Yamaha 6K1 Manuals

Manuals and User Guides for Yamaha 6K1. We have 1 Yamaha 6K1 manual available for free PDF download: Service Manual

Yamaha 6K1 Service Manual

Yamaha 6K1 Service Manual (387 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 8 MB

Table of Contents

Illustrations
3
Model Indication
3
Important Information
4
How to Use this Manual
5
Symbols
6
Contents
7
Chapter 1. General Information

8
- Identification
  9
- Serial Number
  9
- Starting Serial Numbers
  9
- Safety While Working
  10
- Fire Prevention
  10
- Ventilation
  10
- Self-Protection
  10
- Good Working Practices
  11
- Disassembly and Assembly
  12
- Special Tools
  13
- Measuring
  13
- Diagnosis
  15
- Diagnosis Record
  15
- Static Test
  15
- Dynamic Test
  15
- Removing and Installing
  16
Chapter 2. Specifications

19
- General Specifications
  20
- Maintenance Specifications
  22
- Power Unit
  22
- Dimensions
  28
- Tightening Torques
  30
- Specified Torques
  30
- General Torques
  32
Chapter 3. Periodic Inspections and Adjustments

33
- Maintenance Interval Chart
  35
- Top Cowling
  37
- Checking the Top Cowling Fit
  37
- Fuel System
  37
- Checking the Fuel Line
  37
- Checking the Fuel Filter
  38
- Measuring the Fuel Pressure
  39
- Checking the Fuel Pressure
  39
- Measuring Steps
  39
- Checking the Mechanical Fuel Pump Oil Level
  40
- Changing the Mechanical Fuel Pump Oil
  40
- Control System
  41
- Synchronizing the Throttle Valves
  41
- Adjusting the Throttle Position Sensor
  42
- Adjusting the Engine Idling Speed
  43
- Adjusting the Remote Control Shift Cable
  44
- Adjusting the Remote Control Throttle Cable
  44
- Checking the Drive Belt
  45
- Adjusting the Crank Position Sensor
  46
- Checking the Cooling Water Discharge
  46
- Oil Injection System
  46
- Checking the Oil Strainer
  46
- Synchronizing the Oil Pump
  47
- Air Bleeding the Oil Injection System
  48
- Checking the Electric Oil Pump
  48
- Power Trim and Tilt System
  49
- Checking the Power Trim and Tilt Fluid Level
  49
- Adjusting the Trim Sensor Cam
  50
- Lower Unit
  50
- Checking the Gear Oil Level
  50
- Changing and Checking the Gear Oil
  51
- Recommended Gear Oil
  51
- Total Amount
  51
- Checking the Lower Unit
  52
- Checking the Anodes
  52
- Checking the Battery
  53
- Checking the Spark Plugs
  54
- Lubrication Points
  56
Chapter 4. Fuel System

57
Chapter 5. Power Unit

115
- Flywheel Magnet Assembly
  117
- Removing/Installing the Flywheel Magnet Assembly
  117
- Removing the Flywheel Magnet Assembly
  118
- Flywheel Magnet Assembly Holder
  118
- Universal Puller
  118
- Installing the Flywheel Magnet Assembly
  119
- Disconnecting/Connecting the Leads
  120
- Disconnecting/Connecting the Hoses
  122
- Removing/Installing the Exhaust Expansion Chamber
  123
- Installing the Apron
  125
- Removing/Installing the Power Unit
  126
- Suspending the Power Unit
  127
- Installing the Power Unit
  127
- Stator Assembly
  128
- Removing/Installing the Stator Assembly
  128
- Control Unit
  130
- Removing/Installing the Control Unit Assembly
  130
- Fuse Holder
  132
- Removing/Installing the Fuse Holder
  132
- Disassembling/Assembling the Fuse Holder
  133
- Junction Box Assembly
  134
- Removing/Installing the Junction Box Assembly
  134
- Disassembling/Assembling the Junction Box Assembly
  137
- Wire Harnesses
  139
- Removing/Installing the Main Wire Harness
  139
- Removing/Installing the Sub Wire Harness
  141
- Removing/Installing the Injector Wire Harness
  142
- Starter Motor
  144
- Removing/Installing the Starter Motor
  144
- Oxygen Density Sensor
  147
- Installing the Oxygen Density Sensor
  147
- Reed Valves
  148
- Removing/Installing the Reed Valves
  148
- Checking the Reed Valve Assembly
  150
- External Fittings
  151
- Removing/Installing the External Fittings
  151
- Cylinder Head Covers
  154
- Removing/Installing the Cylinder Head Covers
  154
- Checking the Thermostats
  156
- Removing/Installing the Cylinder Heads
  157
- Checking the Cylinder Heads
  159
- Exhaust Covers
  160
- Removing/Installing the Exhaust Covers
  160
- Checking the Pressure Control Valve
  162
- Crankcase
  163
- Removing/Installing the Crankcase
  163
- Assembling the Oil Seal Housing
  165
- Installing the Crankcase
  165
- Cylinder Body Assembly
  166
- Disassembling/Assembling the Cylinder Body Assembly
  166
- Disassembling/Assembling the Piston and Connecting Rod Assemblies
  169
- Disassembling/Assembling the Crankshaft Assembly
  170
- Disassembling the Upper Bearing Housing
  171
- Removing the Bearing and Oil Pump Drive Gear
  171
- Checking the Cylinder Body
  172
- Checking the Pistons
  173
- Calculating the Piston-To-Cylinder Clearance
  173
- Checking the Piston Pins and Small-End Bearings
  174
- Checking the Piston Rings
  174
- Checking the Oil Pump Driven Gear
  175
- Checking the Labyrinth Rings
  176
- Checking the Crankshaft
  176
- Installing the Oil Pump Drive Gear
  177
- Installing the Bearing
  177
- Installing the Piston Rings and Piston
  177
- Assembling the Upper Bearing Housing
  178
- Installing the Crankshaft Assembly
  179
- Installing the Piston and Connecting Rod Assemblies
  179
Chapter 6. Lower Unit

180
- Removing/Installing the Lower Unit
  184
- Removing the Propeller
  186
- Removing the Trim Tab
  186
- Checking the Propeller
  186
- Installing the Propeller
  187
- Water Pump
  188
- Removing/Installing the Water Pump
  188
- Checking the Impeller Housing
  190
- Checking the Impeller and Impeller Housing Cup
  190
- Checking the Woodruff Key
  190
- Installing the Impeller and Impeller Housing
  190
- Shift Rod Assembly
  192
- Removing/Installing the Shift Rod Assembly
  192
- Removing the Shift Rod Assembly
  193
- Removing/Installing the Propeller Shaft Housing Assembly
  194
- Disassembling/Assembling the Propeller Shaft Housing
  196
- Disassembling/Assembling the Propeller Shaft Assembly
  197
- Removing the Propeller Shaft Housing Assembly
  198
- Disassembling the Propeller Shaft Housing
  198
- Propeller Shaft Housing Assembly
  199
- Checking the Reverse Gear
  199
- Checking the Bearings
  199
- Checking the Propeller Shaft Housing
  199
- Checking the Dog Clutch
  200
- Checking the Propeller Shaft
  200
- Assembling the Propeller Shaft Housing
  200
- Installing the Propeller Shaft Housing Assembly
  201
- Drive Shaft
  202
- Removing/Installing the Drive Shaft
  202
- Removing the Pinion
  204
- Disassembling the Drive Shaft Housing Assembly
  204
- Disassembling the Forward Gear Assembly
  204
- Checking the Pinion
  205
- Checking the Drive Shaft
  205
- Assembling the Forward Gear Assembly
  205
- Assembling the Drive Shaft Housing Assembly
  206
- Installing the Pinion
  207
- Lower Case Assembly
  208
- Disassembling/Assembling the Lower Case Assembly
  208
- Disassembling the Lower Case Assembly
  209
- Checking the Drive Shaft Sleeve
  209
- Checking the Needle Bearing
  209
- Assembling the Lower Case Assembly
  209
- Disassembling/Assembling the Propeller Shaft Housing Assembly
  222
- Selecting the Pinion Shims
  239
- Selecting the Forward Gear Shims
  241
- Selecting the Reverse Gear Shims
  243
- Measuring the Reverse Gear Backlash
  253
- Shimming
  255
- Selecting the Pinion Shims
  256
- Selecting the Reverse Gear Shims
  258
- Selecting the Forward Gear Shims
  259
- Selecting the Propeller Shaft Shims
  261
- Selecting the Reverse Gear
  265
Chapter 7. Bracket Unit

273
- Bottom Cowling
  275
- Removing/Installing the Bottom Cowling
  275
- Disassembling/Assembling the Bottom Cowling
  277
- Disassembling/Assembling the Shift Rod Assembly
  280
- Upper Case Assembly
  281
- Removing/Installing the Upper Case Assembly
  281
- Disassembling/Assembling the Upper Case Assembly
  283
- Exhaust Manifold Assembly
  285
- Clamp Brackets
  287
- Removing/Installing the Clamp Brackets
  287
- Steering Arm
  289
- Removing/Installing the Steering Arm
  289
- Swivel Bracket Assembly
  290
- Disassembling/Assembling the Swivel Bracket Assembly
  290
- Power Trim and Tilt Unit
  292
- Removing/Installing the Power Trim and Tilt Unit
  292
- Removing the Power Trim and Tilt Unit
  294
- Bleeding the Power Trim and Tilt Unit
  294
- Reservoir and Power Trim and Tilt Motor
  296
- Checking the Reservoir
  297
- Checking the Gear Pump Housing Filter
  297
- Installing the Power Trim and Tilt Motor
  298
- Filling the Reservoir
  299
- Measuring the Hydraulic Pressure
  301
- Tilt Ram Assembly and Gear Pump Unit
  304
- Removing the Tilt Ram End Screw
  306
- Removing the Gear Pump Unit
  306
- Disassembling the Gear Pump Unit
  306
- Checking the Tilt Ram
  307
- Checking the Gear Pump Unit
  307
- Assembling the Gear Pump Unit
  308
- Installing the Gear Pump Unit
  309
- Installing the Tilt Ram
  309
- Trim Ram Assemblies and Free Piston
  311
- Removing the Trim Ram End Screws
  312
- Removing the Free Piston
  312
- Checking the Trim Rams
  313
- Checking the Free Piston
  313
- Checking the Trim Ram Cylinders
  313
- Installing the Free Piston
  313
- Installing the Trim Rams
  314
Chapter 8. Electrical Systems

316
- Electrical Components
  319
- Port View
  319
- Starboard View
  320
- Aft View
  322
- Top View
  323
- Wire Harness
  324
- Electrical Component Analysis
  327
- Digital Circuit Tester
  327
- Measuring the Peak Voltage
  327
- Peak Voltage Adaptor
  327
- Measuring a Low Resistance
  328
- Ignition System
  329
- Checking the Ignition Spark Gap
  330
- Checking the Fuses
  331
- Checking the Fuse Holder
  331
- Measuring the Control Unit Output Peak Voltage
  332
- Measuring the Pulser Coil Output Peak Voltage
  333
- Checking the Spark Plug Caps
  334
- Ignition Control System
  335
- Measuring the Crank Position Sensor Output Peak Voltage
  336
- Measuring the Engine Cooling Water Temperature Sensor Resistance
  337
- Checking the Thermo Switch Continuity
  337
- Checking the Oil Level Sensor Continuity
  338
- Measuring the Throttle Position Sensor Output Voltage
  338
- Checking the Shift Position Switch
  339
- Fuel Control System
  340
- Checking the Oxygen Density Sensor
  343
- Checking the Atmospheric Pressure Sensor
  344
- Checking the Intake Air Temperature Sensor
  345
- Checking the Fuel Injectors
  346
- Checking the Fuel Pressure Sensor
  347
- Checking the Water Detection Switch
  348
- Starting System
  349
- Checking the Wire Harness Continuity
  350
- Checking the Wire Connections
  350
- Checking the Starter Relay
  350
- Disassembling/Assembling the Starter Motor
  351
- Removing the Starter Motor Pinion
  355
- Checking the Starter Motor Pinion
  355
- Checking the Armature
  355
- Measuring the Brushes
  356
- Checking the Magnetic Switch Relay
  357
- Charging System
  359
- Measuring the Rectifier/Regulator Output Peak Voltage
  360
- Measuring the Lighting Coil Output Peak Voltage
  361
- Oil Feed Pump Control System
  362
- Checking the Oil Level Sensor/Switch Continuity
  363
- Checking the Emergency Switch
  364
- Checking the Oil Pump
  364
- Power Trim and Tilt System
  365
- Checking the Power Trim and Tilt Relay
  366
- Checking the Trailer Switch Continuity
  367
- Measuring the Trim Sensor Resistance
  367
- Disassembling/Assembling the Power Trim and Tilt Motor
  368
- Removing the Stator
  370
- Removing the Brush
  370
- Checking the Armature
  371
- Installing the Brush
  372
- Installing the Armature
  372
- Installing the Stator
  372
Chapter 9. Trouble Analysis

373
- Trouble Analysis Chart
  374
- Self-Diagnosis
  378
- Diagnosis Code Indication
  378
- Diagnosis the Electronic Control System
  378
- Diagnosis Code Chart
  379
- Troubleshooting for High-Pressure Direct Injection
  380
- Wiring Diagram
  383
- Color Code
  385

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