caout- 2) Retire la caja de caucho. chouc. 3) Retire el soporte giratorio de la caja 3) Démonter l’étrier de fixation du superior.
  • Page 228 BRKT DISASSEMBLY K25009-0 DISASSEMBLY 1) Remove the tension spring and remove the clamp bracket bolt. 2) Remove the clamp bracket and remove the tilt lever. 3) Remove the pin from tilt lock arm and tilt lock plate. 4) Referring to the illustration, disassemble the bracket.
  • Page 229 DEMONTAGE BRKT DESMONTAJE K25009-0 K25009-0 DEMONTAGE DESMONTAJE 1) Enlever le ressort de tension et la 1) Retire el resorte de tensión y el vis d’étrier de presse. perno del soporte de abrazadera. 2) Déposer la presse et le levier d’in- 2) Retire el soporte de abrazadera y la clinaison.
  • Page 230 BRKT INSPECTION K30001-0 INSPECTION MOUNTING-BOLT 1) Visually inspect the bolts, and replace all of them if any are bent or corroded. RUBBER MOUNTS 1) Visually inspect the rubber mounts, and replace them if they show signs of peeling, cracking or wear.
  • Page 231 VERIFICATION BRKT INSPECCION K30001-0 K30001-0 VERIFICATION INSPECCION VIS DE MONTAGE PERNOS DE SUJECION 1) Examiner les vis et remplacer 1) Inspeccione los pernos y cámbielos toutes celles qui sont courbées ou todos si cualquiera de ellos está rouillées. doblado o muestra señales de corro- sión.
  • Page 232 BRKT ASSEMBLY/ INSTALLATION K35009-0 ASSEMBLY 1) Referring to the illustration, assemble the bracket. 2) Assemble the tilt lock arm and the tilt lock plate. 3) Connect the rods to the tilt lock plate and the tilt lever. 4) Align the spring direction with the tilt lever then install the clamp bracket bolt.
  • Page 233 ASSEMBLAGE/INSTALLATION BRKT MONTAJE/INSTALACION K35009-0 K35009-0 ASSEMBLAGE MONTAJE 1) En se référant à la figure, remonter 1) Consulte la figura y monte el sopor- le support. 2) Remonter le bras et la plaque de 2) Monte el brazo de bloqueo de incli- verrouillage d’inclinaison.
  • Page 234 ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ..................8-1 WIRING DIAGRAM.....................8-2 REMOVAL........................8-3 MAGNETO BASE ....................8-3 CLEANING, INSPECTION AND REPAIR ..............8-5 SPARK-PLUG .......................8-5 PULSER COIL ......................8-5 CHARGE COIL .....................8-5 LIGHTING COIL (OPTION) ..................8-5 IGNITION COIL ....................8-6 REPLACEMENT OF SPARK-PLUG CAP.............8-6 CDI UNIT ......................8-7 RECTIFIER ......................8-8 ENGINE STOP LANYARD SWITCH ..............8-8 INSTALLATION ......................8-9...
  • Page 235 ELEC CHAPITRE 8 CAPITULO 8 EQUIPEMENT SISTEMA ELECTRIQUE ELECTRICO EQUIPEMENT ELECTRIQUE ...8-1 COMPONENTES ELECTRICOS ........8-1 SCHEMA DE RACCORDEMENT......8-2 DIAGRAMA DE CABLEADO ..8-2 DEPOSE ..........8-3 EXTRACCION .......8-3 MAGNETO........8-3 BASE DE LA MAGNETO ..8-3 NETTOYAGE, VERIFICATION ET LIMPIEZA, INSPECCION Y REPARATION ........8-5 REPARACION........8-5 BOUGIE ........8-5 BUJIA ..........8-5...
  • Page 236: Electrical Components

    ELEC ELECTRICAL COMPONENTS M20003-0 ELECTRICAL COMPONENTS 1 Flywheel magneto 2 Lighting coil 3 Charge coil 4 C.D.I. unit 5 Ignition coil 6 Spark plug 7 Rectifier 8 Engine stop lanyard switch...
  • Page 237 EQUIPEMENT ELECTRIQUE ELEC COMPONENTES ELECTRICOS M20003-0 M20003-0 EQUIPEMENT COMPONENTES ELECTRIQUE ELECTRICOS 1 Volant magnetique 1 Magneto del volante 2 Bobine d’eclairage 2 Bobina de illuminación 3 Bobinage de charge 3 Bobina de carga 4 Unité C.D.I. 4 Unidad C.D.I. 5 Bobine d‘allumage 5 Bobina de encendido 6 Bougie d’allumage 6 Bujía...
  • Page 238: Wiring Diagram

    ELEC WIRING DIAGRAM M30000-0 WIRING DIAGRAM 1 C.D.I. unit : Black 2 Charge coil : Brown 3 Pulser coil : Green 4 Lighting coil : Orange 5 Engine stop lanyard switch : Red 6 2P consent : White 7 Rectifier G/W : Green/White 8 Ignition coil W/R : White/Red...
  • Page 239 SCHEMA DE RACCORDEMENT ELEC DIAGRAMA DE CABLEADO M30000-0 M30000-0* SCHEMA DE DIAGRAMA DE RACCORDEMENT CABLEADO 1 Allumage transistorisé 1 Unidad CDI (encendido por descarga del 2 Bobine de charge condensador) 3 Bobine d’impulsions 2 Bobina de carga 4 Bobine d’éclairage 3 Bobina de impulsos 5 Cordon/coupe-contact de securite 4 Bobina de alumbrado...
  • Page 240: Removal

    ELEC REMOVAL M40007-0 REMOVAL MAGNETO BASE 1) Disconnect the starting gear protection device. 2) Remove the manual starter. 3) Loosen the flywheel nut. 1. Place the flywheel nut Wrench flush on the crankshaft. 2. The major load must be carried in the direc- tion of the arrows, for if not the holder may easily slip off.
  • Page 241 DEPOSE ELEC EXTRACCION M40007-0 M40007-0 DEPOSE EXTRACCION MAGNETO BASE DE LA MAGNETO 1) Débrancher le dispositif de protec- 1) Desconecte el dispositivo de protec- tion du lanceur. ción del engranaje de arranque. 2) Enlever le lanceur manuel. 2) Retire el mecanismo de arranque 3) Desserrer l’écrou du volant.
  • Page 242 ELEC REMOVAL 5) Remove the woodruff key from the crankshaft keyway using of a screwdriver. NOTE: Take special care not to damage the surface of the crankshaft. When removing the flywheel magneto, lift it up while tilting it slightly. Do not allow the mag- neto to contact the timing plate.
  • Page 243 DEPOSE ELEC EXTRACCION 5) Déposer la clavette Woodruff du 5) Retire la chaveta Woodruff de la logement de clavette de vilebrequin ranura para chaveta del cigüeñal à l’aide d’un tournevis. con un destornillador. N.B.: NOTA: Faire attention à ne pas endommager la Procure no dañar la superficie del cigüe- surface du vilebrequin.
  • Page 244: Cleaning, Inspection And Repair

    ELEC CLEANING, INSPECTION AND REPAIR M51000-0* CLEANING, INSPECTION AND REPAIR SPARK-PLUG 9 Refer to page 3-14. M51502-0* PULSER COIL Check the resistance of the pulser coil. Pulser coil resistance: Black – White/Red: 95.0 – 116.0 Ω at 20 deg.C (68 deg.F) M51800-0* CHARGE COIL Check the resistance of the charge coil.
  • Page 245 NETTOYAGE, VERIFICATION ET REPARATION ELEC LIMPIEZA, INSPECCION Y REPARACION M51000-0* M51000-0* NETTOYAGE, VERIFICA- LIMPIEZA, INSPECCION TION ET REPARATION Y REPARACION BOUGIE BUJIA 9 Se rélérer à la page 3-14. 9 Consulte la página 3-14. M51502-0* M51502-0* BOBINES D’IMPULSIONS BOBINAS PULSADORAS Contrôler la résistance des bobines Compruebe la resistencia de las bobinas d’impulsions.
  • Page 246: Ignition Coil

    ELEC CLEANING, INSPECTION AND REPAIR M52502-0* IGNITION COIL 1) Inspect the high-tension cables and spark-plug caps for damage and cracks. 2) Measure the resistance of the primary coil. Ignition coil resistance: Primary coil: 0.26 – 0.35 Ω at 20 deg.C (68 deg.F) 3) Measure the resistance of the secondary coil.
  • Page 247 NETTOYAGE, VERIFICATION ET REPARATION ELEC LIMPIEZA, INSPECCION Y REPARACION M52502-0* M52502-0* BOBINE DE ALLUMAGE BOBINA DE ENCENDIDO 1) Vérifier que le câble haute tension 1) Inspeccione los cables de alta ten- et le capuchon de la bougie ne sont sión y los casquillos de las bujías pas endommagés ou fissures.
  • Page 248: Cdi Unit

    ELEC CLEANING, INSPECTION AND REPAIR M53509-0* CDI UNIT 1) Measure the resistances of the CDI unit using Yamaha pocket tester. : White W/R : White/Red : Brown : Black : Orange Unit: kΩ Charge Pulser Ground Ignition Stop Ground Ground ∞...
  • Page 249 NETTOYAGE, VERIFICATION ET REPARATION ELEC LIMPIEZA, INSPECCION Y REPARACION M53509-0 M53509-0 BLOC CDI UNIDAD CDI 1) Mesure des résistances de l’alluma- 1) Mida las resistencias de la unidad ge électronique CDI. CDI. : Blanc : Blanco W/R : Blanc/Rouge W/R : Blanco/rojo : Brun : Marrón : Noir...
  • Page 250: Rectifier

    ELEC CLEANING, INSPECTION AND REPAIR M56500-0 RECTIFIER 1) Check the continuity of the rectifier. Tester Black Green Green/White Tester Black Continuity Continuity Continuity ∞ ∞ Green Continuity ∞ ∞ Green/White Continuity ∞ ∞ ∞ ∞ : No Continuity If continuity is not as specified, replace the rectifier. M59000-0 ENGINE STOP LANYARD SWITCH 1) Remove the lock-plate and check for continuity...
  • Page 251 NETTOYAGE, VERIFICATION ET REPARATION ELEC LIMPIEZA, INSPECCION Y REPARACION M56500-0 M56500-0 REDRESSEUR RECTIFICADOR 1) Contrôler le redresseur dans les 1) Compruebe la cintinuidad del recti- sens de passage et de blocage. ficador. Contrôleur Vert/ Verificador Verde/ Noir Vert Noir Negro Verde Rojo Contrôleur...
  • Page 252 ELEC INSTALLATION M61000-0* INSTALLATION FLYWHEEL MAGNETO 1) Install the magneto base on to the rectifier- plate. 2) Install the flywheel rotor on the crankshaft so that the woodruff key fits in the keyways in the crankshaft and flywheel rotor. 3) Lock the flywheel rotor with the washer and nut to the specified torque.
  • Page 253 INSTALLATION ELEC INSTALACION M61000-0* M61000-0* INSTALLATION INSTALACION VOLANT MAGNETIQUE MAGNETO DEL VOLANTE 1) Placer le stator de magnéto sur la 1) Instale la base del magneto en la plaque de rentenue. placa de retención. 2) Installer le volant sur le vilebrequin 2) Instale el rotor del volante en el de façon que la clavette à...
  • Page 254 TRBL SHTG CHAPTER 9 TROUBLE-SHOOTING TROUBLE-SHOOTING DIAGRAM ................9-1 HOW TO TROUBLE-SHOOT................9-1 ENGINE IS HARD TO START OR WILL NOT START..........9-2 ROUGH IDLING ......................9-6 ENGINE STALLS .......................9-7 ENGINE WILL NOT STOP ..................9-8 GEAR SHIFTING IS IMPOSSIBLE OR HARD ............9-9...
  • Page 255 TRBL SHTG CHAPITRE 9 CAPITULO 9 DEPANNAGE LOCALIZATION Y REPARACION DE TABLEAU DE DEPANNAGE ..9-1 AVERIAS QUE FAIRE ENCAS DE PANNE?........9-1 DIAGRAMA DE LOCALIZACION LE MOTEUR A DU MAL A Y REPARACION DE AVERIAS...9-1 DEMARRER OU REFUSE DE COMO LOCALIZAR Y DEMARRER........9-2 REPARAR AVERIAS....9-1 LE RALENTI EST...
  • Page 256: Trouble-Shooting Diagram

    TRBL SHTG TROUBLE-SHOOTING DIAGRAM O20000-0 TROUBLE-SHOOTING DIAGRAM Trouble? Symptoms of Basic checking Repair of adjust trouble Check the equipment visually or by operating according to pre- delivery check or periodic check procedures. Symptom of trouble is Locating the possible Simulation test evident cause of trouble Discover the conditions under...
  • Page 257: Engine Is Hard To Start Or Will Not Start

    TRBL SHTG ENGINE IS HARD TO START OR WILL NOT START O30001-0* ENGINE IS HARD TO START OR WILL NOT START Is there enough fuel in the tank? Add fuel. Can the starter rope be pulled? GO TO (P.9-3) Check the recoil starter pawl drive Can the crankshaft be turned? (P.5-27) Can the compression be felt when pulling the...
  • Page 258 TRBL SHTG ENGINE IS HARD TO START OR WILL NOT START Is the compression of crankcase normally? Check the following parts and replace as Check the leakage of compression from the necessary: crankcase. 1) Oil seal 2) Crank case - cracked, distortion, scratches on mating surfaces.
  • Page 259 TRBL SHTG ENGINE IS HARD TO START OR WILL NOT START Is the piston or cylinder cracked, scratched or Replace. deformed? Is the piston ring damaged or worn? Replace. Are the oil-seal in good condition? Replace. RE-CHECK Does the engine stop lanyard switch remain Replace.
  • Page 260 TRBL SHTG ENGINE IS HARD TO START OR WILL NOT START Are the CDI-unit terminals connected correctly? Connect correctly. Are the ignition-coil, charge-coil and pulser coil Replace. all in good condition? Is the CDI-unit in good condition? Replace. RE-CHECK Is there sufficient fuel in the tank? Add fuel.
  • Page 261: Rough Idling

    TRBL SHTG ROUGH IDLING O50000-0* ROUGH IDLING Is the fuel fresh? Replace the fuel. Are all wiring connections tight? Tighten. Are the spark-plugs tightly screwed in? Tighten. (P.3-14) Does sparking take place in all cylinders? GO TO (P.9-4) Is the lighting coil used to supply a heavy load? Disconnect the load.
  • Page 262: Engine Stalls

    TRBL SHTG ENGINE STALLS O60001-0* ENGINE STALLS (A) The engine stalls in any gear. Is the fuel-hose connected correctly? Correct. (P.3-3) Is the engine warmed-up? Warm it up. Does the choke function normally? Repair. Is the choke placed in the set position? Place in set position.
  • Page 263: Engine Will Not Stop

    TRBL SHTG ENGINE STALLS/ENGINE WILL NOT STOP (B) Engine stalls when gear is changed. In addition to the above check points, go through the following: Is something coiled around the propeller? Remove it. Disassemble the lower unit and check. Is the propeller stiff to turn in neutral? (P.6-2 –...
  • Page 264: Gear Shifting Is Impossible Or Hard

    TRBL SHTG GEAR SHIFTING IS IMPOSSIBLE OR HARD O90002-0* GEAR SHIFTING IS IMPOSSIBLE OR HARD STOP THE ENGINE Do not start the engine during following inspections. Disconnect the Battery terminals. Move shift handle to “Neutral”, “Forward” and “Reverse”. Turn propeller and check that gears are in “Neutral”, “Forward” and “Reverse”. (1) MANUAL HANDLE MODEL Is the shift rod correctly by the joint nut? Connect correctly.
  • Page 265 TRBL SHTG TABLEAU DE DEPANNAGE O20000-0 TABLEAU DE DEPANNAGE En panne? Premières vérifications Symptômes Réparer ou régler Contrôler visuellement le matériel ou faire un essai de fonctionnement en se référant à la liste de contrôle d’avant livraison ou au tableau des vérifications périodiques Test de simulation Panne évidente...
  • Page 266 TRBL LE MOTEUR A DU MAL A DEMARRER OU REFUSE SHTG DE DEMARRER O30001-0* LE MOTEUR A DU MAL A DEMARRER OU REFUSE DE DEMARRER Y a-t-il assez de carburant dans le réservoir? Faire le plein. Le câble de démarrage peut-il être tiré? VOIR (P.9-3) Peut-on tourner le vilebrequin?
  • Page 267 TRBL LE MOTEUR A DU MAL A DEMARRER OU REFUSE SHTG DE DEMARRER Contrôler les pièces suivantes et les remplacer si La compression du vilebrequin est-elle normale? nécessaire: Y a-t-il fuite de compression? 1) Joint à huile 2) Carter moteur – plans de joints fissurés, tordus ou rayés.
  • Page 268 TRBL LE MOTEUR A DU MAL A DEMARRER OU REFUSE SHTG DE DEMARRER Le piston ou le cylindre sont-ils fissurés, rayés ou déformés? Remplacer. Le segment de piston est-il abîmé ou usé? Remplacer. Les joints d’huile sont-ils en parfait état? Remplacer.
  • Page 269 TRBL LE MOTEUR A DU MAL A DEMARRER OU REFUSE SHTG DE DEMARRER Les sorties du bloc CDI sont-elles correctement branchées? Corriger. La bobine d’allumage, les bobines de charge et la bobine Remplacer. d’impulsions sont-elles en parfait état? Le bloc CDI est-il en parfait état? Remplacer.
  • Page 270 TRBL SHTG LE RALENTI EST DEFECTUEX O50000-0* LE RALENTI EST DEFECTUEX Le carburant est-il propre? Vidanger le carburant. Les connexions sont-elles bien serrées? Serrer. Les bougies sont-elles bien serrées? Serrer. (P. 3-14) Y a-t-il production d’étincelles dans tous les cylindres? VOIR (P.9-4) La bobine d’éclairage alimente-t-elle une charge qui...
  • Page 271 TRBL SHTG LE MOTEUR CALE O60001-0* LE MOTEUR CALE (A) Le moteur cale en marche AV comme en marche AR. La canalisation d’essence est-elle correctement raccordée? Corriger. (P. 3-3) Le moteur est-il chaud? Laisser chauffer le moteur. Le starter fonctionne-t-il normalement? Réparer.
  • Page 272 TRBL SHTG LE MOTEUR CALE/LE MOTEUR NE S’ARRETE PAS (B) Le moteur cale au passage marche AV/marche AR. Passer les points précédents en revue ainsi que les suivants: Un corps étranger est-il enroulé sur l’hélice? L’ôter Démonter le bloc inférieur et contrôler. Au point mort, l’hélice tourne-t-elle difficilement? (P.
  • Page 273 TRBL LE PASSAGE MARCHE AV/ SHTG MARCHE AR EST IMPOSSIBLE OU DIFFICILE O90002-0* LE PASSAGE MARCHE AV/MARCHE AR EST IMPOSSIBLE OU DIFFICILE COUPER LE MOTEUR. Ne pas démarrer le moteur durant les vérifications suivantes. Débrancher les cosses de la batterie. Actionner la tringle de l’inverseur au “Point mort”...
  • Page 274 TRBL DIAGRAMA DE LOCALIZACION Y REPARACION DE SHTG AVERIAS O20000-0 DIAGRAMA DE LOCALIZACION Y REPARACION DE AVERIAS Anomalía? Comprobación básica. Sintomas de la ano- Reparar o ajustar malía Compruebe el equipo visualmente o en funcionamiento, de acuerdo con la com- probación previa a la entrega o los pro- cedimientos de comprobación periódi- Prueba de simulación...
  • Page 275 TRBL RESULTA DIFICIL ARRANCAR EL MOTOR, O NO SHTG ARRANCA O30001-0* RESULTA DIFICIL ARRANCAR EL MOTOR, O NO ARRANCA ¿Hay suficiente combustible en el depósito? Añada combustible. ¿Puede tirar del cable del motor de arranque? VAYA AL PASO (P. 9-3) Compruebe el trinquete del motor de arranque de ¿Puede hacer girar el cigüeñal? retroceso.
  • Page 276 TRBL RESULTA DIFICIL ARRANCAR EL MOTOR, O NO SHTG ARRANCA Compruebe las siguientes piezas y cámbielas si es ¿Es normal la compresión del cárter? ¿Ha comprobado si necesario: existen fugas de compresión en el cárter? 1) Retén de aceite 2) Cárter – agrietado, deformado, rayas en las superficies de acoplamiento.
  • Page 277 TRBL RESULTA DIFICIL ARRANCAR EL MOTOR, O NO SHTG ARRANCA ¿Está agrietado, rayado o deformado el pistón o el cilindro? Cámbielo. ¿Está dañado o desgastado el segmento? Cámbielo. ¿Están en buen estado los retenes de aceite? Cámbielos. VUELVA A COMPROBARLO ¿Permanece cerrado el interruptor del acollador de parada Cámbielo.
  • Page 278 TRBL RESULTA DIFICIL ARRANCAR EL MOTOR, O NO SHTG ARRANCA ¿Están conectados correctamente los terminales de la uni- Conéctelos correctamente. dad CDI? ¿Están en buen estado la bobina de encendido, la bobina de Cámbielas. carga y la bobina pulsadora? ¿Está en buen estado la unidad CDI? Cámbiela.
  • Page 279 TRBL SHTG VELOCIDAD DE RALENTI DESIGUAL O50000-0* VELOCIDAD DE RALENTI DESIGUAL ¿Está utilizando combustible nuevo? Cambie el combustible. ¿Están apretadas todas las conexiones del cableado? Apriételas. ¿Están apretadas correctamente las bujías? Apriételas. (P. 3-14) ¿Se produce una chispa en todos los cilindros? VAYA AL PASO (P.
  • Page 280 TRBL SHTG EL MOTOR SE PARA O60001-0* EL MOTOR SE PARA (A) El motor se para en cualquier marcha. ¿Está conectado correctamente el tubo de llegada del com- Conéctelo correctamente. (P. 3-3) bustible? ¿Está caliente el motor? Déjelo calentar. ¿Funciona normalmente el estrangulador? Repárelo.
  • Page 281 TRBL SHTG EL MOTOR SE PARA/EL MOTOR NO SE PARA (B) El motor se para al cambiar de marcha Además de los pasos anteriores, compruebe los siguientes: ¿Hay algo enrollado en ha hélice? Desenróllelo. Resulta dificil girar la hélice mientras el motor está en punto Desmonte la unidad inferior y compruébela.
  • Page 282 TRBL SHTG CAMBIO DE MARCHAS IMPOSIBLE O DIFICIL O90002-0* CAMBIO DE MARCHAS IMPOSIBLE O DIFICIL PARA EL MOTOR. No arranque el motor mientras realiza las siguientes inspecciones. Retire los terminales de la batería. Coloque la palanca de cambio en “Punto Muerto”, “Avance” y “Marcha Atrás”. Gire la hélice y compruebe que los engranajes están en las posiciones de “Punto Muerto”, “Avance”...
  • Page 284 YAMAHA MOTOR CO., LTD. Printed in Japan July. 2003 – 1.1 × 1 ! (E, F, S) Printed on recycled paper...