Home

T9.9W/F9.9W Service Manual

1. 5 14 CYLINDER PISTON CE CONNECTING ROD OIL CLEARANCE 1 Measure e Oil clearance Out of specification Replace con necting rod and cap as a set Connecting rod oil clearance 0 021 0 045 mm 0 0008 0 0018 in e Assemble the connecting rod and the cap referring the marking eDo not assemble connecting rod and the cap with 41 and 2 together e Clean the bearing portions of the con necting rod e Install the connecting rod to the crank shaft e Put a piece of plastigauge onto the crank pin e Install the connecting rod cap NOTE e Make sure that the 66803 marks on the connecting rods face toward the fly wheel side of the crankshaft e Do not turn the connecting rod or crank shaft until clearance measurement has been completed e Tighten the bolts in sequence in two steps of torque Bolt M8 1st 6 Nm 0 6 kg 4 3 ft Ib 2nd 12 Nm 1 2 m kg 8 7 ft Ib e Remove the bolts and the connecting rod cap e Measure the compressed plastigauge width on each crank pin KITO N 7277222 0 5 16 CYLINDER PISTON AND ASSEMBLY AND INSTALLATION PISTON AND CONNECTING ROD 1 Install e Expander ring e Side ring 2 Install e Piston ring 2nd D e Piston ring top NOTE e Align the piston ring gap with the pin of the piston e Cil the
2. SHUM 2918 enig YAMAHA MOTOR CO LTD Printed in USA Jan 1998 x 1 5 CR 18616 01 83 T9 9W 9
3. STEERING HANDLE Cable removal Extent of removal Extent of removal Part name CE Steering handle disassembly Remarks A 1 Screw Fitting plate Bolt Bracket Ring nut Refer to REMOVAL POINTS Bolt Steering handle Screw Handle grip Screw D 319 MANOA AWN Steering handle left Bolt Shift arm Cotter pin Shift cable 2 2 Throttle cable Shift lever Nut Stop switch 7 17 sch sch sch sch sch 3 sch MI NM sch pl sch HY STEERING HANDLE PREPARATION FOR REMOVAL 9 9 9 9 except for Europe and Canada Disconnect the control cables at engine side K SA NS Extent of removal Cable removal and Steering handle disassembly Extent of removal Part name Remarks Screw Fitting plate Bolt Bracket Ring nut Bushing Steering handle 1 Screw Handle grip Screw Steering handle 2 Throttle cable Refer to REMOVAL POINTS 333 N a 7 18 STEERING HANDLE REMOVAL POINTS RING NUT 1 Remove e Ring nut 0 e Washer 2 e Washer wave 3 e Washer nylon NOTE e Turn the steering handle backward eFit a standard head screwdriver into the slit in the ring nut eSet the screwdriver using the steering bracket as a fulcrum e Turn steering handle forward and
4. eege tege iv ea sa n Nana GE AE Aa Ee CE 5 2 SPOR WIRE LERNEN 5 2 INSTALLATION E 5 3 POWER UNIT a Aa eso roro ege 5 3 RECOIL STARTER GG aaa 5 4 BATTERY LEAD sarsa eag aan D ave RE CERE eene Se eege Edge Ee 5 FLYWHEEL COVE R Ga 5 5 CYLINDER PISTON AND 5 6 PREPARATION FOR 11444 4 444 14444 2 nena nenne 5 6 NOTE REMOVAL AND 5 7 REMOVAL POINTS eren AS aaa ts nissan re arte ie 5 7 FLYWHEEL MAGNETO 6 EEN 5 7 TIMING CIE WE 5 8 DRIVE GEAR na se e Ee get NEE 5 8 INSPECTION AND 5 8 FLYWHEEL MAGNETO 55200 eeu eo eoe otro Ne Ka DEE GA nnne noraen 5 8 nui 5 8 TIMING 5 9 uisigdueripgee EE 5 9 CYLINDER 5 9 PISTON BE 5 10 PISTON CLEARANCE 5 11 PISTON PIN angan awa aa AN an NGANA TEN a aa 5 11 PISTON RING ER ERR 5 12 CRANKSHAFT tie a BEN a EE BAEN AAN AR a ER swans 5 12 CRANKSHAFT MAIN BEARING CLEARANCE 5 13 COMBI
5. 05 qt cm US Imp oz 86 10W 30 10W 40 SE SF SE SF SE SF CC 1 0 1 06 0 88 Hypoid gear oil 90 6 185 6 25 6 51 Tilt angle at 12 boat transom Tilt up angle at 12 boat transom Shallow water angle Steering angle left right Gear shift position Gear ratio Reduction system Propeller direction rear view Propeller drive system 1 2 3 4 6 7 Except for Europe and Canada For Europe and Canada Over head camshaft YAMALUBE 4 is recommended Forward Neutral Reverse Degree Degree 8 12 16 20 70 Degree Degree Pump Octane Number Research octane Motor octane 2 GEAR CASE LUBE is recommended in USA Tilt angle 20 37 37 F N R 13 27 2 08 Spiral bevel gear Clock wise Spline SPEC co MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Model F8B T9 9 FT9 9A F9 9 F9 9B CYLINDER HEAD Warp limit 0 1 0 004 Lines indicate straightedge measurement CYLINDER Bore size Wear limit Taper limit 59 00 59 02 2 323 2 324 59 1 2 326 0 08 0 003 CAMSHAFT Cam dimensions Intake Intake Exhaust A Exhaust Camshaft runout limit 24 541 24 641 0 966 0 970 20 137 20 237 0 793 0 797 24 578 24 678 0 968 0 972 20 178 20 278 0 794 0 798 0 1 0 004 CAM BELT Cam belt type Belt stack Co
6. 8 25 ELECTRICAL 5 ELECTRICAL 5 MANUAL STARTER MODEL Lighting coil Ignition coil WIR White Red G Green Ground 9 CDI unit Br Brown Pulser coil Charge coil Engine stop switch L Blue GAN Green White 4 Oil pressure switch Oil pressure B Black R Red Rectifier regulator indicator lamp W White 6 42 Electrothermal Pink CDI unit Y R Yellow Red T ya ELEC ELECTRICAL COMPONENTS ELECTRICAL STARTER MODEL Lighting coil Ground Fuse holder Fuse holder Pulser coil Charge Oil pressure switch 7 Rectifier regulator Ground CDI unit Ignition coil CDI unit Engine stop switch 3 Oil pressure indicator lamp Starter switch 5 Starter relay Electrothermal valve ai GO X d N Q gt D BANA p White Red Brown R Blue Black White Pink Yellow Red Green Orange GAN Green White B W Black White ELECTRICAL COMPONENTS gt REMOTE CONTROL MODELS T9 9ER FT9 9AE Lighting coil Ignition coil W R White Red GAN Green White Ground CDI unit Br Brown R Red Fuse holder 3 Wiring harness L Blue B W Black White Fuse holder Starter relay B Black Y Yellow Pulser coil Charge Elect
7. 8 5 Peak voltage measurement ss 8 5 Low resistance 1 2 1 8 5 IGNITION 6 6 2 2 2 2 8 6 WIRING 444 8 44 8 6 IGNITION SPARK 1 01 1 412 48 2 1 1 ona sen ano kuas 8 7 CDI SYSTEM PEAK VOLTAGE 0 nnne nnns 8 8 SPARKPEUG deene Eder ge 8 10 SPARK PLUG 8 11 ENGINE STOP SWITCH 8 11 MAIN SWITCH a Ka ara a een eR go eue e roce Po ER 8 12 IGNITION CONTROL SYSTEM 8 13 WIRING 8 13 OIL PRESSURE 8 14 OIL PRESSURE INDICATOR nnn 8 14 STARTING 6 8 8 16 WIRING 0 1 0 12 14 1 14 8 16 BATTERY 8 17 aUi EIER
8. BRKT UPPER CASING AND BOTTOM COWLING Extent of removal D Bottom cowling removal Upper casing removal Mount rubber removal Extent of removal Part name Remarks i Cable end throttle Cable end shift Screw Shift lever Bolt Shift rod pin Bolt Shift stay Panel stay Bolt Bottom cowling Bolt Bolt Exhaust guide Dowel pin Rubber seal Oil seal Pipe Relief valve Seal Oil pan Dowel pin Upper casing Bolt Rubber housing Mount rubber side Mount rubber under Nut Bolt Clamp Mount rubber upper T9 9 FT9 9A models only F8B F9 9 F9 9B models only NM NM NM NID D sch sch ODM ajA W i 2 Loosen the screw 0050 0 INSPECTION CLAMP LEVER 1 Inspect e Clamp lever Wear Damage Replace BRKT UPPER CASING AND BOTTOM COWLING BOTTOM COWLING 1 Inspect e Bottom cowling Crack Damage Replace OIL PAN AND EXHAUST GUIDE 1 Inspect e Oil pan e Exhaust guide Crack Damage Replace EXHAUST MANIFOLD 1 Inspect e Exhaust manifold Carbon deposits Clean Crack Corrosion Replace UPPER CASING 1 Inspect e Upper casing Crack Damage OIL STRAINER 1 Inspect Oil strainer Contamination Clean Damage gt Replace BRKT UPPER CASING AND BOTTOM COWLING SHIFT MECHANISM 1 Inspect e Shift rod Shift l
9. BRKT UPPER CASING AND BOTTOM COWLING CES 7 3 3 XS Engine stop switch 22 4 Nm 0 4 m kg 2 9 ft Ib 4 Ku Install Grommet 1 Fuel joint 3 e Fuel hose e Clip 5 e Engine stop switch 6 Install e Bottom cowling 1 e Washer Gi e 3 Install Grommet shift shaft D Grommet 2 Water 3 Install Lever stay 1 e Washer 2 Bushing e Clamp lever 2 e Collar 5 e Wave washer 6 e Washer 7 e Bolt e Rubber seal 9 e Bolt BRKT UPPER CASING AND BOTTOM COWLING ED 7 Install e Shift link e Bushing 2 e Shift lever 3 e Shift arm 4 e Accelerator stopper 5 e Shift arm 6 e Accelerator arm 7 e Bushing e Bolt 9 e Shift rod e Pin 9 e Washer 2 e Cotter pin 3 e Cotter pin e Spring 45 e Bracket e 7 8 Install T9 9MH FT9 9AMH F9 9MH F9 9BMH e Stay 1 e Bolt 0 e Guide 3 e Start in gear protection wire 4 9 install FBBE FT9 9AE T9 9EH FT9 9AEH F9 9BE F9 9EH F9 9BEH e Stay D e Bolt 0 e Neutral switch 3 7 10 BRKT BRACKET UNIT CE K15650 0 BRACKET UNIT PREPARATION FOR REMOVAL Remove the power unit Remove the upper casing and bottom cowling 12 Nm 1 2 m kg 8 7 ft Ib 45 Nm 4 5 kg 32 ft Ib 7 11 BRACKET UNIT CE Extent of removal
10. EH 21 Nm 2 1 m kg 15 ft Ib 5 Install e Apron e Screw 2 5 3 5 4 6 Install Oil level gauge 1 7 Connect Water hose 1 Water hose 0 Water hose 3 Blow by hose Fuel hose 5 RECOIL STARTER 1 Install Start in gear protection wire 1 e Lock nut 2 Adjust e Start in gear protection cable length Refer to page 3 11 3 Install e Starter grip D NOTE LL enc Pass the starter rope through the front panel and starter grip and make a knot in the end of the rope then put it into the starter grip 4 Install e Grip cover 1 NOTE maan After installing the grip cover untie the knot and let the rope wind around the starter POWER UNIT REMOVAL CE BATTERY LEAD 1 Install e Battery lead Refer to pages 8 2 8 4 NOTE Connect the battery lead to both of the starter motor and starter relay FLYWHEEL COVER 1 Install e Grommet 1 e Collar 2 e Flywheel cover 3 e Hinge pin e Screw 5 NOTE LLL LLL Secure the L shaped portion to the holder 2 Install e Electrical leads e Terminal cover e Screw Refer to pages 8 1 8 4 3 Connect e Throttle link 4 Adjust Throttle link length Refer to page 3 14 5 5 CYLINDER PISTON CYLINDER PISTON CRANKSHAFT PREPARATION FOR REMOVAL Remove the power unit Remove the following parts e CD
11. GENERAL SPECIFICATIONS Worldwide USA CANADA Unit Model F9 9BMH F9 9BEH F9 9MH F9 9EH F9 9BE Overall length Overall width Overall height 5 1 X S L X 5 L X Boat transom height Weight without propeller Maximum output Speed range at full throttle Speed range at idling Speed range at trolling Maximum fuel consumption mm mm mm mm in mm in mm in mm in mm kg Ib kg Ib kg Ib 863 34 0 993 39 1 2 392 154 430 16 9 2 1 004 39 5 1 131 44 5 381 15 0 508 20 0 43 0 95 44 0 97 575 22 6 325 12 8 43 5 96 44 5 98 41 5 91 42 5 94 h US Imp 5 7 3 9 9 5 000 4 500 5 500 950 50 850 50 3 8 1 00 0 84 5 500 Engine type Number of cylinders Total displacement Bore and stroke Compression ratio Spark plug Number of carburetor Carburetor starting system Manifold arrangement Exhaust system Lubrication system Ignition system Starting system cm cu in mm x mm x in NGK number 4 stroke OHC 2 232 14 16 59 0 x 42 4 2 32 x 1 67 9 3 1 6 5 1 Prime start Cross flow Through propeller boss Wet sump CDI Electric starter Manual starter Fuel rating Engine oil type Engine oil pan capacity Gear oil type Gear oil capacity SAE
12. IN 5 500 5 512 mm 0 2165 0 2170 in Replacement steps NOTE _____________________ Heat the cylinder head in an oven to 200 C 392 F to ease guide removal and installation and to maintain correct inter ference fit e Remove the valve guide using the valve guide remover OZ Valve guide remover 1122 90890 06801 Install the circlip and guide new using the valve guide installer and valve guide remover lt Valve guide installer 2 6308 90890 06802 After installing valve guide the valve guide using the valve guide 1 to obtain stem to guide clearance 02 guide 1196 90890 06804 5 Eliminate from valve seat 6 Inspect Valve seat Wear Pitting Reface the valve seat 5 29 CYLINDER HEAD VALVE AND ED 7 e Valve seat width 8 Out of specification Resurface Valve seat width 0 6 0 8 mm 0 024 0 031 in Measurement steps e Apply the Mechanic s dye to the valve face e Install the valve into the cylinder head e Press the valve through the valve guide onto the valve seat to make a clear pattern e Measure the valve seat width Wher ever the valve seat and valve face made contact bluing will have been removed 8 Reface e Valve seat Us
13. Worldwide Worldwide 304623 703474 472276 788442 101224 413584 762552 010452 308168 200421 500514 101488 402044 5 000490 L 301713 5 200158 1 500786 5 100302 1 400964 FT9 9AMH T9 9MH FT9 9AEH T9 9EH 6G8 F9 9BMH F9 9MH F9 9BEH F9 9EH 6G9 1 1 SAFETY WHILE WORKING CES SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol lowed by Yamaha dealers their mechanics FIRE PREVENTION Gasoline petrol is highly flammable Petroleum vapor is explosive if ignited Do not smoke while handling gasoline petrol and keep it away from heat sparks and open flames VENTILATION Petroleum vapor is heavier than air and if inhaled in large quantities will not support life Engine exhaust gases are harmful to breathe When test running an engine indoors maintain good ventilation SELF PROTECTION Protect your eyes with suitable safety spec tacles or safety goggles when using com pressed air when grinding or when doing any operation which may cause particles to fly off Protect hands and feet by wearing safety gloves or protective shoes appropriate to the work you are doing OILS GREASES AND SEALING FLUIDS Use only genuine Yamaha oils grease and sea
14. _ _ Always replace the guide if the valve is replaced Always replace the oil seal if the valve is removed CYLINDER HEAD VALVE AND CE VALVE SPRING 1 Measure e Compressed force Out of specification Replace Compressed force Set length 8 90 100 24 4 mm 9 0 10 0 kg 0 96 in 19 8 22 0 lb 2 Measure e Spring tilt 3 Out of specification Replace x limit E 1 1 mm 0 043 in 5 34 CYLINDER VALVE AND gt 5 35 ASSEMBLY AND INSTALLATION OIL PUMP ASSEMBLY 1 Install e Pump housing D e Outer rotor 2 e Inner rotor 3 e Shaft e O ring e Pump cover 6 e Screw 7 NOTE ee e Align the shaft with the hole in the inner rotor shaft and insert e Cil the rotors liberally before installing the pump cover CYLINDER HEAD 1 Install e Cil seal D e Screw 2 e Anode 3 e O ring e Bolt 5 NOTE 2 Install the oil seal with its manufacture s marks or numbers facing outward N Bolt A 18 Nm 1 8 m kg 13 ft Ib 2 Apply Engine oil Onto valve and oil seal NOTE Always use a new oil seal 5 36 CYLINDER HEAD VALVE AND CAMSHAFT CE 3 Install e Valve intake D e Oil seal e Spring seat 3 e Valve spring 4 e Spring retainer 5 e Valve cotter 6 NOTE 228 down the valve
15. 90890 06704 Use the following equation to calculate the pinion shim thickness T3 FT9 9A T3 5 99 F8B 9 98 6 05 Available shim thickness FT9 9A 0 10 0 14 0 18 0 35 and 0 50 mm F8B F9 9B 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm LOWER UNIT 6 18 2 Adjust e Forward gear shim thickness Adjustment steps e Measure the dimension Mv1 Shimming plate 90890 06701 Digital caliper 90890 06704 e Use the following equation to calculate the pinion shim thickness T1 FT9 9A T1 16 50 F8B F9 9B T1 16 60 Mv1 Available shim thickness FT9 9A 0 10 0 14 0 18 0 35 and 0 50 mm F8B F9 9B 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm 3 Adjust e Reverse gear shim thickness Adjustment steps e Measure the dimension Mv2 Shimming plate 90890 06701 Digital caliper 90890 06704 e Use the following equation to calculate the pinion shim thickness T2 FT9 9A T2 81 00 Mv2 F8B F9 9B T2 80 57 Mv2 Available shim thickness FT9 9A 0 10 0 14 0 18 0 35 and 0 50 mm F8B F9 9B 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm LOWR e LOWER UNIT CED BACKLASH MEASUREMENT NOTE L e Both forward and reverse gear backlash should be measured e If both the forward and reverse gear back lash are larger than specified the pinion may be too high eif both the forwa
16. Bearing Pitting Rumbling Replace DRIVE SHAFT 1 Inspect Drive shaft Wear Damage Replace PROPELLER SHAFT 1 Inspect Propeller shaft Wear Damage Replace 6 8 e LOWER UNIT gt DOG CLUTCH 1 Inspect Dog clutch Wear Damage gt Replace SLEEVE 1 Inspect Sleeve Wear Damage Replace PROPELLER ANODE Refer to pages 3 1 3 2 ASSEMBLY AND INSTALLATION FORWARD GEAR 1 Install T9 9 FT9 9A Forward gear shim 1 Taper roller bearing Forward gear NOTE shim is installed 9 9 9 9 model only 1 Install F8B F9 9 F9 9B e Taper roller bearing D e Forward gear 0 6 9 LOWER UNIT gt 1 Install Spring D e Plunger e Dog clutch 3 e Cross pin 4 e Cross pin ring NOTE Zaa Install the clutch with the F mark toward the forward gear side REVERSE GEAR 1 Install e Needle bearing Drive rod 4 071 90890 06604 Needle bearing attachment YB 6081 90890 06616 F8B F9 9 F9 9B T9 9 FT9 9A 0 mm 0 in F8B F9 9 F9 9B 0 mm 0 in NOTE s Instali the needle bearing with its manufac ture s marks or numbers toward the propel ler side 2 Install Oil seal D Oil seal installer 4 YB 6078 4 Drive 6229 T9 9 FT9 9A 4 5 5 0 mm 0 18 0 20 F8B F9 9 F9 9B 3 0 3 5 mm 0 12
17. Part name 9 Symbol mark Q ty Exploded diagram Pour E CYLINDER HEAD VALVE AND CAMSHAFT CE CYLINDER HEAD VALVE AND CAMSHAFT gt CYLINDER HEAD VALVE CAMSHAFT NOTE ON REMOVAL AND REASSEMBL Y PREPARATION FOR REMOVAL Betore servicing clean the power unit Remove the power unit Remove gasket adhered to the contacting surface Remove the following parts Take care not to scratch the contacting surfaces when removing the cylinder and cylinder head CDI unit Rectifier regulator For reassembly the removed parts should be cleaned with solvent and apply the gear to the ignition Flywheel magneto sliding surfaces Stator assembly Timing belt 3 1 Intake manifold removal 2 Cylinder head removal A 3 pump assembly removal 4 Valve disassembly meam enm QoS o wem gt intako RAS i Bott gt Jat 16 1 5 m amp g 11 20d 30 Nm 3 0 22 fib Extent of removal Refer to REMOVAL POINTS the screw Peter to REMOVAL POINTS Refer to REMOVAL POINTS Valve intake Refer to REMOVAL POINTS Valve exhaust 1 1 REMOVAL POINTS CYLINDER HEAD 1 Remove Cylinder head D NOTE To remove the cylinder head insert bar between the cylinder head and cylinder body and then seperate it Do not to scratch th
18. e By pass hose 5 NOTE Always use a new gasket STARTER MOTOR 1 Install e Bracket 1 e Bolt 2 2 Install e Battery lead 1 e Nut 2 e Starter motor 3 e Bolt 4 S Nut 25 4 Nm 0 4 m kg 2 9 ft Ib 3 Install e Relay bracket e Starter relay assembly 1 e Bolt 2 e Battery lead 3 e Washer 4 e Nut 5 NOTE eSecure together with the starter relay ground lead 8 e Connect the battery lead to both of the starter motor and starter relay N Nut A 4 Nm 0 4 m kg 2 9 ft Ib CYLINDER PISTON CRANKSHAFT CE FLYWHEEL MAGNETO 1 Install e Dowel pin 1 e Stator bracket 2 e Screw 3 e Stator assembly e Bolt 5 e Woodruff key 6 N Install e Flywheel magneto 1 e Washer e Nut 3 Flywheel holder YB 6139 90890 06522 Nut 100 Nm 10 0 m kg 72 ft Ib 5 22 CYLINDER HEAD VALVE AND CYLINDER HEAD VALVE PREPARATION FOR REMOVAL Remove the power unit Remove the following parts CDI unit e Rectifier regulator Ignition coil Flywheel magneto Stator assembly Timing belt 2 Nm 0 2 m kg 1 4 Ib 8 Nm 0 8 m kg 5 8 ft Ib 13 Nm 1 3 m kg 9 4 ft Ib 18 Nm 1 8 m kg 13 ft Ib 1st 15 Nm 1 5 m kg 11 ft ib 2nd 30 Nm 3 0 m kg 22 ft Ib 5 23 CYLINDER HEAD VALVE AND CAMSHAFT GE NOTE ON REMOVAL
19. 2 Place a suitable container under the outboard motor 3 Remove drain plug Oil level plug Drain the gear oil 4 Fill e Gear oil Recommended oil Hypoid gear oil SAE 90 Oil capacity T9 9 FT9 9A 320 3 10 82 us oz 11 26 Imp oz F8B F9 9 F9 9B 185 m 6 25 6 51 Imp 5 Check Gear oil level 6 Install e level plug Oil drain plug 3 5 ADJ PERIODIC SERVICE 3 6 D36730 0 SPARK PLUG 1 Remove Spark plug 2 Inspect Electrode D Wear Damage Replace insulator color 2 Distinctiy different color check the engine condition Color guide Medium to light tan color Normal Whitish color Lean fuel mixture Plugged fuel mixture Air leak Wrong settings Blackish color Excessive idling Electrical malfunction rich carburetion Defective spark plug 3 Clean Spark plug Clean the spark plug with a spark plug cleaner or wire brush 4 Inspect Spark plug type Incorrect Replace Standard spark plug CR5HS F8B NGK CR6HS T9 9 FT9 9A F9 9 F9 9B 5 Measure Spark plug gap Out of specification Use a wire gauge Spark plug gap 0 6 0 7 mm 0 024 0 028 in INSP PERIODIC SERVICE 3 7 6 Tighten Spark plug NOIE deem Eid Before installing a spark plug clean the gasket surface and plug surface Also it is suggested to apply a thin film of Anti
20. 7 Install e Arm spring D e Stopper arm 2 e Washer 3 e Spring washer 2 e Bolt 5 Firmly hold the rope or the rope will be pulled in NOTE Lue eHook the spring onto the starter housing and stopper arm e Align the arrow marks on the collar and stopper arm e After assembling wind the rope 4 turns clock wise around the sheave drum to contract the spring e While holding the rope firmly tie the rope temporarily to the starter roller RECOIL STARTER CED 8 Install Washer 1 Bushing Pinion Friction spring 5 Washer 7 Lock nut Do not open the spring end to fit it or the gap will become large thus making the spring unusable It should fit in the same manner as a piston ring 9 Install e Protector 1 e Damper 2 e Guide plate 3 e Spring washer 4 e Bolt 5 NOTE E a Put the protector into the loop of the friction spring 10 Install e Recoil starter assembly 1 e 2 11 Install e Start in gear protection wire Refer to page 5 4 5 46 Lou CHAPTER 6 LOWER UNIT Fe idu 6 1 PREPARATION FOR REMOVAL 9 9 9 9 6 1 NOTE ON REMOVAL AND 6 2 PREPARATION FOR REMOVAL F8B F9 9 F9 9B 6 3 NOTE ON REMOVAL AND REASSEMBLY sssssannsrnnsesesserenseneserun
21. yams dois u91iMs 9 9 1 ainsse1d 0 1109 AJLA aBieug BunuBr1 102 18sind 103385 D SUUAA enig 1 18 T9 9EH FT9 9AEH 6 uoniuD 6 EUJ19U 041909 3 0 181984 6 1914018 AZL J010uJ 1931018 6 UOJIMS CD voz UOJIMS 0 dois 6 yams 1015 9 1 1 88914 10 109 1109 7 Dunufr 109 Ajquesse 101816 oJyAW U8819 U9910 288 enig peu euuM T9 9ER FT9 9AE 49 BABA 19143204 D Aejai 1911916 0 AZL Aisneg 1911916 8 voz esn4 91 88919 10 1109 191e9U eBueu Bunubr 102 101815 D O 9A 9 10
22. 0 14 in 6 10 LOWR LOWER UNIT gt 3 Install e Ball bearing 025 Bearing installer YB 6015 90890 06632 Drive YB 6071 90890 06606 NOTE _ Install the bearing with its manufacture s marks or numbers facing outward 4 Install e O ring D e Reverse gear shim 2 e Reverse gear 3 e O ring 2 OIL SEAL HOUSING 1 Install e O ring D Oil seal installer YB 6022 Drive rod YB 6229 LOWER CASE 1 install 9 9 9 9 Bearing outer 1 Ta Bearing installer 6085 90890 06625 6071 90890 06605 6 11 LOWER UNIT F8B 9 9 9 9 D 0 0 6 12 1 Install F8B 9 9 9 9 e Forward gear shim e Bearing outer race 2 Bearing installer YB 6085 90890 06625 Drive rod YB 6071 90890 06605 NOTE M e The shim is installed for F9 9 F9 9B models only 2 Install e Needle bearing 1 Needle bearing installer YB 6231 Needle bearing attachment T9 9 YB 6298 F9 9 YB 6230 Drive rod 90890 06602 Bearing depth plate 90890 06603 Needle bearing attachment FT9 9A 90890 06618 F8B F9 9B 90890 06617 For USA and CANADA Except for USA and CANADA Depth 8 T9 9 FT9 9A 199 6 200 1 mm 7 86 7 88 in F8B F9 9 F9 9B 182 2 182 7 mm 7 17 7 19 in NOTES cL Install the bearing with its manufacture s
23. 90890 06501 Bearing puller 90890 06535 Stopper guide stand 90890 06538 For USA and CANADA Except for USA and CANADA LOWR LOWER UNIT REVERSE GEAR COMPLETE 1 Remove e Ball bearing Stopper guide plate 90890 06501 Bearing puller 90890 06535 Stopper guide stand 90890 06538 For USA and CANADA Except for USA and CANADA 2 Remove Oil seal 1 Needle bearing 2 Drive rod YB 6071 90890 06604 Needle bearing attachment YB 6081 90890 06616 FORWARD GEAR COMPLETE F8B F9 9 F9 9B 1 Remove e Taper roller bearing D e Forward gear 2 02 Bearing separator 6219 90890 06534 6 6 LOWR LOWER UNIT CED INSPECTION AND REPAIR LOWER CASE 1 Clean Gear case Use a soft brush and solvent 2 Inspect Water passage Mineral deposits Corrosion Clean 3 Inspect Lower case Crack Damage Replace BEARING HOUSING 1 Clean Bearing housing Use a soft brush and solvent 2 Inspect e Bearing housing Crack Damage Replace WATER PUMP HOUSING 1 Inspect Water pump housing Crack Damage Replace IMPELLER 1 Inspect Impeller 4 Crack Damage 6 7 LOWR LOWER UNIT cr SHIFT SHAFT 1 Inspect e Shift plunger Wear Damage Replace 2 Inspect e Boot Break Damage gt Replace 1 Inspect Teeth 0095 Wear Damage BEARING 1 Inspect
24. D Swivel bracket removal Clamp bracket removal 3 Swivel bracket disassembly Extent of removal Part name Remarks I 1 Bolt Steering bracket Bolt Dowel pin Steering shaft Washer Bushing Friction plate Swivel bracket 2 1 1 2 1 1 1 1 1 Bushing 1 O ring 1 Bushing 1 Tilt pin 1 Nut 2 Nut M6 1 Clamp bracket 2 Nut 2 T9 9 FT9 9A models only Tilt lever 1 Pin 1 Tilt plate inner 1 Spring 2 Refer to REMOVAL POINTS Pin 1 Tilt plate outer 1 F8B F9 9 F9 9B models only Drive lever 1 REMOVAL POINTS SPRING 1 Remove e Clip 1 Tilt plate inner 2 Spring 3 Align the holes of the tilt plate inner outer and remove the pin 7 12 K30150 0 INSPECTION CLAMP AND SWIVEL BRACKET 1 Inspect e Clamp bracket e Swivel bracket Crack Damage Replace TILT PLATE 1 Inspect e Tilt plate Crack Damage Replace ASSEMBLY AND INSTALLATION 1 Install T9 9 FT9 9A models Tilt plate outer D 2 e 3 2 e 5 Install F8B 9 9 9 9 models Tilt plate outer 1 e Drive lever e 3 e Collar e Clip 5 Install e Spring e Tilt plate inner 2 e Pin 3 e Clip N NOTE L M M Align the holes of the tilt plate inner and outer after installin
25. 3 1 turns out F8B F9 9 F9 9B 3 1 2 1 3 12 INSP ADJ PERIODIC SERVICE 3 13 IDLE SPEED ADJUSTMENT 1 Start the engine and let it warm up 2 Attach Tachometer To spark plug lead Tachometer YU 8036 A 90890 06760 3 Idle speed Out of specification Adjust Idle speed T9 9 FT9 9A 1 150 50 r min F8B F9 9 F9 9B 950 50 r min 4 Adjust e Idle speed Adjustment steps e Turn the throttle stop screw 1 in or out until specified idle speed is obtained Turning in idle speed becomes higher Turning out Idle speed becomes lower NOTE After adjusting the engine idle speed the throttle link should be adjusted E PERIODIC SERVICE CED THROTTLE LINK ADJUSTMENT NOTE eee Engine idling speed should be adjusted properly before adjusting the throttle link 1 Check e Full open position Incorrect gt Adjust Checking steps Pull the accelerator arm to the full open side Check the throttle lever to the full open position 2 Adjust e Throttle link length Adjustment steps Loosen the lock nut Turn the adjust nut in or out until adjustment is suitable Tighten the lock nut 3 Check e Throttle link free play No free play Replace the throttle link Checking steps e Push the accelerator arm 1 to the full closed side e Make sure the throttl
26. CDI tester P N YU 91022 B Peak volt adapter P N YU 39991 90890 03169 Compression gauge P N YU 33223 90890 06751 Timing light P N YM 33277 A 90890 03141 Tachometer P N YU 8036 A 90890 06760 Mity Vac P N YB 35956 90890 06756 Backlash indicator P N YB 6265 90890 06706 Magnet base P N YU 34481 90890 06705 SPECIAL TOOLS INFO D 6117 2 90890 06501 90890 06521 DP 2522 90890 06522 90890 06515 5 34454 90890 06529 6 YB 6219 90890 06534 lt 8 6139 6228 7 90890 06069 90890 06535 90890 04019 90890 06801 90890 06802 49 1122 42 6308 6 90890 06602 90890 06604 90890 06605 90890 06606 E S gt D 6229 6071 REMOVAL AND INSTALLATION 1 Flywheel puller P N YB 6117 90890 06521 2 Stopper guide plate P N 90890 06501 3 Flywheel holder P N YB 6139 90890 06522 4 Drive shaft holder P N YB 6228 90890 06515 5 Piston ring installer P N YB 34454 90890 06529 6 Bearing separator P N YB 6219 90890 06534 7 Shaft holder P N 90890 06069 8 Bearing puller P N 90890 06535 9 Valve spring compressor P N YM 1253 90890 04019 10 Valve guide remover P N YM 1122 90890 06801 11 Stopper guide stand P N 90890 06538 12 Valve guide installer P N YB 6308 90890 06802 13 Drive rod P N YB 6229 YB 6071 90890 06602 90890 06
27. DIMENSION Symbol used in diagram Unit T9 9 FT9 9A F8B F9 9 F9 9B H4 S L UL mm in 432 17 0 mm in 559 22 0 mm m TEE 114 4 5 126 5 0 33 1 3 65 2 6 2 11 CE TIGHTENING TORQUE Thread Tightening torque Part to be tightened S size Nm kg ft Ib Remarks ENGINE 0 6 4 3 Connecting rod 12 87 mO 06 43 12 s 09 15 11 30 22 1 5 11 Cylinder head 30 22 Crankcase Oil element assembly 0 8 5 8 Exhaust cover 1 2 8 7 Rock arm adjusting screw 0 8 5 8 Drive gear Driven gear 9 4 Flywheel Bracket bolt Steering bracket Upper side mount rubber T9 9 FT9 9A F8B F9 9 F9 9B MI ejej sch MI MI sech bech Plug drain Manifold exhaust mounting Bottom cowling mounting 2 12 SPEC vs GENERAL SPECIFICATIONS CES Nut A Bolt B General torque specifications 8mm 10 mm 12 mm 14mm 17 mm M5 M6 8 2 13 C33500 0 GENERAL TORQUE SPECIFICATIONS This chart specifies the torque for tighten ing standard fasteners with standard clean dry ISO threads at room temperature Torque specifications for special compo nents or assemblies are given in applicable sections of t
28. Fuel pump 4 separator 5 Carburetor 6 Thermostat cover 4 1 FUEL FUEL SYSTEM CED PREPARATION FOR REMOVAL Remove the top cowling e Gasoline petrol is highly flammable and explosive Handle with special care eFailure to check for fuel leakage may result in fire or explosion For USA and Switzerland Extent of removal Fuel joint removal Fuel pump removal Fuel pump disassembly Extent of removal Part name Bolt Fuel joint Fuel strainer Screw Fuel pump Screw Pump body Diaphragm Plunger Spring Diaphragm spring Screw Plate Check valve Pump cover Q lt Disconnect the hose Disconnect the hose Disconnect the hose For USA and Switzerland For USA and Switzerland For USA and Switzerland ch eed ed ch DADAHRWN BO NI sch sch sch sch Pl sch NI eech sch 4 2 FUEL FUEL SYSTEM CE E21650 1 REMOVAL POINTS DIAPHRAGM 1 Remove e Diaphragm 1 Push the plunger hold the plate 2 and turn the diaphragm 90 E21850 0 INSPECTION FUEL JOINT 1 Measure e Fuel joint operation Impossible to maintain the specified pressure for 10 sec Replace Measuring steps e Attach the Mity Vac 5 2 Mity Vac 4 35956 90890 06756 Apply Specified 50 kPa 0 5 7 1 psi E21852 0 FU
29. Top ring Type Dimensions er mm End gap installed mm in Limit T mm in Side installed mm 2nd ring Type Dimensions B x T V mm in End gap installed mm in Limit T mm in Side clearance installed mm in Oil ring Dimensions End gap installed a mm in 1 Except for USA 2 6 0 035 0 065 0 0014 0 0026 EX Left hand PISTON Piston to cylinder clearance mm Piston side D mm 58 950 58 965 2 3209 2 3215 10 0 39 59 25 2 333 59 50 2 343 Plain barrel 1 5 x 2 3 0 06 x 0 09 0 15 0 30 0 006 0 012 0 50 0 020 0 04 0 08 0 002 0 003 aper 1 5 x 2 4 0 06 x 0 09 0 15 0 30 0 006 0 012 0 50 0 020 0 03 0 07 0 001 0 003 2 4 2 5 0 09 0 10 0 20 0 70 0 008 0 028 MAINTENANCE SPECIFICATIONS Item Model F8B T9 9 FT9 9A F9 9 F9 9B CONNECTING ROD Oil clearance big end 0 021 0 045 0 0008 0 0018 CRANKSHAFT Crank width A Runout limit B Main bearing clearance Crankcase mark Bearing color 123 7 123 9 4 87 4 88 0 05 0 002 0 000 0 027 0 0000 0 0011 CARBURETOR Stamped mark Main Nozzle Main Jet Pilot Jet Pilot Screw turn out Valve seat size Float height Idling speed Trol
30. 10W 40 API SE SF SE SF SE SF CC ENGINE OIL REPLACEMENT 1 Place the outboard motor in an upright position 2 Place a suitable container under the outboard motor 3 Remove Oil filler Drain bolt Drain the engine oil 4 Remove Oil filter assembly 3 3 INSP PERIODIC SERVICE CED 5 Inspect Oil filter element Damage Replace Foul Clog Clean 6 Clean Oil filter element Blow out dust in the element from the outer surface using compressed air 7 Install e Drain bolt e Oil filter assembly 2 Drain bolt 8 Nm 0 8 m kg 5 8 ft Ib Oil filter assembly 8 Nm 0 8 m kg 5 8 ft Ib 8 Fill e Engine oil Recommended oil SAE 10W 30 10W 40 SE SF SE SF SE SF CC Oil capacity 1 0 1 06 US qt 0 88 Imp qt 9 Check e Engine oil level Refer to page 3 3 10 Install e Oil filler cap 3 4 ADJ PERIODIC SERVICE CED GEAR LEVEL CHECK 1 Place the outboard motor in an upright position 2 Check e Gear oil level Oil level is low Add oil to proper level Checking steps e Remove the oil drain and oil level plugs Add the gear oi through the oil drain hole until it over flows from the oil level hole Recommended oil Hypoid gear oil SAE 90 Install the oil level plug e Install the oil drain plug GEAR OIL REPLACEMENT 1 Place the outboard motor in an upright position
31. 82 1 16 0 032 0 046 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 10 0 12 0 15 0 18 0 30 0 40 0 50 0 26 0 77 0 23 0 70 0 010 0 030 0 009 0 028 0 51 1 02 0 82 1 16 0 020 0 040 0 032 0 046 0 10 0 14 0 18 0 10 0 12 0 15 0 35 0 50 0 18 0 30 0 40 0 50 0 10 0 14 0 18 0 10 0 12 0 15 0 50 0 18 0 30 0 40 0 50 0 10 0 14 0 18 0 10 0 12 0 15 0 35 0 50 0 18 0 30 0 40 0 50 PROPELLER T9 9 FT9 9A Material No of blades x diameter x pitch Size 1 6G8 45941 00 Size 2 6G8 45943 00 Dual thrust Size 3 6G8 45945 00 Size 4 6G8 45947 00 EL Test propeller 1 90890 01627 Test propeller 2 YB 01627 F8B F9 9 F9 9B Material No of blades x diameter x pitch Size 1 683 45949 00 EL Size 2 683 45947 00 EL Size 3 683 45945 00 EL Size 4 683 45952 00 EL Size 5 683 45943 00 EL Size 6 683 45941 00 EL Dual thrust Size 7 683 W4591 02 EL Size 8 683 W4592 02 EL Test propeller 1 90890 01619 Test propeller 2 YB 01619 Plastic R 11 3 4 x 11 3 x 11 3 4 x 9 1 4 3 x 11 3 4 x 12 1 4 3 x 11 3 4 x 9 1 4 4 000 4 200 4 000 4 200 Aluminum 3 x 9 1 2 x 6 1 2 3x 9 1 4 x 8 3x 9 1 4 x 9 3 x 9 1 4 x 9 3 4 3 x 9 1 4 x 10 1 2 3 x 9 1 4 x 12 3 x 9 3 4 x 8 3 x 9 3 4 x 6 1 2 3 950 4 150 3 950 4 150 MAINTENANCE SPECIFICATIONS ELECTRICAL Item Unit Model F8B T9 9 FT9 9A F9 9 F9 9B I
32. AND REASSEMBLY Before servicing clean the power unit e Remove any gasket adhered to the contacting surface Take care not to scratch the contacting surfaces when removing the cylinder and cylinder head For reassembly clean the removed parts with solvent and apply gear oil to the sliding sur faces Extent of removal Intake manifold removal Cylinder head removal Oil pump assembly removal Valve disassembly Extent of removal Part name 3 Intake manifold 1 Bolt 4 Cylinder head cover 1 Bolt 8 Cylinder head 1 Refer to REMOVAL POINTS Bolt 3 Oil pump assembly 1 Adjust screw 4 Loosen the screw Valve lifter 2 Refer to REMOVAL POINTS Rocker shaft 2 Rocker arm 4 Bolt 1 Driven gear 1 Refer to REMOVAL POINTS Camshaft 1 Valve cotter 4 Valve intake 2 Refer to REMOVAL POINTS Spring retainer 2 Valve exhaust 2 REMOVAL POINTS CYLINDER HEAD 1 Remove e Cylinder head NOTE nn remove cylinder head insert screwdriver between the cylinder head and cylinder body and then separate it Do not to scratch the gasket contact sur faces with the screwdriver ROCKER SHAFT 1 Loosen e Lock nut e Adjust screw CZ Valve adjuster 2 8035 90890 01311 5 24 CYLINDER HEAD VALVE 5 25 2 Remove e Rocker shaft 1 NOTE Use M10 bolt to extract the rocke
33. Carburetor e idie speed e Pilot screw POWER UNIT Spark plug Compression Cylinder head gasket i j Weterpasage 5 9 1 TRBL ANLS 4 TROUBLE ANALYSIS CES Problem Reference Related part chapter IRREGULAR WARNING INDICATION ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS POOR DECELERATION ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING LOOSE TILT HOLDING SHIFTING DIFFICULT POOR BATTERY CHARGING LOWER UNIT Neutral position Clutch Gear Water inlet Water pump Propeller shaft Shifter Pin Shift cam Shift shaft Lower case BRACKET UNIT ELECTRICAL Ignition system Starting system Enrichment control system Ignition control system OIOI 9 2 WIRING DIAGRAM F8BMH F9 9MH F9 9BMH japow edoun3 qz ioo 1 913 D 1 youms dois 6 91 88019 1 einsseid 10 109 ioo 102 4es ngd A quuesse 103215 D pau OJUAN U9910 U9945 Xuld SUU
34. LIT 18616 01 83 HOW USE THIS MANUAL MANUAL FORMAT of the procedures in this manual are organized seguential step by step format The information has been compiled to provide the mechanic with an easy to read handy refer ence that contains comprehensive explanations of all disassembly repair assembly and inspection operations In this revised format the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol e g Bearing Pitting Damage Replace To assist you to find your way about this manual the Section Title and Major Heading is given at the head of every page An Index to contents is provided on the first page of each section THE ILLUSTRATIONS Some illustrations in this manual may differ from the model you have This is because a pro cedure described may relate to several models though only one may be illustrated The name of the model described will be mentioned in the description REFERENCES Reference 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 have the section dealing with the procedure in order to look up the specifications It is important to note the differences in specifications of models Where a procedure relates to more than one model the
35. Low resistance measurement When measuring the resistance of 10 or less using the digital tester the correct measurement cannot be obtained because of the tester s internal resistance To obtain the correct value subtract this internal resistance from the displayed measurement Correct value Displayed measurement Internal resistance NOTE 5 The internal resistance of the tester can be obtained by connecting both of its termi nals IGNITION SYSTEM gt IGNITION SYSTEM WIRING DIAGRAM Spark plug Except for remote control Br Brown 2 Ignition coil model L Blue 3 Charge coil For remote control mode W R White Red 3 Pulser coil T9 9MH FT9 9AMH B O Black Orange 5 Main switch T9 9EH FT9 9AEH B W Black White Stop switch W White 7 stop switch B Black 7P coupler CDI unit 8 6 IGNITION SYSTEM 8 7 IGNITION A WARNING While checking the spark gap be careful not to touch any connection of lead wires of the Ignition spark gap tester e When doing the spark test take special care not to allow leakage from the removed plug cap e This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity 1 Check Ignition spark gap Out of specification Peak voltage measurement Spark gap 9 mm 0 35 in Checking steps e Adjust the spark gap to
36. Seize Compound to the spark plug thread to pre vent future thread seizure NS Spark plug 2 13 Nm 1 3 m kg 9 4 ft Ib NOTE torque wrench is not available when you are installing a spark plug a good esti mate of the correct torque is 1 4 to 1 2 turns part finger tight 2 Have the spark plug torqued to the correct valve as soon as pos sible with a torque wrench TIMING BELT 1 Inspect Timing belt Wear Damage Replace 2 Check Timing belt slack Push the timing belt with your finger Out of specification Replace Timing belt slack 0 10 mm 0 0 4 in ADJ PERIODIC SERVICE CE VALVE CLEARANCE ADJUSTMENT NOTE _ eThe valve clearance must be adjusted when the engine is cool to the touch e Adjust the valve clearance when pis ton is at the Top Dead Center T D C on compression stroke 1 Remove e Screw 1 e Hinge pin 2 e Flywheel cover 3 2 Remove e Bolt Clamp lever 2 3 Remove Hose e Bolt O Cylinder head cover 4 Measure Valve clearance Out of specification Adjust Valve clearance cold Intake 0 15 0 20 mm 0 0059 0 0079 in Exhaust 0 20 0 25 mm 0 0079 0 0098 in 3 8 INSP PERIODIC SERVICE Measurement steps Turn the crankshaft clockwise e Align the 1 on the driven gear with the mark on the cylinder head 2 when 1 piston is at on compres sion
37. distinguished important information in this manual in the following ways The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY 15 INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or deathto the machine operator a bystander or a person inspecting or repairing the outboard motor A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE A NOTE provides key information to make procedures easier or clearer CE HOW TO READ DESCRIPTIONS 1 An easy to see disassembly illustration is mainly provided for a disassembly job 2 Numbers are given the order of a disassembly job in the disassembly illustration 3 An explanation of jobs and notes is presented in an easy to read way by the use of sym bol marks The meanings of the symbol marks are given on the next page 4 A job instruction chart accompanies the assembly illustration providing the order of jobs names of parts notes in jobs etc 5 In addition to the disassembly illustration REMOVAL POINTS is provided to supple ment in detail the explanation which does or cannot necessarily cover the main jobs 6 Jobs necessary before and after those which are not included in the disassembly illustra tion are explained before the same illustration as related jobs D Section Remarks Preparation for removal Removal points Order of removal Extent of removal
38. face and valve seat are polished then clean off all compound NOTE To obtain the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply the fine lapping compound to the valve face and repeat the above steps NOTE Be sure to clean off all compound from the face and valve seat after every lapping operation e Apply the Mechanic s dye to the valve face Install the valve into the cylinder head e Press the valve through the valve guide and onto the valve seat to mark a clear pattern e Measure the valve seat width again If the valve seat width is out of specifica tion reface and lap the valve seat 5 32 5 33 CYLINDER HEAD VALVE AND CAMSHAFT CE gt VALVE 1 Inspect e Valve face Carbon deposits Clean Pitting Wear Grind the face e Valve stem end Mushroom shape or diameter larger than rest of stem Replace 2 Measure e Margin thickness 8 Out of specification Replace Margin thickness 0 5 0 9 mm 0 020 0 035 in 3 Measure e Valve stem diameter 8 Out of specification Replace Valve stem diameter 5 475 5 490 mm 0 2156 0 2161 in 5 460 5 475 mm 0 2150 0 2156 in 4 Measure e Valve stem runout Out of specification Replace Ti 0 016 mm 0 0006 in
39. loosen the ring nut eRepeat this operation until the ring nut comes off INSPECTION SHIFT AND THROTTLE CABLES 1 Inspect e Shift cable e Throttle cable Bend Damage Replace Unsmooth operation Replace STEERING HANDLE 1 Inspect e Steering handle Crack Damage Replace 7 19 BRKT STEERING HANDLE ASSEMBLY AND INSTALLATION STEERING HANDLE T9 9 FT9 9A F8B F9 9 F9 9B for Europe and Canada 1 Install Spring D Steering handle right 3 Stop switch 2 e Nut 5 EN Nut 22 0 4 2 9 ft Ib 2 Install e Grommet D e Throttle cable NOTE E EE Fit the inner cable end in the groove and fit the outer cable end into the hole 3 Install e Shift arm 1 e Shift cable 0 e Collar 3 e Washer 4 e Cotter pin 5 4 Install Bushing Shift lever 2 Wave washer 3 e Shift arm 2 Washer 5 6 e Nut NOTE L LLL e Align the shift lever shaft end with the hole in the shift arm e Fit the shift arm collar to the Neutral posi tion of the spring 7 20 E d STEERING HANDLE CED 5 Install e Steering handle left 1 e Screw 2 NOTE LL Lean eWhen installing steering handle fit the throttle and shift cables correctly in place e After installing the steering handle make sure that the shift lever operates correctly 6 Ins
40. main differences in specifications will be shown in the following table T9 9MH lem F8BMH F8BEH F8BE 9AMH T9 9EH FT9 9AEH Starting system Manual start Electric start Electric start Manual start Electric start Control system Manual control Manual control Remote control Manual control Manual control Tilt system Manual tilt Manual tilt Manual tilt Manual tilt Manual tilt Adjustable Adjustable Adjustable Adjustable Adjustable Ge Ee screw screw screw screw screw u i rew None adjustable None adjustable None adjustable None adjustable None adjustable screw screw screw screw screw Model T9 9ER FT9 9AE F9 9MH F9 9BMH F9 9EH F9 9BEH F9 9BE Electric start Starting system Electric start Manual start Electric start Control system Remote control Manual control Remote control Manual control Tilt system Manual tilt Manual tilt Manual tilt Manual tilt Adjustable Adjustable Adjustable Adjustable EE E screw 1 screw 1 screw screw i None adjustable None adjustable None adjustable None adjustable screw screw screw screw 1 Except for USA and Switzerland 2 For USA and Switzeriand WARNINGS CAUTIONS AND NOTES Attention is drawn to the various Warnings Cautions and Notes with
41. spring and install the valve cotter e Secure the valve cotter onto the valves stem by tapping it lightly with a piece of wood 4 Install Valve exhaust 1 Oil seal 2 Spring seat 3 e Valve spring Spring retainer Valve lifter Valve spring compressor YM 1253 90890 04019 NOTE Hold down the spring and install the spring retainer and slide in the retainer e Secure the valve lifter onto the valves stem by tapping it lightly with a piece of wood CYLINDER HEAD VALVE AND CAMSHAFT CED 5 37 5 Install e Camshaft D e Washer 2 e Woodruff key 3 e Driven gear 2 e Washer 5 e Bolt Flywheel holder YB 6139 90890 06522 6 Apply e Engine oil Onto rocker shaft and rocker arm Install e Rocker shaft exhaust D e Collar 2 e Rocker arm 3 e Compression spring short 4 e Collar 5 e Rocker arm 6 e Compression spring short 7 NOTE install the rocker shaft so that the internal thread side is on your side 8 Install e Rocker shaft intake D e Compression spring long 2 e Rocker arm 3 e Collar 4 e Compression spring short 5 e Rocker arm 6 CYLINDER HEAD VALVE CAMSHAFT CE 5 38 9 Install e O ring D e Oil pump assembly 2 e Bolt 3 NOTE Align the recess in the oil pump shaft with the camshaft projection 10 Install e O
42. stroke NOTE When measuring valve the 2 cylinder turn the driven gear 180 so that the 2 marked on the driven gear aligns with the mark on the cylinder head e Measure the valve clearance using a feeler gauge 5 Adjust Valve clearance Adjustment steps e Loosen the lock nut e Insert the specified feeler gauge 2 into the clearance between the valve stem end and the adjust bolt e Adjust the adjust bolt using a valve adjuster 3 vz Valve adjuster 2 08035 90890 01311 Tighten the lock nut with the feeler gauge inserted IN Lock nut 25 8 Nm 0 8 m kg 5 8 ft Ib NOTE Lock the adjust so that it does not move INSP PERIODIC SERVICE CE 6 Measure e Valve clearance Out of specification Readjust NOTE If too loose or too tight readjust the valve clearance 7 Apply e Engine oil To valve stem and adjust bolt 8 Install e Seal e Cylinder head cover e Bolt e Hose 9 Install e Clamp lever 1 e Bolt 0 10 Install e Flywheel cover 1 e Hinge pin 2 e Collar e Screw 3 3 10 gt 5 CABLE ADJUSTMENT 1 Adjust e Shift cable length Adjustment steps Loosen the lock nut e Remove the cable end e Set the shift lever to neutral Set the shift arm to neutral Turn the cable end in or out until adjustment is s
43. 604 90890 06605 90890 06606 1 6 SPECIAL TOOLS iro Y 49 YB 6295 90890 06618 0 8 49 1196 90890 06804 se 90890 06617 90890 06616 S 90890 06803 17 91043 Qi 6015 90890 06632 6085 90890 06625 gt 14 Needle bearing attachment T9 9 F9 9A P N YB 6298 90890 06618 15 Valve guide reamer P N YM 1196 90890 06804 16 Needle bearing attachment F8B F9 9 F9 9B P N YB 6230 YB 6081 90890 06617 90890 06616 17 Valve seat cutter set P N YM 91043 C 90890 06803 18 Valve adjuster P N YM 8035 90890 01311 19 Oil seal installer P N YB 6022 20 Pinion nut holder P N YB 6078 21 Bearing installer P N YB 6015 YB 6085 90890 06632 90890 06625 22 Pinion height gauge T9 9 FT9 9A P N YB 6299 23 Pinion height gauge F8B F9 9 F9 9B P N YB 34232 24 Bearing housing puller P N YB 06234 90890 06503 25 Slide hammer set P N YB 6096 26 Center bolt P N 90890 06504 27 Shimming plate P N 90890 06701 28 Bearing depth plate P N 90890 06603 SPEC ue CED CHAPTER 2 SPECIFICATIONS GENERAL 5 anane nane 1 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE ET 2 4 LOWER aana aaa agahan sus EE 2 9 EE 2 10 DIMENSION snc an E NEE E 2 11 TIGHTENING 2 12 5 ge
44. 8 17 WIRING 8 8 17 WIRING 44 000000 0000 8 17 ENGINE STOP SWITCH sastran anang Teh 8 17 MAIN SWITEH ten ag AE NANG ANG d DE DNA GA NON NEK EENS 8 17 STARTER SWITCH E AEN 8 17 NEUTRAL SWITCH EE 8 17 STARTER MOTOR an 97 deeg dees 8 19 SERVICE POINTS 8 20 Pinion Belle EE 8 20 Pinion inSpectiODn E 8 20 Armature irnispectlOh 5ici lara aka kan reda obse aka 8 20 Brush holder inspection ss 8 21 eoo Ogre vena teats vn aa dene anah 8 21 CHARGING SYSTEM rere ag TANG a teen 8 22 WIRING DIAGR AM nanas Sn eege 8 22 CHARGING SYSTEM PEAK 8 23 RECTIFIER REGULATORS T9 9 FT9 9A ie 8 24 RECTIFIER REGULATORS F8B F9 9 F9 9B 8 24 FUSE dieat tete edades E ee Eege 8 24 BATTERY m ee eegene eg 8 24 ENRICHMENT CONTROL SYSTEM 8 25 VALVE HEATER COLL iiic e ang a wa bana pra in 8 25 ne otn icio sc ceo nd Haeo ER ERE
45. 9 9A 1 150 50 r min F8B F9 9 F9 9B 950 50 r min e Direct the timing light toward the fly wheel magneto base 7 e Visually check the stationary pointer 2 to verify it is within the required firing range 3 indicated on the flywheel 3 16 FUEL CED CHAPTER 4 FUEL SYSTEM FUEL SYSTEM EE ae 4 1 FUEL CINE LAYOUT eege 4 1 PR PARATION FOR REMOVAL eege EEN 4 2 REMOVAL POINTS EE 4 3 DIAPHRAGM EE 4 3 licia c espejo n 4 3 FUEL JOINT eege 4 3 FUEL STRAINER SEU ERN ieee 4 3 FUEL ET 4 3 ASSEMBLY AND INSTALLATION 4 4 FUEL TEE 4 4 CARBURETOR ang naak ai eye 4 7 PREPARATION FOR 4 7 NOTE ON REMOVAL AND REASSEMBLY 4 8 REMOVAL POINTS Eat Topai a 4 8 JOIN Tsunami n 4 8 INECC 4 9 CARBURETOR BODY EE 4 9 PILOT SCREW Except for USA and Switzerland een 4 9 ET AND NOZZLE Eege 4 9 VISITE 4 9 55 V EE 4 10 DIAPHRAGM TH 4 10 gg asasaran 4 10 CHECK VALVE ES matinale 4 10 ELECTROTHERMAL VALVE 4 10 FUEL D FUEL SYSTEM CED FUEL SYSTEM FUEL LINE LAYOUT Check that the fuel line is correctly installed Except for USA and Switzerland D Fuel join Fuel strainer 8
46. 956 90890 06756 e Apply the specified pressure Specified pressure 50 kPa 0 5 kg cm 7 1 psi 7 Install e O ring D NOTE Always use a new O ring FUEL FUEL SYSTEM 4 6 8 o Install Except for USA and Switzerland e Fuel pump e Screw 2 e Hose 3 e Hose 4 e Clamp 6 Install For USA and Switzerland e Fuel pump D e Screw 2 e Hose 3 e Hose 4 e Clamp 5 e Hose 6 e Hose 7 e Clamp CE FUEL D CARBURETOR E31050 0 CARBURETOR NOTE Pilot screw for USA and Switzerland can not be removed and adjusted PREPARATION FOR REMOVAL Remove the top cowling Disconnect the wire lead WARNING Gasoline petrol is highly flammable and explosive Handle with special care eFailure to check for fuel leakage may result in fire or explosion For USA and Switzerland Except for USA and Switzerland FUEL 1150 0 NOTE REMOVAL AND REASSEMBLY e With the engine mounted the following parts can be removed e Before inspection the removed parts should be cleaned and blow out all passages and jets with compressed air e After removing the carburetor cover the carburetor joint preventing foreign material from entering Extent of removal _ 4 Carburetor removal 2 Electrothermal valve removal 3 Carburetor disassembly Extent of removal Part name Remarks Disconnect the link l
47. 9B Spacer 1 Propeller 2 Washer 3 e Nut 4 e Cotter pin 5 BN Nut 25 13 Nm 1 3 m kg 9 4 ft Ib 6 24 LOWR LOWER UNIT CE 6 25 NOTE If the propeller nut does not align with the propeller shaft hole when the nut is tight ened to specification turn it in further so that they align ct CHAPTER 7 BRACKET UNIT UPPER CASING AND BOTTOM COWLING 7 1 PREPARATION FOR 2 2 20 FERT Fara quip 7 1 INSPECTION WEEN 7 2 CLAMP LEVER DC 7 2 Le 7 3 OIL PAN AND EXHAUST 7 3 5 2 rco Fahnen eb to ena do ia tu aduer 7 3 UPPER CASING Eege 7 3 II TE 7 3 SHIFT 1 7 4 SEALING PARTS Egeter 7 4 MOUNT RUBBER paite eC pe 7 4 ASSEMBLY AND INSTALLATION 7 5 UPPER CASING eege Eege 7 5 BOTEOM COWLING EEN 7 8 BRACKET UNIT asahan danene 7 11 PREPARATION FOR REMOVAL 3 52252 7 11 REMOVAL POINTS aga na Eege 7 12 T EE 7 12 INSPECTION
48. AA KRIER enjg F9 9EH F9 9BEH 1q9 1109 uoniuB 6 1911004 1919158 AZL Meyeg 1 D YOUMs D voz esn4 0 u91IMS 191215 yoyms 4015 8 yams 9 8 19 1 10 einssaid 110 109 1 1109 BunuBr 1100 Ajquesse 101015 7 eBueJQ U9910 2918 8 F9 9BE UOJIMS 5 1109 9A BA On e oJ 1911916 0 AZL Meneg 391215 voz esn4 ainssa1d 110 joo BunuBr 1109 Ajquasse 101816 D MOII9 A 9215 pey MOII8A 20819 enj g uMOAJg peu auuM T9 9MH FT9 9AMH yun 02 6 1109 uoniuB 6 voz esn4 AZL 0 youms 035
49. Clog Dirty NOTE Remove all metal particles with com pressed air 4 Inspect e Armature coil continuity Out of specification Replace Armature coil continuity Commutator segments Continuity Discontinuity Segment Laminations Segment Shaft Discontinuity Brush holder inspection 1 Measure e Brush length Out of specification Replace Brush length 8 9 0 12 5 mm 0 35 0 49 in 2 Check e Brush holder continuity Out of specification Replace Brush holder continuity Brush holder 1 Base 2 Cover inspection 1 Inspect e Cover bushing Wear Damage Replace the cover ELEC CHARGING SYSTEM gt SYSTEM WIRING DIAGRAM 4 Rectifier regulator For T9 9 FT9 9A 2 Lighting For 9 9 9 9 8 2P connector For remote control model 4 7P coupler D For manual starter model 5 Battery For electrical starter model 6 Fuse G Green G W Green White R Red B Black 8 22 CHARGING SYSTEM CHARGING SYSTEM VOLTAGE 1 Measure e Lighting coil output Beyond specification Rectifier reg ulator rectifier measurement Below specification Replace light ing coil T9 9 FT9 9A Lighting coil output peak voltage minimum G G Cranking Open Connect 1 500 3 500 35 Lighti
50. Damage Replace SPIRAL SPRING 1 Inspect e Spiral spring Wear Damage Replace SHEAVE DRUM AND STARTER HOUSING 1 Inspect e Sheave drum 1 e Starter housing 0 Damage Replace PINION 1 Inspect e Pinion Damage Replace P MAS RECOIL STARTER 5 44 ASSEMBLY AND INSTALLATION 1 Install Starter housing D e Thrust washer Spiral spring 3 NOTE 1 After installing the new spiral spring cut the wire holding the spring When reusing the spiral spring set the leading end first in the housing and then fit one turn each time Use special care The spring can easily come off N WARNING The spiral spring may jump out so use spe cial care 2 Install Starter D Sheave drum 2 NOTE Make a knot on one end ePass the rope through the hole in the sheave drum and wind it 5 5 turns around the drum Place the rope in the recess on the drum 3 Install Bushing D e Roller 2 e Washer 3 e Spring washer 4 e Bolt 5 NOTE requis After installing route the starter rope between the starter roller and starter hous ing 4 Install e Starter housing NOTE Fit the spiral spring hook into the sheave drum groove RECOIL STARTER 5 Install e Drum stopper D e Stopper spring 0 e Collar 3 e Washer 4 e Cotter pin 6 6 Install e Cover e Spring washer 2 e Bolt 3
51. EL STRAINER 1 Inspect Fuel strainer Crack Leak Clog Replace E21854 0 FUEL PUMP 1 Inspect Check valve 1 e Diaphragm Damage Replace FUEL D FUEL SYSTEM 2 Inspect e Spring e Diaphragm spring 2 Damage Replace E22050 0 ASSEMBLY AND INSTALLATION FUEL PUMP 1 Install e Pump body e Diaphragm spring 2 e Spring 3 e Plunger 4 NOTE Align the recess plunger with the pump body 2 Install Diaphragm 1 Push the plunger hold the plate 2 and turn the diaphragm 90 3 Install e Pump cover 1 Check valve 2 e Plate 3 e Screw 2 NOTE Una Align the recess in the check valve and plate with the projection of the pump cover FUEL FUEL SYSTEM 4 Install e Pump body Pump cover 2 Screw 3 NOTE After installing check the smooth move ment of the plunger 5 Measure e Fuel pump operation Impossible to maintain the specified pressure for 10 sec Replace Measuring steps e Attach the Mity Vac to the inlet of the fuel pump Mity Vac YE 35956 90890 06756 e Cover the outlet of the fuel pump e Apply the specified pressure Specified pressure 50 kPa 0 5 kg cm 7 1 psi 6 Measure e Fuel pump operation Impossible to maintain the specified pressure for 10 sec Replace Measuring steps e Attach the Mity Vac to the outlet Mity Vac YB 35
52. ER PISTON AND CRANKSHAFT CE gt 4 Check Free play when the piston pin is in the piston There should be no noticeable play Free play exists Replace the pin and or piston PISTON RING 1 Measure Side clearance 2 Using feeler gauge 1 Out of specification Replace piston and or ring Side clearance 0 04 0 08 mm 0 002 0 003 in 0 03 0 07 mm 0 001 0 003 in 2 Measure e End gap Using a feeler gauge Out of specification Replace 0 20 0 70 0 008 0 028 0 15 0 30 mm 0 006 0 012 2nd 0 15 0 30 mm 0 006 0 012 Oil NOTE Install the piston ring into cylinder Push the ring with the piston crown CRANKSHAFT 1 Measure e Runout Use V blocks a dial gauge Out of specification Replace Runout 0 05 mm 0 002 in 5 12 5 13 CYLINDER PISTON AND CRANKSHAFT CE CRANKSHAFT MAIN BEARING CLEARANCE 1 Measure e Oil clearance main journal Out of specification Replace bear ing Main bearing clearance 0 000 0 027 mm 0 0000 0 0011 in Measurement steps Do not interchange the bearings They must be installed in their original posi tions or the correct oil clearance may not be obtained causing engine damage e Clean the bearings main journals and bearing portions of the crankcase and cylinder body e Place the cylinder body on a benc
53. FTER sasaged 5 27 CANSBAET ada 5 27 CYLINDER HEAD 5 28 VT 5 33 MALVE SPRING 5 34 ASSEMBLY AND INSTALLATION eee nennen 5 35 OIL PUMP ASSEMBLY Seco Ho Qon S RES 5 35 CYEINDER HEAD apen na a amen abad 5 35 CYLINDER HEAD COVER 5 39 INTAKE MANIFOLD dans UN ga kan 5 39 QIL SEPARA TOR GANG tie 5 39 RECOIL STARTER 5 41 PREPARATION FOR REMOVAL REENEN 5 41 REMOVAL POINTS Ee 5 42 STARTER guerten 5 42 SPIRAL SPRING C 5 43 INSPECTION ika anga gain nah kn ian ceo aga aa wan 5 43 RR RE 5 43 SPRING E 5 43 SHEAVE DRUM AND STARTER 5 43 PINON ME 5 43 POWER UNIT REMOVAL ED POWER UNIT REMOVAL PREPARATION FOR REMOVAL Drain the engine oil Disconnect the oil lamp lead Remove the top cowling Remove the oil level gauge Remove the terminal cover Disconnect the stop switch leads 21 Nm 2 1 m kg 15 ft Ib 5 1 POWER UNIT REMOVAL CE NOTE ON REMOVAL AND REASSEMBLY e After removing the power unit protect the lubricating system including the oil pan and reli
54. Friction piece 2 e Spring 3 e Washer 4 e Washer nylon 5 e Screw 8 e Handle 7 NOTE Fit the handle grip correctly 3 Install e Steering bracket 1 e Bushing 2 e Washer nylon 3 e Washer e Wave washer 5 e Ring nut 6 e Tube 7 NOTE Pass the throttle cable through the steering handle on the steering bracket 4 Tighten e Ring nut NOTE nn Screw in the ring nut by hand until tight and fit a slotted head screwdriver into the slit in the ring nut Lock the screwdriver with the steering bracket and tighten the ring nut moving the steering handle back and forth 7 23 STEERING HANDLE ED 5 Install e NutO Bracket 2 3 Throttle cable Stopper bracket 5 e Fitting plate 7 6 Adjust e Throttle cable length Refer to page 3 15 7 24 CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL 6 2 22 8 1 MANUAL STARTER MODEL eese 8 1 ELECTRICAL STARTER 1111 0 nnn nne 8 2 REMOTE CONTROL MODELS 9 9 8 3 REMOTE CONTROL MODELS F8BE F9 9BE eene 8 4 ELECTRICAL 6 5 8 INSPECTION aga UN an a a a a KE E SEAN GENEA
55. GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Worldwide USA Overall length Overail width Overall height 5 1 5 L X S L X Boat transom height Weight without propeller Unit Model F8BEH FBBMH F8BE mm in mm in mm in mm in mm in mm in mm in mm in kg Ib kg Ib kg Ib 993 39 1 430 16 9 1 004 39 5 1 131 44 5 381 15 0 508 20 0 43 0 95 44 0 97 575 22 6 325 12 8 43 5 96 41 5 91 44 5 98 42 5 94 Maximum output Speed range at full throttle Speed range at idling Speed range at trolling Maximum fuel consumption Engine type Number of cylinders Total displacement Bore and stroke Compression ratio Spark plug Number of carburetor Carburetor starting system Manifold arrangement Exhaust system Lubrication system Ignition system Starting system kW hp G rpm rpm rpm rpm h US Imp cm cu in mm x mm in x in NGK number 5 9 8 5 000 4 500 5 500 950 50 850 50 3 3 0 87 0 73 5500 4 stroke 2 232 14 16 59 0 x 42 4 2 32 x 1 67 9 3 1 5 5 1 Prime start Cross flow Through propeller boss Wet sump CDI Electric starter Manual stater Fuel rating type Engine oil pan capacity Gear oil type Gear oil capacity Tilt angle at 12 boat transom Tilt up ang
56. GNITION SYSTEM Ignition timing full retard full advance Piston position CDI output peak voltage minimum open connected B Charge coll output peak voltage minimum open connected Br L Pulser coil output peak voltage minimum open connected W R B Spark plug gap Degrees Degrees mm in 5 3 BTDC 35 3 4 78 0 76 0 188 0 030 V cranking V cranking V 1 500 r min V 3 500 r min V cranking V cranking V 1 500 r min V 3 500 r min V cranking V cranking V 1 500 r min V 3 500 r min 0 6 0 7 0 024 0 028 IGNITION CONTROL SYSTEM pressure switch continue discontinue Oil pressure indicator lamp output kPa kg cm psi kPa kg cm psi V 0 10 0 0 1 0 1 4 60 10 0 6 0 1 8 5 1 4 More than 65 STARTING SYSTEM Fuse Starter motor Output Brush length Commutator diameter Commutator under cut Rating V A kW mm in mm 12 20 0 6 9 0 12 5 0 35 0 49 29 0 30 0 1 14 1 18 0 2 0 8 0 01 0 03 30 SYSTEM Lighting output mm in Sec 6 6 G G V cranking V cranking V 1500 r min V 3500 r min 9 0 8 0 9 0 8 0 35 30 75 65 ENRICHMENT CONTROL SYSTEM Valve heater coil resistance at 20 C 68 F 1 Before top dead center 0 24 0 36 MAINTENANCE SPECIFICATIONS
57. I unit e Ignition coil e Rectifier regulator 1st 6 Nm 0 6 m kg 4 3 ft Ib 2nd 12 Nm 1 2 m kg 8 7 ft Ib PE 23 Nm 23m kg TAP Ist 15 Nm 1 5 m kg 11 Ib 2nd 30 Nm 3 0 m kg 23 ft Ib D 100 10 0 kg 72 ft Ib CYLINDER PISTON gt NOTE REMOVAL REASSEMBLY e Before servicing clean the power unit Install the piston and connecting rode in their original cylinders e Each connecting rod and its cap should be kept as a set do not interchange them between cylinders Extent of removal Thermostat removal 2 Stator assembly removal 3 Piston removal 4 Cylinder body disassembly Extent of removal Part name X Remarks H Thermostat cover i Thermostat Nut Flywhee magneto Refer to REMOVAL POINTS Stator assembly Stator bracket Timing belt Refer to REMOVAL POINTS Bolt 10 Crankcase 1 Bolt 4 Connecting cap 2 Crankshaft 1 Drive gear 1 Refer to REMOVAL POINTS Circlip 4 Piston pin 2 Piston 2 Exhaust cover outer 1 Exhaust cover inner 1 Cylinder body 1 REMOVAL POINTS FLYWHEEL MAGNETO 1 Remove e Nut D Flywheel holder YB 6139 90890 06522 2 Remove e Flywheel magneto 1 Flywheel puller YB 6117 90890 06521 5 7 CYLINDER PISTON AND CE 5 8 TIMING BELT 1 Remove e Timing belt
58. NATION OF CRANKCASE AND BEARING 5 14 CONNECTING ROD OIL eene 5 15 ASSEMBLY AND INSTALLATION 2 0 444242 nennen nennen 5 16 PISTON AND CONNECTING nennen 5 16 CYLINDER AND 5 16 EXHAUST COVER trice ee CNN NANA AN NANA ngon 5 18 TIMING BEET DR 5 19 OIL PRESSURE SWITCH sise error 5 20 THERMOSTAT Ed 5 21 STARTER MOTOR 5 21 FLYWHEEL MAGNETO habeh 5 22 we CYLINDER HEAD VALVE CAMSHAFT 5 23 PREPARATION FOR REMOVAL adorate etn pensa ohnehin erui nnn 5 23 NOTE ON REMOVAL AND 5 5 24 REMOVAL POINTS eere cient Seed ege CRAP AES 5 24 CYLINDER HEAD utu hann db vo E 5 24 RI SIAR E 5 24 DRIVEN GEAR EE 5 25 VALVE a wan Aa Na ENGGON 5 25 INSPECTION AND REPAIR recen tranne erp tape Rain restes 5 26 OIL SEPARATOR EY icta re atr triste 5 26 OVE PUMP Ee deeg 5 26 ROCKER SHAFT AND ROCKER 5 26 VALVE LI
59. NOTE LLL Remove the timing belt at the driven gear side DRIVE GEAR 1 Remove e Lock nut e Drive gear D Shaft holder 90890 06069 NOTE Before removing the lock nut straighten the lock washer tab INSPECTION AND REPAIR FLYWHEEL MAGNETO 1 Inspect e Flywheel teeth Wear Damage Replace DRIVE GEAR 1 Remove e Drive gear Wear Damage Replace CYLINDER PISTON CRANKSHAFT CE TIMING BELT 1 Inspect e Timing belt Stretch Wear Damage Replace THERMOSTAT 1 Inspect e Thermostat Stick Damage Replace 2 Measure e Valve opening temperature e Valve lift Out of specification Replace Valve lift temperature Before 58 62 136 144 F Above 70 C Min 3 mm 0 12 in 0 mm 0 in Measurement steps e Suspend the thermostat in a vessel e Place a reliable thermometer in the water e Slowly heat the water e Observe the thermometer while con tinually stirring the water CYLINDER 1 Inspect e Water jacket Mineral deposits Corrosion Clean e Cylinder inner surface Score marks Repair or replace Use 600 800 grit wet sandpaper 5 9 CYLINDER PISTON AND CRANKSHAFT CED 20mm 0 8in 60mm 2 4in 5 10 2 Measure e Cylinder bore D Use cylinder gauge Out of specification Rebore Replace NOTE cylinder D parallel Then find the average of th
60. OWER UNIT BRACKET UNIT ELECTRICAL SYSTEM TROUBLE ANALYSIS SE ZE gt P TRBL c 1 GENERAL INFORMATION IDENTIFICATION nn annee anda tentes 1 1 SERIAL NUMBER it aaa 1 1 STARTING SERIAL NUMBERS 1 1 SAFETY WHILE WORKING 1 2 FORE PREVENTION beet 1 2 VENTILATION E 1 2 SELF PROTEGCTION at aaa des 1 2 OILS GREASES AND SEALING FLUIDS eren 1 2 GOOD WORKING PRACTICES EE 1 3 DISASSEMBLY AND ASSEMBLY 1 4 SPECIAL TOOLS EE 1 5 MEASURING EE 1 5 CE IDENTIFICATION CE A60000 1 IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket NOTE For USA model As an anti theft measure a special label which the outboard motor serial number is stamped is bonded to the portside of the clamp bracket The label is specially treated so that peeling it off causes cranks across 3 D Tee the serial number 4 YAMAHA MOTOR CO OH MADE JAPAN 4 Model 8 Transom height Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows Model Approved Serial model No Number Approved Serial model No Number USA CANADA USA CANADA
61. Piston valve Wear Damage Replace 4 10 FUEL CARBURETOR GES 2 Measure e Electrothermal valve resistance Out of specification Replace Electrothermal valve resistance Black Black 4 8 7 2 Q at 20 C 68 F 3 Check Piston valve height No change Replace Checking steps Connect the 12 V battery e Wait for several minutes Check the piston height E34050 0 ASSEMBLY AND INSTALLATION 1 Install e Float chamber 1 e Spring e Diaphragm 3 e Cover 4 e Screw 5 2 Install e Pilot jet D e O ring 0 e Seal cap e Main nozzle 2 NOTE a Position the nozzle so that the cutaway of the nozzle faces the intake manifold 3 Install e Screw 1 e Main jet NOTE Align the slit in the main nozzle with the screw hole in the carburetor 4 11 FUEL CARBURETOR 4 12 4 Install Needle valve 1 Float Install the valve into the float hinge 5 Install Float 1 0 NOTE 22 After_installing check the smooth ment of the float 6 Measure e Float height Out of specification Fold the tab to adjust float arm height NOTE The float should resting needle valve but not compressing the needle valve 7 Install e O ring D e Drain screw 2 e Gasket 3 e Drain screw 2 FUEL CARBURETOR
62. R REMOVAL WARNING Remove the power unit e Wear proper safety goggle and gloves Remove the flywheel magneto for protecting your eyes and hands Use care the spiral jumps out and may injure a person e When removing the sheave drum use care so that the spiral spring does not jump out RECOIL STARTER CE Extent of removal Recoil starter removal Starter rope removal 3 Recoil starter disassembly Remarks et lt Extent of removal Part name Bolt Recoil starter assembly Bolt Guide plate Bolt Pin Pinion Bolt Stopper arm Bolt Cover Cotter pin Drum stopper Bolt Roller Sheave drum Starter rope Spiral spring Loosen the lock nut COON OT amp WN Refer to REMOVAL POINTS ech rh sch OO sch gt 9 Refer to REMOVAL POINTS REMOVAL POINTS STARTER ROPE 1 Remove Sheave drum 1 Starter NOTE Insert a slotted head screwdriver into the hole in the sheave drum and remove the spiral spring from the sheave drum by pushing the spring 5 42 SPIRAL SPRING 1 Remove Spiral spring 1 NOTE ee Hold the starter housing 2 with the spiral spring facing downward Insert a standard head screw driver into the hole in the sheave drum shaft and push the spiral spring out INSPECTION STARTER ROPE 1 Inspect e Starter rope
63. T ee HA a ue Ee een 6 10 REVERSE GEAR ore rare is eto ced ba ch atta une poena e un ebegan age nk nanges abasa 6 10 OIL reor enn roro ab den ba oen enano eoa 6 11 LOWER Re 6 11 SHIM SELECTION For USA and 6 15 SHIM SELECTION Except for USA and 6 17 BACKLASH MEASUREMENT 6 19 WATER PUMP E 6 23 LOWER UNIT Ehe Se 6 23 PROPELLER eegent pares 6 24 LOWR LOWER UNIT LOWER UNIT PREPARATION FOR REMOVAL T9 9 FT9 9A Drain the gear oil 26 Nm 2 6 m kg 19 ft Ib B 21 Nm 2 1 m kg 15 ft Ib 6 1 A 23748 2 3 a es SX y KO LOWR de LOWER UNIT CE NOTE ON REMOVAL AND REASSEMBLY e Tilt up the engine a little this provides easier oil draining e Remove any gasket adhered to the contacting surface e The shim pack will be reused therefore use care not to damage when removing e For reassembly the removed parts should be cleaned with solvent Extent of removal D Lower unit removal 2 remove 3 Lower unit disassembly Extent of removal Part name 1 Cotter Propeller D Spacer Lock nut Nut Bolt Lower unit Bolt Water pump housing Impeller Woodruff key Gasket Outer plate Screw S
64. YAMAHA a samen ate GEN _ EE T9 9W F9 9W 20000 1 This manual has been prepared Yamaha Motor Company Ltd primarily for use Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment It has been written to suit the needs of persons who have basic understanding of the mechanical and electrical concepts and procedures inherent in the work for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use Because the Yamaha Motor Company Ltd has a policy of continuously improving its prod ucts models may differ in detail from the descriptions and illustrations given in this publica tion Use only latest edition of this manual Authorized Yamaha dealers are notified peri odically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual A10001 0 T9 9W F9 9W SERVICE MANUAL 1997 Yamaha Motor Co Ltd 1st Edition January 1998 rights reserved No part of this publication may be reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of the copyright holder Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature Printed in U S A P N
65. ace upward 2 Install Lock washer 1 e Nut NOTE the projection of the lock to be matched with the mark e After tightening the nut bend the lock washer over the nut Shaft holder 90890 06069 E 23 Nm 2 3 m kg 17 ft Ib 3 Align e Drive gear mark 8 e Cylinder body mark 2 Turn the crankshaft clockwise CYLINDER PISTON CRANKSHAFT ED YAMAHA 4 Align Driven gear mark Cylinder head mark NOTE Turn the camshaft clockwise 5 Install e Timing belt e Protect the belt from water and oil e Do not use an iron lever when installing the belt e Use care not to scratch the belt NOTE emm e Make sure that the YAMAHA mark is not inverted ePlace the timing belt around the drive gear and then around the driven gear e When placing the timing belt around the driven gear lock both drive and driven gears so that they do not turn OIL PRESSURE SWITCH 1 Install e Oil pressure switch 1 NS Oil pressure switch 22 9 Nm 0 9 m 6 5 ft Ib 2 Install Switch lead 0 Screw 3 Cover 4 NOTES IL C Route the switch lead over the recess in the cylinder body BN Screw 2 Nm 0 2 m kg 1 4 ft Ib CYLINDER PISTON AND CRANKSHAFT gt 5 21 THERMOSTAT 1 Install Thermostat 1 e Gasket 2 e Thermostat cover 3 e Bolt
66. als of the starter relay as shown e Connect a 12V battery Brown lead Positive terminal Black lead 2 Negative terminal e Check that there is continuity between the starter relay terminals 8 18 ELEC STARTER MOTOR STARTER MOTOR Extent of removal Starter motor disassembly Part name 4 Nm 0 4 mekg 2 9 ftelb Brush disassembly Remarks Clip Pinion stopper Spring Pinion Through bolt Always use a new circlip Refer to REMOVAL POINTS Rear cover Washer Stator Armature Washer t 0 25 mm t 2 0 mm Washer Washer Front cover Screw Brush holder t 0 15 mm t 1 0 mm Brush spring Brush 8 19 ae EG lt gt SERVICE 5 removal 1 Remove e Clip D NOTE Using a pry bar pry off the clip Pinion inspection 1 Inspect e Pinion teeth Wear Damage Replace 2 Check e Clutch movement Damage Replace NOTE Rotate the clockwise and check that it moves freely Also try to rotate the pinion counterclockwise and confirm that it locks Armature inspection 1 Inspect e Commutator Dirty Clean with 600 abrasive paper 2 Measure e Commutator diameter Out of specification Replace 8 20 8 21 Check Commutator under cut
67. c Always follow these preventive measures e Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury e Wear protective eye gear when handling or working near batteries Antidote EXTERNAL e SKIN Wash with water EYES with water for 15 minutes and get immediate medical attention Antidote INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries generate explosive hydrogen gas Always follow these preventive measures Charge batteries in a well ventilated area e Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes e DO NOT SMOKE when charging han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN NOTE 222 Batteries very among manufacturers Therefore the following procedures may not always apply Consult your battery manufacturer s instructions e Disconnect the black negative lead first to prevent the risk of shorting 1 Inspect Battery fluid level Battery fluid specific gravity E ADJ PERIODIC SERVICE ENGINE LEVEL CHECK 1 Place the outboard motor in an upright position 2 Check Engine oil level Oil level should be between the maxi mum F and minimum L marks Oil level is low Add oil to proper level Recommended oil SAE 10 30
68. case 24 Pinion height gauge E 9 9 6299 4 F9 9 34232 e Measure the clearance and determine the shim thickness Less than To be decreased by 0 45 mm 0 50 measurement than increased 0 55 mm measurement 0 50 Less than To be decreased by 1 15 mm 1 20 measurement than To be increased 1 25 mm measurement 1 20 LOWR amp LOWER UNIT 6 16 Example F8B F9 9 F9 9B If measurement 1 02 mm Decrease shim thickness by 1 20 1 02 0 18 mm If measurement 1 32 mm Increase shim thickness by 1 32 1 20 Available shim thickness T9 9 0 10 0 14 0 18 and 0 50 mm F9 9 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm NOTE a __ ___ eForward and reverse shim selection will be done by BACKLASH MEASURE MENT section Since the smallest shim available is 0 10 mm if the measurement is between T9 9 0 45 and 0 55 mm or F9 9 1 15 and 1 25 mm do not change the shim L LOWER UNIT 6 17 SHIM SELECTION Except for USA and CANADA NOTE eWhen reassembling lower unit with the original gear case and Inner parts shim selection is not reguired eWhen the gear case or inner parts carry out the shim selection 1 Adjust Pinion shim thickness Adjustment steps e Measure the thicknesses of bearing and washer OZ Digital caliper
69. ch position Yellow 8 12 IGNITION CONTROL SYSTEM IGNITION CONTROL SYSTEM WIRING DIAGRAM B L P CDI unit 0 Oil pressure indicator lamp 3 Oil pressure switch Except for remote model For remote model 8 13 Black Blue Pink Yellow Red OIL PRESSURE SWITCH 1 Measure e Continuity Out of specification Replace Measurement steps Connect the Mity 1 Connect the tester 2 ty Vac YB 35956 90890 06756 the specified pressure switch 0 10 0 0 1 2 Continuity 0 1 4 psi 60 10 kPa 0 6 0 1 Discontinuity 8 5 1 4 psi OIL PRESSURE INDICATOR LAMP 1 Check e Oil pressure indicator lamp operation Out of specification Replace Checking steps Connect the digital tester for engine side leads D Pink lead Positive terminal 2 Black lead Negative terminal Start the engine e Check the voltage of output Cl Output voltage mi More than AC 65V Stop the engine Connect the oil pressure indicator lamp to engine side leads e Start the engine e Check the oil pressure indicator lamp for green indication 8 14 IGNITION CONTROL SYSTEM 8 15 WARNING careful not to touch the ignition sys tem leads while performing testing High voltage electric shock may cau
70. coil resistance Black B Black B 0 24 0 36 at 20 C 68 F NOTE When measuring the resistance of 10 or less using the digital tester the correct measurement cannot be obtained Refer to Lower resistance measurement ELECTROTHERMAL VALVE Refer to CARBURETOR in chapter 4 8 25 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ioes rire roii timete ng Seg ngakena uan den 9 1 TROUBLE ANALYSIS CHART dier 9 1 ord ANLS TROUBLE ANALYSIS CED TROUBLE ANALYSIS NOTE The following items should be checked before the Trouble analysis chart is consulted 1 The battery is charged and its specific gravity is within specification 2 There are no incorrect wiring connections 3 Wiring connections are properly secured and are not rusty 4 The lanyard is attached to the engine stop switch 5 The shift position is neutral 6 Fuel is reaching the carburetor 7 The rigging and engine settings are correct 8 Engine is free from any Hull problem TROUBLE ANALYSIS CHART Problem Reference Related part chapter ENGINE WILL NOT START ROUGH IDLING ENGINE STALLS POOR DECELERATION ENGINE WILL NOT STOP POOR PERFORMANCE OVERHEATING LOOSE STEERING LOOSE TILT HOLDING SHIFTING DIFFICULT IRREGULAR WARNING INDICATION POOR BATTERY CHARGING FUEL SYSTEM Fuel hose Fuel joint Fuel filter Fuel pump
71. e a 30 45 and 85 valve seat cut ter 02 Valve seat cutter set 91043 90890 06803 When twisting cutter keep an even down ward pressure 4 5 kg to prevent chatter marks 5 30 Pown CYLINDER HEAD VALVE AND CAMSHAFT CED Cut sections as follows Resurfacing steps Valve seat is centered on valve face but it is too wide Valve seat cutter set Desired result 85 cutter To reduce valve seat width Valve seat is in middle of the valve face but it is too narrow Valve seat cutter set Desired result Valve seat is too narrow and it is near valve margin Valve seat cutter set Desired result 85 cutter To center the first seat and to achieve its width Valve seat is too narrow and it is located near the bottom edge of the valve face Valve seat cutter set 30 cutter To center the pea seat and to increase its width 5 31 CYLINDER HEAD VALVE CAMSHAFT gt 9 Valve Valve seat NOTE After refacing the valve seat the valve and valve guide the valve seat and valve face should be lapped Lapping steps coarse lapping compound to the valve face Be sure no compound enters the gap between the valve stem and guide e Apply a molybdenum disulfide oil to the valve stem Install the valve into the cylinder head Turn the valve until the valve
72. e gasket surfaces by the screw driver ROCKER SHAFT 1 Loosen Lock nut Adjust gt Vatve adjuster 0035 00690 01311 4 50001 1 4 SYMBOLS Symbols to designed as thumb tabs to indicate the content of a chapter General Information Specifications 9 Periodic Inspection and Adjustment Fuel System 5 Power Unit 6 Lower Unit 7 Bracket Unit Electrical System 9 Trouble analysis Symbols to indicate specific data Special Tool Specified liquid 2 Specified grease 49 Specified engine speed Specified torque 9 Specified measurement Specified electrical value Resistance Voltage V Electric current Symbol 2 to in an exploded diagram indicate grade of lubricant and location of lubrication point 2 Apply Yamaha engine oil Apply Yamaha gear case lubricant Apply molybdenum disulfide oil Apply water resistant grease Yamaha marine grease A Yamaha marine grease Symbols 6 to in an exploded diagram indicate grade of sealing or locking agent and location of application point 6 Apply Gasket Maker Apply LOCTITE No 271 Red LOCTITE 63 Apply LOCTITE No 242 Blue LOCTITE 6 Apply LOCTITE No 572 NOTE In this manual the above symbols may not be used in every case INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT is L
73. e lever is on the full closed position e Check that the throttle link 2 has free play on the throttle lever side 3 14 INSP ADJ PERIODIC SERVICE 3 15 CED THROTTLE CABLE ADJUSTMENT NOTE _ 6 8 Engine speed throttle link should be adjusted properly before adjusting the throttle cable 1 Check e Full open position Incorrect Adjust Checking steps e Turn the throttle grip to the full open side Check the throttle lever to the full open position 2 Adjust Throttle cable length Adjustment steps Loosen the lock nut Remove the cable end 0 Pull the accelerator arm to the full open side Turn the cable end in or out until adjustment is suitable Fit the cable end to the pin marked with M on the accelerator arm Push the cable end stopper to secure the cable end Tighten the lock nut IGNITION TIMING CHECK NOTE eebe Ignition timing is advanced by the CDI unit automatically Therefore only the checking procedure is shown in this section 1 Attach Tachometer Timing light To spark plug lead for 1 cylinder 2 Tachometer YU 8036 A 90890 06760 Timing light YU 33277 A 90890 03141 2 Check e Ignition timing Incorrect firing range Check fly wheel and or pickup assembly Checking steps e Warm up the engine and set it at the specified speed Engine speed T9 9 FT
74. e measurement Standard Wear limit Cylinder 59 00 59 02 mm 59 1 mm bore D 2 323 2 324 in 2 326 Cylinder 0 08 mm taper T 0 003 in D Maximum Dia D Dg T Maximum D or Dj Minimum D PISTON 1 Inspect e Piston wall Wear Scratch Damage Replace 2 Measure Piston diameter Use a micrometer Out of specification Replace Distance Piston dia 10 mm 58 950 58 965 mm 0 39 in 2 3209 2 3215 in Oversize 1 159 25 mm 2 333 2 59 50 mm 2 343 in Standard Except for USA NOTE e Measure specific distance 8 from the bot tom edge CYLINDER PISTON AND CE PISTON CLEARANCE 1 Calculate e Piston clearance Out of specification Replace piston and piston ring and or cylinder PISTON CYLINDER PISTON CLEARANCE _ BORE DIAMETER Piston clearance 0 035 0 065 mm 0 0014 0 0026 in PISTON PIN 1 Inspect e Piston pin Signs of heat discoloration gt Replace 2 Measure e Piston pin diameter Use a micrometer 1 Out of specification Replace Piston pin diameter 13 996 14 000 mm 0 5510 0 5512 in 3 Check e Free play when the piston pin is into small end of connecting rod There should be no noticeable play Free play exists the pin and or connecting rod as required 5 11 CYLIND
75. eege 7 13 CLAMP AND SWIVEL BRACKET nn eene nnne enn 7 13 IKEA 7 13 ASSEMBLY AND INSTALLATION 7 13 STEERING 25444552545003 gege EEN Eege sy PRG 7 16 PREPARATION FOR REMOVAL T9 9 FT9 9A F8B F9 9 F9 9B for Europe and Canada 7 16 PREPARATION FOR REMOVAL F9 9 F9 9B except for Europe and 7 18 REMOVALS POINTS ett arta venda ek aro ds bua dui UD SUA 7 19 RING NUT 2 ouo creans UR EH Eo EVERE ei 7 19 INSPECTION vice ird d eR 7 19 SHIFT AND THROTTLE CABLES dean aras aanns 7 19 STEERING HANDLE edu 7 19 ASSEMBLY AND enn 7 20 STEERING HANDLE 9 9 9 9 F8B F9 9 F9 9B for Europe and Canada 7 20 STEERING HANDLE F9 9 F9 9B except for Europe and 7 22 BRKT UPPER CASING AND BOTTOM COWLING CED UPPER CASING AND BOTTOM COWLING PREPARATION FOR REMOVAL Remove the power unit Remove the ground lead at the swivel bracket side 3 Nm 0 3 m kg 2 2 ft Ib 5 Nm 0 5 m kg 3 6 ft Ib 8 Nm 0 8 m kg 5 8 ft Ib 10 Nm 1 0 m kg 7 3 ft Ib 12 Nm 1 2 m kg 8 7 ft Ib 21 Nm 2 1 m kg 15 ft Ib 25 Nm 2 5 m kg 18 ft Ib
76. ef valve from dust and dirt Extent of removal Power unit removal Extent of removal Part name Remarks 1 Fuel hose Blow by hose Water hose Water hose Water hose Screw Hinge pin Flywheel cover Grip cover Starter grip Neutral starting device cable Battery lead Screw Apron Bolt Power unit EE 2 3 4 6 7 8 9 Recoil starter model only Refer to REMOVAL POINTS j d sch l3 l3 la Electric starter model only MM REMOVAL POINTS STARTER GRIP 1 Remove e Starter grip NOTE nt mn When removing the starter grip pull out the starter rope and make a knot in the rope so that the rope is not pulled into the starter STOP WIRE 1 Remove S A e Lock nut D Y Start in gear protection cable 2 RAVE 22 Do stop wire before ing the starter grip or it is impossible to pull out the starter when removing it 5 2 INSTALLATION POWER UNIT 1 Apply e Gasket Maker Onto both faces of the gasket NOTE na Clean the contacting surface of crankcase 2 Install e Gasket 1 e Dowel pin 2 e O ring 3 e Seal 3 Install e Power unit 1 NOTE eS elt the crankshaft splines do not mesh with the drive shaft splines turn the flywheel a little so that they can mesh e Use care not to pinch the lead and pipe 4 Install Bolt EN
77. ete Propeller shaft complete Nut Pinion gear Thrust bearing Pinion gear shim Drive shaft Forward gear complete Oil seal housing Sleeve Needle bearing Bearing outer race Forward gear shim Reverse gear Reverse gear shim Ball bearing Needle bearing Cross pin ring Cross pin Dog clutch Taper roller bearing Forward gear Refer to REMOVAL POINTS Refer to REMOVAL POINTS Refer to REMOVAL POINTS Refer to REMOVAL POINTS Refer to REMOVAL POINTS Refer to REMOVAL POINTS sch ss sch sch 2l sl sch MH sch sch NM ms fF sch PF sch oa Refer to REMOVAL POINTS 6 4 Loun de LOWER UNIT CE REMOVAL POINTS SHIFT SHAFT 1 Remove e Screw 1 e Bracket 2 e Shift shaft 3 NOTE Push the projections of the bracket evenly as shown in the illustration and pull the bracket up PINION GEAR 1 Remove e Nut D e Pinion gear 2 Pinion nut holder YB 6078 Drive shaft holder YB 6228 90890 06515 NEEDLE BEARING 1 Remove e Needle bearing 1 tZ Drive rod 6229 90890 06602 Needle bearing attachment T9 9 FT9 9A YB 6298 90890 06618 F9 9 F9 9B YB 6230 90890 06617 a BEARING OUTER RACE reg X 1 Remove e Bearing outer 1 e Forward gear shim F8B F9 9 F9 9B only T9 9 FT9 9A Stopper guide plate
78. ew 2 Wear Damage Replace 3 Check e Free play when the rocker shaft is in place of the rocker arm There should be no noticeable play Free play exists Replace the rocker shaft and or rocker arm VALVE LIFTER 1 Inspect e Valve lifter Scratch Damage Replace CAMSHAFT 1 Inspect e Cam lobes Pitting Scratch Blue discoloration gt Replace 2 Measure Cam lobe length e Cam lobe length Out of specification Replace IN 24 541 24 641 mm 0 966 0 970 in 24 578 24 678 mm 0 968 0 972 in 6 IN 20 137 20 237 mm 0 793 0 797 20 178 20 278 mm 0 794 0 798 CYLINDER 1 Inspect Water jacket Mineral deposits Corrosion Clean Combustion chamber Carbon deposits Clean Use a round scraper 2 Measure Cylinder head warpage Use a straightedge and thickness gauge Out of specification Replace the valve Warpage limit 0 1 mm 0 004 in Resurfacing steps e Place a 400 600 grit wet sandpaper on the surface plate e Resurface the head using a figure eight sanding pattern NOTE Rotate the head several times to avoid removing too much material from one side 3 Inspect e Valve guide 1 Wear Damage Replace 5 28 CYLINDER HEAD VALVE AND CES 4 Measure e Valve guide bore 8 Use a bore gauge Out of specification Replace the valve guide Valve guide
79. g the pin 7 13 BRKT BRACKET UNIT CED 3 Install T9 9 FT9 9A models Rod long Rod short 2 e Tilt lever 3 e Pin e Clip 4 Install e Rod short e Spring e Lever 3 5 Install e Clamp bolt 1 e Bushing 0 6 Install e Clamp bolt e Lever 2 e Bushing short 3 e Bushing long NOTE Install the bushings with the punch mark side inward 7 Install Plate D Control plate Screw 3 e Nut 2 e Bolt 5 e Washer 6 e Nut 0 7 14 7 15 8 Install e Lock plate e Washer 2 e Bolt 3 e Washer plate 4 e Nut 5 NA Nut 12 Nm 1 2 m kg 8 7 ft ib 9 Install e Washer 1 e Clamp bracket 2 e Bolt 3 e Collar 2 e Washer 5 e Nut e Plate 7 e Nut N Nut clamp bolt 22 45 Nm 4 5 m kg 32 5 ft Ib 10 Install e D e Washer wave 2 e Washer plate 3 e Nut 2 11 Install e Steering shaft 1 e Pin e Steering bracket 3 e Bolt 2 e Washer 5 e Bushing 6 XY Bolt EH 13 Nm 1 3 m kg 9 4 ft Ib 12 Install e Friction piece 1 e Bushing e O ring 3 e Bushing 2 e Ground lead 5 BRKT E STEERING HANDLE CED K16050 0 STEERING HANDLE PREPARATION FOR REMOVAL T9 9 FT9 9A F8B F9 9 F9 9B for Europe and Canada Disconnect the control cables at engine side Disconnect the wire leads 4 Nm 0 4 m kg 2 9 ft Ib 7 16 BRKT bd
80. gged belt 0 10 0 0 4 SPEC En MAINTENANCE SPECIFICATIONS gt kem Model F8B T9 9 FT9 9A F9 9 F9 9B VALVE VALVE SEAT VALVE GUIDE Valve clearance cold IN 0 15 0 20 0 0059 0 0079 EX 0 20 0 25 0 0079 0 0098 Valve dimensions Head dia 25 9 26 1 1 020 1 028 21 9 22 1 0 862 0 870 Face width 1 98 3 11 0 078 0 122 1 98 3 11 0 078 0 122 C Seat width F 0 6 0 8 0 024 0 031 0 6 0 8 0 024 0 031 D Margin thickness 0 5 0 9 0 020 0 035 0 5 0 9 0 020 0 035 Stem outside dia 5 475 5 490 0 2156 0 2161 5 460 5 475 0 2150 0 2156 Guide inside dia 5 500 5 512 0 2165 0 2170 5 500 5 512 0 2165 0 2170 Stem to guide clearance 0 010 0 037 0 0004 0 0015 0 025 0 052 0 0010 0 0020 Stem runout limit 0 016 0 0006 2 5 VALVE SPRING Set length valve closed IN mm in EX mm in Compressible forth IN N kg Ib installed EX kg lb Tilt limit IN mm mm Direction of winding Model MAINTENANCE SPECIFICATIONS T9 9 FT9 9A F9 9 F9 9B 24 4 0 96 24 4 0 96 90 100 9 0 10 0 19 8 22 0 90 100 9 0 10 0 19 8 22 0 1 1 0 043 1 1 0 043 Left hand mm in Measuring point Oversize 151 mm 2 mm PISTON RING
81. gt 8 Install e Filter e Check valve 2 e Gasket 3 e Float chamber 4 e Screw 5 9 Install e O ring D e Electrothermal valve 2 e Plate 3 e Screw 2 10 Instail Except for USA and Switzerland e Spring D e Pilot screw 2 e Seal cap 3 NOTE 2 After placing the seal the pilot screw fit it to the groove the carburetor 11 Adjust Except for USA and Switzerland Pilot screw 1 Adjustment steps e Screw in the pilot screw until it is lightly seated Back out by the specified number of turns Pilot screw Except for USA and Switzerland T9 9 FT9 9A 3 1 turns out F8B F9 9 F9 9B 3 1 2 1 turns out 12 Install e Rod D e Washer 2 e Clip 3 NOTE Always use a new clip 4 13 FUEL CARBURETOR 13 Install Gasket D e Spacer Washer 3 e Nut 2 14 Connect e Throttle link e Fuel hose 2 15 Connect e Wire lead D 16 install e Gasket 1 e Funnel 2 e Screw 3 17 Adjust Idle speed Refer to page 3 13 4 14 5 POWER UNIT POWER UNIT 5 1 PREPARATION FOR 1 1 11 1 1 4 1 24 4 5 1 NOTE ON REMOVAL AND 8 5 2 REMOVAL POINTS 5555445989009998 9940 Pada nu ENEE 5 2
82. h in an upside down position e install half of the bearings D and crankshaft 2 into the cylinder body 3 NOTE Align the projection of the bearing with the notch in the cylinder body e Put a piece of plastigauge onto the crankshaft journal surface e install half of the bearings into the crankcase NOTE e Align the projection of the bearing with the notch in the crankcase e Do not turn crankshaft until clearance measurement has been completed CYLINDER PISTON CED Tighten the bolts in sequence and two steps of torque Bolt M8 1st 15 Nm 1 5 m kg 11 ft Ib 2nd 30 Nm 3 0 m kg 22 ft Ib Bolt M6 1st 6 Nm 0 6 m kg 4 3 ft Ib 2nd 12 Nm 1 2 m kg 8 7 ft Ib Remove the bolts and the crankcase Measure the compressed plastigauge width on each main journal COMBINATION OF CRANKCASE AND BEARING 1 Crankcase Mark Housing size 33 032 33 040 mm 1 3005 1 3008 in 33 024 33 032 mm 1 3002 1 3005 in 33 016 33 024 mm 1 2998 1 3002 in 2 Bearing Indication Bearing size 1 508 1 512 mm 0 0594 0 0595 in 1 504 1 508 mm 0 0592 0 0594 in 1 500 1 504 mm 0 0591 0 0592 in 3 Combination Combine the crankcase and bearing by the following chart Crankcase mark A Bearing indication Black
83. h the jection the grommet e install the water tube so its position is not reversed E d UPPER CASING AND BOTTOM COWLING 7 7 8 Install Exhaust guide 1 O ring 0 e Relief valve 3 e Grommet 4 e Pipe guide e Screw 6 e Pipe 7 e Rubber seal NS Relief valve 22 8 Nm 0 8 m 5 8 ft Ib the screw with blue LOCTITE 242 9 Install Oil seal 1 Washer 2 e Pipe 3 e Bushing e Nut e Seal 6 e Gasket 7 e Bolt 8 Nut 5 Nm 0 5 kg 3 6 ft Ib Bolt 10 Nm 1 0 kg 7 3 ft Ib NOTE e Always use a new oil seal eTorque the bolts in the sequence embossed on the exhaust guide e Install the pipes with their water discharge end facing the oil pan 10 Install e Dowel pin e Gasket 2 e Bolt 3 NOTE Always use a new gasket UPPER CASING AND BOTTOM COWLING CE 11 Apply e Gasket Maker onto both face of the gasket NOTE Clean the contacting surface of the crank case 12 Install e Dowel pin e Gasket 2 e O ring 3 e Rubber seal 4 e Rubber seal 5 NOTE Always use a new gasket K35150 0 BOTTOM COWLING 1 Install e Grommet e Collar 2 2 Install e Shift stay 1 e Panel stay e Bolt 3 e Front panel 4 e Seal rubber 5 e Hinge pin 6 e Cotter pin 7 e Grommet shift rod NOTE Always use a new cotter pin
84. han 0 26 mm To be increased by measurement 0 51 2 5 More than 0 77 mm F8B F9 9 F9 9B To be decreased by 0 47 measurement 2 3 Less than 0 23 mm To be increased by measurement 0 47 2 3 More than 0 70 mm Example T9 9 FT9 9A measurement 0 25 mm Decrease shim thickness by 0 51 0 25 2 5 0 26 2 5 0 10 mm If measurement 1 26 mm Increase shim thickness by 1 26 0 51 2 5 0 75 2 5 0 3 mm Available shim thickness T9 9 FT9 9A 0 10 0 14 0 18 0 35 and 0 50 mm F8B F9 9 F9 9B 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm LOWR de LOWER UNIT Eo NOTE ______________________ Since the smallest shim available is 0 10 mm if the measurement is between T9 9 F9 9A 0 26 and 0 77 mm or F8B F9 9 F9 9B 0 23 and 0 70 mm do not change the shim 2 Measure Reverse gear backlash Out of specification Adjust Backlash T9 9 FT9 9A 0 51 1 02 mm F8B F9 9 F9 9B 0 82 1 16 mm Measurement steps e Place the shift shaft in neutral e Load the reverse gear by installing the propeller without the front side spacer CD and tighten the nut NOTE 2 Lightly tighten by hand until the pressure of the propeller shaft on the reverse gear restricts movement enough to allow backlash measurement Set the lower unit upside down Attach the backlash indicator on the drive shaft e Attach the dial gauge on the gea
85. hift shaft Bolt Reverse gear complete Propeller shaft complete Nut Pinion gear Thrust bearing Pinion gear shim Drive shaft Forward gear complete Oil seal housing Sleeve Needle bearing Bearing outer race Reverse gear Reverse gear shim Ball bearing Needle bearing Cross pin ring Cross pin Dog clutch Taper roller bearing Forward gear shim Forward gear Refer to REMOVAL POINTS Refer to REMOVAL POINTS Refer to REMOVAL POINTS Refer to REMOVAL POINTS Refer to REMOVAL POINTS Refer to REMOVAL POINTS lt 2 3 2 3 sch zc sch sch e ss gt schl sch sch LOWR e LOWER UNIT PREPARATION FOR REMOVAL F8B 9 9 9 9 Drain the gear oil 6 3 LOWR LOWER UNIT CED NOTE ON REMOVAL AND REASSEMBLY Tilt up the engine a little this provides easier oil draining Remove any gasket adhered to the contacting surface The shim pack will be reused therefore use care not to damage when removing e For reassembly the removed parts should be cleaned with solvent Extent of removal D Lower unit removal Impeller remove Lower unit disassembly Extent of removal Part name Cotter pin Nut Propeller Spacer Lock nut Nut Bolt Lower unit Bolt Water pump housing Impeller Woodruff key Gasket Outer plate Screw Shift shaft Bolt Reverse gear compl
86. his manual To avoid causing warpage tighten multi fastener assemblies in a crisscross fashion and in progressive stages until the specified torque is reached INSP ADJ Q 3 PERIODIC INSPECTION AND ADJUSTMENT PERIODIC SERVICE messe men saa ae naka D S REOR YAT REGE 3 1 MAINTENANCE SCHEDULE reese dene 3 1 ein 3 1 PROPELLER eeben ne 3 2 EE 3 2 ENGINE OIL LEVEL CHECK aeterna zero Ee piano 3 3 ENGINE OIL REPLACEMENT iiio o auo onda eno in EY ead RR kPa nas ce 3 3 GEAR OIL LEVEL CHECK ren dee eege vases 3 5 GEAR REPLACEMENT 3 5 SPABK E 3 6 BEL E 3 7 VALVE CLEARANCE ADJUSTMENT nenne nta enano 3 8 SHAFT CABLE ADJUSTMINT 2 0 Ya aga SP uino DR En ER S ena 3 11 START IN GEAR PROTECTION ADJUSTMENT 3 11 NEUTRAL OPENING LIMIT ADJUSTMENT enne 3 12 PILOT SCREW ADJUSTMENT rinses onrera epp 3 12 IDLE SPEED ADJUST MEN EE 3 13 THROTTLE LINK ADJUSTMENT iknrnno ooa Eoo EY npn tae 3 14 THROTTLE CABLE ADJUSTMENT 5 vnica rains ra i nin 3 15 IGNITION TIMING CHECK ug pe enossau inp Dion ya 3 15 PERIODIC SERVICE MAINTENANCE SCHEDULE The following chart be taken a hel
87. ink e Bushing e Cable end Wear Damage Replace SEALING PARTS 1 Inspect Rubber seal Crack Damage gt Replace MOUNT RUBBER 1 Inspect e Mount rubber Wear Damage gt Replace 7 4 BRKT UPPER CASING AND BOTTOM COWLING K35050 0 ASSEMBLY AND INSTALLATION UPPER CASING 1 Install e Mount rubber e Rubber seal 2 e Clamp 3 e Plate e Bolt 5 NOTE clamp should be installed with the screwed side facing downward ES Screw 22 0 3 kg 2 2 ft Ib 2 Install e Upper casing 1 e Seal e Stopper 3 e Mount rubber 4 e Bolt 5 e Hose 6 e Seal 7 Install e Upper casing D e Bracket 2 e Nut 3 Nut 2 25 Nm 2 5 m kg 18 ft Ib 7 5 BRKT bd UPPER CASING AND BOTTOM COWLING 4 Install e Mount rubber under D e Mount rubber side 2 e Rubber housing 3 e Ground lead 4 e Bolt 5 5 Install e Seal 1 e Gasket 2 e Exhaust manifold 3 e Oil pan e Bolt 5 K Bolt 22 12 Nm 1 2 m kg 8 7 ft Ib NOTE ee Align the exhaust manifold with the oil pan hole Always use a new gasket 6 Install Oil strainer 1 e Bolt 0 e O ring e Drain plug e Rubber damper 5 Drain plug 2 8 Nm 0 8 m kg 5 8 ft Ib 7 Install e Grommet 1 e Water tube 2 NOTE Align hole oil pan wit
88. ioned ones SAFETY WHILE WORKING CED 4 3 Non reusable items When reassembling always use new gaskets packings O rings oil seals split pins and circlips etc DISASSEMBLY AND ASSEMBLY 1 Clean parts with compressed air when disassembling them 2 Oil the contact surfaces of moving parts before assembly 3 After assembly check that moving parts operate normally 4 Install bearing with the manufacturer s markings on the side exposed to view and liberally oil the bearings 5 When installing oil seals apply a light coating of water resistant grease to the outside diameter SPECIAL TOOLS YU 3097 1256 SG Ter 2 39299 A 90890 01252 90890 06752 YU 39991 90890 03169 5 9 33223 90890 06751 Ce 6 YU 33277 A 90890 03141 WA SQ 90890 06760 90890 06756 20 90890 06706 90890 06705 80701 0 SPECIAL TOOLS The use of correct special tools recom mended 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 NOTE __________ eFor USA and Canada use part numbers starting with J YB YM YU or e For others use part numbers starting with 90890 MEASURING 1 10 Dial gauge and stand P N YU 3097 YU 1256 90890 01252 Digital multi meter P N J 39299 90890 06752
89. le at 12 boat transom Shallow water angle Steering angle left right Gear shift position Gear ratio Reduction system Propeller direction rear view Propeller drive system 1 Over head camshaft P O N 7 SAE API US Imp qt SAE cm US Imp oz 86 10W 30 10W 40 SE SF SE SF SE SF CC 1 0 1 06 0 88 Hypoid gear oil 79074 185 6 25 6 51 Degree Degree Degree 2 Pump Octane Number Research octane Motor octane 2 3 YAMALUBE 4 is recommended 4 GEAR CASE LUBE is recommended in USA 5 Forward Neutral Reverse 8 12 16 20 70 Tilt angle 20 37 37 F N R 5 13 27 2 08 Spiral bevel gear Clock wise Spline SPEC u GENERAL SPECIFICATIONS Item Worldwide USA Model FT9 9AMH FT9 9AEH FT9 9AE T9 9MH T9 9EH T9 9ER Overall length Overall width Overall height S L 6 1 5 1 X Boat transom height Weight without propeller mm mm in mm in mm in mm mm mm in mm in kg Ib kg Ib kg Ib 993 39 1 575 22 6 430 16 9 325 12 8 1 051 41 4 1 178 46 4 1 254 49 4 381 15 0 508 20 0 635 25 0 44 5 98 45 5 100 43 5 96 45 0 99 46 0 101 44 0 97 45 5 100 Maximum output Speed range at full throttie Speed range at idling Speed range at t
90. ling fluids or those recommended by Yamaha a EEE SAFETY WHILE WORKING CED Under normal conditions of use there should be no hazards from the use of the lubricants mentioned in this manual How ever safety is all important and by adopt ing good safety practices any risk is minimized A summary of the most important precau tions is as follows 1 While working maintain good stan dards of personal industrial hygiene 2 Clothing which has become contami nated with lubricants should be changed as soon as practicable and laundered before further use 3 Avoid skin contact with lubricants do not for example place a soiled wiping rag in one s pocket 4 Hands and any other part of the body which have been in contact with lubri cants or lubricant contaminated cloth ing should be thoroughly washed with hot water and soap as soon as practica ble 5 To protect the skin the application of a suitable barrier cream to the hands before working is recommended 6 A supply of clean lint free cloths should be available for wiping purposes 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 instruc tions When tightening bolts nuts and screws tighten the large sizes first and tighten inner positioned fixings before outer posit
91. ling speed THERMOSTAT Valve opening temperature Full open temperature Valve lift at full open temp 1 Except for USA and Switzerland 2 For Switzerland 3 For USA 4 Except for Switzerland r min r min C F C F mm in 2 7 6J606 6G905 66810 2 6G920 3 6G805 6G810 66820 3 2 2 0 087 86 82 2 48 6J710 3 1 2 1 3 1 3 1 2 1 __ 2 3 1 2 0 047 25 5 1 1 0 04 950 50 850 50 1 150 50 950 50 1 000 50 850 50 58 62 136 144 70 158 3 0 12 SPEC ue MAINTENANCE SPECIFICATIONS Unit T9 9 FT9 9A F9 9 F9 9B FUEL PUMP Consumption Diaphragm stroke Plunger stroke LUBRICATION SYSTEM Oil filter type Oil pump type Outer rotor to housing 8 5 Inner rotor to outer rotor TT TN 22 Rotor to housing Relief valve operation pressure Zb r min mm in mm in mm in mm in mm in kpa kg cm psi Min 18 0 2 750 2 4 0 0945 5 8 0 2283 Steel mesh Trochoid type 0 06 0 11 0 0024 0 0043 0 02 0 15 0 0008 0 0059 0 02 0 07 0 0008 0 0028 388 450 3 88 4 50 55 19 64 00 MAINTENANCE SPECIFICATIONS LOWER Item Model T9 9 FT9 9A F9 9 F9 9B GEAR BACKLASH Pinion forward Pinion reverse Pinion shims Forward shims Reverse shims 0 23 0 70 0 009 0 028 0
92. marks or numbers facing outward LOWER UNIT 3 Install Dowel 1 Sleeve 0 e Gasket Oil seal housing 4 NOTE Install the sleeve with projection side back ward 4 Install Forward gear complete 5 Install e Drive shaft e Pinion gear shim e Washer thick 3 e Bearing 2 e Washer thin 5 e Pinion gear 6 e Nut 7 Pinion nut holder YB 6078 Drive shaft holder YB 6228 90890 06515 Nut 22 26 Nm 2 6 m 19 ft Ib 6 Install e Shift shaft Bracket 2 Screw 3 6 13 LOWR LOWER UNIT 6 14 7 Install Propeller shaft complete e Reverse gear complete e Bolt 3 8 Check e Shift cam operation Unsmooth operation Repair NOTE Check that the dog clutch shifts to For ward Neutral and Reverse correctly Loun e LOWER UNIT 6 15 SHIM SELECTION For USA and CANADA NOTE a a eWhen reassembling the lower unit with the original gear case and inner parts shim selection is not required eWhen replacing the gear case or inner parts carry out the shim selection 1 Measure Pinion gear clearance Out of specification Adjust Clearance T9 9 0 45 0 55 mm F9 9 1 15 1 25 mm Measurement steps e Install the drive shaft components and tighten the nut to the specified torque Attach the shimming tool into the gear
93. nd 2 together NOTE n gt Oil the connecting cap and crank pin liber ally Bolt 1st 6 Nm 0 6 m kg 4 3 ft Ib 2nd 12 Nm 1 2 m kg 8 7 ft Ib CYLINDER PISTON CRANKSHAFT ED 5 18 5 Install Dowel 1 Oil seal upper 2 Oil seal lower 3 NOTES Install the oil seal with its manufacture s marks or numbers facing outward 6 Apply Gasket Maker Onto the crankcase NOTE e Clean the contacting surface of the crank case and cylinder body before applying the Gasket maker Gasket maker should be applied so it does not overflow the contacting surface 7 Install e Crankcase 1 8 e M6 NOTE Tighten the bolts in sequence in two steps of torque Bolt 1st 15 Nm 1 5 m kg 11 ft Ib 2nd 30 Nm 3 0 m kg 22 ft Ib M61st 6 Nm 0 6 m kg 4 3 ft Ib 2nd 12 Nm 1 2 m kg 8 7 ft Ib EXHAUST COVER 1 Install e Gasket 1 e Exhaust cover inner 2 e Exhaust cover outer 3 e Bolt NOTES cade Tighten the bolts in sequence in two steps of torque CYLINDER PISTON CRANKSHAFT gt 5 19 TIMING BELT 1 Install Washer 1 e Woodruff key 2 Drive gear 3 Washer 4 NOTE ee The projections the drive gear should fit into the holes in the washers mark side should f
94. ng coil output peak voltage minimum G W B Lighting coil output peak voltage minimum G G Cranking Connect 7 5 Measurement steps e Connect the tester to the lighting coil as shown e Set the tester dial to specification e Crank or start the engine 8 23 8 24 REGULATORS T9 9 FT9 9A 1 Measure e Voltage drop Out of specification Replace Measurement steps Select the function switch of digital tester to Diode inspection mode Measure the voltage drop Tester Black Green White Tester White Green 0 50 0 70 0 75 1 05 0 30 0 50 0 30 0 50 0 30 0 50 0 75 1 05 0 95 1 25 0 65 0 85 0 30 0 50 0 30 0 50 0 65 0 85 Measured value is not affected tester leads connection RECTIFIER REGULATORS F8B F9 9 F9 9B 1 Check e Continuity Out of specification Replace NOTE The digital tester cannot be used for this inspection Tester Green Tester O Continuity co Discontinuity FUSE Refer to STARTING SYSTEM BATTERY Refer to PERIODIC SERVICE in chapter 3 ELEC ENRICHMENT CONTROL SYSTEM CE ENRICHMENT CONTROL SYSTEM D Valve heater coil B Black Electrotherma valve VALVE HEATER COIL 1 Measure e Valve heater coil resistance Out of specification Replace Valve heater
95. nstall e Dowel Gasket e Outer plate e Gasket 2 e Woodruff key 5 e Impeller 2 Install Insert cartridge 1 e Bushing e Cover 3 e Screw 2 e Water pump housing 5 e Plate 6 e Bolt 7 NOTE 22 Apply the impeller with water resistant grease eTurn the drive shaft clockwise when installing the water pump housing LOWER UNIT 1 Install Dowel 1 e Lower unit 2 e Bolt 3 NOTE e Set the shift cam to the reverse position e Hold the shift rod nut in the lowest posi tion e nsert the drive shaft into the crankshaft insert the water tube into the water seal and insert the shift rod into the upper cas ing 6 23 LOWR e LOWER UNIT CED 2 Install e Shift rod D e Shift lever 2 e Nut 3 e Lock nut 4 NOTE alam Install the nut on the shift lever side and screw it in 5 turns 3 Check e Pressure Impossible to maintain the specified pressure for 10 seconds Reinstall Checking steps e Attach the Mity Vac to the oil level hole 2 j YB 35956 90890 06756 e Apply the specified pressure Specified pressure 100 kPa 1 0 kg cm 14 2 psi 4 Fill e Gear oil Refer to page 3 5 PROPELLER 1 Install T9 9 FT9 9A e Spacer 1 e Washer 2 e Propeller 3 e Nut e Cotter pin 5 BN Nut 22 13 Nm 1 3 m kg 9 4 ft Ib 1 Install F8B F9 9 F9
96. od Throttle link Funnel Nut Carburetor Screw Electrothermal valve Clip Screw Float chamber Pin Float Needle valve Screw Cover Diaphragm Filter NN sch BP HO sch sch 31250 0 REMOVAL POINTS JOINT 1 Disconnect e Throttle link Fuel hose 0 4 8 FUEL D CARBURETOR CED E32050 0 INSPECTION CARBURETOR BODY 1 Inspect e Carburetor body Crack Damage Replace Contamination Clean WARNING Protect your eyes with suitable safety tacles or safety goggles when using com pressed air NOTE cn Use a petroleum based solvent for clean ing Blow out all passages with com pressed air Never use a wire 2052 0 PILOT SCREW Except for USA and Switzerland 1 Inspect Pilot screw Bend Wear gt Replace E32054 0 JET AND NOZZLE 1 Inspect Main jet Pilot jet Check valve Main nozzle Contamination Replace E32056 0 NEEDLE VALVE 1 Inspect e Needle valve Grooved wear Replace 4 9 FUEL CARBURETOR E32058 0 FLOAT 1 Inspect e Float Crack Damage Replace E32150 0 DIAPHRAGM 1 Inspect Diaphragm Damage gt Replace E32152 0 FILTER 1 Inspect e Filter Contamination Clean Damage Replace E32154 0 CHECK VALVE 1 Inspect e Check vaive Damage gt Replace 2156 0 ELECTROTHERMAL VALVE 1 Inspect Needle valve 1 e
97. pful guide to the intervals between maintenance procedures Remarks PERIODIC SERVICE Initial 10 hours Battery Bolts and nuts Carburetor Cooling water passages Engine oil Fuel strainer Fuel tank Gear oil Greasing points Idle speed Ignition timing Oil filter Outboard motor body Propeller Spark plug Timing belt Throttle link Valve clearance Inspect Check Retighten Clean Adjust Clean Replace Inspect Replace Clean Replace Grease Adjust Check Clean Replace Inspect inspect Clean Adjust Check Adjust Measure Adjust 1 50 100 hours 200 hours 3 months 6 months 1 year O O O O O O O O Q ANODE 1 Inspect Anode Wear Damage Replace Do not paint the anode or the outboard may be corroded 2 Clean Anode Use a wire brush NOTE Remove all trace of oil or grease After cleaning polish the contact surfaces of the anode mount and re install Never paint the anode To ensure good electrical contact keep the anode contact surface clean of oil or grease INSP ADJ PERIODIC SERVICE 3 2 PROPELLER 1 Inspect Propeller e Spline Wear Damage gt Replace D36721 0 BATTERY WARNING Battery electrolyte is dangerous it contains sulfuric acid which is poisonous and highly causti
98. pistons and rings liberally 3 install e Piston 1 e Connecting rod 2 e Piston pin 3 e Circlip 4 NOTE e Mold mark 8 faces in the same direction as the UP mark on the piston e Always use a new circlip e Oil the pistons piston pins and connect ing rods liberally CYLINDER AND CRANKCASE 1 Install e Piston assembly 7 e Cylinder body 2 Piston slider YB 34454 90890 06529 The piston should installed with the UP mark the piston crown facing toward the flywheel side CYLINDER PISTON gt NOTE Position the ring end before insert ing the piston Align the piston ring gap top and 2nd with the pin of the piston Side rail end gap Expander ring end Piston ring 2nd end gap Piston ring top end gap 2 Install Crankshaft main bearing NOTE Align the projection of the bearings with notch in the cylinder body and crankcase 3 Install Thrust plate Crankshaft NOTE ee elnstall the thrust plates so that the oil groove side is on the crank side e When installing the crankshaft on the inder body be sure to fit the thrust plate tab in the cut of the cylinder body 4 Install Connecting cap e Bolt 2 e Assemble the connecting rod and its cap referring the marking e not assemble connecting rod and cap with 1 a
99. ps e Connect the tester to the charge coil as shown e Set the tester dial to specification e Crank or start the engine IGNITION SYSTEM CE 3 Measure e Pulser coil output test 3 Beyond specification Replace CDI unit Below specification Replace pulser coil T9 9 FT9 9A Pulser coil output peak voltage minimum W R Pulser coil output peak voltage minimum W R Measurement steps Connect the tester to the pulser coil as shown Set the tester dial to specification ij Range Crank or start the engine SPARK PLUG Refer to PERIODIC SERVICE in chapter 3 8 10 SYSTEM CES SPARK PLUG CAP 1 Inspect e Spark plug cap Loosen gt Tighten Crack Damage Replace Replacement steps e Remove the spark plug cap by turning the cap counterclockwise Install the spark plug cap by turning the cap clockwise until it stops 2 Measure For Canada and Europe Spark plug cap resistance Out of specification Replace lij Spark plug cap resistance rl 4 0 6 0 ENGINE STOP SWITCH 1 Check e Continuity Out of specification Replace Leads color White Black Installed Removed Installed Removed Install and depress the button MAIN SWITCH 1 Check Continuity Out of specification Replace Leads color Swit
100. r case and make the dial gauge stem contact the mark on the indicator gt Dial gauge YU 3097 90890 01252 Magnet base YU 34481 90890 06705 Backlash indicator YB 6265 90890 06706 6 21 LOWR amp LOWER UNIT e While pulling the drive shaft down ward slowly turn the drive shaft clock wise and counterclockwise then measure the backlash when the drive shaft stops at each direction e Determine the shims to be added or removed according to the specified T9 9 FT9 9A be decreased by 0 77 measurement 2 5 increased measurement 0 77 2 5 Less than 0 51 mm More than 1 02 mm F8B F9 9 F9 9B To be decreased by 0 99 measurement 2 3 To be increased by measurement 0 99 2 3 Less than 0 82 mm More than 1 17 mm Example F8B T9 9 F9 9B If measurement 0 74 mm Decrease shim thickness by 0 99 0 74 2 3 0 25 2 3 0 11 If measurement 1 79 mm Increase shim thickness by 1 79 0 99 2 3 0 80 2 3 0 35 mm Available shim thickness T9 9 FT9 9A 0 10 0 14 0 18 0 35 and 0 50 mm F8B F9 9 F9 9B 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm len VE Since the smallest shim available is 0 10 mm if the measurement is between 9 9 FT9 9A 0 51 and 1 02 mm or F8B F9 9 F9 9B 0 82 and 1 17 mm do not change the shim 6 22 Loun de LOWER UNIT 1 I
101. r shaft DRIVEN GEAR 1 Remove e Bolt D e Driven gear 2 Flywheel holder YB 6139 90890 06522 VALVE 1 Remove e Valve cotter 1 e Valve 2 7 Valve spring compressor 4 YM 1253 90890 04019 NOTES a Hold down the valve spring and remove the valve cotter 2 Remove Vaive lifter Spring retainer 1 Vaive 2 lt 4 Valve spring compressor YM 1253 90890 04019 NOTE Hold down the valve spring remove the valve lifter and slide out the retainer 3 CYLINDER HEAD VALVE AND CAMSHAFT ED INSPECTION AND REPAIR OIL SEPARATOR o 1 Measure Reed valve warpage Out of specification Replace Reed valve warpage limit 0 2 mm 0 008 in 1 Measure e Clearance 8 between outer rotor and pump housing e Clearance 6 between inner rotor 3 and outer rotor e Clearance between outer rotor 1 and pump housing Use a feeler gauge Out of specification Replace oil pump assembly Clearance 0 06 0 11 mm 0 0024 0 0043 in 0 02 0 15 mm 0 0008 0 0059 in 0 02 0 07 mm 0 0020 0 0028 in ROCKER SHAFT AND ROCKER ARM 1 Measure e Rocker shaft diameter Out of specification Replace Rocker shaft diameter 12 941 12 951 mm 0 5095 0 5099 in 5 26 CYLINDER VALVE CE D 2 Inspect e Rocker arm 1 Scratch Damage Replace e Adjust scr
102. rd and reverse gear back lash are smaller than specified the pinion may be too low elf either of these conditions exists then check the pinion shim selection 1 Measure e Forward gear backlash Out of specification Adjust Backlash T9 9 FT9 9A 0 26 0 77 mm F8B F9 9 F9 9B 0 23 0 70 mm Measurement steps e Place the shift shaft in neutral A Load the forward gear with the bear ing housing puller on the propeller shaft NOTE Lightly tighten by hand until the pressure of the propeller shaft on the forward gear restricts movement enough to allow backlash measurement 7 Bearing housing puller YB 6234 90890 06503 Universal puller YB 6117 Stopper guide stand 90890 06501 Center bolt 90890 06504 Set the lower unit upside down Attach the backlash indicator on the drive shaft e Attach the dial gauge on the gear case and make the dial gauge stem contact the mark on the indicator LOWR de LOWER UNIT YU 3097 90890 01252 Magnet base YU 34481 90890 06705 Backlash indicator YB 6265 90890 06706 02 Dial gauge e While pulling the drive shaft down ward slowly turn the drive shaft clock wise counterclockwise then measure the backlash when the drive shaft stops at each direction e Determine the shims to be added or removed according to the specifica tion T9 9 FT9 9A To be decreased by 0 51 measurement 2 5 Less t
103. ring D e Dowel pin 2 e Gasket 3 e Cylinder head assembly 4 e Bolt 6 MS 1st 15 Nm 1 5 m kg 11 ft Ib 2nd 30 Nm 3 0 m kg 22 ft Ib When installing the cylinder head on the cylinder body set the piston at bottom dead center BDC otherwise the piston may butt against valves thus damaging them NOTE e Apply the engine oil to the thread of each cylinder head fixing bolt and seat surface eTighten the bolts in sequence and two steps of torque 11 Install e Timing belt Refer to page 5 20 12 Adjust e Valve clearance Refer to page 3 8 CYLINDER HEAD VALVE AND CAMSHAFT CE CYLINDER HEAD COVER 1 Install e Seal D e Cylinder head cover e Bolt 3 e O ring Gi e Oil filler cap 5 INTAKE MANIFOLD 1 Install e Stud bolt e Gasket 2 e intake manifold 3 e Bracket 4 e Clamp 5 e Bolt e Clamp 7 e Washer e Nut OIL SEPARATOR 1 Install e Reed valve 3 e Washer 2 as Screw 3 EST 2 Install e Oil separator body 1 e Gasket 2 e Breather 3 e Screw 2 e Gasket 5 e Cover 6 e Screw 7 5 39 CYLINDER HEAD AND CE NOTE Always use a new gasket NG Screw 2 2 Nm 0 2 m kg 1 4 ft Ib 3 Install Oil separator Screw 2 Hose long 3 short 4 breather 5 5 40 RECOIL STARTER CED RECOIL STARTER PREPARATION FO
104. rolling Maximum fuel consumption kW hp rpm rpm rpm rpm h US Imp gal rpm 7 3 9 970 4 500 4 000 5 000 1 150 50 1 000 50 3 3 0 87 0 73 9 5 000 Engine type Number of cylinders Total displacement Bore and stroke Compression ratio Spark plug Number of carburetor Carburetor starting system Manifold arrangement Exhaust system Lubrication system Ignition system Starting system cm cu in mm x mm in x in NGK number 4 stroke 2 232 14 16 59 0 x 42 4 2 32 x 1 67 9 3 1 CR6HS 1 Prime start Cross flow Through propeller boss Wet sump CDI Manual starter Electric starter Fuel rating Engine oil type Engine oil pan capacity Gear oil type Gear oil capacity SAE US Imp qt SAE cm US Imp oz 86 10W 30 10W 40 SE SF SE SF SE SF CC 1 0 1 06 0 88 Hypoid gear oil 90 320 10 82 11 26 Tilt angle at 12 boat transom Tilt up angle at 12 boat transom Shallow water angle Steering angle left right Gear shift position Gear ratio Reduction system Propeller direction rear view Propeller drive system 1 Over head camshaft 2 Pump Octane Number Research octane Motor octane 2 3 YAMALUBE 4 is recommended 4 5 Forward Neutral Reverse Degree Degree Degree Degree GEAR CASE LUBE is recommended in USA 8 12 16 20 70 37 37 F N R 5 13 38 2 92 Spiral bevel gear Clock wise Spline
105. rothermal valve W White 6 Oil pressure switch P Pink Rectifier regulator Y R Yellow Red Ground G Green CDI unit 8 3 ELECTRICAL COMPONENTS REMOTE CONTROL MODELS F9 9BE Lighting coil Ignition coil W R White Red G W Green White Ground CDI unit Br Brown R Red 3 Fuse holder Wiring harness L Blue B W Black White 4 Fuse holder Starter relay B Black Y Yellow Pulser coil Charge coil Electrothermal valve Ww White 6 Oil pressure switch P Pink 7 Rectifier regulator Y R Yellow Red Ground G Green CDI unit ELECTRICAL ANALYSIS CED ELECTRICAL ANALYSIS INSPECTION All measuring instruments should be han died with special care or the correct mea surement is impossible On an instrument powered by dry batter ies they should be checked for voltage periodically and replaced if necessary NOTES R X O O indicates the terminals between which there is a continuity of electricity i e a closed circuit at the respective switch position Peak voltage measurement NOTE oae mE Ee e The coil output varies greatly at cranking speed eProper readings cannot be found when cranking a cold engine with the spark plugs installed and with a weak battery RK Digital tester J 39299 90890 06752 Peak volt adapter YU 39991 90890 03169
106. se injury Make the test with the motor placed ina test tank NOTE Before testing the oil pressure indicator lamp operation oil pressure switch should be tested STARTING SYSTEM ED STARTING SYSTEM WIRING DIAGRAM Fuse For remote control model 7P coupler For switch pane model 9 Main switch Except for remote control model Starter motor Battery B Black 6 Starter switch Br Brown 7 Neutral switch R Red Starter relay 8 16 STARTING SYSTEM gt Refer to PERIODIC SERVICE chapter 3 FUSE 1 Check Fuse Blown gt Replace rating mi 12V 20A WIRING HARNESS 1 Check e Continuity Discontinuity Replace WIRING CONNECTION 1 Check e Wiring connection Poor connection Correct ENGINE STOP SWITCH Refer to IGNITION SYSTEM MAIN SWITCH Refer to IGNITION SYSTEM STARTER SWITCH 1 Check e Continuity Out of specification Replace Leads color Red Brown NEUTRAL SWITCH 1 Check e Continuity Out of specification Replace Leads color Length 19 5 20 5 mm 0 77 0 81 in 18 5 19 5 mm 0 73 0 77 in STARTING SYSTEM CES STARTER RELAY 1 inspect e Brown lead terminal e Black lead terminal Loose gt Tighten 2 Check e Relay operation Does not function Replace Checking steps e Connect the tester between the termi n
107. specification by turning the adjusting knob gt tester f YM 34487 90890 06754 e Connect the spark plug cap to spark gap tester Remove the spark plugs from the engine e Crank the engine and check the spark gap through the discharge window IGNITION SYSTEM 8 8 GED CDI SYSTEM PEAK VOLTAGE A WARNING While taking a CDI unit check be careful not to touch any connection of lead wires NOTE elf there is no spark or the spark is weak continue with the CDI test good spark is obtained the problem is not with the CDI system but possibly the spark plug or another component is defec tive 1 Measure e CDI unit output test 1 Below specification Replace igni tion coil T9 9 FT9 9A CDI output peak voltage minimum CDI output peak voltage minimum r min _ Cranking 1 500 3 500 Open Connect 85 85 Measurement steps e Connect the tester to the CDI unit as shown Set the tester dial to specification e Crank or start the engine IGNITION SYSTEM 8 9 GE 2 Measure e Charge coil output test 2 Below specification charge T9 9 FT9 9A Charge coil output peak voltage minimum Br L Cranking Open Connect 1 500 3 500 Charge coil output peak voltage minimum Br L 1 500 3 500 Measurement ste
108. sreesre 6 4 REMOVAL ellc 6 5 daa d let ducs 6 5 PINION GEAR E DIRE 6 5 NEEDLE 2 nho e NT Uga n TENAN Na 6 5 BEARING OUTER 4 4 1 1 6 5 REVERSE GEAR 1 1 nennen nnne 6 6 FORWARD GEAR COMPLETE F8B F9 9 F9 9B 6 6 INSPECTION AND REPAIR 6 7 LOWER CASE 2 6 7 BEARING HOUSING eit ardana penan taaa Ni arandar use 6 7 WATER PUMP HOUSING 6 7 IMPELLER E 6 7 SHIPTSHART AN NINA Ga Gg Neni 6 8 GEAR NEEN 6 8 BEARING na ANK PA Ga an ere de 6 8 DRIVESHAFT en aa ga d 6 8 PROPELLER SHAF T eara aa a baane ga Wg nawa En da ener aaa 6 8 DOG CLUTCH NEE 6 9 SLEEVE EE 6 9 PROPELLER ANODE iiinis esanen SE 6 9 ASSEMBLY AND INSTALLATION 6 9 FORWARD GEAR nanang an aaia sa 6 9 PROPELLER SHAF
109. tall e Steering grip 1 e Friction piece 2 e Spring 3 e Washer 2 e Washer nylon 5 e Screw 6 e Handle grip 7 NOTE Fit the handle grip correctly 7 Install e Steering handle 1 e Bolt short 2 e Bolt long 3 8 Install e Steering bracket 1 e Bushing 0 e Washer nylon 3 e Washer 4 e Wave washer 5 e Ring nut 6 e Tube 7 NOTE ceci init mi Pass the throttle and shift cables and stop switch leads through the steering handle on the steering bracket 7 21 STEERING HANDLE GEO 9 Tighten e Ring nut NOTE m Screw in the ring nut by hand until tight and fit a slotted head screwdriver into the slit in the ring nut Lock the screwdriver with the steering bracket and tighten the ring nut by moving the steering handle back and forth 10 Install e Nut 0 e Bracket 2 e Bolt 3 e Shift cable 4 e Throttle cable 5 e Stopper bracket 6 e Fitting plate 7 e Screw NOTE When installing the shift cable set the shift lever in the forward position 11 Adjust Throttle cable length Refer to page 3 15 STEERING HANDLE F9 9 F9 9B except for Europe and Canada 1 Install e Throttle cable 1 e Steering handle upper 2 e Steering handle under 3 e Nut 2 e Screw 5 Fit the inner cable end in groove fit the outer cable end into the hole 7 22 BRKT STEERING HANDLE ED 2 Install e Steering grip e
110. uitable Fit the cable end to the pin marked with M on the shift arm e Push the cable end stopper to secure the cable end e Tighten the lock nut START IN GEAR PROTECTION ADJUSTMENT 1 Check e Start in gear protection operation Incorrect Adjust 2 Adjust e Start in gear protection cable length Adjustment steps e Set the shift lever to neutral e Remove the hinge pin and throw down the front panel 1 e Loosen the lock nut 2 e Adjust the adjuster 3 so that the arrow marks 4 on the lock arms 5 align with each other e Tighten the lock nut INSP PERIODIC SERVICE CES NEUTRAL OPENING LIMIT ADJUSTMENT 1 Check Neutral opening control operation Incorrect Adjust 2 Adjust e Accelerator arm position Adjustment steps e Attach the tachometer 22 Tachometer YU 8036 A 90890 06760 Set the shift lever to neutral e Start the engine e Turn the throttle grip so that the engine speed is specified Engine speed 3 200 50 r min e Loosen bolt Contact accelerator arm and shift rod link e Tighten the bolt PILOT SCREW ADJUSTMENT NOTE n Pilot screw for the USA and Switzerland can not be adjusted Except for USA and Switzerland 1 Adjust e Pilot screw Adjustment steps e Screw in the pilot screw 1 until it is lightly seated e Back out by the specified number of turns Pilot screw T9 9 FT9 9A

T9.9W/F9.9W Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents