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6V, 8V Service Manual - Page web de dEdIUS

Contents

1. D SOT 6 5 Bearing MOUSING asa TET 6 5 Water pump NOUSINO u ucu NENGNA AE 6 6 6 6 SNIN TOG en 6 6 EE 6 6 BEANN T 6 6 Drive NOTTE TT TT TRE 6 7 Propeler shan E 6 7 DOG CEN EE 6 7 e EEN NE NER MP EEN 6 7 Propeler Anode 6 7 ASSEMBLY AND INSTALLATION e 6 8 0 8 8 dab a 6 8 Reverse TEE 6 8 Oil seal hasan 6 9 MOWER EE 6 10 Backlasn AEE 6 11 Water pump OAI EH 6 16 LoWer 6 17 6 17 LowR LOWER UNIT LOWER UNIT PREPARATION FOR REMOVAL e Drain the gear oil 10 Nm 1 0 m kg 7 2 ft Ib 8 11 Nm 1 1 m kg 8 0 ft Ib 17 Nm 1 7 m kg 12 ft Ib LOWER UNIT NOTE ON REMOVAL AND REASSEMBLY e Tilt up the engine a little marks easier oil draining e Remove any gasket adhered to the contacting surface e The shim pack will be re use therefore use care not to damage when removing eFor reassembly the removed parts should be cleaned with solvent Extent of removal D Lower unit removal 2 Impeller remove 3 Lower unit disassembly xten
2. 5 5 NOTE ON REMOVAL AND REASSEMBL Y 5 6 REMOVAL sneiisn ied 5 6 Flywheel magneto 5 6 E ENN 5 7 Cradkshaft and pistom Eerad 5 8 Piston DM GND ET 5 8 Piston pin and small end Dearing 5 8 duce 5 8 Eegen 5 8 INSPECTION AND REPAIR u u cai obras n yas ek S EE MS Aor ERAS 5 9 EENS 5 9 FIywheel A 5 9 Exhaust mamio ld rsr aree uu D w aS kas 5 9 Exhaust UE 5 10 DOUS INO DOT C NITE 5 10 Hoed VIIVO a KA 5 10 Cylinder DOGV NETTE E aa 5 11 PISTOM u do ius Soma sa bla quoi EE 5 12 Piston to cylinder clearance 5 13 Piston and small end bearing 5 13 E taSs 5 14 Q 5 15 ASSEMBLY AND INSTALLATION 5 16 2125101115 5 16 Piston and piston TING 0000 5 16 Crankshaft oco Ka ab aa ki aaa Na gak 5 16 Oil seal BEE 5 17 Reed 5 17 Cylinder body and crankcase 5 18 Exhaust SEENEN 5 19 Fxhaustmanmlold EE 5 19 Cylinder Head COVEN tere
3. 7 9 STEERING 7 11 PREPARATION FOR 0 7 11 7 12 ie de kaha 7 12 7 12 A 7 12 Steering handle i nece Eae u Rape uay 7 12 ASSEMBLY AND INSTALLATION 7 13 3 0 0 BRKT x UPPER CASING AND BOTTOM COWLING UPPER CASING AND BOTTOM COWLING PREPARATION FOR REMOVAL e Remove the power unit e Remove the lower unit AT3Nm 03m kg 22 ft 167 8 4 Nm 0 4 m kg 2 9 ft Ib 6 Nm 0 6 m kg 4 3 ft Ib D 10 Nm 1 0 kg 7 2 ft Ib x UPPER CASING AND BOTTOM COWLING Extent of removal Bottom cowling removal 2 Mount rubber removal 3 Upper casing d sassembly Extent of removal Screw 4 Shift handle 3 Bolt 2 4 Bracket 2 o 5 Shift rod 1 x E x 7 Bolt 4 8 Bottom cowling 1 9 2 10 Lower mount rubber 2 housing 11 Lower front mount rubber 1 5 12 Lower side mount rubber 2 13 Bolt 2 14 Upper mount rubber 1 housing 15 Upper front mount rubber 1 w aa 17 Upper casino INSPECTION AND REPAIR Shift mechanism 1 Inspect e Shift rod lever e Shift handle 2 e Shift rod 3 Wear Bend Damage gt Replace Bottom cowling 1 Inspect e Bottom cow
4. As antitheft measure a special label on 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 cracks across the serial number D Model name 2 Approved model No 3 Transom height 4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as fol lows Starting bo model serial No 5 003802 L 303150 5 100101 L 400101 2 28 008601 L 2 28 UL 700101 5 100101 L 100101 6 4 SAFETY WHILE WORKING 1 2 SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol lowed by Yamaha dealers and their mechanics FIRE PREVENTION Gasoline petrol is highly flammable Petroleum vapor is explosive if ignited Do not smoke while handling 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 if appro
5. 5 22 Pown RECOIL STARTER RECOIL STARTER PREPARATION FOR REMOVAL e Removal the top cowling Wear a proper safety goggle and gloves for protect your eyes and hands Because the spiral jumps out and may injure a person 5 Nm 0 5 kg 3 6 ft Ib 8 4 Nm 0 4 m kg 2 9 ft Ib 5 23 RECOIL STARTER Extent of removal 7 Recoil starter removal 2 Recoil starter disassembly Extent of removal Order 1 Start in gear protection wire Bolt Recoil starter assembly Circlip Drive pawl Remarks Disconnect the wire at starter side M Drive pawl spring Rope guide Cover Starter handle Nut Bolt Sheave drum Spiral spring Refer to REMOVAL POINTS REMOVAL POINTS Sheave drum 1 Turn e Sheave drum 1 Turn the sheave drum clockwise until the spiral spring is free NOTE e Turn the sheave drum so that the cutaway on the outer surface of the sheave drum faces toward the starter handle e Pass the starter rope through the cut 2 Remove e Nut e e Bushing e Sheave drum 1 NOTE Insert slotted head screwdriver into the hole in the sheave drum and remove the spiral spring from the sheave drum by pushing the spring Spiral spring 1 Remove e Spiral spring NOTE Be careful so that the spiral spring does not pop out when removing it Remove it by allowing it out
6. 90890 06645 1 10 12 Universal puller P N YB 6117 13 Needle bearing installer P N YB 6169 14 Bearing housing puller P N YB 06234 15 Bearing inner race attachment P N 90890 06645 es 2 GENERAL SPECIFICATIONS 2 1 MAINTENANCE 5 2 3 2 3 Ke 2 5 pe etree 2 5 2 8 2 9 GENERAL TORQUE SPECIFICATIONS 2 9 GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Unit 8MH WEE 006 D DIMENSIONS Overall length Overall width Overall height 802 31 6 343 13 5 977 38 5 1 104 43 5 Ser 381 15 0 508 20 0 Se 436 17 2 aT 028 0400 27 59 5 29 63 9 27 59 5 29 63 9 27 5 60 6 29 5 65 0 27 5 60 6 29 5 65 0 28 61 7 Boat transom height O M transom height Weight S PERFORMANCE Full throttle speed range Output ISO Max fuel consumption ENGINE Engine type 4 500 5 500 5 9 8 5 000 4 5 10 5 500 4 000 5 000 4 4 6 4 500 3 6 8 5 000 2 stroke Cylinder number 2 Total displacement cm cu in 165 10 07 Bore x Stroke mm x mm 50 x 42 in x in 1 97 x 1 65 Compression rat
7. Turn the pilot screw outward to specifi cation Pilot screw 1 1 8 1 4 turns out e Start the engine and allow it to warm up for a few minutes e Turn the throttle stop screw Q in or out until specified idle speed is obtained Turning in gt Idle speed becomes higher Turning out gt Idle speed becomes lower IGNITION TIMING ADJUSTMENT 1 Check e Ignition timing at full advanced Incorrect Adjust Checking steps e Disconnect the joint link 1 Slowly turn the flywheel clockwise e Align the timing plate with specification on the flywheel indicator ignition timing at full advanced B T D C 35 1 e Align the marks on the magneto base and flywheel by turning the magneto base e Check the magneto base 2 to contact the stopper plate 3 INSP 4o ADJ PERIODIC SERVICE 2 Adjust e Ignition timing at full advanced Adjustment steps e Remove the spark plugs e Attach the dial gauge in the spark plug hole of No 1 upper cylinder Dial gauge YU 3097 90890 01252 Dial gauge stand YU 1256 the flywheel clockwise or the impeller blade will be twisted the other way thus reducing pump perfor mance e Set the timing plate at TDC e Turn the flywheel to align the timing plate with specification on the fly wheel indicator e Loosen the stopper plate set bolt 2 e Align the marks on the magneto base 3 and flywheel b
8. kg 18 ft Ib 1st 4 Nm 0 4 m kg 2 9 ft Ib 2nd 8 Nm 0 8 m kg 5 8 ft Ib D 1st 6 Nm 0 6 m kg 4 3 ft Ib 2nd 11 Nm 1 1 m kg 8 0 ft Ib NOTE ON REMOVAL AND REASSEMBLY e Before servicing clean the power unit e Note the piston and connecting rod for cylinder 1 and 42 their should be reset in the orig inally e Remove any gasket adhered to the contacting surface e Take care not to scratch the contacting surfaces when removing the cylinder and cylinder head ME e For reassembly the removed parts should be cleaned with solvent and apply the engine oil to the sliding surfaces Extent of removal D Thermostat removal 2 Reed valve removal 3 Cylinder body disassembly 4 Crankshaft bearing removal Extent of removal Starter pulley Nut Flywheel magneto Stator assembly Magneto base retainer seal housing Cylinder head cover Thermostat Exhaust manifold Exhaust cover Oil seal housing Intake manifold Reed valve assembly Crankcase Cylinder body Crankshaft and piston Piston pin clip Piston pin Small end needle bearing Piston 21 ring 22 Crankshaft bearing 23 Crankshaft assembly REMOVAL POINTS Flywheel magneto 1 Remove e Nut 1 For USA and CANADA Except for USA and CANADA 5 6 CYLINDER PISTON AND CRANKSHAFT 611 5 7 2 Remove e Flywheel magneto 1 Flywheel puller YB 6117 90890 06521 e Keep the nut side f
9. 2 to C D I unit as shown C D I tester YU 91022 1 Load coil YU 91022 3 8 11 INSPECTION In this test connect the load coil provided along with the tester between the C D I unit output and the ground e Set the tester switch and dial to speci fied Wl ve em Dial setting MEE e Cranking the engine NOTE Lu LL ue e The coil output varies greatly cranking speed eCranking the cold engine with the plugs in and a weak battery cannot be found proper readings 4 Check e Charge coil output test 2 No indication Replace Checking steps e Disconnect the Brown Br and Black B leads from the charge coil e Remove the spark plugs e Connect the C D I tester 1 to charge coil 2 as shown C D I tester YU 91022 1 e Set the tester switch and dial to speci fied e Cranking the engine NOTE e The coil output varies greatly cranking speed e Cranking the cold engine with the plugs in and a weak battery can not be found proper readings 8 12 ELEC INSPECTION 5 Check e Pulser coil output test 3 No indication Replace Checking steps eDisconnect the White Red W R and Black B leads from the pulser coil e Remove the spark plugs Connect the C D I tester to pulser coil 2 as shown C D tester YU 91022 1 e Set the tester switch and dial to speci fied L e Cranking the engine
10. Rotate the pinion clockwise and check that it freely Also try to rotate the pinion coun terclockwise and confirm that it locks Brush 1 Measure e Brush length Out of specification Replace brush holder assembly d Brush length 4 5 7 5 mm 0 18 0 30 in Brush holder 1 Check e Brush holder continuity Out of specification Replace Brush holder continuity Positive brush holder 1 Earth 2 8 18 ELEC STARTER MOTOR 8 19 Armature 1 Inspect e Commutator surface Dirt Burnt Clean with 600 grit wet or dry sandpaper 2 Measure e Commutator diameter Out of specification Replace Commutator diameter 19 4 20 0 mm 0 76 0 79 in 3 Check e Mica undercut Clog Dirt Clean NOTE _ Remove all particles of mica and metal by compressed air 4 Check e Armature coil continuity Out of specification Replace ELEC STARTER MOTOR 5 Measure e Commutator deflection Use a dial gauge and block Out of specification Replace Deflection limit 0 05 mm 0 002 in ASSEMBLY 1 Install e Brush 1 e Brush spring 2 e Brush holder 3 e Rear cover 4 e Washer 5 spring e Nut 6 2 Install e Rear cover 1 e O ring 2 e Washer t 1 0 mm 3 e Armature 4 e Ring 5 e Washer 1 0 5 mm 6 e Washer 1 0 25 mm 7 e Stator e O ring 9 e Front cover e Through bolt NOTE Align the
11. Side clearance Top 0 02 0 06 mm 0 0008 0 0024 2nd 0 03 0 07 mm 0 0012 0 0028 in Top 2nd CYLINDER PISTON AND CRANKSHAFT Crankshaft 1 Measure e Crank width e Crank width B Out of specification Replace Crank width 39 90 39 95 mm 1 571 1 573 in Crank width 101 7 102 0 mm 4 004 4 016 in 2 Measure e Runout Use a V blocks and dial gauge Out of specification Replace Runout limit 0 03 mm 0 0012 in 3 Measure e Axial play Out of specification Replace Axial play limit 2 0 mm 0 08 in 4 Inspect e Crankshaft bearing Abnormal noise Turn roughly Damage Replace ow dry the bearing without spinning it marking scratches on the bearing balls 5 15 PowR CYLINDER PISTON AND CRANKSHAFT ASSEMBLY AND INSTALLATION Bearing 1 Install e Bearing D e Bearing 2 NOTE Place the plate under the connecting rod big end slip the bearing over the crank shaft and press fit the bearing e After placing the plate under the big end make sure the connecting rod is held in a vertical position e When press fitting the bearing be sure to force the inner race Do not force the outer race Piston and piston ring 1 Install e Piston ring 2nd 1 e Piston ring top 2 NOTE e Piston rings should be replaced as a set eTake care not to scratch the piston or break piston ri
12. e Magneto control lever 2 2 Remove e Arm rod 1 A Except for Europe model For Europe model 3 Remove e Start in gear protection wire 1 0 5 2 Pown POWER UNIT REMOVAL AND INSTALLATION 5 3 4 Remove e Bolt 1 e Throttle wire stay 2 5 Remove e Bolt 1 e Power unit By shaking the power unit lightly lift it off ASSEMBLY AND INSTALLATION Power unit 1 Install e Dowel 2 e Gasket 2 NOTE e Always use the new gasket e Clean the contacting surfaces of crank case and bottom cowling 2 Install e Power unit 1 NOTE Insert the drive shaft into the crankshaft If the splines will not come in complete mesh rotate the flywheel a little so that they are in mesh correctly POWER UNIT REMOVAL AND INSTALLATION 3 Install e Bolt 1 4 install e Throttle wire stay 1 e Bolt 2 5 Install e Start in gear protection wire 6 Check e Start in gear protection operation Incollect Adjust Refer to page 3 13 m 9 7 Install e Arm rod A Except for Europe model For Europe model 8 Install e Magneto control lever 1 e Screw 2 e Magneto control rod NOTE Face the arrow mark T upward 5 4 Pown CYLINDER PISTON AND CRANKSHAFT CYLINDER PISTON AND CRANKSHAFT PREPARATION FOR REMOVAL e Remove the power unit e Remove the starter assembly 45 Nm 4 5 m kg 32 ft Ib 25 Nm 2 5 m
13. FUEL LEAKAGE EE WATER LEAKAGE 3 6 SE EE 3 6 ENGINE AND LOWER UNIT NOISE aaa 3 6 IDEE SPEED n eE enu e tede Sen 3 6 3 6 MOTOR EE 3 6 INSTRUCTING THE NEW 3 6 PERIODIC SERVICE peint tipo 3 7 MAINTENANCE SCHEDULE esee MOMS 3 7 dee 3 8 3 8 3 9 3 10 EIERE 3 10 EE 3 10 3 11 ENGINE MOUNTING BOLTS AND FLYWHEEL 3 13 START IN GEAR PROTECTION 3 13 IDLE SPEED ADJUSTMENT 3 13 IGNITION TIMING ADJUSTMENT tnnc 3 14 THROTTLE CONTROL LINK AD USTMENT 3 16 GREASING POINISuu u uu a ua Sus 3 17 W PREDELIVERY SERVICE PREDELIVERY SERVICE CONTENTS Electrical wiring Fuel line Gear oil level Operation of controls and moving parts Fuel leakage Water leakage Exhaust leakage Engine and lower unit noise d A a E RM Idle speed e Ignition timing Motor exterior esch N Instructing new owner 3 1 ERVICE ADJ PREDELIVERY S ELECTRICAL WIRING D C D I unit B Black 2 Ignition coil Br Brown CUBE LEE 8 Rectifier regulator G Green 5 2P connector GAN Green White 5 Engine stop switch 0 Orange R Red ForEurope model W White W R White
14. Measure e Charge coil resistance Out of specification Replace Charge coil resistance Brown Br Black B 81 99 at 20 C 68 Pulser coil 1 Measure e Pulser coil resistance Out of specification Replace Pulser coil resistance White Red W R Black B 92 112 Q at 20 C 68 F C D I unit 1 Measure e C D I unit resistance Out of specification Replace NOTE e Digital tester can not be used for this inspection Use analogue tester eC D l resistance values will vary from meter to meter especially with electronic digital meters For some testers polarity of leads is reversed B Black Br Brown G Green Orange W White W R White Red 5 Ure e Needle swings once and returns to home position oo Discontinuity 8 9 ELEC INSPECTION 8 10 C D I system NOTE elf there is no spark or the spark is weak continue with the C D I test elf a good spark is obtained the problem is not with the C D I system but possibly the spark plug or other component is defective eUse the following special tool in this inspection C D I tester YU 91022 B e If lamp dose not light check tester batter ies If they are installed correctly and are good check the clip leads for faulty con nections If no fault can be found refer to the warranty statement for instructions for sending the tester
15. e Fuel line Leak Repair 4 3 FUEL CARBURETOR E20050 0 CARBURETOR PREPARATION FOR REMOVAL ePetrol gasoline is highly inflammable e Remove the top cowling and explosive Handle with special care e Remove the front panel eFailure to check for fuel leakage may result in fire or explosion 4 4 FUEL CARBURETOR E31150 0 NOTE ON 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 not to enter foreign material Extent of removal 1 Carburetor removal 2 Carburetor disassembly 8 Fuel pump disassembly Extent of removal Order Q ty 1 Intake silencer Choke rod Carburetor Screw Float chamber body Screw Float pin Float Needle valve Cap Pilot jet Main jet Main nozzle Pilot screw Screw Body outer Diaphragm Body inner Diaphragm 00 40 Refer to REMOVAL POINTS l3 lI 3 A 3 A Beers REMOVAL POINTS Float 1 Remove Screw 1 e Float pin 2 e Float 3 e Needle valve 4 NOTE The needle valve is removed together with the float 4 5 CARBURETOR E32050 0 INSPECTION Carburetor body 1 Inspect e Carburetor body Crack Damage gt Repla
16. 2 Green R Red 2 7 MAINTENANCE SPECIFICATIONS DIMENTION Worldwide Uni 6 _ 05 8MH mm in 436 17 2 mm in 563 22 2 mm in 626 24 6 mm in 115 4 5 in 128 5 0 mm in 19 0 75 mm in 60 2 36 H4 2 8 MAINTENANCE SPECIFICATIONS TIGHTENING TORQUE Part Thread Tightening torque 4 2 np mome Nm Pe NO N NO D d Spakpug 2 25 28 UPPER CASING AND GEAR CASE bracket m 7 97 51 Me a H i s wo v i e GENERAL TORQUE SPECIFICATIONS eneral torque specifications This chart specifies the torque for tighten Nm m kal ft 16 ing standard fasteners with standard clean M5 dry 150 threads at room temperature M6 8 0 58 Torque specifications for special compo MB 18 nents or assemblies are given in applicable sections of this manual To avoid causing M10 36 M12 warpage tighten multi fastener assemblies in crisscross fashion in progressive stages until the specified torque is reached 2 9 INSP AD CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT PREDELIVERY SERVICE a 3 1 7 3 3 1 ELECTRICAL WIRING eege 3 2 3 4 GEAR OIL LEVEL dan CEN 3 5 OPERATION OF CONTROLS AND MOVING PARTS uu 3 5
17. 5 19 Oil Seal BOUSIDO ME 5 20 Flywh eel mag etOoxuu yuyu UU 5 20 RECOIL STARTER TREE MERE N 5 23 PREPARATION FOR REMOVAL 5 d uses aa deeg ta 5 23 REMOVAL EHNEN 5 24 5 24 8 tas aya sss 5 24 Spiral ELAT EEIE pe 5 25 INSPEC Drive pawi and 2 suspa Suasana 2 5 25 BUSRO au aa u TNT 5 25 5 25 8 6 ees 5 25 9 ASSEMBLY AND INSTALLATION 5 26 EES 5 26 POWER UNIT REMOVAL AND INSTALLATION 20050 0 POWER UNIT REMOVAL AND INSTALLATION PREPARATION FOR REMOVAL e Remove the top cowling e Disconnect the wire leads e Remove the carburetor e Disconnect the throttle cables at the lever side Nm 0 4 m kg 4 3 ft Ib 4 Pown POWER UNIT REMOVAL AND INSTALLATION NOTE ON REMOVAL AND REASSEMBLY e Before servicing clean the power unit e Remove any gasket adhered to the contacting surface Extent of removal D Power unit removal Extent of removal 1 Magneto control rod 2 3 4 5 6 7 Magneto control lever Arm rod Start in gear protection wire Throttle wire stay 1 Bolt Power unit 1 1 1 1 Refer to REMOVAL POINTS REMOVAL POINTS Power unit 1 Remove e Magneto control rod e Screw 1
18. D 0 03 0 0012 shaft side clearance 0 2 0 7 0 008 0 027 Maximum small end axial 2 0 0 08 play F THERMOSTAT Opening temperature 48 52 118 126 Full opening temperature C CF 60 140 Valve lift mm in More than 3 0 12 REED VALVE Valve stopper height 4 5 0 2 0 177 0 008 Valve warpage limit 0 2 0 008 CARBURETOR Identification Mark 6H601 6G101 Float height mm in 14 2 0 0 55 0 08 Valve seat size mm in 1 2 0 047 498 2 2 0 087 2 4 0 094 445 1 1 8 1 4 Main jet M J Main nozzle M N Pilot jet P J Pilot screw P S Idle speed rom 900 50 Trolling speed rpm 800 50 RECOIL STARTER mm in turns out 2 4 MAINTENANCE SPECIFICATIONS LOWER USA CANADA GEAR BACKLASH 0 25 0 75 0 25 0 75 1 9 2 0 2 1 2 2 0 10 0 12 0 15 0 18 0 30 0 40 0 50 Pinion forward S S T Pinion reverse S S T Pinion shims Forward shims Reverse shims PROPELLER Size Blade x diameter x pitch 0 10 3x8 1 2x6 1 2 N 3x8 1 2x7 1 2 N 3x8 1 2x8 1 2 N 3x9x5 N 3x9x7 N 90890 01625 90890 01625 4 500 4 700 5 300 5 500 TEST PROPELLER Engine speed ELECTRICAL Model 8CM em 8MH IGNITION TIMING Ignition timing at full retarded B T D C 4 1 at full advanced B T D C 35 1 Piston position at fuli
19. EE 8 8 8 9 0 CON nm 8 9 RR a 8 9 C 8 10 LIGHTING SYSTEM EE 8 14 LIQHUnQ Menu pP 8 14 RecUTfierregulal iu sm a 8 14 EEN 8 15 ELECTRIC STARTING SYSTEM U U L 8 15 F SO eege ee 8 15 8 8 15 ill 8 16 ese Sus 8 16 STARTER Qa wa wie a aces a Gua Ea 8 17 PREPARATION FOR REMOVAL A 8 17 REMOVAL del RRE E 8 18 8 18 INSPECTION ERN 8 18 8 18 sri mcr 8 18 Sieft Be TEE 8 18 eebe 8 19 EE 8 20 WIRING INSPEG ub u una ose 8 21 Wiring 8 21 EE 8 21 ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS CN 8cm vj scEM D C D I magneto 7 C D I unit 5 Rectifier regulator Charge coil 8 Stop switch 69 Pulser coil Engine stop switch Lighting coil 8 2P connector For Europe model only 6 Ignition coil 2 it differs on specification 4 Nm 0 4 m kg 2 9 ft Ib 5 Nm 0 5 m kg 3 6 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 8 1 ELEC ELECTRICAL COMPONENTS les am v D C D I magneto 6 Engine stop switch 1 Charge coil 2 Starting motor 7 Starter switch 3
20. Except for U S A H 10 mm 0 4 in from the bottom edge CYLINDER PISTON AND CRANKSHAFT Piston to cylinder clearance 1 Calculate e Piston to clearance Out of specification Replace piston and piston ring and or cylinder Piston _ Cylinder Piston clearance bore diameter Piston clearance 0 040 0 045 mm 0 0016 0 0018 in Piston pin and small end bearing 1 Inspect e Piston pin e Small end bearing Signs of heat discoloration gt Replace Scratch Damage gt Replace 2 Measure e Piston pin diameter Use a micrometer Out of specification Replace Piston pin diameter 11 996 12 000 mm 0 4723 0 4724 in 3 Check e Free play when the piston pin is inserted in the piston There should be no noticeable for the play Free play exists Replace the pin and or piston 5 13 5 14 CYLINDER PISTON AND CRANKSHAFT Piston ring 1 inspect e Piston ring Breakage Damage Replace 2 Measure e End gap Use a feeler gauge Out of specification Replace N Measuring point H 0 15 0 35 mm Top Top 0 006 0 014 in A 0 15 0 35 mm 2 36 in 0 006 0 014 in NOTE install the piston ring into the cylinder Push the ring with the piston crown e H 60 mm 2 36 in from the contact face 3 Measure e Side clearance Use a feeler gauge Out of specification Replace piston and or ring
21. one turn of the winding each time RECOIL STARTER INSPECTION Drive pawl and spring 1 Inspect e Drive pawl Crack Wear Damage Replace e Drive pawl spring Broken Bent Damage Replace Bushing 1 Inspect Bushing Crack Damage gt Replace Sheave drum 1 Inspect e Sheave drum Crack Damage Replace Starter rope 1 Inspect e Starter rope Broken Wear Damage Replace NOTE When replacing the rope cut it to speci fied length and burn the rope end so that it will not fray Starter rope length 1 850 mm 72 8 in Spiral spring 1 Inspect e Spiral spring Broken Bent Damage Replace Pown RECOIL STARTER ASSEMBLY AND INSTALLATION Recoil starter 1 Install e Spiral spring 1 NOTE e After installing the new spiral spring cut the wire holding the spring e When reusing the spiral spring set the leading end first in the case and then fit one turn each time WARNING The spiral spring may jump out so use spe cial care 2 Install e Starter rope 1 e Sheave drum 2 NOTE Make a knot in the starter rope leaving a 20 to 25 mm 0 8 to 1 0 in portion of the rope end 3 Install e Rope guide 1 e Rubber seal 2 Damper e Starter handle 4 e Cover 5 NOTE einsert the rope through the rope holes and knot the end e Wind the rope 2 1 2 turns around the sheave drum e Plac
22. outboard motor in an upright position ePlace a suitable container under the outboard motor e Remove the oil drain and level plugs e Drain the gear oil e Fill the gear oil 3 10 INSP PERIODIC SERVICE Recommended oil GEAR CASE LUBE USA or Hypoid gear oil SAE 490 Oil capacity 160 cm 5 41 US oz 5 63 Imp oz e Check the gear oil level e Install the oil level plug e Install the oil drain plug SPARK PLUG 1 Remove e Spark plug 2 Inspect e Electrode 1 Wear Damage gt Replace e Insulator color 2 Normal condition is a medium to light tan color Distinctly different color Check the engine condition White color Lean fuel mixture e Plugged filter jet e Air leak e Wrong setting Blackish color Electrical malfunction e Defective spark plug e Excess oil used 3 Clean e Spark plug Clean the spark plug with a spark plug cleaner or wire brush ADJ ox G a INSP PERIODIC SERVICE 3 12 4 Inspect e Spark plug type Incorrect Replace Standard spark plug NGK B7HS 10 NGK BR7HS 10 noise suppressor type 5 Measure e Spark plug gap 8 Out of specification Adjust Use a wire gauge Spark plug 0 9 1 0 mm 0 035 0 039 in 6 Tighten e Spark plug ce Before installing a spark plug clean the gasket surface and plug surface Also it is suggested to apply a thin film of Anti Seize Compound to the
23. provided for a disassembly job 2 Numbers are given in 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 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 6 Remarks Preparation for removal Removal points 3 Order of removal Extent of removal 4 Part name 9 Symbol mark 5 Q ty Exploded diagram CYLINOER HEAD VALVE AND CAMSHAFT CYLINDER HEAD VALVE AND CAMSHAFT CYLINDER HEAD VALVE CAMSHAFT PREPARATION FOR REMOVAL Remove the power unn Remove the folcwng pene Surtaces For resenembly the removed parte be Cleaned with Solvent and apply the geer to the 8 1 intake meniteid removel 2 Olinder head removal 3 pump essermbly remove 4 Valve WARNINGS CAUTIONS AND NOTES x Attention is drawn to the various Warnings Cautions and Notes whic
24. 1 Bearing puller 90890 06535 Stopper guide stand 90890 06538 LOWR LOWER UNIT 6 4 2 Remove e Bushing pinion gear Drive rod YB 6229 90890 06652 Bushing attachement YB 6028 90890 06650 Bearing outer race 1 Remove e Bearing outer race 1 e Forward gear shim 2 Slide hammer set MESE 8 90890 06501 Bearing puller 90890 06535 Stopper guide stand 90890 06538 For USA and CANADA Except for USA and CANADA Reverse gear 1 Remove e Ball bearing 1 Stopper guide plate 90890 06501 Bearing puller 90890 06535 Stopper guide stand 90890 06538 For USA and CANADA Except for USA and CANADA LOWER UNIT 6 5 2 Remove e Oil seal 1 e Bushing 2 Drive rod 90890 06652 Bushing attachment 90890 06649 Forward gear complete 1 Remove e Taper roller bearing 1 e Forward gear 2 Bearing separator YB 6219 90890 06534 INSPECTION AND REPAIR Lower case 1 Clean e Gear case Use a soft brush and solvent 2 Inspect e Water passage Mineral deposits Corrosion Clean 3 Inspect e Lower case Crack Damage gt Replace Bearing housing 1 Clean e Bearing housing Use a soft brush and solvent 2 Inspect e Bearing housing Crack Damage Replace de LOWER UNIT Water pump housing 1 Inspect e Water pump housing
25. AIR Thermostat 1 Inspect Thermostat Stick Damage Replace 2 Measure Valve opening temperature e Valve lift Out of specification Replace Below 48 52 C 118 126 F Above 60 6 140 F Measurement steps e Suspend thermostat in a vessel e Place reliable thermometer in a water e Heat water slowly eObserve thermometer while stirring water continually Flywheel magneto face 7 em 1 Inspect e Flywheel teeth Wear Damage Replace Exhaust manifold 1 Inspect e Exhaust manifold Carbon deposits gt Clean Crack Corrosion Replace CYLINDER PISTON AND CRANKSHAFT Exhaust cover 1 Inspect e Exhaust cover Crack Damage gt Replace Carbon deposit gt Clean inder and exhaust cover Oil seal housing 1 Inspect e Cil seal housing Crack Damage gt Replace Reed valve 1 Inspect e Reed valve Crack Damage gt Replace 2 Measure e Valve bending Out of specification Replace 3 Measure e Valve Stopper height Out of specification Replace Valve stopper height 4 5 0 2 mm 0 177 0 008 in 5 10 e CYLINDER PISTON AND TOTO ee Ds and and Da D and 2 5 11 Cylinder body 1 Inspect e Water jacket Material deposit Corrosion Clean e Cylinder inner surface Score marks Pep
26. B 0 25 0 35 at 20 C 68 When measuring the resistance of 10 or less using the digital tester the correct measurement cannot be obtained Refer to Lower resistance measurement 3 Measure e Secondary coil resistance Out of specification Replace Secondary coil resistance High tension cord 6 8 10 2 kO at 20 C 68 F Engine stop switch 1 Check e Continuity Out of specification Replace i 99 White Black KS Stop switch 1 Inspect e Continuity Out of specification Replace Color White Black Push the button 8 7 ELEC INSPECTION Ignition spark gap WARNING eWhile taking spark check be careful not to touch any connection of lead wires of the Ignition spark gap tester eWhen doing the spark test take special care not to allow leakage from the removed plug cap eThis check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity 1 Check e Ignition spark gap Out of specification Replace Checking steps e Adjust the spark gap to the specified by turning the adjust knob Spark gap tester YM 34487 90890 06754 Spark gap 9 mm 0 35 in e Connect the spark plug cap to the spark gap tester eRemove the spark plugs from the engine eCranking the engine and check sparks of ignition system seen through dis charge window 8 8 ELEC INSPECTION Charge coil 1
27. Crack Damage Replace impeller 1 Inspect e Impeller Crack Damage gt Replace Shift rod 1 Inspect Shift plunger Wear Damage Replace 2 Inspect e Boot Break Damage Replace Gear 1 Inspect e Teeth e Dogs Wear Damage gt Replace Bearing 1 Inspect e Bearing Pitting Rumbling Replace 6 6 Loun LOWER UNIT Drive shaft 1 Inspect e Drive shaft Wear Damage Replace Propeller shaft 1 Inspect e Propeller shaft Wear Damage Replace Dog clutch 1 Inspect e Dog clutch Wear Damage gt Replace Sleeve 1 Inspect e Sleeve Wear Damage Replace Propeller Anode Refer to page 3 8 6 7 LOWR de LOWER UNIT 6 8 ASSEMBLY AND INSTALLATION Forward gear 1 Install e Taper roller bearing 1 e Forward gear 2 Bearing inner race attachment 90890 06645 Propeller shaft 1 Install e Spring 1 e Plunger 2 e Dog clutch 3 e Cross pin 4 e Cross pin ring 5 e Washer 6 NOTE Install the clutch with F mark toward the forward gear side Reverse gear 1 Install e Bushing Drive rod 90890 06652 Bushing attachment 90890 06649 Depth 0 mm 0 in LOWER UNIT 2 Install e Oil seal Oil seal installer YB 6021 Drive rod YB 6229 Depth 10 0 10 5 mm 0 39 0 41 in Depth b 3 0 3 5 mm 0 12 0 14 in 3 Install e Ball bearing 1 Beari
28. GEAR SHIFTING GEAR SHIFTING GEAR SHIFTING IS IMPOSSIBLE WARNING Do not start engine during this inspection Manual handle model Move shift handle to ward and Reverse Check Irregularities of the shifting system YES Neutral Turn propeller and check that gears are in Neutral Forward and Reverse For Shift rod connector Connect Correctly correctly Shift rod power unit side Disconnected Shift cam lower casing side Incorrect move Shift plunger Cross pin Dogs clutch dog Wear Damage Dogs gears Wear Damage 9 8 TRBL SHTG ELECTRICAL SYSTEM E MODEL ELECTRICAL SYSTEM ELECTRIC STARTER MODEL BATTERY IS NOT CHARGED Check Irregularities of the Battery n NO fluid Charge electrical system specific grav Replace Check output voltage 13 5 16 5V 5 500 rpm Max Inspect Replace Lighting coll Rectifier Damage Lead wire Reni Faulty Damage RESTART Replace E HIS ITEM THE YAMAHA LIBRARY LIT 18616 01 64 M 1111861 601 64
29. NOTE e The coil output varies greatly cranking speed e Cranking the cold engine with the plugs in and a weak battery can not be found proper readings ELEC INSPECTION LIGHTING SYSTEM Lighting coil 1 Measure e Lighting coil resistance Out of specification Replace Lighting coil resistance Green G Green G 0 36 0 44 Q at 20 68 NOTE When measuring the resistance of 10 or less using the digital tester the correct measurement cannot be obtained Refer to Lower resistance measurement Rectifier regulator ecm v eceM For Europe model 1 Check e Continuity Out of specification Replace NOTE Digital tester can not be used for this inspection Use the analogue tester B Black G Green G W Green White R Red 8 14 O Continuity Discontinuity ELEC INSPECTION Rectifier sw etw v ecm scM Je 1 Check e Continuity Out of specification Replace NOTE Digital tester can not be used for this inspection Use the analogue tester B Black G1 2 Green R Red 8 15 O Continuity Discontinuity ELECTRIC STARTING SYSTEM sw Je Blown Replace Fuse rating Starter relay 1 Inspect e Brown lead terminal e Black lead terminal Loose Tighten ELEC INSPECTION 2 Check e Relay operation Does not function Replace Che
30. Pulser coil 3 Starter relay Ignition coil Lighting coil 4 Neutral switch 9 C D I unit i 5 Rectifier Fuse 7 Nm 0 7 kg 5 1 ft Ib 4 Nm 0 4 m kg 2 9 ft Ib WIRING DIAGRAM WIRING DIAGRAM ew acm a B Black m Br Brown D CDI unit 2 connector 4 G Green 2 Charge coil 7 Rectifier regulator GM Green White 3 Pulser coil Ignition coil O Orange 4 Lighting For Europe model R Red 5 Engine stop switch W White Stop switch W R White Red 2 8 3 ELEC WIRING DIAGRAM em ace D C D I unit Neutral switch 2 Charge coil 9 Starter motor 3 Pulser coil 00 Starter relay 4 Lighting coil 49 Fuse 5 Engine stop switch 42 Rectifier 6 Starter switch 43 Ignition coil Battery Black Brown Green Green White Orange Red White White Red ELEC INSPECTION INSPECTION 09 NEE 022 240604 0402724222 9 9 E CC Ge measuring instruments should be dled 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 Low resistance measurement When measuring the resistance of 10 less using the digital tester the correct measurement cannot be obtained because of
31. Red 3 2 PREDELIVERY SERVICE eM D C D I unit B SCH jv 2 Ignition coil Br Brown 3 Neutral switch G Green 4 Starter switch G W Green White Engine stop switch O Orange 6 Battery R Red 7 Starter motor W White Fuse W R White Red 9 Starter relay Rectifier w B G S 7 gt AN TERSA UI SS UN ees 2 SS 3 3 INSP ADJ PREDELIVERY SERVICE FUEL LINE D Carburetor 2 Fuel hose 3 Fuel strainer 4 Hose joint 3 4 3 5 023000 0 GEAR OIL LEVEL Remove the oil drain 4 and oil level plugs and add the gear oil through the oil drain hole until it overflows from the oil level hole Refit the plugs The oil level plug first OPERATION OF CONTROLS AND MOVING PARTS 1 Check shift control for normal opera tion 2 Check steering control for smooth oper ation 3 Check throttle control for smooth oper ation 4 Check ignition timing for normal opera tion 5 Check cowling lock and release mecha nism for normal operation 6 Check starting system for normal oper ation DOCERE DC PPP PR RR Aaf NENNEN SEAN R us 52 96004 5550054 weens un ES Mi Be ee S se a 25 1 fuel mixture to start the engine WARNING Befo
32. Refer page Bolts and nuts Retightening SEN Adjustment NS D Cooling water passage Replacement Fuel strainer ENNL NN NNNM _ e D 2 Replacement Adjustment Outboard motor body Inspection NE mee Retightening im Se G SIE 3 0 5 6 5 em 0 5 P 3 Cleaning Adjustment Start in gear protection Throttle link 3 13 S9 D INSP ADJ PERIODIC SERVICE 3 8 ANODE 1 inspect e Anode Wear Damage gt Replace GEN p 2 H d Do not paint may be corroded 2 Clean e Anode Use a wire brush NOTE Remove all trace of or grease After cleaning polish the contact surfaces of the anode mount and re install Never paint the anode To sure good elec trical contact keep the anode contact sur face clean of oil or grease PROPELLER 1 Inspect e Propeller e Spline Wear Cracks Damage Replace INSP Q ADJ PERIODIC SERVICE 3 9 BATTERY scu Jen v 9 AA WARNING Battery electrolyte is poisonous and gerous causing severe burns etc con tains sulfuric acid Avoid contact with skin eyes or clot
33. air Use 600 800 grit wet sandpaper cylinder and cylinder head 2 Inspect e Exhaust wall Crack Damage Replace Carbon deposit Clean Use a round scraper Do not scratch the fitting surfaces of the cylinder and exhaust cover 3 Measure e Cylinder bore D Use cylinder gauge Out of specification Rebore or replace NOTE u x Measure the cylinder bore D in parallel Then find the average of the measurement SICE Cylinder 50 00 50 03 mm 50 1 bore D 1 9685 1 9697 in 1 972 in Cylinder 0 08 mm taper T 0 003 in D Maximum Dia D1 De Maximum Di or D2 Minimum Ds 06 100 mm 3 94 in B 90 mm 3 70 in O 35 mm 1 38 in Pown CYLINDER PISTON AND CRANKSHAFT 5 12 Piston 1 Inspect e Piston wall Wear Scratch Damage Replace 2 Inspect e Piston head e Piston ring groove Carbon deposit Clean ATE I 281 1 EOS Z h the piston crown Do not scratc 3 Measure e Piston pin boss inside diameter Use a micrometer Out of specification Replace Piston pin boss inside diameter 12 004 12 015 mm 0 4726 0 4730 in 4 Measure e Piston diameter D Use a micrometer Out of specification Replace 4 Measuring point H Piston diameter 49 955 49 980 mm Standard 1 9667 1 9677 in 50 25 mm 1 978 in 50 50 mm 1 988 in NOTE
34. ane Motor octane 2 L 210 2 2 MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Mode Unit em CYLINDER Bore size 50 00 50 03 1 9685 1 9697 Wear limit 50 1 1 972 Taper limit 0 08 0 003 Out of round limit 0 05 0 002 PISTON Identification mark Piston clearance Limit Diameter Measuring point H G 0 040 0 045 0 0016 0 0018 0 095 0 0037 49 955 49 980 1 9667 1 9677 10 0 4 0 5 0 02 Exhaust side 12 004 12 015 0 4726 0 4730 Off set Off set direction Pin boss inside diameter Ring groove clearance installed Top 0 02 0 06 0 0008 0 0024 2nd 0 03 0 07 0 0012 0 0028 Over size piston diameter 1st 50 25 1 978 2nd 50 50 1 988 PISTON PIN Diameter mm in 11 996 12 000 0 4723 0 4724 PISTON RING 1ST Type Keystone Dimensions B x T 2 0 x 2 0 0 079 x 0 079 End gap installed 0 15 0 35 0 006 0 014 Limit T 0 55 0 022 PISTON RING 2ND Type Barrel Dimensions B x T 2 0 x 2 0 0 079 x 0 079 End gap installed 0 15 0 35 0 006 0 014 Limit 0 55 0 022 Except for U S A 2 3 MAINTENANCE SPECIFICATIONS ma Unit em 8MH CRANK SHAFT Crank width A 39 90 39 95 1 571 1 573 Crank width B 101 7 102 0 4 004 4 016 Deflection limit
35. arburetor Clean fuel tank Replace fuel Fuel Fuel is deteriorated or dirty Fuel Empty or fuel level is low Fuel hose Leakage Flattened Broken Disconnected Top up the fuel tank Replace fuel hose Reconnect Priming pump Check valve Rubber pump damaged Fuel joint Damage Leakage RESTART Check Check that spark is strong YES NO Engine stop switch Check if the lock plate is out of place Set the lock plate in place Spark plug Incorrect gap Carbon deposits Dirty Oily or burnt Plug cap Faulty No contact Ignition coil D Incorrect resistance eplace NO x 9 1 x Clean Adjust Replace ENGINE AND RELATED PARTS x Pulser coil YES Replace Incorrect resistance Charge coil Benice Incorrect resistance Sa x C D I unit Incorrect resistance RESTART Check Check to see that the compression of each cyl inders normally YES Re check ignition and fuel NO Disassemble the power unit and check the fol lowing parts Reed valve Cracks Damage Oil seals Leakage Damage Labyrinth seal gt Damage Cylinder head gasket Leakage Damage Piston Worn Broken Scuffed Cylinder wall Piston ring 9 2 TRBL 4 x ISHTG lt ENGINE AND RELATED PARTS POWER LOSS Check Boat is loaded properly YES Ch
36. back to Electro Spe cialities inc WARNING While taking C D I unit check be careful not to touch any connection of lead wires of the C D I tester 1 Check e C D I tester for high scale No indication Replace the tester Checking steps e Place switch in HIGH position e Plug the capacitive clip into an elec tric outlet 117 VAC for ten seconds WARNING Do not touch the plug pins on the capaci tive clip while plugging it and depressing the button An electric shock will result e Remove the capacitive clip from the outlet e Set the tester dial 3 to 50 or below e Connect the capacitive clip ELEC INSPECTION Yellow Y lead Capacitive clip N terminal Red R lead Capacitive clip P terminal eDepress the button on the capacitive clip eThe indicator lamp on the tester should light 2 Check e C D I tester for low scale No indication Replace the tester Checking steps e Place switch in LOW position eSet the tester dial 2 to 50 or below e Connect the 12 V battery Red R lead Positive terminal Yellow Y lead Negative terminal e The indicator lamp on the tester should light 3 Check e C D I unit output test 1 No indication Replace Checking steps e Disconnect the Black B and Orange O leads from the ignition coil e Remove the spark plugs e Connect the C D I tester and load coil
37. ce Contamination Clean NOTE e Use a petroleum based solvent for d ing Blow out all passages with comp ed air e Do not use a wire E32052 0 Pilot screw 1 Inspect e Pilot screw Bend Wear gt Replace E32054 0 Jet and nozzle 1 Inspect e Main jet e Pilot jet e Main nozzle Contamination Replace E32056 0 Needle valve 1 inspect e Needle vaive Grooved wear Replace E32058 0 Float 1 Inspect e Float Crack Damage gt Replace FUEL WM CARBURETOR 34050 0 ASSEMBLY AND INSTALLATION Fuel pump 1 Install e Body D inner e Check valve 2 e Screw 3 e Nut 4 2 Install e Gasket 1 e Diaphragm 2 e Body 3 inner e Gasket 4 e Diaphragm 5 e Body 6 outer e Screw 7 Carburetor 1 Install e Main nozzle 1 e Main ler e Pilot jet 3 e Cap 4 NOTE Install the main nozzle by holding its end with a hole 2 Install e Needle valve e Float 2 e Float pin 3 e Screw 4 NOTE u The float pin should be fit in the slit the carburetor and locked with the screw e When installing the float in the carburetor place the needle valve in the valve seat e After installing check for smooth move ment the float 4 7 FUEL CARBURETOR 4 8 3 Measure e Float height Out of specification Fold the tab to adjust float arm height Float height 14 2 mm 0 55 0 08 NOTE e
38. cking steps e Connect a tester Q x 1 between the terminals of the starter relay as shown e Connect a 12 V battery Brown lead Positive terminal 2 Black lead gt Negative terminal e Check that there is continuity between the starter relay terminals Starter switch 1 Inspect e Continuity Out of specification Replace Color Red Brown Neutral switch 1 Inspect e Continuity Out of specification Replace Distance Color Brown Brown Free 196 205mm Push 18 5 19 5 mm 9 0 73 0 77 in 8 16 ELEC STARTER MOTOR STARTER MOTOR 2 WARNI cM To avoid dangers of an electric shock be sure to disconnect the battery cables from the battery before removing the starter motor PREPARATION FOR REMOVAL e Disconnect the battery cables e Extent of removal Starter motor disassembly Clip Refer to REMOVAL POINTS Pinion stopper Spring Pinion Through bolt Front cover Stator Armature assembly Washer Washer Ring Rear cover Washer Brush holder Brush N N NG 2 8 17 ELEC STARTER MOTOR REMOVAL POINTS Pinion 1 Remove e Clip e Pinion stopper 2 e Pinion 3 NOTE Using a screw driver pry off the clip INSPECTION Pinion 1 Inspect e Pinion teeth Wear Damage gt Replace 2 Check e Clutch movement Damage gt Replace NOTE
39. cut in the cover with the projec tion on the stator Do not scratch the brushes when installing the armature on the rear cover 8 20 STARTER MOTOR 3 Install e Pinion 1 e Spring 2 e Pinion stopper 3 e Clip 4 NOTE Make sure the clip tightly fits in the pinion stopper WIRING INSPECTION Wiring harness 1 Check e Continuity Out of specification gt Replace Checking steps e Check the continuity between the termi nal side and each connector Cores and pins of identical colors must be con nected or a continuity test can not be made elf any of the cores are open circuit replace the wring harness Wiring connection 1 Check e Wiring connection Poor connection Correct SHT TRBL e CHAPTER 9 TROUBLESHOOTING ENGINE AND RELATED PARTS 9 1 ENGINE DOES NOT START ENGINE TURNS OVER BUT STALLS ENGINE RUNS IRREGULARLY STOPS OR IDLES ROUGHLY 9 1 9 3 L NO NE NISEIRI cote eccentric 9 6 GE All 9 8 GEAR SHIFTING IS IMPOSSIBLE 9 8 ELECTRICAL SYSTEM ELECTRIC STARTER 9 9 NOT CHARGED EE 9 9 TRBL 5 SH e ENGINE AND RELATED PARTS ENGINE AND RELATED PARTS ENGINE DOES NOT START ENGINE TURNS OVER BUT STALLS ENGINE RUNS IRREGULARLY STOPS OR IDLES ROUGHLY Check Loosen the drain screw and make sure fuel arrives at the c
40. d according to the specified To be decreased by 0 50 measurement 1 6 Less than 0 25 mm To be increased by measurement 0 50 1 6 More than 0 75 mm Example If measurement 0 20 mm Decrease shim thickness by 0 50 0 20 1 6 0 30 1 6 0 18 mm If measurement 0 82 mm Increase shim thickness by 0 82 0 50 1 6 0 32 1 6 0 20 mm NOTE L Since the smallest shim available is 0 10 mm if the measurement is between 0 25 and 0 75 mm do not change the shim Available shim thickness 0 10 0 12 0 15 0 18 0 30 0 40 and 0 50 mm LOWR LOWER UNIT 2 Measure e Reverse gear backlash Out of specification Adjust Backlash 0 25 0 75 mm Measuring steps e Place the shift shaft in neutral e Set the lower unit upside down e Attach 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 Dial gauge YU 3097 90890 01252 Magnet base YU 34481 90890 06705 Backlash indicator YB 6265 90890 06265 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 eDetermine the shims to be added or removed according to the specified To be decreased by Less than 0 25 mm 0 50 ER To be increased by More than measureme
41. e om d G EL k 4 qr e IE 4 4 6 YAMAHA Outboards 160 6V 8V SERVICE MANUAL 20000 1 NOTICE This manual has been prepared by the Yamaha Motor Company Ltd primarily for use by 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 a basic understanding of the mechanical and electrical concepts and procedures inherent in the work for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use 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 the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of this manual A10001 0 6 8V SERVICE MANUAL 1996 Yamaha Motor Co LTD 1st Edition July 1996 All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means including photocopying and recording with out 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 na
42. e shaft into the crankshaft insert the water tube into the water seal and insert the shift rod into the upper cas ing 2 Install e Shift rod connector 1 e Bolt 2 Bolt 10 Nm 1 0 m kg 7 2 ft Ib 3 Apply e Gear oil Refer to page 3 10 Propeller 1 Install e Spacer 1 e Propeller 2 e Washer 3 e Nut 4 e Cotter pin 5 KR Nut 17 Nm 1 7 m kg 12 ft Ib 6 17 7 BRACKET UNIT UPPER CASING AND BOTTOM COWLING ns PREPARATION FOR REMOVAL 7 1 INSPECTION AND REPAIR 7 2 Shift 7 2 Bottom COWIIHO 6 7 2 ipo TOVO aaa abaan ses 7 3 taies 7 3 MOUNT lee EEN 7 3 cava ocean 7 3 ASSEMBLY AND 7 4 7 4 ee mE 7 5 BRACKET 7 7 PREPARATION FOR 7 7 7 8 Steering bracket and pivot shaft 7 8 Clamp and swivel bracket 7 8 7 9 ASSEMBLY AND INSTALLATION
43. e the rope at the cutaway 5 26 RECOIL STARTER 5 27 4 Install e Sheave drum 1 NOTE Position the inner end of the spiral sprir on the retainer post of the sheave drum 5 Install e Bushing 1 e Washer 2 e Bolt 3 e Nut 4 Bolt 4 Nm 0 4 m kg 2 9 ft Ib 6 Install e Rope guide 1 e Bolt KR Bolt 5 Nm 0 5 kg 3 6 Ib 7 Set e Spiral spring NOTE Wind up the spring 3 turns countercioc wise with the starter rope 8 Install e Drive spring 4 e Drive 2 e Circlip 3 Pown RECOIL STARTER 5 28 9 Check e Starter operation Rough operation Repair 10 Install e Recoil starter assembly 1 e Bolt e Start in gear protection wire 11 Adjust e Start in gear protection wire Refer to page 3 13 LOWR e CHAPTER 6 LOWER UNIT E E 6 1 PREPARATION FOR REMOVAL arosine 6 1 NOTE ON REMOVAL AND REASSEMBLY 6 2 REMOVAL POINT EE 6 3 lt ET EE 6 3 Reverse gear 00 86 6 3 gn ele Se ET 6 3 6 3 ana k augu 6 4 6 4 Forward gear 6 E 6 5 INSPECTION AND REPAIR 6 5
44. eck Irregularities of the lower unit NO NO YES Check the distribution of the load on the boat Improper load distribution Overload Propeller load distribution Boat hull Fouled with seaweeds and shells Trim angle Adiust Improper J Transom height Too lower or higher Air draw Cavitation Clean boat hull CRUISING NO Reselection Propeller selection Make sure the engine runs at 4 500 5 500 rpm with wide open throttle Propeller Bent Broken Loosely fit Water inlet Clogged Water pump Worn Broken NO NO ICRUISING TRBL SHT ENGINE AND RELATED PARTS X Check Irregularities of the carburation NO YES Clean fuel tank Replace fuel Fuel Fuel is deteriorated or dirty Fuel hose Leakage Bent Kinked Flattened Broken Fuel strainer Clogged Fuel pump Broken Carburetor Clogged Water is in mixture Replace Adjust Clean Replace CRUISING Check Check that spark is strong YES NO Spark plug Incorrect gap Carbon Geh SE deposits Dirty Oily or burnt Plug cap Faulty No contact Incorrect timing CRUISING 9 4 ENGINE AND RELATED PARTS X Check Make su re the compres sion of each cylinders normally YES Re check ignition and fuel system NO Disassemble the power u
45. ege e The float should be resting on the needle valve but not compressing the needle valve eTake measurement at the end surface of the float opposite to its pivot side 4 Install e O ring D float chamber e Float chamber body e Screw 3 Install e Gasket 1 mixing cover e Mixing cover 2 e Screw 3 6 Install e Spring e Pilot screw 2 FUEL D CARBURETOR 7 Adjust e Pilot screw Adjustment steps e Screw in the pilot screw until itis lightly seated e Back out by the specified number of turns lt Pilot screw 1 1 8 1 4 turns out 8 Install e Gasket 1 e Intake silencer 2 e Collar 3 e Bolt 4 uL E El e 9 Install e Throttle link Q gt e Fuel hose 10 Adjust e Idle speed Refer to page 3 13 3 14 4 9 5 POWER UNIT POWER UNIT REMOVAL AND 5 1 PREPARATION FOR REMOVAL 5 1 NOTE ON REMOVAL AND REASSEMBLY 5 2 REMOVAL ee 5 2 FOwer EE 5 2 ASSEMBLY AND INSTALLATIONN UM 5 3 POW CU T 5 3 CYLINDER PISTON AND 5 5 PREPARATION FOR REMOVAL
46. h Mid important information in this manual in the following way The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instruction could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the outboard motor A CAUTION indicates special precautions that must be taken to avoid damage to the out board motor NOTE ae A NOTE provides key information to make BEER clearer 50001 1 4 SYMBOLS Symbols D to 9 are designed as thumb tabs to indicate the content of a chapter 60 General Information 2 Specifications 3 Periodic Inspection and Adjustment 4 Fuel System 5 Power Unit 6 Lower Unit 7 Bracket Unit Electrical System 9 Troubleshooting Symbols 40 to 46 indicate specific data Special tool p Specified liquid 42 Specified grease 43 Specified engine speed Specified torque 5 Specified measurement Specified electrical value Resistance Voltage V Electric current A Symbol 47 to in an exploded diagram indicate grade of lubricant and location of lubrication point 4 Apply Yamaha 2 stroke outboard motor oil Apply Yamaha gear case lubricant Apply molybdenum disulfide oil 09 Apply water resistant grease Yamaha marine grease A Yamaha marine grease Symbols to 64 in an exploded diagram indicate grade of sealing or
47. haft Friction piece Throttle cable Steering handle 7 11 11 12 IE gt gt lI lI 3 BRKT x STEERING HANDLE INSPECTION Throttle shaft 1 Inspect e Throttle shaft Wear Crack Damage Replace Bushing 1 Inspect e Bushing e Wear Crack Damage Replace Friction piece 1 Inspect e Friction piece 2 Wear Crack Damage Replace f Steering handle 1 Inspect e Steering handle Wear Crack Damage Replace 7 12 BRKT STEERING HANDLE 7 13 ASSEMBLY AND INSTALLATION Steering handle 1 N A Install e Throttle shaft 1 e Friction 2 e Throttle wire 3 e Plate 4 e Screw 5 Install e Bushing 1 e Spring 2 e Washer 3 e Steering grip 4 e Handle grip 5 e Screw 6 e Screw 7 e Pin 8 Install e Bushing 1 e Steering handle assembly 2 e Plate 3 e Wave washer 4 e Bushing 5 e Cover 6 e Bolt 7 Check e Steering handle operation Rough operation Repair 8 ELECTRICAL SYSTEM ELECTRICAL Sere 8 1 WIRING DIAGRAM RE 8 3 8 5 SYSTEM EEN 8 5 e EE 8 5 SPar I CID 8 5 8 6 ENGINE STOP SWITCH 8 7 SWOR a eege 8 7 e e
48. hing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or miik Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Venti late when charging or using in a closed space Always wear eye protection when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE e Batteries vary 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 e Battery fluid level e Battery fluid specific gravity INSP Q PERIODIC SERVICE FUEL LINE 1 Inspect e Fuel line Crack Leak Damage Replace FUEL STRAINER Refer to page 4 2 GEAR OIL 1 Check Gear oil level level is low Add oil to proper level Checking steps e Place the outboard motor in an upright position e Remove oil drain 1 and oil level 2 plugs e Add the gear oil through the oil drain hole until it over flows from the oil level hole Recommended oil GEAR CASE LUBE USA or Hypoid gear oil SAE 90 e install the oil level plug e Install the oil drain plug 2 Check e Gear oil Dirt gt Replace Replacement steps e Place the
49. io 7 00 Compression pressure kPa 1 079 psi 10 8 153 Carburetor number 1 Intake system Reed valve Cross scavenging Through prop boss Scavenging system Exhaust system Cooling system Water Electric Electric Ignition system CDI Advance type Mechanical Alternator for charging Alternator for lighting Carburetor starting system Spark plug NGK 12 6 12 6 Choke valve type 2 1 GENERAL SPECIFICATIONS 2 Model Worldwide Unit 6 86 USA CANADA 6 0 1 8 Resistant spark plug NGK 7 BR7HS 10 FUEL AND LUBRICATION Fuel Fuel rating Fuel type Engine oil type Regular gasoline Min 86 Pre mixed fuel amp oil 2 stroke outboard motor oil Engine oil grade TC W3 Mixing ratio G 100 1 Gear oil type Hypoid gear oil SAE 20 Gear oi quantity 160 US oz 5 4 Imp oz 5 6 BRACKET Tilt angle 4 8 12 16 20 Tilt up angle 81 Shallow water cruising angle Tilt 37 Steering angle left right 60 60 DRIVE UNIT Gear shift position F N R Gear ratio 13 27 2 08 Gear type Straight bevel gear Clutch type Dog clutch Propeller direction Clockwise back views Propeller drive system Propeller series mark ELECTRICAL Spline N Battery capacity Cold cranking Amps ri Pump Octance Number Reserch oct
50. ions When tightening bolts nuts and screws tighten the large sizes first and tighten inner positioned fixings before outer positioned ones AXE E SAFETY WHILE WORKING 3 Non reusable items Always use new gaskets packings O rings split pins and circlips etc on reassembly DISASSEMBLY AND ASSEMBLY 1 Clean parts with compressed air on dis assembling them 2 Oil the contact surfaces of moving parts on assembly 3 After assembly check that moving parts operate normally 4 Install bearings 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 1 4 SPECIAL TOOLS A80701 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 U S A and Canada use part number starting with YB YU or YW e For others use part number starting with 90890 YU 3097 90890 01252 FOR TUNE UP YU 1256 1 Dial gauge and stand P N YU 3097 YU 1256 90890 01252 2 Digital multi meter P N YU 34899 A 90890 06752 3 C D I tester P N YU 91022 B 1 5 melt SPECIAL TOOLS 4 Compression gauge YU 33223 1 90890 06751 P N YU 33223 1 90890 06751 5 Timing
51. joint link 5 so that the control lever comes to contact with the magneto base e Connect the joint link e Check the throttle valve to fully open position GREASING POINTS 1 Apply e Water resistant grease FUEL 4 FUEL SYSTEM PUEL SYSTEM u kula a u iss 4 1 PREPARATION FOR REMOVAL 4 1 INSPECTION xii oet u ED ista ERA 4 2 PEU nee t E TL u uuu 6 ASSEMBLY AND INSTALLATION 4 2 JOU 4 3 CARBURETOR e M M MUR 4 4 PREPARATION FOR REMOVAL E g 4 4 NOTE ON REMOVAL AND REASSEMBLY 4 5 HEMOVAL POINTS Da REP M DG aa 4 5 EE 4 5 tetera eee eases 4 6 e VE 4 6 lee 4 6 Ber 4 6 Needle ValVB 0 4 6 oat iu a H quwan 4 6 ASSEMBLY AND INSTALLATION H 4 7 PUG 4 7 Carburetor eesse Ee Ee 4 7 FUEL FUEL SYSTEM E20050 0 FUEL SYSTEM A WARNING PREPARATION FOR REMOVAL ePetrol gasoline is highly inflammable e Remove the top cowling and explosive Handle with special care eFailure to check for fuel leakage may re
52. light P N YU 33277 A 90890 03141 6 Tachometer P N YU 8036 A 90890 06760 7 Mity Vac P N YB 35956 90890 06756 YB 35956 90890 06756 8 Spark gap tester P N YB 34487 90890 06754 90890 06754 SPECIAL TOOLS 90890 01625 9 Tester propeller P N 90890 01625 FOR POWER UNIT SERVICE 1 Flywheel puller P N YB 6117 90890 06521 2 Flywheel holder P N YB 6139 90890 06522 3 Bearing separator P N YB 6219 90890 06534 FOR LOWER UNIT SERVICE 1 Backlash indicator P N YB 6265 90890 06706 90890 06706 1 7 SPECIAL TOOLS 2 Stopper guide plate 90890 06501 P a 9 4 90890 06501 3 Slide hammer set YB 6096 P N YB 6096 4 Bearing separator 90890 06534 P N YB 6219 90890 06534 5 Bearing puller 90890 06535 P N M ZC RE 90890 06535 90890 06538 6 guide stand 90890 06538 1 8 SPECIAL TOOLS 7 Drive rod P N YB 6229 YB 6071 90890 06605 90890 06606 90890 06652 90890 06605 90890 06606 90890 06652 YB 6229 YB 6071 8 Bushing attachment YB 6028 90890 06649 P N YB 6028 90890 06650 90890 06649 90890 06650 9 Magnet base P N YU 34481 90890 06705 10 Bushing installer P N YB 6029 90890 06601 6029 11 Bearing oil seal installer 8605 7 90890 06634 YB 6021 90890 06628 P N YB 6015 YB 6021 YB 6167 YB 6167 90890 06634 90890 06628 SPECIAL TOOLS YB 6117
53. ling Crack Damage gt Replace 7 2 BRKT UPPER CASING AND BOTTOM COWLING Clamp lever 1 Inspect e Clamp lever Wear Damage gt Replace Sealing parts 1 Inspect e Rubber seal Crack Damage Replace Mount rubber 1 Inspect e Mount rubber Wear Damage gt Replace Upper casing 1 Inspect e Upper casing Crack Damage Replace 7 3 BRKT Yx UPPER CASING AND BOTTOM COWLING ASSEMBLY AND INSTALLATION Upper casing 1 Install e Grommet 1 short transom model e Boot 2 long transom model 2 Install e Upper front mount rubber 1 e Upper side mount rubber NOTE Hook the upper side mount rubber on to the housing rib 3 Install e Steering bracket 1 e Upper mount rubber housing 0 e Bolt 3 NOTE On the long transom model the upper cas ing boot should be fit over the pivot shaft 4 Install e Lower side mount rubber 1 e Lower mount rubber housing 2 e Lower front mount rubber 3 NOTE ns The lower front mount rubber should be set between the two bolts 7 4 BRKT UPPER CASING AND BOTTOM COWLING 7 5 Bottom cowling 1 Install e Bottom cowling 1 e Seal rubber 2 NOTE The rubber seal should be so installed that its lip faces downward 2 Install e Bottom cowling D e Shift rod 2 e Screw 3 e Bolt 4 EN Screw Hy 3 Nm 0 3 m 2 2 ft Ib NOTE When placing the bottom cowling on the uppe
54. locking agent and location of application point 0 Apply Gasket Maker Apply LOCTITE No 271 Red LOCTITE 03 Apply No 242 Blue LOCTITE Apply LOCTITE No 572 NOTE In this manual the above symbols may not be used in every case 0000 0 INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT im FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT BRKT 7 1 p 2 ADJ E26 ELECTRICAL SYSTEM 8 TROUBLESHOOTING TRBL 9 SHTG icol CHAPITRE 1 GENERAL INFORMATION IDENTIFICATION u d auda 1 1 SERIAL NUMBE Rua qua 1 1 STARTING SERIAL NUMBERS I nnn 1 1 SAFETY WHILE WORKING 1 2 PIRE PREVENTION uuu uuu ON 1 2 EE 1 2 ee 1 2 OILS GREASES AND SEALING FLUIDS eee 1 2 GOOD WORKING PRACTICES ENEE 1 3 DISASSEMBLY AND ASSEMBLY 1 4 1 5 1 5 FOR POWER UNIT SERVICE pietro sio eee 0 anana nan oisi 1 7 FOR LOWER UNIT r ne kaa aa ga aaa 1 7 I IDENTIFICATION YAMAHA TIT YAMAHA MOTOR CO LTD W MADE IN JAPAN PAYS D ORIGINE JAPON 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 NOJE
55. lush with the crank shaft end until the flywheel comes off the tapered portion of the crankshaft eTo prevent damage to the engine or tools screw in the flywheel magneto puller set bolts evenly and completely so that the puller plate is parallel to the fly wheel Crankcase 1 Remove e Bolt 1 e Crankcase 2 NOTES LL EE Insert a flat head screwdriver between the tabs on both the right and left sides of the crankcase and cylinder and pry the two apart 520 SE D crankcase CYLINDER PISTON AND CRANKSHAFT Crankshaft and piston 1 Remove e Crankshaft and piston 1 NOTE Remove the crankshaft by lightly tapping it with a plastic hammer Piston pin clip 1 Remove e Piston pin clip 1 not piston pin hole edge Piston and small end bearing 1 Remove e Piston pin clip e Small end needle bearing 2 NOTE When the piston pins pistons and small end needle bearings are reused they should be marked with No 1 and 2 so that they are not confused Piston ring 1 Remove e Piston ring the piston ring from the piston by opening the ring to the least possible width Bearing 1 Remove e Bearing NOTE Hold the bearing with the bearing separator and force out the crankshaft with a press Bearing separator 6219 90890 06534 CYLINDER PISTON AND CRANKSHAFT INSPECTION AND REP
56. ng installer YB 6015 90890 06634 Drive rod YB 6071 90890 06606 NOTE Install the bearing with its manufacture s marks or numbers facing outward 4 Install e O ring e Reverse gear shim 2 Reverse gear 3 Oil seal housing 1 Install e Bushing Bushing attachment YB 6028 90890 06650 Drive rod 6229 90890 06652 Depth 5 mm 0 20 in 2 Install e Oil seal D Depth 3 0 3 5 mm 0 12 0 14 in 6 9 Loun de LOWER UNIT 3 Install e Boot e Shift shaft Lower case 1 Install e Forward gear shim 1 e Bearing outer race 2 Bearing installer YB 6167 90890 06628 Drive rod YB 6071 90890 06605 2 Install e Bushing 1 Bushing installer YB 6029 90890 06601 Needle bearing installer YB 6169 Bushing attachment YB 6028 90890 06650 3 Install e Dowel pin 1 e Sleeve 2 e Gasket 3 e Oil seal housing 4 e Bolt 4 Install e Forward gear complete 1 LOWR LOWER UNIT 6 11 5 Install e 1 6 Install e Drive shaft 1 e Pinion gear shim 2 e Pinion gear 3 e Circlip 4 7 Install e Propeller shaft complete 1 e Reverse gear complete 2 e Bolt 3 NOTE Face the arrow mark T upward 8 Check e Shift cam operation Rough operation Repair NOTE u U u uuu u L Check that the dog clutch shifts to For ward Neutral and Reverse correc
57. ngs eAlign the each ring end gap with their locating pins e After fitting the rings check that they move smoothly e Apply 2 stroke outboard motor oil to the pistons and rings Crankshaft and piston 1 Install e Small end needle bearing NOTE Apply 2 stroke outboard motor oil to the bearing 5 16 powr E CYLINDER PISTON AND CRANKSHAFT 5 17 2 Install e Piston e Piston pin 2 e Piston pin clip 3 NOTE e Mold mark 8 faces in the same direction as the UP mark on the piston e When no piston is replaced be sure to re install the pistons in their original cylin der e Always use the new circlip e Apply 2 stroke outboard motor oil to the piston pin seal housing 1 Install e Cil seal 1 e Oil seal 2 e O ring 3 NOTE e Apply water resistant grease to the oil seal lip and the O ring e When press fitting the oil seal be sure that it faces in the correct direction e Always use the new O ring Reed valve assembly 1 Install e Reed valve 1 e Valve stopper 2 e Screw 3 NOTE Apply blue LOCTITE No 242 to screw S Screw AN 1 Nm 0 1 m kg 0 7 ft Ib CYLINDER PISTON AND CRANKSHAFT Cylinder body and crankcase 1 Install e Cylinder body e Crankshaft and piston 2 a e Apply 2 stroke outboard motor oil to cylinder wall piston and its rings e Align the pis
58. nit and check the fol lowing parts Reed valve Cracks Damage Oil seals Leakage Damage Labyrinth seal gt Damage IReplace Cylinder head gasket Leakage Damage Piston Worn Cylinder wall Broken Scuffed Piston ring 9 5 TRBL SHTG ENGINE AND RELATED PARTS ENGINE MISFIRES First check for spark to find cause Check Irregularities of the carburation NO Fuel YES Clean fuel tank Fuel is deteriorated or dirty Replace fuel Fuel strainer Carburetor RESTART Check Check that spark is strong Spark plug Clean Adjust YES NO Incorrect gap Carbon depos Replace its Dirty Oily or burned Plug cap Broken or not tightly fitted Ignition coil Defective check resistance Out of specification Pulser coil Incorrect resistance Charge coil Incorrect resistance Ignition timing Incorrect timing NO 9 6 i 12 ENGINE AND RELATED PARTS x C D I Unit el Incorrect resistance eplace RESTART Check Make sure the compres sion of each cylinders normally YES Re check ignition and fuel NO Disassemble the power unit and check the following parts Reed valve Cracks Damage seals Leakage Damage Labyrinth seal Damage Cylinder head gasket Leakage Damage Piston Worn Cylinder wall Broken Piston ring Scuffed 9 7 TRBL SHT
59. nspect e Steering bracket e Pivot shaft Crack Damage Replace Clamp and swivel bracket 1 Inspect e Clamp bracket e Swivel bracket Crack Damage gt Replace 7 8 BRKT BRACKET Tilt plate 1 Inspect e Tilt plate Crack Damage Replace ASSEMBLY AND INSTALLATION 1 Install e Drive lever 1 e Pin 2 e Crip 3 NOTE Face the arrow mark 8 upward 2 Install e Spring e Tilt plate 2 outer e Spring 3 e Tilt plate 4 inner e Pin 5 e Crip 6 NOTE Align the holes of the tilt plate inner and outer after installing the pin 3 Install e Bushing D e Pin 2 4 Install e Clamp bracket 1 e Friction piece 2 e Bolt 3 e Collar 4 e Nut 9 7 9 BRKT L d BRACKET UNIT 5 Install e Bolt 1 e Plate 2 e Nut 3 KR Nut gt 7 Nm 0 7 kg 5 1 ft Ib 6 Install e Steering shaft 1 e Washer 2 e Bushing 3 NOTE Lu ank aa ere it Apply water resistant grease to steering shaft 7 Install e Friction piece 1 e O ring 2 e Bushing 3 e Bushing 7 10 STEERING HANDLE STEERING HANDLE PREPARATION FOR REMOVAL e Remove the carburator Extent of removal Steering handle removal 2 Steering handle disassembly xtent of removal Remarks Part name Bolt Bushing Steering handle assembly Screw Steering grip jushing Screw Screw Throttle s
60. nt 0 50 0 75 mm ig Example If measurement 0 15 mm Increase shim thickness by 0 50 0 15 1 6 0 35 1 6 0 22 0 20 mm If measurement 0 85 mm Decrease shim thickness by 0 85 0 50 1 6 0 35 1 6 0 224 0 20 mm Loun LOWER UNIT Available shim thickness 0 10 mm NOTE Since the smallest shim available is 0 10 mm if the measurement is between 0 25 and 0 75 mm do not change the shim Loun LOWER UNIT Water pump 1 Install e Outer plate 1 e Gasket 2 e Woodruff key 3 e Impeller 2 Install e Insert cartridge 1 e Bushing e Water pump housing 3 e Plate 4 e Bolt 5 WD Le 6 Apply the impeller with water resistant grease e Align the hole in the water pump housing with the projection in the insert cartridge when assemblying them Turn the drive shaft clockwise when installing the water pump housing e Apply Loctite 572 to the bolts NG Bolt 2 11 Nm 1 1 m kg 8 0 ft Ib 3 Check e Leakage Leak Reinstall Checking steps e Attach the Mity Vac to the oil level hole Mity Vac 35956 90890 06756 e Apply the specified pressure Specified pressure 100 1 0 kg cm2 142 psi e Check that the pressure is held for 10 seconds 6 16 Loun LOWER UNIT Lower unit 1 Install e Dowel pin 1 e Lower unit 2 e Bolt 3 NOTE e Shift the gear in reverse e Insert the driv
61. over 2 e Clamp 3 e Bolt 4 NOTE e Apply 2 stroke outboard motor oil to the bolts EE e Tighten the bolts in sequence and in two steps of torque Bolt cylinder head cover 1st 4 Nm 0 4 m kg 2 9 ft ib 2nd 8 Nm 0 8 m kg 5 8 ft Ib Oil seal housing 1 Install e Oil seal Q e 0 Apply water resistant grease to the oil seal lip and the O ring 2 Install Oil seal housing 1 Flywheel magneto 1 Install e Starter stay e Bolt Pown CYLINDER PISTON AND CRANKSHAFT 5 21 2 install e Friction plate 1 e Retainer 2 e Bolt 3 e Retainer ring 4 NOTE Apply water resistant grease to the retainer ring 3 Install e Bushing 1 NOTE Apply water resistant grease to both inner and outer surfaces of the bushing 4 Install e Stator assembly 1 e Screw 2 5 Check e Stator assembly Stiff gt Repair 6 Install e Woodruff key 1 7 Install e Flywheel magneto 1 e Washer 2 e Nut 3 NOTE e Make sure the woodruff key is properly seated in the keyway of the crankshaft e Apply 2 stroke outboard motor oil to both surfaces of the washer CYLINDER PISTON AND CRANKSHAFT Flywheel holder YB 6139 90890 06522 For USA and CANADA Except for USA and CANADA M 8 Install e Starter pulley 1 e Bolt 2 Nut 45 Nm 4 5 kg 32 ft Ib
62. priate to the work you are doing OILS GREASES AND SEALING FLUIDS Use only genuine Yamaha oils greases and sealing fluids or those recommended by Yamaha EET SAFETY WHILE WORKING 1 3 Under normal conditions of use there should be no hazards from the use of the lubricants mentioned in this manual but safety is all important and by adopting good safety practices any risk is mini mized A summary of the most important precau tions is as follows 1 While working maintain good stan dards of personal industrial hygiene Clothing which has become contami nated with lubricants should changed as soon as practicable and laundered before further use Avoid skin contact with lubricants do not for example place a soiled wiping rag in one s pocket 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 To protect the skin the application of a suitable barrier cream to the hands before working is recommended A supply of clean lint free cloths shouid 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 dont improvise Tightening torque Follow the torque tightening instruc t
63. r casing use care so that the rubber seal does not come off the bottom cowling 3 Install e Shift spring 1 4 Install e Bracket 1 e Shift rod lever 2 NOTE The brackets should be so positioned that their round corner sides face outward BRKT UPPER CASING AND BOTTOM COWLING 5 Install e Shift rod lever 1 e Shift rod 2 e Bolt 3 NOTE i U uu uuu u the shift rod into the hole in the other arm e Turn the shift rod lever 180 backward Bolt 6 Nm 0 6 m kg 4 3 ft Ib F Bg fee 6 Install e Shift handle e Screw 2 e Grommet 3 e Clamp hook 2 e Clamp lever 5 Screw 4 Nm 0 4 kg 2 9 ft Ib 7 6 BRKT x BRACKET UNIT BRACKET UNIT PREPARATION FOR REMOVAL e Remove the power unit e Remove the upper casing and bottom cowling A 5 Nm 0 5 m kg 3 6 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Yx BRACKET UNIT Extent of removal 1 Swivel bracket removal D Clamp bracket removal 3 Swivel bracket disassembly Soit Steering bracket Washer Bushing Friction plate D mp ONG 25 58 Remarks xtent of remova 9 Swivel bracket Bushing O ring Bushing Clamp bracket Pin Tilt plate inner Tilt plate outer Pin Drive lever Carrying handle lI INSPECTION Steering bracket and pivot shaft 1 I
64. re attempting to check the starting system replace the propeller with the specified test propeller and install the motor in a test tank Test propeller 90890 01625 7 Check for normal operation of the engine stop system PREDELIVERY SERVICE D24500 0 FUEL LEAKAGE Check for fuel leakage INSP ADJ D25000 0 WATER LEAKAGE Check for water leakage D25500 0 EXHAUST LEAKAGE Check for exhaust leakage D26000 0 ENGINE AND LOWER UNIT NOISE Check the engine and lower unit for abnor mal noise D26500 0 IDLE SPEED Check that the engine speed at fully closed throttle is correct D27000 0 IGNITION TIMING Check that the ignition timing at fully closed and fully open throttle positions is correct D27500 0 MOTOR EXTERIOR Check the motor exterior for any flaking of the paint and if necessary touch up with paint of the original color D28000 1 INSTRUCTING THE NEW OWNER Instruct the new owner on the operation of all controls and the break in procedure Also advise him propeller to boat matching 3 6 PERIODIC SERVICE D30000 0 PERIODIC SERVICE MAINTENANCE SCHEDULE The following chart may be taken as a helpful guide to the intervals between maintenance procedures Ls Interval Thereafter every Item Remarks 10 hours 50 hours 100 hours 100 hours 200 hours Break in 3 months 6 months 6 months 12 months Inspection Replacement
65. retarded B T D C 0 08 0 04 0 0031 0 0016 at full advanced B T D C 4 79 0 26 0 189 0 010 STARTER MOTOR Output Brush length 7 5 0 30 7 5 0 30 Wear limit 4 5 0 18 4 5 0 18 Commutator diameter 20 0 0 79 20 0 0 79 Limit 19 4 0 76 19 4 0 76 Clutch type Over running Rating 2 5 MAINTENANCE SPECIFICATIONS Worldwide USA CANADA NEUTRAL SWITCH Distance A ON i 18 5 19 5 18 5 19 5 0 73 0 77 0 73 0 77 Distance OFF i 19 6 20 5 19 6 20 5 STATOR ASSEMBLY Pulser coil resistance 92 112 W R B Charge coil resistance 81 99 Br B Lighting voltage minimum 12 3 000 Lighting voltage 13 5 16 5 5 500 maximum Lighting coil resistance 0 36 0 44 G G Pole number 4 IGNITION COIL Primary coil resistance 0 25 0 35 Secondary coil resistance 6 8 10 2 high tension cords SPARK PLUG Gap 0 9 1 0 0 035 0 039 resistance 0 9 1 0 0 035 0 039 MAINTENANCE SPECIFICATIONS Worldwide Unit 6CEM 8CEM RNC ONE C D I UNIT Resistance e Needle swings once and returns to home position oo Discontinuity Black Brown Green Orange White White Red RECTIFIER REGURATOR sw SCH jvjsceM O Continuity Discontinuity B Black Green G W Green White R Red RECTIFIER 6 scu LISER 4 O Continuity Discontinuity B Black G1
66. spark plug threads to pre vent future thread seizure IN Spark plug AN 25 Nm 2 5 kg 18 ft Ib NOTE If a 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 Have the spark plug torqued to the correct value as soon as pos sible with a torque wrench INSP Q PERIODIC SERVICE ADJ ENGINE MOUNTING BOLTS AND FLYWHEEL NUT 1 Check Engine mounting e Flywheel nut Loosen Tighten START IN GEAR PROTECTION ADJUSTMENT 1 Check e Start in gear protection operation Incorrect Adjust 2 Adjust e Start in gear protection wire Adjustment steps e Set the shift lever to neutral Loosen the lock nut e Adjust the start in gear protection wire adjust bolt so that the end of the starter stop plunger aligns with the cen ter of the hole in the starter case Tighten the lock nut IDLE SPEED ADJUSTMENT NOTE After adjusting the engine idle speed the throttle control link should be adjusted 1 Measure e Idle speed Out of specification Adjust Idle speed 900 50 rpm e Measuring steps e Start the engine and let it warm up eAttach the tachometer to spark plug lead Tachometer YU 8036 A 90890 06760 YU 8036 A 2 Adjust e idle speed Adjustment steps e Turn the pilot screw 1 until it is lightly seated
67. sult in fire or explosion 3 Nm 0 3 m kg 2 2 ft Ib Extent of removal D Front panel removal 2 Fuel joint removal 3 Fuel strainer removal Extent of removal 1 D 2 3 Choke joint Disconnect the joint at carbu retor side Screw Front panel Bolt Fuel joint Fuel strainer 4 1 Disconnect the fuel hose EE FUEL m FUEL SYSTEM 4 2 E21850 0 INSPECTION Fuel joint 1 Inspect e Fuel joint Crack Leak Damage Replace 2 Measure e Fuel joint operation Impossible to maintain the specified pressure for 10 sec Replace Measuring steps e Attach the Mity vac Mity vac YB 35956 90890 06756 e Apply the specified pressure Specified pressure 50 kPa 0 5 kg cm 7 1 psi Fuel strainer 1 Inspect e Fuel strainer Crack Leak Clog Replace E22050 0 ASSEMBLY AND INSTALLATION Fuel strainer 1 Install Fuel strainer 1 e Fuel hose 0 to carburetor e Fuel hose 3 from fuel joint NOTE The direction mark should be installed facing to the carburetor FUEL FUEL SYSTEM Fuel joint 1 Install e Fuel joint 1 e Fuel hose 2 to fuel filter e Clip 3 e Bolt 4 2 Install e Front panel 1 e Screw 2 N Screw 3 Nm 0 3 m kg 2 2 ft Ib 3 Connect e Choke joint NOTE After installing check the smooth move ment of the choke knob 4 Check
68. t of remova Order Part name Q ty Hemarks As required ale O Om gt Q N otter pin Nut Propeller Spacer Bolt Shift rod connector Bolt Lower unit Bolt Water pump housing Impeller Woodruff key Refer to REMOVAL POINTS 13 Gasket 14 Outer plate 15 Bolt 16 Reverse gear complete 17 Propeller shaft complete 18 Circlip 19 Pinion gear 20 Pinion gear shim 21 Drive shaft 22 Forward gear complete 23 Bolt 24 seal housing 25 Shift shaft 26 Bushing 27 Sleeve 7 Refer to REMOVAL POINTS 30 Forward gear shim 31 Reverse gear 32 Reverse gear shim 33 Ball bearing 34 Bushing 35 Cross pin ring 36 TOSS 1 37 Dog clutch 1 38 Forward gear 1 Reiter to REMOVAL POINTS Refer to REMOVAL POINTS LOWER UNIT 6 3 REMOVAL POINTS Shift shaft 1 Remove e Bolt 1 e Shift rod connector 2 Reverse gear complete 1 Remove e Reverse gear complete Bearing housing puller YB 6234 Universal puller YB 6117 NOI m Fit a flat head screwdriver into one of the two notches in the bearing housing flange and pry the housing off slightly Pinion gear 1 Remove e Circlip 1 e Pinion gear 2 e Pinion gear shim 3 Bushing 1 Remove e Bushing 0 oil seal housing Stopper guide plate 90890 0650
69. the tester s internal resistance To obtain the correct value subtract this internal resistance from the displayed mea surement Correct value Displayed measurement Inter nal resistance NOTE The internal resistance of the tester can be obtained by connecting both of its termi nals IGNITION SYSTEM Spark plug Refer to page 3 11 Spark plug cap 1 Inspect e Spark plug cap Loosen Tighten Crack Damage Replace ELEC INSPECTION 8 6 Replacement steps Except for Canada and Europe Remove spark plug cap by pulling the cap and remove the plug cap spring from the high tension cable e Cut about distance off the end of the high tension cable Distance 5 mm 0 2 in e Referring to the diagram strip about 5 mm 0 2 in of the insulation off the end of the high tension cable and fit the plug cap spring e Push the cap spring into the plug cap D Bend 2 Contact Replacement steps For Canada and Europe eRemove the spark plug cap by turning the cap counterclockwise Avoid removing the plug cap by pulling the wire hard Remove it by turning in and out einstall the plug cap by turning the cap clockwise until it stops Ignition coil 1 inspect e High tension cord Crack Damage gt Replace ELEC INSPECTION 2 Measure e Primary coil resistance Out of specification Replace Primary coil resistance Orange O Black
70. tly Backlash measurement NOTE e Both forward and reverse gear backiash should be measured e If both the forward and reverse gear back lash are larger than specified the pinion may be too high LOWR de LOWER UNIT elf both the forward 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 0 25 0 75 mm Measuring steps e Place the shift shaft in neutral e Load the forward gear with the bearing 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 Bearing housing puller YB 6234 Universal puller YB 6117 e Set the lower unit upside down e 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 Lown LOWER UNIT 6 13 Dial gauge YU 3097 90890 01252 Magnet base YU 34481 90890 06705 Backlash indicator YB 6265 90890 06265 eWhile 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 remove
71. ton ring end gaps with the respective locating pins eFit the bearing and the labyrinth seal locating pins in the cylinder body 2 Apply e Gasket maker Onto the connecting surfaces of the crankcase and cylinder body NOTE eClean the connecting surfaces of the crankcase and cylinder body before applying the Gasket Maker e Gasket maker should be so applied that it does not overflow the contacting surface 3 Install e Dowel pin e Crankcase 1 e Reed valve assembly e Intake manifold 2 e Bolt 3 VIS e Apply blue LOCTITE No 242 to the bolts e Tighten the bolts in sequence and in two steps of torque Bolt 1st 6 Nm 0 6 m kg 4 3 ft Ib 2nd 11 Nm 1 1 m kg 8 0 ft Ib 5 18 CYLINDER PISTON AND CRANKSHAFT 4 Install e seal housing 1 NOTE Apply water resistant grease to connectinc surface of oil seal housing Exhaust cover 1 Install e Gasket 1 e Exhaust inner cover 2 e Exhaust outer cover 3 e Bolt 4 NOTE e Apply LOCTITE No 572 to the bolts e Tighten the bolts in sequence and in two steps of torque Bolt 1st 4 Nm 0 4 m kg 2 9 ft Ib 2nd 8 Nm 0 8 m kg 5 8 ft Ib Exhaust manifold 1 install e Exhaust manifold 1 e Bolt 2 Cylinder head cover 1 Install e Thermostat d e Collar 2 5 19 CYLINDER PISTON AND CRANKSHAFT 5 20 2 Install e Gasket 1 e Cylinder head c
72. ture Printed in USA P N LIT 18616 01 64 HOW USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential 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 j d PU 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 mE Bearings E Pitting Damage Replace To assist you to find your way about this manual the Section Title and Major Heading 15 given the head of every page 0 An Index to contents is provided on the first page of each Section MODEL INDICATION Multiple models are shown in this manual These indications are noted as follows 6MH USA CANADA 8MH USA CANADA THE ILLUSTRATIONS i some illustrations in this manual may differ from model you have This is because cedure described may relate to several models though only one may be illustrated The name of model described will be mentioned in the description REFERENCES These have been kept to a minimum however when you are referred to another section of the manual you are told the page number to go to HOW TO READ DESCRIPTIONS 1 An easy to see disassembly illustration is mainly
73. y turning the mag neto base e Adjust the stopper plate so that the it to contact with the magneto base stopper 5 NOTE Press the stopper plate against the full advanced side of the magneto base Ignition timing at full advanced B T D C 35 1 Tighten the stopper plate set bolt e Connect the joint link THROTTLE CONTROL LINK ADJUSTMENT NOTE Before adjusting the throttle control link the ignition timing should be adjusted 1 Check e Full open position Incorrect gt Adjust Checking steps e Set the shift lever to forward position e Fully open the throttle grip e Check the magneto base stopper 1 so that the it to contact with the stopper plate 2 e Check the throttle valve in full opened 2 Adjust e Throttle control link Adjustment steps e Remove the joint link 1 e Set the shift lever to forward position e Bring the stopper on the full advanced side of the magneto base to contact the magneto base stopper e Fully open the throttle grip e Adjust the cable adjuster on the pull throttle cable 2 until to fully open the carburetor throttle valve eTighten the look nut 3 on the pull throttle cable e Adjust the cable adjuster on the push throttle cable 2 until there is 3 mm 0 12 in free play on the throttle grip Tighten the lock nut 3 16 3 17 e Adjust the length of the

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