Yamaha F15B Service Manual
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Yamaha F15B Service Manual

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F15B
SERVICE MANUAL
290535
6D4-28197-5F-11

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Summary of Contents for Yamaha F15B

  • Page 1 F15B SERVICE MANUAL 290535 6D4-28197-5F-11...
  • Page 2 NOTICE This manual has been prepared by Yamaha 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.

  • Page 3: Table Of Contents

    Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Electrical systems ELEC Troubleshooting TRBL SHTG Index...

  • Page 5: General Information

    INFO General information How to use this manual.................1-1 Manual format....................1-1 Symbols .....................1-2 Safety while working..................1-3 Fire prevention...................1-3 Ventilation ....................1-3 Self-protection....................1-3 Parts, lubricants, and sealants ..............1-3 Good working practices ................1-4 Disassembly and assembly ...............1-4 Identification ....................1-5 Applicable model ..................1-5 Serial number ....................1-5 Propeller selection ..................1-5 Propeller size .....................1-5 Selection ....................1-5...

  • Page 6: How To Use This Manual

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list.

  • Page 7: Symbols

    7 Apply Yamaha 4-stroke motor oil q Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) w Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)

  • Page 8: Safety While Working

    Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the out- board motor. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous.

  • Page 9: Good Working Practices

    Safety while working Disassembly and assembly 6. Keep a supply of clean, lint-free cloths for 1. Use compressed air to remove dust and wiping up spills, etc. dirt during disassembly. Good working practices 2. Apply engine oil to the contact surfaces Special service tools of moving parts before assembly.

  • Page 10: Identification

    Propeller size The size of the propeller is indicated on the outside of the propeller boss. 6B410010 YAMAHA MOTOR CO., LTD. 6B410030 MADE IN JAPAN PAYS D'ORIGINE JAPON a Propeller diameter (in inches) b Propeller pitch (in inches)

  • Page 11: Predelivery Checks

    Identification/Propeller selection/Predelivery checks Predelivery checks Recommended engine oil: To make the delivery process smooth and 4-stroke outboard motor oil efficient, the predelivery checks should be API: SE, SF, SG, SH or SJ completed as explained below. SAE: 10W-30 or 10W-40 Oil quantity: Checking the fuel system (without oil filter replacement)

  • Page 12: Checking The Steering System

    INFO General information NOTE: Checking the remote control cables The optimum mounting height is affected by 1. Check that the remote control cable prop- the combination of the boat and the outboard er position. motor. To determine the optimum mounting height, test run the outboard motor at differ- 2.

  • Page 13: Checking The Engine Stop Lanyard Switch

    Predelivery checks Checking the engine stop lanyard Checking the cooling water pilot switch hole 1. Check that the engine turns off when the 1. Check that cooling water is discharged engine stop lanyard switch is pushed or from the cooling water pilot hole. the engine stop lanyard is pulled from the engine stop lanyard switch.

  • Page 14: Break-In

    INFO General information Break-in During the test run, perform the break-in operation in the following 4 stages. 1. For the first hour of operation a: Run the engine at 2000 r/min or at approximately half throttle. 2. For the second hour of operation b: Run the engine at 3000 r/min or at approxi- mately three-quarter throttle.

  • Page 15: Specifications

    SPEC Specifications General specifications ...................2-1 Maintenance specifications ................2-3 Power unit ....................2-3 Lower unit ....................2-6 Electrical ....................2-7 Dimensions ....................2-8 Tightening torques..................2-10 Specified torques ..................2-10 General torques ..................2-11 6D45F11...
  • Page 16 SPEC Specifications General specifications Model Item Unit F15BMH F15BM Dimensions Overall length mm (in) 1,001 (39.4) 643 (25.3) Overall width mm (in) 427.5 (16.8) 369 (14.5) Overall height mm (in) 1,080 (42.5) — mm (in) 1,207 (47.5) Transom height mm (in) 440 (17.3) —...

  • Page 17: General Specifications

    General specifications Model Item Unit F15BMH F15BM Fuel and oil Fuel type Unleaded regular gasoline Engine oil type 4-stroke outboard motor oil Engine oil grade SE, SF, SG, SH or SJ 10W-30 or 10W-40 Engine oil quantity (with oil filter replacement) 1.2 (1.27, 1.06) (US qt, lmp qt) (without oil filter replacement)

  • Page 18: Maintenance Specifications

    SPEC Specifications Maintenance specifications Power unit Model Item Unit F15BMH F15BM Power unit Minimum compression 765 (7.8, 111) pressure (*1) (kgf/cm , psi) Lubrication oil pressure (*2) 330 (3.36, 48) at idle speed (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.10 (0.0039) (lines indicate straightedge...
  • Page 19 Maintenance specifications Model Item Unit F15BMH F15BM 2 nd ring Dimension B mm (in) 1.47–1.49 (0.0579–0.0590) Dimension T mm (in) 2.50–2.70 (0.0984–0.1063) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.02–0.04 (0.0008–0.0016) Over size 1 st mm (in) 59.25 (2.33) 2 nd mm (in)
  • Page 20 SPEC Specifications Model Item Unit F15BMH F15BM Stem diameter Intake mm (in) 5.475–5.490 (0.2156–0.2161) Exhaust mm (in) 5.460–5.475 (0.2150–0.2156) Guide inside diameter Intake and exhaust mm (in) 5.500–5.512 (0.2165–0.2170) Stem-to-guide clearance Intake and exhaust mm (in) 0.025–0.052 (0.0010–0.0020) Stem run-out limit mm (in) 0.01 (0.0004) Valve springs...

  • Page 21: Lower Unit

    Maintenance specifications Model Item Unit F15BMH F15BM Thermostat Opening temperature °C (°F) 58.0–62.0 (136.40–143.60) Fully open temperature °C (°F) 70.0 (158.00) Valve open lower limit mm (in) 3.0 (0.12) Carburetor ID mark 6D400 Float height mm (in) 9.5–10.5 (0.37–0.41) Valve seat size mm (in) 1.4 (0.06) Main jet...

  • Page 22: Electrical

    SPEC Specifications Electrical Model Item Unit F15BMH F15BM Ignition system and ignition control system Ignition timing Degree BTDC 30 Spark plug gap mm (in) 0.8–0.9 (0.031–0.035) Spark plug cap resistance kΩ 4.0–6.0 Ignition coil resistance Ω Primary coil (O–B) 0.16–0.24 Secondary coil (spark plug wire–spark plug wire) kΩ...

  • Page 23: Dimensions

    Maintenance specifications Dimensions Exterior mm (in) 168 (6.6) 526 (20.7)* 475 (18.7) 330.5 (13.0) 297 (11.7)* S: 718 (28.3) 74.5 (2.9) L: 831 (32.7) 6D4001M 355.5 (14.0) *1: For tiller control model 6D45F11...
  • Page 24 SPEC Specifications Clamp bracket mm (in) 103 (4.1) 103 (4.1) 70.5 (2.8) 70.5 (2.8) 2 (0.1) 92.5 (3.6) 92.5 (3.6) 30 (1.2) 56 (2.2) 6D4002M 6D45F11...
  • Page 25 Maintenance specifications/Tightening torques Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Power unit Crankcase bolt Cylinder head bolt Cylinder head cover bolt Exhaust cover and thermostat cover bolt Breather cover bolt Anode bolt Anode screw —...
  • Page 26 SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Bracket unit Engine stop lanyard switch nut — 0.25 Grease nipple Tiller handle bracket nut — Tiller handle bracket lock nut — Upper case mount bolt Upper rubber mount nut Lower rubber mount nut Clamp bracket through nut —...
  • Page 27 Periodic checks and adjustments Special service tools..................3-1 Maintenance interval chart................3-2 Fuel system ....................3-3 Checking the fuel line ................3-3 Checking the fuel filter ................3-3 Power unit .......................3-3 Checking the engine oil ................3-3 Changing the engine oil................3-3 Replacing the oil filter ................3-4 Checking the timing belt ................3-5 Replacing the timing belt ................3-5 Checking the spark plugs ................3-6...

  • Page 28: Chk Adj

    Periodic checks and adjustments Special service tools Digital tachometer 90890-06760 Timing light 90890-03141 Leakage tester 90890-06840 Oil filter wrench 90890-01426 6D45F11...

  • Page 29: Maintenance Interval Chart

    Inspection / replacement Cooling water passages Cleaning Cowling clamp Inspection Fuel filter Inspection / cleaning (can be disassembled) Fuel system Inspection Fuel tank (Yamaha Inspection / cleaning portable tank) Gear oil Change Greasing points Greasing Idling speed (carburetor Inspection / adjustment...

  • Page 30: Fuel System

    Periodic checks and adjustments Fuel system Power unit Checking the fuel line Checking the engine oil 1. Place the outboard in an upright position. (fuel joint to carburetor) 1. Remove the fitting plate 1, and then 2. Remove the engine oil dipstick, wipe it check the fuel hose connections and fuel clean, and then insert it back.

  • Page 31: Replacing The Oil Filter

    Fuel system/Power unit Replacing the oil filter 3. Place a drain pan under the drain hole, and then remove the drain bolt 2 and let 1. Place a rag under the oil filter, and then remove the filter. the oil drain completely. 6D430060 Oil filter wrench: 90890-01426...

  • Page 32: Checking The Timing Belt

    Periodic checks and adjustments 4. Check the interior b and the exterior c 3. Install the oil filter, and then tighten it to the specified torque. of the timing belt for cracks, damage, or wear. Replace if necessary. 6D430080 6D430100 Oil filter wrench: 90890-01426 Do not turn the flywheel magnet counter-...

  • Page 33: Checking The Spark Plugs

    Power unit 2. Check the timing mark aligned, then 3. Check the electrodes for erosion and install the new timing belt carefully on to excessive carbon or other deposits, and the sprockets. the gasket for damage. Replace the spark plug if necessary. 4.

  • Page 34: Checking The Thermostat

    Periodic checks and adjustments Checking the thermostat Checking the cooling water 1. Remove thermostat. Refer passages “Thermostat” in chapter 5. 1. Check the cooling water inlet covers 1 and cooling water inlet for clogging. 2. Suspend the thermostat in a container of Clean if necessary.

  • Page 35: Adjusting The Throttle Cable

    Power unit/Control system NOTE: 3. Loosen the locknut 1 and adjust the If the starter rope cannot be pulled out, the length of the throttle cable (pull-side)2 start-in-gear protection is working correctly. with the adjusting nut 3 until the stopper 4 on the pully contact the stopper plate a on the bracket, then tighten the lock- 3.

  • Page 36: Checking The Gearshift Operation

    Periodic checks and adjustments (For remote control model) 6. Check the throttle cable for smooth oper- 1. Check that the throttle cable for smooth ation. operation, looseness, fraying or damage. NOTE: Replace if necessary. If the remote control cables cannot be prop- erly adjusted at the engine side, make adjust- 2.

  • Page 37: Checking The Engine Idle Speed

    Control system Checking the engine idle speed 3. Loosen the locknut 1, remove the clip 2, and then disconnect the shift cable 1. Start the engine and warm it up for 5 min- joint 3. utes. 2. Attach the special service tool to spark plug wire #1 1, then check the engine idle speed.

  • Page 38: Checking The Ignition Timing

    Periodic checks and adjustments Checking the ignition timing 4. Check that the line a on the flywheel 1. Start the engine and warm it up for 5 min- magnet is advances automatically, when utes. the engine speed increased. 2. Attach the special service tool to spark plug wire #1 1, and then check the engine idle speed.

  • Page 39: Lower Unit

    Control system/Bracket/Lower unit Replacing the gear oil 2. Fully tilt the outboard motor up, then sup- port it with the tilt support lever 1 to 1. Fully tilt the outboard motor down. check the lock mechanism of the lever. 2. Place a drain pan under the drain screw 1, remove the drain screw, then the check screw 2 to drain the oil.

  • Page 40: Chk Adj

    Periodic checks and adjustments Checking the propeller 5. Install the check screw, quickly install the 1. Check the propeller blades and splines drain screw, then tighten them to the spec- for cracks, damage, or wear. Replace if ified torque. necessary. Check and drain screw: General 9 N·m (0.9 kgf·m, 6.6 ft·lb)

  • Page 41: Checking The Top Cowling

    Lower unit/General Checking the top cowling 1. Check the fitting of the top cowling by pushing on it with both hands. 6D430360 6D430010 2. Check the top cowling for cracks or other damage. Replace if necessary. 3. Check the hooks and rivets for wear or damage.
  • Page 42 Periodic checks and adjustments 2. Apply corrosion resistant grease to the area shown. 6B430300 3-15 6D45F11...

  • Page 43: Fuel

    FUEL Fuel system Special service tools..................4-1 Hose routing ....................4-2 Fuel line......................4-3 Checking the fuel joint ................4-4 Checking the fuel filter ................4-4 Carburetor.......................4-5 Disassembling the carburetor ..............4-8 Checking the carburetor ................4-8 Assembling the carburetor.................4-9 Adjusting the throttle link rod ..............4-10 Adjusting the pilot screw................4-10 Fuel pump .....................4-11 Checking the fuel pump................4-12 Disassembling the fuel pump ..............4-12...

  • Page 44: Fuel System

    FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 90890-06756 Digital caliper 90890-06704 Digital tachometer 90890-06760 6D45F11...

  • Page 45: Hose Routing

    Special service tools/Hose routing Hose routing 6D440010 1 Fuel hose (Fuel joint to fuel filter) 2 Fuel hose (Fuel filter to fuel pump) 3 Fuel hose (Fuel pump to carburetor) 4 Breather hose 5 Pilot water hose 6D45F11...

  • Page 46: Fuel Line

    FUEL Fuel system Fuel line 10 N·m (1.0 kgf·m, 7.2 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 6D44010E Part name Q’ty Remarks Fuel joint M6 × 20 mm Bolt Clamp Clip Hose Hose Hose Fuel filter assembly M4 ×...

  • Page 47: Checking The Fuel Joint

    Fuel line Checking the fuel joint 1. Visually check the fuel joint for cracks or damage. 2. Connect the special service tool at the outlet of fuel joint. 3. Apply the specified pressure to check that the pressure is maintained for 10 seconds.

  • Page 48: Carburetor

    FUEL Fuel system Carburetor 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 6D44030E Part name Q’ty Remarks M6 × 30 mm Bolt Intake manifold Gasket Not reusable M6 × 30 mm Bolt Dowel pin Throttle link...
  • Page 49 Carburetor 4.5 N·m (0.45 kgf·m, 3.3 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 6D44040E Part name Q’ty Remarks Carburetor body Float chamber O-ring Not reusable Float Float pin Needle valve Screw Cover plate Gasket Not reusable Main nozzle Main jet Pilot jet Plug Pilot screw...
  • Page 50 FUEL Fuel system 4.5 N·m (0.45 kgf·m, 3.3 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 6D44040E Part name Q’ty Remarks Gasket Not reusable Screw Filter Plastic Screw Spring Plate Screw 6D45F11...

  • Page 51: Disassembling The Carburetor

    Carburetor Disassembling the carburetor 3. Check the main jet 1, pilot jet 2, and main nozzle 3 for clogging and contam- NOTE: ination. Clean or replace whenever 9 Write down how many turns you have actu- appropriate. ally turned out the pilot screw. 9 Disassembled jets and other components should be sorted out and kept in order, so that they can be re-assembled in their orig-...

  • Page 52: Assembling The Carburetor

    FUEL Fuel system 6. Measure the float height a. Replace the 2. Install the needle valve 5, float 6, float pin 7, and screw 8 as shown, and then float and needle valve, if out of specifica- tion, as a set. the check the float for smooth operation.

  • Page 53: Adjusting The Throttle Link Rod

    Carburetor Adjusting the throttle link rod 2. Turn the pilot screw 1 in direction a or 1. Turn the pully 1 to the fully open position b until the engine idle speed has been as shown, and then push the carburetor specified.

  • Page 54: Fuel Pump

    FUEL Fuel system Fuel pump 1.5 N·m (0.15 kgf·m, 1.1 ft·lb) 6D44020E Part name Q’ty Remarks Fuel pump housing Fuel pump body Fuel pump cover Plate valve Diaphragm Spring Plunger Spring M4 × 9 mm Screw Diaphragm Screw 4-11 6D45F11...

  • Page 55: Checking The Fuel Pump

    Fuel pump Checking the fuel pump 6. Apply the specified positive pressure and 1. Place a drain pan under the fuel hose check that there is no air leakage. connections, and then disconnect the Disassemble the fuel pump if necessary. fuel hoses from the fuel pump.

  • Page 56: Checking The Diaphragm And Valves

    FUEL Fuel system Assembling the fuel pump 2. Push down on the plunger and the 1. Align the plunger and diaphragm installa- diaphragm, turn the fuel pump body 1 tion holes a , and then install the plunger approximately 90° to a position where the into the diaphragm.
  • Page 57 Fuel pump — MEMO — 6D45F11 4-14...

  • Page 58: Powr

    POWR Power unit Special service tools..................5-1 Power unit .......................5-3 Checking the compression pressure ............5-3 Checking the oil pressure ................5-3 Checking the oil pressure switch ...............5-4 Checking the valve clearance..............5-4 Disassembling the manual starter ............5-12 Checking the spiral spring ...............5-12 Assembling the manual starter ..............5-13 Removing the power unit.................5-14 Timing belt and sprockets................5-17 Removing the timing belt and sprockets ..........5-18...
  • Page 59 Checking the crankshaft pin oil clearance..........5-42 Checking the crankshaft main journal oil clearance.......5-43 Selecting the crankshaft main journal bearing ........5-44 Assembling the piston and connecting rod assemblies ......5-45 Assembling the cylinder block ..............5-47 Installing the power unit................5-49 6D45F11...

  • Page 60: Power Unit

    POWR Power unit Special service tools Ball bearing attacment Compression gauge 90890-06635 90890-03160 Flywheel holder Valvespring compressor 90890-06522 90890-04019 Valvespring compressor attachment Flywheel puller 90890-06320 90890-06521 Valve lapper Crankshaft aligner 90890-04101 90890-03107 Valve guide remover/installer Driver rod LS 90890-06801 90890-06606 6D45F11...
  • Page 61 Special service tools Valve guide istaller Oil filter wrench 90890-06802 90890-01426 Valveguide reamer Piston slider 90890-06804 90890-06529 Valve seat cutter holder Vacuum/pressure pump gauge set 90890-06756 90890-06316 Valve seat cutter 90890-06312, 90890-06313 90890-06314, 90890-06315 Shaft holder 90890-06069 6D45F11...

  • Page 62: Power Unit

    POWR Power unit Power unit 5. If the measured compression pressure is below specification, or it varies among Checking the compression pressure the cylinders, add a small amount of 1. Start the engine, warm it up for 5 min- engine oil to the cylinder, and check the utes, and then turn it off.

  • Page 63: Checking The Oil Pressure Switch

    Power unit Checking the oil pressure switch Checking the valve clearance 1. Install the special service tool onto the oil 1. Remove the manual starter and timing pressure switch as shown. belt cover and then disconnect the spark plug caps 1, spark plugs and fuel hoses. 2.
  • Page 64 POWR Power unit 5. Turn the flywheel clockwise and align the Valve clearance: “2” mark c on the driven sprocket with Intake d: the “M” mark b on the cylinder head. 0.15–0.25 mm (0.0059–0.0098 in) Exhaust e: 0.20–0.30 mm (0.0079–0.0118 in) 7.
  • Page 65 Power unit 8 N·m (0.8 kgf·m, 5.8 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6D45010E Part name Q’ty Remarks Cover Collar Sheave drum Drive pawl Spiral spring Drive plate Drive pawl spring Coil spring Pawl spring Circlip M6 × 16 mm Bolt Starter rope Starter plunger...
  • Page 66 POWR Power unit 8 N·m (0.8 kgf·m, 5.8 ft·lb) 7 N·m (0.7 kgf·m, 5.2 ft·lb) 6D45010E Part name Q’ty Remarks Washer Bolt Washer M6 × 28 mm Bolt Starter panel assembly Oil pressure warning lamp assembly M6 × 20 mm Bolt 6D45F11...
  • Page 67 Power unit 10 N·m (1.0 kgf·m, 7.2 ft·lb) 110 N·m (11 kgf·m, 81 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 6D45040E Part name Q’ty Remarks Flywheel magnet assembly Woodruff key Washer M6 × 30 mm Bolt Choke rod Fitting plate M6 ×...
  • Page 68 POWR Power unit 8 N·m (0.8 kgf·m, 5.8 ft·lb) 21 N·m (2.1 kgf·m, 16 ft·lb) 6D45020E Part name Q’ty Remarks M8 × 45 mm Bolt Gasket Not reusable Dowel pin Oil strainer Dipstick Relief valve O-ring Not reusable Cover Hose Band 6D45F11...
  • Page 69 Power unit 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 18 N·m (1.8kgf·m, 13 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 18 N·m (1.8 kgf·m, 13 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb)
  • Page 70 POWR Power unit 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 6D45060E Part name Q’ty Remarks Pully Free axle lever M6 × 10 mm Bolt Washer M6 × 55 mm Bolt Bracket Collar...

  • Page 71: Disassembling The Manual Starter

    Power unit Disassembling the manual starter 4. Remove the starter rope 5. 1. Remove the drive plate 1 and spring 2. 5. Remove the drive pawl 6 and springs 7 from the sheave drum. 6D450100 The sheave drum can pop out. Hold the sheave drum with your hand, then pull it out.

  • Page 72: Assembling The Manual Starter

    POWR Power unit Assembling the manual starter 6. Wind the starter rope 1 twice around the 1. Install the starter rope 1 into the sheave sheave drum 2 in the direction of the drum 2. arrow shown in the illustration. 2.

  • Page 73: Removing The Power Unit

    Power unit NOTE: 12. Pull the manual starter handle complete- Install the sheave drum, then set the spiral ly, then measure the starter rope length. spring by turning the sheave drum. Adjust if the starter rope length is out of specification.
  • Page 74 POWR Power unit 2. Remove the nut on the flywheel magnet. Flywheel puller: 90890-06521 4. Remove the Woodruff key. 5. Disconnect the engine stop lanyard switch leads and ground lead. 6D450220 Apply force in the direction of the arrows shown. While working, do not allow the flywheel holder to slip off the flywheel.
  • Page 75 Power unit 13. Remove the spark plug caps, CDI unit 0, 8. Disconnect the fuel hose from the fuel fil- ignition coil q, oil pressure switch and ter, and then remove the “Fuel system”. spark plugs. 9. Disconnect the pilot water hose 4. 6D450330 6D450270 14.

  • Page 76: Timing Belt And Sprockets

    POWR Power unit Timing belt and sprockets 13 N·m (1.3 kgf·m, 9.6 ft·lb) 54 N·m (5.4 kgf·m, 39 ft·lb) 6D45050E Part name Q’ty Remarks Driven sprocket M6 × 20 mm Bolt Washer Washer Woodruff key Timing belt Breather hose Drive sprocket Retaining plate Woodruff key 5-17...

  • Page 77: Removing The Timing Belt And Sprockets

    Timing belt and sprockets Removing the timing belt and 3. Remove the timing belt 4 from the driven sprockets sprocket side. 1. Set the cylinder #1 piston position to TDC of the compression stroke by aligning the “1” mark a on the driven sprocket with the “M”...

  • Page 78: Checking The Timing Belt And Sprockets

    POWR Power unit Checking the timing belt and 2. Install the Woodruff key 3, drive sprock- et 4. sprockets 1. Check the interior and exterior of the tim- ing belt for cracks, damage, or wear. Replace if necessary. 6D450420 NOTE: Align the key groove of the crankshaft and the mark on the cylinder block.
  • Page 79 Timing belt and sprockets 8. Tighten the driven sprocket bolt 6 to the specified torque. 6D450450 6D450460 9 Do not twist, turn inside out, or bend the timing belt beyond the maximum limit of Flywheel holder: 25 mm (1.0 in) e e , otherwise it may be 90890-06522 damaged.

  • Page 80: Cylinder Head

    POWR Power unit Cylinder head 15 N·m (1.5 kgf·m,11 ft·lb) 6 N·m (0.6 kgf·m,4.4 ft·lb) 30 N·m (3.0 kgf·m, 22 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 6D45070E Part name Q’ty Remarks...
  • Page 81 Cylinder head 14 N·m (1.4 kgf·m, 10 ft·lb) 6D45080E Part name Q’ty Remarks Cylinder head Valve spring seat Not reusable Rocker shaft Intake valve Exhaust valve Valve spring Valve spring retainer Valve cotter Valve stem seal Not reusable Collar r= 22.5 mm Collar r= 15 mm r= 8.5 mm...
  • Page 82 POWR Power unit 14 N·m (1.4 kgf·m, 10 ft·lb) 6D45080E Part name Q’ty Remarks Camshaft assembly Woodruff key Oil seal Not reusable 5-23 6D45F11...

  • Page 83: Removing The Cylinder Head

    Cylinder head Removing the cylinder head 4. Remove the oil pump 1, gasket, rocker 1. Remove the spark plugs. arm shaft 2, spring, collar and rocker arm assembly 3. 2. Remove the cylinder head cover bolts in the sequence shown. 6D450510 6D450490 3.

  • Page 84: Checking The Valve Springs

    POWR Power unit 2. Measure the valve spring tilt b. Replace 6. Remove the intake valve and exhaust valves. if out of specification. 6D450560 Valve spring tilt limit b: 1.5 mm (0.06 in) Checking the valves 1. Check the valve face for pitting or wear. Replace if necessary.

  • Page 85: Checking The Valve Guides

    Cylinder head 3. Measure the valve stem diameter b. Valve guide inside diameter limit a: Replace if out of specification. 5.500–5.512 mm (0.2165–0.2170 in) Replacing the valve guides 1. Remove the valve guide 1 by striking the special service tool from the combustion chamber side.

  • Page 86: Checking The Valve Seat

    POWR Power unit 4. Measure the valve seat contact width a 3. Insert the special service tool into the valve guide 2, and then ream the valve where the blueing dye is adhered to the guide. valve face. Reface the valve seat if the valve is not seated properly or if the valve seat contact width is out of specification.

  • Page 87: Refacing The Valve Seat

    Cylinder head Refacing the valve seat 1. Reface the valve seat with the valve seat Do not over cut the valve seat. Make sure cutter. to turn the cutter evenly downward at a pressure of 40–50 N (4–5 kgf, 8.8–11 lbf) to prevent chatter marks.

  • Page 88: Checking The Rocker Arms And Rocker Arm Shaft

    POWR Power unit 6. If the valve seat contact area is too wide and situated in the center of the valve face, use a 5° cutter to cut the top edge of the valve seat, a 60° cutter to cut the bottom edge to center the area and set its width.

  • Page 89: Checking The Camshaft

    Cylinder head 2. Measure the camshaft run-out. Replace if out of specification. 6D450770 6D450790 Rocker arm inside diameter b: 13.000–13.018 mm (0.5118–0.5125 in) Camshaft run-out limit: Rocker arm shaft outside diameter c: 0.03 mm (0.0012 in) 12.941–12.951 mm (0.5095–0.5099 in) 3.

  • Page 90: Checking The Cylinder Head

    POWR Power unit Checking the cylinder head 2. Measure the oil pump rotor clearances as 1. Eliminate carbon deposits from the com- shown. Replace if out of specification. bustion chambers and check for deterio- ration. 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in five directions as shown.

  • Page 91: Installing The Cylinder Head

    Cylinder head 2. Install the valve 2, spring seat 3, valve 4. Lightly tap the spring retainer with a plas- spring 4, and spring retainer 5 in the tic hammer to set the valve cotter secure- sequence shown, and then attach the special service tool.
  • Page 92 POWR Power unit 3. Check that the camshaft Woodruff key 6. Assemble the oil pump as shown. groove a is in the position shown in the illustration. Adjust if necessary. 6D451016 NOTE: 6D450905 Be sure to assemble the oil pump so that the “8”...

  • Page 93: Cylinder Block

    Cylinder head/Cylinder block Cylinder block 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 6 N·m (0.6 kgf·m,4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb) 40 N·m (4. 0kgf·m, 30 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 18 N·m (1.8 kgf·m, 13 ft·lb) 6D45090E...
  • Page 94 POWR Power unit 8 N·m (0.8 kgf·m, 5.8 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb) 6 N·m (0.6 kgf·m,4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb) 40 N·m (4. 0kgf·m, 30 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 18 N·m (1.8 kgf·m, 13 ft·lb) 6D45090E Part name...
  • Page 95 Cylinder block 15 N·m (1.5 kgf·m,11 ft·lb) 30 N·m (3.0 kgf·m, 22 ft·lb) 10 N·m (1.0 kgf·m,7.2 ft·lb) 21 N·m (2.1 kgf·m, 16 ft·lb) 6 N·m (0.6 kgf·m,4.4 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb) 6D45100E Part name Q’ty Remarks Cylinder body Crankcase Dowel pin...

  • Page 96: Disassembling The Cylinder Block

    POWR Power unit Disassembling the cylinder block 4. Check the anode on the exhaust cover. 1. Place a rag under the oil filter, and then Clean the anode’s surface, and replace if remove the filter. it has been eroded into half its size or smaller.

  • Page 97: Disassembling The Piston And Connecting Rod Assemblies

    Cylinder block Disassembling the piston and 9. Remove the crankcase bolts in the connecting rod assemblies sequence shown. 1. Remove the clips 1 with pliers, and then remove the piston pin 2. 2. Remove the top ring 3 2nd piston ring 4 and oil ring set 5.

  • Page 98: Checking The Cylinder Bore

    POWR Power unit Checking the cylinder bore Checking the piston clearance 1. Measure the cylinder bore (D –D ) at 1. Rebore the cylinder or replace the piston measuring points a, b, and c, and in and piston rings as a set, or the cylinder direction d (D ), which is parallel block, or all parts if out of specification.

  • Page 99: Checking The Piston Ring Grooves

    Cylinder block Checking the piston ring grooves 2. Level the piston ring 1 in the cylinder 1. Measure piston ring grooves. with a piston crown. Replace the piston if out of specification. 3. Check the piston ring end gap d at the specified measuring point.

  • Page 100: Checking The Piston Pin Boss Bore

    POWR Power unit Checking the connecting rod small Piston ring side clearance: end inside diameter Top ring a: 1. Measure the connecting rod small end 0.04–0.08 mm inside diameter a. Replace the connect- (0.0016–0.0032 in) ing rod if out of specification. Second ring b: 0.02–0.04 mm (0.0008–0.0016 in)

  • Page 101: Checking The Crankshaft

    Cylinder block Checking the crankshaft 2. Put a piece of Plastigauge ® (PG-1) onto 1. Measure the crankshaft journal diameter the crank pin, parallel to the crankshaft. a, crank pin diameter b, and crank pin width c. Replace the crankshaft if out of specification.

  • Page 102: Checking The Crankshaft Main Journal Oil Clearance

    POWR Power unit NOTE: Do not turn the connecting rod until the crank Install the bearings in their original posi- pin oil clearance measurement has been tions. completed. NOTE: Connecting rod bolt: Insert the projection a of the bearing into the 1st: 10 N·m (1.0 kgf·m, 7.2 ft·lb) notch in the cylinder body.

  • Page 103: Selecting The Crankshaft Main Journal Bearing

    Cylinder block Selecting the crankshaft 7. Tighten the crankcase bolts to the speci- main journal bearing fied torques in two stages and in the sequence shown. 1. When replacing the main bearing, select the suitable bearing as follows. 2. Check the bearing color code indicator a is marked on the cylinder block.

  • Page 104: Assembling The Piston And Connecting Rod Assemblies

    POWR Power unit 6. If the oil clearance is below specification, 3. Offset the piston ring end gaps as shown. check the main bearing color and clean the contact surface of the cylinder body and the main bearing, and then check the main journal oil clearance again.
  • Page 105 Cylinder block 5. Install half of the bearings 8 into the 7. Install the connecting rod cap e to the cylinder body 9. connecting rod, and then tighten the con- necting rod bolts r to the specified torques in two stages. 6D451430 NOTE: Insert the projection d of the bearing into the...

  • Page 106: Assembling The Cylinder Block

    POWR Power unit Assembling the cylinder block Crankcase bolt (M8): 1–4 1. Install half of the bearings 1 into the 1st: 15 N·m (1.5 kgf·m, 11 ft·lb) crankcase, then dowel pins 2. 2nd: 30 N·m (3.0 kgf·m, 22 ft·lb) Crankcase bolt (M6): 5–0 2.
  • Page 107 Cylinder block 7. Installing the dowel pins, new gasket and 11. Adjust the valve clearance. Refer to cylinder head assembly. “Checking the valve clearance”. Valve clearance: 8. Check that the camshaft Woodruff key Intake: groove a is in the position shown in the 0.15–0.25 mm (0.0059–0.0098 in) illustration.

  • Page 108: Installing The Power Unit

    POWR Power unit 4. Install the throttle cable 5 (Pull side) to 18. Install the fuel system. Refer to “Fuel sys- the pully 6. tem” in the chapter 4. NOTE: 19. Install the new O-ring, relief valve and oil Be sure the throttle grip is in the fully close strainer assembly.
  • Page 109 Cylinder block NOTE: 13. Tighten the flywheel magnet nut to the Adjust the throttle cable to slack off. specified torque. 8. Turn the throttle grip from fully closed to fully open and back. Check stopper is contact a, b and for each cable slack. 9.
  • Page 110 POWR Power unit 18. Using the adjusting nut w, align the wire 15. Fill the engine oil to specified quantity. end e with the mark c on the starter Refer to “Replacing the engine oil” in the chapter 3. case. Recommended engine oil: 4-stroke outboard motor oil API: SE, SF, SG, SH or SJ...

  • Page 111: Lowr

    LOWR Lower unit Special service tools..................6-1 Lower unit .......................6-4 Water pump.....................6-6 Removing the lower unit ................6-7 Removing the water pump.................6-7 Checking the water pump................6-8 Propeller shaft housing .................6-9 Removing the propeller shaft housing assembly........6-10 Disassembling the propeller shaft housing assembly ......6-10 Disassembling the propeller shaft assembly ...........6-11 Checking the propeller shaft housing ............6-11 Checking the propeller shaft ..............6-11...

  • Page 112: Lower Unit

    LOWR Lower unit Special service tools Bearing puller assembly Dial gauge set 90890-06535 90890-01252 Stopper guide plate Stopper guide stand 90890-06501 90890-06538 Bearing housing puller claw S Center bolt 90890-06504 90890-06564 Drive shaft holder 1 Driver rod SL 90890-06515 90890-06602 Bearing depth plate Bearing Separator 90890-06603...
  • Page 113 Special service tools Ball bearing attachment Driver rod SS 90890-06632 90890-06604 Driver rod LL Bearing outer race attachment 90890-06605 90890-06625, 06627 Bearing inner race attachment Driver rod LS 90890-06606 90890-06644 Needle bearing attachment Bushing attachment 90890-06613, 90890-06616 90890-06649 Needle bearing attachment Driver rod L3 90890-06617 90890-06652...

  • Page 114: Lower Unit

    LOWR Lower unit Shimming plate 90890-06701 Digital caliper 90890-06704 Magnet base B 90890-06844 Backlash indicator 90890-06706 Magnet base plate 90890-07003 6D45F11...
  • Page 115 Special service tools/Lower unit Lower unit 18 N·m (1.8 kgf·m, 13 ft·lb) 17 N·m (1.7 kgf·m, 12 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 6D46010E Part name Q’ty...
  • Page 116 LOWR Lower unit 18 N·m (1.8 kgf·m, 13 ft·lb) 17 N·m (1.7 kgf·m, 12 ft·lb) 5 N·m (0.5 kgf·m, 3.7 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 6D46010E Part name Q’ty Remarks...

  • Page 117: Water Pump

    Lower unit/Water pump Water pump 18 N·m (1.8 kgf·m, 13 ft·lb) 18 N·m (1.8 kgf·m, 13 ft·lb) View A 6D46020E Part name Q’ty Remarks Woodruff key Impeller Water pump housing Insert cartridge O-ring Not reusable Dowel pin Rubber seal M8 × 45 mm Bolt Plate M8 ×...

  • Page 118: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 6. Disconnect the shift rod. Loosen the adjuster while holding the locknut. 1. Remove the clip for the engine stop lan- yard switch. NOTE: Set the gear shift in reverse first. 2. Set the gear shift in the neutral position. 7.

  • Page 119: Checking The Water Pump

    Water pump Checking the water pump 5. Check the outer plate cartridge for cracks 1. Check the water pump housing 1 for or damage. Replace if necessary. deformation. Also check the insert car- tridge 2 for wear or deformation. 6D460030 2.

  • Page 120: Propeller Shaft Housing

    LOWR Lower unit Propeller shaft housing 8 N·m (0.8 kgf·m, 5.8 ft·lb) 3.0 — 3.5 mm 0 mm (0.1181 — 0.1387 in) 6D46030E Part name Q’ty Remarks Shift plunger Dog clutch Cross pin Cross pin ring Spring Washer Reverse gear O-ring Not reusable Reverse gear shim...

  • Page 121: Removing The Propeller Shaft Housing Assembly

    Propeller shaft housing Removing the propeller shaft 3. Remove the ball bearing. housing assembly 1. Remove the bolts and remove the pro- peller shaft housing assembly by prying the tabs apart with flat-head screw- drivers. 6B460110 6D460070 Stopper guide plate 1: 90890-06501 NOTE: Stopper guide stand 2:...

  • Page 122: Disassembling The Propeller Shaft Assembly

    LOWR Lower unit Checking the propeller shaft 1. Check the propeller shaft for bends or Shimming is required when the reverse wear. Replace if necessary. gear, ball bearing, or propeller shaft hous- ing is replaced. Disassembling the propeller shaft assembly 1.

  • Page 123: Assembling The Propeller Shaft Assembly

    Propeller shaft housing Assembling the propeller shaft 2. Install new oil seals into the propeller assembly shaft housing to the specified depth. 1. Insert the spring 1. 2. Install the dog clutch 2 so that the “F” mark faces the forward gear, and insert the cross pin 3.
  • Page 124 LOWR Lower unit 4. Install the reverse gear and shim into the propeller shaft housing. 6B460180 NOTE: Shimming is required when the reverse gear or ball bearing is replaced. 6-13 6D45F11...

  • Page 125: Drive Shaft And Lower Case

    Drive shaft and lower case Drive shaft and lower case 25 N·m (2.5 kgf·m, 18 ft·lb) 6D46040E Part name Q’ty Remarks Drive shaft Bearing housing Drive shaft sleeve Needle bearing Not reusable Pinion gear shim Forward gear Taper roller bearing Not reusable Forward gear shim Pinion nut...

  • Page 126: Removing The Drive Shaft And Forward Gear

    LOWR Lower unit Removing the drive shaft and 4. Remove the drive shaft sleeve. forward gear 5. Remove the forward gear. NOTE: Shimming is required when the forward gear Disassembling the lower case or taper roller bearing is replaced. 1. Remove the taper roller bearing outer race.

  • Page 127: Checking The Bearing Housing

    Drive shaft and lower case Checking the bearing housing Checking the pinion gear and 1. Check the bearing housing for cracks or forward gear damage. Also check the bushing for 1. Check the pinion gear teeth for cracks or wear, and the oil seals for damage. wear.

  • Page 128: Checking The Bearings

    LOWR Lower unit Checking the bearings Checking the shift rod 1. Check the needle bearing and the thrust 1. Check the shift rod for deformation or bearing for run-out or roughness. wear. Replace if necessary. Replace if necessary. Shimming is required when the thrust bearing is replaced.
  • Page 129 Drive shaft and lower case Install the needle bearing. 4. Install the bushing using a press. 6B460360 Needle bearing attachment 3: 90890-06617 6D460120 Driver rod SL 4: 90890-06602 Driver rod SS 7: Bearing depth plate 5: 90890-06604 90890-06603 Bushing attachment 8: 90890-06649 Depth a: 5.

  • Page 130: Installing The Drive Shaft

    LOWR Lower unit Installing the drive shaft Drive shaft holder 1 1: 1. Install the drive shaft sleeve, shift rod, 90890-06515 new gasket, bearing housing assembly, forward gear, drive shaft, shim, thrust Pinion nut: bearing, and pinion gear. 25 N·m (2.5 kgf·m, 18 ft·lb) 9 Shimming is required when the drive Installing the propeller shaft shaft housing or the drive shaft is...

  • Page 131: Installing The Water Pump

    9 Align the groove on the impeller with the Woodruff key. Installing the water pump 9 Apply Yamaha grease A on the sliding face 1. Install the dowels 1, the outer plate car- between the impeller and the outer plate tridge 2.

  • Page 132: Installing The Lower Unit

    6D460200 NOTE: To install the water pump housing, apply Yamaha grease A to the inner face of the water pump housing assembly, and then turn the drive shaft clockwise while pushing down 6D460220 on the pump housing.
  • Page 133 Drive shaft and lower case 6. Insert the gear oil tube into the drain hole Trim tab bolts: and fill the gear oil until it flows out of the 8 N·m (0.8 kgf·m, 5.8 ft·lb) check hole and no air bubbles are visible. 5.

  • Page 134: Shimming

    LOWR Lower unit Shimming M3-10 mm (0.39 in) 6D460240 6-23 6D45F11...

  • Page 135: Selecting The Pinion Shims

    Shimming Shimming 3. Select the pinion shim(s) (T3) as follows. NOTE: Calculated numeral 9 Shimming is not required when assembling Use shim more than less than the original lower case and inner parts. 1.13 1.20 1.13 9 Shimming is required when assembling the 1.20 1.30 1.20...

  • Page 136: Selecting The Reverse Gear Shims

    LOWR Lower unit 2. Calculate the shim thickness. Forward gear shim thickness (T1) = 16.60 - M2 3. Select the forward gear shim(s) (T1) as follows. Calculated numeral 6B460570 at 1/100th place Use shim more than less than Shimming plate 1: 0.00 0.02 0.00...

  • Page 137: Backlash

    Shimming/Backlash Backlash 5. Install the backlash indicator onto the drive shaft (13 mm [0.51 in] in diameter), Measuring the forward and reverse then the dial gauge onto the lower unit. gear backlash 1. Remove the water pump assembly. 2. Set the gearshift to the neutral position. 6B460430 3.
  • Page 138 LOWR Lower unit 7. Add or remove shims if out of specifica- tion. Forward gear Shim thickness backlash Less than To be decreased by (0.52 - M) × 0.43 0.19 mm (0.0075 in) More than To be increased by (M - 0.52) × 0.43 0.86 mm (0.0339 in) M: Measurement Available shim thicknesses:...

  • Page 139: Brkt

    BRKT Bracket unit Special service tools..................7-1 Tiller handle ....................7-2 Bottom cowling ....................7-4 Upper case and bracket unit.................7-7 Disassembling the oil pan................7-13 Disassembling the upper case ..............7-13 Checking the upper case.................7-14 Assembling the upper case ..............7-14 6D45F11...

  • Page 140: Special Service Tools

    BRKT Special service tools Special service tools Needle bearing attachment 90890-06614 Driver rod SS 90890-06604 6D45F11...

  • Page 141: Tiller Handle

    Special service tools/Tiller handle Tiller handle 10 N·m (1.0 kgf·m, 7.2 ft·lb) 23 N·m (2.3 kgf·m, 17 ft·lb) 2.5 N·m (0.25 kgf·m, 1.8 ft·lb) 3.4 N·m (0.34 kgf·m, 2.5 ft·lb) 6D47010E Part name Q’ty Remarks Screw Washer Throttle friction adjuster Bushing Not reusable Washer...
  • Page 142 BRKT Bracket unit 10 N·m (1.0 kgf·m, 7.2 ft·lb) 23 N·m (2.3 kgf·m, 17 ft·lb) 2.5 N·m (0.25 kgf·m, 1.8 ft·lb) 3.4 N·m (0.34 kgf·m, 2.5 ft·lb) 6D47010E Part name Q’ty Remarks Friction piece Cotter pin Not reusable Throttle grip assembly Bushing Spring 6D45F11...

  • Page 143: Bottom Cowling

    Tiller handle/Bottom cowling Bottom cowling 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 6D47020E Part name...
  • Page 144 BRKT Bracket unit 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 6D47020E Part name Q’ty...
  • Page 145 Bottom cowling 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 6D47020E Part name Q’ty...

  • Page 146: Upper Case And Bracket Unit

    BRKT Bracket unit Upper case and bracket unit 8 N·m (0.8 kgf·m, 5.8 ft·lb) 21 N·m (2.1 kgf·m, 16 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 27 N·m (2.7 kgf·m, 20 ft·lb) 32 N·m (3.2 kgf·m, 23 ft·lb) 6D47030E 3 N·m (0.3 kgf·m, 2.2 ft·lb) 2.5 N·m (0.25 kgf·m, 1.8 ft·lb)
  • Page 147 Upper case and bracket unit 8 N·m (0.8 kgf·m, 5.8 ft·lb) 21 N·m (2.1 kgf·m, 16 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb) 11 N·m (1.1 kgf·m, 8.1 ft·lb) 27 N·m (2.7 kgf·m, 20 ft·lb) 32 N·m (3.2 kgf·m, 23 ft·lb) 6D47030E 3 N·m (0.3 kgf·m, 2.2 ft·lb) 2.5 N·m (0.25 kgf·m, 1.8 ft·lb)
  • Page 148 BRKT Bracket unit 7.5 N·m (0.75 kgf·m, 5.5 ft·lb) 4 N·m (0.4 kgf·m, 2.9 ft·lb) 6D47040E Part name Q’ty Remarks Steering bracket Screw Ground lead Friction piece M6 × 20 mm Bolt Rubber seal Bushing O-ring Not reusable Bushing Washer Pivot shaft bushing M8 ×...
  • Page 149 Upper case and bracket unit 2 N·m (0.2 kgf·m, 1.5 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 22 N·m (2.2 kgf·m, 16 ft·lb) 6D47050E Part name Q’ty Remarks Plate Starboard clamp bracket Tilt lock arm M6 ×...
  • Page 150 BRKT Bracket unit 2 N·m (0.2 kgf·m, 1.5 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 22 N·m (2.2 kgf·m, 16 ft·lb) 6D47050E Part name Q’ty Remarks Spring Spring Washer Tilt lock shaft Circlip Shaft Tilt rod Transom clamp pad Screw...
  • Page 151 Upper case and bracket unit 2 N·m (0.2 kgf·m, 1.5 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 22 N·m (2.2 kgf·m, 16 ft·lb) 6D47050E Part name Q’ty Remarks Reverse lock plate Shaft Screw Spring Circlip Collar Washer...

  • Page 152: Disassembling The Oil Pan

    BRKT Bracket unit Disassembling the oil pan 4. Check the exhaust pipe, oil pan for dam- 1. Remove the oil pan 1 and buffer plate 2 age or corrosion. Replace if necessary. gasket from the upper case. 6D470060 Disassembling the upper case 1.

  • Page 153: Checking The Upper Case

    Upper case and bracket unit Assembling the upper case 2. Remove the lower mount brackets 4. 1. Install the new oil seal 1 to the oil pan using the special service tools. 6D470090 6D470040 Driver rod SS 2: 90890-06604 Checking the upper case Needle bearing attachment 3: 1.
  • Page 154 BRKT Bracket unit 4. Install the rubber seal q and water tube 6. Install the buffer plate u to the oil pan. w to the upper mount e. NOTE: Face the “FRONT” mark side to install. 5. Install the upper mount e and lower mount brackets r.

  • Page 155: Elec

    ELEC Electrical systems Special service tools..................8-1 Checking the electrical components ............8-2 Measuring the peak voltage ..............8-2 Measuring low resistance ................8-2 Electrical components ...................8-3 Top view.....................8-3 Starboard view...................8-4 Aft view ......................8-5 Wiring harness ....................8-6 Ignition and ignition control system ............8-7 Checking the ignition spark gap ..............8-7 Checking the spark plug caps ..............8-7 Checking the ignition coil................8-8 Checking the pulser coil ................8-8...

  • Page 156: Electrical Systems

    ELEC Electrical systems Special service tools Ignition tester 90890-06754 Digital circuit tester 90890-03174 Peak voltage adaptor B 90890-03172 6D45F11...

  • Page 157: Checking The Electrical Components

    Special service tools/Checking the electrical components Checking the electrical Measuring low resistance When measuring a resistance of 10 or less components with the digital circuit tester, the correct mea- Measuring the peak voltage surement cannot be obtained because of the internal resistance of the tester.

  • Page 158: Electrical Components

    ELEC Electrical systems Electrical components Top view Tiller control model Remote control model 6D480020 1 Rectifier regulator 9 Engine stop lanyard switch connector (for 2 Pulser coil remote control model: 701 remote control 3 Lighting coil type) 4 Spark plug 5 Ignition coil å...

  • Page 159: Starboard View

    Electrical components Starboard view 6D480030 1 CDI unit å Install the connector in the proper direction as 2 Oil pressure switch shown. 3 Ignition coil ∫ Pass each spark plug wire through the grom- met. ç Cover the oil pressure switch lead, ignition coil lead and charge coil lead with the plastic tube after connecting the same color leads.

  • Page 160: Aft View

    ELEC Electrical systems Aft view ç ´ ∂ 6D480040 1 Pulser coil å To the lighting coil. 2 CDI unit leads ∫ To the warning lamp. 3 Rectifier regulator leads ç Tighten with the CDI unit ground lead and the engine stop lanyard switch ground lead.

  • Page 161: Wiring Harness

    Electrical components/Wiring harness Wiring harness 6D480050 1 CDI unit 0 Spark plug : White 2 Lighting coil q Rectifier regulator G/W: Green /White 3 Charge coil W/G: White/Green 4 Oil pressure switch Br : Brown Y/R : Yellow/Red 5 Pulser coil : Green 6 Ignition coil : Blue...

  • Page 162: Ignition And Ignition Control System

    ELEC Electrical systems Ignition and ignition control Checking the spark plug caps 1. Check the spark plug caps for cracks or system damage. Replace if necessary. Checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. 2.

  • Page 163: Checking The Ignition Coil

    Ignition and ignition control system Checking the ignition coil Checking the pulser coil 1. Remove the spark plug cap from the 1. Connect the digital circuit tester with spark plug. peak voltage adaptor B to the connector. 2. Disconnect the ignition coil lead. 2.

  • Page 164: Checking The Charge Coil

    ELEC Electrical systems Digital circuit tester: 90890-03174 Peak voltage adapter B: 90890-03172 Charge coil peak voltage: Brown (Br) – Blue (L) Unloaded Loaded r/min Cranking 1,500 3,500 DC V 6D480140 Pulser coil resistance (use as reference): White/green (W/G) – Black (B) 234.0 –...

  • Page 165: Checking The Cdi Unit

    Ignition and ignition control system Checking the CDI unit Checking the oil pressure warning 1. Connect the digital circuit test leads to lamp the orange and black leads from the CDI 1. Disconnect the connector from oil pres- unit. sure switch. 2.

  • Page 166: Checking The Engine Stop Lanyard Switch

    ELEC Electrical systems Checking the engine stop lanyard switch 1. Check the engine stop lanyard switch for continuity. Replace if there is no continu- ity. 6B480160 Lead color White (W) Black (B) Clip removed a Clip installed b Engine shut-off button pushed c 2.

  • Page 167: Charging System

    Charging system Charging system Checking the rectifier regulator 1. Connect the digital circuit test leads to Checking the lighting coil the red and black or ground leads from 1. Connect the digital circuit tester lead to the rectifier regulator. the lighting coil. 2.
  • Page 168 ELEC Electrical systems — MEMO — 8-13 6D45F11...
  • Page 169 TRBL TRBL SHTG SHTG Troubleshooting Power unit .......................9-1 Ignition system...................9-1 Fuel system ....................9-3 Compression pressure................9-4 Lower unit .......................9-6 6D45F11...

  • Page 170: Trbl Shtg

    TRBL TRBL SHTG SHTG Troubleshooting NOTE: 9 To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 4–8 for safe maintenance procedures. 9 Check that all electrical connections are tight and free from corrosion. Power unit Symptom: Manual starter turns but engine will not start.
  • Page 171 Power unit Ignition system (continued from previous page) Measure the CDI unit output peak voltage. Does the out- put peak voltage Check the connection exceed specifi- of the leads from CDI unit. cation values? Measure the charge coil output peak voltage. Does the out- put peak voltage Replace the charge coil.

  • Page 172: Fuel System

    TRBL SHTG Troubleshooting Fuel system 9 Consult this chart after the ignition system has been checked. Check for water accumulation or clogging of the fuel filter and inside the carburetor. 9 Clean the fuel system from the Is there water fuel tank to the fuel filter and or residue? carburetor float chamber.

  • Page 173: Compression Pressure

    Power unit Compression pressure 9 Consult this chart after the ignition and fuel systems have been checked. NOTE: Measure the compression Since this outboard motor is equipped with an automatic decom- pressure. pression mechanism, accurate data may be difficult to obtain due to differences in the way the starter rope is pulled.
  • Page 174 TRBL SHTG Troubleshooting Symptom: The engine idle speed does not remain steady. Check the throttle cable and link operation. Are they operat- Adjust the throttle cable and ing correctly? throttle link. Check the operation of the carburetor. Is the carburetor operat- Check the ignition system chart.

  • Page 175: Lower Unit

    Lower unit Lower unit Symptom: The forward and reverse gear shift mechanism does not operate properly. Check the shift lever operation. Is it operating Check the shift lever shaft and correctly? spring. Check the shift rod connection. Is it connected Connect correctly or replace the properly and in shift rod as necessary.
  • Page 176 Index Checking the electrical components ...8-2 Checking the engine idle speed....3-10 Adjusting the pilot screw ......4-10 Checking the engine oil.......3-3 Adjusting the throttle cable......3-8 Checking the engine oil level ......1-6 Adjusting the throttle link rod ....4-10 Checking the engine stop Aft view............8-5 lanyard switch ...........1-8 After test run ..........1-9...
  • Page 177 Checking the start-in-gear protection..3-7 Checking the steering system.....1-7 General .............3-13 Checking the thermostat ......3-7 General specifications.........2-1 Checking the tilt operation......3-11 General torques.........2-11 Checking the timing belt......3-5 Good working practices ......1-4 Checking the timing belt and sprockets ..5-19 Checking the top cowling ......3-14 Checking the upper case ......7-14 Hose routing..........4-2 Checking the valve clearance .....5-4...
  • Page 178 Index Refacing the valve seat......5-28 Removing the cylinder head .....5-24 Removing the drive shaft and forward gear ..........6-15 Removing the lower unit ......6-7 Removing the power unit ......5-14 Removing the propeller shaft housing assembly ........6-10 Removing the timing belt and sprockets..........5-18 Removing the water pump ......6-7 Replacing the gear oil .......3-12...
  • Page 180 YAMAHA MOTOR CO., LTD. Printed in Japan Oct. 2003 – 0.4 × 1 ! Printed on recycled paper...

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