Yamaha | 40V | Service manual | Yamaha 40V Service manual

WORLD WIDE
40V, 50H
USA/CANADA
40W, 50W
SERVICE
MANUAL
LIT-18616-01-81
290320
E
A20000-0
NOTICE
This manual has been prepared by the Yamaha Motor Company primarily for use by Yamaha
dealers and their trained mechanics when performing maintenance procedures and repairs to
Yamaha 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 products, models may differ in detail from the descriptions and illustrations given in this publication. 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*
40V/50H
SERVICE MANUAL
1997 Yamaha Motor Corporation, USA
1st Edition, August 1997
All 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.
LIT-18616-01-81
E
HOW TO 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 complied to provide the mechanic with an easy to read, handy reference 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.,
● Bearings
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.
MODEL INDICATION
Multiple models are shown in this manual. These indications are noted as follows.
Model name
40VMH
40VMHD
40VMHO
40VMO
USA and
CANADA name
C40MH
Indication
40VMH
40VMHD
40VMHO
40VMO
Model name
40VETO
50HMHO
50HMHD
50HMO
USA and
CANADA name
40TR
Indication
40VETO
40VWH
40VE
40VEO
40VEHTO
40VET
C40ER
40ER
P40TH
C40TR
40VWH
40VE
40VEO
40VEHTO
40VET
50HMDO
50HWHD
50HEDO
50HET
50HETO
50ER
C50TR
50TR
50HEDO
50HET
50HETO
40MH
50HMHO
50HMHD
50HMO
50HMDO
50HWHD
THE ILLUSTRATIONS
Some illustrations in this manual may differ from the model you have. This is because a procedure 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.
E
WARNINGS, CAUTIONS AND NOTES
Attention is drawn to the various Warnings, Cautions and Notes which distinguish important
information in this manual in the following ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
SPECIFICATIONS
These are given in bold type at each procedure. It is not necessary to leave the section dealing with the procedure in order to look up the specifications.
It is important to note the differences in specifications of models. When a procedure relates to
more than one model, the main differences in specifications will be shown in a following table.
Model name
40VMH
40VMHD
40VMHO
40VMO
40VWH
40VE
40VEO
40VEHTO
40VET
Starting system
Manual
Manual
Manual
Manual
Manual
& Electric
Electric
Electric
Electric
Electric
Control system
Tiller
Tiller
Tiller
Remote
Tiller
Remote
Remote
Tiller
Remote
PTT
PTT
Trim/Tilt system
Lubrication system
Manual tilt Hydro tilt Manual tilt Manual tilt Hydro tilt Manual tilt Manual tilt
Pre-Mixed Pre-Mixed
Oil injection Oil injection
Pre-Mixed Pre-Mixed Oil injection Oil injection Pre-Mixed
Warning indicator
lamp
1
1
1
1
1
1
3
—
—
Enrichment system
Choke
Choke
Choke
Choke
Prime Start
Prime Start
Prime Start
Prime Start
Prime Start
Model name
40VETO
50HMHO
50HMHD
50HMO
50HMDO
50HWHD
50HEDO
50HET
50HETO
Starting system
Electric
Manual
Manual
Manual
Manual
Manual &
Electric
Electric
Electric
Electric
Control system
Remote
Tiller
Tiller
Remote
Remote
Tiller
Remote
Remote
Remote
Trim/Tilt system
PTT
Hydro tilt
Hydro tilt
PTT
PTT
Lubrication system
Manual tilt Hydro tilt Manual tilt Hydro tilt
Oil injection Oil injection Pre-Mixed Oil injection Oil injection Pre-Mixed Oil injection Oil injection Oil injection
Warning indicator
lamp
3
1
1
1
1
1
3
—
—
Enrichment system
Prime Start
Choke
Choke
Choke
Choke
Prime Start
Prime Start
Prime Start
Prime Start
E
HOW TO READ DESCRIPTIONS
1. A disassembly installation job mainly consists of the exploded diagram 1.
2. The numerical figures represented by the number 2 indicates the order of the job steps.
3. The symbols represented by the number 3 indicates the contents and notes of the job.
For the meanings of the symbols, refer to the next page(s).
4. The REMOVAL AND INSTALLATION CHART 4 is attached to the exploded diagram and
explains the job steps, part names, notes for the jobs, etc.
5. The SERVICE POINTS, other than the exploded diagram, explains in detail the items difficult to explain in the exploded diagram or REMOVAL AND INSTALLATION CHART, the
Service points requiring the detailed description 5, etc.
E
1
A50001-1-4
2
GEN
INFO
SYMBOLS
Symbols 1 to 9 are designed as thumbtabs to indicate the content of a chapter.
SPEC
3
1
2
3
4
5
6
7
8
9
4
INSP
ADJ
FUEL
5
6
LOWR
POWR
7
General Information
Specifications
Periodic Inspection and Adjustment
Fuel System
Power Unit
Lower Unit
Bracket Unit
Electrical System
Trouble-analysis
8
BRKT
–
ELEC
9
Symbols 0 to F indicate specific data:
0
0
A
B
C
D
E
F
TRBL
ANLS
B
C
D
E
F
Special tool
Specified liquid
Specified grease
Specified engine speed
Specified torque
Specified measurement
Specified electrical value
[Resistance (Ω), Voltage (V), Electric current
(A)]
T.
A
+
R.
Symbol G to J in an exploded diagram
indicate grade of lubricant and location of
lubrication point:
G
H
G
E
I
J
A
M
K
L
GM
LT
271
M
N
LT
LT
242
572
G
H
I
J
Apply Yamaha 2-stroke outboard motor oil
Apply Yamaha gear-case lubricant
Apply molybdenum disulfide oil
Apply water resistant grease (Yamaha
grease A, Yamaha marine grease)
Symbols K to N in an exploded diagram
indicate grade of sealing or locking agent,
and location of application point:
K
L
M
N
Apply Gasket maker
Apply LOCTITE No. 271 (Red LOCTITE)
Apply LOCTITE No. 242 (Blue LOCTITE)
Apply LOCTITE No. 572
NOTE:
In this manual, the above symbols may not
be used in every case.
E
A30000-0
INDEX
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC INSPECTION AND
ADJUSTMENT
FUEL SYSTEM
POWER UNIT
LOWER UNIT
BRACKET UNIT
GEN
INFO
SPEC
INSP
ADJ
FUEL
POWR
LOWER
BRKT
–
ELECTRICAL SYSTEM
TROUBLE-ANALYSIS
+
ELEC
TRBL
ANLS
1
2
3
4
5
6
7
8
9
GEN
INFO
E
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION............................................................................................. 1-1
SERIAL NUMBER ..................................................................................... 1-1
STARTING SERIAL NUMBERS ............................................................... 1-1
SAFETY WHILE WORKING ............................................................................ 1-2
FIRE PREVENTION ................................................................................... 1-2
VENTILATION........................................................................................... 1-2
SELF-PROTECTION.................................................................................. 1-2
OILS, GREASES AND SEALING FLUIDS................................................ 1-2
GOOD WORKING PRACTICES ................................................................ 1-3
DISASSEMBLY AND ASSEMBLY ........................................................... 1-4
SPECIAL TOOLS ............................................................................................. 1-5
MEASURING ............................................................................................ 1-6
REMOVAL AND INSTALLATION ............................................................ 1-8
1
2
3
4
5
6
7
8
9
GEN
INFO
IDENTIFICATION
E
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:
As an 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.
1
2
3
4
Model name
Approved model No.
Transom height
Serial number
STARTING SERIAL NUMBERS
The starting serial number blocks are as follows:
Model
Worldwide
40VMH
USA,
CANADA
Starting
serial No.
6H4
S: 010262 ~
L: 310801 ~
L: 560290 ~
S: 191877 ~
L: 491566 ~
S: 290284 ~
L: 860312 ~
L: 510116 ~
S: 060285 ~
L: 360173 ~
S: 110760 ~
L: 842362 ~
X: 740146 ~
L: 430386 ~
L: 921505 ~
S: 880367 ~
L: 544974 ~
X: 900196 ~
C40MH
40VMHD
—
40VMHO
40MH
40VMO
—
40VWH
—
40VE
C40ER
40VEO
40ER
40VEHTO
40VET
P40TH
C40TR
40VETO
40TR
Model
Approved
model
code
Worldwide
50HMHO
50HMHD
50HMO
50HMDO
50HWHD
USA,
CANADA
—
—
—
—
—
50HEDO
50ER
50HET
C50TR
50HETO
50TR
1-1
Approved
model
code
Starting
serial No.
6H5
S: 190662 ~
L: 310380 ~
S: 260189 ~
L: 560258 ~
L: 850194 ~
S: 090431 ~
L: 521079 ~
L: 900101 ~
S: 210142 ~
L: 444058 ~
X: 750216 ~
GEN
INFO
SAFETY WHILE WORKING
E
SAFETY WHILE WORKING
The procedures given in this manual are
those recommended by Yamaha to be followed by Yamaha dealers and their
mechanics.
FIRE PREVENTION
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 is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe.
When test-running an engine indoors,
maintain good ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety
glasses or safety goggles when using compressed 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 appropriate 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.
1-2
GEN
INFO
SAFETY WHILE WORKING
E
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 minimized.
A summary of the most important precautions is as follows:
1. While working, maintain good standards of personal and industrial
hygiene.
2. Clothing which has become contaminated 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 wipingrag in one’s pocket.
4. Hands and any other part of the body
which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with
hot water and soap as soon as practicable.
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 instructions. When tightening bolts, nuts and
screws, tighten the large sizes first, and
tighten inner-positioned fixings before
outer-positioned ones.
1-3
GEN
INFO
SAFETY WHILE WORKING
E
3. Non-reusable items
Always use new gaskets, packings, Orings, split-pins and circlips etc. on
reassembly.
DISASSEMBLY AND ASSEMBLY
1. Clean parts with compressed-air on disassembling 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
GEN
INFO
SPECIAL TOOLS
E
A80000-0*
SPECIAL TOOLS
The use of correct special tools recommended by Yamaha will aid the work and enable accurate assembly and tune-up. Improvisations and use of improper tools can cause damage to
the equipment.
NOTE:
● For U.S.A. and Canada, use part number starting with “YB-”, “YU-” or “YW-”.
● For others, use part number starting with “90890-”.
1-5
GEN
INFO
SPECIAL TOOLS
E
MEASURING
Tool name
1
2
3
4
5
6
7
8
9
10
11
Tachometer
Dynamic spark tester
C.D.I. tester
Mity Vac
Pressure tester
Dial indicator
Backlash indicator
Magnetic flexible stand
Backlash adjusting plate
Thickness gauge
Pinion height gauge
12
Digital caliper
13
14
15
16
17
18
19
20
21
22
23
24
Gauge block
Adapter plate
Gauge base
Clamp
Shimming plate
Base plate
Compression spring
Press plate
Gauge pin
Digital multimeter
Pocket tester
Spins test harness
Tool No.
Except for
USA and
USA and
Canada a
Canada b
YU-08036-A 90890-06760
YM-34487 90890-06754
YU-91022-B
N.A.
YB-35956
90890-06756
YB-35956
90890-06762
YU-03097
90890-01252
YB-06265
90890-06706
YU-34481
90890-06705
YB-07003
N.A.
YU-26900-9
N.A.
N.A.
90890-06702
N.A.
90890-06704
YB-34432-9
YB-34432-10
YB-34432-11
YB-34432-17
N.A.
YB-34446-1
YB-34446-3
YB-34446-4
YB-34446-7
YU-34899-A
YU-03112
YB-06757
N.A.
N.A.
N.A.
N.A.
90890-06701
N.A.
N.A.
N.A.
N.A.
90890-06752
90890-03112
90890-06757
1-6
Use for:
Idle speed
Ignition system
Ignition system
Fuel joint
Lower case
Backlash
Backlash
Backlash
Backlash
Shimming
Pinion shimming
Pinion
Forward
shimming
shimming
Pinion shimming
Pinion shimming
Pinion shimming
Pinion shimming
Forward shimming
Forward shimming
Forward shimming
Forward shimming
Forward shimming
Electrical
Electrical
Peak voltage measurement
GEN
INFO
SPECIAL TOOLS
E
1-7
GEN
INFO
SPECIAL TOOLS
E
REMOVAL AND INSTALLATION
Tool name
1
Small end bearing
needle installer
Tool No.
Except for
USA and
USA and
Canada a
Canada b
YB-06106
90890-06526
2
Bearing separator
YB-06219
90890-06534
3
4
Flywheel holder
Flywheel puller
YB-06139
YB-06117
90890-06522
90890-06521
5
Stopper guide plate
N.A.
90890-06501
6
7
8
9
Bearing housing puller
Center bolt
Universal puller
Oil seal installer
YB-06234
N.A.
YB-06117
YB-06168
90890-06503
90890-06504
N.A.
N.A.
10
Needle bearing remover
YB-06112
90890-06614
11
Needle bearing installer
YB-06111
90890-06614
12
Bearing outer race puller
clow
N.A.
90890-06535
Use for:
Small end
Reverse gear
bearing
Crank shaft
Forward
bearing
gear inner
bearing
Flywheel
Flywheel
Reverse gear
bearing
Propeller
shaft housing Drive shaft
outer bearing
Propeller shaft housing
Propeller shaft housing
Propeller shaft housing
Propeller shaft oil seal
Propeller shaft
needle bearing
Propeller shaft
needle bearing
Reverse gear bearing
13
Stopper guide stand
14
Slide hammer set
YB-06096
15
16
17
Pinion nut wrench
Socket adapter
Drive shaft holder
Needle bearing attachment
Drive shaft needle bearing depth stop
Bearing installer
Bearing installer
Bearing installer
N.A.
N.A.
YB-06079
Forward
Reverse gear
90890-06538
gear outer
bearing
bearing
Drive shaft
outer bearing
Reverse gear
N.A.
Forward
bearing
gear outer
bearing
90890-06505
Pinion nut
90890-06506
Pinion nut
90890-06517
Pinion nut
YB-06063
90890-06614
Drive shaft needle bearing
YB-34473
N.A.
Drive shaft needle bearing
YB-06167
YB-06110
YB-06270-A
90890-06628
90890-06627
90890-06640
Drive shaft oil seal
Drive shaft outer bearing
Forward gear inner bearing
18
19
20
21
22
N.A.
1-8
GEN
INFO
SPECIAL TOOLS
E
1-9
GEN
INFO
SPECIAL TOOLS
Tool name
23
E
Tool No.
Except for
USA and
USA and
Canada a
Canada b
N.A.
90890-06523
25
26
27
Bearing outer race puller
Bearing outer race puller
clow
Bearing installer
Shift rod wrench
Tilt cylinder wrench
28
Bearing depth plate
N.A.
90890-06603
29
Driver rod - SL
N.A.
90890-06602
30
Driver rod - SS
N.A.
90890-06604
31
32
33
Driver rod - L
Driver rod - S
Driver rod - M10
YB-06071
N.A.
N.A.
90890-06605
90890-06606
90890-06652
24
N.A.
Use for:
Forward gear outer bearing
90890-06532
Forward gear outer bearing
YB-41446
90890-06626
YB-06052
N.A.
YB-06175-2B 90890-06544
Forward gear outer bearing
Shift rod
PTT
Propeller
Drive shaft
shaft needle needle bearbearing
ing
Drive shaft needle bearing
Propeller shaft
needle bearing
Bearing and oil seal
Bearing and oil seal
Bearing and oil seal
1-10
SPEC
E
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................... 2-1
MAINTENANCE SPECIFICATIONS................................................................ 2-7
ENGINE..................................................................................................... 2-7
LOWER...................................................................................................... 2-9
ELECTRICAL ........................................................................................... 2-10
DIMENSION 1......................................................................................... 2-13
DIMENSION 2......................................................................................... 2-15
TIGHTENING TORQUE................................................................................. 2-17
SPECIFIED TORQUE .............................................................................. 2-17
GENERAL TORQUE ............................................................................... 2-18
1
2
3
4
5
6
7
8
9
SPEC
GENERAL SPECIFICATIONS
E
GENERAL SPECIFICATIONS
Item
Model
Unit
Worldwide
USA, CANADA
DIMENSION:
Over-all length
Over-all width
Over-all height
40VMH
C40MH
40VMHD
—
1,281 (50.4)
mm (in)
mm (in)
40VMO
—
40VWH
—
670 (26.4)
1,281 (50.4)
349 (13.7)
mm (in)
S
L
X
40VMHO
40MH
1,223 (48.1)
360 (14.2)
—
1,223 (48.1)
mm (in)
1,350 (53.1)
mm (in)
—
—
Boat transom height
S
L
X
WEIGHT:
(with aluminum propeller)
S
L
X
PERFORMANCE:
Output (ISO)
Full throttle operating
range
Maximum fuel consumption
ENGINE:
Type
Number of cylinder
Total displacement
Bore × Stroke
Compression ratio
Number of carburetor
Intake system
Scavenging system
Control system
Starting system
Ignition system
Alternator output
Enrichment system
Advance type
Spark plug (NGK)
For CANADA and
Europe
Exhaust system
Cooling system
Lubrication system
mm (in)
381 (15.0)
—
381 (15.0)
mm (in)
508 (20.0)
mm (in)
—
381 (15.0)
—
kg (lb)
74 (163)
—
75.8 (167)
71.5 (158)
—
kg (lb)
76.5 (169)
84 (185.2)
77.5 (171)
74 (163)
81.5 (179.7)
kg (lb)
—
kW (hp)/rpm
29.4 (40)/5,000
rpm
4,500 ~ 5,500
L (US gal,
Imp gal)/
h at rpm
18.5 (4.9, 4.1) at 5,500
2 stroke - L
3
3
cm (cu. in)
698 (42.6)
mm (in)
67.0 × 66.0 (2.64 × 2.60)
6.00
3
Reed valve
Loop charge
Tiller control
Remote control
Tiller control
Manual &
Electric
Manual
CDI
80W
12-80
80W
Choke valve
12-6A
Prime start
Electric automatic
B7HS-10
BR7HS-10
Through propeller boss
Water
Pre-mixed fuel & oil
2-1
Oil injection
Pre-mixed
fuel & oil
SPEC
GENERAL SPECIFICATIONS
E
Item
Worldwide
USA, CANADA
FUEL AND LUBRICATION:
Fuel type
Fuel rating
Engine oil type/grade
Mixing ratio
Engine oil tank capacity
Gear oil type
Gear oil quantity
BRACKET:
Trim/tilt system
Tilt angle
Tilt-up angle
Trim angle
Shallow water crushing
angle
Steering angle
DRIVE UNIT:
Gear shift position
Gear ratio
Gear type
Clutch type
Propeller direction
Propeller drive system
Propeller series mark
ELECTRICAL:
Battery capacity
Cold cranking
Model
Unit
40VMH
C40MH
40VMHD
—
40VMHO
40MH
40VMO
—
40VWH
—
Regular gasoline
1
P.O.N.*
Min. 86
2-stroke outboard motor oil / TC-W3
50 : 1
—
50 : 1
—
1.5 (1.6, 1.3)
—
L (US qt,
Imp qt)
Hypoid gear oil-SAE#90
cm3 (US oz,
Imp oz)
430 (14.5, 15.1)
Manual tilt
degree
8, 12, 16, 20, 24
—
degree
66
69
8, 12, 16, 20, 24
66
degree at 12˚
transom
—
–4 ~ 20
—
degree
Tilt angle +18
—
Tilt angle +18
degree
(left + right)
—
—
Tilt angle +18
40 + 40
F-N-R
1.85 (24/13)
Spiral bevel gear
Dog clutch
Clockwise
Spline
G
Ah (kC)
—
70 (252)
Amps
—
380
*1: Pump Octane Number ; (Research octane + Motor octane)/2
2-2
SPEC
GENERAL SPECIFICATIONS
E
Item
Model
Unit
Worldwide
USA, CANADA
DIMENSION:
Over-all length
Over-all width
Over-all height
40VE
C40ER
40VEO
40ER
40VEHTO
P40TH
40VET
C40TR
40VETO
40TR
mm (in)
670 (26.4)
1,281 (50.4)
646 (25.4)
mm (in)
349 (13.7)
360 (14.2)
350 (13.8)
S
L
X
mm (in)
1,192 (46.9)
S
L
X
mm (in)
mm (in)
mm (in)
—
1,192 (46.9)
—
1,433 (56.4)
—
381 (15.0)
1,319 (51.9)
—
1,433 (56.4)
Boat transom height
WEIGHT:
(with aluminum propeller)
S
L
X
PERFORMANCE:
Output (ISO)
Full throttle operating
range
Maximum fuel consumption
ENGINE:
Type
Number of cylinder
Total displacement
Bore × Stroke
Compression ratio
Number of carburetor
Intake system
Scavenging system
Control system
Starting system
Ignition system
Alternator output
Enrichment system
Advance type
Spark plug (NGK)
For CANADA and
Europe
Exhaust system
Cooling system
Lubrication system
381 (15.0)
mm (in)
508 (20.0)
mm (in)
—
635 (25.0)
—
635 (25.0)
kg (lb)
73.5 (162)
74.5 (164)
—
85.5 (189)
kg (lb)
76 (168)
77.3 (170)
kg (lb)
—
80.5 (177)
90 (198)
87 (191.8)
—
88 (194)
91.5 (201.7)
kW (hp)/rpm
29.4 (40)/5,000
rpm
4,500 ~ 5,500
L (US gal,
Imp gal)/
h at rpm
18.5 (4.9, 4.1) at 5,500
2 stroke - L
3
3
cm (cu. in)
698 (42.6)
mm (in)
67.0 × 66.0 (2.64 × 2.60)
6.00
3
Reed valve
Loop charge
Remote control
Tiller control
Remote control
Electric
CDI
6A
12-6
6A
Pre-mixed
fuel & oil
Oil injection
Prime start
Electric automatic
B7HS-10
BR7HS-10
Through propeller boss
Water
Pre-mixed
fuel & oil
2-3
Oil injection
SPEC
GENERAL SPECIFICATIONS
E
Item
Worldwide
USA, CANADA
FUEL AND LUBRICATION:
Fuel type
Fuel rating
Engine oil type/grade
Mixing ratio
Engine oil tank capacity
Gear oil type
Gear oil quantity
Model
Unit
40VE
C40ER
Shallow water crushing
angle
Steering angle
DRIVE UNIT:
Gear shift position
Gear ratio
Gear type
Clutch type
Propeller direction
Propeller drive system
Propeller series mark
ELECTRICAL:
Battery capacity
Cold cranking
40VEHTO
P40TH
40VET
C40TR
40VETO
40TR
Regular gasoline
1
P.O.N.*
Min. 86
2-stroke outboard motor oil / TC-W3
L (US qt,
Imp qt)
50 : 1
—
50 : 1
—
—
1.5 (1.6, 1.3)
—
1.5 (1.6, 1.3)
Manual tilt
Power trim/
tilt
Hypoid gear oil-SAE#90
cm3 (US oz,
Imp oz)
430 (14.5, 15.1)
BRACKET:
Trim/tilt system
Tilt angle
Tilt-up angle
Trim angle
40VEO
40ER
Power trim/
tilt
Manual tilt
degree
8, 12, 16, 20, 24
—
degree
66
69
degree at 12˚
transom
—
–4 ~ 20
degree
—
Tilt angle +18
degree
(left + right)
—
40 + 40
F-N-R
1.85 (24/13)
Spiral bevel gear
Dog clutch
Clockwise
Spline
G
Ah (kC)
70 (252)
Amps
385
*1: Pump Octane Number ; (Research octane + Motor octane)/2
2-4
380
385
SPEC
GENERAL SPECIFICATIONS
E
Item
Worldwide
USA, CANADA
DIMENSION:
Over-all length
Over-all width
Over-all height
S
L
X
Boat transom height
S
L
X
WEIGHT:
(with aluminum propeller)
S
L
X
PERFORMANCE:
Output (ISO)
Full throttle operation
range
Maximum fuel consumption
ENGINE:
Type
Number of cylinder
Total displacement
Bore × Stroke
Compression ratio
Number of carburetor
Intake system
Scavenging system
Control system
Starting system
Ignition system
Alternator output
Enrichment system
Advance type
Spark plug (NGK)
For CANADA and
Europe
Exhaust system
Cooling system
Lubrication system
Model
Unit
mm (in)
50HMHO 50HMHD 50HMO 50HMDO 50HWHD 50HEDO
—
—
—
—
—
50ER
1,281 (50.4)
670 (26.4)
349 (13.7)
360 (14.2)
349 (13.7)
mm (in)
1,223 (48.1)
—
1,223 (48.1)
—
mm (in)
—
1,350 (53.1)
—
1,350 (53.1)
mm (in)
670 (26.4)
360 (14.2)
1,192 (46.9)
—
mm (in)
381 (15.0)
—
381 (15.0)
mm (in)
—
508 (20.0)
—
—
381 (15.0)
1,192 (46.9)
1,433 (56.4)
—
381 (15.0)
508 (20.0)
—
—
kg (lb)
75 (165)
81.5 (180)
71.5 (158)
kg (lb)
—
84 (185)
—
kg (lb)
—
1,319 (51.9)
—
mm (in)
C50TR
1,281 (50.4)
mm (in)
50HETO
50TR
50HET
—
81.5 (180)
82 (181)
90 (198)
635 (25.0)
—
85.5 (188)
84.5 (186) 87 (191.8) 88 (194)
—
91.5 (202)
kW (hp)/rpm
36.8 (50)/5,000
rpm
4,500 ~ 5,500
L (US gal,
Imp gal)/
h at rpm
22 (5.8, 4.8) at 5,500
2 stroke - L
3
cm3 (cu. in)
698 (42.6)
mm (in)
67.0 × 66.0 (2.64 × 2.60)
6.00
3
Reed valve
Loop charge
Tiller control
Remote control
Manual
Tiller
control
Manual
& Electric
Remote control
Electric
CDI
80W
6A
Choke valve
Prime start
Electric automatic
B8HS-10
BR8HS-10
Through propeller boss
Water
Oil
Pre-Mixed
injection fuel & Oil
2-5
Oil injection
Pre-Mixed
Oil
Pre-Mixed
Oil
fuel & Oil injection fuel & Oil injection
SPEC
GENERAL SPECIFICATIONS
Item
Worldwide
USA, CANADA
FUEL AND LUBRICATION:
Fuel type
Fuel rating
Engine oil type/grade
Mixing ratio
Engine oil tank capacity
Gear oil type
Gear oil quantity
Model
Unit
Tilt-up angle
Trim angle
Shallow water crushing angle
Steering angle
DRIVE UNIT:
Gear shift position
Gear ratio
Gear type
Clutch type
Propeller direction
Propeller drive system
Propeller series mark
ELECTRICAL:
Battery capacity
Cold cracking
50HMHO 50HMHD 50HMO 50HMDO 50HWHD 50HEDO
—
—
—
—
—
50ER
50HET
C50TR
50HETO
50TR
Regular gasoline
P.O.N.*1
Min. 86
2-stroke outboard motor oil / TC-W3
—
L (US qt,
Imp qt)
50 : 1
1.5
(1.6, 1.3)
—
—
50 : 1
—
50 : 1
—
—
1.5
(1.6, 1.3)
—
1.5
(1.6, 1.3)
Manual
tilt
Power
trim/tilt
1.5 (1.6, 1.3)
Hypoid gear oil-SAE#90
3
cm (US oz,
Imp oz)
BRACKET:
Trim/tilt system
Tilt angle
E
degree
430 (14.5, 15.1)
Manual
Manual
Hydro tilt
tilt
tilt
8, 12, 16,
8, 12, 16,
—
20, 24
20, 24
Hydro tilt
—
degree
66
69
66
69
degree at
12˚ transom
—
–4 ~ 20
—
–4 ~20
Tilt angle
+18
—
degree
—
degree
(left + right)
40 + 40
F-N-R
1.85 (24/13)
Spiral bevel gear
Dog clutch
Clockwise
Spline
G
Ah (kC)
—
70 (252)
Amps
—
380
*1: Pump Octane Number ; (Research octane + Motor octane)/2
2-6
SPEC
MAINTENANCE SPECIFICATIONS
E
MAINTENANCE SPECIFICATIONS
ENGINE
Item
CYLINDER HEAD:
Warpage limit
CYLINDER:
Bore size
Wear limit
Taper limi
Out of round limit
PISTON:
Identification mark
Piston clearance
Limit
Diameter D
Measuring point H
Pin boss inside diameter
Ring groove clearance (installed)
top
2nd
Over size piston
Diameter
1st*1
2nd
PISTON PIN:
Diameter
PISTON RING (1st):
Type
Dimensions (B × T)
End gap (installed)
Limit
PISTON RING (2nd):
Type
Dimensions (B × T)
End gap (installed)
Limit
CONNECTING ROD:
Small end diameter
CRANK SHAFT ASSEMBLY:
Crank width A
Crank width B
Runout limit D
Big end side clearance E
Small end axial play limit F
Unit
Model
40 hp
50 hp
mm (in)
0.1 (0.004)
mm (in)
mm (in)
mm (in)
mm (in)
67.00 ~ 67.02 (2.638 ~ 2.639)
67.10 (2.642)
0.08 (0.003)
0.05 (0.002)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
W
0.060 ~ 0.065 (0.0024 ~ 0.0026)
0.115 (0.0045)
66.940 ~ 67.000 (2.6354 ~ 2.6378)
10 (0.4)
18.008 ~ 18.015 (0.7090 ~ 0.7093)
mm (in)
17.995 ~ 18.000 (0.7085 ~ 0.7087)
mm (in)
mm (in)
mm (in)
mm (in)
Keystone
2.0 × 2.6 (0.08 × 0.10)
0.40 ~ 0.60 (0.016 ~ 0.024)
0.80 (0.031)
mm (in)
mm (in)
mm (in)
mm (in)
Keystone
2.0 × 2.6 (0.08 × 0.10)
0.40 ~ 0.60 (0.016 ~ 0.024)
0.80 (0.031)
mm (in)
22.005 ~ 22.008 (0.8663 ~ 0.8665)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
53.90 ~ 53.95 (2.122 ~ 2.124)
32.88 ~ 33.10 (1.294 ~ 1.303)
0.03 (0.001)
0.20 ~ 0.70 (0.008 ~ 0.028)
2.0 (0.08)
*1: Except for U.S.A.
2-7
0.04 ~ 0.08 (0.002 ~ 0.003)
0.03 ~ 0.07 (0.001 ~ 0.003)
67.25 (2.648)
67.50 (2.657)
SPEC
MAINTENANCE SPECIFICATIONS
Item
THERMOSTAT:
Opening temperature
Full-opening temperature
Valve lift
OIL INJECTION PUMP:
Identification mark
Specified discharge
REED VALVE:
Valve stopper height
Valve bending limit
CARBURETOR:
Identification mark
Float height
Valve seat size
Main jet
(M.J.)
Main nozzle
(M.N.)
Main air jet
(M.A.J.)
Pilot jet
(P.J.)
Pilot air jet
(P.A.J.)
Pilot screw
(P.S.)
Starter jet
(S.J.)
Electrothermal valve resistance
(color — color)
Idle speed
RECOIL STARTER:
Starter rope length
Unit
E
Model
40 hp
˚C (˚F)
˚C (˚F)
mm (in)
50 hp
48 ~ 52 (118 ~ 126)
60 (140)
3 (0.12)
63D00
3
cm (US
oz, Imp oz)
1.60 ± 0.50 (0.054 ± 0.017, 0.056 ± 0.018)
mm (in)
mm (in)
6.0 ± 0.2 (0.24 ± 0.01)
0.2 (0.01)
(M model)
(E, W model)
(M model)
63B00
mm (in)
mm (in)
#
mm (in)
#
#
#
turns out
mm (in)
Ω (color)
rpm
mm (in)
2-8
(E, W model)
63D00
62W00
62X00
15.0 ± 1.0 (0.59 ± 0.04)
1.2 (0.05)
115 118(M)
125
130
3.0 (0.12)
3.2 (0.13) 3.0 (0.12)
160
130
140
60
62
75
90
80
1-1/2 ± 1/4
1-5/8 ± 1/4 1-3/8 ± 1/4
—
1.0 (0.04)
—
1.0 (0.04)
2.32 ~ 3.48
2.32 ~ 3.48
—
—
(L — B)
(L — B)
800 ± 50
2,095 (82.5)
SPEC
MAINTENANCE SPECIFICATIONS
E
LOWER
Item
GEAR BACKLASH:
Pinion - forward
Pinion - reverse
Pinion shims
Forward shims
Reverse shims
PROPELLER:
Material
No. of blades × diameter × pitch
Test propeller 1
rpm
Test propeller 2
rpm
POWER TRIM AND TILT:
Fluid type
Fluid capacity
Brush length
Wear limit
Commutator diameter
Limit
Commutator under cut
Unit
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
in
r/min
r/min
3
cm (US
oz, Imp oz)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
2-9
Model
40 hp
50 hp
0.18 ~ 0.45 (0.007 ~ 0.018)
0.71 ~ 0.98 (0.028 ~ 0.039)
0.05, 0.08, 0.12, 0.30, 0.50
0.05, 0.08, 0.12, 0.30, 0.50
0.05, 0.08, 0.12, 0.30, 0.50
Aluminum
3 × 10 × 15
3 × 10-1/4 × 14
3 × 10-3/4 × 16
3 × 10-3/4 × 17
3 × 10-3/8 × 13
3 × 10-5/8 × 12
3 × 11-1/8 × 13
3 × 11-1/4 × 14
3 × 11-3/8 × 12
3 × 11-5/8 × 11
3 × 11-3/4 × 10
3 × 12-1/4 × 9
90890-01611
4,900 ~ 5,100
YB-1611
4,900 ~ 5,100
Stainless steel
3 × 10-1/4 × 14
3 × 10-1/4 × 15
3 × 10-1/4 × 16
3 × 10-5/8 × 13
3 × 11-1/4 × 14
3 × 11-1/2 × 13
3 × 12 × 11
3 × 12 × 12
90890-01611
5,250 ~ 5,450
YB-1611
5,250 ~ 5,450
ATF (Dexiron2)
434 (14.7, 15.3)
10 (0.39)
3.5 (0.14)
22 (0.87)
21 (0.83)
1.5 (0.06)
SPEC
MAINTENANCE SPECIFICATIONS
E
ELECTRICAL
Item
IGNITION TIMING:
Ignition timing
(full retarded)
(full advanced)
(cam roller pick-up)
Piston position
(full advanced)
STARTER MOTOR:
Type
Output
Brush length
Wear limit
Commutator diameter
Limit
Commutator under cut
Limit
Clutch type
Pinion-ring gear gap
Rating
RECTIFIER REGURATOR:
Output peak voltage
(R – B)
@ cranking
@ 1,500 r/min
@ 3,500 r/min
NEUTRAL SWITCH:
Length a (on)
Length b (off)
FUSE:
Rating
THERMO SWITCH (Pink lead):
On temperature
Off temperature
THERMO SWITCH (Orange lead):
On temperature
Off temperature
WARNING LAMP:
Rating
TRIM SENSOR:
Resistance 1 (max)
Resistance 2 (max)
STATOR ASSEMBLY:
Pulser coil resistance 1
Pulser coil resistance 2
Pulser coil resistance 3
Unit
degree
degree
degree
mm (in)
Model
40 hp
50 hp
A.T.D.C. 7 ± 1
B.T.D.C. 25 +3
–1
A.T.D.C. 7
B.T.D.C. 3.93 +0.97
–0.30
(0.155 +0.038
–0.012 )
mm (in)
Sec.
Bendix
0.6
12.5 (0.49)
9.0 (0.35)
30.0 (1.18)
29.0 (1.14)
0.8 (0.03)
0.2 (0.01)
Over running
3.0 ~ 5.0 (0.12 ~ 0.20)
30
V
V
V
8.5
25
25
mm (in)
mm (in)
18.5 ~ 19.5 (0.73 ~ 0.77)
19.5 ~ 20.5 (0.77 ~ 0.81)
V-A
12-10
˚C (˚F)
˚C (˚F)
90 ~ 96 (194.0 ~ 204.8)
76 ~ 90 (168.0 ~ 194.0)
˚C (˚F)
˚C (˚F)
38 ~ 52 (100.4 ~ 125.6)
26 ~ 34 (78.8 ~ 93.2)
V
1.7
Ω (color)
Ω (color)
360 ~ 540 (P — B)
800 ~ 1,200 (O — B)
Ω (color)
Ω (color)
Ω (color)
168 ~ 252 (W/R — B)
168 ~ 252 (W/B — B)
168 ~ 252 (W/G — B)
kW
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
2-10
SPEC
MAINTENANCE SPECIFICATIONS
Item
Charge coil resistance
Charging current (minimum)/rpm
Charging current (maximum)/rpm
Lighting voltage (minimum)/rpm
Lighting voltage (maximum)/rpm
Lighting coil resistance
Pole number
Charge coil output peak voltage
(minimum)
(Br – L)
@ cranking
@ 1,500 r/min
@ 3,500 r/min
Pulser coil output peak voltage
(minimum) (W/R, W/B, W/G – B)
@ cranking
@ 1,500 r/min
@ 3,500 r/min
C.D.I unit output peak voltage
(minimum)
(B/O, B/W, B/Y – B)
@ cranking
@ 1,500 r/min
@ 3,500 r/min
Lighting coil output peak voltage
(minimum)
(G – G/W)
@ cranking
@ 1,500 r/min
@ 3,500 r/min
CDI UNIT:
Over revolution limiter revolution
limit
Over heat controlled revolution
IGNITION COIL:
Type
Primary coil resistance
Secondarily coil resistance
SPARK PLUG:
Gap
Unit
Model
Ω (color)
A/rpm
A/rpm
V/rpm
V/rpm
Ω (color)
40 hp
50 hp
368 ~ 552 (Br — L)
3/3,000
5 ~ 7/5,500
12.0/3,000
13.5 ~ 16.5/5,500
0.56 ~ 0.84 (G/W — G)
6
V
V
V
145
160
130
V
V
V
3.0
9.0
15.0
V
V
V
125
140
110
V
V
V
9.0
25
25
rpm
5,800 ~ 6,200
rpm
1,600 ~ 2,400
Ω (color)
kΩ (color)
Single
0.18 ~ 0.24 (B/W — B)
2.72 ~ 3.68 (B/W — High tension cord)
mm (in)
ENGINE OIL LEVEL SENSOR:
Float position lower a
mm (in)
Float position high b
mm (in)
OIL LEVEL WARNING LAMP:
Rating:
E
V-mA
2-11
0.9 ~ 1.0 (0.035 ~ 0.039)
Electric starting
Manual starting
model
model
56.8 ~ 59.8
56.8 ~ 59.8
(2.24 ~ 2.35)
(2.24 ~ 2.35)
32.8 ~ 35.8
—
(1.29 ~ 1.41)
1.7-20 (Red)/ 2.2-20 (Yellow)/2.1-20 (Green)
SPEC
MAINTENANCE SPECIFICATIONS
2-12
E
SPEC
MAINTENANCE SPECIFICATIONS
DIMENSION 1
2-13
E
SPEC
MAINTENANCE SPECIFICATIONS
E
Model
Symbol
L6
L7
H4
H9
H12
W5
A1
A2
A3
T1
Unit
:S mm (in)
:L
:UL
mm (in)
:S mm (in)
:L
:UL
mm (in)
:S mm (in)
:L
:UL
mm (in)
degree
degree
degree
mm (in)
40VMH
40VMHO
40VWH
50HMHO
40VMO
50HMO
40VE
40VEO
798 (31.4)
50HMDO
40VMHD
50HMHD
50HWHD
40VEHTO
40VET
40VETO
50HEDO
50HET
50HETO
—
822 (32.4)
—
822 (32.4)
—
1,040 (40.9)
910 (35.8)
937 (36.9)
—
1,010 (39.8)
433 (17.0)
401 (15.8)
408 (16.1)
—
1,040 (40.9)
418 (16.5)
—
387 (15.2)
410 (16.1)
535 (21.1)
—
410 (16.1)
—
651 (25.6)
537 (21.1)
—
649 (25.6)
683 (26.9)
671 (26.4)
—
651 (25.6)
696 (27.4)
—
688 (27.1)
118 (4.6)
—
—
118 (4.6)
—
219 (8.6)
171 (6.7)
—
219 (8.6)
340 (13.4)
40
62
65
—
–4
600 (23.6)
2-14
SPEC
MAINTENANCE SPECIFICATIONS
DIMENSION 2
MANUAL TILT MODEL
HYDRO TILT/PTT MODEL
2-15
E
SPEC
Symbol
B1
B2
B3
B4
B5
B6
B9
B11
B12
B13
B14
D1
D2
C1
C2
C3
MAINTENANCE SPECIFICATIONS
Unit
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
E
Model
Manual tilt
62.5 (2.5)
208 (8.2)
121.5 (4.8)
32 (1.3)
131.5 (5.2)
245 (9.6)
25 (1.0)
90.5 (3.6)
57 (2.2)
122 (4.8)
156 (6.1)
10.5 (0.4)
26 (1.0)
30 (1.2)
66 (2.6)
—
2-16
Hydro and PTT
126 (5.0)
254 (10.0)
163.5 (6.4)
50.8 (2.0)
180 (7.1)
355 (14.0)
18.5 (0.7)
—
—
—
—
13 (0.5)
55.5 (2.2)
—
—
69 (2.7)
SPEC
TIGHTENING TORQUE
E
TIGHTENING TORQUE
SPECIFIED TORQUE
M6
14
M6
6
M8
8
Nut
Bolt
Bolt
Nut
Bolt
M16
M10
M8
M12
M6
Nut
Nut
Bolt
Bolt
Bolt
Bolt
Nut
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
1
5
2
1
1
30
40
16
75
5
3.0
4.0
1.6
7.5
0.5
22
29
11
54
3.6
M10
7/8 UNF
M12
M2
M3
M4
7/8 UNF
7/8 UNF
2
2
1
8
8
8
2
2
38
20
38
21
21
21
45
24
3.8
2.0
3.8
2.1
2.1
2.1
4.5
2.4
27
14
27
15
15
15
32
17
M8
M6
M3
—
—
M4
M6
M5
—
1
3
5
1
1
4
4
2
2
7
9
4
90
70
4
7
4
11
0.7
0.9
0.4
9.0
7.0
0.4
0.7
0.4
1.1
5.1
6.5
2.9
65
50
2.9
5.1
2.9
8.0
Bolt
2-17
E
Bolt
LT
14
572
M8
LT
Bolt
572
12
3
LT
M3
M14
572
Bolt
Bolt
LT
12
15
80
2.9
5.8
0.7
18
11
20
2.9
5.8
3.6
8.0
11
20
242
LOWER:
Propeller
Lower unit
Propeller shaft housing
Pinion nut
Water inlet
BRACKET:
Tiller handle mounting
Steering friction mounting
Tiller handle pivot
Muffler
Exhaust manifold
Exhaust guide
Clamp bracket (manual tilt)
Clamp bracket
PTT UNIT:
Plug screw
Tilt cylinder ass’y
Motor unit
Tilt cylinder end bolt
Inner cylinder end bolt
Gear pump
Bottom cover
Retaining plate
Main valve
M6
2.1
11
0.4
0.8
0.1
2.5
1.5
2.8
0.4
0.8
0.5
1.1
1.5
2.8
LT
Crank case
Bolt
21
110
4
8
1
25
15
28
4
8
5
11
15
28
572
Exhaust cover
1st
2nd
1st
2nd
1st
2nd
1st
2nd
8
1
LT
Cylinder head
M8
M16
Remarks
242
Reed valve
Spark plug
Bolt
Nut
Tightening torque
Nm
m•kg
ft•lb
LT
1st
2nd
Q‘ty
572
Intake manifold
Thread
size
LT
ENGINE:
Engine unit
Flywheel
Part
name
572
Part to tightened
SPEC
TIGHTENING TORQUE
Nut (A)
Bolt (B)
8 mm
10 mm
12 mm
14 mm
17 mm
M5
M6
M8
M10
M12
E
GENERAL TORQUE
General torque
specifications
Nm m•kg ft•lb
5.0
0.5
3.6
8.0
0.8
5.8
18
1.8
13
36
3.6
25
43
4.3
31
This chart specifies the torques for tightening standard fastners with standard clean
dry ISO threads at room temperature.
Torque specifications for special components or assemblies are given in applicable
sections of this manual. To avoid causing
warpage, tighten multifastener assemblies
in crisscross fashion, in progressive stages
until the specified torque is reached.
2-18
INSP
ADJ
E
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART .............................................................. 3-1
PERIODIC SERVICE ........................................................................................ 3-2
FUEL SYSTEM.......................................................................................... 3-2
Fuel line.............................................................................................. 3-2
CONTROL SYSTEM ................................................................................. 3-2
Throttle link adjustment.................................................................... 3-2
Throttle cable adjustment................................................................. 3-3
Shift cable adjustment ...................................................................... 3-4
Start-in-gear protection adjustment ................................................ 3-5
Idle speed adjustment....................................................................... 3-5
OIL INJECTION SYSTEM......................................................................... 3-6
Oil tank water drain........................................................................... 3-6
Oil pump link adjustment ................................................................. 3-6
POWER TRIM AND TILT SYSTEM .......................................................... 3-7
Power trim and tilt fluid .................................................................... 3-7
LOWER UNIT............................................................................................ 3-8
Gear oil............................................................................................... 3-8
Lower unit leakage check ................................................................. 3-8
GENERAL.................................................................................................. 3-9
Anode ................................................................................................. 3-9
Battery ................................................................................................ 3-9
Spark plug........................................................................................ 3-10
Grease points................................................................................... 3-11
1
2
3
4
5
6
7
8
9
INSP
ADJ
MAINTENANCE INTERVAL CHART
E
MAINTENANCE INTERVAL CHART
The following chart should be considered strictly as a guide to general maintenance intervals.
Depending on operating conditions, the intervals of maintenance should be changed.
Initial
Item
Remarks
10 hours
(Break-in)
COWLING:
Cowling clamp
Inspection
FUEL SYSTEM:
Fuel line
Inspection
Fuel filter
Cleaning
Carburetor
Cleaning
POWER UNIT:
Water leakage
Inspection
Motor exterior
Inspection
Exhaust leakage
Inspection
Cooling water passage Cleaning
CONTROL SYSTEM:
Throttle link
Inspection/Adjustment
Throttle cable
Inspection/Adjustment
Shift cable
Inspection/Adjustment
Start-in-gear projection Inspection/Adjustment
Idle speed
Inspection/Adjustment
OIL INJECTION SYSTEM:
Oil tank water drain
Cleaning
hose
Oil pump link
Inspection/Adjustment
POWER TRIM AND TILT SYSTEM:
Power trim and tilt fluid Inspection
LOWER UNIT:
Gear oil
Change
Lower unit leakage
Inspection
Propeller
Inspection
GENERAL:
Anode
Inspection
Battery
Inspection
Spark plug
Cleaning/Adjustment/
Replacement
Wiring and connector Adjustment/Reconnect
Bolts and nuts
Retightening
Grease points
Greasing
3-1
Every
50 hours 100 hours 200 hours
(3 months) (6 months) (1 year)
Refer
page
—
3-2
4-3
4-9
—
—
—
—
3-2
3-3
3-4
3-5
3-5
3-6
3-6
3-7
3-8
3-8
6-2
3-9
3-9
3-10
—
—
3-11
INSP
ADJ
FUEL SYSTEM/CONTROL SYSTEM
E
PERIODIC SERVICE
FUEL SYSTEM
Fuel line
1. Inspect:
● Fuel line
Break/Leak/Damage → Replace.
CONTROL SYSTEM
Throttle link adjustment
1. Check:
● CDI unit indicator
Incorrect → Adjust.
Checking steps:
● Turn the magneto control lever 1 so
that its adjusting screw contacts the
full retarding stopper a.
● Check the CDI unit indicator so that it
aligns with the specified marking on
the plate.
Full retarded position:
ATDC 7˚
●
●
Turn the magneto control lever so that
it contacts the full advance adjusting
screw b.
Check the CDI unit indicator so that it
aligns with specified marking on the
plate.
Full advanced position:
BTDC 25˚
2. Adjust:
● Ignition timing
Adjustment steps:
● Adjust the length a of the full retarding screw 1 to specification.
Full retarding screw length:
20 mm (0.79 in)
3-2
INSP
ADJ
CONTROL SYSTEM
E
●
●
●
●
Loosen the lock nut 2.
Disconnect the magneto control rod 3
at the CDI unit.
Turn the magneto control lever so that
its adjusting screw contacts the full
retarding stopper b.
Adjust the magneto control rod length
so that the CDI unit indicator aligns
with the specified marking on the
plate.
Full retarded position:
ATDC 7˚
●
●
●
Connect the magneto control rod.
Turn the magneto control lever so that
it contacts the full advance adjusting
screw 4.
Adjust the full advance adjusting
screw so that the CDI unit indicator
aligns with the specified marking on
the plate.
Full advanced position:
BTDC 25˚
Throttle cable adjustment
NOTE:
Before adjusting the throttle cable, the
throttle link should be adjusted.
1. Check:
● Full-open position
Incorrect → Adjust.
Checking steps:
● Set the shift lever to the forward position.
● Open the throttle grip fully.
● Check the throttle valve lever so that it
contacts the full opening stopper.
2. Adjust:
● Throttle cable joint position
Adjustment steps:
Loosen the lock nut 1.
● Remove the clip 2.
● Disconnect the cable joint at the magneto control lever.
● Close the throttle grip fully.
●
3-3
INSP
ADJ
CONTROL SYSTEM
E
●
●
●
Turn the magneto control lever 3 so
that its adjusting screw contacts the
full retarding stopper a.
Adjust the position of the cable joint
until its hole aligns with the set pin.
Install the clip and tighten the lock nut.
WARNING
The cable joint should be screwed in more
than 8 mm (0.31 in).
NOTE:
Put the “UP” mark upward.
3. Check:
● Throttle operation
Unsmooth operation → Repair.
Shift cable adjustment
1. Check:
● Shift operation
Incorrect → Adjust.
2. Adjust:
● Shift cable joint position
Adjustment steps:
● Set the shift handle 1 in neutral.
● Align the center of the set pin 2 with
the mark a on the bracket.
● Adjust the position of the cable joint
until its hole aligns with the set pin.
● Install the clip 3 and tighten the lock
nut 4.
WARNING
The cable joint should be screwed in more
than 8 mm (0.31 in).
NOTE:
Put the “UP” mark upward (manual starter
model only).
3. Check:
● Shift operation
Unsmooth operation → Repair.
3-4
INSP
ADJ
CONTROL SYSTEM
E
Start-in-gear protection adjustment
1. Check:
● Start-in-gear protection operation
Incorrect → Adjust.
2. Adjust:
● Start-in-gear protection wire
Adjustment steps:
● Set the shift lever in neutral.
● Loosen the lock nut 1.
● Adjust the start-in-gear protection wire
adjust nut 2 so that the end of the
starter stop-plunger aligns with the
center of the hole in the starter case.
● Tighten the lock nut.
Idle speed adjustment
NOTE:
Before adjusting the idle speed, be sure to
adjust the throttle link.
1. Measure:
● Idle speed
Out of specification → Adjust.
Idle speed:
800 ± 50 rpm
Measuring steps:
● Start the engine and allow it to warm
up for a few minutes.
● Attach the tachometer to the high tension lead of the cylinder #1.
Tachometer:
YU-08036-A/90890-06760
2. Adjust:
● Idle speed
Adjustment steps:
● Loosen the idle adjusting screw 1 and
fully close the throttle valve.
● Loosen the throttle lever securing
screws 2 of upper and middle carburetors by turning the screws clockwise.
3-5
INSP
ADJ
CONTROL SYSTEM/OIL INJECTION SYSTEM
●
●
E
Turn in the pilot screw until it is lightly
seated.
Turn out the pilot screw to specification.
Pilot screw (turns out):
40 hp: 1-1/2 ± 1/4
50 hp (M model): 1-5/8 ± 1/4
50 hp (EM, E model): 1-3/8 ± 1/4
●
●
Start the engine and allow it to warm
up for a few minutes.
Attach the tachometer to high tension
lead of the cylinder #1.
Tachometer:
YU-08036-A/90890-06760
●
Adjust the throttle stop screw in or out
until specified idle speed is obtained.
Turning in → Idle speed becomes higher.
Turning out → Idle speed becomes lower.
●
While lightly pushing the throttle lever
of the lower carburetor in the direction
of the arrow (full-closed), tighten the
throttle lever securing screw of the
upper and middle carburetors by turning the screws counterclockwise.
OIL INJECTION SYSTEM
Oil tank water drain
1. Check:
● Drain hose 1
Contamination → Drain.
NOTE:
Remove the drain hose at the upper side
and drain the contaminates.
Oil pump link adjustment
1. Check:
● Clearance a
Out of specification → Adjust.
Clearance a:
1.0 mm (0.04 in)
3-6
INSP
ADJ
OIL INJECTION SYSTEM/
POWER TRIM AND TILT SYSTEM
E
Checking steps:
● Fully open the carburetor throttle
valve.
● Check the clearance a between the oil
pump lever and full open side stopper.
2. Adjust:
● Oil pump link joint position
Adjustment steps:
● Loosen the lock nut.
● Remove the oil pump link joint at the
pump.
● Fully open the carburetor throttle
valve.
● Set the oil pump lever 1 mm off the full
open side stopper.
● Adjust the position of the link joint
until its hole aligns with the oil pump
set pin.
● Connect the link joint.
● Check that the throttle valve opens
fully.
● Tighten the lock nut.
● Install the washer and clip.
POWER TRIM AND TILT SYSTEM
Power trim and tilt fluid
1. Check:
● Fluid level
Fluid level is low → Fill.
Checking steps:
● Tilt up the outboard, and lock it with
the tilt lock lever.
● Remove the plug screw.
● Check that the fluid level is immediately below the fluid hole.
WARNING
To prevent the hydraulic fluid from spurting out by cancelling the internal pressure,
the PTT unit should be kept fully tilted up
(the tilt rod being fully lengthened).
2. Fill:
● Yamaha power trim and tilt fluid
T.
R.
3-7
Plug screw:
7 Nm (0.7 m • kg, 5.1 ft • lb)
INSP
ADJ
LOWER UNIT
E
LOWER UNIT
Gear oil
1. Check:
● Gear oil
Milky oil → Replace the oil seal.
Slag oil → Check the gear, bearing
and dog.
2. Check:
● Gear oil level
Oil level is low → Add oil to proper
level.
3. Replace:
● Gear oil
Replacement steps:
● Tilt up the motor.
● Place a pan under the drain plug 1.
● Remove the drain plug, then the oil
level plug 2 and drain the oil thoroughly.
● Place the outboard motor in an upright
position.
● Fill the gear oil through the drain hole
until it overflows at the level hole.
Recommended oil:
GEAR CASE LUBE (USA) or
Hypoid gear oil, SAE #90
Oil capacity:
430 cm3 (14.5 US oz,15.1 Imp oz)
●
Refit the oil level plug and then oil
drain plug.
Lower unit leakage check
1. Check:
● Pressure holding
Pressure falls → Inspect seals and
component parts.
Checking steps:
● Attach the tester to the oil-level hole.
Pressure tester:
YB-35956/90890-06762
●
Apply the specified pressure.
Pressure:
100 kPa (1.0 kg/cm2, 14.2 psi)
●
3-8
Check that the pressure is held as
specified for 10 seconds.
INSP
ADJ
LOWER UNIT/GENERAL
E
NOTE:
Do not over-pressurize. Excess pressure
may cause the air to leak out.
GENERAL
Anode
1. Inspect:
● Anode 1
● Trim tab 2
● Anode [(bracket bottom) except for
manual tilt model] 3
Scale → Clean.
Oil/grease → Clean.
Wear/Excessively consumed → Replace.
CAUTION:
Do not oil, grease or paint the anode, or the
function of the sacrificial anode will be
spoiled.
Battery
WARNING
Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin,
eyes, or clothing.
Antidote:
EXTERNAL; Flush with water.
INTERNAL: Drink large quantities of water or
milk. 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. Ventilate when charging or using in a closed
space.
Always wear eye protection when working
near batteries.
KEEP OUT OF REACH OF CHILDREN.
3-9
INSP
ADJ
GENERAL
E
NOTE:
● Batteries
vary among manufacturers.
Therefore the following procedures may
not always apply. Consult your battery
manufacturer’s instructions.
● Disconnect the black negative lead first to
prevent the risk of shorting.
1. Inspect:
● Battery fluid level
● Battery fluid specific gravity
Spark plug
1. Inspect:
● Electrode 1
Worn/Damaged → Replace.
● Insulator color 2
Distinctly different color → Check the
engine condition.
Color guide:
Normal:
Medium to light tan color
Whitish color: Lean fuel mixture
● Plugged fuel mixture
● Air leak
● Wrong setting
Blackish color:
Electrical malfunction
● Defective spark plug
● Defective ignition system
● Rich mixture
● Excessive idling
2. Clean:
● Spark plug
Clean the spark plug with a plug
cleaner or wire brush.
3. Inspect:
● Spark plug type
Standard spark plug:
40hp: B7HS-10
For CANADA and Europe:
BR7HS-10
50hp: B8HS-10
For CANADA and Europe:
BR8HS-10
3-10
INSP
ADJ
GENERAL
E
4. Measure:
● Electrodes gap a
Out of specification → Regap.
Gap:
0.9 ~1.0 mm (0.035 ~ 0.039 in)
5. Tighten:
● Spark plug
NOTE:
Before installing the spark plug, clean the
gasket surface and the plug surface.
T.
Spark plug:
25 Nm (2.5 m • kg, 18 ft • lb)
R.
NOTE:
If a torque wrench is not available, a good
estimate of the correct torque is a further 1/4
to 1/2 turns b on finger-tightened a spark
plug.
Grease points
1. Apply:
● Water resistant grease
3-11
FUEL
E
CHAPTER 4
FUEL SYSTEM
FUEL JOINT, FUEL FILTER AND FUEL PUMP .............................................. 4-1
EXPLODED DIAGRAM ............................................................................. 4-1
REMOVAL AND INSTALLATION CHART ............................................... 4-2
FUEL LINE LAYOUT................................................................................. 4-3
M model ............................................................................................. 4-3
EM, E model....................................................................................... 4-3
SERVICE POINTS ..................................................................................... 4-4
Fuel joint inspection.......................................................................... 4-4
Fuel filter inspection.......................................................................... 4-4
Fuel pump inspection ....................................................................... 4-4
CARBURETOR REMOVAL.............................................................................. 4-5
EXPLODED DIAGRAM ............................................................................. 4-5
REMOVAL AND INSTALLATION CHART ............................................... 4-6
CARBURETOR................................................................................................. 4-7
EXPLODED DIAGRAM ............................................................................. 4-7
REMOVAL AND INSTALLATION CHART ............................................... 4-8
SERVICE POINTS ..................................................................................... 4-9
Carburetor inspection ....................................................................... 4-9
Carburetor assembly....................................................................... 4-10
PRIME STARTER........................................................................................... 4-11
EXPLODED DIAGRAM ........................................................................... 4-11
REMOVAL AND INSTALLATION CHART ............................................. 4-12
SERVICE POINTS ................................................................................... 4-13
Fuel enrichment pump inspection ................................................. 4-13
Fuel enrichment valve inspection .................................................. 4-13
OIL TANK ...................................................................................................... 4-15
EXPLODED DIAGRAM ........................................................................... 4-15
REMOVAL AND INSTALLATION CHART ............................................. 4-16
OIL LINE LAYOUT .................................................................................. 4-17
SERVICE POINTS ................................................................................... 4-18
Oil tank inspection........................................................................... 4-18
Oil strainer inspection..................................................................... 4-18
Check valve inspection ................................................................... 4-18
OIL PUMP ...................................................................................................... 4-19
EXPLODED DIAGRAM ........................................................................... 4-19
REMOVAL AND INSTALLATION CHART ............................................. 4-20
1
2
3
4
5
6
7
8
9
FUEL
FUEL JOINT, FUEL FILTER AND FUEL PUMP
FUEL JOINT, FUEL FILTER AND FUEL PUMP
EXPLODED DIAGRAM
4-1
E
FUEL
FUEL JOINT, FUEL FILTER AND FUEL PUMP
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
0
A
B
C
D
Procedure/Part name
FUEL JOINT, FUEL FILTER AND
FUEL PUMP REMOVAL
Oil tank ass’y
Clip
Fuel hose (joint - filter)
Bolt (with washer)
Fuel joint
Clip
Fuel hose (joint - filter)
Fuel hose (filter - pump)
Nut
Fuel filter
Clip
Fuel hose (filter - pump)
Fuel hose (pump - joint pipe)
Bolt (with washer)
Fuel pump ass’y
Fuel pump gasket
FUEL FILTER DISASSEMBLY
Body cover
Filter cup
O-ring
Filter element
FUEL PUMP DISASSEMBLY
Screw (with washer)
Body
Diaphragm
Gasket
Body
Diaphragm gasket
Diaphragm
Screw
Seat valve
Nut
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “OIL TANK”.
1
1
1
1
2
1
1
1
1
2
1
1
2
1
1
6 × 25 mm
6 × 40 mm
1
1
1
1
3
1
1
1
1
2
1
2
2
2
Reverse the removal steps for installation.
4-2
FUEL
FUEL JOINT, FUEL FILTER AND FUEL PUMP
FUEL LINE LAYOUT
M model
1 Fuel pump
2 Fuel filter
W, E model
1 Fuel pump
2 Fuel filter
3 Electrothermal valve
4-3
E
FUEL
FUEL JOINT, FUEL FILTER AND FUEL PUMP
E
SERVICE POINTS
Fuel joint inspection
1. Inspect:
● Fuel joint
Crack/Leak/Damage → Replace.
2. Measure:
● Fuel joint operation
Impossible to maintain the specified
pressure for 10 sec. → Replace.
Measuring steps:
● Attach the Mity vac.
Mity vac:
YB-35956/90890-06756
●
Apply the specified pressure.
Specified pressure:
50 kPa (0.5 kg/cm2, 7.1 psi)
Fuel filter inspection
1. Inspect:
● Filter element
● Filter cup
Crack/Leak/Clog → Replace.
Contamination → Clean.
Fuel pump inspection
1. Inspect:
● Body
Crack/Leak/Damage → Replace.
2. Inspect:
● Seat valve
Crack/Distortion → Replace.
3. Inspect:
● Diaphragm
Damage → Replace.
4-4
FUEL
CARBURETOR REMOVAL
CARBURETOR REMOVAL
EXPLODED DIAGRAM
4-5
E
FUEL
CARBURETOR REMOVAL
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
Procedure/Part name
CARBURETOR REMOVAL
Oil tank ass’y
Screw
Screw
Washer
Silencer
Seal
Clip
Fuel hose (joint pipe - cab.1)
Fuel hose (joint pipe - cab.2)
Fuel hose (joint pipe - cab.3)
Q’ty
10
11
Clip
Pulser hose
1
1
12
13
Clip
Fuel enrichment hose
1
1
14
15
16
Bolt
Electrothermal valve lead (black)
Electrothermal valve lead (blue)
1
1
1
17
18
19
20
21
Accelerator lever rod
Oil pump link rod
Link joint
Choke link rod
Link joint
1
1
1
1
1
22
23
24
25
26
27
Choke lever joint
Link joint
Bolt
Carburetor bracket
Carburetor ass’y
Gasket
2
4
6
1
3
3
2
2
4
1
3
3
1
1
1
Service points
Follow the left “Step” for removal.
Refer to “OIL TANK”.
6 × 40 mm
6 × 55 mm
NOTE:
Disconnect the hose at the carburetor
side.
E model
NOTE:
Disconnect the hose at the carburetor
side.
NOTE:
Disconnect the hose at the intake manifold side.
NOTE:
Disconnect the coupler at the lighting
coil.
Oil injection model
M model
NOTE:
After installing, check the smooth movement of the choke knob.
6 × 95 mm
Reverse the removal steps for installation.
4-6
FUEL
CARBURETOR
E
CARBURETOR
EXPLODED DIAGRAM
4-7
FUEL
CARBURETOR
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
Procedure/Part name
CARBURETOR DISASSEMBLY
Carburetor ass’y
Drain screw
O-ring
Screw (with washer)
Carburetor cover
Cover packing
Pilot adjusting screw
Q’ty
1
1
3
1
1
1
Service points
Follow the left “Step” for removal.
Refer to “CARBURETOR REMOVAL”.
4 × 14 mm
CAUTION:
Do not damage the tip of the pilot screw
by over-tighten it.
7
8
9
10
11
12
13
14
15
Spring
Stopping screw
Spring
Screw (with washer)
Float chamber
Float chamber packing
Screw
Arm pin
Float
1
1
1
4
1
1
1
1
1
16
17
18
19
20
21
22
23
24
Needle valve
Needle valve clip
Valve seat
O-ring
Main jet
Main nozzle
Cap
Pilot jet
Carburetor body
1
1
1
1
1
1
1
1
1
Middle carburetor only
4 × 14 mm
4 mm
NOTE:
The float is removed together with the
needle valve and the clip.
Reverse the removal steps for installation.
4-8
FUEL
CARBURETOR
E
SERVICE POINTS
CAUTION:
Do not use steelwire for cleaning the jets as
this may enlarge the jet diameters and seriously affect performance.
Carburetor inspection
1. Inspect:
● Carburetor body
Crack/Damage → Replace.
Contamination → Clean.
2. Inspect:
● Pilot screw
Bend/Wear → Replace.
3. Inspect:
● Main jet
● Pilot jet
● Main nozzle
Contamination → Replace.
4. Inspect:
● Needle valve
Grooved wear → Replace.
5. Inspect:
● Float
Crack/Damage → Replace.
6. Inspect:
● Collar 1
Wear/Damage → Replace.
4-9
FUEL
CARBURETOR
E
Carburetor assembly
1. Install:
● Needle valve
● Float 1
● Float pin 2
● Screw 3
NOTE:
float pin should be fit in the slit the
carburetor and locked with the screw.
● When installing the float in the carburetor,
place the needle valve in the valve seat.
● After installing, check the smooth movement of the float.
● The
2. Measure:
● Float height a
Out of specification → Fold the tab b
to adjust float arm height.
Float height a:
15.0 ± 1.0 mm (0.59 ± 0.04 in)
NOTE:
float should be resting on the needle
valve, but not compressing the needle
valve.
● Take measurement at the end surface of
the float opposite to its pivoted side.
● The
3. Adjust:
● Pilot screw
Adjustment steps:
● Screw in the pilot screw until it is
lightly seated
● Back out by the specified number of
turns.
Pilot screw:
40hp: 1-1/2 ± 1/4 (turns out)
50hp:
M model: 1-5/8 ± 1/4 (turns out)
E, EM model: 1-3/8 ± 1/4 (turns out)
4-10
FUEL
PRIME STARTER
E
PRIME STARTER
EXPLODED DIAGRAM
4-11
FUEL
PRIME STARTER
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
PRIME STARTER DISASSEMBLY
Carburetor ass’y
Screw (with washer)
Electrothermal valve
Clip
Fuel enrichment hose
Clip
Fuel hose (cover - chamber)
Screw (with washer)
Pump cover ass’y
Diaphragm gasket
Diaphragm
Valve body
Screw
Seat valve
Nut
O-ring
Q’ty
2
1
1
1
2
1
4
1
2
1
1
2
2
2
1
Service points
Follow the left “Step” for removal.
Refer to “CHARBURETOR REMOVAL”.
4 × 10 mm
M3
Reverse the removal steps for installation.
4-12
FUEL
PRIME STARTER
E
SERVICE POINTS
Fuel enrichment pump inspection
1. Inspect:
● Body
Crack/Leak/Damage → Replace.
2. Inspect:
● Seat valve
Crack/Distortion → Replace.
3. Inspect:
● Diaphragm
Damage → Replace.
Fuel enrichment valve inspection
1. Inspect:
● Needle valve 1
● Piston valve 2
Wear/Bend/Damage → Replace.
2. Measure:
● Fuel enrichment valve resistance
Out of specification → Replace.
Fuel enrichment valve resistance:
Blue - Black
2.32 ~ 3.48 Ω at 20˚C (68˚F)
NOTE:
When measuring the resistance of 10 Ω or
less using the digital tester, the correct
measurement cannot be obtained. Refer to
“Lower resistance measurement” section in
chapter 8.
3. Measure:
● Piston valve height a
No change → Replace.
Checking steps:
● Connect the 12 V battery.
● Wait for several minutes.
● Check the piston height.
4-13
FUEL
PRIME STARTER
E
4-14
FUEL
OIL TANK
E
OIL TANK
EXPLODED DIAGRAM
4-15
FUEL
OIL TANK
E
REMOVAL AND INSTALLATION CHART
Step
Q’ty
1
2
Procedure/Part name
OIL TANK REMOVAL
Clip
Oil drain hose
3
4
5
6
7
Clip
Oil inlet hose
Clip
Oil return hose
Oil level sensor lead coupler
1
1
1
1
1
8
9
10
11
Bolt (with washer)
Oil level sensor lead
Bolt (with washer)
Oil tank ass’y
OIL TANK DISASSEMBLY
Oil level sensor
Oil strainer
Strainer gasket
Oil tank cap
Hook
Hook band
Filler tube band
Filler tube
Special washer
Ball chain
Special washer
Protector
Oil return hose
Check valve
Oil return hose
Clip
Oil inlet hose
Clip
Oil drain hose
Collar
Grommet
Oil tank
2
1
1
1
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
I
J
K
L
1
1
Service points
Follow the left “Step” for removal.
NOTE:
Drain oil from the oil tank.
NOTE:
Disconnect the coupler.
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
3
3
1
Reverse the removal steps for installation.
4-16
FUEL
OIL TANK
E
OIL LINE LAYOUT
1
2
3
4
5
Electrothermal valve (EM, E model)
Oil level sensor
Oil drain hose
Oil tank
Oil pump
4-17
FUEL
OIL TANK
E
SERVICE POINTS
Oil tank inspection
1. Inspect:
● Oil tank
Crack → Replace.
Oil strainer inspection
1. Inspect:
● Oil strainer
Crack/Clog → Replace.
Contamination → Clean.
Check valve inspection
1. Check:
● Check valve operation
Does not function → Replace.
NOTE:
Check the operation of the check valve to
ensure the air is blown only in the arrow
direction.
4-18
FUEL
OIL PUMP
E
OIL PUMP
EXPLODED DIAGRAM
4-19
FUEL
OIL PUMP
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
Procedure/Part name
OIL PUMP REMOVAL
Engine oil
Clip
Oil inlet hose
Clip
Oil return hose
Clip
Plate washer
Link joint
8
9
10
11
Clip
Oil delivery hose #1
Oil delivery hose #2
Oil delivery hose #3
Q’ty
1
1
1
1
1
1
1
3
1
1
1
Service points
Follow the left “Step” for removal.
Refer to “OIL TANK”.
NOTE:
Disconnect the joint at the pump side.
250 mm
180 mm
90 mm
NOTE:
When connecting the hose, feed oil into it
while taking care not to allow air to enter.
12
13
14
15
Bolt
Bolt
Oil pump
O-ring
1
1
1
1
Reverse the removal steps for installation.
4-20
POWR
E
CHAPTER 5
POWER UNIT
POWER UNIT REMOVAL ............................................................................... 5-1
EXPLODED DIAGRAM ............................................................................. 5-1
REMOVAL AND INSTALLATION CHART ............................................... 5-2
RECOIL STARTER ........................................................................................... 5-3
EXPLODED DIAGRAM ............................................................................. 5-3
REMOVAL AND INSTALLATION CHART ............................................... 5-4
SERVICE POINTS ..................................................................................... 5-5
Sheave drum removal ...................................................................... 5-5
Spiral spring removal ....................................................................... 5-5
Starter stopping plunger inspection................................................ 5-5
Drive pawl and spring inspection .................................................... 5-6
Rope roller and collar inspection ..................................................... 5-6
Bushing inspection............................................................................ 5-6
Sheave drum inspection................................................................... 5-6
Spiral spring inspection.................................................................... 5-6
Starter rope inspection ..................................................................... 5-6
Starter rope installation .................................................................... 5-7
Sheave drum installation.................................................................. 5-7
Spiral spring setting.......................................................................... 5-7
Recoil starter checking...................................................................... 5-7
FLYWHEEL MAGNETO AND MAGNETO BASE ........................................... 5-9
EXPLODED DIAGRAM ............................................................................. 5-9
REMOVAL AND INSTALLATION CHART ............................................. 5-10
SERVICE POINTS ................................................................................... 5-11
Flywheel magneto removal............................................................ 5-11
ELECTRICAL UNIT REMOVAL ..................................................................... 5-13
EXPLODED DIAGRAM ........................................................................... 5-13
REMOVAL AND INSTALLATION CHART ............................................. 5-14
ELECTRICAL UNIT ........................................................................................ 5-15
EXPLODED DIAGRAM ........................................................................... 5-15
REMOVAL AND INSTALLATION CHART ............................................. 5-16
REED VALVE AND CHECK VALVE.............................................................. 5-17
EXPLODED DIAGRAM ........................................................................... 5-17
REMOVAL AND INSTALLATION CHART ............................................. 5-18
SERVICE POINTS ................................................................................... 5-19
Reed valve inspection ..................................................................... 5-19
1
2
3
4
5
6
7
8
9
POWR
CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER....................... 5-21
EXPLODED DIAGRAM ........................................................................... 5-21
REMOVAL AND INSTALLATION CHART ............................................. 5-22
SERVICE POINTS ................................................................................... 5-23
Cylinder head inspection ................................................................ 5-23
Thermostat inspection .................................................................... 5-24
CRANKCASE AND CYLINDER BODY .......................................................... 5-25
EXPLODED DIAGRAM ........................................................................... 5-25
REMOVAL AND INSTALLATION CHART ............................................. 5-26
EXPLODED DIAGRAM ........................................................................... 5-27
REMOVAL AND INSTALLATION CHART ............................................. 5-28
SERVICE POINTS ................................................................................... 5-29
Cylinder body inspection................................................................ 5-29
Piston to cylinder clearance ........................................................... 5-30
Oil pump driven gear inspection ................................................... 5-30
Cylinder body and crankcase installation ..................................... 5-30
CRANK SHAFT AND PISTON ...................................................................... 5-31
EXPLODED DIAGRAM ........................................................................... 5-31
REMOVAL AND INSTALLATION CHART ............................................. 5-32
SERVICE POINTS ................................................................................... 5-33
Piston pin clip removal ................................................................... 5-33
Piston pin and small end bearing removal ................................... 5-33
Piston ring removal......................................................................... 5-33
Bearing removal .............................................................................. 5-33
Piston inspection ............................................................................. 5-33
Piston pin and small end bearing inspection................................ 5-34
Piston ring inspection ..................................................................... 5-35
Crankshaft inspection ..................................................................... 5-36
Piston and piston ring installation ................................................. 5-37
Crankshaft and piston installation ................................................. 5-37
E
1
2
3
4
5
6
7
8
9
POWR
POWER UNIT REMOVAL
POWER UNIT REMOVAL
EXPLODED DIAGRAM
5-1
E
POWR
POWER UNIT REMOVAL
E
REMOVAL AND INSTALLATION CHART
Step
Q’ty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Procedure/Part name
POWER UNIT REMOVAL
Bolt
Engine stop switch lead (black)
Engine stop switch coupler (blue)
Maine switch lead coupler
Oil level sensor lead coupler
Oil level warning lamp lead
Trim sensor lead coupler
Extension wire lead coupler
PTT motor lead
PTT switch lead coupler
Choke lever rod
Start-in-gear projection wire
Clip
Shift cable
Clip
Throttle cable
Bolt
Fitting plate ass’y
19
20
21
22
23
24
25
26
27
28
29
Pilot water hose
Fuel hose (Fuel joint - Fuel filter)
Bolt (with washer)
Bolt (with washer)
Screw
Apron
Bolt (with washer)
Bolt (with washer)
Engine unit
Dowel pin
Upper case gasket
1
1
1
1
2
1
6
2
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
Service points
Follow the left “Step” for removal.
M model
E model
EHTO model
PTT model
M model
NOTE:
When installing the fitting plate, lift the
tiller handle straight up.
6 × 45 mm
6 × 20 mm
8 × 45 mm
Reverse the removal steps for installation.
5-2
POWR
RECOIL STARTER
E
RECOIL STARTER
EXPLODED DIAGRAM
5-3
POWR
RECOIL STARTER
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
Procedure/Part name
RECOIL STARTER REMOVAL
Lock nut
Start-in-gear protection wire
Q’ty
1
1
1
2
3
4
5
6
7
8
9
0
A
B
C
D
E
F
G
H
Bolt (with washer)
Recoil starter ass’y
Dowel pin
RECOIL STARTER DISASSEMBLY
Start-in-gear protection wire
Spring
Starter stopping plunger
Circlip
Drive pawl
Drive pawl spring
Bolt (with washer)
Stay
Rope roller
Collar
Nut
Bolt (with washer)
Nut
Bolt (with washer)
Plane washer
Bushing
Sheave drum
Spiral spring
3
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
I
J
K
L
M
N
O
Starter case
Cover
Starter handle
Damper
Seal
Rope guide
Rope
1
1
1
1
1
1
1
5-4
Service points
Follow the left “Step” for removal.
NOTE:
Disconnect the wire at the bottom cowling side.
6 × 35 mm
6 × 30 mm
6 × 12 mm
6 × 20 mm
NOTE:
● When installing the new spiral spring,
do not cut the wire holding the spring.
● When reusing the spiral spring, set the
leading end first in the case and then fit
one turn each time.
2,095 mm
Reverse the removal steps for installation.
POWR
RECOIL STARTER
E
SERVICE POINTS
Sheave drum removal
1. Turn:
● Sheave drum 1
Turn the sheave drum clockwise until
the spiral spring is free.
NOTE:
● Turn
the sheave drum so that the cutaway
on the outer surface of the sheave drum
faces toward the starter handle.
● Pass the starter rope through the cut.
2. Remove:
● Sheave drum 1
WARNING
When removing the sheave drum, be sure
to turn the sheave drum upside down to
prevent the spiral spring from popping up
at you.
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.
Spiral spring removal
1. Remove:
● Spiral spring 1
WARNING
Be careful so that the spiral spring does not
pop out when removing it. Remove it by
allowing it out one turn of the winding
each time.
Starter stopping plunger inspection
1. Inspect:
● Starter stopping plunger
Crack/Wear/Damage → Replace.
5-5
POWR
RECOIL STARTER
E
Drive pawl and spring inspection
1. Inspect:
● Drive pawl
Crack/Wear/Damage → Replace.
● Drive pawl spring
Broken/Bent/Damage → Replace.
Rope roller and collar inspection
1. Inspect:
● Rope roller
● Collar
Crack/Wear/Damage → Replace them
as a set.
Bushing inspection
1. Inspect:
● Bushing
Crack/Damage → Replace.
Sheave drum inspection
1. Inspect:
● Sheave drum
Crack/Damage → Replace.
Spiral spring inspection
1. Inspect:
● Spiral spring
Broken/Bent/Damage → Replace.
Starter rope inspection
1. Inspect:
● Starter rope
Fray/Wear/Damage → Replace.
NOTE:
When replacing the rope, cut it to the specified length and burn the rope end so that it
will not travel.
Starter rope length:
2,095 mm (82.5 in)
5-6
POWR
RECOIL STARTER
E
Starter rope installation
1. Install:
● Starter rope
NOTE:
● Insert the rope through the rope holes and
knot the end.
● Wind the rope 1-9/10 turns around the
sheave drum.
● Place the rope at the cutaway.
Sheave drum installation
1. Install:
● Sheave drum 1
NOTE:
Position the inner end of the spiral spring
on the retainer post of the sheave drum.
Spiral spring setting
1. Set:
● Spiral spring
NOTE:
Wind up the spring 2-1/2 turns counterclockwise with the starter rope.
Recoil starter checking
1. Check:
● Starter operation
Unsmooth operation → Repair.
5-7
POWR
RECOIL STARTER
E
5-8
POWR
FLYWHEEL MAGNETO AND MAGNETO BASE
FLYWHEEL MAGNETO AND MAGNETO BASE
EXPLODED DIAGRAM
5-9
E
POWR
FLYWHEEL MAGNETO AND MAGNETO BASE
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Procedure/Part name
FLYWHEEL MAGNETO AND
MAGNETO BASE REMOVAL
Recoil starter ass’y
Screw
Screw
Washer
Flywheel cover
Collar
Bolt (E model)
Bolt (M model)
Starter pulley (E model)
Starter pulley (M model)
Packing
Flywheel nut
Washer
Screw (with washer)
Timing plate
Flywheel magneto
Woodruff key
Bolt
Base ass’y
Gasket
Q’ty
1
2
3
1
3
3
3
1
1
1
1
1
1
1
1
1
3
1
1
Service points
Follow the left “Step” for removal.
Refer to “RECOIL STARTER”.
6 × 40 mm
6 × 35 mm
8 × 14 mm
8 × 20 mm
5 × 10 mm
6 × 18 mm
Reverse the removal steps for installation.
5-10
POWR
FLYWHEEL MAGNETO AND MAGNETO BASE
E
SERVICE POINTS
Å
Flywheel magneto removal
1. Remove:
● Flywheel nut
Flywheel holder:
YB-06139/90890-06522
Å For USA and CANADA
ı Except for USA and CANADA
ı
CAUTION:
The major load should be carried in the
direction of the arrows. If not, the holder
may easily slip off.
2. Remove:
● Flywheel magneto
Universal puller:
YB-06117/90890-06521
Å For USA and CANADA
ı Except for USA and CANADA
CAUTION:
● Keep
Å
the nut side flush with the crankshaft end until the flywheel comes off the
tapered portion of the crankshaft.
● To prevent damage to the engine or
tools, screw in the flywheel magnetopuller set-bolts evenly and completely so
that the puller plate is parallel to the flywheel.
ı
5-11
POWR
FLYWHEEL MAGNETO AND MAGNETO BASE
5-12
E
POWR
ELECTRICAL UNIT REMOVAL
ELECTRICAL UNIT REMOVAL
EXPLODED DIAGRAM
Å
5-13
E
POWR
ELECTRICAL UNIT REMOVAL
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
ELECTRICAL UNIT REMOVAL
Thermo switch coupler
Wire harness coupler
Electrothermal valve lead
Lighting coil lead
CDI unit lead coupler
Bolt (with washer)
Fitting plate ass’y
Battery cable
Q’ty
9
10
11
12
13
14
15
Bolt (with washer)
PTT switch coupler
PTT motor lead
Bolt (with washer)
Bolt (with washer)
Electrical unit
Magneto control rod
2
1
2
4
1
1
1
16
17
18
19
20
21
Bolt (with washer)
CDI unit
Bolt
Magneto control lever
Spring
Accelation cam
2
1
1
1
1
1
2
1
1
2
7
2
1
1
Service points
Follow the left “Step” for removal.
Pink and black leads
Blue lead
Green leads
NOTE:
Remove the battery cable at the grommet.
PTT model
Sky blue and light green leads
6 × 30 mm
8 × 25 mm
NOTE:
Disconnect the rod from the CDI unit.
Reverse the removal steps for installation.
Å: Setting length
5-14
POWR
ELECTRICAL UNIT
E
ELECTRICAL UNIT
EXPLODED DIAGRAM
5-15
POWR
ELECTRICAL UNIT
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Procedure/Part name
ELECTRICAL UNIT DISASSEMBLY
Electrical unit
Fuse
Clamp
Bolt (with washer)
Clamp
Bolt (with washer)
Rectifier regurator
Nut
Spring washer
Bracker
Relay holder
Starter relay
Bolt (with washer)
Bolt (with washer)
Bolt (with washer)
PTT relay
Bracket
Collar
Grommet
Q’ty
1
1
1
1
1
1
2
1
1
1
1
2
1
2
1
1
3
3
Service points
Follow the left “Step” for removal.
Refer to “ELECTRICAL UNIT REMOVAL”.
PTT model
Reverse the removal steps for installation.
5-16
POWR
REED VALVE AND CHECK VALVE
REED VALVE AND CHECK VALVE
EXPLODED DIAGRAM
5-17
E
POWR
REED VALVE AND CHECK VALVE
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
Procedure/Part name
REED VALVE AND CHECK
VALVE REMOVAL
Oil tank ass’y
Carburetor ass’y
Clip
Oil delivery hose
Bolt (with washer)
Q’ty
3
3
12
Service points
Follow the left “Step” for removal.
Refer to “OIL TANK” in chapter 4.
Refer to “CARBURETOR REMOVAL” in
chapter 4.
Oil injection model
6 × 12 mm
NOTE:
Tighten the bolts in sequence and in two
steps of torque.
4
5
6
7
8
9
10
11
12
13
Neutral switch stay
Intake manifold ass’y
Screw (with washer)
Reed valve ass’y
Valve plate gasket
Reed valve plate
Clip
Oil delivery hose 1
Oil delivery hose 2
Oil delivery hose 3
1
1
6
3
2
1
6
1
1
1
WH, EHTO model
5 × 14 mm
Oil injection model
250 mm
180 mm
90 mm
NOTE:
When connecting the hose, feed oil into it
while taking care not to allow air to enter.
14
1
2
3
4
Check valve
REED VALVE DISASSEMBLY
Screw (with washer)
Valve stopper
Reed valve
Reed valve body
3
4
2
2
1
Reverse the removal steps for installation.
5-18
POWR
REED VALVE AND CHECK VALVE
SERVICE POINTS
Reed valve inspection
1. Inspect:
● Reed valve
Crack/Damage → Replace.
2. Measure:
● Valve bending a
Out of specification → Replace.
Valve bending limit:
0.2 mm (0.01 in)
3. Measure:
● Valve stopper height b
Out of specification → Replace.
Valve stopper height:
6.0 ± 0.2 mm (0.24 ± 0.01 in)
5-19
E
POWR
REED VALVE AND CHECK VALVE
5-20
E
POWR
CYLINDER HEAD, THERMOSTAT AND EXHAUST
COVER
CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER
EXPLODED DIAGRAM
5-21
E
POWR
CYLINDER HEAD, THERMOSTAT AND EXHAUST
COVER
E
REMOVAL AND INSTALLATION CHART
Step
1
2
Procedure/Part name
CYLINDER HEAD, THERMOSTAT
AND EXHAUST COVER REMOVAL
Spark plug cap
Spark plug
Bolt (with washer)
Q’ty
Service points
Follow the left “Step” for removal.
Disconnect the cap from the plug.
3
14
8 mm
NOTE:
Tighten the bolts in sequence and in two
steps of torque.
3
4
5
6
7
8
9
10
11
12
13
Cylinder head ass’y
Cylinder head gasket
Flat head screw
Anode
THERMOSTAT REMOVAL
Oil tank ass’y
Bolt (with washer)
Thermostat cover
Thermostat cover gasket
Thermostat
EXHAUST COVER REMOVAL
Oil tank ass’y
Clip
Pilot water hose
Bolt (with washer)
Bolt (with washer)
1
1
2
2
2
1
1
1
Refer to “OIL TANK” in chapter 4.
6 × 25 mm
Refer to “OIL TANK” in chapter 4.
1
1
14
13
6 × 35 mm
Oil injection model
NOTE:
Tighten the bolts in sequence and in two
steps of torque.
14
15
16
17
1
Exhaust outer cover
Outer cover gasket
Exhaust inner cover
Inner cover gasket
CYLINDER COVER DISASSEMBLY
Bolt (with washer)
1
1
1
1
4
6 × 25 mm
NOTE:
Tighten the bolts in sequence.
2
3
4
5
6
Cylinder head cover
Head cover gasket
Straight screw
Gasket
Cylinder head
1
1
1
1
1
Reverse the removal steps for installation.
5-22
POWR
CYLINDER HEAD, THERMOSTAT AND EXHAUST
COVER
E
SERVICE POINTS
Cylinder head inspection
1. Inspect:
● Water jacket
Material deposit/Corrosion → Clean.
● Cylinder inner surface
Score marks → Clean.
Use #600 ~ 800 grit wet sandpaper.
CAUTION:
Do not scratch the fitting surfaces of the
cylinder and cylinder cover.
2. Measure:
● Cylinder head warpage
Use a straightedge and thickness
gauge.
Out of specification → Resurface or
replace.
Warpage limit:
0.1 mm (0.004 in)
Resurfacing steps:
● Place a 400 ~ 600 grit wet sandpaper
on the surface plate.
● Resurface the head using a figureeight sanding pattern.
NOTE:
Rotate the head several times to avoid
removing too much material from one
side.
5-23
POWR
CYLINDER HEAD, THERMOSTAT AND EXHAUST
COVER
E
Thermostat inspection
1. Inspect:
● Thermostat
Stick/Damage → Replace.
2. Measure:
● Valve opening temperature
● Valve lift
Out of specification → Replace.
Water temperature
Valve lift
Below 48 ~ 52 ˚C
(118 ~ 126 ˚F)
Above 60 ˚C
(140 ˚F)
0 mm
(0 in)
Min.3 mm
(0.12 in)
Measuring steps:
● Suspend thermostat in a vessel.
● Place reliable thermometer in a water.
● Heat water slowly.
● Observe thermometer, while stirring
water continually.
5-24
POWR
CRANKCASE AND CYLINDER BODY
CRANKCASE AND CYLINDER BODY
EXPLODED DIAGRAM
5-25
E
POWR
CRANKCASE AND CYLINDER BODY
E
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
CRANK CASE AND CYLINDER
BODY REMOVAL
Oil tank ass’y
Oil pump
Carburetor ass’y
Q’ty
Refer to “OIL TANK” in chapter 4.
Refer to “OIL PUMP” in chapter 4.
Refer to “CARBURETOR REMOVAL” in
chapter 4.
Refer to “RECOIL STARTER”.
Refer to “FLYWHEEL MAGNETO AND
MAGNETO BASE”.
Refer to “POWER UNIT REMOVAL”.
Recoil starter ass’y
Magneto base ass’y
1
2
3
4
5
6
7
Power unit
Clip
Drain less hose
Drain less hose
Drain less hose
Drain less hose
Bolt (with washer)
Bolt (with washer)
Service points
Follow the left “Step” for removal.
8
1
1
1
1
6
8
200 mm
310 mm
360 mm
240 mm
6 mm
8 mm
NOTE:
Tighten the bolts in sequence and in two
steps of torque.
8
9
Crank case
Cylinder body
1
1
10
Dowel pin
CRANK CASE DISASSEMBLY
Bolt (with washer)
Engine hanger
Bolt (with washer)
Stay (left)
Bolt (with washer)
Bolt (with washer)
Stay (right)
Bolt (with washer)
Fuel filter bracket
Collar
Plate washer
Oil pump driven gear
O-ring
2
1
2
3
4
5
6
7
8
9
0
A
B
C
2
1
3
1
1
2
1
1
1
1
1
1
1
5-26
NOTE:
Film-coat the crank case mating surface
with Gasket Maker or equivalent.
6 × 14 mm
6 × 25 mm
6 × 20 mm
8 × 25 mm
6 × 14 mm
Oil injection model
POWR
CRANKCASE AND CYLINDER BODY
EXPLODED DIAGRAM
5-27
E
POWR
CRANKCASE AND CYLINDER BODY
E
REMOVAL AND INSTALLATION CHART
Step
D
E
F
G
H
Procedure/Part name
Hose nipple
Hose joint
Check valve
Check valve
Hose joint
Q’ty
1
3
2
2
1
Service points
Reverse the removal steps for installation.
5-28
POWR
CRANKCASE AND CYLINDER BODY
E
SERVICE POINTS
Cylinder body inspection
1. Inspect:
● Water jacket
Material deposit/Corrosion → Clean.
● Cylinder inner surface
Score marks → Clean.
Use #600 ~ 800 grit wet sandpaper.
NOTE:
Do not scratch the fitting surfaces of the
crank case and cylinder head.
2. Inspect:
● Exhaust wall
Crack/Damage → Replace.
Carbon deposit → Clean.
Use a round scraper.
NOTE:
Do not scratch the fitting surfaces of the cylinder and exhaust cover.
3. Measure:
● Cylinder bore “D”
Use cylinder gauge.
Out of specification → Rebore or
replace.
NOTE:
Measure the cylinder bore “D” in parallel.
Then, find the average of the measurement.
Standard
Cylinder 67.00 ~ 67.02 mm
bore “D” (2.638 ~ 2.639 in)
Taper
—
limit T:
Out of
—
round limit
Wear limit
67.10 mm
(2.642 in)
0.08 mm
(0.003 in)
0.05 mm
(0.002 in)
D = Maximum Dia. (D1 – D6)
T = (maximum D1 or D2) – (minimum D5
or D6)
A: 10 mm (0.4 in) below the cylinder top
B: 5 mm (0.2 in) above the exhaust port
C: 5 mm (0.2 in) below the scavenging port
5-29
POWR
CRANKCASE AND CYLINDER BODY
E
Piston to cylinder clearance
1. Calculate:
● Piston clearance
Out of specification → Replace piston
and piston ring and/or cylinder.
Piston
clearance
=
Cylinder
bore
–
Piston
diameter
Piston clearance:
0.060 ~ 0.065 mm
(0.0024 ~ 0.0026 in)
Oil pump driven gear inspection
1. Inspect:
● Oil pump driven gear
Crack/Pitting/Wear → Replace.
Cylinder body and crankcase installation
1. Install:
● Cylinder body
● Crankshaft and piston
NOTE:
● Align the piston ring end gaps with the
respective locating pins.
● Fit the bearing and the labyrinth seal
locating pins in the cylinder body.
2. Apply:
● Gasket maker
Onto the connecting surfaces of the
crankcase and cylinder body.
NOTE:
● Clean the connecting surfaces of the
crankcase and cylinder body before applying the Gasket maker.
● Gasket maker should be so applied that it
does not overflow the contacting surface.
5-30
POWR
CRANK SHAFT AND PISTON
CRANK SHAFT AND PISTON
EXPLODED DIAGRAM
5-31
E
POWR
CRANK SHAFT AND PISTON
E
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
CRANK SHAFT AND PISTON
REMOVAL
Crank case
Q’ty
1
2
3
4
Bolt (with washer)
Oil seal housing
Plane washer
Crankshaft ass’y
1
1
1
1
5
6
Circlip
Piston pin clip
2
6
Service points
Follow the left “Step” for removal.
Refer to “CRANK CASE AND CYLINDER
BODY”.
6 × 20 mm
NOTE:
Remove the crankshaft by lightly tapping
it with a plastic hammer.
CAUTION:
Always use the new clip.
7
8
Piston pin
Piston pin washer
3
6
CAUTION:
The washer should be placed with their
convex sides facing the piston.
9
Small end bearing needle
3
CAUTION:
Do not a mixture of new and used bearing needles in the same small end.
10
11
12
Piston
Piston ring
Bearing
3
6
2
CAUTION:
When installing the bearing, the seal-cap
side should be installed towards the flywheel side.
13
Oil pump drive gear
1
Oil injection model
CAUTION:
When installing the gear, the chamfered
bore edge side should be installed
towards the flywheel side.
14
1
2
3
Spacer
OIL SEAL HOUSING DISASSEMBLY
O-ring
Oil seal
Oil seal
1
Pre-mixed model
1
1
2
Reverse the removal steps for installation.
5-32
POWR
CRANK SHAFT AND PISTON
E
SERVICE POINTS
Piston pin clip removal
1. Remove:
● Piston pin clip
NOTE:
Take care not to damage piston pin hole
edge.
Piston pin and small end bearing removal
1. Remove:
● Piston pin clip
● Small end needle bearing
NOTE:
When the piston pins, pistons, and small
end needle bearings are reused, they
should be marked with No. 1, 2 and 3 so
that they are not confused.
Piston ring removal
1. Remove:
● Piston ring
NOTE:
Remove the piston ring from the piston by
opening the ring to the least possible width.
Bearing removal
1. Remove:
● Bearing
NOTE:
Hold the bearing with the bearing separator, and forth out the crankshaft with a
press.
Bearing separator:
YB-06219/90890-06534
Piston inspection
1. Measure:
● Piston diameter
Use a micrometer.
Out of specification → Replace.
5-33
POWR
CRANK SHAFT AND PISTON
E
Standard
Measuring
point “H”
Piston diameter
10 mm
(0.4 in)
66.940 ~ 67.000 mm
(2.6354 ~ 2.6378 in)
Over size piston diameter:
1*: 67.25 mm (2.648 in)
2: 67.50 mm (2.657 in)
*: Except for U.S.A.
2. Measure:
● Piston pin boss inside diameter
Use a micrometer.
Out of specification → Replace.
Piston pin boss inside diameter:
18.008 ~ 18.015 mm
(0.7090 ~ 0.7093 in)
Piston pin and small end bearing inspection
1. Inspect:
● Piston pin
● Small end bearing
Signs of heat discoloration →
Replace.
Scratch/Damage → Replace.
2. Measure:
● Piston pin diameter
Use a micrometer.
Out of specification → Replace.
Piston pin diameter:
17.995 ~ 18.000 mm
(0.7085 ~ 0.7087 in)
3. Check:
● 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.
5-34
POWR
CRANK SHAFT AND PISTON
E
Piston ring inspection
1. Inspect:
● Piston ring
Breakage/Damage → Replace.
2. Measure:
● End gap
Use a feeler gauge.
Out of specification → Replace.
End gap:
Top: 0.40 ~ 0.60 mm
(0.016 ~ 0.024 in)
2nd: 0.40 ~ 0.60 mm
(0.016 ~ 0.024 in)
End gap limit:
Top: 0.80 mm (0.031 in)
2nd: 0.80 mm (0.031 in)
Measuring point
20 mm (0.8 in)
NOTE:
Install the piston ring into the cylinder. Push
the ring with the piston crown.
3. Measure:
● Side clearance
Use a thickness gauge.
Out of specification → Replace piston
and/or ring.
Side clearance:
Top: 0.04 ~ 0.08 mm
(0.002 ~ 0.003 in)
2nd: 0.03 ~ 0.07 mm
(0.001 ~ 0.003 in)
5-35
POWR
CRANK SHAFT AND PISTON
E
Crankshaft inspection
1. Measure:
● Crank width A
● Crank width B
Out of specification → Replace.
Crank width A:
53.90 ~ 53.95 mm
(2.122 ~ 2.124 in)
Crank width B:
32.88 ~ 33.10 mm
(1.294 ~ 1.303 in)
2. Measure:
● Runout
Use a V-blocks and dial gauge.
Out of specification → Replace.
Runout limit:
0.03 mm (0.001 in)
3. Measure:
● Axial play
Out of specification → Replace.
Axial play limit:
2.0 mm (0.08 in)
4. Inspect:
● Crankshaft bearing
Pitting/Rumbling → Replace.
CAUTION:
● Do
not spin bearing with air blower; this
can damage the bearing.
● Also take care not to scratch the bearing
balls when cleaning.
5. Inspect:
● Oil pump drive gear
Crack/Pitting/Wear → Replace.
5-36
POWR
CRANK SHAFT AND PISTON
E
Piston and piston ring installation
1. Install:
● Piston ring (2nd)
● Piston ring (top)
CAUTION:
● Take
care not to scratch the piston or
break piston rings.
● Align the each ring end gap with their
locating pins.
● After fitting the rings, check that they
move smoothly.
NOTE:
Piston rings should be replaced as a set.
Crankshaft and piston installation
1. Install:
● Small end bearing needle
Needles per piston:
31 pieces
Small end bearing needle
installer:
YB-06106/90890-06526
2. Install:
● Piston 1
● Piston pin 2
● Piston pin clip 3
CAUTION:
Do not allow the clip open ends to meet
the piston pin slot.
NOTE:
● Mold mark a faces in the same direction
as the “UP” mark on the piston.
● When no piston is replaced, be sure to reinstall the pistons in their original cylinder.
5-37
LOWR
E
CHAPTER 6
LOWER UNIT
LOWER UNIT REMOVAL ............................................................................... 6-1
EXPLODED DIAGRAM ............................................................................. 6-1
REMOVAL AND INSTALLATION CHART ............................................... 6-2
SERVICE POINTS ..................................................................................... 6-2
Propeller inspection .......................................................................... 6-2
WATER PUMP................................................................................................. 6-3
EXPLODED DIAGRAM ............................................................................. 6-3
REMOVAL AND INSTALLATION CHART ............................................... 6-4
SERVICE POINTS ..................................................................................... 6-4
Water pump housing inspection...................................................... 6-4
Impeller and insert cartridge inspection ......................................... 6-4
PROPELLER SHAFT AND REVERSE GEAR................................................... 6-5
EXPLODED DIAGRAM ............................................................................. 6-5
REMOVAL AND INSTALLATION CHART ............................................... 6-6
SERVICE POINTS ..................................................................................... 6-7
Propeller shaft housing removal...................................................... 6-7
Propeller shaft housing disassembly .............................................. 6-7
Reverse gear inspection ................................................................... 6-8
Bearing inspection ............................................................................ 6-8
Propeller shaft housing inspection .................................................. 6-8
Dog clutch inspection ....................................................................... 6-8
Propeller shaft inspection................................................................. 6-8
Propeller shaft housing assembly ................................................... 6-9
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD ................................... 6-11
EXPLODED DIAGRAM ........................................................................... 6-11
REMOVAL AND INSTALLATION CHART ............................................. 6-12
EXPLODED DIAGRAM ........................................................................... 6-13
REMOVAL AND INSTALLATION CHART ............................................. 6-14
SERVICE POINTS ................................................................................... 6-15
Pinion nut removal.......................................................................... 6-15
Forward gear disassembly ............................................................. 6-15
Lower case disassembly................................................................. 6-15
Pinion and forward gear inspection .............................................. 6-16
Drive shaft inspection ..................................................................... 6-16
Shift cam inspection ....................................................................... 6-16
Bearing inspection .......................................................................... 6-16
Sleeve inspection ............................................................................ 6-17
Lower case inspection .................................................................... 6-17
Lower case assembly...................................................................... 6-17
Drive shaft oil seal housing assembly........................................... 6-18
Forward gear assembly .................................................................. 6-18
Pinion nut installation ..................................................................... 6-18
1
2
3
4
5
6
7
8
9
LOWR
SHIMMING .................................................................................................... 6-19
SHIM SELECTION (FOR USA AND CANADA) ..................................... 6-19
Pinion gear shim ............................................................................. 6-19
Forward gear shim .......................................................................... 6-21
Reverse gear shim........................................................................... 6-22
SHIM SELECTION (EXCEPT FOR USA AND CANADA) ...................... 6-23
Pinion gear shim ............................................................................. 6-23
Forward gear shim .......................................................................... 6-25
Reverse gear shim........................................................................... 6-26
BACKLASH MEASUREMENT................................................................ 6-26
Forward gear ................................................................................... 6-27
Reverse gear .................................................................................... 6-28
E
1
2
3
4
5
6
7
8
9
LOWR
LOWER UNIT REMOVAL
LOWER UNIT REMOVAL
EXPLODED DIAGRAM
6-1
E
LOWR
LOWER UNIT REMOVAL
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
Procedure/Part name
LOWER UNIT REMOVAL
Clamp
Hose
Cotter pin
Propeller nut
Q’ty
5
6
7
8
9
10
11
12
13
14
15
16
Plane washer
Spacer
Propeller
Spacer
Bolt (with washer)
Trim tab
Bolt (with washer)
Bolt (with washer)
Nut
Spring washer
Plane washer
Lower unit
1
1
1
1
1
1
1
4
4
4
4
1
17
18
19
20
Dowel pin
Extension
Dowel pin
Stud bolt
2
1
2
4
1
1
1
1
Service points
Follow the left “Step” for removal.
NOTE:
If the propeller nut does not align with
the propeller shaft hole when the nut is
tightened to specification, turn it in further so that they align.
8 × 25 mm
10 × 40 mm
X model
NOTE:
Insert the drive shaft into the crankshaft.
If the splines will not come in complete
mesh, rotate the propeller shaft a little so
that they are in mesh correctly.
X model
Reverse the removal steps for installation.
SERVICE POINTS
Propeller inspection
1. Inspect:
● Blade
● Spline
Wear/Crack/Damage → Replace.
6-2
LOWR
WATER PUMP
E
WATER PUMP
EXPLODED DIAGRAM
6-3
LOWR
WATER PUMP
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
Procedure/Part name
WATER PUMP REMOVAL
Lower unit ass’y
Bolt
Washer
Water pump housing
Q’ty
4
5
O-ring
Insert cartridge
1
1
6
7
8
9
10
11
12
Impeller
Woodruff key
Cartridge plate
Plate gasket
Pin
Water seal cover
Water seal rubber
1
1
1
1
2
1
1
4
4
1
Service points
Follow the left “Step” for removal.
Refer to “LOWER UNIT REMOVAL”.
8 × 30 mm
NOTE:
When installing the water pump housing,
align the hole in it with the projection in
the insert cartridge.
NOTE:
When installing the cartridge, turn the
drive shaft clockwise.
Reverse the removal steps for installation.
SERVICE POINTS
Water pump housing inspection
1. Inspect:
● Water pump housing
Crack/Damage → Replace.
Impeller and insert cartridge inspection
1. Inspect:
● Impeller
● Insert cartridge
Crack/Damage → Replace.
6-4
LOWR
PROPELLER SHAFT AND REVERSE GEAR
PROPELLER SHAFT AND REVERSE GEAR
EXPLODED DIAGRAM
6-5
E
LOWR
PROPELLER SHAFT AND REVERSE GEAR
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
Procedure/Part name
PROPELLER SHAFT AND
REVERSE GEAR REMOVAL
Gear oil
Propeller
Flange bolt
Propeller shaft housing ass’y
Plane washer
Propeller shaft ass’y
PROPELLER SHAFT HOUSING
DISASSEMBLY
Reverse gear
Reverse gear shim
Ball bearing
4
5
6
7
O-ring
O-ring
Oil seal
Needle bearing
1
2
2
1
8
1
9
0
Propeller shaft housing
PROPELLER SHAFT DISASSEMBLY
Cross pin ring
Cross pin
1
1
A
B
C
D
Shift plunger
Shift slider
Spring
Dog clutch
1
1
1
1
E
Propeller shaft
1
1
2
3
4
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “LOWER UNIT” in chapter 3.
Refer to “LOWER UNIT REMOVAL”.
2
1
1
1
1
*
1
NOTE:
Install the bearing with its manufacture’s
marks or numbers facing outward.
NOTE:
Install the bearing with its manufacture’s
marks or numbers facing outward.
NOTE:
By pushing the shift plunger, bring the
cross pin hole in the clutch dog with the
hole in the shift slider.
NOTE:
Install the clutch with “F” mark toward
the forward gear side.
Reverse the removal steps for installation.
*: As required
6-6
LOWR
PROPELLER SHAFT AND REVERSE GEAR
E
SERVICE POINTS
Å
Propeller shaft housing removal
1. Remove:
● Propeller shaft housing ass’y
Bearing housing puller:
YB-06234................................ 1
90890-06503........................... 3
Universal puller:
YB-06117................................ 2
Stopper guide plate:
90890-06501........................... 4
Center bolt:
90890-06504........................... 5
ı
Å For USA and CANADA
ı Except for USA and CANADA
Propeller shaft housing disassembly
1. Remove:
● Reverse gear
Bearing separator:
YB-06219/90890-06534
Stopper guide plate:
90890-06501
Bearing puller:
90890-06535
Stopper guide stand:
90890-06538
Å
2. Remove:
● Ball bearing 1
Slide hammer set:
YB-06096................................ 2
Stopper guide plate:
90890-06501........................... 3
Bearing puller:
90890-06535........................... 4
Stopper guide stand:
90890-06538........................... 5
ı
Å For USA and CANADA
ı Except for USA and CANADA
6-7
LOWR
PROPELLER SHAFT AND REVERSE GEAR
3. Remove:
● Oil seal 1
● Needle bearing 2
Driver rod:
YB-06071/90890-06652
Needle bearing attachment:
YB-06112/90890-06614
Reverse gear inspection
1. Inspect:
● Tooth
● Dog
Wear/Damage → Replace.
Bearing inspection
1. Inspect:
● Bearing
Pitting/Rumbling → Replace.
Propeller shaft housing inspection
1. Clean:
● Propeller shaft housing
Use a soft brush and solvent.
2. Inspect:
● Propeller shaft housing
Crack/Damage → Replace.
Dog clutch inspection
1. Inspect:
● Dog clutch
Wear/Damage → Replace.
Propeller shaft inspection
1. Inspect:
● Propeller shaft
Wear/Damage → Replace.
6-8
E
LOWR
PROPELLER SHAFT AND REVERSE GEAR
E
Propeller shaft housing assembly
1. Install:
● Needle bearing
Å
Depth a:
3.0 ~ 3.5 mm (0.12 ~ 0.14 in)
Depth b:
23.0 ~ 23.5 mm (0.91 ~ 0.93 in)
Driver rod:
YB-06071................................ 1
90890-06604........................... 3
Needle bearing attachment:
YB-06111................................ 2
90890-06614........................... 4
Bearing depth plate:
90890-06603........................... 5
ı
Å For USA and CANADA
ı Except for USA and CANADA
2. Install:
● Oil seal
Depth a:
4.0 ~ 4.5 mm (0.16 ~ 0.18 in)
Oil seal installer:
YB-06168
Driver rod:
YB-06071
6-9
LOWR
PROPELLER SHAFT AND REVERSE GEAR
6-10
E
LOWR
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD
EXPLODED DIAGRAM
6-11
E
LOWR
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
Procedure/Part name
DRIVE SHAFT, FORWARD GEAR
AND SHIFT ROD REMOVAL
Gear oil
Lower unit ass’y
Water pump
Propeller shaft ass’y
Q’ty
Pinion nut
Pinion gear
Drive shaft
Drive shaft oil seal housing ass’y
Plane washer
Forward gear ass’y
Shift rod ass’y
Shift cam
1
1
1
1
1
1
1
1
Refer to “LOWER UNIT” in chapter 3.
Refer to “LOWER UNIT REMOVAL”.
Refer to “WATER PUMP” in chapter 5.
Refer to “PROPELLER SHAFT AND
REVERSE GEAR”.
A
B
C
DRIVE SHAFT OIL SEAL HOUSING DISASSEMBLY
Oil seal cover
O-ring
Oil seal
Drive shaft oil seal housing
SHIFT ROD DISASSEMBLY
O-ring
Shift rod oil seal housing
O-ring
Oil seal
Circlip
Shift rod
LOWER CASE DISASSEMBLY
Drive shaft bearing outer race
Pinon gear shim
Drive shaft sleeve
D
Drive shaft needle bearing
1
E
Forward gear bearing outer race
1
1
2
3
4
5
6
7
8
9
0
Service points
Follow the left “Step” for removal.
NOTE:
Set the “UP” mark upward.
1
1
2
1
1
1
1
1
1
1
1
*
1
* As required
6-12
NOTE:
Align the sleeve locating-rib with the
recess in the lower case.
NOTE:
Install the bearing with its manufacture’s
marks or numbers facing outward.
LOWR
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD
EXPLODED DIAGRAM
6-13
E
LOWR
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD
E
REMOVAL AND INSTALLATION CHART
Step
F
G
H
I
J
K
L
M
N
Procedure/Part name
Forward gear shim
Screw
Water inlet cover 1
Water inlet cover 2
Nut
Hose nipple
Bolt (with washer)
Anode
Lower case
Q’ty
*
1
1
1
1
1
1
1
1
Service points
Reverse the removal steps for installation.
* As required
6-14
LOWR
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD
E
SERVICE POINTS
Pinion nut removal
1. Remove:
● Pinion nut
Drive shaft holder:
YB-06079/90890-06517 ......... 1
Pinion nut wrench:
90890-06505........................... 2
Socket adapter:
90890-06506........................... 3
Forward gear disassembly
1. Remove:
● Taper roller bearing 1
● Forward gear 2
Bearing separator:
YB-06219/90890-06534
Lower case disassembly
1. Remove:
● Drive shaft bearing outer race 1
Å
Slide hammer set:
YB-06096................................ 2
Stopper guide plate:
90890-06501........................... 3
Bearing puller:
90890-06535........................... 4
Stopper guide stand:
90890-06538........................... 5
Å For USA and CANADA
ı Except for USA and CANADA
ı
6-15
LOWR
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD
E
2. Remove:
● Drive shaft needle bearing
Needle bearing attachment:
YB-06063/90890-06614 ......... 1
Driver rod:
YB-06071/90890-06652 ......... 2
3. Remove:
● Forward gear bearing outer race
Å
Slide hammer set:
YB-06096................................ 1
Bearing outer race puller:
90890-06523........................... 2
Bearing outer race puller claw:
90890-06532........................... 3
Stopper guide stand:
90890-06538........................... 4
ı
Å For USA and CANADA
ı Except for USA and CANADA
Pinion and forward gear inspection
1. Inspect:
● Tooth
● Dog
Wear/Damage → Replace.
Drive shaft inspection
1. Inspect:
● Drive shaft
Wear/Damage → Replace.
Shift cam inspection
1. Inspect:
● Shift cam
Wear/Damage → Replace.
Bearing inspection
1. Inspect:
● Bearing
Pitting/Rumbling → Replace.
6-16
LOWR
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD
E
Sleeve inspection
1. Inspect:
● Sleeve
Wear/Damage → Replace.
Lower case inspection
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.
Lower case assembly
1. Install:
● Forward gear shim 1
● Forward gear bearing outer race 2
Bearing installer:
YB-41446/90890-06626
Driver rod:
YB-06071/90890-06605
2. Install:
● Drive shaft needle bearing
Å
Depth a:
182.5 ~ 183 mm (7.19 ~ 7.20 in)
Bearing installer:
YB-06063................................ 1
90890-06614........................... 4
Driver rod:
YB-06071................................ 2
90890-06602........................... 5
Driveshaft needle bearing
depth stop:
YB-34473................................ 3
Bearing depth plate:
90890-06603........................... 6
ı
Å For USA and CANADA
ı Except for USA and CANADA
6-17
LOWR
DRIVE SHAFT, FORWARD GEAR AND SHIFT ROD
E
3. Install:
● Pinion gear shim
● Drive shaft bearing outer race
Bearing installer:
YB-06110/90890-06627 ......... 1
Driver rod:
YB-06071/90890-06606 ......... 2
Drive shaft oil seal housing assembly
1. Install:
● Oil seal 1
Depth a:
0.0 ~ 0.5 mm (0.00 ~ 0.02 in)
Bearing installer:
YB-06167/90890-06628
Driver rod:
YB-06071/90890-06605
Forward gear assembly
1. Install:
● Forward gear
● Taper roller bearing
Å
Bearing installer:
YB-06270-A ............................ 1
90890-06640........................... 2
Å For USA and CANADA
ı Except for USA and CANADA
ı
Pinion nut installation
1. Install:
● Pinion nut
Drive shaft holder:
YB-06079/90890-06517 ......... 1
Pinion nut wrench:
90890-06505........................... 2
Socket adapter:
90890-06506........................... 3
6-18
LOWR
SHIMMING
E
SHIMMING
NOTE:
Shim selection requirement guide:
● Not required when;
reassembling with original case and inner
parts.
● Numeric calculation is required when;
reassembling with original inner parts
and the new case. (Difference between
original and new case)
● Measurement and adjustment is required
when;
replacing the inner part(s).
SHIM SELECTION
(FOR USA AND CANADA)
Pinion gear shim
NOTE:
Find pinion gear shim thickness (T3) by
selecting shims until the specified measurement (M) is obtained with the special tool.
1. Calculate:
● Specified measurement (M)
Specified measurement (M) =
0.30 mm + P/100
NOTE:
● P is the deviation of the lower case dimension from standard. It is stamped on the
trim tab mounting surface of the lower
case in 0.01 mm units. If the P mark is
missing or unreadable, assume a P mark
of “0”, and check the backlash when the
unit is assembled.
● If the P value is negative (–), then subtract
the P value from the measurement.
Example:
If P mark is “+5”, then M = 0.30 mm + (+5)/100
= 0.30 + 0.05 mm
= 0.35 mm
If P mark is “–5”, then M = 0.30 mm + (–5)/100
= 0.30 – 0.05 mm
= 0.25 mm
6-19
LOWR
SHIM SELECTION
E
2. Install:
● Shimming gauge
● Drive shaft
● Bearing 1
● Shim(s) 2
Gauge block:
YB-34432-9............................. 3
Adapter plate:
YB-34432-10........................... 4
Gauge base:
YB-34432-11........................... 5
Clamp:
YB-34432-17........................... 6
NOTE:
● Attach the adapter plate to the gauge base
using 4 bolts of appropriate sizes.
● Fix the shimming gauge to the drive shaft
so that the shaft is at the center of the
hole.
● If the original shim(s) is unavailable, start
with a 0.50 mm shim.
3. Install:
● Pinion
● Pinion nut
T.
Pinion nut:
75 Nm (7.5 m • kg, 54 ft • lb)
R.
4. Check:
● Specified measurement (M)
Out of specified measurement →
Adjust.
Thickness gauge:
YU-26900-9
NOTE:
● Check
the fit between the shimming
gauge and lower surface of the pinion.
● Perform the same measurement at three
points on the pinion nut.
5. Adjust:
● Shim(s)
Remove or add
Available shim thickness:
0.05, 0.08, 0.12, 0.30 and 0.50 mm
6-20
LOWR
SHIMMING
E
Forward gear shim
NOTE:
Find forward gear shim thickness (T1) by
selecting shims until the specified measurement (M) is obtained with the special tool.
1. Calculate:
● Specified measurement (M)
Specified measurement (M) =
0.06 mm + F/100
NOTE:
● F is the deviation of the lower case dimension from standard. It is stamped on the
trim tab mounting surface of the lower
case in 0.01 mm units. If the F mark is
missing or unreadable, assume an F mark
of “0”, and check the backlash when the
unit is assembled.
● If the F value is negative (–), then subtract
the F value from the measurement.
Example:
If F mark is “+5”, then M
= 0.06 mm + (+5)/100
= 0.06 + 0.05 mm
= 0.11 mm
If F mark is “–5”, then M = 0.06 mm + (–5)/100
= 0.06 – 0.05 mm
= 0.01 mm
2. Install:
● Shimming gauge
● Bearing 1
● Shim(s) 2
Base plate:
YB-34446-1............................. 3
Compression spring:
YB-34446-3............................. 4
Press plate:
YB-34446-4............................. 5
Gauge pin:
YB-34446-7............................. 6
NOTE:
● Tighten the nut four turns after contact
with the spring.
● If the original shim(s) is unavailable, start
with a 0.50 mm shim.
6-21
LOWR
SHIMMING
E
3. Check:
● Specified measurement (M)
Out of specified measurement →
Adjust.
Thickness gauge:
YU-26900-9
NOTE:
Check the fit between the shimming gauge
and lower surface of the press plate.
4. Adjust:
● Shim(s)
Remove or add.
Available shim thickness:
0.05, 0.08, 0.12, 0.30 and 0.50 mm
Reverse gear shim
NOTE:
● Find reverse gear shim thickness (T2) by
backlash measurement.
● Measure the backlash with the original
shim(s).
● If the original shim(s) is unavailable, start
with a 0.50 mm shim.
Available shim thickness:
0.05, 0.08, 0.12, 0.30 and 0.50 mm
6-22
LOWR
SHIMMING
E
SHIM SELECTION
(EXCEPT FOR USA AND CANADA)
Pinion gear shim
NOTE:
Find pinion gear shim thickness (T3) by
selecting shims until the specified measurement is obtained with the special tool.
1. Install:
● Pinion height gauge
● Drive shaft
● Bearing
Pinion height gauge:
90890-06702
NOTE:
● Fix the pinion height gauge to the drive
shaft so that the shaft is at the center of
the hole.
● Tighten the wing nuts 1/4 turn after contacting the fixing plate.
2. Install:
● Pinion
● Pinion nut
T.
Pinion nut:
75 Nm (7.5 m • kg, 54 ft • lb)
R.
3. Measure:
● Measurement (M)
Digital caliper:
90890-06704
NOTE:
● Measure the fit between the pinion height
gauge and lower surface of the pinion.
● Perform the same measurement at three
points on the pinion.
4. Calculate:
● Pinion gear shim thickness (T3)
Pinion gear shim thickness (T3) =
M – 11.30 mm + P/100
6-23
LOWR
SHIMMING
E
NOTE:
the average of the measurement (M).
● P is the deviation of the lower case dimension from standard. It is stamped on the
trim tab mounting surface of the lower
case in 0.01 mm units. If the P mark is
missing or unreadable, assume a P mark
of “0”, and check the backlash when the
unit is assembled.
● If the P value is negative (–), then subtract
the P value from the measurement.
● Find
Example:
If M is “11.70 mm” and P mark is “+5”,
then T3 = 11.70 mm – 11.30 + (+5)/100
= 0.40 + 0.05 mm
= 0.45 mm
If M is “11.70 mm” and P mark is “–5”,
then T3 = 11.70 mm – 11.30 + (–5)/100
= 0.40 – 0.05 mm
= 0.35 mm
5. Select:
● Pinion gear shim
Calculated numeral
at 1/100th place
Rounded
numeral
more than
or less
0.00
0.02
0.02
0.02
0.05
0.05
0.05
0.08
0.08
0.08
0.10
0.10
Available shim thickness:
0.05, 0.08, 0.12, 0.30 and 0.50 mm
Example:
If T3 is “0.44 mm”,
then pinion gear shim = 0.45 mm
If T3 is “0.39 mm”,
then pinion gear shim = 0.40 mm
6-24
LOWR
SHIMMING
E
Forward gear shim
NOTE:
Find forward gear shim thickness (T1) by
selecting shims until the specified measurement (M) is obtained with the special tool.
1. Measure:
● Measurement (M)
Shimming Plate:
90890-06701
Digital caliper:
90890-06704
NOTE:
Measure the length between the shimming
plate and the bearing outer race after turning the outer race 2 to 3 times.
2. Calculate:
● Forward gear shim thickness (T1)
Forward gear shim thickness
(T1) = 22.75 + F/100 – M
NOTE:
● F is the deviation of the lower case dimension from standard. It is stamped on the
trim tab mounting surface of the lower
case in 0.01 mm units. If the F mark is
missing or unreadable, assume an F mark
of “0”, and check the backlash when the
unit is assembled.
● If the F value is negative (–), then subtract
the F value from the measurement.
Example:
If M is “22.30 mm” and F mark is “+5”,
then T1 = 22.75 mm + (+5)/100 – 22.30
= 0.45 + 0.05 mm
= 0.50 mm
If M is “22.30 mm” and F mark is “–5”,
then T1 = 22.75 mm + (–5)/100 – 22.30
= 0.45 – 0.05 mm
= 0.40 mm
6-25
LOWR
SHIMMING
E
3. Select:
● Forward gear shim
Calculated numeral
at 1/100th place
Rounded
numeral
more than
or less
0.00
0.02
0.00
0.02
0.05
0.02
0.05
0.08
0.05
0.08
0.10
0.08
Available shim thickness:
0.05, 0.08, 0.12, 0.30 and 0.50 mm
Example:
If T1 is “0.45 mm”,
then forward gear shim = 0.42 mm
If T1 is “0.50 mm”,
then forward gear shim = 0.48 mm
Reverse gear shim
NOTE:
● Find reverse gear shim thickness (T2) by
backlash measurement.
● Measure the backlash with the original
shim(s).
● If the original shim(s) is unavailable, start
with a 0.50 mm shim.
Available shim thickness:
0.05, 0.08, 0.12, 0.30 and 0.50 mm
BACKLASH MEASUREMENT
NOTE:
● Do not install the water pump components when measuring the backlash.
● Both forward and reverse gear backlashes
should be measured.
● If both the forward and reverse gear backlashes are large than specified, the pinion
may be too high.
● If both forward and reverse gear backlashes are smaller than specified, the pinion may be too low.
● If either of these conditions exists, then
check the pinion shim selection.
6-26
LOWR
SHIMMING
E
Forward gear
1. Measure:
● Forward gear backlash
Out of specification → Adjust.
Backlash:
0.18 ~ 0.45 mm (0.007 ~ 0.018 in)
Measuring steps:
● Set the bearing housing puller for
pushing the propeller shaft.
Bearing housing puller:
YB-6234/90890-06503
Universal puller:
YB-6117
Stopper guide plate:
90890-06501
Center bolt:
90890-06504
T.
Center bolt:
5 Nm (0.5 m • kg, 3.6 ft • lb)
R.
●
●
Set the lower unit upside down.
Attach the backlash indicator on the
drive shaft (18 mm in diameter).
Backlash indicator:
YB-6265/90890-06706
●
Attach the dial gauge on the gear case,
and make the dial gauge stem contact
the mark on the indicator.
Backlash adjusting plate:
YB-07003
Dial gauge:
YU-03097/90890-01252
Magnet base:
YU-34481/90890-06705
●
6-27
While pulling the drive shaft, slowly
turn the drive shaft clockwise and
counterclockwise; then, measure the
backlash when the drive shaft stops in
each direction.
LOWR
SHIMMING
E
2. Adjust:
● Forward gear shim(s)
NOTE:
Adjust the shim(s) to be added or removed
according to specification.
Forward
Shim thickness
gear backlash
Less than 0.18 mm
To be decreased
by (0.31 – measurement) × 0.56
More than 0.45
mm
To be increased by
(measurement –
0.31) × 0.56
Available shim thickness:
0.05, 0.08, 0.12, 0.30 and 0.50 mm
Reverse gear
1. Measure:
● Reverse gear backlash
Out of specification → Adjust.
Backlash:
0.71 ~ 0.98 mm (0.028 ~ 0.039 in)
Measuring steps:
● Load the reverse gear by installing the
propeller with the front side facing
backward, and tighten the propeller
nut.
T.
Propeller nut:
5 Nm (0.5 m • kg, 3.6 ft • lb)
R.
●
Attach the backlash indicator on the
drive shaft (18 mm in diameter).
Backlash indicator:
YB-6265/90890-06706
●
6-28
Attach the dial gauge on the gear case,
and make the dial gauge stem contact
the mark on the indicator.
LOWR
SHIMMING
E
Backlash adjusting plate:
YB-07003
Dial gauge:
YU-03097/90890-01252
Magnet base:
YU-34481/90890-06705
●
While pulling the drive shaft, slowly
turn the drive shaft clockwise and
counterclockwise; then, measure the
backlash when the drive shaft stops at
each direction.
2. Adjust:
● Reverse gear shim(s)
NOTE:
Adjust the shim(s) to be added or removed
according to specification.
Reverse gear
backlash
Shim thickness
Less than 0.71 mm
To be decreased
by (0.85 – measurement) × 0.56
More than 0.98
mm
To be increased by
(measurement –
0.85) × 0.56
Available shim thickness:
0.05, 0.08, 0.12, 0.30 and 0.50 mm
6-29
BRKT
E
CHAPTER 7
BRACKET UNIT
TILLER HANDLE REMOVAL........................................................................... 7-1
EXPLODED DIAGRAM ............................................................................. 7-1
REMOVAL AND INSTALLATION CHART ............................................... 7-2
TILLER HANDLE.............................................................................................. 7-3
EXPLODED DIAGRAM ............................................................................. 7-3
REMOVAL AND INSTALLATION CHART ............................................... 7-4
EXPLODED DIAGRAM ............................................................................. 7-5
REMOVAL AND INSTALLATION CHART ............................................... 7-6
SERVICE POINTS ..................................................................................... 7-6
Control cable inspection ................................................................... 7-6
Bushing inspection............................................................................ 7-6
Shift lever inspection ........................................................................ 7-6
Friction piece inspection................................................................... 7-6
Steering handle inspection............................................................... 7-6
LINK ASS’Y DISASSEMBLY .......................................................................... 7-7
EXPLODED DIAGRAM ............................................................................. 7-7
REMOVAL AND INSTALLATION CHART ............................................... 7-8
SERVICE POINTS ..................................................................................... 7-8
Throttle arm inspection .................................................................... 7-8
Throttle shift ass’y inspection .......................................................... 7-8
Cam plate inspection ........................................................................ 7-8
Bushing inspection............................................................................ 7-8
SHIFT ACTUATOR AND BOTTOM COWLING.............................................. 7-9
EXPLODED DIAGRAM ............................................................................. 7-9
REMOVAL AND INSTALLATION CHART ............................................. 7-10
UPPER CASE REMOVAL .............................................................................. 7-11
EXPLODED DIAGRAM ........................................................................... 7-11
REMOVAL AND INSTALLATION CHART ............................................. 7-12
SERVICE POINTS ................................................................................... 7-12
Rubber mount inspection ............................................................... 7-12
Mount bolt inspection..................................................................... 7-12
UPPER CASE AND EXHAUST MANFOLD .................................................. 7-13
EXPLODED DIAGRAM ........................................................................... 7-13
REMOVAL AND INSTALLATION CHART ............................................. 7-14
CLAMP BRACKET (Manual tilt) ................................................................... 7-15
EXPLODED DIAGRAM ........................................................................... 7-15
REMOVAL AND INSTALLATION CHART ............................................. 7-16
1
2
3
4
5
6
7
8
9
BRKT
E
CLAMP BRACKET (Hydro tilt, Power trim and tilt) ................................... 7-17
EXPLODED DIAGRAM ........................................................................... 7-17
REMOVAL AND INSTALLATION CHART ............................................. 7-18
STEERING BRACKET.................................................................................... 7-19
EXPLODED DIAGRAM ........................................................................... 7-19
REMOVAL AND INSTALLATION CHART ............................................. 7-20
SWIVEL BRACKET ........................................................................................ 7-21
EXPLODED DIAGRAM ........................................................................... 7-21
REMOVAL AND INSTALLATION CHART ............................................. 7-22
SWIVEL BRACKET DISASSEMBLY ............................................................. 7-23
EXPLODED DIAGRAM ........................................................................... 7-23
REMOVAL AND INSTALLATION CHART ............................................. 7-24
TILT UNIT REMOVAL ................................................................................... 7-25
EXPLODED DIAGRAM ........................................................................... 7-25
REMOVAL AND INSTALLATION CHART ............................................. 7-26
TILT CYLINDER, PUMP HOUSING AND MOTOR REMOVAL.................... 7-27
EXPLODED DIAGRAM ........................................................................... 7-27
REMOVAL AND INSTALLATION CHART ............................................. 7-28
SERVICE POINTS ................................................................................... 7-28
TILT CYLINDER ............................................................................................. 7-29
EXPLODED DIAGRAM ........................................................................... 7-29
REMOVAL AND INSTALLATION CHART ............................................. 7-30
SERVICE POINTS ................................................................................... 7-31
Tilt cylinder disassembly ................................................................ 7-31
Inner cylinder disassembly............................................................. 7-31
Tilt rod inspection ........................................................................... 7-31
Tilt cylinder inspection.................................................................... 7-31
Tilt piston inspection....................................................................... 7-31
Spring inspection ............................................................................ 7-31
Free piston inspection..................................................................... 7-31
Inner cylinder assembly.................................................................. 7-32
Tilt cylinder assembly ..................................................................... 7-32
PUMP HOUSING .......................................................................................... 7-33
EXPLODED DIAGRAM ........................................................................... 7-33
REMOVAL AND INSTALLATION CHART ............................................. 7-34
PTT MOTOR .................................................................................................. 7-35
EXPLODED DIAGRAM ........................................................................... 7-35
REMOVAL AND INSTALLATION CHART ............................................. 7-36
SERVICE POINTS ................................................................................... 7-37
Motor inspection ............................................................................. 7-37
Motor assembly............................................................................... 7-38
1
2
3
4
5
6
7
8
9
BRKT
TILLER HANDLE REMOVAL
TILLER HANDLE REMOVAL
EXPLODED DIAGRAM
7-1
E
BRKT
TILLER HANDLE REMOVAL
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Procedure/Part name
TILLER HANDLE REMOVAL
Bolt
Clamp
Screw
Bolt
Collar
Clamp
Bolt
Engine stop switch lead (black)
Engine stop switch coupler (blue)
Main switch lead coupler
Oil level sensor lead coupler
Trim sensor lead coupler
Extension wire lead coupler
Clip
Shift cable
Clip
Throttle cable
Bolt
Fitting plate ass’y
20
21
22
Clamp
Engine stop switch lead
Main switch lead
1
1
1
23
24
25
Extension wire lead
Nut
Tiller handle ass’y
STEERING FRICTION
DISASSEMBLY
Bolt (with washer)
Plane washer
Friction plate ass’y
Collar
Nut
1
2
1
1
2
3
4
5
Q’ty
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
Service points
Follow the left “Step” for removal.
Steering friction model
E model
Steering friction model
M model
E model
EHTO/TH model
NOTE:
When installing the fitting plate, lift the
tiller handle straight up.
M model
NOTE:
Align the taped end of the battery cable
and the extension wire lead with the end
of the grommet.
2
2
1
2
2
Reverse the removal steps for installation.
7-2
BRKT
TILLER HANDLE
E
TILLER HANDLE
EXPLODED DIAGRAM
7-3
BRKT
TILLER HANDLE
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
TILLER HANDLE DISASSEMBLY
Tiller handle ass’y
Screw
Screw
Cover
Nut
Engine stop switch ass’y
Clamp
Cable clamp
Circlip
Throttle cable
Shift cable
Bolt (with washer)
Cable bracket
Screw (with washer)
Shift lever cover
Bolt (with washer)
16
17
18
19
20
21
22
23
24
25
26
27
28
Screw
Handle grip ass’y
Plain washer
Spring
Bushing
Bolt (with washer)
Shift lever
Bushing
Washer
Cotter pin
Friction knob
Nut
Bolt (with washer)
Q’ty
4
3
1
1
1
1
2
2
1
1
2
1
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
4
Service points
Follow the left “Step” for removal.
Refer to “TILLER HANDLE REMOVAL”.
6 × 16 mm
6 × 40 mm
Shorter cable
Longer cable
6 × 16 mm
NOTE:
Loosen the bolts temporarily.
6 × 16 mm
NOTE:
When installing the bolts, tighten them
temporarily.
29
30
31
32
33
34
Link ass’y
Friction piece
Grommet
Nylon nut
Plane washer
Bolt
1
1
1
1
1
1
7-4
BRKT
TILLER HANDLE
E
EXPLODED DIAGRAM
7-5
BRKT
TILLER HANDLE
E
REMOVAL AND INSTALLATION CHART
Step
35
36
37
38
39
Procedure/Part name
Collar
Wave washer
Bracket
Steering handle
Bushing
Q’ty
1
1
1
1
2
Service points
Reverse the removal steps for installation.
SERVICE POINTS
Control cable inspection
1. Inspect:
● Throttle cable
● Shift cable
Kink/Fray/Stick → Replace.
Bushing inspection
1. Inspect:
● Bushing
Wear/Crack/Damage → Replace.
Shift lever inspection
1. Inspect:
● Shift lever
Wear/Crack/Damage → Replace.
Friction piece inspection
1. Inspect:
● Friction piece
Wear/Crack/Damage → Replace.
Steering handle inspection
1. Inspect:
● Steering handle
Wear/Crack/Damage → Replace.
7-6
BRKT
LINK ASS’Y DISASSEMBLY
LINK ASS’Y DISASSEMBLY
EXPLODED DIAGRAM
7-7
E
BRKT
LINK ASS’Y DISASSEMBLY
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Procedure/Part name
LINK ASS’Y DISASSEMBLY
Circlip
Throttle arm shaft
Throttle arm
Screw (with washer)
Throttle shaft ass’y
Screw
Spring guide
Roller
Actuator
Spring
Circlip
Cam plate
Bushing
Frame
Stopper
Q’ty
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
Service points
Follow the left “Step” for removal.
6 × 16 mm
Neutral opening limit model
Reverse the removal steps for installation.
SERVICE POINTS
Throttle arm inspection
1. Inspect:
● Tooth
Wear/Damage → Replace.
Throttle shift ass’y inspection
1. Inspect:
● Throttle shift
Wear/Bent/Damage → Replace.
Cam plate inspection
1. Inspect:
● Cam plate
Wear/Crack/Damage → Replace.
Bushing inspection
1. Inspect:
● Bushing
Wear/Crack/Damage → Replace.
7-8
BRKT
SHIFT ACTUATOR AND BOTTOM COWLING
SHIFT ACTUATOR AND BOTTOM COWLING
EXPLODED DIAGRAM
7-9
E
BRKT
SHIFT ACTUATOR AND BOTTOM COWLING
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
Procedure/Part name
SHIFT ACTUATOR AND BOTTOM COWLING REMOVAL
Power unit ass’y
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “POWER UNIT REMOVAL” in
chapter 5.
Shift actuator ass’y
Bolt (with washer)
Fitting plate ass’y
Grommet
PTT motor lead and trim sensor
lead
1
2
1
1
1
6
Grommet
1
NOTE:
When installing the trim sensor leads and
PTT motor leads, align the taped end a
of the PTT motor leads with the end of
the grommet.
7
8
9
10
11
12
13
Bolt
Plane washer
Bottom cowling ass’y
Seal rubber
Collar
Grommet
Grommet
SHIFT ACTUATOR ASS’Y
Plug screw
Spring
Ball
Clip
Clip
Bushing
Plane washer
Shift rod lever
Cotter pin
Plane washer
Shift actuator
Bushing
Shift rod
4
4
1
1
4
4
1
6 × 30 mm
1
2
3
4
5
6
7
8
9
0
A
B
C
PTT model
NOTE:
Disconnect the leads from the clamp.
1
1
1
1
1
1
1
1
1
1
1
1
1
Reverse the removal steps for installation.
7-10
BRKT
UPPER CASE REMOVAL
UPPER CASE REMOVAL
EXPLODED DIAGRAM
7-11
E
BRKT
UPPER CASE REMOVAL
E
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
UPPER CASE REMOVAL
Power unit
Q’ty
Lower unit ass’y
Bottom cowling
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Bolt (with washer)
Bolt (with washer)
Lower mount housing
Mount damper
Nut
Nut
Plane washer
Lead wire
Plane washer
Upper case ass’y
Lower rubber mount
Washer
Plane washer
Mounting bolt
Bolt (with washer)
Upper rubber mount
Plate
Plane washer
Mounting bolt
1
4
2
2
2
2
2
1
2
1
2
2
2
2
3
1
1
2
2
Service points
Follow the left “Step” for removal.
Refer to “POWER UNIT REMOVAL” in
chapter 5.
Refer to “LOWER UNIT REMOVAL” in
chapter 6.
Refer to “SHIFT ACTUATOR AND BOTTOM COWLING”.
6 × 12 mm
8 × 30 mm
12.8 × 22.5 mm
12.8 × 22.5 mm
13 × 34 mm
8 × 35 mm
Reverse the removal steps for installation.
SERVICE POINTS
Rubber mount inspection
1. Inspect:
● Rubber mount
Wear/Crack/Damage → Replace.
Mount bolt inspection
1. Inspect:
● Mount bolt
Wear/Bent/Damage → Replace.
7-12
BRKT
UPPER CASE AND EXHAUST MANIFOLD
UPPER CASE AND EXHAUST MANIFOLD
EXPLODED DIAGRAM
7-13
E
BRKT
UPPER CASE AND EXHAUST MANIFOLD
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Procedure/Part name
UPPER CASE AND EXHAUST
MANIFOLD
Upper case ass’y
Bolt (with washer)
Upper case
Dowel pin
EXHAUST MANIFOLD REMOVAL
Muffler seal
Seal rubber
Bolt (with washer)
Exhaust guide
Grommet
Water tube
Seal rubber
Washer
Upper case gasket
Bolt (with washer)
Exhaust manifold
Exhaust manifold gasket
Muffler
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “UPPER CASE REMOVAL”.
2
1
2
1
1
4
1
1
1
1
1
1
3
1
1
1
8 × 30 mm
8 × 30 mm
Reverse the removal steps for installation.
7-14
BRKT
CLAMP BRACKET
E
CLAMP BRACKET (Manual tilt)
EXPLODED DIAGRAM
7-15
BRKT
CLAMP BRACKET
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
1
2
3
4
5
6
7
8
9
0
Procedure/Part name
CLAMP BRACKET REMOVAL
(Manual tilt)
Upper case ass’y
Spring
Circlip
Plane washer
Tilt stop lever
Pin
Tilt pin
Grease nipple
Lead wire
Nut
Plane washer
Bolt
Collar
Cap
Self lock nut
Clamp bracket plate
Clamp bracket 2 ass’y
Plane washer
Shallow water drive lever
Spring
Tilt lever
Swivel bracket ass’y
Plane washer
Clamp bracket 1 ass’y
Clamp bracket bolt
Self lock nut
Bushing
CLAMP BRACKET DISASSEMBLY
Circlip
Plane washer
Clamp bracket plate
Wave washer
Pin
Circlip
Plane washer
Wave washer
Clamp bracket plate
Pin
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “UPPER CASE REMOVAL”.
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
*: Shallow water drive model
1
1
1
1
1
1
1
1
1
1
Reverse the removal steps for installation.
7-16
BRKT
CLAMP BRACKET
E
CLAMP BRACKET (Hydro tilt, Power trim and tilt)
EXPLODED DIAGRAM
7-17
BRKT
CLAMP BRACKET
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
1
2
3
4
5
6
7
8
Procedure/Part name
CLAMP BRACKET REMOVAL
(Hydro tilt, Power trim and tilt)
Upper case ass’y
PTT motor lead
Trim sensor coupler
Band
Bolt (with washer)
Wire lead
Bolt (with washer)
Wire lead
Grease nipple
Wire lead
Tilt rod ass’y
Nut
Plane washer
Stud bolt
Clamp bracket spacer ass’y
Nut
Cap
Self lock nut
Clamp bracket 2
Plane washer
Swivel bracket ass’y
Plane washer
Clamp bracket 1
Bushing
Clamp bracket bolt
Self lock nut
ANODE REMOVAL
Bolt (with washer)
Wire lead
Bolt (with washer)
Wire lead
Anode
TRIM SENSOR REMOVAL
Band
Screw
Trim sensor
Q’ty
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
Service points
Follow the left “Step” for removal.
Refer to “UPPER CASE REMOVAL”.
PTT model
PTT motor lead - Trim sensor lead
6 × 10 mm
PTT model 6 × 10 mm
NOTE:
Before installing the clamp bracket bolt,
tighten the nut on its grooved side until it
stops.
PTT model
PTT model
6 × 16 mm
Reverse the removal steps for installation.
7-18
BRKT
STEERING BRACKET
STEERING BRACKET
EXPLODED DIAGRAM
7-19
E
BRKT
STEERING BRACKET
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Procedure/Part name
STEERING BRACKET REMOVAL
Upper case ass’y
Flange bolt
Seal rubber
Circlip
Lower mount housing
Steering bracket
Plane washer
Bushing
O-ring
Bushing
Friction piece
Bushing
O-ring
Bushing
Swivel bracket ass’y
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Service points
Follow the left “Step” for removal.
Refer to “UPPER CASE REMOVAL”.
Manual tilt model
Manual tilt model
Reverse the removal steps for installation.
7-20
BRKT
SWIVEL BRACKET
E
SWIVEL BRACKET
EXPLODED DIAGRAM
7-21
BRKT
SWIVEL BRACKET
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Procedure/Part name
SWIVEL BRACKET REMOVAL
(Manual tilt)
Upper case ass’y
Clamp bracket
Steering bracket
Tilt lock rod 1
Tilt lock rod 2
Rod joint
Clip
Tilt lever shaft
Tilt lever
Tilt lock rod 3
Tilt lock rod 4
Clip
Pin
Lever 1
Spring
Lever 2
Spring
Clip
Tilt lock plate shaft
Washer
Spring
Collar
Tilt lock ass’y
Shallow water drive lever
Clip
Cotter pin
Tilt lock shaft
Tilt lock plate 1
Tilt lock arm
Tilt lock plate 2
Q’ty
1
1
3
1
1
1, 2*
1, 2*
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
2
1
1
1
1
Service points
Follow the left “Step” for removal.
Refer to “UPPER CASE REMOVAL”.
Refer to “CLAMP BRACKET”.
Refer to “STEERING BRACKET”.
Shallow water drive model
*: Shallow water drive model
*: Shallow water drive model
*: Shallow water drive model
*: Shallow water drive model
Reverse the removal steps for installation.
7-22
BRKT
SWIVEL BRACKET DISASSEMBLY
SWIVEL BRACKET DISASSEMBLY
EXPLODED DIAGRAM
7-23
E
BRKT
SWIVEL BRACKET DISASSEMBLY
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
Procedure/Part name
SWIVEL BRACKET REMOVAL
(Hydro tilt, power trim and tilt)
Upper case ass’y
Clamp bracket
Steering bracket
Bolt (with washer)
Spring hook
Spring
Spring pin
Distance collar ass’y
Tilt support lever 1
Bushing
Bushing
Tilt support lever 2
Bushing
Swivel bracket
Q’ty
1
1
1
2
1
1
1
1
1
2
1
Service points
Follow the left “Step” for removal.
Refer to “UPPER CASE REMOVAL”.
Refer to “CLAMP BRACKET”.
Refer to “STEERING BRACKET”.
6 × 10 mm
Reverse the removal steps for installation.
7-24
BRKT
TILT UNIT REMOVAL
TILT UNIT REMOVAL
EXPLODED DIAGRAM
7-25
E
BRKT
TILT UNIT REMOVAL
E
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
TILT UNIT REMOVAL
Tilt up
Q’ty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
PTT motor lead
Band
Bolt (with washer)
Wire lead
Bolt (with washer)
Wire lead
Tilt rod ass’y
Nut
Plane washer
Stud bolt
Clamp bracket spacer ass’y
Bushing
Nut
Crip
Shaft pin
Tilt unit
Bushing
Collar
1
3
1
1
1
1
1
1
1
1
1
2
1
2
1
1
2
1
Service points
Follow the left “Step” for removal.
NOTE:
Turn the tilt support lever toward clamp
bracket and support the outboard.
PTT model
PTT motor lead - Trim sensor lead
6 × 10 mm
Reverse the removal steps for installation.
7-26
BRKT
TILT CYLINDER, PUMP HOUSING AND MOTOR
REMOVAL
TILT CYLINDER, PUMP HOUSING AND MOTOR REMOVAL
EXPLODED DIAGRAM
7-27
E
BRKT
TILT CYLINDER, PUMP HOUSING AND MOTOR
REMOVAL
E
REMOVAL AND INSTALLATION CHART
Step
1
Procedure/Part name
TILT CYLINDER, PUMP HOUSING AND MOTOR REMOVAL
Power trim and tilt unit
Plug screw
Q’ty
1
Service points
Follow the left “Step” for removal.
Refer to “TILT UNIT REMOVAL”.
Drain hydraulic oil.
WARNING
When removing the plug screw, PTT unit
should be fully tilt up positioned.
2
3
4
5
6
7
8
9
10
11
12
13
O-ring
Socket bolt
Tilt cylinder ass’y
O-ring
O-ring
Screw
PTT motor ass’y
O-ring
Spring
Filter
Connector shaft
Pump housing ass’y
1
3
1
2
1
3
1
1
1
1
1
1
12.6 × 8.8 mm
8.5 × 5.5 mm
17.5 × 14.5 mm
65.3 × 59.4 mm
Reverse the removal steps for installation.
SERVICE POINTS
WARNING
● The
PTT unit should be fully tilt up positioned (all the tilt rod should be fully
lengthen) for disassembly to cancel the
internal pressure and prevent the hydraulic fluid from spurting out.
● After removing the tilt motor or oil reservoir, do not push down the tilt rod. It may
cause hydraulic fluid to spurt out from
the port.
CAUTION:
Do not wipe components of the hydraulic
system with rags, paper, tissues, or the like
as fibers from such material will cause malfunction if they enter the system.
NOTE:
Tilt cylinder removal is not required for the
cylinder repair.
7-28
BRKT
TILT CYLINDER
E
TILT CYLINDER
EXPLODED DIAGRAM
7-29
BRKT
TILT CYLINDER
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
Procedure/Part name
TILT CYLINDER DISASSEMBLY
Tilt cylinder ass’y
Tilt cylinder end screw
Tilt cylinder
Tilt rod ass’y
Ball
Q’ty
1
1
1
6
Service points
Follow the left “Step” for removal.
Refer to “TILT CYLINDER, PUMP HOUSING AND MOTOR REMOVAL”.
3.18 mm
NOTE:
Be sure to remove the steel balls on the
lower side of the inner cylinder when
removing the tilt cylinder.
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
O-ring
O-ring
Inner cylinder end screw
Tilt rod sub ass’y
Trim piston
O-ring
Backup ring
O-ring
O-ring
Circlip (larger)
Valve plate
Spring
Stopper plate
Circlip (smaller)
Free piston
O-ring
Circlip
Valve seal
Inner cylinder
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
54.7 × 47.7 mm
58.5 × 54.5 mm
50.7 × 43.7 mm
35.7 × 28.7 mm
39.0 × 35.0 mm
35.7 × 28.7 mm
Reverse the removal steps for installation.
7-30
BRKT
TILT CYLINDER
E
SERVICE POINTS
Tilt cylinder disassembly
1. Loosen:
● Tilt cylinder end screw
Tilt cylinder wrench:
YB-06175-2B/90890-06544
Inner cylinder disassembly
1. Loosen:
● Inner cylinder end screw
Tilt cylinder wrench:
YB-06175-2B/90890-06544
CAUTION:
Vise the top of the inner cylinder with the
tilt rod pulled out in its full length, or the
cylinder may be deformed.
Tilt rod inspection
1. Inspect:
● Tilt rod
Bend/Excessive corrode → Replace.
Rust lightly → Polish (with #400-600
abrasive paper).
Tilt cylinder inspection
1. Inspect:
● Tilt cylinder
Crack/Excessive corrosion → Replace.
2. Inspect:
● Cylinder inner
Scratch on the cylinder inner wall →
Replace.
Tilt piston inspection
1. Inspect:
● Tilt piston
Excessive scratch → Replace.
Spring inspection
1. Inspect:
● Spring
Crack/Deformation → Replace.
Free piston inspection
1. Inspect:
● Free piston
Excessive scratch → Replace.
7-31
BRKT
TILT CYLINDER
E
Inner cylinder assembly
1. Fill:
● ATF (Dexiron type 2)
to inner cylinder.
NOTE:
Depress the tilt rod fully and fill the inner
cylinder with ATF before installing the end
screw.
2. Tighten:
● Inner cylinder end screw
Tilt cylinder wrench:
YB-06175-2B/90890-06544
Tilt cylinder assembly
1. Install:
● Ball 1
● Tilt cylinder 2
NOTE:
● Apply the grease to the balls to prevent
them from falling down.
● To find any ball that may fall, turn the
inner cylinder unit upside down to install
the tilt cylinder.
2. Fill:
● ATF (Dexiron type 2)
to tilt cylinder.
3. Tighten:
● Tilt cylinder end screw
Tilt cylinder wrench:
YB-06175-2B/90890-06544
7-32
BRKT
PUMP HOUSING
E
PUMP HOUSING
EXPLODED DIAGRAM
7-33
BRKT
PUMP HOUSING
E
REMOVAL AND INSTALLATION CHART
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Procedure/Part name
PUMP HOUSING DISASSEMBLY
Pump housing ass’y
Socket bolt
Gear pump
O-ring
Bolt (with washer)
Bottom cover
O-ring
Clip
Inlet hose
Screw
Retaining plate
Spring
Valve support pin
Valve seat
Spring
Valve seat
Valve support pin
Valve seat
O-ring
Filter
Main valve
O-ring
O-ring
Shuttle piston
O-ring
Circlip
Valve body
O-ring
O-ring
Valve seal
Spring
Pin
Valve seal
Circlip
Manual valve
Ball
O-ring
Pump housing
Q’ty
4
1
2
4
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Service points
Follow the left “Step” for removal.
Refer to “TILT CYLINDER, PUMP HOUSING AND MOTOR REMOVAL”.
8.5 × 5.5 mm
78.5 × 74.5 mm
55 ~ 59 mm
8.8 × 4.3 mm
8.8 × 21.8 mm
13.7 × 10.7 mm
17.1 × 12.3 mm
14.5 × 11.5 mm
12.6 × 8.8 mm
10.6 × 6.8 mm
9.6 × 5.8 mm
6.2 × 27.0 mm
3.97 mm
22.6 × 17.8 mm
Reverse the removal steps for installation.
7-34
BRKT
PTT MOTOR
E
PTT MOTOR
EXPLODED DIAGRAM
7-35
BRKT
PTT MOTOR
E
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
POWER TRIM AND TILT MOTOR
DISASSEMBLY
Power trim and tilt motor ass’y
Q’ty
Service points
Follow the left “Step” for removal.
Refer to “TILT CYLINDER, PUMP HOUSING AND MOTOR REMOVAL”.
1
2
3
Screw
Stator
Armature ass’y
3
1
1
4
5
6
7
8
9
10
11
12
13
14
Plane washer
O-ring
Brush ass’y
Screw (with washer)
Lead wire
Brush ass’y
Cover plate
Circuit breaker
Brush spring
Base
Oil seal
1
1
1
2
1
1
1
1
2
1
1
NOTE:
When installing the armature, hold the
armature shaft to prevent the armature
coming off from the base assembly.
55.8 × 52.0 mm
Reverse the removal steps for installation.
7-36
BRKT
PTT MOTOR
E
SERVICE POINTS
Motor inspection
1. Inspect:
● Commutator
Dirty → Clean with #600 abrasive
paper.
2. Inspect:
● Segment undercut
Clog → Clean.
NOTE:
Remove all particles of metal with compressed air.
3. Measure:
● Commutator diameter
Out of specification → Replace.
Commutator diameter:
Limit 21 mm (0.83 in)
4. Inspect:
● Armature coil continuity
Out of specification → Replace.
Armature coil continuity:
7-37
Commutator segments
Continuity
Segment - Laminations
Discontinuity
Segment - Shaft
Discontinuity
BRKT
PTT MOTOR
E
5. Inspect:
● Circuit breaker
Discontinuity → Replace.
6. Inspect:
● Lead wire
Discontinuity → Replace.
7. Measure:
● Brush length a
Out of specification → Replace.
Brush length a:
Limit 3.5 mm (0.14 in)
8. Inspect:
● Base
Crack/Damage → Replace.
9. Inspect:
● Stator bushing
● Base bushing
Wear/Damage → Replace the stator
or the base.
10. Inspect:
● Base oil seal
Wear/Damage → Replace.
Motor assembly
1. Check:
● Motor operation
Out of specification → Repair.
Motor operation:
7-38
Blue (+), Green (–)
Clockwise
Green (+), Blue (–)
Counterclockwise
ELEC
–
+
E
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS ......................................................................... 8-1
OIL INJECTION MODEL........................................................................... 8-1
MH, MHO, MO, MDO MODEL ................................................................. 8-2
WHD, WH, E, EDO, EO MODEL ............................................................... 8-3
ET, ETO MODEL ....................................................................................... 8-4
EHTO MODEL........................................................................................... 8-5
ELECTRICAL UNIT COMPONENTS ............................................................... 8-6
E, EO MODEL ........................................................................................... 8-6
ET, ETO MODEL ....................................................................................... 8-7
ELECTRICAL ANALYSIS................................................................................. 8-8
INSPECTION............................................................................................. 8-8
Peak voltage measurement .............................................................. 8-8
Low resistance measurement .......................................................... 8-8
IGNITION SYSTEM ......................................................................................... 8-9
IGNITION SPARK GAP........................................................................... 8-10
CDI SYSTEM PEAK VOLTAGE .............................................................. 8-10
SPARK PLUG.......................................................................................... 8-12
SPARK PLUG CAP.................................................................................. 8-12
ENGINE STOP SWITCH ......................................................................... 8-13
MAIN SWITCH........................................................................................ 8-14
IGNITION CONTROL SYSTEM .................................................................... 8-15
THERMO SWITCH.................................................................................. 8-16
OIL LEVEL SENSOR ............................................................................... 8-16
WARNING LAMP ................................................................................... 8-17
OIL LEVEL WARNING LAMP................................................................. 8-18
CDI UNIT................................................................................................. 8-18
STARTING SYSTEM ..................................................................................... 8-19
BATTERY ................................................................................................ 8-20
WIRING HARNESS................................................................................. 8-20
WIRING CONNECTION.......................................................................... 8-20
ENGINE STOP SWITCH ......................................................................... 8-20
MAIN SWITCH........................................................................................ 8-20
NEUTRAL SWITCH ................................................................................ 8-20
STARTER RELAY.................................................................................... 8-21
FUSE ....................................................................................................... 8-21
1
2
3
4
5
6
7
8
9
ELEC
–
+
STARTER MOTOR ........................................................................................ 8-23
EXPLODED DIAGRAM ........................................................................... 8-23
REMOVAL AND INSTALLATION CHART ............................................. 8-24
SERVICE POINTS ................................................................................... 8-25
Pinion removal ................................................................................ 8-25
Pinion inspection............................................................................. 8-25
Armature inspection ....................................................................... 8-25
Brush holder inspection.................................................................. 8-26
Cover inspection.............................................................................. 8-27
CHARGING SYSTEM .................................................................................... 8-28
CHARGING SYSTEM PEAK VOLTAGE................................................. 8-29
FUSE ....................................................................................................... 8-29
BATTERY ................................................................................................ 8-29
ENRICHMENT CONTROL SYSTEM............................................................. 8-30
LIGHTING COIL ...................................................................................... 8-30
ELECTROTHERMAL VALVE .................................................................. 8-30
RECTIFIER REGULATOR........................................................................ 8-30
POWER TRIM AND TILT CONTROL SYSTEM ............................................ 8-31
BATTERY ................................................................................................ 8-32
FUSE ....................................................................................................... 8-32
PTT SWITCH........................................................................................... 8-32
PTT RELAY ............................................................................................. 8-32
TRIM SENSOR........................................................................................ 8-33
E
1
2
3
4
5
6
7
8
9
ELEC
–
+
ELECTRICAL COMPONENTS
E
ELECTRICAL COMPONENTS
OIL INJECTION MODEL
1 Electrothermal valve
2 Oil level sensor
L
B
8-1
: Blue
: Black
ELEC
–
+
ELECTRICAL COMPONENTS
MH, MHO, MO, MDO MODEL
1
2
3
4
5
6
7
8
9
0
Oil level sensor
Warning lamp
Charge coil
Lighting coil
Pulser coil
CDI unit
Ignition coil
2P consent*
Rectifier regulator*
Thermo switch
Å
ı
Ç
Î
‰
Ï
Ì
To engine stop switch
To 6
To 6
To 6
To 1
To 2
To 4
*: Europe model
8-2
E
B
Br
B/O
B/W
B/Y
L
O
O/G
P
Y/R
W
: Black
: Brown
: Black/Orange
: Black/White
: Black/Yellow
: Blue
: Orange
: Orange/Green
: Pink
: Yellow/Red
: White
ELEC
–
+
ELECTRICAL COMPONENTS
WHD, WH, E, EDO, EO MODEL
1
2
3
4
5
6
7
8
9
Oil level sensor
Electrothermal valve
Oil level warning lamp
Charge coil
Lighting coil
Pulser coil
CDI unit
Starter relay
Ignition coil
0
A
B
C
Fuse
Thermo switch
Rectifier regulator
Starter motor
Å To wire harness
ı To 5
Ç To 7
Î To remote control
‰ To 3
Ï To 1
Ì To battery
Ó To 2
*: Single lamp model
8-3
E
B
Br
B/O
B/W
B/Y
L
O
O/G
P
Y/R
W
: Black
: Brown
: Black/Orange
: Black/White
: Black/Yellow
: Blue
: Orange
: Orange/Green
: Pink
: Yellow/Red
: White
ELEC
–
+
ELECTRICAL COMPONENTS
ET, ETO MODEL
1
2
3
4
5
6
7
8
9
0
P.T.T. switch
Oil level sensor
Electrothermal valve
Oil level warning lamp
Charge coil
Lighting coil
Pulser coil
CDI unit
Starter relay
P.T.T. relay
A
B
C
D
E
Ignition coil
Fuse
Thermo switch
Rectifier regulator
Starter motor
Å
ı
Ç
Î
To P.T.T. motor
To trim meter
To wire harness
To 6
‰ To 8
Ï To 0
Ì To remote control
Ó To 4
È To 2
Ô To battery
 To 3
Ò To 1
*: ET model
8-4
E
B
Br
B/O
B/W
B/Y
L
Lg
O
O/G
P
Sb
Y/R
W
: Black
: Brown
: Black/Orange
: Black/White
: Black/Yellow
: Blue
: Light green
: Orange
: Orange/Green
: Pink
: Sky blue
: Yellow/Red
: White
ELEC
–
+
ELECTRICAL COMPONENTS
EHTO MODEL
1
2
3
4
5
6
Main switch
Main switch lead
Engine stop switch lead
Battery cable
Extension wire harness
Neutral switch
Å To trim sensor
ı To oil level sensor
Ç To starter motor and starter
relay
Î To starter relay
‰ To 10P coupler
8-5
E
B
Br
B/O
B/W
B/Y
L
O
O/G
P
Y/R
W
: Black
: Brown
: Black/Orange
: Black/White
: Black/Yellow
: Blue
: Orange
: Orange/Green
: Pink
: Yellow/Red
: White
ELEC
–
+
ELECTRICAL UNIT COMPONENTS
ELECTRICAL UNIT COMPONENTS
B
Br
B/O
B/W
B/Y
L
O
O/G
P
Y/R
W
E, EO MODEL
1
2
3
4
5
E
Starter motor
Rectifier regulator
Ignition coil
Fuse
Starter relay
a Bracket
b Ground terminal
8-6
: Black
: Brown
: Black/Orange
: Black/White
: Black/Yellow
: Blue
: Orange
: Orange/Green
: Pink
: Yellow/Red
: White
ELEC
–
+
ELECTRICAL UNIT COMPONENTS
ET, ETO MODEL
1
2
3
4
5
6
E
B
Br
B/O
B/W
B/Y
L
O
O/G
P
Y/R
W
Starter motor
Rectifier regulator
Ignition coil
Starter relay
P.T.T. relay
Fuse
a Bracket
b Ground terminal
8-7
: Black
: Brown
: Black/Orange
: Black/White
: Black/Yellow
: Blue
: Orange
: Orange/Green
: Pink
: Yellow/Red
: White
ELEC
–
+
ELECTRICAL ANALYSIS
E
ELECTRICAL ANALYSIS
INSPECTION
CAUTION:
All measuring instruments should be handled with special care, or the correct measurement is impossible.
On an instrument powered by dry batteries, the latter should be checked for voltage
periodically and replaced, if necessary.
NOTE:
“
” 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:
● The coil output varies greatly at cranking
speed.
● Cranking a cold engine with the plugs in
and a weak battery does not enable
proper readings.
Digital multimeter:
J-39299
Peak volt adapter:
YU-39991
Low resistance measurement
When measuring a resistance of 10 Ω 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:
The internal resistance of the tester can be
obtained by connecting both of its terminals.
8-8
ELEC
–
+
IGNITION SYSTEM
E
IGNITION SYSTEM
1
2
3
4
5
6
7
8
9
Br : Brown
L
: Blue
W/R : White/Red
W/B : White/Black
W/G : White/Green
B/O : Black/Orange
B/W : Black/White
B/Y : Black/Yellow
W : White
B
: Black
Spark plug
Ignition coil
Charge coil
Pulser coil
Main switch
Engine stop switch
10P coupler
7P coupler
CDI unit
Å Manual starter model
ı Electrical starter model
8-9
ELEC
–
+
IGNITION SYSTEM
E
IGNITION SPARK GAP
WARNING
● While
checking the spark be careful not to
touch any connection of lead wires of the
“Ignition spark gap tester”.
● When doing the spark test, take special
care not to allow leakage from the plug
cap which has been removed.
● This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
present.
1. Check:
● Ignition spark gap
Out of specification → Replace.
Spark gap:
9 mm (0.35 in)
Checking steps:
● Adjust the spark gap to specification
by turning the adjusting knob.
Spark gap tester:
YM-34487/90890-06754
●
●
●
Connect the spark plug cap to the
spark gap tester.
Remove the spark plugs from the
engine.
Crank the engine and check the sparks
from the ignition system through the
discharge window.
CDI SYSTEM PEAK VOLTAGE
WARNING
While taking CDI unit check be careful not
to touch any connection of lead wires of
the “Digital tester”.
NOTE:
● If there is no spark, or the spark is weak,
continue with the CDI test.
● If a good spark is obtained, the problem is
not with the CDI system, but possibly the
spark plug or other component is defective.
8-10
ELEC
–
+
IGNITION SYSTEM
E
1. Measure:
● CDI unit output (test #1)
Beyond specification → Replace ignition coil.
Below specification → Measure
charge coil output.
Repeat checking two times.
CDI output:
125 V @ cranking
140 V @ 1,500 r/min
110 V @ 3,500 r/min
Measuring steps:
● Disconnect the ignition coil couple.
Connect the 3 pins test harness.
3 pins test harness:
YB-06443, 90890-06757
●
●
Connect the tester to the measurement
terminal.
Set the tester dial to specification.
Range:
.—
......
V
●
Crank or start the engine.
2. Measure:
● Charge coil output (test #2)
Below specification → Replace charge
coil.
Beyond specification → Measure
pulser coil output.
Charge coil output:
(Br – L) 145 V @ cranking
160 V @ 1,500 r/min
130 V @ 3,500 r/min
Measuring steps:
● Connect the tester to the charge coil.
● Set the tester dial to specification.
Range:
.—
......
V
●
8-11
Crank or start the engine.
ELEC
–
+
IGNITION SYSTEM
E
3. Measure:
● Pulser coil output (test #3)
Beyond specification → Replace CDI
unit.
Below specification → Replace pulser
coil.
Pulser coil output:
3.0 V @ cranking
9.0 V @ 1,500 r/min
15.0 V @ 3,500 r/min
Measuring steps:
● Disconnect the pulse coil couple. Connect the 3 pins test harness.
3 pins test harness:
YB-06443, 90890-06757
●
●
Connect the tester to the measurement
terminal.
Set the tester dial to specification.
Range:
.—
......
V
●
Crank or start the engine.
SPARK PLUG
Refer to “GENERAL” in chapter 3.
SPARK PLUG CAP
1. Inspect:
● Spark plug cap
Loosen → Tighten.
Crack/Damage → Replace.
2. Measure: (For Canada and Europe)
● Spark plug cap resistance
Out of specification → Replace.
Spark plug cap resistance:
4.0 ~ 6.0 kΩ
8-12
ELEC
–
+
IGNITION SYSTEM
E
Replacement steps:
(Except for Canada and Europe)
● Remove the spark-plug cap by pulling
the spark-plug cap.
● Remove the plug-cap spring.
● Strip the insulation cover 5 mm (0.2 in)
a and spread the core wires outward.
● Fit the plug-cap spring close to the
spread core wires and bend the spring
end for clamping.
● Install the plug-cap spring into the
spark-plug cap.
Replacement steps:
(For Canada and Europe)
● Remove the spark-plug cap by turning
the cap counterclockwise.
● Install the spark-plug cap by turning
the cap clockwise until it stops.
ENGINE STOP SWITCH
Å
1. Check:
● Continuity
Out of specification → Replace.
Checking leads color
White
ı
Remove the
lock-plate Å
Install the
lock-plate ı
Push the button
Ç
Ç
8-13
Black
ELEC
–
+
IGNITION SYSTEM
E
MAIN SWITCH
1. Check:
● Continuity
Out of specification → Replace.
Checking leads color
Switch
White Black Red Yellow Brown
position
OFF
ON
START
8-14
ELEC
–
+
IGNITION CONTROL SYSTEM
IGNITION CONTROL SYSTEM
Y/R
P
O
O/G
B
1
2
3
4
5
6
7
Thermo switch
CDI unit
Warning lamp
Oil level sensor
Oil level warning lamp
Oil level sensor
Meter
Å
ı
Ç
Î
Pre-mixed model
Oil injection and warning lamp model
Oil injection and oil level warning lamp model
Oil injection and meter warning lamp model
8-15
: Yellow/Red
: Pink
: Orange
: Orange/Green
: Black
E
ELEC
–
+
IGNITION CONTROL SYSTEM
E
THERMO SWITCH
1. Measure:
● Thermo switch continuity
Out of specification → Replace.
Thermo switch continuity
temperature:
Orange (O) — Orange/Green (O/G)
a 38 ~ 52˚C (100.4 ~ 125.6˚F)
b 26 ~ 34˚C (78.8 ~ 93.2˚F)
Pink (P) — Black (B)
a 90 ~ 96˚C (194.0 ~ 204.8˚F)
b 76 ~ 90˚C (168.0 ~ 194.0˚F)
1 Discontinuity
2 Continuity
3 Discontinuity
Å Temperature
ı Time
Measuring steps:
● Suspend thermostat in a vessel.
● Place reliable thermometer in a water.
● Heat water slowly.
● Observe thermometer, while stirring
water continually.
OIL LEVEL SENSOR
1. Measure:
● Oil level sensor continuity
Out of specification → Replace.
Float
position
Checking leads color
1G
2B
3 P 4 G/R
a ON
a OFF
b OFF
b ON
Float length:
a 56.8 ~ 59.8 mm (2.24 ~ 2.35 in)
b 32.8 ~ 35.8 mm (1.29 ~ 1.41 in)
8-16
ELEC
–
+
IGNITION CONTROL SYSTEM
Float
position
E
Checking leads color
1P
2B
a OFF
a ON
Float length:
a 56.8 ~ 59.8 mm (2.24 ~ 2.35 in)
WARNING LAMP
1. Check:
● LED (Light emitting diode) lighting
No lighting → Replace.
Battery voltage:
1.5 V
Yellow/Red lead → Positive terminal.
Pink lead → Negative terminal.
CAUTION:
Use only originally pen light battery (1.5 V),
other than batteries such as alkaline battery
/ higher voltage one will be burnt the diode.
NOTE:
LED has an direction for electrical current.
Therefore try reverse connection if there is
no lighting.
8-17
ELEC
–
+
IGNITION CONTROL SYSTEM
E
OIL LEVEL WARNING LAMP
1. Check:
● LED (Light emitting diode) lighting
No lighting → Replace.
Battery voltage:
1.5 V
Green LED
Yellow/Red lead → Positive terminal.
Green lead → Negative terminal.
Yellow LED
Yellow/Red lead → Positive terminal.
Black lead → Negative terminal.
Red LED
Yellow/Red lead → Positive terminal.
Green/Red lead → Negative terminal.
CAUTION:
Use only ordinally pen light battery (1.5 V),
other than batteries such as alkaline battery
/ higher voltage one will be burnt the diode.
NOTE:
LED has an direction for electrical current.
Therefore try reverse connection if there is
no lighting.
CDI UNIT
Refer to “IGNITION SYSTEM”.
8-18
ELEC
–
+
STARTING SYSTEM
E
STARTING SYSTEM
1
2
3
4
5
6
7
8
B
Br
R
Fuse
10P coupler
7P coupler
Main switch
Starter motor
Battery
Neutral switch
Starter relay
Å Except for remote control model
ı Remote control model
8-19
: Black
: Brown
: Red
ELEC
–
+
STARTING SYSTEM
E
BATTERY
Refer to “GENERAL” in chapter 3.
WIRING HARNESS
1. Check:
● Continuity
Discontinuity → Replace.
WIRING CONNECTION
1. Check:
● Wiring connection
Poor connection → Correct.
ENGINE STOP SWITCH
Refer to “IGNITION SYSTEM”.
MAIN SWITCH
Refer to “IGNITION SYSTEM”.
NEUTRAL SWITCH
1. Check:
● Continuity
Out of specification → Replace.
Length
Free 18.5 ~ 19.5 mm
a (0.73 ~ 0.77 in)
Push 19.5 ~ 20.5 mm
b (0.77 ~ 0.81 in)
8-20
Checking leads color
Brown
Brown
ELEC
–
+
STARTING SYSTEM
E
STARTER RELAY
1. Inspect:
● Brown lead terminal
● Black lead terminal
Loose → Tighten.
2. Check:
● Relay operation
Does not function → Replace.
Checking steps:
Connect the tester between the terminals of the starter relay as shown.
● Connect a 12 V battery.
●
Brown lead 1 → Positive terminal
Black lead 2 → Negative terminal
●
Check that there is continuity between
the starter relay terminals.
FUSE
1. Check:
● Fuse
Blown → Replace.
Fuse rating:
12 V - 10 A
8-21
ELEC
–
+
STARTING SYSTEM
8-22
E
ELEC
–
+
STARTER MOTOR
E
STARTER MOTOR
EXPLODED DIAGRAM
8-23
ELEC
–
+
STARTER MOTOR
E
REMOVAL AND INSTALLATION CHART
Step
Procedure/Part name
Q’ty
STARTER MOTOR DISASSEMBLY
Starter motor ass’y
1
Clip
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Pinion stopper
Spring
Pinion
Through bolt
Front cover
Washer
Washer
Washer
Starter ass’y
Armature ass’y
Washer
Nut
Spring washer
Plain washer
Bushing
O-ring
Bushing
Screw
Brush holder
Brush (+)
Rear cover
O-ring
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
Service points
Follow the left “Step” for removal.
Refer to “ELECTRICAL UNIT REMOVAL”
in chapter 5.
NOTE:
Using a pry bar, pry off the clip.
25 × 1.0 mm
25 × 0.15 mm
25 × 2.0 mm
16 × 0.25 mm
Reverse the removal steps for installation.
8-24
ELEC
–
+
STARTER MOTOR
E
SERVICE POINTS
Pinion removal
1. Remove:
● Clip 1
NOTE:
Using a pry-bar, pry off the clip.
Pinion inspection
1. Inspect:
● Pinion teeth
Wear/Damage → Replace.
2. Check:
● Clutch movement
Damage → Replace.
NOTE:
Rotate the pinion clockwise, and check that
it freely. Also try to rotate the pinion counterclockwise and confirm that it locks.
Armature inspection
1. Inspect:
● Commutator
Dirty → Clean with #600 abrasive
paper.
2. Measure:
● Commutator diameter
Out of specification → Replace.
Commutator diameter:
Limit 29 mm (1.14 in)
8-25
ELEC
–
+
STARTER MOTOR
E
3. Check:
● Commutator under cut
Clog/Dirty → Clean.
NOTE:
Removal all particles of mica and metal by
compressed air.
4. Measure:
● Commutator under cut
Out of specification → Replace.
Commutator under cut:
Limit 0.2 mm (0.01 in)
5. Inspect:
● Armature coil continuity
Out of specification → Replace.
Armature coil continuity:
Commutator segments
Continuity
Segment - Laminations
Discontinuity
Segment - Shaft
Discontinuity
Brush holder inspection
1. Measure:
● Brush length a
Out of specification → Replace.
Brush length a:
Limit 9.0 mm (0.35 in)
8-26
ELEC
–
+
STARTER MOTOR
E
2. Check:
● Brush holder continuity
Out of specification → Replace.
Brush holder continuity:
Brush holder 1 - Base 2
Discontinuity
Cover inspection
1. Inspect:
● Cover bushing
Wear/Damage → Replace the cover.
8-27
ELEC
–
+
CHARGING SYSTEM
E
CHARGING SYSTEM
1
2
3
4
G : Green
G/W : Green/White
R
: Red
B
: Black
Rectifier regulator
Lighting coil
Battery
Fuse
8-28
ELEC
–
+
CHARGING SYSTEM
E
CHARGING SYSTEM PEAK VOLTAGE
1. Measure:
● Rectifier regulator input
Below specification → Lighting coil
measurement.
Rectifier regurator input:
(electrical model)
8.5 V @ cranking
25 V @ 1,500 r/min
25 V @ 3,500 r/min
Measuring steps:
● Connect the tester to the rectifier/regulator as shown.
● Set the tester dial to specification.
Range:
.—
......
V
●
Crank or start the engine.
2. Measure:
● Lighting coil output
Beyond specification → Replace rectifier/regulator.
Below specification → Replace lighting coil.
Lighting coil output:
9.0 V @ cranking
25 V @ 1,500 r/min
25 V @ 3,500 r/min
Measuring steps:
● Connect the tester to the lighting coil
as shown.
● Set the tester dial to specification.
Range:
.—
......
V
●
Start the engine.
FUSE
Refer to “STARTING SYSTEM”.
BATTERY
Refer to “GENERAL” in chapter 3.
8-29
ELEC
–
+
ENRICHMENT CONTROL SYSTEM
E
ENRICHMENT CONTROL SYSTEM
G : Green
G/W : Green/White
L
: Blue
B
: Black
1 Rectifier regulator
2 Lighting coil
3 Electrothermal valve
LIGHTING COIL
Refer to “CHARGING SYSTEM”.
ELECTROTHERMAL VALVE
Refer to “PRIME STARTER” in chapter 4.
RECTIFIER REGULATOR
Refer to “CHARGING SYSTEM”.
8-30
ELEC
–
+
POWER TRIM AND TILT CONTROL SYSTEM
POWER TRIM AND TILT CONTROL SYSTEM
1
2
3
4
5
6
7
R
Lg
Sb
B
P.T.T. motor
P.T.T. relay
P.T.T. switch
3P coupler (Black)
10P coupler
Fuse
Battery
Å Bottom cowl P.T.T. switch model
ı To remote control
8-31
: Red
: Light green
: Sky blue
: Black
E
ELEC
–
+
POWER TRIM AND TILT CONTROL SYSTEM
E
BATTERY
Refer to “GENERAL” in chapter 3.
FUSE
Refer to “STARTING SYSTEM”.
PTT SWITCH
1. Check:
● Continuity
Out of specification → Replace.
Switch
position
Checking leads color
Sky
blue
Red
Light
green
UP
Free
DN
PTT RELAY
1. Inspect:
● PTT relay continuity
Out of specification → Replace.
PTT relay continuity:
Sky blue (Sb) - Black (B)
Light green (Lg) - Black (B)
Continuity
Terminal 1 - Terminal Terminal 2 - Terminal -
Continuity
Terminal 1 - Terminal +
Terminal 2 - Terminal +
Discontinuity
2. Check:
● Relay operation
Does not function → Replace.
Checking steps:
● Connect the tester between the terminals of the PTT relay as shown.
● Connect a 12 V battery.
Light green (Lg) lead → Positive terminal
Black (B) → Negative terminal
●
8-32
Check that there is continuity between
the PTT relay terminals.
ELEC
–
+
POWER TRIM AND TILT CONTROL SYSTEM
●
●
E
Connect the tester between the terminals of the PTT relay as shown.
Connect a 12 V battery.
Sky blue (Sb) lead → Positive terminal
Black (B) → Negative terminal
●
Check that there is continuity between
the PTT relay terminals.
TRIM SENSOR
1. Measure:
● Trim sensor resistance
Out of specification → Replace.
Trim sensor resistance:
Pink (P) - Black (B)
360 ~ 540 Ω
Orange (O) - Black (B)
800 ~ 1200 Ω
NOTE:
Turn the lever and measure the resistance
changing gradually.
8-33
TRBL
ANLS
E
CHAPTER 9
TROUBLE-ANALYSIS
TROUBLE ANALYSIS ..................................................................................... 9-1
TROUBLE ANALYSIS CHART ................................................................. 9-1
1
2
3
4
5
6
7
8
9
TRBL
ANLS
TROUBLE ANALYSIS
E
TROUBLE ANALYSIS
NOTE:
Following items should be obtained before “trouble analysis”.
1. Battery is charged and its specified gravity is in specification.
2. There is no incorrect wiring connection.
3. Wiring connections are surely engaged and without any rust.
4. Lanyard is installed to the engine stop switch.
5. Shift position is in neutral.
6. Fuel is coming to the carburetor.
7. Correct rigging and engine setting are obtained.
8. Engine is free from any “Hull problem”.
TROUBLE ANALYSIS CHART
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
HARD SHIFTING
Check elements
TILT MOTOR WILL NOT RUN
LOOSE TILT HOLDING
LOOSE STEERING
OVERHEATING
POOR PERFORMANCE
ENGINE WILL NOT STOP
ENGINE STALLS
ROUGH IDLING
ENGINE WILL NOT START
Trouble mode
Relative part
FUEL SYSTEM
Fuel hose
Fuel joint
Fuel filter
Fuel pump
Carburetor
Pilot screw setting
Idle speed
POWER UNIT
Compression
Reed valve
Cylinder head gasket
Seal
Cylinder body
Piston ring
Crank case
Piston
Link adjustment
Bearing
Thermostat
Water passage
9-1
Reference
Chapter
4
4
4
4
4
4
3
5
5
5
5
5
5
5
5
3
5
5
5
TRBL
ANLS
TROUBLE ANALYSIS
POOR BATTERY CHARGING
IRREGULAR WARNING INDICATION
HARD SHIFTING
Check elements
TILT MOTOR WILL NOT RUN
LOOSE TILT HOLDING
LOOSE STEERING
OVERHEATING
POOR PERFORMANCE
ENGINE WILL NOT STOP
ENGINE STALLS
ROUGH IDLING
ENGINE WILL NOT START
Trouble mode
E
Relative part
LOWER UNIT
Neutral position
Clutch
Gear
Water inlet
Water pump
Propeller shaft
Shifter/Pin
Shift cam
Shift shaft
Lower case
BRACKET UNIT
Bracket
Mount rubber
Shift actuator
PTT unit
Fluid level
Relief valve
Fluid passage
PTT motor
PTT control system
ELECTRICAL
Ignition system
Starting system
Enrichment control system
Ignition control system
Charging system
9-2
Reference
Chapter
6
6
6
6
6
6
6
6
6
6
7
7
7
7
7
7
7
8
8
8
8
8
8
YAMAHA MOTOR Corporation, USA
Printed in U.S.A.
Printed on recycled paper
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